Abstract:
A post processing fitment applicator for applying a fitment to a formed, filled and sealed carton is disclosed herein. The post processing fitment applicator may be utilized in conjunction with a linear form, fill and seal packaging machine such as a TETRA REX® packaging machine. The post processing fitment applicator includes a supply of fitments, a plurality of fitment carriers, a conveyor system and a hot melt dispenser. The plurality of fitment carriers are disposed on a continuous track that partially parallels the movement of a series of formed, filled and sealed cartons on the conveyor system. The plurality of fitment carriers is capable of applying a fitment to a formed, filled and sealed carton as it is moving along the conveyor system. Each of the plurality of fitment carriers may include a fitment holder and a fitment displacement mechanism.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a fitment or closure applicator. More specifically, the present invention relates to a post processing fitment applicator for formed, filled and sealed gable top cartons. 
     2. Description of the Related Art 
     Gable top cartons have long been the preferred package for milk and milk related products. Recently, gable top cartons have assumed a new role as the preferred package for juices, particularly orange juice. The consumers preference for gable top cartons is at least partially generated by the perception of freshness associated with the gable top carton. The opposing top panels meeting to form the gable top with a top fin creates an image of a fresh, healthy product contained within the carton. The only detraction from this image was the lack of a tight reseal of the carton after the initial opening of the carton by a consumer. The integrated closure formed from the side of the top of the carton allowed for good pourability, however, the resealing was adequate at best. 
     This minor detraction was alleviated with the introduction of plastic fitments applied to the gable top cartons. The fitments, which generally include a spout with a flange and a cap, allowed for a tight reseal of the carton after the initial opening. The use of fitments on cartons further enhanced the consumer&#39;s perception that gable top cartons contained fresh and healthy products. 
     In the rush to meet the consumer&#39;s demand, the packaging industry developed new packaging/filling machines that applied a fitment to cartons prior to sterilization or filling. The demand to have packaging machines with the smallest “footprint” (the area of the machine) in a dairy meant that most older machines did not have sufficient space within the machine to incorporate a fitment applicator. This rendered older machines without the ability to provide a carton with a fitment thereby reducing their value to the dairy or like facility. Thus a need to apply a fitment on a formed, filled and sealed carton grew throughout the packaging industry. 
     Another problem necessitating the need to apply a fitment on a formed, filled and sealed carton pertains to maintaining a sterile environment within a form, fill and seal packaging machine to produce an extended shelf life (“ESL”) product, a high acid ambient distribution (“HAAD”) product, or an aseptic product. The ESL product allows for a product to have double or triple the refrigerated shelf life of a non-ESL product. The HAAD product allows for a high acid (pH&lt;4.5) product such as orange juice to be stored unrefrigerated for an extended time period. The aseptic product allows for any product to be stored unrefrigerated for an extended time period. All of these products need to be produced in a sterile, contaminant-free environment. 
     Current in-line fitment applicators generate substantial amounts of possible contaminants such as dust, paper particles and fitment particles. Ultrasonic fitment applicators generate the greatest amount of contaminants due to the enormous sealing pressures utilized during application of the fitment to the carton. Other applicators such as hot melt fitment applicators may introduce undesirable chemicals, and also may provide inadequate seals. Although the use of induction heat sealing avoids some of the potential problems of in-line applicators, such induction heat sealing applicators necessitate the use of a carton with an aluminum barrier layer which increases the cost of the package. Further, the deliver of fitments from a supply of fitments introduces contaminants into the packaging machine environment. 
     Some post processing fitment applicators are currently available from the packaging industry. However, these applicators are little more than stand-alone reproductions of current in-line fitment applicators. Such applicators are not the denouement of post processing fitment applicators from the packaging industry. 
     BRIEF SUMMARY OF THE INVENTION 
     It is a primary object of the present invention to provide a post processing fitment applicator to apply a fitment to a formed, filled and sealed carton. 
     It is an additional object of the present invention to provide a post processing fitment applicator that is capable of properly orienting a fitment for placement on a carton. 
     It is an additional object of the present invention to provide a post processing fitment applicator that is capable of applying a fitment to a moving formed, filled and sealed carton. 
     One aspect of the present invention is a post processing fitment applicator for applying fitments to each of a series of formed, filled and sealed cartons. The applicator includes a conveyor, a continuous track, a plurality of fitment carriers, a chute and a hot melt dispenser. The conveyor transports the series of formed, filled and sealed cartons through the applicator. The continuous track is partially positioned in proximity to the conveyor. Each of the plurality of fitment carriers is moveable about the continuous track for placing a fitment on a formed, filled and sealed carton. The chute delivers fitments from a supply of fitments to each of the plurality of fitment carriers at a receiving point along the continuous track. The hot melt dispenser is disposed subsequent to the receiving point along the continuous track and coats each of the fitments on each of the plurality of fitment carriers with hot melt. 
     Each of the plurality of fitment carriers of the post processing fitment applicator may include a fitment holder for holding a fitment and a fitment displacement mechanism for placing the fitment on a formed, filled and sealed carton. The supply of fitments of the post processing fitment applicator may include a hopper connected to the chute, a holding bin, and an elevator disposed to transport fitments from the bin to the hopper. The conveyor system may transport a set number of cartons at predetermined intervals for application of fitments to the cartons. The post processing fitment applicator may also include a housing encompassing at least the continuous track and the hot melt dispenser. Each of the plurality of fitment carriers of the post processing fitment applicator may be moveable toward and away from the cartons being conveyed on the conveyor system. The fitment displacement mechanisms of the post processing fitment applicator may include an U-shaped frame with a projection thereon for engagement with a fitment. 
     Another aspect of the present invention is a method for applying a fitment to a formed, filled and sealed carton. The first step of the method includes placing a fitment in a fitment carrier being moved along a continuous track. The next step includes rendering the fitment in an adhesive state. The next step includes conveying the formed, filled and sealed carton along a conveyor system disposed in relation to a portion of the continuous track. The final step includes applying the fitment in the adhesive state to the carton as the carton is conveyed along the conveyor system. 
     The method may also include centering the formed, filled and sealed carton by a plurality of projections on the fitment carrier before applying the fitment. The rendering step of the method may include dispensing hot melt to the back of the fitment. The rendering step of the method may alternatively include heating the back of the fitment to a temperature greater than the melting temperature of the fitment. The fitment applying step of the method may include engaging the back of the fitment to a pre-scored area of the formed, filled and sealed carton while the fitment is within the fitment holder, and displacing the fitment from the fitment holder by actuation of the fitment displacement mechanism. The method may also include orienting the fitment prior to placement of the fitment on the fitment carrier. 
     Yet another aspect of the present invention is a post processing fitment applicator that includes means for transporting cartons, a plurality of fitment carriers, means for moving each of the fitment carriers, a chute and means for rendering the back of the fitment in an adhesive state. Each fitment carrier places a fitment on a formed, filled and sealed carton. The moving means moves each of the plurality of fitment carriers at a movement equal to that of the transporting means for the series of formed, filled and sealed cartons. The chute delivers fitments from a supply of fitments to each of the plurality of fitment carriers at a receiving point. The rendering means renders the back of the fitment in an adhesive state. 
     Each of the plurality of fitment carriers of this embodiment of the applicator may include a fitment holder for holding a fitment and a fitment displacement mechanism for placing the fitment on a formed, filled and sealed carton. The supply of fitments of this embodiment of the applicator may include a hopper connected to the chute, a holding bin, and an elevator disposed to transport fitments from the bin to the hopper. The rendering means of this embodiment of the applicator may include means for heating the back of the fitment with hot air to a melting temperature of the fitment. The applicator of this embodiment may include a housing. The applicator of this embodiment may also include means for moving each of the cartons toward and away from the cartons being transported by the transport means. The rendering means of the applicator of this embodiment may include means for inducing a current in the back of the fitment to heat the back of the fitment to a melting temperature of the fitment. 
     Having briefly described the present invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     There is illustrated in FIG. 1 a schematic perspective view of the post processing fitment applicator of the present invention. 
     There is illustrated in FIG. 2 a top perspective view of the post processing fitment applicator of the present invention. 
     There is illustrated in FIG. 3 an isolated view of a fitment carrier of the plurality of carriers of the post processing fitment applicator of the present invention. 
     There is illustrated in FIG. 4 an isolated view of the plurality of fitment carriers of the post processing fitment applicator of the present invention applying fitments to cartons. 
     There is illustrated in FIG. 5 a reverse view of the plurality of fitment carriers of FIG.  4 . 
     There is illustrated in FIG. 6 a top perspective view of a carton with a fitment thereon applied by the post processing fitment applicator of the present invention. 
     There is illustrated in FIG. 7 a top plan view of the carton of FIG.  6 . 
     There is illustrated in FIG. 8 a side view of the carton of FIG.  6 . 
     There is illustrated in FIG. 9 a plan view of one possible fitment utilized by the post processing fitment applicator of the present invention. 
     There is illustrated in FIG. 10 a modified view of the fitment of FIG.  9 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As shown in FIGS. 1 and 2, the post processing fitment applicator of the present invention is generally designated  20 . The post processing fitment applicator  20  may be directly downline from a linear form, fill and seal packaging machine, not shown, such as a TETRA REX® packaging machine available from Tetra Pak, Incorporated of Chicago, Ill. In such an arrangement, as soon as the finished cartons exit the packaging machine, the cartons are conveyed to the post processing fitment applicator  20 . Alternatively, the post processing fitment applicator  20  may be placed in a different section of a dairy or like facility in order to isolate the packaging machine or the post processing fitment applicator  20 . Yet, it is not inconceivable to locate the post processing fitment applicator  20  at a completely different site from the packaging machine, such as the final distribution site of the finished product. 
     The post processing fitment applicator  20  generally includes a housing  21 , a conveyor system  22 , a continuous track  24 , a supply of fitments  26 , a hot melt dispenser  28  and a plurality of fitment carriers  30 . The housing  21  encompasses the components of the post processing fitment applicator  20  that are involved in the fitment application operation in order to provide an enclosed controlled environment for the application of fitments  40  to cartons  50  conveyed along the conveyor system  22 . The housing  21  not only provides for climate control, it also lessens the amount of contaminants that could interfere with the application operation on the post processing fitment applicator  20 . The housing  21  also creates a safer operating environment for an user of the post processing fitment applicator  20 . On the housing  21  may be a control panel  23  for allowing an user of the post processing fitment applicator  20  to input the necessary parameters such as the conveyance speed, the hot melt temperature, the orientation of the fitment  40 , and the like. The operation of the post processing fitment applicator  20  may be controlled by a programmable logic circuit (“PLC”) that generates the necessary commands and provides safety warnings in order for the post processing fitment applicator  20  to operate in an efficient and safe manner. 
     The supply of fitments  26  is generally composed of a hopper for the fitments  42 , a delivery chute  44  which transports the fitments  40  from the hopper  42  to a receiving point  46 , and an elevator  48  connected a holding bin  49  and positioned to transport fitments  40  from the bin  49  to the hopper  42 . In operation, the fitments  40  are loaded into the bin  49  for transport to the hopper  42 . The hopper  42  places one fitment  40  at a time onto the chute  44  where upon the fitments  40  are transported to the receiving point for placement on a fitment carrier  30 . The chute  44  may have various orienting components to properly orient each fitment  40  before placement on a fitment carrier  30 . 
     The plurality of fitment carriers  30  are connected to the continuous track  24  for movement thereabout in predetermined intervals. The continuous track  24  with the plurality of carriers  30  thereon, is disposed to have a portion above part of the conveyor system  22  for application of fitments  40  to moving cartons  50  that are conveyed along the conveyor system  22 . Each of the fitment carriers  30  retrieves a fitment  40  from the receiving point  46  where upon the fitment carrier  30  with the fitment  40  thereon is transported on the continuous track  24  to the hot melt dispenser  28 . The hot melt dispenser  28  applies on predetermined quantity of hot melt to the back of each of the fitments  40 . Preferably, the hot melt may be applied to only a flange portion of the fitment  40 . The hot melt provides the adhesive necessary for the fitment  40  to be attached to the carton  50 . The hot melt may include a tank, a hose and a dispenser gun (all of which are not shown). The operating temperature may vary from 180 degrees Celsius to 200 degrees Celsius. Alternatively, the hot melt dispenser  28  may be replaced with another means for adhesion of a fitment  40  to a carton  50 . One possibility would be to substitute a fitment heater for the hot melt dispenser  28 . Such an alternative would heat the back of the fitment  40  through forced hot air or current induced heating in order to impart sufficient heat to the fitment  40  to commence melting of the thermoplastic fitment  40 . 
     From the hot melt dispenser  28 , each of the fitment carriers  30  is maneuvered for temporary engagement with a carton  50  in order to apply the fitment  40  to the carton  50  as the carton  50  is conveyed along the conveyor system  22 . 
     A fitment carrier  30  is illustrated in FIG.  3 . Each of the fitment carriers  30  are generally composed of a body  31 , a fitment holder  32 , a fitment displacement mechanism  34 , a pair of arms  36   a  and  36   b , and projections  38   a-d , not shown in FIG.  3 . The fitment holder  32  accepts a fitment  40  at the receiving point  46  through aperture  35 . The fitment holder  32  also holds the fitment on the carton  50  during the initial contact. The fitment displacement mechanism  34  pushes the fitment  40  from the fitment holder  32  onto the carton  50 . The fitment displacement mechanism  34  may be a U-shaped frame  37  with a prong  39  thereon. The projections  38   a-d  act to center the carton  50  for proper positioning of the fitment  40  thereon. 
     As shown in FIGS. 4 and 5, each of the plurality of fitment carriers  30  performs a seven step application operation for application of a fitment  40  to a carton  50 . The term seven step may be a misnomer since the application operation is continuous while each of the cartons  50  is conveyed along the conveyor system  22  at a predetermined rate to match the movement of the fitment carriers  30 . Using the seven cartons  50   a-g  and the seven fitment carriers  30   a-g  shown in FIGS. 3 and 4 to demonstrate the seven step application operation, the operation begins with a fitment carrier  30   a  aligning itself with a carton  50   a . The proper alignment is very important to ensure that the fitment is placed over the pre-scored area of the carton  50 . The pre-scored area is a partially incised area which defines the aperture for access to the product contained within the carton  50 . This weakened area allows for a fitment with a plunger, cutting edge or some other means for rupturing the pre-scored area to create the aperture in the carton  50  upon the initial access by the consumer. The area of the carton  50  may also be an aperture with a membrane. 
     The fitment carrier  30   b  and carton  50   b  demonstrate the next step where the fitment carrier  30   b  begins its descent toward to gable top of the carton  50   b . The fitment  40  on the carrier  30   b  has yet to contact the carton  50   b . At the next step illustrated by the fitment carrier  30   c  and the carton  50   c , the fitment carrier  30   c  centers the carton  50   c  for placement of the fitment  40  thereon. During this step, the fitment displacement mechanism  34  contacts the fitment  40  being held in the fitment holder  32  for displacement thereof. 
     At the next step, illustrated by the fitment carrier  30   d  and the carton  50   d , the fitment  40  contacts the carton  50   d . As the fitment  40  contacts the carton  50   d , the hot melt begins to adhere to the carton  50   d  in order to create a tight bond between the fitment  40  and the carton  50   d . The fitment displacement mechanism  34  applies a force on the fitment  40  to ensure a tight bond between the fitment  40  and the carton  50   d . The fitment  40  is still within the fitment holder  32  during this step. 
     At the next step, illustrated by the fitment carrier  30   e  and the carton  50   e , the fitment holder  32  retracts while the fitment displacement mechanism  34  holds the fitment  40  on the carton  50   e . The fitment  40  should be held for a set amount of time to allow for adhesion to occur between the fitment  40  and the carton  50   e . At the next step, illustrated by the fitment carrier  30   f  and the carton  50   f , the fitment displacement mechanism  34  retracts allowing the fitment  40  to adhere to the carton  50   f . The final step, illustrated by the fitment carrier  30   g  and the carton  50   g , has the fitment carrier  30   g  returning to its commencement state. 
     The movement of the fitment carriers  30  in relation to the cartons  50  may be actuated by a camming mechanism or servomotors. The movement of the continuous track  24  with the plurality of carriers  30  thereon may be accomplished by rotating drums driven by a servomotor or central shaft. 
     As shown in FIGS. 6-8, a carton has a gable top  52  with a top fin  54  and a fitment  40  thereon. The fitment  40  should be applied a certain distance from the side panel  56  in order to ensure good pourability. The carton  50  may a pre-scored area, not shown, or have a pre-punched aperture covered with a membrane. The membrane should be composed of a material that may be easily ruptured by the fitment  40 . As shown in FIGS. 9 and 10, the fitments  40  may have a tamper evidence means. 
     From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims.