Process and apparatus for applying wrapped packages to cups

A method and apparatus are disclosed for applying wrapped packages to each cup associated with a nested stack of cups. The stack of cups is continuously fed through a channel defined by a conveyor belt assembly and a pair of rotatable cylindrical rollers having helical continuous grooves formed therein along a fixed path without rotating the cups. The cups are partially denested by the rollers to expose a package receiving surface of each cup. A rotatable applicator assembly retrieves a wrapped packages from a holding bin and applies the package to then exposed package receiving surface of each cup. The packages are removably secured to the cups by an adhesive applied between the package and the package receiving surface of each cup prior to the application of the package to the cup. The wrapped package is urged into engagement with the package receiving surface of each cup by a package compression device. The cups are renested as the cups exit the channel such that the package is held in compressive communication the cup. The nested cups are then packaged and shipped to the desired location.

BACKGROUND OF THE INVENTION 
This invention relates to packaging equipment, and in particular to an 
apparatus and method for rapidly applying wrapped packages, such as 
wrapped trading cards, to the outside off frustoconical containers. 
In an attempt to generate increased sales, many retailers such as fast food 
restaurants, gas stations, movie theaters and other entertainment venues 
often host contests or provide free souvenirs to customers when they 
purchase products. Some contests include game pieces, literature, or 
instant winner scratch off cards which are affixed to food containers such 
as soft drink cups or buckets of popcorn. Souvenirs such as stickers or 
trading cards depicting athletes or movie characters are also distributed 
to customers in a similar manner. Since the game piece or souvenir may be 
damaged by an employee or packaging equipment during shipment or handling 
or by the customer when it is removed from the container, it is often 
preferable to place the souvenir or game piece within a wrapped package 
prior to affixing it to the container. 
Application of wrapped packages to the containers at packaging facilities 
previously has been slow and costly. A problem exists in establishing an 
apparatus or method for use at a packaging facility that allows for such 
wrapped packages to be quickly, expeditiously and securely attached to the 
containers on an automated basis. Therefore, it is desirable to develop an 
automated apparatus and method that allows for rapidly applying wrapped 
packages to any frustoconical container. It is further desirable to 
develop an automated system that requires no special handling of the 
containers at the packaging facility. Since such frustoconical containers 
are typically nested together for shipment to reduce the shipping volume, 
it is desirous for the apparatus to receive the nested containers prior to 
their packaging for shipment, partially denest the containers, apply the 
wrapped packages to the containers, and then renest the containers for 
shipment. 
SUMMARY OF THE INVENTION 
Accordingly, one object of the present invention is to provide a new and 
improved apparatus and method for rapidly applying wrapped packages to a 
frustoconical container. 
Another object of this invention is to provide an apparatus and method for 
rapidly applying wrapped packages to frustoconical containers having means 
for automatically feeding and advancing into the apparatus a stack of 
nested containers so that the apparatus partially denests the containers, 
applies the wrapped packages to the containers, and then renests the 
containers for shipment. 
Another object of this invention is to provide an apparatus and method for 
rapidly applying wrapped packages to frustoconical containers that is 
adapted to accomplish secure application of wrapped packages to the 
containers by applying an adhesive to either a package receiving surface 
of the container or to the container receiving surface of the package. 
Still another object of this invention is to provide an apparatus for 
rapidly applying wrapped packages to frustoconical containers having means 
to compressively communicate and affix the wrapped package to the 
container during adhesive set. 
Another object of this invention is to provide an apparatus and method for 
rapidly applying wrapped packages to frustoconical containers that is 
highly reliable in operation, safe and easily maintained. 
Yet another object of this invention is to provide an apparatus and method 
for rapidly applying wrapped packages to frustoconical containers that 
does not require special operator skills or training for operation. 
Still another object of this invention is to provide an apparatus and 
method for applying wrapped packages to frustoconical containers which can 
be inserted into a conventional container printing line prior to final 
packaging of the nested containers. 
These and other objects and advantages will become apparent to those 
skilled in the art in light of the following disclosure and accompanying 
drawings. 
In accordance with the invention, generally stated, an apparatus for high 
speed application of a wrapped package to each of a plurality of 
frustoconical containers that are normally maintained in a fully nested 
position is disclosed that includes means for storing a supply of wrapped 
packages. The apparatus further includes rotatable applicator means. The 
rotatable applicator means includes a base mounted for rotation in a first 
direction and a plurality of individually rotatable members positioned on 
the base for rotation in an opposite direction. Suction means associated 
with each the member are aligned with the wrapped packages for detachably 
engaging a wrapped package and applying the wrapped package to an exterior 
side wall package receiving surface associated with the frustoconical 
container. 
The apparatus also includes a conveyor belt assembly for continuously 
feeding the containers in rapid succession past the suction means along a 
longitudinal feed path. Means is provided for partially denesting the 
containers prior to application of the wrapped package to the container. 
Means is further provided for renesting the containers after the wrapped 
package is removably secured to each container. The apparatus also 
includes means for applying an adhesive between the package and the 
package receiving surface of the container when each container is 
partially denested and prior to the application of the package to the 
container. Means is further provided for applying a compressive force to 
the wrapped package after the package is attached to the container as the 
adhesive sets. 
Another aspect of the present invention is of an apparatus for high speed 
application of a wrapped package to an exterior package receiving side 
wall associated with a frustoconical container by feeding a plurality of 
nested containers therethrough. The apparatus includes a holding bin for 
holding and downwardly supplying successively from a pile of wrapped 
packages the bottom package of the pile. A substantially flat disk is 
mounted for rotation in a first direction. A plurality of arms 
individually rotatable in an opposite direction extend outwardly from a 
first side of the disk parallel to the axis of rotation of the rotating 
disk. The rotation of each arm is synchronized with respect to the other 
arms and with respect to the rotation of the disk. Suction means extend 
radially outwardly from the outermost end of each rotatable arm. The 
suction means are provided for detachably engaging the bottom wrapped 
package from the holding bin, and applying the wrapped package to the 
package receiving surface associated with the frustoconical container. 
A conveyor belt assembly is provided for continuously feeding the 
containers in rapid succession past the suction means along a feed path. 
The rate at which the containers are fed along the feed path is 
synchronized with respect to the rotational speeds of the disk and the 
arms so that a wrapped package is applied by the suction means to each 
container as the container passes through the apparatus. A pair of 
threaded cylindrical rollers are disposed along the feed path so as to 
define a channel therebetween for receiving and confining the containers 
as the containers are fed through the channel. The rollers have uniform 
helical grooves formed therein for engaging each container as the 
containers pass through the channel, and partially denesting the 
containers prior to application of the wrapped package to the container, 
and renesting the containers after the wrapped package is removably 
secured to each container. The apparatus also includes means for applying 
an adhesive between the package and the package receiving surface of each 
wrapped package after the package is detachably engaged by the suction 
means and before the wrapped package is applied to the package receiving 
surface of the container. Means is provided for preventing lateral 
movement of the container when the wrapped package is applied to the 
package receiving surface of the container. Means is further provided for 
applying a compressive force to the wrapped package after the package is 
attached to the container as the adhesive sets. 
Yet another aspect of the present invention is that of a method for 
applying wrapped packages to each cup associated with a nested stack of 
cup, comprising the steps of: 
feeding the stack of cups through a channel so that an exterior side wall 
package receiving surface of each cup is maintained in a relatively 
upright position as the cup passes through the channel; 
partially denesting the cups to expose the package receiving surface of 
each cup; 
retrieving a wrapped package from a pile of wrapped packages; 
applying adhesive between the wrapped package and the package receiving 
surface of the cup; 
transferring the wrapped package into alignment with the package receiving 
surface of the cup; 
removably securing the wrapped package to the package receiving surface of 
the cup; 
applying compressive force to the wrapped package after the wrapped package 
is applied to the cup; and 
renesting the cups. 
Still another aspect of the present invention is that of a method for 
applying wrapped packages to each cup associated with a nested stack of 
cups, comprising the steps of: 
continuously feeding the stack of cups along a fixed path without rotating 
the cups; 
partially denesting the cups to expose a portion of the outer surface of 
each cup; 
applying adhesive and a wrapped package to the exposed outer surface of 
each cup; 
urging the wrapped package into engagement with the cup surface; and 
renesting the cups. 
Other objects and features will be apparent and in part pointed out 
hereinafter.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
FIGS. 1-4 show an apparatus which is used in this invention. FIG. 5 is a 
schematic block flow diagram which shows the steps of the method used to 
apply wrapped articles successively to frustoconical containers prior to 
them being placed into packages for shipment. 
Referring first to FIG. 5, the general method involves the steps of 
starting with a stack of nested printed plastic frustoconical cups; 
separating the cups by partially denesting by passing the stack through 
denesting rollers to expose an outer side wall on each cup; applying a 
spot of adhesive to the exposed side wall or alternatively to a wrapped 
article to be adhered to the container side wall; removing a wrapped 
article from a stack of such articles; placing the article on the glue 
spot on the container, or if the glue is placed on the article, placing 
the glue spot on the article on the container; renesting the containers to 
hold the article firmly in place on the cup while the glue dries; and 
packing the renested containers for shipment. 
Referring now to FIG. 1, there is shown the apparatus, indicated generally 
at 10, for rapidly applying a wrapped package 12 to each of a plurality of 
frustoconical containers 14 such as cups. The contents of the wrapped 
package 12 can include, for example, trading cards, stickers, game pieces, 
literature or the like that are disposed within a disposable wrapping, 
such as plastic or cellophane, where the wrapping is discarded when the 
package 12 is opened. The wrapping can be transparent or opaque, and 
provides protection for the contents during shipping and handling of the 
container 14. 
The basic structure of the cups 14 is well know, and includes a base 16, a 
frustoconical side wall 18 extending upwardly from the base 16, and a 
radially extending rim 20 integrally formed with the upper circumference 
of the side wall 18 so as to define an opening 22 into which a beverage 
may be poured. Each side wall 18 has an external side wall package 
receiving surface 24 onto which one of the wrapped packages 12 is 
removably secured by the apparatus 10. Any type of wrapped package 12 can 
be used in conjunction with the present invention provided that it is 
substantially flat and sufficiently pliable so as to generally conform to 
the shape of the cup side wall 18 when the cups 14 are renested position 
after the packages 12 are secured to the cups 14. While this invention is 
discussed in terms of its application with respect to cups 14, it will be 
appreciated that any similarly constructed frustoconical container 14, 
such as a can or shell, can be used in conjunction with the method and 
apparatus 10 of my present invention. 
As will be explained in detail hereinafter and shown in FIGS. 2 and 3, the 
apparatus 10 includes several individual stations at which steps of the 
process are performed. These include an input conveyor I which moves a 
stack of nested cups 14 from a prior step in the processing, such as a 
printing step, if the apparatus 10 is installed in an existing processing 
line, or it may be the initial station if the apparatus 10 is free 
standing and operating on cups previously processed elsewhere. A second 
station includes a denesting conveyor device II which partially separates 
the nested cups 14 to expose a package receiving surface 24 on each said 
cup 14. A third station III is a glue applicator station, and is where a 
spot of adhesive is applied to each cup package receiving surface 24. 
A fourth station is an article applicator station IV where a wrapped 
article 12 is removed from a supply of such articles and moved into 
engagement with the glue spot on the cup surface 24. A final station V is 
a cup renesting station where the cups 14 with the articles 12 attached 
are renested into a nested stack, and the articles are held in position on 
the cup surface 24 until the adhesive has dried. 
The article applicator station IV includes a high speed rotatable 
applicator assembly 26 having a substantially flat, rectangular, rotatable 
base disk 28 with a plurality of individually rotatable arms 30 positioned 
at the four corners of the base 28 and extending outwardly from a first 
side 32 of the disk 28 in a perpendicular fashion with respect to the base 
disk 28 as shown in FIGS. 1 and 2. In the preferred embodiment, four arms 
extend outwardly from the rotatable disk. The axis of rotation of each arm 
30 is parallel to the axis of rotation of the disk 28. When the apparatus 
is activated, the disk 28 rotates in a first or clockwise direction, while 
the arms 30 rotate in a relatively opposite or counterclockwise direction 
as shown in FIG. 3. As will be discussed below, the relative speeds of 
rotation for the disk 28 and the arms 30 are variable and synchronized. 
Furthermore, the rotation of each arm 30 is also synchronized with respect 
to the other rotating arms. 
A bracket in the form of a rectangular block 34 is securely mounted in 
close proximity to the distal end of each arm 30 in a perpendicular 
fashion as shown in FIGS. 1-4. The bracket 34 is fixed on the arm 30 and 
rotates therewith. Each block 34 has a suction device or applicator 36 
that extends radially outwardly from one end of the block 34 with respect 
to the axis of rotation of the arm 30. The suction device 36 is aligned 
with a holder 38 which retains a stack or wrapped articles 12. The suction 
dispenser is designed for detachably engaging the wrapped packages 12 
stored in the holding bin 38, and transferring the wrapped packages 12 
into alignment with the package receiving surface 24 of the cups 14. As 
shown in FIGS. 1-3, the holding bin 38 holds and downwardly supplies 
successively from a stack of wrapped packages the bottom package 12 of the 
pile. The holding bin 38 is positioned so that the bottom package of the 
pile is detachably engaged by the suction device 36 as each suction device 
36 passes the holding bin 38 upon rotation of the rotatable conveyor and 
applicator assembly 26. When the wrapped package 12 is properly aligned 
with the package receiving surface 24 of the cup 14 (FIG. 4), the package 
12 is released from the suction device 36 and removably secured to the 
container 14 by adhesive previously applied to the container 14. 
The apparatus 10 also includes a conveyor belt assembly 40 that supports a 
bottom surface of each cup 14, and continuously feeds the cups 14 in rapid 
succession past the rotatable applicator assembly 26. The rate at which 
the cups 14 are fed past the rotating assembly 26 is controlled and 
synchronized with respect to the rotational speed of the rotating assembly 
26. 
A pair of threaded rollers 44 are disposed along the longitudinal sides of 
the conveyor belt assembly 40 so as to define a channel 46 therebetween 
for receiving and confining the cups 14 as the cups are fed through the 
channel 46 in a uniform manner (see FIG. 2). The rollers 44 are mounted 
for synchronized rotation about individual parallel axes of rotation. The 
axes of rotation for the rollers 44 are preferably spaced equidistant from 
a central axis defining the channel 46. The position of the rollers 44 
with respect to the central axis of the channel 46 can be adjusted to 
accommodate containers 14 having various diameters. 
The rollers 44 employed in the present invention are commercially 
available, and designed such that each roller 44 includes a helical groove 
56 formed therein for engaging the rim 20 of the cup 14. The cups 14 enter 
and exit the channel 46 in a fully nested position. The spacing between 
the consecutive windings of the helical groove 56 gradually increases in 
an identical fashion from a minimum separation distance (region A) to a 
maximum separation distance (region B) in the midsection of the rollers 44 
and then gradually decreases back to the minimum separation distance 
(region C). 
As the cups 14 pass through the channel 46, the cups 14 are maintained in a 
fully nested position in Station II as they pass along the windings 
separated by the minimum separation distance (region A), and then 
gradually partially denested in Stations III and IV so as to fully expose 
a package receiving surface 24 of each cup 14 as the cup 14 passes along 
the windings separated by the maximum separation distance (region B). The 
wrapped package 12 is applied to the cup 14 by the suction device 36 
associated with the rotatable conveyor assembly 26 when the package 
receiving surface 24 of the cup 14 is fully exposed. 
As shown in FIGS. 1 and 2, a pair of separators 48a and 48b are provided in 
region B to prevent lateral movement of the cups when a wrapped package is 
applied to each cup. Each separator 48a, 48b includes a relatively 
horizontal surface extending from a support frame 70 (discussed below) 
over the rollers 44 and a vertical surface extending downwardly from the 
horizontal surface partially between the rollers 44 and the cups in region 
B to prevent lateral movement of the cups. The separator 48a positioned 
opposite the rotatable applicator assembly 26 has a opening or indentation 
50 formed therein to allow for passage of the rotatable arms 30 
therethrough. 
After the wrapped package 12 is secured to the package receiving surface 
24, the cups 14 are then gradually renested in Station V so as to be 
maintained in a fully nested position as the cups 14 exit the channel 46 
(region C). The package receiving surface 24 of each cup 14 is maintained 
in a relatively upright position at all times as the cup 14 passes through 
the channel 46. In other words, the cups 14 do not rotate as they pass 
through the channel 46. 
At Station III an adhesive applicator 58 applies a suitable adhesive either 
to the package receiving surface 24 of the cups 14 as the cups are 
gradually partially denested and prior to the application of the wrapped 
package 12 thereto at Station IV (as shown in FIGS. 2 and 3), or to a cup 
receiving surface 60 of the wrapped package 12 after the package 12 is 
removed from the holding bin 38 by the suction device 36 and prior to the 
application of the package 12 to the cup 14 (not shown). In the preferred 
embodiment, the adhesive used is a latex adhesive. When the wrapped 
package 12 is later removed by the customer, the adhesive adheres to the 
packaging so that the adhesive does not mar the exterior surface of the 
cup 14 or the contents of the package 12. 
The rotation of the arms 30 and disk 28 are synchronized with respect to 
each other and with respect to the feed rate of the cups 14 through the 
channel 46 so that the wrapped package 12 is released by the suction 
device 36 and secured by the adhesive to each cup 14 as the cup 14 passes 
through region B when the package receiving surface 24 of the cup 14 is 
fully exposed. After the wrapped package 12 is applied to the cup 14, the 
cup 14 is passed under a package compression device 62 that compressively 
communicates and affixes the wrapped package 12 to the package receiving 
surface 24 of the cup 14 as the adhesive sets. In the preferred 
embodiment, the compression device 62 includes a pair of skate wheels 64 
extending downwardly from and pivotally mounted to a support structure 66 
as shown in FIGS. 1-3. The skate wheels 64 apply a compressive force to 
the package 12 and cup 14 after the package 12 is secured to the package 
receiving surface 24 as the package 12 and cup 14 pass through the channel 
46. In addition to the compressive force provided by the compression 
device 62, the package 12 is held in compressive communication with the 
cup 14 when the cups 14 are fully renested in region C as the cups 14 exit 
the channel 46. After the cups 14 exit the channel 46, the nested cups 14 
are then ready for packaging and shipment to the desired location. 
The apparatus 10 further includes a support structure(s), indicated 
generally at 70 in FIG. 1, used to support and properly position the 
holding bin 38, conveyor belt assembly 40, the rotatable applicator 
assembly 20, the threaded rollers 44, the adhesive applicator 58, and the 
package compression device 62. The support structure shown in FIG. 1 is 
set forth for illustrative purposes only, and can be modified or 
reconfigured so long as the above mentioned components of the apparatus 10 
remain properly aligned. 
The foregoing description is set forth only for illustrative purposes only 
and is not meant to be limiting. Numerous variations, within the scope of 
the appended claims will be apparent to those skilled in the art in light 
of the foregoing description and accompanying drawings.