FIELD OF THE INVENTION The present invention generally relates to rigid packaging. More specifically, it relates to rigid packaging with a dispenser and a receptacle that secures the dispenser. Furthermore, it relates to automated methods for placing the dispenser on the receptacle, manufacturing the rigid packaging and manufacturing the dispenser.
BACKGROUND Powdered or granulated substances such as but not limited to nutritional supplements, baby formulas, ground coffee, dry soaps and other substances are often sold and thereby stored in a rigid package. It is common place for a manufacturer or distributer of such substances to specify an amount of the substance to be used per serving or per application. Furthermore, it is common place for these substances to be measured by volume. As a result, these substances are often sold with a measuring scoop or dispenser.
Typically, suppliers of granulated substances who also supply a dispenser, place the dispenser in the container along with the substance. This is problematic for a number of reasons. First, the dispenser may become covered by the substance hindering retrieval of the dispenser. Second, retrieval of the dispenser often results in the user getting the substance on their hands. Third, retrieval of the dispenser often results in contaminating the substance via the user's hands which may result in spoilage or degradation of the substance.
Currently there are a few solutions for dispenser storage on the market that seek to secure the dispenser above the substance. The current dispenser storage solutions fail to meet all of the needs of the market and the filling operations that support that market. Some of these solutions greatly increase the size of the container. Other solutions do not prevent the dispenser from disengaging the receptacle during transportation and handling. Other solutions store the dispenser outside the safety seal leaving the dispenser vulnerable to tampering. Still other solutions are not user friendly in approach. Furthermore, current solutions do not allow for easy implementation of automated filling utilizing existing equipment.
SUMMARY OF THE INVENTION The present invention consists of a container system with a dispenser for powdered or granulated substances, the methods for inserting the dispenser during filling operations and the methods for manufacturing the container and dispenser.
The container system is comprised of a rigid container with a receptacle for a dispenser, a dispenser with a coupling feature that couples to the container's receptacle and a closure. These items work as a system such that the dispenser becomes trapped on the receptacle when the closure is in place.
The container system is further presented with features to enable automated placement of the dispenser within the interior of the container. During the filling process additional machine or machines may index the container's receptacle and guide the dispenser such that the dispenser is coupled to the receptacle.
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is an exploded view of the preferred embodiment of the container system.
FIG. 2 is a section view of the preferred embodiment of the container system illustrating how the dispenser is secured.
FIG. 3 is a section view of the preferred embodiment of the container system illustrating the use of a typical safety seal with the container system.
FIG. 4 is a top view of the preferred embodiment of the dispenser.
FIG. 5 is an isometric view of the preferred embodiment of the dispenser.
FIG. 6 is an isometric view of an alternative embodiment of the dispenser.
FIG. 7 is an isometric view of an additional alternative embodiment of the dispenser.
FIG. 8 is a variety of isometric views of possible alternative embodiments of the dispenser.
FIG. 9 is an isometric view of the preferred embodiment of the container.
FIG. 10 is a detail view of the rim and receptacle on the preferred embodiment of the container.
FIG. 11 is a detail view of the preferred embodiment of the untrimmed blow molded container.
FIG. 12 is an illustration of how the preferred embodiment of the untrimmed blow molded container could be trimmed following blow molding.
FIG. 13 is an exploded view of the preferred embodiment of the untrimmed blow molded container after trimming which shows the scrap pieces.
FIG. 14 is an exploded view of an alternative embodiment of the untrimmed blow molded container after trimming in which a single scrap piece has been produced.
FIG. 15 is an illustration of an alternative means for adding the receptacle to the container.
FIG. 16 is a detail view of an alternative embodiment of the container which has multiple dispenser receptacles.
FIG. 17 is a detail view of an alternative embodiment of the container which has dispenser receptacles and does not require proper orientation to ensure coupling of the dispenser to the receptacle.
FIG. 18 is an exploded view of an alternative embodiment of the container constructed of multiple materials and parts.
FIG. 19 is a section view of an alternative embodiment illustrating the use of a typical closure and safety seal.
FIG. 20 is an isometric view of an alternative embodiment of the container with flat surfaces.
FIG. 21 is an illustration of the preferred embodiment of the indexing machine.
FIG. 22 is a detail view of the preferred embodiment of the indexing machine illustrating the produced movement and orientation of the container.
FIG. 23 is a detail view of the preferred embodiment of the indexing machine illustrating the movement of the indexing arm.
FIG. 24 is an illustration of the preferred embodiment of the dispenser insertion guide.
FIG. 25 is a section view of the preferred embodiment of the dispenser insertion guide.
FIG. 26 is an illustration of an alternative embodiment of an indexing machine that incorporates the dispenser insertion guide.
FIG. 27 is a detail view of an alternative embodiment an indexing machine that incorporates a dispenser insertion guide.
FIG. 28 is another detail view of an alternative embodiment of an indexing machine that incorporates the dispenser insertion guide.
FIG. 29 is an illustration of an alternative embodiment of an indexing machine that has been incorporated into a rotary filling system which includes a dispenser guide that is integrated into the rotary filling funnels.
FIG. 30 is an isometric view of a rotary indexer.
FIG. 31 is a detail view of an alternative embodiment of an indexing machine that has been incorporated into a rotary filling system showing the interaction of the rotary filling funnel, rotary indexer and container.
FIG. 32 is a detail view of an alternative embodiment of an indexing machine that has been incorporated into a rotary filling system showing the interaction of the dispenser and integrated guide of the rotary filling funnel.
Other aspects of the present invention shall be more readily understood when considered in conjunction with the accompanying drawings, and the following detailed description, neither of which should be considered limiting.
DETAILED DESCRIPTION The present invention is directed to a rigid packaging system incorporating a container, a dispenser and a closure where the dispenser can be stowed in the container above the container's contents such that the dispenser cannot be removed from the stowed location when the closure is in place. Additionally, the present invention is directed to the means of manufacturing components of the container system. Finally, the present invention is directed to the means of orienting the container and inserting the dispenser as the container is filled by automated equipment. The inventive concept is presented herein across multiple embodiments.
Referring now to FIG. 1, which is the preferred embodiment of the packaging system consisting of the generally cylindrical polymer container 30, a scoop like polymer dispenser 20 and polymer closure 10. The dispenser 20 is stowed near the opening of the container 30. The dispenser 20 is in close proximity to the closure 10 when the closure 10 is secured to the container 30.
In the container's preferred embodiment, the container is constructed of a rigid polymer material which forms a cylindrical body with a single opening and formed threads near the opening for securing a closure. The container may comprise a single wall in the case of a cylindrical container or a number of walls to form a polygon. The walls are connected to form a closed object having a perimeter. At the bottom of the walled perimeter, the container bottom where a floor is attached to the walls to form a seal (i.e., universally attached). Near the top of the walled perimeter is an opening wherein the container may be filled and users may access substances residing in the interior of the container. A rim may be created around the opening encircling the walled surfaces which make up the container or may exist on an intermediary piece (i.e., top of the cylinder) which makes up the top of the container.
Adjacent and concentric to the opening is a lip in which a receptacle for a dispenser is formed. The receptacle contains an indexing surface that can be used with automated filling equipment to position the receptacle such that the dispenser can be coupled to the receptacle. The receptacle is positioned close enough to the container's opening such that the receptacle may be formed during the same blow molding and trimming operations used to form the container body. Furthermore, the receptacle sits far enough below the lip such that when the dispenser is hanging on the receptacle it does not interfere with common safety seal materials and technologies. Additional embodiments of the container will be discussed.
Referring to the dispenser, the dispenser handle contains a hook like coupling feature that engages the receptacle on the container. Additionally, the dispenser contains an insertion guide or guides within its handle. In the dispenser's preferred embodiment, the dispenser has a pair of insertion guides in the coupling feature of the handle. The insertion guides may be used with automated filling equipment to couple the dispenser to the container's receptacle. The dispenser is typically formed out of a polymer material using an injection molding process. Additional embodiments of the dispenser will be discussed.
Throughout this specification the dispenser is shown as having a hook and the container having a receptacle for attachment of the hook. While this configuration is presented as a preferred embodiment, it should be understood that the hook and receiver are provided as an example of a paired mating arrangement. Alternative embodiments could include positioning the hook within the interior of the container and a receptacle (also referred to as a receiver) positioned on the proximal end of the handle opposite the scoop. In other arrangements, the paired mating connectors could include snaps, hook and loop textiles, post and holes, etc.
Referring now to FIG. 2, which is a section view of the preferred embodiment of the packaging system. In this view the dispenser 20 has been coupled to the receptacle 301 which is an integral part of container 30. There is a space 321 in between dispenser 20 and closure 10 when the dispenser 20 is coupled to the receptacle 301 and container 30 is in an upright orientation. The space 321 ensures that the dispenser 20 does not interfere with the interaction of the closure 10 and container 30 and such that a seal between the closure 10 and container 30 can be achieved. Also, the space 321 is less than the space required to decouple the dispenser 20 from the receptacle 310. As a result, with the closure 10 secured to the container 30 it is not possible to decouple the dispenser 20 for the receptacle 301.
Referring now to FIG. 3, which is a section view of the preferred embodiment of the packaging system which includes a safety seal 40. A safety seal is common means of ensuring the contents of the container are not tampered with in between the time that the container is filled and time the container is first opened by the consumer. Furthermore, a typical safety seal is fused to a container creating a more complete seal than a closure alone can achieve. As a result, the use of a safety seal is common practice for many of the products sold in rigid packaging. With regard to the subject rigid packaging system, when the dispenser 20 is coupled to the receptacle 310 and the container 30 is in the upright orientation there is a space 322 in between the dispenser 20 and safety seal 40. The space 322 is adequate to ensure the methods used create a seal between the container 30 and safety seal 40 do not cause the safety seal 40 to fuse to dispenser 20 or otherwise cause damage to the dispenser 20.
It should be understood that in some embodiments the closure may be a type of lid, such as a screw top or friction fit, or other type of closure mechanism for selectively sealing the container.
Referring now to FIG. 4, which is a top view of the preferred embodiment of the dispenser 20. The dispenser 20 is comprised of a bowl 204 and a handle 201. At the end of the handle 201 is a hook like coupling feature 202. The coupling feature 202 extends past the handle 201 by a distance 203. This distance 203 is adequate to ensure the side of the handle 201 does not interfere with coupling to a receptacle while using automated means to insert the dispenser 20 into the container 30.
Referring now to FIG. 5, an isometric view of the preferred embodiment of the dispenser 20. At the end of the coupling feature 202 are two insertion guides 205 which protrude past the top surface 209 and bottom surface 210 of the handle 201. The insertion guides 205 can be used to engage track like or guiding features incorporated in automated means of inserting the dispenser 20.
Referring now to FIG. 6, an isometric view of the first alternate embodiment of the dispenser 21. The coupling feature 202 has two insertion guides 206 consisting of a depression that protrudes inward from the top surface 209 and bottom surface 210 of the handle 201. The insertion guides 206 can be used to engage track like guiding features incorporated in automated means of inserting the first alternate embodiment of the dispenser 21.
Referring now to FIG. 7, an isometric view of the second alternate embodiment of the dispenser 22 with additional features to aide in filling the dispenser when the container is nearly empty of its contents. The bowl 204 contains a flat surface 207 that enhances the user's ability to fill the dispenser's bowl 204 while the second alternate embodiment of the dispenser 22 is in contact with the bottom surface of the container. The bowl radius 208 that is adjacent to the flat surface 207 of the bowl 204 is similar or equal to the radius in the bottom corner of the container. The similar or equal nature of the two radii further aides in the user's ability to fill the bowl 204 with material from the bottom corner of the container.
Referring now to FIG. 8, which illustrates a third alternate embodiment of the dispenser 23 and a fourth alternate embodiment of the dispenser 24. These alternate embodiments illustrate how the coupling feature may be oriented differently or that multiple coupling features may be present. Furthermore, these alternate embodiments illustrate that the shape and size of the bowl may vary including a bowl with a rounded or contoured bottom.
Additional embodiments of the dispenser may include various alternate locations of the handle, the addition of markings or graduations or the incorporation of esthetic designs. In general the dispenser is constructed of a polymer material and is formed using an injection molding process with a single parting die. Alternative materials including but not limited to paper like materials and metals may be used.
Referring now to FIG. 9, which is an isometric view of the preferred embodiment of the container 30. The preferred embodiment of the container 30 is constructed of polymer material and is generally cylindrical in shape with an opening at one end. The lip 302 of the opening is generally flat and circular in shape. The receptacle 301 is set below the lip and protrudes into the opening of the container 30.
Referring now to FIG. 10, which is a detailed view of the lip 302 and receptacle on the preferred embodiment of the container 30. The distance 323 in which the receptacle 301 sits below the lip 302 is adequate such that the dispenser is not able to decouple from the receptacle 301 and does not interfere with the closure or safety seal when in place.
Still referring to FIG. 10, the receptacle is formed from a section of the container's 30 material. The material has a void 304 which is an adequate size and shape for the coupling feature of the dispenser to pass through.
Still referring to FIG. 10, the receptacle 301 has one or more indexing features 303. To index the container 30, the container 30 is rotated. The indexing feature 303 is a feature that may be used to prevent rotation when it comes in contact with a mechanism or device or feature intended to stop the rotation of the container 30. When the indexing feature 303 makes contact with the mechanism or device or feature the location of the receptacle is known which facilitates automated insertion of the dispenser.
Still referring to FIG. 10, the receptacle 301 has a surface 305 with adequate length, straightness and location to perform the function of leveling the contents of the dispenser. Once the dispenser has been filled, the contents of the dispenser may protrude past the top of its bowl. The user may slide the dispenser across the surface 305 removing the excess contents from the dispenser and allowing those contents to fall into the container 30.
Cylindrical polymer containers are generally manufactured via blow molding process. In this process a plastic parison is extruded through an open die, the die is closed around the parison, the parison is pressurized with compressed air and expands to take the form of the die, the die is opened and the molded component is trimmed. The preferred method of manufacturing the container 30 is to form all features using the blow molding process.
Referring now to FIG. 11, which is a detailed view of the preferred embodiment of the container 30 illustrating the container's 30 shape during the blow molding process after the die has opened and before the container 30 has been trimmed. At this point in the blow molding process there is no opening in the top surface 324. In the center of the top surface 324 is the typical flash 307 created by the parison. To form the receptacle, there is a recess 308 in the top surface 324. In the center of the recess 308 is a blister 309. The material in the recess 308 will form the receptacle and the blister 309 will be trimmed off creating the void in the receptacle. Additionally, there is a recess 306 in the top surface 324 to allow a knife to begin trimming at a depth adequately below the material forming blister 309 and above the material forming the recess 308.
Referring now to FIG. 12, which is an illustration of how the preferred embodiment of the container is trimmed. Knife 310 is lowered into the recess 306 such that the blade is at a level below the material creating the blister 309 and above the material creating the recess 308. The knife follows the illustrated path 311 creating an opening in the container 30 and a receptacle for the dispenser.
Referring now to FIG. 13, an exploded view of the container 30, the scrap material 312 from the opening and the scrap material 313 from the blister. These are the resulting pieces after the top of the container is trimmed.
Referring now to FIG. 14, an exploded view of an alternative method for trimming container 30 such that there is a single piece of scrap material 314. A single piece of scrap material 314 is achieved by adding a piece of connecting material 315 to join the scrap material from the opening and the scrap material from the blister.
Referring now to FIG. 15, which is an illustration of an alternative means for adding the receptacle to the container. Here the body 325 of the container 30 is formed by the blow molding process and the top is trimmed off leaving a raw edge 317. The rim 316 is formed by injection molding and contains the receptacle 301. The rim 316 is then joined to the body 325 by spin welding, ultrasonic welding or other joining technology.
In addition to the preferred embodiment of the container there are alternative embodiments that should be considered as the invention. A few examples are described as follows. These examples are to be considered illustrative and not limiting.
Referring now to FIG. 16, a detail view of an alternative embodiment of the container 30 which has two or more receptacles 301. The presence of multiple receptacles 301 requires less rotation of the container 30 before an indexing surface comes in contact with a mechanism or device or feature intended to stop the rotation of the container 30.
Referring now to FIG. 17, a detail view of an alternative embodiment of the container 30 which has a series of receptacles 301 that encircle the entire circumference of the container's 30 lip 302. The receptacles are form by a series of voids 304 in the container's 30 material. In automated filling operations the location of the axis of a cylindrical container is typically known. Having a continuous series of receptacles 301 encircling the lip 302 and knowing the location of the axis of the container 30 negates the need to rotate the container 30 to facilitate automated insertion of the dispenser.
Referring now to FIG. 18, which is an exploded view of an alternative embodiment of the container 31 constructed of multiple materials and parts. The body 319 is a hollow cylinder or tube generally constructed of a paper, cardboard, polymer or other material. The bottom 320 and top 318 are affixed to opposite ends of the body 319. The bottom 320 and top 318 are generally made of metal or polymer. There is a receptacle formed 301 into the top 318 and recessed adequately such that the dispenser is not able to decouple from the receptacle 301 and does not interfere with the closure or safety seal when in place.
Referring now to FIG. 19, which is a section view of an alternative embodiment of the container 31 illustrating the use of a typical closure and safety seal. Here the dispenser 20 is coupled to the receptacle 310. A safety seal 50 and the closure 11 are both in place.
Referring now to FIG. 20, which is an isometric view of an alternative embodiment of the container 32. In place of the generally cylindrical shape of the preferred embodiment, this container 32 has relatively flat sides creating a square or rectangular shape to the body. There may also be additional features such as grab handles, graduated markings or decorative embellishments. The flat surfaces of the body may be used to index the receptacle 301 in place of indexing features that are integral to the receptacle 301. Multiple receptacles 301 may be present and the locations of the receptacles may correlate to the flat surfaces of the body.
Rigid packaging is generally filled through automated means. The process involves loading the containers onto a conveying system with the containers spaced at a regular interval. Once on the conveying system the containers pass through a number of machines that clean, fill, insert dispensers, label, and seal the containers. The present invention includes the addition of a machine or machines to the current process. The additional machine or machines index the container's receptacle and guides the dispensers such that the dispensers are coupled to the receptacle.
Referring to the automation of coupling the dispenser to the receptacle on the container, the preferred embodiment is a mechanism that can be used with a variety of filling systems including rotary fillers and augur fillers. Common to filling machinery is a conveying system, or conveyor, that moves the container through a series of operations. The conveyor passes through or under the mechanism which positions the container on the fill line conveyor such that it is in a consistent and desired orientation and then couples the dispenser onto the receptacle before the container passes through the filler.
To reposition the container, the container passes in between an indexing chain assembly positioned alongside the conveyor and a friction generating feature positioned on the opposite side of the conveyor.
The indexing chain assembly travels in the same direction of the conveyor and at the same speed as the conveyor. The fiction generating feature is situated parallel to the conveyor and is stationary or traveling at a speed that is different than the indexing chain assembly. Engaging opposite sides of the container with elements that are moving different speeds creates a rotational force and causes the container to rotate. The distance the container travels while in between the indexing chain assembly and the friction generating feature is sufficient for the container to complete one or more rotations.
The indexing chain assembly is comprised of a series of links. The shape of the links includes a spacing feature which engages the container and allows it to rotate while maintaining each container's position on the conveyor relative to the other containers.
There is an indexing arm installed on each link of the indexing chain assembly. The indexing arm can be lowered into the opening of the container where it engages with the lip of the container's opening.
In the preferred embodiment, the means of raising the indexing arm is a pivot incorporated into the indexing arm and a surface that engages the indexing arm causing it to rotate about the pivot. As the indexing arm rotates the portion of the indexing arm engages the container raises. Conversely, the indexing arm is lowered as it passes from underneath the surface.
In operation, as the container travels on the conveyor it encounters the indexing chain and friction generating feature. As the container passes in between the indexing chain and friction generating feature, the indexing chain links engages the outer surface of the container and the indexing arm is lowered to engage the lip of the opening of the container. Concurrently, the friction generating feature engages the outer surface of the container causing the container to rotate as it passes in between the indexing chain and friction generating feature. Once the indexing arm makes contact with the indexing feature of the container the outer surface of the container overcomes the static friction produced by the friction generating feature causing the outer surface of the container to slide on the friction generating surface. This stops rotation of the container. Before the container disengages the indexing chain, the container disengages from the friction generating feature such that the rotational force on the container is no longer produced. The indexing arm then disengages from the container. The container is now oriented on the conveyor with the receptacle in a repeatable and desired position.
In the case where the indexing arm engages the container such that the indexing arm is contacting the top surface of the receptacle, the rotation of the container will cause the receptacle to pass from underneath the indexing arm. Once the indexing arm is clear of the receptacle, the indexing arm is free to lower and fully engages the container.
With respect to coupling the dispenser on the receptacle, after passing through the indexing machine, the fill line conveyor passes under a dispenser insertion guide.
In its preferred embodiment, the dispenser insertion guide consists of a bowl channel and handle channel that maintain a handle down orientation of the dispenser. Adjacent to the bowl channel is a slide surface under which a deep channel transitions into a shallow channel. The deep channel and shallow channel are open to the slide. The slide surface protrudes into the deep channel and shallow channel creating a lip at the top edge of the deep channel and shallow channel on both sides of the deep channel and shallow channel.
In operation, dispensers are sorted using conventional sorting machinery and then feed into the dispenser inserting guide such that the dispenser's handle is oriented below the dispenser's bowl and the coupling feature's opening faces the direction of dispenser movement. The dispenser is moved through the dispenser inserting guide using conventional means similar to other dispenser inserting equipment. As the dispenser's bowl moves from the bowl channel onto the slide surface, the bowl channel ends before the bottom of the handle channel. This causes rotation of the dispenser so that the handle is oriented above the bowl. The dispenser is now falling with the bowl contacting the sliding surface and the handle is pulled into the wide channel. As the dispenser continues to fall, the insertion guides on the handle's coupling feature come in contact with the lips on the deep channel. The deep channel transitions into the shallow channel to ensure the location of the coupling feature as the coupling feature leaves the dispenser inserting guide and engages the receptacle on the container.
Referring now to FIG. 21, which is an illustration of the preferred embodiment of the indexing machine 50. This embodiment is suitable for intermittent or continuous movement of the conveying system making this embodiment compatible with multiple types of filling systems such as auger fillers and rotary fillers.
Still referring to FIG. 21, conveyor 501 passes through the indexing machine 50. On one side of the conveyor 501 is an indexing chain assembly 508 consisting of a series of links 505 on which an indexing arm 506 is affixed. The series of links 505 ride on track frame 527. The links 505 are constructed such that there are spacing features 507. The spacing features 507 of adjacent links 505 form a shape that interacts with the container 30 maintaining the spaced relation between consecutive containers 30. There is an indexing arm lifting surface 504 affixed above the indexing chain assembly where the indexing chain assembly 508 is not adjacent to the conveyor 501 and as the indexing arm assembly 508 is transitioning to and from travel that is adjacent to the conveyor 501. Alongside the conveyor opposite the indexing chain assembly 508 is a friction producing surface 503 which is affixed to a friction producing support 502.
Still referring to FIG. 21, in operation, containers 30 are equally spaced and traveling on a conveyor 501. When adjacent to the conveyor, the direction of indexing chain assembly travel 510 and the direction of conveyor travel 509 are the same. Furthermore, the speeds, accelerations, starts and stops of the indexing chain assembly 508 and conveyor 501 are synchronized. As a container 30 enters the indexing machine 50 the spacing features 507 of adjacent links 505 engage the container. The indexing arm 506 clears the indexing arm lifting surface 504 causing the indexing arm 506 to engage with the container 30. As the container passes in between the friction producing surface 503 and the indexing chain assembly 508, the friction producing surface 503 causes the container 30 to rotate about its central axis until the indexing arm 506 contacts the indexing feature of the container 30 which stops the rotation of the container 30 with the container's 30 receptacle in a known orientation. The container 30 then moves past the friction producing surface. As the indexing chain assemble 508 transitions away from adjacent travel with the conveyor 501 the indexing arms 506 engage the indexing arm lifting surface 504 and disengage the container 30. As the container 30 exits the indexing machine 50 it continues to travel on the conveyor 501 equally spaced and uniformly oriented.
Still referring to FIG. 21, in the special case where the indexing arm 506 is lowered on top of the container's 30 receptacle 301, the rotation of the container 30 will move receptacle 301 out from under the indexing arm 506 so that the indexing arm 506 can fully engage the container 30.
Referring now to FIG. 22, which is a detail view of the preferred embodiment of the indexing machine illustrating the produced movement and orientation of the container. The direction of container rotation 511 results as the conveyor 501 and indexing chain assembly 508 move past the stationary friction producing surface 503. The container 30 rotates until the indexing feature 303 of receptacle 301 makes contact 512 with indexing arm 506.
Referring now to FIG. 23, which is a detail view of the preferred embodiment of the indexing machine illustrating the movement of the indexing arm. As the path of the indexing chain assembly 508 moves away from the conveyor 501, the indexing arm 506 moves under the indexing arm lifting surface 504 and rotates about a pivot in the indexing chain link causing it to disengage the container 30.
Referring now to FIG. 24, which is an illustration of the preferred embodiment of the dispenser insertion guide. Dispensers 20 are sorted by conventional means and are fed into the dispenser insertion guide 60. The dispenser insertion guide extends over the conveyor 501. On the conveyor 501 is a series of containers 30 that are moving through the filling operation which have been uniformly spaced and oriented prior to the dispenser inserting operation. The containers 30 pass under the dispenser insertion guide 60 such that the lips 606 on the shallow channel 605 direct the dispenser 20 onto receptacle 301. The insertion process can place dispensers 20 during intermittent or continuous movement of the conveyor 501. For intermittent movement of the conveyor, the locations of the receptacle 301 and dispenser insertion guide 60 coincide when the conveyor 501 is stopped so the dispenser 20 can be inserted. For continuous movement of the conveyor 501, the positioning of the receptacle 301 is synchronized with the fall of the dispenser 20. The length of the receptacle 301 and the shape of the dispenser 20 provide tolerance to the synchronized position of the receptacle 301 and fall of the dispenser 20.
Referring now to FIG. 25, which is a section view of the preferred embodiment of the dispenser insertion guide. As the dispensers 20 are fed into the dispenser insertion guide 60 they are oriented with the handle 201 below the bowl 204 and the coupling feature 202 opening toward the container 30. The dispensers 20 enter into a queueing area comprised of bowl channel 607 and a handle channel 608 which maintain proper orientation of the dispenser 20. As the dispenser is pushed out of the queueing area, the bowl channel 607 transitions into the sliding surface 611 before the handle channel 608 transitions into the deep channel 604. This causes the bowl 204 to rotate in the direction 602 around the end of the handle 201. After the bowl 204 rotates past the end of the handle 201, the handle moves in the direction 603 down the deep channel 604. As the bowl 204 slides down the sliding surface 611 the insertion guides 205 on the dispenser 20 engage the lips 606 of the sliding surface 611 the protrude into the deep channel 604 and shallow channel 605. The interaction of the lips 606 to the insertion guides 205 and the bowl 204 to the sliding surface guide the dispenser onto the receptacle. As the dispenser 20 moves down in the shown direction 603 the insertion guides move from the deep channel 604 into the shallow channel 605 further refining the location of the coupling feature 202. As the coupling feature 202 exits the dispenser insertion guide 60 it passes through the receptacle creating a union between the coupling feature 202 and receptacle 301.
Referring now to FIG. 26, which is an illustration of an alternative embodiment of an indexing machine 51 that incorporates the dispenser insertion guide 60. The fill line conveyor 501 passes through the alternative embodiment of an indexing machine 51. To one side of the conveyor 501 is a container holding block 514 which is affixed to an actuator 515 such that the holding block travel 517 extends over and retracts from the conveyor 501. On the side of the conveyor opposite the container holding block 514 and actuator 515 is a means of container rotation 518. The dispenser insertion guide 60 extends over means of container rotation 518 and overhangs the conveyor 60. The indexing arm 506 is affixed to a pivot 527 and actuator 513. The actuator 513 causes indexing arm travel 516.
Referring now to FIG. 27, which is a detail view of an alternative embodiment of an indexing machine 51 that incorporates the dispenser insertion guide 60. During operation of the alternative embodiment of an indexing machine 51, the conveyor 501 runs intermittently advancing the containers 30 a distance equal to the interval in between containers 30 in the direction of conveyor travel 509 per period of motion. During periods when the conveyor 501 stops moving, there is a container 30 under the dispenser insertion guide 60 and in front of the container holding block 514. The actuator 515 then extends over the conveyor 501 in the direction of the holding block travel 517 so that the container holding block 514 is holding the container 30 against the means of container rotation 518. Next the actuator 513 moves the indexing arm 506 such that it engages the container 30.
Referring now to FIG. 28, which is another detail view of an alternative embodiment of an indexing machine 51 that incorporates the dispenser insertion guide 60 and continuing to discuss the operation of the alternative embodiment of an indexing machine 51. With the container holding block 514 holding the container 30 against the means of container rotation 518 and the indexing arm 506 has engaging the container 30 the means of container rotation 518 is activated. The container 30 rotates in the direction of container rotation 511. Once the indexing feature 303 on the receptacle 301 contacts the indexing arm 506 the container 30 stops rotating with the receptacle 301 properly located under the dispenser insertion guide 60. Once contact between the indexing arm 506 and the indexing feature 303 are made, the means of container rotation will slip on the surface of the container 30 without causing the container 30 to rotate. Next the means of container rotation 518 is deactivated and the dispenser is coupled to the receptacle. Finally, the actuator 515 retracts the container holding block 514, the actuator 513 disengages the indexing arm 506 from the container 30 and the conveyor 301 advances the next container 30 into the alternative embodiment of an indexing machine 51.
Still referring to FIG. 28, in the special case where the indexing arm 506 is lowered on top of the container's 30 receptacle 301, the rotation of the container 30 will move receptacle 301 out from under the indexing arm 506 so that the indexing arm 506 can fully engage the container 30.
Referring now to FIG. 29, which is an illustration of an alternative embodiment an indexing machine 52 that has been incorporated into a rotary filling system. In brief, a rotatory filling system pulls the containers off the fill line conveyor and onto a carousel. The containers are filled as the carousel rotates and then returned to the conveyor. A rotary filling system allows for continuous high speed movement of the fill line while providing settling time for the product into the containers.
Still referring to FIG. 29, the alternative embodiment an indexing machine 52 is comprised of a carousel 519 with multiple container locations 528 and an equal number of filling funnels 520. Attached to the bottom of each filling funnel 520 is a rotary indexer 521 that serves to index the container 30 and create a seal with the container 30. Additionally, there is a means of container rotation 518 that is tangent or concentric to the carousel 519 and near the location where the containers leave the conveyor 501 to enter the carousel 519.
Still referring to FIG. 29, in operation the fill line conveyor 501 travels into the alternative embodiment an indexing machine 52. The containers 30 are transferred onto the carousel 519 and travel in the direction of carousel travel 522. Once the containers 30 are transferred onto the carousel the rotary indexer 520 is lowered onto the opening of container 30 such that it is seated on top of the container's receptacle. As the container 30 passes the means of container rotation, the container rotates under the rotary indexer 521 until the rotary indexer 521 aligns with the receptacle on container 30 which causes the rotary indexer 521 to drop past the receptacle, stopping rotation of the container 30 and forming a seal with the container 30. The dispenser is inserted into the container 30 while the container 30 is filled. The dispensers are guided onto the receptacle using the insertion guides that are integrated into the filling funnel 520. The rotary indexer 521 is lifted off the container 30 as the container 30 is directed back onto the conveyor 501.
Referring now to FIG. 30, which is an isometric view of a rotary indexer 521. There is a sealing surface 529 toward the bottom of the rotary indexer 521 that is sized appropriately for the container being filled. There is a protrusion 523 that extends below the sealing surface 529 which has a void 524. The void 524 is sized appropriately so the protrusion 523 can travel past the container's receptacle when aligned with the void 524.
Referring now to FIG. 31, which is a detail view of an alternative embodiment an indexing machine 52 that has been incorporated into a rotary filling system showing the interaction of the rotary filling funnel, rotary indexer and container. The rotary indexer 521 is formed such that the rotary indexer 521 is able to move vertically on the filling funnel while not allowing for rotation of the rotary indexer 521. When the rotary indexer 521 is lowered onto the container's 30 opening the protrusion 523 is seated on the receptacle 301. As the container 30 rotates the receptacle 301 aligns with the void 524 and the rotary indexer 521 lowers onto the container 30 creating a seal with sealing surface 529. When the container's receptacle is located in the void 524 the container is unable to rotate.
Referring now to FIG. 32, which is a detail view of an alternative embodiment an indexing machine 52 which shows the interaction of the dispenser 20 and integrated guide 525 of the filling funnel 520. When the container's receptacle 301 is located in the void 524 the receptacle 301 is located directly below the insertion guide 525. The handle of dispenser 20 engages the insertion guide 525 with the guides that are integrated into the coupling feature of the dispenser 20 and travels to the receptacle 301.
Different features, variations and multiple different embodiments have been shown and described with various details. What has been described in this application at times in terms of specific embodiments is done for illustrative purposes only and without the intent to limit or suggest that what has been conceived is only one particular embodiment or specific embodiments. It is to be understood that this disclosure is not limited to any single specific embodiments or enumerated variations. Many modifications, variations and other embodiments will come to mind of those skilled in the art, and which are intended to be and are in fact covered by both this disclosure. It is indeed intended that the scope of this disclosure should be determined by a proper legal interpretation and construction of the disclosure, including equivalents, as understood by those of skill in the art relying upon the complete disclosure present at the time of filing.
