Abstract:
An apparatus for disposing a premium package on an exterior panel of a cereal or foodstuff box includes a supply or stacking station, a cereal compressing station, a premium inserting station, a cover applying and sealing station and a conveyor assembly which moves the boxes horizontally from one station to the next. The boxes are stacked in the stacking station positioned over the conveyor assembly and removed serially and individually by transverse members of the conveyor assembly. The compressing station includes a synchronous plunger which engages a previously formed opening or cut out in the box and ensures a suitable space within the box for the premium package. The premium package which is sealed by a first layer of transparent material is installed in the cut out either manually or by a synchronous loader. The sealing station applies a second, larger adhesive, preferably transparent cover over the premium package which secures it to the box.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to an apparatus for securing an accessory to a box for foodstuffs and more specifically to an apparatus for mounting a premium package in an opening in a box for cereal, foodstuff or other consumer product. 
     As an aid to the marketing of breakfast cereals, it is a common practice of many cereal manufacturers to include a premium in the cereal box to promote the sale of the cereal beyond the marketability of the product itself. It will be appreciated that such promotional devices must meet several requirements. First of all, because the premiums are typically given away with the product, that is, they are provided at no additional cost to the consumer, such devices must be relatively inexpensive. Additionally, such premiums must have the ability to be easily included with the product without disruption of the normal handling of such product. Thus, it is desirable that the promotional product be includable with the product without requiring different boxes, cartons and the like which would increase the cost of such promotion. Similarly, the promotional device should not require special handling or care by the manufacturer and retailer of the product beyond that normally given. Finally and most importantly, the promotional device should have consumer appeal to maximize the promotional value of the device. 
     Promotional devices include items such as coupons, toys, novelty items and the like which are placed within the product box. It can then be appreciated that the promotional device is hidden. Typically, therefore, access to the promotional device occurs only after consumption of most, if not all, of the product. Thus, the promotional value of the premium is reduced because only facsimile or representations of the premium, appearing on the outside of the box, are visible to the purchaser are available at the time of purchase and customer enjoyment of the premium is delayed. 
     Inclusion of the premium within the product box is disadvantageous for other reasons. First, as the premium cannot be seen from the outside of the box, it is impossible for the manufacturer to verify that a premium is actually present in any particular box without opening the box and destroying its marketability. Omission of the premium can cause customer dissatisfaction and may actually reduce market appeal of the product. Additionally, in order to promote the sale of the product with a particular premium, the outside of the box must include printing advertising the existence of the premium. Accordingly, it is necessary to inventory a variety of different cartons with different graphics corresponding to the particular premium utilized. Once again, the overall cost of the promotion is increased. 
     U.S. Pat. No. 5,379,886 represents a significant advancement in the inclusion of promotion premiums in packaging which overcomes many of the shortcomings described above and experienced in the prior art. Nonetheless, it is apparent that improvements in the art of premium packaging and apparatus facilitating such packaging are desirable and the present invention is directed thereto. 
     BRIEF SUMMARY OF THE INVENTION 
     An apparatus for disposing a premium package on an exterior panel of cereal or foodstuff box includes a supply or stacking station, a cereal compressing station, a premium inserting station, a cover applying and sealing station and a conveyor assembly which moves the boxes horizontally from one station to the next. The boxes are stacked in the stacking station positioned over the conveyor assembly and removed serially and individually by transverse members of the conveyor assembly. The compressing station includes a synchronous plunger which engages a previously formed opening in the box and ensures a suitable space within the box for the premium package. The premium package which is sealed by a first layer of transparent material is installed in the cut out either manually or by a synchronous loader. The sealing station includes an adjustable pressure plate which holds the premium package in place while a second, larger adhesive and transparent cover is disposed over the premium package and secures it to the box. 
     It is thus an object of the present invention to provide an apparatus which installs a premium package on a cereal or foodstuff box. 
     It is another object of the present invention to provide an apparatus wherein various supplying, compressing and sealing stations operate in synchronism. 
     It is a still further object of the present invention to provide an apparatus for assembling a premium package into a pre-formed opening on a panel of a cereal or foodstuff box. 
     It is a still further object of the present invention to provide an apparatus for applying a premium package to an opening in a box which is retained thereon by an adhesive cover. 
     Further objects and advantages of the present invention will become apparent by reference to the following description of the preferred embodiment and appended drawings wherein like reference numbers refer to the same component, element or feature. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a side, elevational view of an apparatus for mounting premium packages in pre-formed opening in cereal boxes; 
     FIG. 2 is a diagrammatic perspective view of a cereal box showing the physical locations of the premium package and a transparent overlay; 
     FIG. 3 is fragmentary, enlarged, perspective view of a portion of a cereal box with a premium package disposed therein; 
     FIG. 4 is a front, elevational view of a carton stacking station of an apparatus according to the present invention; 
     FIG. 5 is a front, elevational view of a compressing station of an apparatus according to the present invention; 
     FIG. 6 is a fragmentary, front, elevational view of a compressing station of an apparatus according to the present invention illustrating a plunger extended into a cereal box; 
     FIG. 7 is a side, elevational view of a compressing station of an apparatus according to the present invention. 
     FIG. 8 is a full, sectional view of a phase adjusting mechanism of a compressing station of an apparatus according to the present invention taken along line  8 — 8  of FIG.  7 . 
     FIG. 9 is a front, elevational view of a labeling/sealing station of an apparatus according to the present invention; 
     FIG. 10 is an enlarged, fragmentary view of the label-applying portion of an apparatus according to the present invention; 
     FIG. 11 is a top, plan view of a conveyor drive mechanism of an apparatus according to the present invention; and 
     FIG. 12 is a fragmentary, side, elevational view of a conveyor tensioning mechanism of an apparatus according to the present invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to FIG. 1,  2  and  3 , an apparatus for disposing premium packages in pre-formed openings in cereal boxes is illustrated and generally designated by the reference number  10 . The apparatus  10  includes a stacking station  12 , a compressing station  14 , a premium supplying station  16  and a cover applying and sealing station  18  which are all disposed serially along and proximate a conveyor assembly  20 . As noted in FIG. 1, the conveyor assembly  20  moves cartons or boxes  24  for cereal and other foodstuff from left to right. The apparatus  10  accepts, as illustrated in FIGS. 2 and 3, the cereal cartons or boxes  24  which include a pre-formed or pre-existing typically rectangular cut-out or opening  26  which receives a pre-formed package or tray  30  having a premium  32  disposed therein and a transparent overlay  34  secured to a peripheral flange  36  of the tray  30  to retain the premium  32  within the tray  30 . The premium  32  may be a coupon, toy, novelty item or additional edible ingredients or toppings. 
     Referring now to FIG. 4, the stacking station  12  is disposed at one end of the conveyor assembly  20  and includes front and rear rectangular frame members  38  (one of which is illustrated in FIG. 4) which straddle and are secured to respective front and rear longitudinal frame members  40  which form a portion of the conveyor assembly  20 . Extending between the front and rear frame members  38  and secured thereto by suitable fasteners is a slightly inclined left guide plate  42  and a pair of adjustable right guide bars  44 . Also secured to the front and rear frame members  38  are respective pairs of front and rear guide bars  46 . The top of the right guide bar  44  and the front and rear guide bars  46  are curved outwardly. Spacing or separation from an opposed guide bar  46  or the guide plate  42  is adjustable by lockable and releasable adjustment mechanisms  48  in order to adapt the stacking station  12  to receive different sizes of boxes or cartons  24 . Cooperatively, the left guide plate  42 , the right guide bars  44  and the front and rear guide bars  46  define an adjustable rectangular hopper which receives a plurality of boxes or cartons  24  in a stack as illustrated in FIGS. 1 and 4. It will be appreciated that the stacking station  12  must receive the cartons or boxes  24  in the same orientation with the cut-out or opening or  26  always on the upper panel of the carton or box  24  and always disposed in the same location. 
     As is illustrated in FIGS. 4 and 7, the conveyor assembly  20 , includes a pair of front and rear continuous link chains  52  having transversely disposed members  54  secured to the front and rear chains  52  which engage and translate the individual cartons or boxes  24 . Front and rear adjustable guide rails  56  which are supported by a plurality of longitudinally spaced apart adjustable stanchion assemblies  58  maintain the boxes or cartons  24  in an appropriate transverse position as they move along the conveyor assembly  20 . 
     Turning now to FIGS. 5,  6 ,  7  and  8 , the compressing station  14  is illustrated and includes a stationary upright support or frame member  62  which is secured to the rear longitudinal frame member  40  of the conveyor assembly  20 . The vertical frame member  62  in turn, supports upper and lower cantilever frame members  64  and  66 , respectively. The upper cantilever frame member  64  in turn supports a right angle drive assembly  68  which receives rotary power through a vertical shaft  70  and redirects it at a 1:1 drive ratio to a horizontal shaft  72  which terminates in a drive member  74  having an eccentric drive pin  76 . The eccentric drive pin  76  is received within a suitable bearing  78  on a reciprocating arm  80 . Secured to and spaced from the rear face of the reciprocating arm  80  is a guide rod  82  which is slidably received within a pivotally mounted journal bearing or bushing  84 . The pivoting bushing  84  is secured to the lower cantilever frame member  66 . At the lower terminus of the reciprocating member  80  is mounted a compression member or plunger  86 . The plunger  86  preferably defines a slight downward and inward taper on its side faces and defines width and depth slightly smaller than the corresponding dimensions of the cut-out or openings  26  in the cartons  24 . The plunger  86  also includes a travel guide  87  secured to one side wall of the plunger  86  which externally indicates proper travel (penetration) of the plunger  86  into the box  24 . It will be appreciated that the plunger  86  is secured to the reciprocating member  80  by removable fasteners  88  such that various sizes of the plunger  86  may be selectively secured to the reciprocating arm  80  to complement a particular size of cut-out or opening  26  in the boxes or cartons  24 . 
     As shown in FIGS. 5 and 6, rotation of the shaft  72  effects reciprocation of the reciprocating arm  80  and the plunger  86  to slightly compress cereal  90  or other foodstuff in the box or carton  24  as the boxes or cartons  24  pass the compression station  12  on the conveyor assembly  20 . The box or carton  24  to the left in FIG. 5 illustrates the disposition of the cereal  90  or other foodstuff prior to action at the compression station  14 . FIG. 6 illustrates the maximum advance of the plunger  86  into the box or carton  24  and the box or carton  24  on the right in FIG. 5 illustrates the effect of such compression where a depression  92  in the cereal  90  which is directly below the cut-out or opening  26  in the cereal box  24  is visible. 
     Referring again to FIGS. 7 and 8, the compressing station  14  includes a synchronizing or phase adjusting mechanism  100 . The vertical drive shaft  70  terminates in a first or upper flange  102  having a plurality of arcuate slots  104 . Received within each of the arcuate slots  104  is a cap screw or similar threaded fastener  106  which extends into a complementarily threaded opening (not illustrated) in a matching second or lower flange  110  which is secured to and driven by an output shaft  112  of a right angle drive assembly  114 . An input shaft  116  provides rotary energy to the right angle drive assembly  114 . Depending upon the location of the cut out or opening  26  in the box or carton  24  and other variables, it may be necessary to adjust the phase of the reciprocating arm  80  and the plunger  86  relative to the input drive shaft  116 . In order to achieve such adjustment, the cap screws  106  are loosened and the upper flange  102  is rotated relative to the lower flange  110 . When proper synchronism or phase is achieved, that is, the plunger  86  accurately and repeatedly aligns with and enters the cut-out or opening  26  in each carton or box  24  as they move along the conveyor assembly  20 , the cap screws  106  may then be re-tightened. 
     Referring again to FIG. 1, on the downstream side of the compressing station  14 , the trays or packages  30  including the premiums  32  are inserted into the cut-outs  26  of the boxes  24 . Such insertion may be achieved manually through the use of skilled workers (not illustrated) or automatically through the use of a pick and place mechanical or robot arm  118 . In either event, it will typically be preferable to include one or more bins  120  or other supply device such as a conveyor or stacker (both not illustrated) disposed on or adjacent the front longitudinal frame member  40  of the conveyor assembly  20  to hold and maintain a supply of the packages or trays  30 . 
     Referring to now to FIGS. 9 and 10, the conveyor assembly  20  next moves the cartons or boxes  24  with the inserted premium trays  30  to the cover applying and sealing station  18 . The cover applying and sealing station  18  includes a plurality of vertical supports  122  which may be attached to the longitudinal frame members  40  or otherwise supported. The right vertical supports  122  include height adjustment assemblies  124  such as cooperating slots and thumbscrews which adjustably, vertically position and pivotally secure a restraining plate  126 . The restraining plate  126  extends across the width of the conveyor assembly  20  and between the vertical supports  122  and provides a down force to fully or substantially fully seat and retain the premium trays  30  in the cut outs  26  of the boxes  24  as they enter the cover applying and sealing station  18 . The restraining plate  126  includes an upwardly angled, oblique portion  128  which forms a tapering throat to ensure that the boxes  24  and the premium trays  30  are properly engaged by the restraining plate  126  and pass thereunder. The left vertical supports  122  receive register pins  129  which extend horizontally from the restraining plate  126 , stabilize it and limit its downward travel. 
     The cover applying and sealing station  18  also includes a frame or housing  130  which supports a feed roll  132  which supplies a two component tape  134 . As shown in FIG. 10, the tape  134  includes a continuous, relatively thin and flexible transparent substrate  136  having spaced apart black or opaque transverse bars or markers  138  and thicker, preferably transparent adhesive covers or labels  140  disposed upon the flexible substrate  136  between each of the transverse markers  138 . While the covers or labels  140  are preferably transparent so that the premium  32  and the presence of the premium  32  may readily be ascertained, it is anticipated that text, symbols or pictures may also be included on the covers or labels  140 . The substrate  136  is recovered and wound upon a discard spool  142  for eventual disposal or recycling. A pair of parallel idler rollers  144 A and  144 B compressively engage a drive roller  146  and drive the two component tape  134 , drawing off the tape  134  from the supply spool  132  and providing the substrate  136  to the discard spool  142 . 
     As illustrated in FIG. 10, in order to ensure proper location of the adhesive cover  140  upon each of the cartons or boxes  24  over the premium package  30 , the cover applying and sealing station  18  includes a first sensor  148  which senses the leading edge of each of the cartons or boxes  24 . The first sensor  148  is preferably a photoelectric sensor but may be any type of optical, laser or less desirably, a mechanical sensor, capable of accurately and repeatedly providing an output signal or a change in an output signal indicating the arrival of a leading edge of a carton or box  24  at the location of the first sensor  148 . A second sensor  152  is disposed on a pivotable application assembly  154  at a location proximate the location where the labels  140  are applied to the cartons or boxes  24 . The second sensor  152  is arranged to detect the black or opaque transverse markers  138  on the substrate  136 . Preferably, the location of the second sensor  152  is longitudinally adjustable such that the location of the transverse marker  138  at which the second sensor  152  generates a pulse or a change in an output condition may be adjusted to accommodate various size adhesive labels  140  and other variables which may necessitate an adjustment in the timing and thus location of the second sensor  152 . The first and second sensors  148  and  152  provide signals to a processor or other control device (not illustrated) which ultimately control a motor driving the drive roller  146 . 
     As also illustrated in FIG. 10, it will be appreciated that the application assembly  154  includes a relatively thin blade or plate  156  over which the dual component tape  134  passes and reverses direction. Preferably, the restraining plate  126  is notched to receive the blade or plate  156  and extends to the right, beyond it in order to achieve maximum stabilization of the cartons  24 . An upper guide plate  157  also guides the dual component tape  134  and, with the plate  156 , defines a narrow throat through which the dual component tape  134  passes. As the leading edge of a box or carton  24  is sensed by the first sensor  148 , and one of the opaque transverse markers  138  is likewise sensed by the second sensor  152 , the drive roller  146  is activated to advance the dual component tape  134 . As the substrate  136  reverses direction at the end of the blade or plate  156 , the transparent adhesive cover  140 , because it is relatively thicker and stiffer, continues to the right as illustrated in FIG.  10  and engages the box or carton  24  in the desired location. 
     It will be appreciated that the adhesive on the covers  140  must provide sufficient adherence to secure the premium package or tray  30  to the box  24  but not so great adherence that it fails to release from the substrate  136  as it curves around the end of the blade or plate  156 . In the particular example illustrated, the cover  140  is disposed adjacent the leading edge of the box and beyond the lip of the package or tray  30  such that it engages the top surface of the box  24 , thereby sealing the tray  30  to the top surface of the box  24 . A pressure-applying device such as a brush  158  or similar flexible, low friction component such as a roller applies a force to the top surface of the cover  140  thereby assisting its securement to the carton or box  24 . A second brush  160  or similar pressures applying device such as a roller, downstream of the first brush  158 , further smoothes and secures the label  140  to the carton or box  24 . 
     The assembly of the premium package  30  to the carton or box  24  is now complete and the cartons or boxes  24  so configured may be removed from the conveyor assembly  20  and stacked or packaged as necessary. 
     Referring now to FIGS. 11 and 12, a drive assembly  170  for the conveyor assembly  20  is illustrated. As noted, the conveyor assembly  20  includes pair of parallel chains  52  supported by and translating along the front and rear longitudinal frame members  40 . At suitable spaced apart intervals on the chains  22  are secured transverse members  54  which engage and translate the cartons or boxes  24 . At one end of the frame members  40 , the conveyor chains  52  engage drive sprockets  172  which are secured to a transverse drive shaft  174  driven by an electric motor  176  through a speed reduction unit  178 . The drive shaft  174  is also directly coupled to a right angle drive assembly  182  having an output coupled to and driving the drive shaft  116  which provides synchronous drive energy to the compressing station  14  described above and illustrated in FIGS. 5 through 8. By commonly driving the conveyor assembly  20  and the compressing station  14  with the drive assembly  170 , synchronism of the action of the plunger  86  relative to the location of the openings  26  in the boxes  24  may be maintained. Moreover, the phase adjustment assembly  100  illustrated in FIG. 8 may be utilized to achieve proper synchronism. 
     In order to ensure smooth operation of the conveyor assembly  20  and particularly to improve operation of the conveyor assembly  20  at higher production speeds, the conveyor assembly  20  preferably includes a tensioning mechanism  190 . The tensioning mechanism  190  includes a pair of idler sprockets  192  which preferably engage the drive chains  52  adjacent the drive sprockets  172 . The idler sprockets  192  are disposed upon a transverse shaft  194  which is biased by one or a pair of tension springs  196  in such a manner that any slack or looseness of the drive chains  52  is absorbed. A pair of return idlers  198  mounted upon a transverse shaft  200  guide and direct the drive chains to horizontal return supports or channels  202 . 
     It will be appreciated that although the foregoing description relates to an apparatus for externally mounting a premium package on a cereal or foodstuff box, the apparatus is, of course, not so limited, but has broad utility and applicability with boxes containing virtually any product such as sundries (hair care products, tissues, vitamins and cold remedies), frozen and packaged foods, and other products in highly competitive and impulse purchase markets wherein such a premium may positively influence the purchasing decision. 
     The foregoing disclosure is the best mode devised by the inventors for practicing this invention. It is apparent, however, that apparatus incorporating modifications and variations will be obvious to one skilled in the art of packaging machines. Inasmuch as the foregoing disclosure presents the best mode contemplated by the inventors for carrying out the invention and is intended to enable any person skilled in the pertinent art to practice this invention, it should not be construed to be limited thereby but should be construed to include such aforementioned obvious variations and be limited only by the spirit and scope of the following claims.