Abstract:
An apparatus and an automated method are disclosed by which embossed seals are created in the necks of corked bottles. A die is employed with an image bearing die surface. The bottle moves along an automated bottle track. Molten seal material is introduced into the cavity above the cork in the neck of the bottle. The image bearing surface of the seal embossing mechanism is superimposed over the mouth of the bottle containing the molten seal material. The seal embossing mechanism is centered relative to the top of the bottle. The die surface is extended from the seal embossing mechanism into contact with the surface of the molten seal material. The mechanism is motivated along an automated seal track coincident with the movement of the bottle along the automated bottle track with the image bearing die surface in contact with the molten seal material until the material has cooled so that the die impression will be retained by the sealing material. The image bearing die surface is then retracted.

Description:
This application is a continuation-in-part of and claims priority from U.S. patent application, Ser. No. 09/384,904, filed Aug. 27, 1999 now U.S. Pat. No. 6,205,744, and U.S. patent application, Ser. No. 09/480,917, filed Jan. 11, 2000 now U.S. Pat. No. 6,349,524, the disclosures of which are incorporated herein by reference in their entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to sealing corked bottles, and, more particularly, to automated methods and apparatus by which seals having high quality embossed images are formed in necked bottles. 
     Current methods for sealing the tops of corked bottles have various drawbacks. A common method involves the use of metal foils secured over the entire mouth and some of the neck of the bottle. Although this method provides a tamper resistant seal, the metal foils have been commonly made of lead, which has been shown to leave traces of the poisonous chemical on the glass surface of the mouth of the bottle. The more recent adoption of nontoxic metal foils has not been fully successful and better methods of sealing the neck of the bottle are still desired. 
     Another current method involves the insertion of a preformed thermoplastic disc in the cavity in the neck of the bottle above the cork. In order to create a seal over the cork, the neck of the bottle is heated to a point at which the thermoplastic material will melt. The heating of the bottle, especially to a temperature at which the thermoplastic disc will fully liquify, presents problems when the contents of the bottle are heat sensitive, such as wine. Additionally, the heating of the bottle may produce imperfections in the bottle&#39;s material, thus creating potential weak points in the neck of the bottle. 
     The present invention provides a means for creating an aesthetically pleasing seal over the corks of necked bottles without compromising the integrity of the bottle or its contents. Additionally, this method deals solely with thermoplastic materials which are safe if traces remain on the mouth of the bottle. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to an apparatus and an automated method by which embossed seals are created in the necks of corked bottles. A die is employed with an image bearing die surface. The bottle moves along an automated bottle track. Molten seal material is introduced into the cavity above the cork in the neck of the bottle. The image bearing surface of the seal embossing mechanism is superimposed over the mouth of the bottle containing the molten seal material. The top of the bottle is centered relative to the seal embossing mechanism. The die surface is extended from the seal embossing mechanism into contact with the surface of the molten seal material. The mechanism is motivated along an automated seal track coincident with the movement of the bottle along the automated bottle track with the image bearing die surface in contact with the molten seal material until the material has cooled so that the die impression will be retained by the sealing material. The image bearing die surface is then retracted. 
     In the preferred embodiment of the present invention, the mouth of the bottle is generally centered below the seal embossing mechanism by lowering a cone shaped centering member over seal embossing mechanism the mouth of the bottle before the molten seal material is allowed to cool in the neck of the bottle. The seal embossing mechanism is then centered more accurately by inserting a circular centering piston into the mouth of the bottle. The die surface on which there is a die image is then lowered from the seal embossing mechanism into contact with the surface of the molten seal material. Contact between a seal embossing surface and the surface of the molten seal material is maintained while the bottle and a seal embossing mechanism are simultaneously motivated down the track. Contact between a seal embossing surface and the surface of the molten seal material is maintained for a period of time long enough to allow for the seal material to cool to a state in which the seal impression will be maintained. 
     In accordance with the preferred embodiment of the invention, the seal embossing mechanism for forming the embossed seal in the neck of the bottle includes an actuator guide block and a die holder coupled with the actuator guide block using an actuator spring. The die holder is moveable relative to the actuator guide block between a rest position and a compressed position. The actuator spring is compressed in the compressed position to bias the die holder toward the rest position. The die holder includes a die stem having a die support portion and a spring seat. A centering member may be coupled with the spring seat by an engagement spring, if necessary, and would thus be movable relative to the spring seat between a rest position and a compressed position. 
    
    
     The novel features which are characteristic of the invention, as to organization and method of operation, together with further objects and advantages thereof will be better understood from the following description considered in connection with the accompanying drawings in which a preferred embodiment of the invention is illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a cross-sectional view of a neck of a corked bottle which has been sealed with a thermoplastic material in accordance with the teachings of the preferred embodiment of the present invention; 
     FIG. 2 is a perspective view of the seal of FIG. 1; 
     FIG. 3 is a front elevation view of a bottle sealing apparatus in accordance with an embodiment of the present invention; 
     FIG. 4 is a side elevation view of the bottle sealing apparatus of FIG. 3; 
     FIG. 5 is a rear elevation view of the bottle sealing apparatus of FIG. 3; 
     FIG. 6 is a front elevation view of a die truck assembly in accordance with an embodiment of the present invention; 
     FIG. 7 is a side elevation view of the die truck assembly of FIG. 6 with partial cross sections; 
     FIG. 8 is a cross sectional view of the die truck assembly of FIG. 6 taken along line I—I; 
     FIG. 9 is a side elevation view of the die truck assembly of FIG. 6 illustrating the compression of the actuator spring; 
     FIG. 10 is a side elevation view of the die truck assembly of FIG. 6 illustrating the compression of the engagement spring; 
     FIG. 11 is a side elevation view of the die truck assembly of FIG. 6 illustrating the compression of the die stem spring; 
     FIG. 12 is a side elevation view of the die truck assembly of FIG.  6  and the bottle neck and cork of FIG. 1; 
     FIG. 13 is a side elevation view of the die truck assembly of FIG.  6  and the bottle neck and cork of FIG. 1 illustrating the initial centering of the die truck assembly over the neck of the bottle; 
     FIG. 14 is a side elevation view of the die truck assembly of FIG.  6  and the bottle neck and cork of FIG. 1 illustrating the further centering of the die truck assembly over the neck of the bottle; and 
     FIG. 15 is a side elevation view of the die truck assembly of FIG.  6  and the bottle neck and cork of FIG. 1 illustrating the insertion of the die surface of the die truck assembly into the neck of the bottle. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The preferred embodiment of the bottle sealing method and apparatus of the present invention employs a die having a die surface with a die image of a logo or design. The die surface is used to form a seal with a logo or design in a bottle cavity in the neck of the bottle over the cork. The seal is formed by first introducing an amount of molten seal material into the bottle cavity. The die having a die surface with a die image is then brought into contact with the molten seal material in the bottle cavity. The molten seal material cools while in contact with the die surface having a die image and thus an embossed surface is created on the upper surface of the seal material. 
     FIG. 1 illustrates a bottle neck  10  with cork  12  disposed therein. A seal  22  provided by the preferred embodiment of the method and apparatus of the present invention is disposed in a bottle cavity  14  in the bottle neck  10  above cork  12 . The seal material is typically a thermoplastic material such as an organic polymer material, a synthetic thermoplastic material, or beeswax which melts when heated but which is a solid at room temperature. The top surface  20  of seal  22  facing outward and away from cork  12  is embossed to provide a design which is indicative of origin of the wine, or decorative, or both. FIG. 2 shows the seal material  22  with the embossed surface  20 . 
     Bottle Sealing Apparatus 
     FIGS. 3 and 4 illustrate the preferred embodiment of a bottle sealing apparatus  30  for sealing corked bottles by forming the seals  22  of FIGS. 1 and 2 in an automated process. Apparatus  30  includes an upper main support frame  32  connected with and supported above lower support frame  34 . Mounted on upper support frame  32  is an endless drive chain  36 , which travels along a path which includes a generally horizontal upper path portion  38  and a generally horizontal lower path portion  40  which are each generally straight. At the ends of path portions  38  and  40  chain  36  traverses a drive sprocket  42  and a guide sprocket  44  to form an oval-shaped carousel. 
     A plurality of die truck assemblies such as assembly  50  (only two are shown) are spaced along and coupled with endless drive chain  36 , which is driven to move the die truck assemblies continuously in a clockwise direction in the front elevation view of FIG.  3 . Each die truck assembly  50  includes a die cavity. Die truck assemblies  50  are desirably evenly spaced along endless drive chain  36 . Die truck assemblies  50 .are disposed with the die cavities oriented upward along upper path portion  38  of drive chain  36 , and are disposed with the die cavities oriented downward along lower path portion  40 . 
     A bottle conveyor  64  is provided below and disposed generally parallel to lower path portion  40  for conveying bottles  66  along a track in the same direction as die truck assemblies  50  along lower path portion  40 . While bottles  66  move along conveyor  64 , the speed of drive chain  36  is synchronized with the speed of conveyor  64  to generally align each die truck assembly  50  with the neck of one bottle. Upper support frame  32  includes a wheel track  68 , as best seen in FIG. 3, which generally tracks the path of drive chain  36  for guiding assemblies  50 . Wheel track  68  includes an offset portion along lower path portion  40  of drive chain  36 . The offset portion is offset in the downward direction, thereby guiding the actuation portions of die truck assemblies  50  downward to engage with the necks of bottles  66  over a portion of travel of endless drive chain  36  along lower path portion  40 . 
     Prior to engaging die truck assemblies  50  with bottles  66 , applicator  70  is provided near the start of lower path portion  40  for introducing an amount of molten seal material through nozzle  71  into the cavity in the neck of each bottle  66 , as seen in FIGS. 3 and 5. A reciprocator  72  is desirably provided for cyclically moving applicator  70  to follow the movement of each bottle  66  for a deposition time and to introduce the molten seal material into the cavity of the bottle  66  during the deposition time period. Reciprocator  72  begins at a first position and moves applicator  70  to a position to maintain nozzle  71  of applicator  70  in general alignment with the cavity of bottle  66 . Upon reaching the specified position, reciprocator  72  separates applicator  70  from bottle  66  and returns it to the first position to meet the next bottle  66  and begin the next cycle of reciprocating movement. The reciprocating motion can be generated by, for example, a rotating cam. In one embodiment, the deposition time is about 40-50 milliseconds for a travel distance of about 2 inches. 
     To ensure that the spacing between bottles  66  on conveyor  64  matches the spacing between die truck assemblies  50  on drive chain  36  for proper alignment and engagement of bottles  66  with assemblies  50 , a bottle guide  76  is provided near the start of conveyor  64  to guide bottles  66  onto conveyor  64  with spacing which matches the spacing between assemblies  50 . As best seen in FIGS. 3 and 5, the bottle guide in the embodiment shown is a timing screw  76  with a specific pitch. Rotating timing screw  76  advances bottles  66  and feeds them onto conveyor  64 . The speed of rotation of timing screw  76  is synchronized with the speed of drive chain  36  to generally align the necks of bottles  66  as they travel on conveyor  64  with die truck assemblies  50 . 
     As shown in FIG. 5, a single drive motor  80  is desirably provided for driving drive sprocket  42 , reciprocator  72 , and timing screw  76  in synchronism for forming seals  22  on bottles  66 . Drive motor  80  is typically a variable speed motor, and rotates main drive shaft  82 . Drive shaft  82  is coupled with gearbox  84  which is in turn coupled to sprocket drive belt  86  which drives drive sprocket  42  and drive chain  36  in rotation. The preferred embodiment employs a pair of horizontally spaced drive chains  36  which move in unison and provide a more secured connection with die truck assemblies  50  by coupling the two sides of assemblies  50 . Main drive shaft  82  also drives reciprocator  72  through reciprocator drive belt  94  rotating a cam. Main drive shaft  82  further drives timing screw  76  through timing screw drive belt  98 . 
     Drive belts  86 ,  90 ,  94 ,  98 , and gearbox  84  preferably provide the proper rotational reductions and gear ratios so as to synchronize the movement and speed of drive sprocket  42 , reciprocator  72 , and timing screw  76 . This ensures that timing screw  76  feeds bottles  66  with the same spacing to match those between die truck assemblies  50 , and that reciprocator  72  moves applicator  70  at the same speed as each bottle  66  over the deposition time period. In this way, the process rate of the entire apparatus  30  can be easily changed by simply adjusting the speed of single drive motor  80  while preserving the synchronism of the various components. 
     In the preferred embodiment, apparatus  30  is easily adjustable to process bottles  66  of different heights. As shown in FIG. 5, drive chain  36 , drive sprocket  42 , applicator  70 , reciprocator  72 , and drive motor  80  are attached to upper support frame  32 . Timing screw  76  and bottle conveyor  64  are attached to lower support frame  34 . The vertical position of upper support frame  32  is adjustable relative to lower support frame  34  via a pair of jacking screws  102 . The height adjustment of upper frame  32  varies the vertical spacing between die truck assemblies  50  and bottle conveyor  64 , thereby adapting apparatus  30  to processing bottles  66  with different heights. 
     Die Truck Assembly 
     FIGS. 6-15 show details of die truck assembly  50 . Assembly  50  includes carrier plate  120  which is connected to drive chain  36 . Carrier plate  120  includes a U-shaped recess  121  and a pair of holes  123 . Actuator guide block  126  is generally fixed to carrier plate  120  by fastener  128  and includes grease fitting  129 , as seen in FIG.  7 . Actuator guide tube  130  is disposed through the opening  127  of guide block  126  and the U-shaped recess  121  of carrier plate  120 . Guide pin  132  is connected to guide tube  130  and constrained to move generally vertically along guide slot  134  in guide block  126 , thereby restricting the movement of guide tube  130  to the vertical direction relative to guide block  126  (FIGS.  6  and  7 ). 
     As best seen in FIGS. 6 and 7, wheel bracket  136  is coupled to the top of guide tube  130  by fasteners  131  at one end and to actuator wheel  138  at the other end through spacer  140 . Inner wheel support  142  is coupled in the interior of wheel  138  by retainer clip  144 . Wheel  128  is coupled with wheel track  68  and rolls on the wheel track as assembly  50  is driven by drive chain  38 . As shown in FIGS. 6-8, actuator spring  148  is coupled between guide tube  130  and guide block  126 , and is compressible from the rest position shown to allow guide tube  130  to move downward relative to guide block  126 . 
     Spring seat  150  is attached to guide tube  130 , as best seen in FIG.  8 . Die stem  152  is disposed inside guide tube  130  and is slidable relative thereto generally in a vertical direction. Attached to the upper end of die stem  152  is stop  154  which defines the limit of downward movement of die stem  152  relative to guide tube  130 . At the lower end of die stem  152  is die support portion  156  for supporting die  157  having a die surface  159  with a die image for forming embossed surface  20  on seal  22  (FIGS.  1  and  2 ). Die  157  is desirably made using a minting process which produces a high quality die with consistency and long life at a relatively low cost. Blocking member  158 , shown in FIG. 8 as including a pair of jam nuts, is attached to die stem  152  and spaced below spring seat  150  by a distance. Guide tube  130  and die stem  152  form a die holder for supporting die  157 . The movements of guide tube  130  and die stem  152  facilitate formation of embossed seal portion  16  in die truck assembly  50 . 
     Centering member  160  is coupled with die stem  152  near die support portion  156  and is slidable generally vertically relative to die stem  152 . Centering member  160  has a generally conical shape enlarging in a direction away from spring seat  150 . As seen in FIG. 8, the conical inner surface of centering member  160  conveniently centers the cavity above cork  12  in neck  10  of bottle  66  with respect to die  157  of die truck assembly  50  when die stem  152  is moved downward to engage with the bottle. 
     Die truck assembly  50  also includes inner cone  161 , as illustrated in FIG. 12, for further centering of the assembly with bottle. Inner cone  161  is a cylindrical shaft which is contained within the upper section of centering member  160 . Inner cone  161  is in operable contact with die stem  152  and is able to move in a vertical direction within centering member  160 . Contained within inner cone  161  is die  157 . 
     Centering member  160  desirably includes a plurality of openings  162  to facilitate cooling of bottle neck  10  to hasten the solidification of molten seal material  14  therein to form seal  22 . Centering member  160  includes retaining portion  164  which limits the downward movement of centering member  160  relative to die stem  152  and prevents it from separating from die stem  152 . Inner wall  165  of centering member  160  is disposed around die  157  which is recessed from the edge of inner wall  165  to form the die cavity for making embossed seal portion  16 . 
     Engagement spring  166  is coupled between spring seat  150  on guide tube  130  and centering member  160  and inner cone  161 . The compression of engagement spring  166  from its rest position shown in FIG. 8 allows centering member  160  to move upward relative to guide tube  130  and die stem  152 . The upward movement also provides tolerance in movement of centering member  160  to adapt assembly  50  to bottles  66  having slightly varying heights. As best illustrated in FIGS. 13 through 15, the compression of engagement spring  166  and upward movement of centering member  160  is the initial step in a process culminating in contact between die surface  159  and molten seal material  22 . 
     As centering member  160  is brought into contact with bottle neck  10 , die truck assembly  50  is generally aligned with the bottle neck (FIG.  13 ). Further compression of engagement spring  166  causes inner cone  161  to lower itself into the cavity above cork  12  in bottle neck  10  (FIG.  14 ). Lower edges  163  of inner cone  161  are angled outward so that as the inner cone is lowered into bottle neck  10 , the bottle neck becomes exactly centered below die truck assembly  50 . As illustrated in FIG. 15, after inner cone  161  has centered assembly  50 , die surface  159  is lowed from inside cylindrical inner cone  162  and brought into contact with molten seal material  22 . 
     Die stem spring  170  is coupled between spring seat  150  on guide tube  130  and blocking member  158  on die stem  152 . The compression of die stem spring  170  from its rest position as shown in FIG. 8 permits upward movement of die stem  152  relative to guide tube  130 . This upward movement allows die stem  152  to adapt to corks  12  of slightly varying depths from the openings of necks  10  of bottles  66  so as to exert a generally consistent pressure on molten seal material  14  to form finished seal  22  regardless of cork depth. 
     Note that actuator spring  148 , engagement spring  166 , and die stem spring  170  may be relaxed but are typically in slight compression in the rest position shown in FIGS. 6-8 to bias the components of die truck assembly  50  in specific positions relative to each other. 
     The triple telescoping action of die tuck assembly  50  is illustrated in FIGS. 9-11. Carrier plate  120  is attached to a pair of guide tracks  174  which are connected with drive chain  36  to travel around the path of the drive chain. In a preferred embodiment, apparatus  30  includes a pair of parallel drive chains  36  supporting the two sides of carrier plate  120  through the pair of guide tracks  174  and moving in unison to transport assemblies  50 . For the purposes of the following discussion, carrier plate  120  serves as a reference for vertical movements of the various components of assembly  50 . In FIG. 9 the offset portion of wheel track  68  along lower path portion  40  of drive chain  36  pushes actuator spring  148  against guide block  126 . The downward movement of these components forming the actuation portion of assembly  50  causes die stem  152  and centering member  160  to move downward with guide tube  130 . 
     When centering member  160  meets neck  10  of bottle  66 , it is pushed upward by neck  10  and toward carrier plate  120  to compress engagement spring  166 , which maintains the engagement between centering member  160  and bottle neck  10 , as shown in FIG.  10 . The upward movement of centering member  160  relative to die stem  152  causes inner cone  161  to protrude from inside centering member  160  and for die  157  to protrude from inside inner cone  161 . 
     In FIG. 11, die stem spring  170  is compressed when die stem  152  is pushed upward by cork  12  and molten seal material  14  in bottle neck  10 . The upward movement allows die stem  152  to adapt to corks  12  of slightly varying depths from the openings of necks  10 , so as to exert a generally consistent pressure to form finished seal  22  regardless of cork depth. 
     After die truck assembly  50  is disengaged from bottle  66 , the biasing forces of actuator spring  148 , engagement spring  166 , and die stem spring  170  return the components of assembly  50  to the rest position shown in FIGS. 6-8. In an alternative embodiment, actuator spring  148  is eliminated so that die truck assembly  50  provides a double telescoping action. Instead of pushing actuator wheel  138 , bracket  136 , and guide tube  130  downward to engage assembly  50  with neck  10  of bottle  66 , bottle  66  is moved upward to meet assembly  50 . In such a system, the third telescoping action of moving guide tube  130  downward to engage with the bottle neck is not needed. 
     Bottle Sealing Procedure 
     The bottle sealing process employing apparatus  30  of FIGS. 3-5 with die truck assembly  50  of FIGS. 6-11 is described as follows. Referring to FIGS. 3-5, drive motor  80  is turned on to drive chain  36  to move die truck assemblies  50 . Assemblies  50  are transported by drive chain  36  to lower path portion  40 . 
     Before assemblies  50  reach lower path portion  40 , bottles  66  are fed through timing screw  76  to bottle conveyor  64  which are synchronized in movement with assemblies  50  to align necks  10  of bottles  66  with assemblies  50 . The applicator  70  is activated to introduce an amount of the molten seal material into the cavity of each bottle  66  before it is transferred to bottle conveyor  64 . When bottle  66  is aligned with die truck assembly  50 , the offset portion of wheel track  68  on upper support frame  32  pushes the components of assembly  50  except carrier plate  120  and guide block  126  downward to engage the assembly with bottle neck  10 . At this time, the seal material in bottle neck  10  is sufficiently molten to be impressed but may be cooled using cooling nozzles  62  so that it will retain the impression created by the die surface image. 
     The triple telescoping action provided by actuator spring  148 , engagement spring  166 , and die stem spring  170  of assembly  50  maintains the engagement between centering member  160  and bottle neck  10  along lower path portion  40  of travel of the assembly. A generally consistent pressure is exerted by the die surface  159  of assembly  50  on molten seal material to form finished seal  22 , as illustrated in FIGS. 9-11. The molten seal material is sufficiently cooled so that the embossed surface  20  thereon is preserved upon separation of the die surface  159  from embossed surface  20 , and the heat of the molten seal material in the bottle cavity does not cause melting of embossed surface  20 . 
     During the engagement of die truck assemblies  50  with bottle necks  10 , the offset portion of wheel track  68  keeps the actuation portion of each assembly in the downward position, thereby maintaining continued contact of die  157  with embossed seal portion  16  during the formation of finished seal  22  in bottle neck  10 . This minimizes disturbance of the embossed image on the seal to avoid “blocking” of the die image on die  157  with seal residue by premature movement of the die surface  159  and the embossed surface on the seal. 
     At the end of lower path portion  40 , wheel track  68  exits the offset portion and allows springs  148 ,  166 , and  170  to raise the actuation portions of die truck assemblies  50  in a generally vertical direction to disengage them from bottles  66 , as shown in FIGS. 3 and 5. 
     The methods and apparatus of the present invention permit the sealing of corked bottles at ambient temperature. The formation of the embossed seal is initiated by injecting molten seal material into the cavity above the cork in the neck of the bottle. While contact is maintained between the die surface  159  and the top layer of the molten seal material, an image is created on the seal material. Moreover, it is possible to form a seal with a “squeeze-up” finish having a hand-made look by squeezing up the molten seal material around the edge. The amount of squeeze up can be controlled by varying the temperature and/or volume of molten seal material  14  applied in the cavity of the bottle neck. 
     While a preferred embodiment of the present invention has been disclosed by way of example, it is evident that modifications and adaptations of that embodiment will occur to those skilled in the art. It is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention, as set forth in the following claims.