Cross-Reference to Related Application

This application claims the benefit of U.S. Provisional Patent Application No. 61/630,965, filed December 22, 201 1.

Incorporation by Reference

The disclosure of U.S. Provisional Patent Application No. 61/630,965, which was filed on December 22, 201 1 , is incorporated by reference as if presented herein in its entirety, for all purposes.

Background of the Invention

The present disclosure generally relates generally to packaging machinery for closing and securing cartons in a closed configuration. More specifically, the present disclosure relates to a tape application system or other packaging machine for applying sealing tape to a carton, the tape application system having an actuator to facilitate application of the sealing tape.

Summary of the Disclosure

In general, one aspect of the disclosure is directed to a tape application system for sealing a carton. The tape application system comprises a first tape applicator in the path of travel of a carton to be sealed and a second tape applicator in the path of travel of a carton to be sealed. An actuator is operatively connected to at least one of the first tape applicator and the second tape applicator and is for moving the first tape applicator and the second tape applicator relative to the path of travel of the carton to be sealed. A control device is operatively connected to actuator to initiate actuation of the actuator.

In another aspect, the present disclosure is generally directed to a retrofit kit for a tape application system having a first tape applicator and a second tape applicator. The retrofit kit comprises an actuator for being configured to be operatively connected to at least one of the first tape applicator and the second tape applicator and for moving the first tape applicator and the second tape applicator relative to the path of travel of a carton to be sealed. A control device is for being operatively connected to the actuator to initiate actuation of the actuator. In another aspect, the disclosure is generally directed to a method of applying tape to a carton. The method comprises moving a first tape applicator and a second tape applicator simultaneously relative to a path of travel of a carton to be sealed, and dispensing a length of sealing tape onto the carton in response to moving the first tape applicator and the second tape applicator.

In another aspect, the disclosure is generally directed to a method of modifying a tape application system for sealing a carton. The tape application system has a first tape applicator and a second tape applicator. The method comprises obtaining a retrofit kit comprising an actuator and a control device. Operatively connecting the actuator to at least one of the first tape applicator and the second tape applicator. The actuator being configured for moving the first tape applicator and the second tape applicator relative to a path of travel of the carton to be sealed. The method comprises positioning the control device to detect the presence of the carton to be sealed, and operatively connecting the control device to the actuator to initiate actuation of the actuator upon detection of the presence of the carton to be sealed.

Other aspects, features, and details of the present disclosure can be more completely understood by reference to the following detailed description of exemplary embodiments taken in conjunction with the drawings and from the appended claims.

Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures. Further, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.

Brief Description of the Drawings

Fig. 1 is a schematic of a tape application system, according to an embodiment of the disclosure.

Fig. 2 is an elevation view of a portion of the tape application system of Fig. 1.

Fig. 3 is a perspective view of a portion of the tape application system of Fig. 1.

Fig. 4 is a schematic of a tape application system, according to an additional embodiment of the disclosure. Figures 5-7 illustrate travel of a carton through a tape application system, according to an embodiment of the disclosure.

Corresponding parts are designated by corresponding reference numbers throughout the drawings.

Detailed Description of the Exemplary Embodiments

The present disclosure generally relates to packaging machinery for sealing cartons that contain articles such as containers, bottles, cans, etc. The packaging machinery can be a part of a packaging line wherein cartons are loaded with articles, closed, and sealed by the application of sealing tape.

Fig. 1 is a schematic elevation view of a tape application system, generally indicated at 1, of a first embodiment of the disclosure. The tape application system 1 can be generally similar to and/or have similar components as conventional tape application systems, such as the case sealers that are commercially available from Loveshaw, An ITW Company (see www.loveshaw.con . such as the variety of models of LITTLE DAVID® Case Sealers. Also, case sealers sold by 3M Corporation of St. Paul, MN, such as the variety of models of 3M- MATIC® Case Sealers, may have similar components or features of the present disclosure.

As shown in Fig. 1, the tape application system 1 comprises an upper tape application assembly 3 and a lower tape application assembly 5. In the illustrated embodiment, each of the upper tape application assembly 3 and the lower tape application assembly 5 has like or similar components and such like or similar components will be identified with identical reference numbers between the two assemblies. The upper tape application assembly 1 is for applying sealing tape 7 to the upper portion of the front end FE of a carton C, the top T of the carton, and the upper portion of the back end BE of the carton. The lower tape application assembly 3 is for applying sealing tape 7 to the lower portion of the front end FE of the carton C, the bottom B of the carton, and the lower portion of the back end BE of the carton. Both the upper tape application assembly 1 and the lower tape application assembly 3 apply sealing tape 7 to the carton C as the carton is moved between the tape application assemblies on a packaging line 1 1 in the direction of arrow Al. The packaging line 1 1 can be part of a larger packaging line that assembles the carton C through various folding steps, or the packaging line can be a smaller packaging line that receives the assembled cartons from the larger packaging line that assembles and/or loads the cartons. In one embodiment, the packaging line 1 1 is a conveyor belt that transports the cartons C through the tape application assemblies 3, 5 but the packaging line could be other article movement mechanisms (e.g., cooperating belts that contact a respective side of the cartons C, rollers, etc.) without departing from the disclosure. In other embodiments, one of the upper or lower tape assemblies 3, 5 could be omitted so that the tape application system 1 includes only a single (upper or lower) tape application assembly.

As shown in Fig. 1, the upper and lower tape application assemblies 3, 5 include a base or housing 15. A tape support bracket 17 is mounted to the housing 15 and includes a roll 19 of sealing tape 7 mounted above or below the base 15. The sealing tape 7 can be any conventional type of sealing tape used to close cartons or any other suitable sealing tape. Each of the tape application assemblies 3, 5 include two tape applicators 22, 24 that are pivotably mounted to the base 15. The tape applicator 22 is located in the upstream direction closest to the entry of the incoming carton C to be sealed, and the tape applicator 24 is located in the downstream direction closest to the exit of the carton that is leaving the tape application system 1. Each tape applicator 22, 24 includes a roller 25, 27 rotatably mounted at a respective end of the tape application arm 21, 23. Each of the upstream rollers 25 has tape 7 in contact therewith so that the upstream rollers initiate application of the tape to the carton C upon entry of the carton into the assemblies 3, 5. The tape application arms 21, 23 are operatively connected by an arm linkage 29. The upstream connecting arms 21 are pivotable in the direction of arrow A2 to raise or lower the upstream connecting arms, and the downstream connecting arms 23 are pivotable in the direction of arrow A3 to raise or lower the downstream connecting arms. The arm linkage 29 causes both the upstream tape application arm 21 and the downstream tape application arm 23 of a respective taper assembly 3, 5 to pivot (e.g., to be raised or lowered) at the same time upon initiation of pivoting of one of the connecting arms. The tape applicators 22, 24 could be alternatively configured such that each arm 21, 23 is independently raised or lowered without departing from the disclosure.

As shown in Fig. 1 each tape application assembly 3, 5 includes a control valve 33 (broadly "control device") having a control valve actuator 35 that is connected to the control valve. In one embodiment, the control valve 33 is a Model No. 201-C air valve manufactured by Ingersoll-Rand Company and commercially available from W. W. Grainger, Inc. as Item No. 2F893. The control valve 33 could be any other suitable valve without departing from the disclosure. In the illustrated embodiments, the control valve 33 is connected to a compressed air supply 37 via compressed air piping 39.

As shown in Figs. 1 and 2, a tape arm actuator 41 is operatively connected to the control valve 33 via compressed air piping 43. In the illustrated embodiment, the tape arm actuator 41 is operatively connected to the downstream tape arm 23 via a linkage 45. In one embodiment, the tape arm actuator 41 can be an air cylinder having a ¾ inch bore, 2 inch (50 mm) stroke such as Model No. 6W100 SPEED AIRE® air cylinder commercially available from W.W. Grainger, Inc. Alternatively, the tape arm actuator could have a 3 inch (75 mm) stroke and be a Model No. 6W133 SPEEDAIRE® air cylinder commercially available from W.W. Grainger, Inc. Alternatively, the tape arm actuator 41 could be an air cylinder having an alternative size (e.g., bore, stroke, etc.) or could be a different type of actuator (e.g., electric operated cylinder, motor, hydraulic cylinder, or any other mechanical actuator). Also, the tape arm actuator 41 could be otherwise positioned to act on the tape arm 23, or the actuator could be positioned to act on the tape arm 21 without departing from the disclosure.

In one exemplary embodiment, a method of closing a carton C is provided wherein tape 7 is applied to the carton to close the carton. Figs. 5-7 generally illustrate the method of closing the carton C that is described with relation to the parts and components shown in Fig. 1. The carton C enters the tape application system 1 via packaging line 1 1 and the front end FE of the carton contacts the roller 25 of the upper and lower upstream tape arm 21. The roller 25 applies tape to the front end FE of the carton C. Upon contact of the upstream rollers 25, the control valve 33 is actuated by contact of the carton with the control valve actuator 35. The actuation of the control valve 33 causes compressed air to flow to the tape arm actuator 41 which extends arm 47 of each tape arm actuator in the direction of arrows A4. The extension of the arm 47 causes the downstream tape arm 23 to pivot in the direction of arrow A3. Because the upstream tape arm 21 is operatively connected to the trail tape arm 23 by linkage 29, the extension of the arms 47 also causes the simultaneous pivoting of the upstream tape arm 21 in the direction of arrow A2. The actuation of the actuator 41 causes simultaneous movement of the first tape applicator 22 and the second tape applicator 24 relative to the path of travel of the carton C.

Fig. 6 shows the tape application system 1 after initial actuation of the tape arm actuator 41. In one embodiment, the pivoting of the tape arms 21, 23 of the first and second tape applicators 22, 24 positions the lead roller 25 of the upper tape application assembly 3 in contact with the top T of the carton C as the carton moves through the tape application system 1 in the direction of arrow Al, and positions the lead roller 25 of the lower tape application assembly 5 in contact with the bottom B of the carton C as the carton moves through the tape application system. In this way tape 7 can be dispensed from the rolls 19 and applied to the carton extending up or down at least a portion of the front end FE of the carton C and across the top T or bottom B of the carton to secure top or bottom flaps together in a closed position. As the carton C travels in the direction of arrow Al and passes a sufficient distance through the tape application system 1, the control valve 33 is deactivated by movement of the control valve actuator 35 caused by the carton being out of contact with the control valve actuator. The deactivation of the control valve 33 causes the compressed air flow to the tape arm actuator 41 to stop and the arm 47 to retract. The retraction of the arm 47 causes the tape arms 21, 23 of the tape applicators 22, 24 to pivot in the directions opposite arrows A2, A3 so that the rollers 25, 27 are lowered (for the upper tape assembly 3) or raised (for the lower tape assembly 5). As shown in Fig. 7, the downstream roller 27 contacts the back end B of the carton C to press against the sealing tape 7 that has been applied so that the sealing tape is secured to the back end of the carton C. The closed and sealed carton C continues down the packaging line 1 1 for further handling.

Figs. 2 and 3 show various components of the tape application system 1 described above.

Fig. 4 illustrates a tape application system 1 of a second embodiment. The second embodiment is generally similar to the first embodiment, and like or similar reference numbers will be used to indicate like or similar components shown in the two embodiments. In the second embodiment, the control valve 33 with control valve actuator 35 has been replaced by control valve 33a that is activated by an upstream photoelectric sensor 51 and a downstream photoelectric sensor 53. Each of the photoelectric sensors 51 is operatively connected to the control valve 33a by wiring 34, indicated schematically on Fig. 4, to provide indication of the presence or lack of presence of the carton C in the line of sight of each respective sensor. Dashed lines 57, 59 indicate that line of transmission from a respective sensor 51, 53 that can by a light beam or other type of transmission (e.g., infrared, photoelectric, etc.) without departing from the disclosure. Further, the sensors 51 , 53 are shown mounted on the support or housing 15 of the tape application assemblies 3, 5, but the sensors 51, 53 could be otherwise mounted and/or positioned without departing from the disclosure. The sensors 51, 53 can be any suitable photoelectric sensor or switch or any other type of sensor for detecting the location of the carton C. In an alternative embodiment, the sensors 51, 53 can be oriented to direct a respective line of transmission across the packaging line (e.g., generally perpendicular to the line of travel Al on the packaging line).

In one embodiment of a method of applying tape 7 to the carton 7, when the upstream sensor 51 of each tape application assembly 3, 5 senses the presence of the carton C on the packaging line 1 1, and a signal is sent to the control valve 33a to provide compressed air to the tape arm actuator 41 to actuate and pivot the tape arms 21 , 23 to raise (upper tape assembly 3) or lower (lower tape assembly 5) the tape arms in a similar manner as the first embodiment. The carton C is further conveyed through the tape application system 1 with tape 7 being applied to the front end FE and top T of the carton in a similar manner as the previous embodiment. Once the front end FE of the carton C is advanced on the packaging line 11 to the downstream sensors 53, the downstream sensors 33a sense that the back end BE of the carton has passed the sensors and send a corresponding signal to the control valve 35 to stop the flow of compressed air to the tape arm actuator 41 to lower (upper tape assembly 3) or raise (lower tape assembly 5) the tape arms 21, 23 in a similar manner as the first embodiment. Tape 7 is then applied to the back end BE of the carton C and is secured to the carton by contact with the downstream rollers 27.

In one embodiment, the components of the tape application system can be supplied in a retrofit kit to be installed on an existing tape application system. In one embodiment, one or more of the components in the retrofit can include the tape arm actuator 41, the control valve 33, and the control valve actuator 35. Further, the retrofit kit can optionally include the linkage 29 that is for operatively connecting the tape arms 21, 23, and the linkage 47 for connecting the actuator 41 to the one of the tape arms 21 , 23. Alternatively, the retrofit kit can include compressed air piping 39 or any other part or item that is needed to install the components of the kit on the tape application system. Further, multiple retrofit kits could be supplied for installation one both upper and lower tape application assembly of an existing tape application system.

A retrofit kit for installation on an existing tape application system could include one or more components of the second embodiment, such as tape arm actuator 41, control valve 33a, sensors 51 , 53, linkages 29, 47, and/or any other components (e.g., compressed air piping 38, wiring 34) that could be used to install the components of the retrofit kit.

In one embodiment, the disclosure can be directed to a method of modifying an existing tape application system having a first tape applicator 22 and a second tape applicator 24. The method can comprise obtaining a retrofit kit including the tape arm actuator and the control valve or device 33 or 33a, operatively connecting the actuator 41 to at least one of the first tape applicator 22 and the second tape applicator 24, positioning the control device to detect the presence of the carton C to be sealed, and operatively connecting the control device to the actuator to initiate actuation of the actuator upon detection of the presence of the carton to be sealed. In one embodiment, the control valve 33 with actuator 35 can be installed to sense the presence of the carton C and control actuation of the actuator 41. Alternatively, the control valve 33a with sensors 51, 53 can be installed to sense the presence of the carton C and control actuation of the actuator 41. The retrofit kit can include any of the components listed above (e.g., linkages 47, 29, compressed air piping 33, wiring 34, etc.) and the method of modifying the tape application system can comprise installing any of the components included in the retrofit kit without departing from the scope of this disclosure.

The tape application system 1 or retrofit kit of any of the illustrated or non-illustrated embodiments of the disclosure could have other features, or the features shown and described could be otherwise positioned without departing from the disclosure.

The foregoing description of the disclosure illustrates and describes various embodiments. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are within the scope of the disclosure as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.