Abstract:
A post processing cap applicator for applying a cap to a closure spout after erection, spout attachment, filling and sealing of a carton accommodates custom caps. Cartons are conveyed through the applicator in a first forward direction. A cap supply is configured to dispense caps and to position an edge of a cap in a path defined by movement of the closure spout through the applicator. The closure spout engages the edge of the cap. The applicator includes a rotating, torque-applying element and a drive operably connected to the torque-applying element. The drive is operable in a first direction to tighten the cap onto the spout to a predetermined torque and, once the predetermined torque is reached, to stop tightening the cap. A method for post processing cap application is also disclosed.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to closure cap application subsequent to forming, filling and sealing a package. More particularly, the invention relates to a method for applying a cap to a closure after processing of a package on which the closure is affixed. 
     Gable top cartons have become widely used and accepted. One form of the gable top carton includes a carton having a plastic or like spout affixed to the carton for dispensing product. For example, one widely recognized use is for packaged juices. In such an arrangement, a plastic spout is affixed to the carton. A cap is threaded on to the spout for resealing the carton after initial use. 
     In one typical arrangement, the spout includes a membrane that extends across the inner portion thereof. The membrane provides a seal both for hygienic purposes, as well as tamper evidence. In a typical form, fill and seal operation, carton blanks are fed along a conveyance path on which the cartons are erected (i.e., formed and sealed), sterilized, filled and sealed. After erection, and prior to filling, a closure is affixed to the carton at one of the slanted gable panels. 
     In known form, fill and seal operations, the spout or closure and its cap are affixed to the carton as a unitary assembly. That is, the spout having the cap threaded thereon is inserted into an interior portion of the carton and is moved into contact so that a flange of the closure rests against an inner surface of the carton. To do this, the spout and cap are inserted through an opening in the gable panel wall of the carton. An ultrasonic welding horn is brought into contact with the carton to weld the closure flange to the carton interior. Subsequently, the carton is sterilized, filled and top sealed. An exemplary arrangement for mounting or affixing the fitments is disclosed in Sweeney, U.S. Pat. No. 6,145,275, which patent is incorporated herein by reference. 
     It has been found that in certain instances, it is desirable to use non-standard closure caps on the containers. For example, it may be that certain caps are easier for an individual having limited mobility of their fingers to remove from the package. It may also be that certain packagers or bottlers wish to have other than a “standard” threaded cap on a particular package. These include over-sized or not fully round caps. Other functional, as well as aesthetic reasons may be present for “custom” capping. 
     Known spout or fitment applicators simply cannot accommodate custom capping. A variety of arrangements are known for supporting and moving fitments (generally referring to the spout and cap “package”) into engagement with the container. However, these known arrangements require that the spout or fitment, have the cap attached thereto, prior to insertion through the opening in the side wall or gable panel of the carton. These arrangements may not, because of their limitations, provide this “custom” capping ability. More specifically, many such “custom” caps will not fit through standard pre-punched carton panel openings. 
     Accordingly, there exists a need for an arrangement by which custom caps can be applied to containers. Such custom caps may be oversized and thus, cannot be inserted through an opening in the gable panel of the carton. Desirably, such a custom capping arrangement permits the use of these oversized closures as well as non-symmetrical or creatively designed cap configurations. Most desirably, the custom caps can be applied to cartons processed or packaged on conventional form, fill and seal packaging machines using conventional or standard pre-punched carton blanks. 
     BRIEF SUMMARY OF THE INVENTION 
     A post processing cap applicator applies a cap to a closure spout after erection, spout attachment, filling and sealing of a carton. The applicator permits the use of custom caps on standard and non-standard cartons having standard and non-standard, attached spouts. 
     The applicator includes a cap supply, means for maintaining engagement of the cap with the spout, means for rotating the cap to a predetermined torque, means for determining when the predetermined torque is achieved and means for halting rotation of the cap upon sensing the predetermined torque. 
     The applicator can include chute means for conveying caps to the cartons. The means for maintaining engagement of the cap with the spout can be biased and the means for rotating the cap can be reversible. 
     In one embodiment, the applicator includes a conveyor for moving the cartons through the applicator. The conveyor moves in a first forward direction. The cap supply is configured to dispense caps and to position an edge of a cap in a path defined by movement of the closure spout through the applicator. The closure spout engages the edge of the cap. 
     The torque-applying element is a rotating member such as a rotating belt. In one embodiment, the belt is a reversible member. A drive is operably connected to the torque-applying element and is operable in a first direction to tighten the cap onto the spout to a predetermined torque. Once the predetermined torque is reached, the element stops tightening the cap. 
     The drive can be configured to reverse direction of the torque-applying element upon sensing that the predetermined torque has been reached. In one embodiment, the conveyor is configured to move the cartons through the applicator at a predetermined rate. Upon reversing direction of the torque-applying element, the drive operates to match a rotational speed of the torque-applying element to a predetermined rate of the cartons moving through the conveyor. A preferred drive is a servomotor. 
     In an alternate embodiment, the belt rotates in one direction. During a cap tightening phase, the belt moves at a first speed that is less than the speed of the conveyor. Upon reaching a predetermined torque, the belt speed increases to match the line speed (i.e., corresponding to the rate at which the cartons move through the conveyor). 
     The cap supply can include a chute for delivering caps to respective cartons. The chute is disposed to position the cap edge in the closure spout path. A retention assembly is disposed at about an end of the chute to retain the cap at the end of the chute for engagement by the spout. The retention assembly can include a biased retention element. 
     The applicator can include a pressure plate cooperating with the torque-applying element to urge the cap onto the spout. Preferably, the torque-applying element is a reversibly rotating belt. 
     The applicator can further include a lateral movement inhibiting member disposed on a side of the cap opposite the torque-applying element. The inhibiting member can be formed as a surface positioned on an opposite side of the cap that is contacted by the torque-applying element. The surface can be smooth. Alternately, the surface can be frictional or can be formed to accommodate odd-shaped caps. The lateral movement inhibiting surface can be formed coextensive with the pressure plate. 
     The conveyor can include first and second rotating conveying belts for engaging first and second sides of the carton, respectively. Preferably, the torque-applying element is a reversibly rotating capping belt disposed on the first side of the carton above the first conveying belt. 
     The capping belt is configured to rotate in a direction opposite of the first conveying belt when tightening the cap onto the spout and configured to reverse direction upon reaching the predetermined torque. When in the reverse direction, the capping belt speed is matched to the conveyor speed so as to not loosen the cap. 
     A method for applying a cap to a carton in a post-processing closure cap applicator in which the carton is erected, has a spout attached thereto, is filled and sealed, includes the steps of conveying the carton through the cap applicator at a predetermined speed, engaging a cap with the spout, rotating the cap to a predetermined torque, sensing when the predetermined torque is reached and ceasing rotation of the cap. 
     The step of rotating the cap can include the step of contacting the cap with a torque-applying element and can include the step of rotating the torque-applying element to apply a torque to the cap 
     The method can also include the step ceasing torque-applying rotation of the torque-applying element upon reaching the predetermined torque and reversing the torque-applying element upon reaching the predetermined torque. 
     A preferred method includes the step of conveying the cap to the spout and maintaining a pressure on the cap as it is engaged with the spout. 
     These and other features and advantages of the present invention will be apparent from the following detailed description, in conjunction with the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein: 
     FIG. 1 is a perspective illustration of an embodiment of a post processing cap applicator in accordance with the principles of the present invention; 
     FIG. 2 is another perspective illustration shown with portions of the applicator in cross-section for ease of viewing; 
     FIG. 3 is a partial cross-sectional schematic illustration showing two cartons as they are conveyed through the applicator, a first carton being at the cap chute exit and a second carton being at the torque-applying station; 
     FIG. 4 is an enlarged view of the cap chute exit showing the carton spout “pulling” the cap from the chute; 
     FIG. 5 is a perspective illustration showing the torque-applying assembly in contact with a cap; 
     FIG. 6 is an enlarged view of the circled portion of FIG. 5; 
     FIGS. 7A and 7B are schematic illustrations of one embodiment of the applicator showing the torque-applying element in the torquing mode in FIG.  7 A and in the conveying mode in FIG. 7B; and 
     FIGS. 8A and 8B are schematic illustrations of an alternate embodiment of the applicator showing the torque-applying element in the torquing mode in FIG.  8 A and in the conveying mode in FIG.  8 B. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiment illustrated. It should be further understood that the title of this section of this specification, namely, “Detailed Description Of The Invention”, relates to a requirement of the United States Patent Office, and does not imply, nor should be inferred to limit the subject matter disclosed herein. 
     Referring now to the figures and in particular to FIG. 1, there is shown an arrangement for post processing closure cap application. The post processing closure cap applicator  10  is configured for use in conjunction with a form, fill and seal packaging machine such as that disclosed in Giacomelli et al., U.S. Pat. No. 5,819,504, commonly assigned herewith and incorporated herein by reference. 
     In a conventional, form and seal packaging machine, subsequent to forming and sealing the bottom of the carton, the carton advances to a station at which a spout is affixed to the carton. An applicator such as that disclosed and described in the aforementioned U.S. Pat. No. 6,145,275 to Sweeney can be used. At such a station, a spout is carried by an anvil or a mandrel into an interior portion of the carton. The anvil is advanced so that the spout flange is moved into engagement with an interior surface of the carton. 
     An ultrasonic welding horn is brought into contact with the carton exterior surface and the flange is sealed to the carton interior surface by application of ultrasonic energy. Other arrangements for moving the closures into the carton and sealing or welding the closures to the carton will be recognized by those skilled in the art. 
     As will also be recognized by those skilled in the art, the spout or fitment has a cap fitted thereon. Typically, caps are threaded onto the spouts. To this end, the cap (which is the widest portion of the fitment other than the spout flange) must be sized, relative to the opening in the carton, so that the cap readily fits through the panel opening and within the ultrasonic sealing horn. As such, the closure caps must be of a relatively standard size and configuration or shape. 
     It has been found that it is often desirable to use different sizes and configurations of caps. That is, it has been found that it is desirable to use caps other than the standard closure cap. Many of these custom caps are larger than typical caps. They can also be out-of-round or have scalloped or otherwise non-circular shapes. In addition, many such caps have a diameter that is larger than the conventional opening in the carton gable panel through which the spout is positioned for sealing. 
     As will be recognized by those skilled in the art, the opening size is dictated by certain limitations. For example, there must be sufficient area for the closure flange to be sealed or welded to the carton panel. As such, the size of the opening is limiting vis-à-vis the size of conventional closure packages (and consequently closure caps). 
     In an arrangement in accordance with the present invention, the spout portion of the closure is affixed to the carton in accordance with the operation of a conventional form, fill and seal packaging machine. The spout can be mounted on a mandrel or anvil and inserted into the interior portion of the carton. An ultrasonic welding horn engages the carton, over the spout, and the flange portion of the spout is sealed to the carton interior surface. Subsequently, the carton is sterilized and filled. Subsequent to filling, the top panels of the carton are folded and sealed to one another to form the sealed package. Alternately, of course, the spout can be post-applied to the carton with the flange, for example, adhered to an outside surface of the carton gable panel. 
     After the package is sealed (e.g., top fin F sealed), it can undergo a subsequent sterilization in accordance with known methods. A cap is then affixed to the spout in a post-processing application. 
     Referring now to FIGS. 1 and 2, generally, there is shown at  10  one embodiment of an apparatus for post-processing cap C application. The apparatus  10  can be installed at about the end of the conventional, form, fill and seal packaging machine. Alternately, the apparatus  10  can be a separate, stand-alone unit for post application of caps C. 
     In the illustrated embodiment, the apparatus  10  includes a conveyor  12  for moving the packages, containers or cartons P through the applicator section. The illustrated conveyor  12  includes a pair of moving belts  14 ,  16  that grip the container P on opposing sides W 1 , W 1  and move the container P through the applicator  10 . As shown, the belts  14 ,  16  grip the container P on a side W 1  on which the cap C is to be applied, and an opposing side W 2 . 
     As will be recognized by those skilled in the art, the conveyor  12  is configured to move at one or more predetermined speeds so as to move the cartons P therethrough at an indexed, predetermined rate. 
     Referring to FIGS. 3-4, the applicator  10  further includes a cap supply, indicated generally at  18 . In the illustrated embodiment, the supply  18  includes a chute portion  20  through which the caps C traverse. As best seen in FIG. 4, the chute  20  is positioned so that an edge C e  of the cap C drops below an edge  22  of the chute  20 . Thus, as a carton P passes beneath the chute  20 , an edge S e  of the closure spout S “catches” the edge C e  of the cap C. In this manner, the cap C is pulled from the chute  20  by the carton P conveyed along the conveyor  12 . 
     In a present embodiment, a minimum retention pressure is applied to each cap C at the chute exit  30 . Presently, this means for maintaining engagement of the cap C with the spout S (e.g., this pressure) is applied by a retention assembly  24 . The retention assembly  24  includes a biased element  26  that exerts a downward pressure onto the cap C at the chute exit  30 . In the illustrated embodiment, the element  26  is a ball or like element positioned in an opening  28  for reciprocating movement. The ball  26  is biased by a spring  32 . In this manner, as a cap C is positioned at the chute exit  30 , the biased element  26  prevents the cap C from “jumping” up as it is engaged by the edge S e  of the passing spout S. This slight downward pressure on to the cap C assures that the spout S positively engages and “pulls” the cap C as the carton P moves passed the chute exit  30 . Essentially, the ball  26  stops the cap C at the correct position at the chute exit  30  and holds back subsequent or upstream cap C, thus singulating the caps C. 
     As seen in FIGS.  2  and  5 - 7 B, the carton P, having the cap C applied thereto, then moves into a torque-applying (torquing) station, indicated generally at  34 . At the torquing station  34 , the cap C is engaged on one side C s2  to limit or prevent lateral movement (i.e., movement transverse to the direction of conveyance, as indicated generally at  36 ), and on another side C s1  by a torque-applying (torquing) element  38 . In the illustrated embodiment, a surface  40  is provided opposite the torquing element  38  to prevent lateral movement. 
     In addition, the torquing station  34  includes an upper pressure plate  42 , as seen in FIGS. 3 and 6, that is configured to engage the top T of the cap C applied on the carton P. In this manner, as the cap C is torqued (e.g., rotated) onto the spout S (as will be described below) the cap C is maintained in contact with the spout S, and thus the cap C threads are maintained engaged with the spout S threads. 
     In a present embodiment, the torquing element  38  is configured as a rotating belt. The belt  38  is positioned so as to engage a side C s1  of the cap C opposite of the gable carton fin F. Because the cap C is rotated clockwise to tighten, the belt  38  rotates in a counter-clockwise direction (see FIG.  7 A). Thus, the belt  38  rotates in a direction opposite of its corresponding conveying belt  12 . Nevertheless, because the carton P is moving, the capping belt  38  effects a tightening of the cap C. As will be appreciated, the lateral movement preventing surface  40  is positioned between the cap C and the carton fin F. 
     The capping belt  38  is driven by a motor  44 . In a present embodiment, the motor  44  is configured to sense the torque change on the belt  38  (as a change in voltage). Those skilled in the art will appreciate that as the cap C “tightens” onto the spout S, the force (as a rotational force or torque) required to continue tightening will increase. This increased torque is “sensed” by the motor as an increase in the voltage or current required to continue operation (i.e., turning ) of the motor  44 . Thus, the motor  44  can be used to sense or monitor the torque on the cap C as an adjunct of the power requirement of the motor  44  or an adjunct of the torque required to continue tightening the cap C. 
     Once a desired torque on the cap C is achieved, the motor  44  changes direction and speed to match the line or carton P conveyance speed (the speed of the conveyor  12 ). That is, the capping belt  38  reverses direction, matches the “line speed” to assist in moving the carton P out of the conveyor  12  and, assures that the cap C remains tightened on the spout S. 
     As shown schematically in FIGS. 7A and 7B, the capping belt  38  tightens the cap C on to the spout S (by moving in a counter-clockwise direction to rotate the cap C in a clockwise direction, as seen in FIG.  7 A), and once a desired torque on the cap C is achieved, the capping belt  38  reverses direction and matches line speed to maintain the tightness on the cap C (as illustrated in FIG.  7 B). In this manner, the cap C is maintained at a desired torque on the spout S without loosening or tightening, subsequent to the capping operation. 
     Referring now to FIGS. 8A and 8B, there is shown an alternate embodiment, or operating scheme in which the belt  138  rotates in the same direction as the conveying belt  112 . However, during the capping phase or period, the belt  138  moves at a lesser rotational speed than the conveying belt, thus effecting tightening of the cap C. Upon reaching the predetermined torque, the speed of the capping belt  138  increase to match the line speed (e.g., a speed corresponding to the conveying belt  112  speed), to maintain tightness of the caps. The relative speeds of the capping and conveying belts are illustrated by the arrows at  150  and  152 , respectively. 
     It is anticipated that various alternative structural elements and materials may be used in the present applicator. For example, the lateral movement limiting surface  40  (that surface opposite of the torquing element  38 ) can be a stationary surface having a smooth finish to permit rotation of the caps. Alternately, the lateral movement limiting surface  40  can be a frictional surface or it can include formations such as crenellations (e.g., teeth) to, for example, accommodate a cap having a toothed-like finish. Alternately still, the surface  40  may be a relatively soft or resilient material (moving or stationary) to permit the application of “odd-shaped” caps. For example, it is anticipated that caps having shapes such as stars, diamonds, hearts, leafs and the like, may be applied using the present applicator. 
     To provide precise control over the torque of the cap C onto the spout S, it is anticipated that a servo-motor  44  will be used to drive the torquing element. Such motors  44  can be precisely controlled vis-à-vis speed, direction and angular rotation so that the torquing element  38  is moved at a desired, predetermined speed. 
     In addition, as set forth above, such motors  44  can be used to sense the torque applied to the cap C by a change in the power required by the motor  44  to operate. To this end the motor  44  is used to sense the torque applied to the cap C and can thus be used to change “mode” from a torquing mode (FIG. 7A) to a conveyance mode (FIG. 7B) in which the torquing element  38  reverses and moves at line speed to assist in moving the carton C through the conveyor  12 . A controller  46  is operably connected to the motor  44  to facilitate control of the direction and speed of the motor  44  and belt  38 . 
     It will also be readily appreciated by those skilled in the art that although the present applicator  10  is described with reference to clockwise and counter-clockwise movement of the belts  14 ,  16  and  38  and the cap C, that the relative location of the capping belt  38  can be can changed or moved from above the first belt  14  to, for example, between the cap C and the carton fin F. All such variations are within the scope and spirit of the present invention. 
     The pressure plate  42  that is present at the chute exit  30  is configured to apply a slight pressure downward to the cap C as it is positioned on the spout S. To this end, the plate  42  can have a slight downward angle, indicated at α, to assist in applying the downward force or urging of the cap C onto the spout S. This enhances placement of the cap C on the spout S and further facilitates properly positioning the cap C on the spout S as it passes the torquing element  38 . 
     As will be recognized by those skilled in the art, the present applicator  10  is described relative to applying threaded caps C to threaded spouts S (i.e., rotating caps C relative and on to spouts S). As, however, will also be recognized by those skilled in the art, aspects of the present applicator  10  can also be incorporated into the application of non-threaded, custom caps, such as lugged caps, snap caps, press-fit caps and the like, to closures. For example, the minimum retention pressure assembly  24  at the chute exit  30  can be used to apply a force to facilitate positive engagement of caps to spouts as the cartons pass the chute exit  30 . Likewise, the pressure plate  42 , and optionally the downward angle a of the plate  42 , that applies a downward pressure onto the cap to assure engagement with the spout, can also be incorporated into a non-threaded closure cap applicator. 
     In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular. 
     The disclosure of each patent cited herein, whether or not done so specifically, is incorporated herein by reference. 
     From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.