PROCESS AND APPARATUS FOR APPLYING FITMENTS TO A CARTON

Corporate Docket No. TRX-0307-PCT

TECHNICAL FIELD The present invention relates to a process and apparatus for applying fitments to a container. Specifically, the present invention relates to a process and apparatus for applying fitments to a gabled top carton.

BACKGROUND ART Forming, filling and sealing machines have been used for decades in the food packaging industry to package items such as milk for distribution to retail outlets such as grocery stores. Generally these machines are fed a paperboard sheet laminated with heat-sealable plastic which is formed to a container configuration, filled with a specific contents and then sealed for distribution elsewhere. A gabled top milk carton is a specific example of the containers formed, filled and sealed by these machines.

Previously, the contents of these containers were dispensed by tearing open one side of the top of the carton to form a pourable spout. However once open, the carton was unable to be tightly resealed to prevent spillage of the contents or the ingress or egress of gases. To alleviate these problems, the packaging industry devised a new generation of cartons integrated with fitments in order to dispense the contents in a resealable manner. This has forced the packaging industry to either design completely new forming, filling and sealing machines to accommodate the application of the fitment with the container, or design a fitment applicator as an add-on component for existing machines. Most of the fitment applicators were designed to place the fitment in a pre- cut hole of the container at one station in the machine and then to attach the

fitment to the container through ultrasound, heat or the like at another station in the machine. One clearly apparent disadvantage of such a dual station fitment applicator is the space requirement for two additional stations on an already crowded forming, filling and sealing machine. Another critical disadvantage to dual station fitment applicators is the potential for displacement of the fitment from the container during transportation from the insertion station to the attachment station. Still another critical disadvantage to dual station fitment applicators is the necessity to index the conveyance of the containers to two additional stations. Recent fitment applicators have attempted to respond to some of these disadvantages, however, there is still a need for a fitment applicator which alleviates all of the disadvantages of the dual station applicators.

DISCLOSURE OF THE INVENTION The present invention provides a fitment applicator that meets the unfulfilled needs for form, fill and seal machines. The present invention is able to accomplish this by providing a single station fitment applicator which requires a minimum of space to apply a fitment to a carton being conveyed along a form, fill and seal machine.

One embodiment of the present invention is a method for applying a fitment to a container having an open end and an incision therein. The first step of the general method is to place an anvil having the fitment engaged thereon longitudinally into the container through the open end until the fitment is aligned with the incision. The next step involves moving the anvil translationally until the fitment is inserted through the incision. The final step is affixing the fitment to the container before substantial disengagement of the fitment from the anvil. The method may also comprise the step of engaging the fitment to the anvil prior to the step of placing the anvil into the container.

An alternative embodiment of the present invention is an apparatus for applying a fitment to a container having an open end and an incision therein. The apparatus comprises an anvil, a fitment dispenser, means for sealing and a drive source. The anvil has a fitment engagement means protruding therefrom and is

capable of longitudinal oscillation between at least a first level and a second level. The anvil is also capable of translational movement at the first level and the second level. The fitment dispenser contains a plurality of fitments for engagement with the fitment engagement means and is located on the first level. The means for sealing the fitment to the container is located on the second level. The drive source is connected to the anvil and provides for longitudinal oscillation of the anvil between the first level and the second level. The drive source also provides for translational movement of the anvil between the fitment dispenser and a longitudinal oscillation position, and translational movement of the anvil between the means for sealing and the longitudinal oscillation position. The means for sealing may be an ultrasonic welding device. The fitment engagement means may be a lobe which engages the fitment for transport from the fitment dispenser to insertion into the incision of the container. The drive source may further comprise a first drive source for longitudinal oscillation and a second drive source for translational movement. The apparatus may further comprise a third drive source for the translational movement of the means for sealing. The apparatus may be a component of a form, fill and seal machine. The apparatus may further comprise an oscillating arm whereon the anvil is supported. The oscillating arm is connected to the drive source and provides translational guidance to the anvil as well as longitudinal oscillation. The oscillating arm may provide longitudinal oscillation of the anvil along a longitudinal arc between the first level and the second level. The fitment dispenser may be a chute terminating on one end at the first level and at a fitments feeder on an opposite end. It is a primary object of the present invention to provide a method and apparatus for attaching fitments to a container in a substantially linear manner.

It is an alternative object of the present invention to provide a fitment applicator apparatus which conserves space on a packaging machine

BRIEF DESCRIPTION OF THE DRAWINGS There is illustrated in FIG. 1 a side view of one embodiment of an apparatus of the present invention.

There is illustrated in FIG. 2A a side view of the apparatus of FIG. 1 at a first point in time.

There is illustrated in FIG. 2B a side view of the apparatus of FIG. 1 at a second point in time.

There is illustrated in FIG. 2C a side view of the apparatus of FIG. 1 at a third point in time. There is illustrated in FIG. 2D a side view of the apparatus of FIG. 1 at a fourth point in time.

There is illustrated in FIG. 2E a side view of the apparatus of FIG. 1 at a fifth point in time.

There is illustrated in FIG. 2F a side view of the apparatus of FIG. 1 at a sixth point in time.

INDUSTRIAL APPLICABILITY The present invention is designed to be a component of a form, fill and seal machine whether as an integrated component of a new machine or as an add- on component to an existing machine. However, those skilled in the pertinent art will recognize possible applications of the present invention other than those mentioned above.

In utilization with a form, fill and seal machine, the present invention is preferably positioned between the partial forming of a container and the filling of such container on the form, fill and seal machine. The present invention has been designed to minimize both time and space in utilization with a form, fill and seal machine. To accomplish the minimization of time and space, the present invention has been designed for minimal translational movement and longitudinal oscillation of an anvil which transports a fitment from a fitment dispenser to a container for attachment thereon in a continual process indexed to the conveyance of containers along a conveyor belt of a form, fill and seal machine.

BEST MODE FOR CARRYING OUT THE INVENTION There is illustrated in FIG. 1 a side view of one embodiment of an apparatus of the present invention. Referring to FIG. 1, the fitment applicator of the present invention is generally designated 20. The applicator 20 has an anvil 22 which is capable of translational movement and longitudinal oscillation. In this embodiment, the longitudinal oscillation is along a longitudinal axis. The anvil 22 has a fitment engagement means 24 protruding from one surface of the anvil 22. The anvil 22 is attached from above to a first drive source 26 by a first lever 28. The first drive source 26 provides for the longitudinal movement of the anvil 22 from a first horizontal plane to a second horizontal plane. Translational movement of the anvil is accomplished by a second drive source 30 which is attached to the anvil 22 by a second lever 32. The anvil 22 may be moved along a horizontal plane from a forward position to a longitudinal pathway position. The movement of the anvil 22 will more thoroughly be described in FIGS. 2A-F. Still referring to FIG. 1 , a fitment dispenser is generally designated 34. The fitment dispenser 34 is composed of a chute 36 which transports fitments 40 from a fitments feeder 42, not shown, to an engagement point 44 at one end of the chute 36 and also located on the first horizontal plane. A fitment 40 placed in the engagement point 44 is positioned to be engaged by the fitment engagement means 24

An ultrasonic sealer is generally designated 46. The ultrasonic sealer 46 consists of a sonotrode 48 and a converter 50. Means for sealing the fitment 40 to the container 52 may be an ultrasonic sealer 46 or other sealing devices such as a heater for heat sealable lamination. The ultrasonic sealer 46 is capable of linear movement toward and away from a container 52 to be attached with a fitment 40. The container 52 is conveyed to a position below the fitment applicator 20 by a conveyor belt 54. The container 52 is partially constructed and has an open end 56 for placement of the anvil 22 therethrough. The container 52 has an incision 58 which has been cut into the container 52 for placement of a fitment therethrough. The fitment 40 has a flanged end which is positioned against the

interior walls of the container 52 while the sprout protrudes through the incision 56. The ultrasonic sealer 46 is horizontally aligned with the incision 58 of the container 52 for temporary engagement of the ultrasonic sealer 46 with the fitment 40 when it is inserted through the incision 56 of the container 52. There is illustrated in FIG. 2A a side view of the apparatus of FIG. 1 at a first point in time. Referring to FIG. 2A, the anvil 22 is at an engagement position along the first horizontal plane. The fitment engagement means 24 is engaged with a fitment 40 at the engagement point 44. At this engagement stage, the ultrasonic sealer 46 is in its resting position. The protrusion which is the fitment engagement means 24 couples with the cavity 45 formed by the spout and cap of the fitment 40. In this manner, the fitment 40 is firmly but not permanently attached to the fitment engagement means 44 which allows for the transport of the fitment 40 from the fitment dispenser 34 to the container 52.

There is illustrated in FIG. 2B a side view of the apparatus of FIG. 1 at a second point in time. Referring to FIG. 2B, the anvil 22 has retracted from the engagement point 44 in a translational motion along a first horizontal plane. The anvil 22 is also positioned on a longitudinal pathway for descent through the open end of the container 52. The time and space saving features of the present invention are apparent from the minimal distance the anvil 22 retracts from the engagement point which is only several centimeters. Also, the potential for disengagement of the fitment 40 before the fitment 40 is inserted through the incision 56 of the container 52 is greatly decreased by designing an applicator 20 with an anvil 22 that transports a fitment 40 such minimal distances.

Still referring to FIG. 2B, a new fitment 40 assumes the position of the previous fitment 40 at the engagement point 44 in the fitment dispenser 34.

Subsequently, an orderly downward movement of the fitments 40 in the chute 36 of the fitment dispenser 34 occurs due to gravitational forces. In this manner, subsequent fitments 40 are prepared for engagement with the fitment engagement means 24. There is illustrated in FIG. 2C a side view of the apparatus of FIG. 1 at a third point in time. Referring to FIG. 2C, the first drive source 26 has lowered the

anvil 22 through the open end of the container 52 and into the interior of the container 52 to a position parallel to the incision 56 along a second horizontal plane. The anvil is lowered along the longitudinal pathway with substantially no translational movement . As generally discussed above, the time and space saving features of the present invention are apparent from the minimal distances the anvil 22 is moved, in this situation along a longitudinal pathway as opposed to the previously mentioned translational movement. Also, as previously mentioned, the potential for the disengagement of the fitment 40 is greatly decreased by having to travel only minimal distances. Still referring to FIG. 2C, the longitudinal pathway the anvil 22 descends along into the container 52 from a first horizontal plane to a second horizontal plane should be a sufficient distance removed from the wall of the container 52 to prevent any interference from the container 52 with the longitudinal movement of the anvil 22. The distance from the wall of the container 52 should also account for the added length of the fitment 40 attached to the fitment engagement means

24. The unobstructed longitudinal movement of the anvil 22 ensures that the fitment 40 will not be dislodged from the fitment engagement means 24 until insertion into the incision 56.

There is illustrated in FIG. 2D a side view of the apparatus of FIG. 1 at a fourth point in time. Referring to FIG. 2D, the anvil 22 has inserted the fitment 40 into the incision 56 of the container 52 at an attachment point 58. The translational movement of the anvil 22 toward the incision 56 along the second horizontal plane is accomplished by the second drive source 30. The anvil 22 is moved forward until the flange of the fitment 40 rests firmly against the wall of the container 52 with spout and cap of the fitment 40 protruding through the incision 56. Once the fitment 40 is in this position, it is ready for permanent attachment to the container 52. The distance the anvil 22 travels from the longitudinal pathway position, as shown in FIG. 2C, to the attachment point 58 along the second horizontal plane is substantially equal to the distance the anvil 22 travels from the engagement point 44, as shown in FIG. 2 A, rearward to the longitudinal pathway position, as shown in FIG. 2B, along the first horizontal

plane. In this manner, the space for the applicator 20 is minimized by designing substantially equal translational distances for the anvil 22. The design also allows for the simplification of the programming of the second drive source 30 in that only translational movement from one position to a second position is needed by the second drive source 30.

Still referring to FIG. 2D, the ultrasonic horn 46 is positioned along the second horizontal plane parallel to the fitment 40 which now protrudes from the container 52. The ultrasonic sealer 46 rests at a sufficient distance from the fitment 40 which allows for the fitment 40 to protrude from the container 52 while the flange of the fitment 40 rests firmly against the wall of the container 52. If the ultrasonic sealer 46 is too close to the fitment 40, then the fitment 40 may become dislodged prior to complete insertion into the incision 56.

There is illustrated in FIG. 2E a side view of the apparatus of FIG. 1 at a fifth point in time. Referring to FIG. 2E, the ultrasonic sealer 46 is now positioned firmly against the exterior of the wall of the container 52 and also encompassing the spout and cap of the fitment 40. Specifically, the sonotrode 48 of the ultrasonic sealer 46 encompasses the spout and cap of the fitment 40 in an aperture 60, not shown. The ultrasonic sealer 46 moves only a minimal distance along the second horizontal plane from its resting position to an activation position as illustrated in FIG. 2E. The translational movement of the ultrasonic sealer 46 is accomplished by a third drive source 62. Similar to the anvil 22, the time and space saving features of the present invention are apparent from the minimal distance that the ultrasonic sealer 46 travels from the resting position to the activation position. Once at the activation position, the ultrasonic sealer 46 generates an ultrasonic sound which vibrates for a predetermined time and at a frequency sufficient to weld the flange of the fitment 40 to the interior of the wall of the container 52. The flange of the fitment 40 is buttressed by the anvil 22 which has sufficient inertia to allow for the proper welding of the flange of the fitment 40 to the wall of the container 52. If the anvil 22 does not possess sufficient inertia, then the fitment 40 might not be completely welded to the container 52, or the cap

might be welded to the spout of the fitment 40. Once the fitment 40 is properly welded to the container 52, the anvil 22 is ready for retraction from the attachment position to the longitudinal pathway position along the second horizontal plane. There is illustrated in FIG. 2F a side view of the apparatus of FIG. 1 at a sixth point in time. Referring to FIG. 2F, the anvil 22 has retracted to the longitudinal pathway position thereby disengaging the fitment 40, which is now welded to the container 52, from the fitment engagement means 24. The anvil 22 is now prepared for ascencion along the longitudinal pathway from the second horizontal plane to the first horizontal plane. Once the anvil 22 is removed from the interior of the container 52, the container 52 is conveyed down the line to another station on the form, fill and seal machine. A subsequent container 52 will then take its place at the applicator 20.

Still referring to FIG. 2F, the ultrasonic sealer 46 has been retracted along the second horizontal plane to its resting position from the activation position. The retraction of the ultrasonic sealer 46 is accomplished by the third driving source 62. The resting position of the ultrasonic sealer 46 provides sufficient distance from the newly welded fitment 40 to allow for the unobstructed conveyance of the container 52 to the next station on the form, fill and seal machine. The anvil 22 then ascends along the longitudinal pathway to the first horizontal plane, as shown in FIG. 1. The process is then repeated for each container 52 which is transported along the conveyor belt 54 to the applicator 20.