CA1188275A - High volume low velocity filling nozzle - Google Patents

Abstract

METHOD AND APPARATUS FOR FORMING
A CONTAINER FOR LIQUIDS
Abstract of the Invention An apparatus and method is disclosed for forming a liquid-tight container having a rectangular cross-section formed from a one-piece, T-shaped blank of paperboard material. The carton preferably includes an access flap and straw element on one side thereof which, when manually lifted, exposes an end of the straw element from which the contents of the carton may be consumed by a user. The apparatus is compact in nature, possessing relatively few transport mechanisms Which advance the T-shaped carton blank; through a plurality of work stations. A
novel method and apparatus for serially applying the straw element and access panel to the carton blank is disclosed, wherein the straw element and a length of polyethylene coated Mylar tape is automatically bonded to the carton blank upon a rotating heat sealing and alignment drum. A conveyor for collating a plural number of the carton blanks about a forming mandrel is also provided, and is positioned transversely to the remainder of the apparatus thereby significantly reducing the overall size of the apparatus. An ultrasonic welder bonds the side seams and end closure panels of the container upon a rotating crossbar mandrel which eliminates any misalignment during the sealing process. A substantially rigid conveyor transport carries a plurality of the carton blanks through pre-form, filler, and end closure work stations, and includes plural anvils for the ultrasonic welding process. An ejector mechanism is additionally provided which ejects the filled carton blanks from the rigid conveyor along a dual direction path, thereby eliminating the possibility of creasing or puncturing the filled and sealed container. The apparatus of the present invention additionally accommodates the production of differing size containers with only minor adjustments.

Description

-~THOD ~ND APPARAT~S FOP~ FO~NG
A CONTAINER FOR LIQ~IDS
Bac~:ground of the Inventi~n ~.S. Patent N~. 3,~0D,677 granted April 2, 1974 to Charles t~. Jones and ~ight La Stetler discloses app~ratus for fo-ring, an~ ~.S. Patent No. 3,775,943 granted Decerber 4, 1973 to Charles WO Jones discloses apparatus ~or filling and sealing straw-~earing cartons. The apparatus and m-thod of the pxesent in~ention, to be described hereinafter, are intended to form, fill, and ~eal si~ilar cartons. T:~e car~on formed by the apparatus and m,ethod of the present invention i5 the type disclosed ; in U.S. Paten~ ~'o. 3,749,330 qranted July 31, 1973 to 15 Charles t~. Jones as ~:ell as ~he i~?rovements thereon as shown in U.S. Patent No. 4,011,984 ~ranted to Mato~ich, Jr. issued ~1a~ch 15, 1977.
This a~plication is related to Canadian a?plication 356,391 and 356,~98 filed July 17, 1980 respectively.

Basically, the car,on disclosed in each of these patents and a?~lications comprises a rec,an~ular cross~
~ection container ~or~d from a one-piece, su~stantially T~sh2ped blank of polye'hylene co2ted paperboard. The 25 carton may be provided on ~ne of its sides with an acoess flap to the inside of which is atta~hed a straw element.
The liquid contents of the carton may be consumed ~y ; lifting the access flap, thereby rotating the etraw to exp~se ~ne end ~L ~he straw ele;~.ent rom which the 3~ contents of the carton m2} ~e dratm into the ~outh, and lowering the other end of ~he straw into a corner of the car on.
In the formation of the carton by the apparatus sh~m in 1~.5. Patent t~c). 3,800,667, ~Dth ends c~f the carton blank are sealed prior to ~h~ filling ~peration.. A5 disclosed in U.5. Patent N~. 3,7~5,943, the access flap is lifted and the carton filled therethrough, after which , , ;.. . :-~S~75 the aperture is sealed by the application of a length of tape. U.S. Patent No. 4,037,370 discloses apparatus for closing and sealing the carton wherein the carton 5 is filled from the top of the container and subsequently a cover member is pressed flat down upon the open end o .
the filled carton and sealed there-to by the melting and cooling of the polyethylene coating on the top of the open~ended Garton. Although these prior art me-thods and 10 apparatus for forming the carton have proven useful in - their limited application, they have presented certain cost, space, and production and reliability problems.
In par-ticular, the prior ar-t apparatus for forming the carton has required an extremely large and elongated 1~ structure wherein aZn individual carton blank was formed, filled, and sealed by progression through a series of work stations oriented in an extended production line manner. This large and elongated structure re~uired a Z considerable amount of space within a plant facility to he ~' 20 devoted to the apparatus, which detracted from the overall efficiency of the device and permitted the installation of the apparatus in only large production facilities.
Further, the prior art apparatus typically 25 facilitated the formation, filling, and sealing of the carton in a serial manner along the production line (i.e~, one carton being formed at a time) which, due to the time required for filling and sealing of the carton, limited production output and necessarily increased 30 production costs.
Additionally, due to the elongate na-tuxe of the apparatus for forming the carton and the intricate mechanical mechanisms and extended transport mechanisms utilized therein r one or more skilled technicians were 35 required to constantly moni-tor and fine tune the apparatus during operation. Further~ the prior art apparatus was incapable of providing a simple ana convenient method of accommodating di-EEering sized containers for different production runs As such, the versatility of the prior art apparatus was severely limited.
Summary of the Present Invention The ~pparatus and method of forming a caxton blank which is the subject of the present invention is a significant improvement over the apparatus and methods disclosed in -the hereinbefore-identified patents and patent applications and significantly eliminates the deficiencies associated with the prior art. The present ¦
i.nvention p:rovides a compac-t apparatus for forming a carton wherein a substantially T-shaped carton blank is provided with a straw element and tape seal, creased into a square, tubular configuration about a forming mandrel, sealed along its side and one end by an ultrasonic welding -, process r pre-formed along its open end by a sexies of dies, filled with a desired liquid by a two-stage filling process, and subsequently sealed along its open end and automatically ejected from the apparatus.
The significant reduction in spaee and compact nature of the apparatus of the presen-t invention is made possible by the -transverse orientation of the mechanism for applying and sealing the straw element to the carton blank with the remainder of the appara-tus of the machine~ This transverse orientation allows the carton blanks to be serially ~one at a time) provided with the straw element and tape seal and subsequently travel in a plurality (in the preferred embodiment four at a -time) through parallel sealing and filling sta-tions. Since the majority oE the production time is consumed in the sealing and filling operations, this plural transport of the cartons through the remainder of the apparatus significantly increases production output of the apparatus, without unnecessarily duplicating the pxeliminary s-ta~es which are capable o-f high speed operation. As such, the apparatus of the present invention may be eEfectively utilized in smaller plant facilities and provide a high production output which heretoEore could no-t be accomplished by the prior art apparatus, ~ithout unnecessary cost increases.
Additionally, the present invention, due to its compact size, significantly reduces the col~plexities of the transport mechanisms as ~ell as the len~th of transport of the carton blanks through the apparatus This reduction of the transport mechanisms substantially reduces the possibility of misalignment of the carton blanks traveling through the apparatus ~nd, as such, provides greater consistency in production output.
Addi-tionally, the present invention, in the preferred embocliment, is provided ~Jith a central hydraulic drive system which powers the major transport systems with the individual work stations along the apparatus being :r 20 pneumatically operated to yield greater reliability for -the apparatus.
In the preferred em~odiment~ the apparatus and method of the present invention proviae a novel tape and straw seal mechanism which bonds and seals a straw element and tape length over the aperture for~ed in one side of the carton blank while the unfolded, T-shaped carton blank is positioned upon a rotating drum. Further, the apparatus and method of the present invention facilitate the end and side sealing of the carton blan~ upon a rotating crossbar at a single work station ~Ji thout the necessity of transferring the carton blank along plural mandrels for each of the individual end and side sealing operations.
Additionally, the present invention provides a novel yoke or mandrel conveyor transpor-t which positively supports and orients the carton blank as it travels through the pre-form apparatus, filling station, end closure station, and ejector mechanism. Further~ a unique positive displacement pump and nozzle assembly utilizing an internally reciprocating spool to proviae positive t`

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filling and shut-off is disclosed~ ¦
Description of the Drawings These and other features of the present invention will become more apparent upon re~erence to the drawings wherein: -Figure 1 is a perspec-tive view oE the apparatus of the present inven-tion illustrating the spacial relationship between the plural l~ork Stations (I-VIII) and the direction o, travel o~ the carton blank as it is transported through the appara-tus;
Figure lA is a perspective view of the carton formed by the apparatus and method of the present invention;
Figure 2 is a schema-tic representation of the processes occùrring at each of the Work Stations (I-VIII) and the orientation of the carton blank as it travels through the apparatus of Figure l;
E'igure 3 is a plan view of the carton blank of the present invention utilized to form the liquid-tight carton of Figure lA;
Figure 4 is an enlarged perspective view oE a portion of the carton blank of Figure 3 illustrating the location of -the tape seal and straw element thereon;
Figure 5 is an enlarged perspective view of the rear end of the apparatus of the present invention taken about lines 5-5 of Figure l;
Figure 6 is an enlarged perspective view o~ the carton blank ~eeder mechanism, heat seal and alignment drum, straw inserter mechanism, and tape applicator of the present invention;
Figure 7 is an elevation view, par-tially broken away, of the carton blank feeder mechanism and heat seal and alignmen-t drum of Figure 6, depicting the cam an~ pneu~atic drive mechanism for the heater plate;
35Figure 8 is an enlarged partial perspective view of the straw inserter mechanism o the present invention;
Figure 8~ i.s an enlarged cross-sectional view taken about lines 8A~8A of Figure 8 illustrating the method in which the individual s-traw elements are transEerred from 7~

the stra~ singul2tor into the stra~ feeder m-chanism;
Figure 2B is an ~nlarged perspective view of the ~traw sinsulator of the present invention illustr2ting the lnternal biasing roller disp~sed therein;
Figure 9 is a sectional view of the stra~ in~erter mech2nis~ taken. ab~u~ lines 9-9 of ~igure ~ illustrating the spacial relations~ip between the straw singulator~
s~raw tra~sport channel, and the rotatin~ drum;
~igure 1~ is an enlarged cross-sec.ion21 Vie~J taken about lir.es 10-lC of Fisure 9 illustratin~ the detailed operation OL the straw inserter mechanism depositing a ~traw onto the periphe~ ~f the heat seal ~nd alignment dr~;
Fisure 11 is an enlarged perspective view Or the tape dispGnser a?~2.atus ~f the~ present invention illustra.ing t~s plural rotating cutter m~ers znd their relat~ve orien,ation ti,h the heat seal and alignment dru~;
Figure 12 is a perspective vie; of the lower rotating çutter m-r~ex of Figure 11 illustrzting the detailed construction thereof;
Fisure 13 i5 an elevation view of the rotating cutter me~bers of Figure 11 in a position for initiall~ contacting the length OL tape;

2~ Fi~u~e 1~ is an elevation vie~7 ~f ~he rotating cutter me.~ers of ~i~ure 11 in a posi~ion for shearing or cutting ~f the tape length;
Figure 15, on sheet 4, is a partial perspective view of the heater plate of the heat seal and alignment Qrum illustrating the detaileQ construction of the undersurface thereof;
~ igurc l is a perspeC~ ive view of the stripper `~heel mechanisr~ and carton pivot mechani sm of the present - ~ in~ention;
~ igure 17 is an enlarged elevation view ~f the stripper 35 ~heel mecha-is~ ~f Fi~l~re ~6 illustratin~ the detailed :~eratic)n the~e~;

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Figure 18 is a perspective view of the carton pivot mechanism of Figure 16 illus-trating the chain loop transport mechanism;
Figure 19 is a partial elevation view of the stripper wheel mechanism and carton pivot mechanism of the present.
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118~2~5 invention showing the initial transfer of the carton blank thereon;
Figure 19A is a partial elevation view identical to Figure 19 bu-t showing ~he final position of the car-ton blank after transfer from the stripper wheel mechanism; ..
Figure 20 is a perspective view of the pre-feeder conveyor andshingling conveyor transport of the present inventlon depicting their relative orientation with the forming mandrels and wrapping and creasing mechanisms;
Figure 21 is a perspective view showing the position of a carton blank of the present invention as it enters theshinyling conveyor transpor-t of Figure 20 and illustrating the manner in which the carton blanks are stacked one beneath the other;
p Figure~22 is a perspective view showing the position of an individual carton hlank as it enters the wrapping ana creasing mechanism, the blank being disposed about the forming mandrel;
Figure 23 is a perspective view of the wrapping and ~reasing mechanism of the present invention illustrating the detailed construction thereof;
Figure 2~ is a perspective view of the wrapping and creasing mechanism of Figure 23 disposed about the 2~ forming mandrel;
Figure 25 is a cross-sectional view of the wrappiny and creasing mechanism of the present invention illus-trating its initial orientation with the forming mandrel as an individual carton blank enters therein;
Figure 26 is a cross-sectional view of the wrapping - and creasing mechanism depicting the initial creasing step of the carton blank about the forming mandrel;
Figure-27 is a cross-sectional-view of the wrapping and creasing mechanism illustrating the final creasing step of the carton blank about the forming mandrel;
Figure 28 is a perspective view of the wrapping and creasing mechanism and forming mandrel oE the 7~

present invention depicting -the mechanism for transferring -the carton blank to the crossbar mandrel o-f Figure 30, Figure 28A is an enlarged cross-sec-tional view of the upper corner detail of both the forming mandrel oE
Figure 28 and the individual crossbar mandrels of Figure 30i Figure 29 is a perspective view of the carton blank of the present invention sho~ing its configuration upon being transferred to th crossbar mandrel of Figure 30;
Figure 30 is a perspective view of -the crossbar mandrel of the present invention having a car-ton blank disposed thereon and illustratiny the spacial rela-tionship betw~en the end folding apparatus, slde sealing anvil, and end sealiny anvil;
Figure 31 is a perspective view of one end of -the crossbar mandrel showing the detailed construction of the forming die rigidly mounted thereto;
Figure 32 is a partial perspective view of the carton blank of the present invention showing its configuration upon completion of its travel through the end folding apparatus of Figure 30;
- 25 Figure 32A is a schematic illustration of the initial step in the operation of the end folcling apparatus of the present invention;
Figure 32B is a schematic illustration of the subsequent step in the operation of the folding apparatus of Figure 32A;
Figure 32C is a schematic illustration of the final step in -the operation of the folding apparatus of Figure 32A dépicting the sealing tab folded tightly over the end of the crossbar mandrel;

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~L88275 Figure 33 is a perspective vie of the crossbar mandrel of the presen-t invention having three carton blanks disposed thereon, illustrating the opera-tion of the end folding apparatus and the end sealing apparatus;
Figure 34 is a perspective view of the carton blank of the present inventionr disposed upon the 10 ~' ~ ' '' . ` , ' ' ''` ' '' ' , .

~L~81~12~75 crassbar mandrel, illus-trating the manner in which the end closure panel is folded over the end of the crossbar mandrel;
Figure 35 is a perspec-~ive view of the carton blank rotator mechanism of ~ork Station IV;
Figure 36 is a partial perspective view oE the carton blank rotator mechanism of Figure 35 illustra-ting the manner in which the carton blank is transferred from the crossbar mandrel of Figure 30 into the fixture of the carton blank rotator mechanism;
Figure 37 is a perspective view oE the carton blank rotatox mechanism of Figure 35 illustrating the 90~
counterclockwise rotation of the carton blank within the fix-ture;
Figure 38 is a perspective view of the carton blank rotator mechanism transferring an individual carton blank from the fixture into the conveyor transport of Figure 39;
, 20 Figure 39 is a partial perspective view of the conveyor transport o:E the present invention illustrating the detailed construction thereof and the orientation of the side loader mechanism located adjacent one end thereof;
Figure 39A is a cross-sectional view -taken about lines A-A of Figure 39;
Figure 40 is a perspective view of the conveyor transport and side loader mechanism of Figure 39 illustrating the operation thereof;
Figure 40A is a perspective view of the side loadex mechanism of Figure 3~ having the conveyor transport removed for illustration;
- Figure 41 is a cross-sectional view of the pre form apparatus of Work Station V taken about lines 35 41-41 of Figure 1 schematically aepicting the three pre-form dies and their relative orien-tation with the carton blank and the conveyor transport;

Figure 42 is a perspective view of the carton blank of the present invention showing its configuration upon completion of the first pre-form die opera-tion of Fiyure 41;
Figure 43 is a perspective view of the first pre-form die being positioned over the carton blank of the present invention;
Figure 44 is a cross-sectional view of the first pre-form die and its orientation with the carton blank of the present invention taken about lines 44-44 of Figure ~3;
Figure 45 is a perspective view of the second : pre-form die of Figure 41 positioned over the open end of the carton blank, depicting the detailed construction thereof;
Figure 4~ is a partial perspective view of the carton blank of the present invention, illustrating the spacial rela-tionship between creasing pins of Figure 45 and the two forward corners thereof;
Figure 46A is a perspective view of the carton blank of Figure 46 illustrating the configuration of : the t~o ~on~ard corners thereof after extension of th~
cre~sing pins;
Figure ~7 is a cross-sectional view of the second pre-Eorm die taken about lines 47-~7 of Figure 45 illustrating the movement of the operator plates thereon;
Figure 48 is a partial perspective vie~ of the forward corner of the carton blank 9f the present invention upon completion of the ~econd pre-form : stage;
Figure ~9 is a perspective view of the third pre-form die of Figure 41;
~` Figure 50 is a partial perspective view o:E the anvil of the conveyor transpor-t illustrating the ~eveled top edge and relieved corner theresn, ~L81~2~75 . ~.Figure 51 is a partial perspective view of the carton blank of the present invention illustrating the configuration of the sealing tab after the interaction of the die of Figure 49 with the anvil of Figure 50;
Figure 51A is a perspective view of the carton blank upon completion of the third pre-form stage operation;
Figure 52 is a cross-sectional view of the lnternal reciprocating spool nozzle and positive displacement metering pump of Work Station VI;
Figure 52A is an alternative embodiment filler nozzle wherein flow metering is -Eacilitated exclusively by an internal reciprocating spool;
Figure 52B is an enlarged fragmerltary vie~7 o~ the stationary cap seal utilized in the filler nozzle of Figure 52A;
Figure 52C is a schematic view of a typical prior art nozzle design show.ing the liquid flow pattern exiting therefrom, r 20 Figure 52D is a schematic view of the internal reciprocating spool nozzle desi~n OI Figures 52 and 52A
depicting the liquid flow pattern exiting therefrom;
Figure 53 is a schematic view of the operating and timing mechanism of the present invention connected to the nozzle and pump assembly of Figure 52;
Figure 54 is a schematic view of the operating and timing mechanism of Figure 53 shown in a normal 3n - -- \ -.

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i.ntake stroke;
Figure 55 is a schematic view of the operating and timing mechanism of Figure 53 illustrating the position of the operating and timing mechanism in a no-fill mode;
Figure 56 is a perspective view of the camming plate mechanism of Work Station VII illustrating its in-terrelationships with the conveyor transport;
- Figure S7 is a cross-sectional vie~J of the ca~ing 10 plate of Figure 56 ta}~en abou~ lines 57~57 of Figure 56;
Fiyure 58 is a perspective view of the sealing die of Work Station VII illustrating the manner in which the open end of the container is sealed to form a liquid-tight carton;
Figure 59 is a perspective view of the support r structure and drive mechanism for the sealing die of Figure 58;
Figure 60 is a cross-sec-tional view taken a~out lines 60-60 of Figure 59;
Figure 61 is a perspective view of -the ejector apparatus of Work Station VIII of the present invention disposed beneath the conveyor transport adjacent one end thereof;
Figure 62 is a perspective view o the ejector apparatus of Figure 51 depicted in its final position wherein the carton blank is ejected from the conveyor transport; and Figure 63 is a plan view of the ejec-tor apparatus of Figure 61 illustrating the outward travel of the U-shaped fixture~
e-tai.led Description of the Preferred Embodiment Overall System Description Re~erring to Figure l there is shown the apparatus 10 of the present inven-tion which forms a particular type of container for liquids 12 (shown in Figure lA) known generally as a Flip and Sip container (a trademark of Nolex Corporation, the assignee of the present invention) and fully disclosed in United States Patent No. 3,7~9,300, granted July 31, 1973, to Charles W.
Jones.
As shown in Figure 1, the apparatus 10 oE the present invention includes a base or frame 14 which supports a plurality of component systems, each of these systems working in conjunction with each other to produce the sealed container 12 (shown in Figure lA) filled with a liquid substance.
For illustration purposes and to show the spacial relationship between the component systems of the present inventio~, the apparatus 10 has been segregated into a series of Work Stations designated generally by the Numerals I
; through VIII. By progression through these Work Stations I
through VIII~ a carton blank 100 initially loaded onto th apparatus 10 at Work Station I is formed into a desired con-figuration, filled and sealed through a series of operations and is ejected from the apparatus 10 at Work Station ~III.
Referring now to Figures 1 and 2, a brief overview and a schematic representation of the processes occurring at each of the Work Stations ~ume~als I through VIII is illustrated. Note that these figures complement one another, Figure 2 showing the carton schematically as it progresses through ~ork Stations I through ~III of Figure 1.
At Work Station I (the Straw and Sealing Tape Applicator Station~ the carton blanks 100 are loaded upon the apparatus 10 and individually transferred to a rotating drum 1~6.
As the blanks 100 rotate with the drum 146, straw elements Inot shown) and tape lengths (not shown) are permanently sealed across apertures 126 formed on the carton blanks 100.
Subsequently, each carton blank 100 is removed from the rotating drum 1~6 by a stripper wheel apparatus 150 which ~: delivers the carton blank 100 to a rotator or pivot mechanism 152 for subsequen~ entry into the Work Station II.

27~ii At Work Station II (Carton Blank Wrapping and ~olding Station), the carton blan]c 100 is transpor-ted transversel~
across -the apparatus 10 and slngularly wrapped and creased into a square, open tube configuration around a forming mandrel (no-t shown). Subsequently, the car-ton blank 100 travels to Work Station I~I (the Seam and End Bondin~
Station) by being transferred onto a ro-tating crossbar mandrel 400 Through a series of operations occurring at Work Station III, the carton side seam is welded, and one end o the carton blank 100 is closed and bonded together to ~orm a liquid-tight seal.
~ t Work Station IV ~Carton Rotator and Conveyor Transport Station), the carton blank 100 is removed from the crossbar mandrel ~00, ro-tated 90 about its longitudinal axist and inserted upon a conveyor transport 550 on which the carton blank will remain until being ejected from the apparatus 10. ~hile disposed upon -this conveyor 550, the carton hlank, supported in a vertical orientation, travels - ~r 20 to ~ork Station V ~the End Closure Pre-Form Station) wherein, through a series o~ three discrete operations, the open end o the carton blank 100 is permanently creased into a configurati.on suitable ~or the subsequent end sealing operation.
2S Having the open end of the carton blank 100 properly creased, the carton blank 100 continues its transport along the conve~or 550 to ~or]c Station VI (Filler Station) whereln the carton is filled with a desired liquid. As represen~ed schema-tically in Figure 2, the filling of the carton blank 100 is accomplished in a two-stage operation b~ a pre-fill nozzle which supplies the sligh-t majority of the li~uid, and a topper nozzle which accurately fills the carton blank to the desired level.with onl~ the latter being adjusted for the two sizes of cartons produced on the apparatus~
Subsequen-tly, -the carton blank 100, filled with liquid, travels to Work Station VII (the End Sealing Station) wherein the open end of the carton blan~ 100 is welded to the square tubular side walls of the container 100~ ~ith the liquid sealed within the cart~n bl nk lG~, the carton 1~0 travels to Wor}; Stati~n VIII
(the Carton Ejector Station) wherein an eject~r m-chanism (not sho~n) removes the carton lDO from the conveyor trznspDrt 55D and ejects the same ~rom the end of the a?paratus 10.
~ s ~ill b~-0~2 ~re ap~arent from the follo;~in~
disclosure, the a~aratus 2nd ~-thod of the present inven.ion provide a hig~ volume pr~ducti~n apparat~s (ap~r~ximately ~4~ cartons per minute) and additionally pro~ide significan. sDace, reliability, and consistency impro~ements over prior art carton f~rming apparatus.
CARTo~ ~L~TT;
Referring now to Fig~lre 3, the~e is sho~!n a carton blan~ 100 ha~ing a generall~ T-sha?~d configuration from t~hich the seale~. an~ liquid-tight carton 1~ (sho~.7n in Fig~re lA) ol the present invention may be formed.

Basically, the carton blank is fo me d ha~ing an elongate centr~l sec.i~n a~d a pair of end panels integrally attached adjacer.t on~ end there~f. During the forming of the carton~
the central section is creased intO a sguare ~ubular 3~ coniguration and sealed al~ng ~ne ~f its edges to f~rm ; the side walls ~ the cart~n with the pair of end panels being subseg~entl~ folded ovex and sealed onto the square tube ~in a particular manner t~ be de5cribed belowl to ~ro~ide the end walls ~f the cart~n. As Will b2~m~ mDre 3~ ap?3rent, the particular carton blan~ c~nfi~uration yields a flat t~p container which xeduc~s the am~unt ~f ~aper ~ ~ .
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stock used in the con-tainer and increases handling and crating processes.
The blank 100 is preferably formed of a paperboard stock having a thickness of approximately fifteen thousandths of an inch and is coated at least on the outside surface thereof (which may be assumed to be the surface seen in Figure 3), and desirably on the inside surface as well, with a substance that will render the paper impervious to liquids intended to be contained within khe carton. The coating substance preferably possesses thermal-responsive adhesive properties such that liquid-tiyht sealing oE the component~ of the blank 100 may be accomplished without the separate application o F conventional adhesive substances at the time of blank forming and processin~. A thin \

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polyethylene film having c~n approximate thic~ness of 1/2 to 1-1/2 mils has been found to include these above properties and is well suited for use in -the present invention, especially when the container 12 is used for potable beverages, such as milk.
As may be s.een, the blank 100 includes an elonyate central section preferably composed of four eq~lal-sized segments 102, 104, 106, and 108, which are separated 10 or delineated by indentation or scoring lines 110. As will be explained in more detail bel~w, these carton segments 102 through 10~ will be folded along the scoring lines 110 to form the side walls of a square tubular configura-tion for the carton 12 of the present invention.
For~ed inteyral with the carton segment 108 are two end closure panels 112 and 114 ~Jhich, in the preferred embodiment, are formed in a general~y square configurati.on, due to the equal width of the carton segments 102-108.
These end panels 112 and 114 are similar in configuration, 20 except -that the end panel 114 incluaes a pair of sealing flaps 116 extending outboard of the segment 108 along opposite edges thereof. Additionally, end panel 112 is delinated or separated from the carton segment 108 by a score line 118. It will be recognized that various size 25 cartons may be formed by differing the lengths of the carton s~gments 102 through 108. It is a unique feature of the present invention that cartons of two different lengths (relating to 1/2 pint and 1/3 quart capacity) may be folded, sealed and filled with only minor adjustments to the 30 apparatus 10~
The carton segmen-ts 102~ 104, and 106 are each additionally provided with a pair of sealing t~bs 120 formed along their free edges by scoring lines 122. At the intersection of the scoring lines 110 and-122, the 35 sealing tabs 120 preferably include a scored V~shaped notch 124 ~hich, as will become more apparent below, aid in the subsequent l.iquid-tight sealing of the end panels 112 and 11~ to ~he carton segments 102-108.

2~i The carton blan]c 100 fur-ther includes an elongate aperture 126 Eormed adjacent the scoxe line 118 and e~tending partially through the length of the carton segment 108O As shown in Figure 4, and as will be e~plained in more detail infra, ~his aperture 126 provides access to the straw element 220 and is overlayed by a length of sealing tape 230A which provides a liquid-tight seal for the carton 100.
Work Station I - Straw and Sealing Tape Applicator Referring now to Figure 5, the component systems comprising Work Station I (Straw and Sealing Tape ~pplicator) of the apparatus of the present invention for forming liquid~containing cartons 12 may be described.
l~ork Station I includes, as major sub-systems, a conveyor ~L: loader 140, a straw inserter 142, a carton blank feeder mechanism 144, a heat seal and alignment ~rum 146r a tape dispenser 148, a stripper wheel 150, and a carton blank ~` pivot mechanism 152.
Prior to a detailed description of each of -these major component sub-sys-tems, a brief overview of the processes occurring a-t ~ork Station I will aid in the complete understanding of the apparatus~
Referring to Figure S, the carton blanks 100 are initially stacked upon the conveyor loader 140 ana travel horiæontally toward the rotating alignment drum 146~ At the end of the conveyor loader 140, -the carton blanks 100 are individually raised in a vertical direction and transferred to the rotating alignment drum 146 by the carton blank feeaer mechanism 144. Prior to this transfer ~ of the blank 100 onto the drum 146, the straw inserter : 142 loads a straw element 220 ~as shown in Figure 6) into a small channel 226 (-shown in Figure 10) formed in the periphery of the drum 146 such that, as the blank 100 is transferred to the drum 146, the straw 220 is located directly under the small aperture 126 ~Figure 4) formed in the blank 100; i~e., the carton blank 100 ~Figure 4) 11~31~Z~5 overlays the straw 220.
The straw 220 and carton blank 100 carried by the drum 146 are subsequently rotated past the tape dispenser 148 where a length of polyethylene coated Mylar substrate tape 230A
(Figure 4) is positioned on the blank 100 over the aperture 126 and straw 220. As the drum 146 continues its counterclock-wise rotation, a heater plate 254, located within the interior of the drum 146, cams outwardly and contacts the carton blank 100, thereby bonding the straw 220 to the tape 230 and concurrently sealing the tape 230 to the carton blank 100 over the aperture 126.
Subsequently, the blank 100 is removed from the drum 146 by stripper wheel 150 which deposits the bl~nk 100 in a hori-zontal plane. The blank 100 is then delivered by the carton blank pivot mechanism 152 to Work Station II of the apparatus for subsequent wrapping and folding around a forming mandrel.
Thus, as will become more apparent from the discussion belowr the carton blank 100, upon completion of its travel through Work Station I, will include a straw 220 and tape seal 230A securely sealed across the aperture 126, as shown in ~igure 4.
Referring again to Figure 5, the detailed construction and operation of the conveyor loader 140 is illustrated. The loader 140 preferably includes a pair of elongate conveyor belts 160 typically formed of rubber having a suitable coefficient of friction to prevent surface slippage thereon.
These belts 160 are stretched or held taut between two pairs of pulleys 162. Each pair of pulleys is mounted upon a shaft 164, one of which is connected to a drive mechanism (not shown) for rotating the pulleys 162 in a counterclockwise direction (as viewed in Figure 5).
The carton blanks 100 are initially stacked in a row upon the conveyor belts 160 in an inverted, T-shaped orientation such that the edge of the end sections 112 and * Trademark , as well as carton segment 108 (as shown in Figure 3), contact the V-belts 160. While positioned on the conveyor belts 160, the vertlcal orientation o~ the stack is maintaine~ by a pressure pla-te 166 which is spring biased in a horizontal direc-tion to travel along the length of the conveyor belts 160 toward the drum 146. As may be easily recognized, the counterclockwise ro-tation of the pulley pairs 162 causes the entire stack of carton blanks 100 to move continuously with -the conveyor belts to~7ard the carton blank feeder mechanism 144.
The loader 1~0 additionally includes a pair of L-shaped alignment blocks 167 at one end thereof, located above one oE the pulley pairs 16~. The vertical distance between the lower sur:Eace of the alignment blocks 167 and the upper surface of the conveyor belts 160 is spaced to provide a sligh-t clearance between the edges of the end panels : 112 and 114 of the car-ton blank 100, and the space bett~een - the bloc]ss 167 is adjusted to closely receive the sealing ~, 20 tabs 120 of the carton segments 106~ Thus, as the carton blank stack 100 moves along the tra~eling conveyor belt, these alignment blocks 167 precisely register each carton blank 100 upon the conveyor loader 140 for subsequent entry : into the carton blank feeder mechanism 144. Additionally, in the preferred embodiment, the outboard alignment block 167 (as viewed f~^om Figure S) is movably mounted in the direction transverse to the plane of the conveyor 14Q such that the space between the blocks 167 may be varied. This variable adjustment accommodates the difFering lengths of the carton segments 102-108 (Figure 3) when the apparatus 10 is modified to produce both the 1/2 pint and 1/3 quart capacity cartons :L2~
As the carton blan~ stack 100 moves beneath the L-shaped alignment blocks 167, each carton blank 100 is sequentially transferred to the heat seal and alignment drum 1.46 by the carton blank feeder mechanism 144. ~s may be seen in Figure 6, the carton blank feeder 7~i mechanism 1~ includes an eleva-tor plate 180 and a pineh roller 18~ which coopera~e to separate a single carton blan~ 100 from the stack and transfer the blan~ 100 onto the heat seal and alignment drum 1~6.
The el.evator plate 180 comprises a generally fla-t plate having a tapered back wall 18~ and a shoulder 186.
formed across its widkh adjacent its leading edge 187.
The shoulder 186 has a small step or recess 188 Eor~ed adjacent one end thereof, which-is sized to receive one of the sealing flaps 116 of the carton blank 100 (as shown in Figure 3). The depth of the shoulder 186 is machined -to be slightly less than the thickness of a single carton blan~ 100 such that the edge of only one carton blank may contact or ride on the shoulder 186 at one time.
Attached to the lower end of the elevator plate 180 is a cammed linkage (not shown) which is connected in a eonventional manner to the mechanism used for rota-ting the drum 146. This ca~ed linkage transforms the xotary motion of the drum 1~6 into reciprocating ver-tical movement o~
the elevator plate 180 as indicated by the arrow 187 in Figure 6.
The earton blank feeder mechanism 1~4 additionally ineludes a pinch roller 182 whieh is located above the elevator plate 180 and in close juxtaposition to the rotating heat seal and alignment drum 146. ~he outside diameter of the pinch roller 182 is formed with a redueed diameter section 190 which extends through approximately a 180 arc. As will be explained in more de-tail below, this reduced diameter section 190 permits the elevator plate 180 to ralse the individual carton blank 100 to a maximum height before the pi,nch roller 182 transEers the earton blank 100 to the rota-ting drum 1~6.
The pinch roller 182 is mounted to a shaft 192 which is connected in a eonventional manner through gears to the drum 1~6, thereby rotatin~ the pinch roller 182 in a clockwise direc-tion as sho~7n by the arrow in F.igure 6.

. !~

~8~ 75 The rotational speed of the pinch roller 182 is proportional to the rota-tional speed oE the drum 1~6 such that the sur:Eace speed of the periphery of the drum 146 and the 5 outside diameter of the pinch roller 182 are equal. The rotation o~ the pinch roller 182 is synchroniæed wi-th the.
reciproca-ting motion of the elevator plate 180 such that the reduced diameter sec-tion 190 of the pinch roller 182.is adjacen-t the periphe:ry of the drum 146 as the car-ton blank 10 100 is raised by the elevator plate 180~ As will be explained below, this synchroniæed movement be-tween the pinch roller 182 and the elevator plate 180 pre registers the carton blank 100 upon the rotating drum 146.
Re:Eerring now to Figure 7, the detailed operation and 15 interrela-tionship be-tween the conveyor loader 1~0, the carton blank feeder mechanism 14~, and the heat seal and alignment dxum 1a~6 may be described. As the carton stack 100 moves along the conveyor loader la~0 past the alignment blocks 167, the elevator plate 180 recipr~cates 20 downward, whereby the lower edge of the shoulder 186 travels below the lower edge o:E the leading car~on blank 100 indicated by the numeral 200.
In this position, the travel o:E -the conveyor loader 140 causes -the leading individual carton blank lOOA
25 to be pushed o~ the conveyor loader 1~0 and onto the shoulder 186 of the elevator plate 180. Since the width o:~ the shoulder 186 is slightly less than the thickness of the carton blank lOOA, and the eleva-tor plate reciprocates closely against the back surface oE the alignment bloc}i 30 167 r on:l.y a single carton blank lOOA is removed :Erom the s-tack 100 and elevated to~7ard the pinch roller 182. Thus, as the single blank lOOA is raised, it slides against the next adjacent blank, which is held stationary by -the alignmen t blocks 167.
As shown in Figure 7, the elevator plate 1~0 ra~ses the individual carton blank lOOA be-tween the rotating drum 1a~6 and -the pinch roller 182 to a height ~herein the f~!

7~;i leading eclge of the carton blank lOOA is sligh-tly above the tangency point between the drum 146 and pinch roller 182 ~s previously mentioned and clearly shown in Figure 7, during this upward travel of the carton blank lOOA and elevator plate 180, the reduced diarneter section 190 of the pinch roller 182 faces the periphery of the drum 146 and is spaced therefrom to provide a small gap 202 into which the leading edye of the carton blank lOOA may be received~
Thus, as may be recognized, this gap 202 allows the carton blank lOOA to ride between the rota-ting drum 1~6 and rotating pinch roller 182, and remain stationary therebetween until the carton blank lOOA is contacted by the leading edge 20 of the larger diameter portion of the pinch roller 182.
15 The applicant has discovered that by allowing the carton blank 100 to remain momentarily stationary in this raised position, the carton blank is pre-registered to within 1/32 of an inch of its proper location on the rotating drum 1~6.
With the carton ~lank lOOA raised to the position 20 illustrated in Figure 7, the cortinued clockwise rotation of the pinch roller 182 causes -the leading edge 20~ of its larger diameter portion to contact -the surface of the carton blank lOOAo Upon contact therewith, the gap 202 is .
significantly narrowed, such that the carton blank lOOA
25 is pinched and propelled upward between the periphery of the drum 146 and pinch roller 182. Since the relative surface speeds of the rotating drum 146 and pinch roller 182 are e~ual, the carton blank lOOA is raised uniformly upward without slippage and removed from the elevator plate To facilitate the transfer of the carton blank-IOOa to the periphery of the drum 1~6, the peripheral surface of the drum 146 is provided with a series of vacuum orifices 1~7 (shown in Figure 11) preferably arranged in a patterned array within the area covered by the carton blank lOOA and connected by a conventional valving and conduit system (not shown) communicating ~ith a remotely located vacuum source z~ ~

(not shown). These apertures 1~7 ac-t upon the inside surface o:E the car-ton blan}~ lOOA to effectively m.aintain the carton blank lOOA pressed against the periphery o:E the 5 drum 146. As may he recoqnized, since the outside diameter of the drum 146 is much greater than the thickness of the.
carton blank lOOA, the slight curvature of the carton blank lOOA upon the arum 1~6 is insufficient to cause creasing or permanent distor-tion of the carton blank ~OOA.
ld To insure the final proper alignment and registration of the carton blank lOOA upon the drum 1~6, a pair of registration tabs ~06 are provided alony both outside ed~es of the drum 146. The peripheral spacing between the tabs 206 is ad~usted to be slightly greater than the width 15 o:E the end sections 114 and 112, respec-tively, of the carton blank lOOA ~as shown in Figure 3). Further, the inside edye of each of the registrati.on -tabs 206 is preferably provided with a chamfer ~Jhich aids in the insertion of the end closure panels 11~1 and 112 after 20 transfer of the carton blank lOOA from -the carton blank feeder mechanism 1~4 to the drum 1~6.
Thus, as the car-ton blank lOOA is pinched between the roller 182 and drum 146 and applied against the periphery of the drum 146, these registration tabs 206 25 receive the end closure panels 114 ana 112, respectivelyr o:E the car-ton blank lOOA at a point adjacen~: the gap 202.
Upon entry of the end closure panels 114 and 112 into the registxation tabs 206, any IrLinor variances in the location of the carton hlank 100 upon the drum 1~6 will be eliminated 30 by the tight fit of the end panels lla~ and 112 within the regis-tration tabs 206 which cause the carton blank to float along the periphery of the drum la6 into its proper position. Subsequently, vacuum is applied to the vacuum orifices 1~7 (shown in Fi~ure 11) to maintain the carton 35 blank 100 in its aligned position upon the periphery oE
the drum 1~6~
Thus, from the above, i-~ may be recognized that the carton blan]~ feeder mechanism l~L~ effec-tively -txansfers 2~
the carton blan~ 100 from the conveyor loader 140 to an accurately aligned posi-tion on the heat sealincJ and alignment drum 1~6.
As previously mentioned, prior to the -transfer of the carton blank 100 onto the rotating drum 1~6, a plastic straw element 220 (preferably formed of polyethylene) must be placed upon the periphery of the drum 1~6, and in the preferred embodiment is accomplished by a straw inserter mechanism 1~2 ReEerring jointly to Figures 5 and 8, the straw inserter 142 is rigidly mounted adjacent the outer surface of the drum 14~ and maintained in a stationary position while the dr~n 1~6 rotates in a counterclockwise direction. The straw inser-ter 1~2 is pre-ferably composed of a straw storage hopper 222, a separator or singulator 223, and a feeder or transport mechanism 224. A plurality of straw elements 220 are stored wi-thin the hopper 222 and are oriented such ~hat the length of each stra~
element 220 is parallel to the axis of rotation of the drum 146. ~t its lower end, the hopper 222 includes an elongate opening 221 ~shoi~m in Figure 8~ the width of which is sli~htly greater than the outside diameter of the straw element 220. As will be explained in more detail below, this opening 221 permits a single straw element 220 to be transferr~d from the singulator 223 to the transport or feeder mechanism 22~.
~ s sho~ in Figures ~ and 8A, the singulator 223 is formed in a cylindrical drum configuration, having an outer shell 201 which includes a plurality of semi-circular grGoves 225 symmetri.cally spaced along its outer periphery~
The width of the grooves 225 is preferably formed slightly greatex than the diameter of the straw element 220 such that a single straw element 220 may be carried therein.
Disposed within the interior of the shell 201 and positioned adjacent its lower edge (as shown in Figure 8A) are a pair of roller members 209 wllich are each mounted for rotation about a shaEt 211~ The shafts 211 axe vertically spaced from the a~is of the outer shell 2~1 and e~tend outboard of the simulator 223 being supported at one end by a pivot arm 203. The roller members 20~
are free to rotate about the shaf-t 211 (in a direction indicated by the a.rrow in Figure 8A~ while the shaft 211 is spring loaded as by way of springs 205 in a downward direction to continuously bias the roller members 209 adjacen-t the lower end of the shell 201.
In the preferred embodiment, the inside diameter of the shell 201 includes a pair of annular recesses 227s ~7hich ex-tend part-way into the grooves 225 forming plural apertures 207. These recesses 227B provide a race or path which aligns the roller members 209 with the shell 201 while the apertures 207 permits the rollers to enter subs-tantially within the interior of the grooves 225.
As shown in Figure 3A, by this particular arrangement, the roller members 209 each selectively contact the portion of each straw element 220 residing directly above the apertures 207 formed by the annular recesses 227B thereby causing the straw elemen-t 220 to be axially pre-stressed into an oval configuration adjacent the lower end of the hopper 222. As will be explained in more detail below, this 25 pre-stressing of the straw element 220 is utilized to provide a self-propelling means for transferring the straw element 220 into the straw feeder or transport mechanism 224.
Referring to Fi~ure 8, it may be seen that the 30 singulator 223 is mounted as b~ way of a cen-ter web (not shown) upon a shaft 227 which is journaled to the walls o:E the hopper 222 for movement in a clockwise direction as indicated by the arrow in Figure g. The ¦
shaft 227 mounts a ratchet mechanism 229 adjacent one 35 end thereof ~hich is activated by a hydraulic or pneumatic actuator 231. This hydraulic or pneumatic actuator 231 is connected to an ex-ternal pressure source (not shown) and is rec~ulated by a valve (not sho~,~m) to periodically ro-tate the shaft 227 and thus the singulator 223 through an angle equal to the spaci.ng between adjacent grooves 225 formed along its periphery. As will be recognized, during this periodic rotation, a single straw element 220 travels toward the opening 221 formed in the bottom of a hopper 222 for deposition into the feeder mechanism 224.
Disposed beneath and positioned tangen-t to the singulator 223 is a feeder mechanism 224 which rotates on a shaft233a connec-ted in a conventional geared manner to the drive mechanism (not shown) o:E the rotating heat seal and alic~nment drum 146. The feeder mechanism 224 preferably includes an enlarged cylindrical end section \

.
-235 having a groove 237 formed axially along its periphery.Disposed wi-thin the groove 237 and reciprocable throughout the leng-th thereof, is an ejector pin 253 which is connected to a mechanical lin~age (not shown) contained within the cylindrical head 235 and synchronized with the rotation of the heat seal and alignment drum 1~6. ~s will be explained in more detail below, the ejector pin 253 transfers an individual straw element 220 toward the periphery of the drum 146 during operation.
An elongate riser 239 is rigidly a-ttached to the shaft 233aand extends from the inboard end of the cylinder Z35 to a position substan-tially benea-th the periphery of the heat seal and alignment drum 146 (as better shown in Figure 9). The top surface oE the riser 239 is provided wi-th a channel 2~1 having a s~uare tubular configuration, -~he interior cross-sectional area of which is slightly greater than that of a single straw element 220. As shown in Figures 8 and 9, this channel member 241 is aligned 20 wi-th the groove 237 formed in the cylindrical end portion 235 such that a straw element 220 may be transferred a~ially throughout the length of the groove 237 and channel member 241. In the preferred embodiment, the channeI
member 241 has a sufficient length to acco~nodate three straw elements 220.
The extreme inward end of the riser 239 ana channel me~ber 241 is provided with a pair of access slots 243 which extend radially inward toward the shaft233a to a depth slightly below the lower surface oE the channel 30 member 241. Further, the top ~ortion of the channel member 241 is removed adjacent these slots 243 which, as will be recognized below, facilitates the removal of the str~w element from the channel member 241. ~s best shown in ~igures g and 10, these slots 243 are aligned 35 with a pair of ca~ming fingers 245 which are rigidly attached to the frame (not shown) of appara-tus 10 and juxtapose the periphery of the heat seal and alignment drum 146. These camming finyexs 245 contact the lower surface of the stra~ element 220 con-tained within the channel member 241, causing the straw element 220 to be transfexred to the periphery of the rotating drum 146 as the feeder mechanism 224 .rotates in a clockwise direc-tion as indicated by the arrow in Fiyure 8.
The periphery o~ the heat seal and alignment drum 146 includes an elongate groove or channel 226 which extends partially across the periphery of the hub 146 ~as indicated by the dotted line in Figure 9). The depth of this groove 226 is slightly less than the diameter of the stra~7 element 220 such that, upon .inser-tion o~ the straw element 220 into the aperture 226, a small portion o~
the diameter of the s-tra~ element 220 protrudes above the periphery of the drum 146.
In the preferred emhodiment, -the groove 226 is formed in an insert member 247 which is attached to and resides ~ ~ithin the interior of the periphery of the heat seal and ; 20 alignment drum 146. As shown, a raised portion 251 of the insert member is flush mounted to the drum 146 and forms a portion of the outer periphery of the rotating drum 146~ Additionally, to maintain the stra~ element 220 within the groove 226 until -the carton blan~ 100 is applied to the drum 146 (in a manner previously described) a shroud 249 (Figure 103 is provided which is minimally spaced from the outer periphery of the drum 146 and extends between the upper end of the camming fingers245 to just below the gap formed bet~een the drum 146 and pinch roller 182 (Figure 7).
In operation, as the heat seal and alignment drum 146 rotates in a counterclockwise direction (as indicated by the arrow in Figure 8), the singulator 223 is rotated through a short distance (in a directiQn indicated by the arrow thereon), by the actuation of the hydraulic or pneumatic cylinder 231. This rotation of the singulator 223 causes a single straw element 220A, .initially located i32~75 at approxima-tely a five olclock position upon the singulato~ 223 (as indicated in Figure 8A), to travel toward the opening 221 of the hopper 222 to an approximate six o~clock position. During this rotational travel, the portion of the stra~7 element 220A residing immediately above the apertures 207 forrned by the annular recesses 227B, contacts the periphery of the roller members 209 and is tightly pressed or s~ueeze~ against the lower wall of the hopper 222 by the springs 205. This squeezing causes the straw element 220A to deform into a pre-stressed oval configuration represented by the numeral 220B in Figure 8A.
In s~nchronism~ with the ro-tation of the si.ngulator 223, the feeder mechanism 224 continuously rotates in a ~lockwise direction (as indicated by the arrow in Figure 8A) so thak the groove 237 formed on the cylinder 235 of ~he feeder mechanism 224 aligns or registers wi-th the opening 221 of the hopper 222 and the groove 225B of the singulator 223. This alignmen-t, which, due to the continuous rotation of the feeder mechanism 224, is maintained for only an instant oE time, causes the single straw element 220B to e~it the groove 225B of the singulator 223 (in a direction indicated by the phantom 25 lined arrow in Figure 8A) and enter the groove 237 formed in the feeder rnechanism 224.
Due to the downward biasing force of the springs 205 as well as the pre stressed oval configuration of the straw element 220B, and the high memory properties of the polyethylene straw element ma-terial, it will be recognized that the transfer be-t~7een the grooves 225B and 237 occurs almost instantaneously, with the straw element 220s in effect being self-propelled or shot from the singulator 223 into the groove 237.
Subse~uent to this transfer of the straw elerllent 220B~
the feeder rnechanism 224 continwes its rotation about the shaft 233 in a clockwise direction as inaicated by the arrow in Figure ~, so -that, due -to the ~roove 237 being formed slightly greater than -the diameter of the straw . t~
., ~1~8~S~

element 220B, the straw element 220B may return to its initial uns-tressed cylindrical configuration. During this rotation, a shroud ~`. substan-tially suxrounding the pexiphery of the cylindrical portion 235 of the Eeeder mechanism 224 r maintains -the stra~ element 220 within the groove 237.
As the groove 237 and s-traw elemen-t 220 rotate to approximately the nine o'cloc~ position, as viewed in Figure 8, the ejector pin 253 rapidly travels throughout the length of -the ~roove 237, thereby causing the stra~7 element 220 contained therein to enter into the channel member 241. The channel member 241 which, as previously mentioned, is formed -to accommodate three strat~ elements, ~ 15 has been preloaded wi-th two straw elements 220 during the previous t~70 reciprocations of the ejec-tor pin 253.
Therefore, this -transfer of the straw element 220 from the groove 237, advances -the outer-mos-t straw element to reside adjacent the extreme end of the channel 241.
Subsequently, the continued rota-tion of the feeder mechanism ~24 causes the leadi.ng edge of the camming fingers 245 to enter into the slots 243 formed in the riser 239 (as shown in Figure 10), and contact the lower surface of the straw element 220. Upon contact with the fingers 245, due to the continued rotation o~ the feeder mechanism 224, the straw 220 cams along the concave upper surface of the camming ~ingers 245 and travels vertically upward toward the periphery o-E the drum 146.
The rotation oE the drum 146 and the feeder 3~ mechanism 224 are s~nchronized such that~ as the feeder mechanism 224 rotates past the camming fingers 245, the groove 226 formed along the periphery of the drum 146 is aligned ~^lith the channel 241. Thus, con-tinued rotation of the Eeeder mechanism 224 causes the stra~J

~IL18B275 elemen-t 220 contained within the channel 241 to enter into -the groove 226 formed along the periphery of the drum 146~ Once inserted in the channel 226, the straw element 220 is maintained therein by the shroud 249 ~as shown in Figure 10) which is minimally spaced from the outer periphery of the drum 146 and extends from the up~er end of the camming finge.rs 245 to just below the gap formed between the drum 146 and pinch roller 182.
After the actuation of the feeder pin 253, during which the single s-traw element 220 is transEerred into the channel me~ber 2~1, the feeder pin 253 rapidly reciprocates back to i-ts initial position as shown in Figure 8 so that the channel 237 i.s free to receive an additional straw element 220 from the singulator 223, and repeat the cycle previously described. Thus, from the above, it will be - recogni2ed that the straw inserter 142 of the present invention provides a simple yet effective mechanism Eor transferring a series of single straw elements 220 from the hopper 222 onto the periphery of the drum 146.
Subsequent to the insertion of the straw element 220 înto the channel 226, the drum 146 continues its counter-clockwise rotation to the location where the carton blank 100 is transferred onto the hub 146 by the carton blank feeder mechanism 144 in the manner previously described.
The location of the channel 226 on the periphery of the drum 146 is designed such that, when the carton blank 100 is transferred onto the drum 146~ the channel 226 and straw element 220 is disposed beneath the aperture 126 of ~he carton element 100 as shown in Figure 4 Thus r by -the operation of the straw inserter 142 and the carton blank feeder mechanism 144, the carton blan}c 100 and straw element 220 are t.ransferred onto the drum 146 in a proper relative orientation for the subsequent tape length heat bonding and sealing operation.
Continued rotation of the drum 146 causes the straw element 220 and carton blank 100 to pass under the tape ,. .

dispenser unit 143 wherein a length o:E tape 230A is deposi-ted over the aperture 126 of the carton blank 100 (as shown in Figure 4)~
Referring to Figure 5, the tape dispenser mechanism 148 includes the following components: a length of tape 230, a pair of tape caps-tans 231 and 232, a tape yuide 233, a back pressure chamber 234, and a supply spool 236.
The supply spool 23~ is rotatably mounted to the housing 238 and stores the length of tape 230 which, in the preferred embodiment, is formed of a polyethylene coated Mylar material. As shown, from the supply spool 236, the -tape 230 is threaded throu~h the tape guiae 233 and disposed between the two tape capstans 231 and 232. Tn operation, the capstans 231 and 232 simultaneously contact the tape length 230, whereby the tape length 230 is cut and transferred to the carton blank 100 disposed upon the rotating heat seal and alignment drum 146.
Referring now to Figure 11, the detailed construction and operation of the tape dispenser 148 r.~ay be descrihed.
As will be recognized, for purposes of illustration, the supply spool 236 and the vacuum char~er 234 have been removed from the apparatus in this figure~ As shown, the -tape capstans 231 and 232 are each mounted on a drive shaft 235 and 237, respectively, which are connected, as by a ~ear train, to the drum 146 to rotate in opposed directions (as indicated by the arrows in Figure 11) in synchronism with the rotating heat seal and al~gnment drum 146.
The upper tape capstan 231 includes a substantially L~shaped housing 239 having a radial]y extending leg 241 The capstan 235 additionally includes a central cavity 243 into which is mounted a pressure plate 245 having a convex surEace and a knife ed~e asser!~ly 247.
The pressure plate 245 is preferabl.y formed having a concave outer surface which includes a series of serrations or a knurl finish thereon~ As better shown in Figure 13, the pressure plate 245 is mounted within the cavi-ty 243 2~i adjacent the leg 241 of the housing 239 and is xetained in position b~ a spring 2~6 compressed ~etween the pressure plate 245 and housing 239. This spring 246 biases the pressure plate 245 in a radially out~,Jard direction, yet permits inwarcl movement of the pressure plate 245 in response to compression forces exerted on the top surface of the pressure plate 245.
A knife edge assen~ly 247 additionally resides within the cavi~y 243 and includes an ~-shaped mounting member 251 onto which a blade 253 is securely mounted.
As shown in Fi.gure 13, the L-shaped mounting member 251 is pivotally attached to the housing 239 by a self-aligning pin 249 which aligns the blade 253 with the other capstan ~32 during rotation to ensure that the tape 230 is sheared completely across i-ts width. Further, the mounting member 251 and blade 253 are bi.ased in a counterclockwise direction against the housing 239 by a pair of springs 255.
As such, the blade 253 is constantly urged against the pressure plate 245 and aligned with the other caps-tan 232 as the pressure plate reciprocates radially inward and outward within the cavity 243.
Referring to Figure 12, it may be seen that the lower tape capstan 232 has a generally semi circular conEiguration and includes a boss or land 257 which extends radially outward therefrom. As with the pressure plate 245 of the upper tape capstan 231, the top surEace of the land 257 is formed in a convex configuration, the radius oE which is complementary to that of the pressure plate 2~5 of the upper tape capstan 231. In addition, the land 257 includes a knife edge 254 adjacent one side thereof which aligns with the blade 253 of the upper capstan 231 d~ring operation to shear the tape length 230 in a manner to be described belo~. The top surEace of the land 257 inclu~es a plurality o:E apertures 259 extendin~ across the length thereof ~hich . are connected to an externally located vacuum source (not shown) ~s will become more apparent from the follotJing description, the vacuum at these aper-tures 259 holds the tape length 230 against the land 257 for subsequent l~ *

,75 3~
deposition upon the periphery of the drum 146.
~s shown in FicJure 11, the tape capstans 231 and 232 are preferably positioned in a subs-tantially vertical S orientation and are spacec'. from one another such that, durinc~ their opposecl xota-tion, the convex sur aces o~ the pressure plate 2~5 and land 257 tangen-tiall~ contact one another. Additionally, the lower tape capstan 232 is mounted in close ~ux-taposition to the rotating drum ~6 1~ such that the outer surface of the land section 257 is minimally spaced Erom the periphery of the rotating drum 1~6 during rotation.
The tape guide 233 is com~osed of a pic-ture fram~-likQ
supPort structure 261 having a pair oE tapered, mating plates 263 and 26~ which are rigidly mounted along the bottom surface of the -Erame 261 and pivotall~ mounted adjacent the median oE the rrame 261, respec-tively. The support frame 261 is additionally pivotally attached intermediate its len~th to a bracket 269 which is ricJidly connected to the frame or housing 23~.
A hydraulic or pneumatic opera-tor 271 a-ttached to the upper end of the frame 261 is provided to adjust the orientation oE the plate members 263 and 265 relative the tape capstans 231 and 232. As will be recoynizedr by energizin~ the operator 271, the support Erame pivots in a coun-terclock~ise direction to position the plates 263,265 proximal the two tape capstans 231 and 232 as illustrated in Fi~ure 13.
The lower surface oE the upper plate member 265 is formed having a shoulaer 267 which extends throucJhout its width. This shoulder 267 forms, in effect, a one-way wedge which permits the upper plate 265 to pivat about its upper pivot axis toward the tape capstans 231 and 232, yet prevents ny pivo-tal movement of the top plate member 3S 265 in the opposite direc-tion therefrom. Further, the top pla-te member 265 is constantly urgecl in -the direction away fxom the capstans 231 ana 232 by a sprinc~ 273 which extencls from the rear surEace oE -the top pla-te member 265 to the ,~,.

~8~275 rigid support bracket 269. I~i-th the tape length 230 threaded between the pla-ke members 265 and 263, the do~nward pivotal movement of the pla-te 265 is cons-trained by the lower plate 265 so -that the tape leng-th 230 is permitted to travel only in the direction toward the tape capstans 231 and 232, as indicated by the arrow in Figure 11.
During the initial star-t-up procedure of the apparatus 10, -the hydraulic actuator 271 is energized, thereby pivoting the plate ~.emb~rs 263 and 265 closely adjacent the tape capstans 231 and 232 to the position indi.cated in Fi.gure 13. As shown, in this initial position, the tape length 230 preferably extends slightly beyond the ends of the plate members 265 and 263 and resides along a plane tangen-t between the tape capstans 231 and 232.
~s the tape capstans 231 and 232 rotate in their opposed directions as indicated by the arrows in Figure 20 13, the leaaing edges of the land 257 and the pressure plate 245 simultaneously contac-t opposite sides of the tape length 230, thereby tightly pinching the tape length 230 against the knurled top surface of the pressure plate 2~5.
The continued rotation of the tape capstans 231 and 232 causes the tape length 230 to be advanced from the tape guide 233 across the width of the concave surface of the land 257. During this ro-tation, the pinching pressure exerted by the land 257 against the top surface of the pressure plate 245 causes the pressure p].ate 245 to reciprocate in a radially inward direction, o~ercoming the opposing force exerted by the biasing spring 2~6.
During this operation, the tape length 230 is advanced from the tape guide 233 while the pressure plate 245 reciprocates within the cavity 243 of the rotating member 231.
As shown in Figure 1~, with the continued opposed rotation of the tape capstans 231 and 232, -the pressure 7~i pl.ate 2~s5 reciprocates radially inward beyoncl the top edge of the blade 253. Additionally, during this rotation, a pair of tabs 2~8 which protrude radially outward from the distal edge o:~ the blade 253 contact the trailing edge oE the knife edge 25~ causin~ the blade.
253 to pivot slightly backwards against the spring 2550 This slight backwarcls`pivoting aligns the cutting blade 253 with the knife edge 25~ so that the blade 253 shears the tape length 230 adjacent -the trailing edge o:E the land section 257 o~ the lower tape capstan 232. The sheared length ol tape 230A (as shown in Figure 1~) is subsequen-tly maintained on the outer surface of -the land 257 of the lower tape capstan 232 during continued rotation of the tape capstans 231 and 232 by the vacuum applied through the ~acuum apertures 259 (shown in Figure 12).
The vacuum is maintained during the conti.nued rotation o~ the capstan 232 ~mtil approximately the seven o'clock position (as viewed from Figure .L~), at which point the tape length is proximal the periphery of the dru;n 1~6 (shown in Figure 11). In this seven o'clock position, the vacuum to the vacuum ports 259 of the lower tape capstan 232 is discontinued, so that the vacuum ports 147 located on the periphery of the heat seal and alignme~t drum 1~6 and acting through the aperture 126 o~ the carton blank 100 pull the tape length 230A from the surEace of -the land section 257 tightly against the periphery of the drum 146.
Referring to Figure ~, the approximate size and orienta-tion of the tape length 230A upon the carton blank 100 may be seen. As shown, -the tape length 230A is formed having a leng-th L which is su:Eficient to extend across the width oE the aperture 126. Additionally~ the ~7idth of the tape length 230 is sized to extend beyond the encls of the aperture 126 onto the carton segment 108 and the end closure panel 112. As will be explainea in more detail below, this extension of the tape length 230a over the aper-ture 126 is necessary to facilitate the heat sealing and bondincJ process whlch subsequently occurs upon the rotatin~ drum 146.
The rotational speed and relative orientation of the tape capstans 231 and 232 must be precisely synchronized .
with the rotation o:E the heat seal and ali~nment drum 146 to insure tha-t the tape lencJth 230A is deposited over the aperture 126 of the carton blank 100 upon the peripher~
of the rotatincJ drum 146. Further, it will be recognized that it is imperative that the vacuum to the ports 259 located upon the land 257 of -the lower tape capstan 232 be discontinued at the proper position to allow the tape len~th 230A to be transferred onto the periphery 15 oE the drum 146.
In the preferred embodiment, the applicant has found that by directly cJearing the shaf-ts 235 and 237 of the tape capstans 231 and 232, respectively, to the drive mechanism of the rotating drum 146 and additionally utilizing a sliaer plate valve (not shown) connected to the vacuum ports 259 to reyulate the applicatlon of vacuum dependent upon the rotational orientation of the caps~an 232, the precision and repetition necessary to facili-tate proper operation of the tape dispenser 148 may be obtained~
Further, the applicant has discovered that~ to maintain the proper orientation of the tape length 230 enterin~ the tape ~uide 233 and to prevent an excess amount of tape 230 from beincJ dispensed from -the tap2 guide 233, it is desirable to power advance the tape length 230 from 30 the supply spool 236 to the tape cluide 233. In the preferred embodiment, this power tape advance is accomplished by a motor drive (not shown) on the spool 236 which is controlled by a pair of pressure sensitive switches (not shown) positioned at different locations within a vacuum 35 chamber 234 (Fi~ure 5). As shown, the vacuum ch~mber 234 is pre:Eerably formed in a rec-tan~ular box~ e confic~uration havin~ a sealed and opened end, respectively. ~ vacuum 2~7S

cluct 277 communica-tes with the vacuum chamber 234 adjacent the sealed encl and is connected to an ex-ternal vacuum source (no-t shown). Disposed midway be-tween the sealed and open ends of the vacuum chamber 23~ is a wire screen or mesh 275 which permits the vacuum to act therethrough yet prevents the tape length 230 from entering into the duct 277. The pair of vacuum switches (not shown) are disposed adjacent the open end o -the chamber 234 and are horizontal~y spaced from one another and the mesh 275.
As shown, the -tape length 230 is wrapped around a spool 279 and inserted into the open end of the vacuum cham~er23~ in a looped configuration. The vacuum, acting through the duc-t 277, pulls the tape loop toward the wire screen 275, causing the vacuum to act upon the side of the -tape length 230 facing the screen 2-75... ~hus, it ~lill be recognized that the pressure switches (not shown) are exposed to vacuum or atmosphere depending upon ~' 20 the location of the tape loop w.ithin -the chamber 23~.
In the preferred embodiment, this alternative exposure to the vacuum or atmospheric pressure is used to control the motor drive (not shown) of the spool 236 witn the motor being actuated when the switch furthest from the screen 275 is under vacuum and deactivated when the switch closest to the screen 275 is under atmospheric pressure. Thus, the amOlmt of tape length 230 available to advancement through the tape guide 230 is automatically regulated to prevent the tape length 230 from being over-advanced during the tape dispensing cycle.

Additionally, it will be recognized that, due to the shearing oE the tape length 230A occurring at a point subs-tantially spaced from the end oE the plate mem~ers 263 and 265 (as sho~m in Figure 14), a short amount of tape 230B extends beyond the plate members 265 and 263 upon each shearing operation. After shearing, the tape end 230B is thus in proper position for the repetition of the tape advancing, shearing, and depositing cycle.
Thus, from the abover it will be recognized that, af-ter passing beneath the tape dispenser unit 148 oE the present invention, a length of tape 230A is cut and placed over the aperture 1~6 and main-tained upon the car-ton blank 100 disposed upon the periphery o the rotating heat seal and alignmen-t drum 146.
The next process per-Eormed in Station 1 is the heat sealing and bonding process wherein the straw element 220 is tack bonded to the tape length 230A and the -tape length 230A is concurrently sealed to the carton blank 100 over the aperture 126. In the preferrea embodiment, this heat sealing and bonding procedure is accomplished on -the rotating drum 146 by a novel heater plate apparatus which is stored in a retra~ted position within -the interior of the drum 146 and intermitently cams outwardly through the periphery of the drum 146 to contact the carton blank 100.
As shown in Figures 6 and 7, the drum 146 includes four square-shaped apertures 250 which are spaced symmetrically around the periphery of the drum 146 ~i.e.S
at ~0 intervals). The leading edge 252 of each of the apertures 250 is located adjacent the rear alignment tab 206 such thatt the aperture 250 is closely positioned near the panel segment 108 when the cart-on blan~ 100 is maintained on the drum 146. Coopera-ting with the aperature 250 is a I' ,~.

~ o heater plate 254 pivotally connected to a cam follower 256 hich rides within a cam 255 (illustrated schematically in Figure 7) and is rigidly mounted within the interior of the drum 1~6~ A hydraulic or pneumatic actuato.r 257 is additionall~ ~ounted to the cam follower 256 adjacen-t-one end and extends to the heater plate 254 at a point located c~bove the heater plate-cam follower pivot. ~s will become more apparent below, duriny rotation of the drum 146V the cam follo~7er 256 rides within the stationary cam 255 thereby extending and retracting the heater.plate 254 through the aperture 250. Upon extension therethrough r the hydraulic actuator 257 is energized and extended throuyh a short distance causing the lower surface of the hea-ter plate 25~ to be pressed firmly down against the periphery of the drum 1~6.
The heater plate 254 preferably includes a xesistive hea-ting ele~ent (no-t shown) w'nich electricall~ he~ts the plate 25~ to a te~.,perature suitable for rapidly tacking `~ 20 the polyethylene straw element ~20 to -the tape 230~ as well as bonding -the polyethylene coating on the Mylar -tape length 230A to the carton blank 100. As shown in Figure 15, the bot-tom surface 259 o~ the heater plate 25~ inclu~es a raised boss 261 formed in a rectangular picture frame-like configuration and a tab member 263 surmounted within the interior thereof, both oE which are preferably formed having a smooth face~ The outsiae dimensions of -the boss 261 are si~ed slightly greater than the aimensions of the aperture 126 of the carton blank 100 such that when -the heater plate 254 is pressed down upon the carton blank 100 disposed upon the periphery of the drum 1~6, the boss 261 and tab 263 contact the peri~leter of the tape length 230A and a localized area of tape length located above the straw elemen-t 220, respectively, as indicated by the sti.ppled lines in Figure 4.
Referring to Figure 7, the cycle of the heater plate ~ 254 w}lich occurs cluring each revolution of the drum 146 ; is illustrated. As the individual carton blank lOOA

1, 32~

~ 1 is transferred to the periphery of the drum 146, in the manner previously described, the heater plate 254A

~indicate~ in phantom lines~ is stored within the interior of the drum 146 so that it does not interfere with the carton blank transfer process. As the drum rotates from a three o'clock position toward the twelve o'clock position, a cam follower 256 riding wi-thin the cam 255 e~tends the heater plate 254s radially outward through an aperture 250 and then slightly for~ard in a counterclockwise dlrection. While in this extended position, a pneumatic actuator 257 is energized in a direction indica-ted by the arrow in Figure 7, thereby firmly pressing the bottom surface 259 ol the heater plate 254B against the carton blanX 100. In the preferred . embodiment~ the cutward reciprocation of the heater p~ate 254B and direct contact against the carton blank 100 occurs rapidly and is comple-ted at approximately the : one o'clock position in Figure 7, As previously mentioned, the heater plate 254 only contacts the car-ton blank 100 in the localized area of the tape length 230A~

straw el.ement 220, and aperture 126 (as indicated by the stippled lines in Figure 4) such that the polyethylene substance coating the remainder of the blank 100 is not ; 25 heated or damaged during this process.

The heater plate 254B remains in contact with the carton blank 100 for approximately 1/2 xe~olution o the drum 146 or until the heater plate 254C rotates past the nine o'clock position as shown in Figure 7~ During this period, the heater plate 254B, heing at an elevated temperature due to a resistive heating element therein (not shown), causes the tape length 230A -to ~e bonded to a portion of the straw element 220 and concurrently be sealed to be the ou-ter surface of the carton blan~ 100.

It will be recognized that the temperature of the heater plate 254 must be maintained at a constant value ~hich is suf~icient to rapidly bond c~na seal the polyethylene straw element 220 to the polyethylene coated tape length 230a and carton blank 100, yet be low enough to prevent vaporization of the polyethylene material or the melting of the Mylar substrate o the tape length Z30a. Further, due to the polyethylene stra~
element being substantially thicker than the polye-thylene coating on the tape length~30a or carton blank 100, and the insulation effects o~ the card~oard carton blanl~ 100, the temperature o~ the heater plate as well as the period o~ time that the heater plate 254 contacts the elements, must be carefully controlled to en~ure a satisEactory seal and bond.
Additionally, the applicant has ~ound that, due to the di~ferent thermal expansion rates o-f the Mylar and polyethylene materials, -the tape length 230A, i~ preheated, will wrinkle during -the bonding process~ As such, the heater plates 25~ must firmly press the tape length ~, 2U 230A against the carton blank 100 and additionally rapidly seal and bond the elements together~
Thus, it will be recognized tha-t, through the reciprocating heater plate 254 and raised boss 261 and tab member 263 o~ the present invention, a rapid, direct heat and pressure bonding o~ the tape length 230~, straw element 220, and car-ton blank 100 may be accomplished (in the preferred embodiment occurring in a time span of approximately lJ2 of a second) which could not readily be accomplished b~ the application o~ a remotely located heating member or preheating o~ the tape length.
Additionally, it should be noted that, although in the pre~erred embodiment the heater 25~ utilizes a resistive heater element, alternative heating and bonding processes which could be adapted to the reciprocating heater plate 25~ (such as ultrasonic ~elding) may be utilized e~ectively.
~ s the drum 1~6 cont~nues to rotate past the nine o'clock position r the cam ~ollower 256 and heater plate ~ 3 254C begin kheir re-traction cycle, remo~in~ the heater ~late 254D from the carton blank 100 and retracting it beneath the aperture 250. As shown, this retraction cycle is complete when the drum 1~6 rotates to approximately the six o'clock position. Thus, after completion of one revolution of the drum 146 (which in the preferrea embodiment occurs in one second), the heater plate 254 bonds the straw element 220 to the tape length 230~ and concurrently provides a li~uid-tight seal across the aperture 126 as shown in Figure 4.
Al-though, for illustration purposes, the operation of only a single heater plate 254 has been described, it will be recoc~nized that four heater pla-tes 254 are provided on ~-5 the drum 1~6 which cooperate with four apertures 250, such -that four carton blan~s 100 are heat sealed and bonded during a single rotation of the drum 1~6. Further, it should be noted that since the polyethylene coating is utili~ea on only one side of the tape length 230A and the Mylar substrate has a substantially higher melting `~ point than polye-chylene, the tape length 230A does not stick or adhere to the lower surface of the heater plate 259 when the heater plate 254 is retracted from the carton blank 100.
After the heat sealing and bonding process has occurred~ the carton blank 100 is removed from the rotating drum 146 and transferred to the carton blank pivot mechanism 152 by the stripper wheel asse~bly 150.
Re-ferring to Figure 16, the stripper ~Jheel assembly 15~
includes a disc element 262 which is securely mounted to a rotating shaft 264. In the preferred embodiment, this shaft 26~ rotates at a speed precisely two times that of the drum 146 (i.e , 2 revolutions per second) such that two carton blan]cs 100 may be removed from the drum 146 during each revolution of the disc 262. The outer periphery 265 of the disc element 262 is located in close proximity to the periphery of the drum 1~6 (better shown in Figure 17~ and is separated from the drum 146 by a r s ~ 4 small space or gap 266. As will be explained in more detail helow, this space 266 permits -the carton blank 100 to be removed from the drum 1~6 and ride or be carried upon the disc 262.
Located generally on one side of the disc 262 and mounted stationary to the housing ~not shown) is a stripper plate or shroud ~68 having a concave inner surface 270 which is spaced concentrically around the periphery of the disc element 262. This concave surface 270 provides a deflector surface for the car-ton hlank 100 and causes the carton blank 100 to conform to the shape of the disc 262.
The disc element 262 is additionally provided with two pairs oE "L"-shaped trans~er ears 272 located on both surfaces o~ the disc 262 ancl spaced 1~0~ apart from each other. These ears 272 extend outward from the surface of the disc 262 in a direction parallel to the shaft 26~ such- that they may span across the width of the periphery of the drum 1~6. Each ear 272 is additionally provided with a pair of tabs 274 having chamfered inner edges 276 which engage or grip the end closure panels 112 and 11~ of the carton blank 100 (Figure 3) during the transfer oE the carton blank 100 from the drum 146 to the disc 262.
The operation of the stripper wheel mechanism 150 : may be easily understood by referring to Figure 16 and 17. The drum 1~6 and disc 262 are illustrated rotating in opposed directions as indicated by the arrows in Figure 16. As the rotating drum 1~6 with the carton elemen-t 30 100 thereon approaches the s-tripper wheel mechanism 150 (i,e~, the si~ o'clock position) r the vacuum supply (not shown) to the vacuum ports 147 (shown in Figure 11~
is discontinued in the near vicini-ty of stripper wheel : mechanism 150~ This discontinuance of the vacuum from the 35 ports 147 allows the leading edge of the cartcn blank 100 to lift from the surface of the drum 146 or spring in a downward direction into the space 266 (as shown in Figv.re 17)~

In this position, continued rota-tion of the drum 1~6 along with -the rotation of the disc element 262 pushes the carton blank 100 into the passayeway formed between the s-tripper plate or shroud 268 and the periphery of the disc 262. Duriny this motion, the carton blank 100 cont~cts the concave surface 270 of the plate 2G8 and bends into an arcuate confiyuration. As the drum 146 and disc 262 continue their opposed synchronized rotation, the tabs 206 10 of the drum 146 and the ears 272 of the tabs 274 of the disc 262, confrant each other in a tangential relationship r so that the tabs 206 and tabs 274 are in a generally parallel configuration as shown in Figure 17.
In this position, the carton blank 100 releases from the registry tabs 20G as well as from the periphery of the drum 146 and is aligned by the tab 274 of the ears 272.
~s may be recoynized, since the tabs 206 and 274 each include chamfered inside edges, transfer of the carton element 100 between the tabs 206 ancl 274 occurs smoothly without hending or deformi.ng the carton blank 100.
Following this transfer of the carton blank 100 between the tabs 206 and 274, continued travel of the carton blank 100 is provided exclusively by the rotation of the dise 262 with the edges of the end panels 112 and 25 114 con-tacting the tabs 274 in a similar manner to that previously described in reference to the rotating drum 146 and with the stripper plate or shroud 268 loosely holding the carton blank 100 against the disc 262.
Subsequently, as the disc 262 rotates throuc~h approximately 30 a 180 arc, the carton blank 100 exits -the stripper wheel mechanism 150 adjacent the lower end of the stripper plate 268 and i.s disengaged from the tabs 274 of the ear pairs 272. Thus, the carton blank 100 is deposited with the straw element 220 facing in a ciownward direction~ upon the 35 horizontal pivot mechanism 152 as shown in Figure 16.
Once the carton blank 100 is disengayed from the ears 272, the disc 262 is free to continue its clock~ise rotation t ~:

%7~;

~ 6 without impar-tin~ any further motion to the carton blan~
lOQ and travels toward the twelve o'clock position to another carton blank 100 on the drum lA6. Thus, as may be recognized, during each 180 rota-tionr the stripper wheel mechanism 150 transfers a carton hlank 100 Erom the ro-tating drum 146 by s-tripping or peeling the carton blank 100 off the periphery of the drum 1~6 and dep~siting it in a horizontal plane for subse~uent transfer to Work S-tation II.
Subsequent to its removal -from the heat seal and alignment drum 146 and prior to total disengagement from the stripper mechanism 150, the carton blank lQ0 ls transferred to the car-ton blank pivot mechanism 152 which lS feeds the carton blank 100 into Work Station I~ (the Mandrel Wrapping and Folding Appara-tus). As shown in Figures 16 and l.~, the pivot mechanism 152 pre~erably includes a continuous chain drive loop 280 which extends between two sprockets 28a and is formed of a plurality of straight link segments 282 fle~ibly interconnected at each end. These chain segments 282 and their flexible interconnections allow the chain 1OGP 280 to follow a substantially semi-circular path as it travels in the direction .indicated by the arrows in Figure 1~.
A pair of support plates 271 and 273, preferably formed of Te-Elon (a registered trademark of E~ I. Du~ont De Nemours) possessing a concave and convex edge configuration, respecti.vely, are rigidly mounted inboard and outboard of the chain loop 280 and form a guide channel t~hich maintains the semi.-circular orientation oE
the chain loop 280. In the preferred e~bodiment, these support p].ates 271 and 273 extend slightly vertically above the chain loop 2~0, thereby formincJ a support surface upon which the three leading carton blan~
segments 102 through 106 of -the car-ton blank 100 may rest upon during transport (as shown in Figures 19 and l9A). Althollgll not shoun for purposes o:E illustra-tion, it will be recognized tha-t a similar pair of plate 2~7S

members is disposed adjacent the lo~er portion of the chain loop 280 to guide the chain loop 280 on its return travel.
The chain loop 280 is provided with five pairs of L shaped channel members 287 (note only two paixs are shown in Figure 18 for illustra-tion purposes~ ~rhich extend in a subs-tantially perpendicular orientation thereto, and ride upon the top surace of ~he plate me~bers 271 and 273. As shown, the channel member pairs 287 are equidistantly spaced fro~ one another along the length of the chain loop 280, and oriented to consecutivel~
receive a car-ton blank 100 from the s-tripper mechanism 150 in a manner described below. The height of the vertical -leg 291 of -these channel member pairs 287 is substan-tially less than the width of the horizontal leg 293, and includes a registry tab 295 adjacent both ends -thereof. These tabs 295 are formed in a manner similar to the registry tabs 274 of the stripper ~heel mechanism 150 and are designed to `r 20 register the carton blank 100 along the edges of the end closure panels 112 and 114 in a manner previously described.
The space between adjacent channel members o each of the channel member pairs 287 is sized to be slightl~
greater than the width of the end closure panels 112 and 25 114 o~ the carton blank 100 (as shown in Figure 3), such that the carton blank 100 may be received therein~
As shown in Figure 18, the chain loop 280 engages a pair of sprockets 284 which are rigidl~ mounted ~L3L81~3Zb7Si adjacent opposi-te ends of a spli-t drive shaft 2~3. This shaft 283 engages a differen~ial gear train (no-t shown) mounted within a differential hcusing 285 which is dri~en from the main drive system (no-t shown) of the rota-ting drum 1~6 and ro-ta-tes the sprockets 28~ in opposed directions as indicated by the a~rows in Figure 18. The rotational. speed of the shaft 283 and thus the surface speed o:E the chain loop 280 is synchronized 10 with the rotation of the disc 262 of the stripper wheel mechanism 150, such that, as the carton blank 100 is deposited in a horizon~al orientation by the stripper mechanism 150 (as previously described), one of -the channel member pairs 287 of the chain loop 280 is aligned beneath the axis of the disc 262 oE the s-tripper wheel mechanism 150 (as shown in Figure 19).
As the car-ton blank 100, carried by the alignment tabs 27~ of the disc 262, approaches the six o'clock position, the L-shaped channel member pair 287 disposed 20 on the chain loop 280 simultaneousl.y extends around the sprockets 28~ to assume the position shown in Figure 19.
In this position, the carton blank segments 10~ through 106 of the carton bl.ank 100 rest upon the support plates 271 and 273 while the frontal edges of the end closure panels 112 and 114 of the carton blank 100 con-tac-t the inside surface o-E the registry tabs 295 of the leading channel member 287. The continued relative movement - of the disc 262 and the chain loop 280 causes the registry tab 295 of the trailing channel member 287 to con-tact the rear edge of the end closure panels 112 and 114, whereby the c~rton blank 100 is completely disengagea from the tabs 27~ o~ the disc 2~2 with the encl closure panels 112 and 11~ as well as the trailing carton segment 108 residing exclusively within the pair of channel members 287 of the chain loop 280 (as shown in Figure l9A)~
Once disposed within the channel pairs 287, the carton blank 100 is transported in a semi-ci.rcular direction ~L188~75 ~ 19 hy t:he continued travel o:E the chain loop 280 (as indicated by the arrow in Figure 18), and deposi-ted adjacent the other sproc]cet 284 for insertion into the 5 pre-feeder conveyor 300 (indicated by the phantom lines in Figure 18). It will be recognized that, as the channel member pairs 287 approach the other sprocket 284, the leading carton blank segments 102 through 10~ extena horizontally keyond the axis of the shaft 273 and are 10 entered between the pre-feeder conveyor 300 and an inclined plate 30g disposed therebeneath (as shown in Figure 18).
The continued travel of the chain loop 280 causes the channel member pair 287 to extend downward over the sprocket 284, whereby the end closure panels 112 and 114 15 of the carton blank 100 are disengaged from the registry tabs 295 c~nd the channel mernber pairs ~87 trave:l. back to their initial position along the lower portion of the chain loop 280. Subsequently, the pre-feeder conveyor 300 engages the end closure panels 112 and 114 of the 20 carton blan}; 100 in a manner to be described below, thereby transferring the carton blank 100 to the carton blank wrapping and creasing mechanism at Work Station I:~.
It will be noted that during the operation of the carton blank pivot mechanism 152, consecutive.cart:on blanks 25 100 are being received from the stripper mechanism 150 between the channel pairs 287 at one end of the chain loop 280, while simultaneously one of the previously entered carton blanks 100 is being transported toward the pre-feeder conveyor 300. Similarly, as a channel pair 287 having a 30 carton blank thereon is traveling to~7ard the conveyor 300, another channel pair 287 is moving back to~Jard the stripper mechanism 150 along the lower path of the chain loop 280 to subsequently receive another carton blan}; 100 from the stripper mechanism 150~ Thus, from the above description, 35 it may be easily recogni~ed that, by travel of the carton :~ blank 100 through Work Station I, a s-traw element and sealing tape is bonded and sealed to the carton blank 100 and the carton blank 100 is positioned upon the pre-feeder conveyor 300 -or subsequent en-try into l~lor} Station Il.
Work Station II - Car-ton Blank Wrappin~ and Fo1ding . _ ~
~eferring again to Figure 5, the component sys~ems comprising Work Station II (Carton Wrapping and Folding .
Apparatus~ of the presen-t invention may be described.
Work S-tation II includes a pre-feeder conveyor 300, a shingling conveyor transport 302, forming mandrels 304, and a plurality of wrapping and creasing mechanisms 360 (no-t shown in Figure 5~ which are disposed adjacent each forming mandrel 304 and positioned beneath the shingling conveyor transport 302.
Basically, at Work Station II, the individual car-ton blanks 100 are transported from the pivot mechanism 152 o~
Work Sta-tion I, and registered for entry into the shingling or stacking conveyor transport 302 by the pre-feeder conveyor 300. Prior to the en-try of the carton blanks 100 in-to -the shingling conveyor -transport 302 t the carton blanks : , 20 100 are ar.ranged in groups of four with each car~on blank 100, within the foursome, partially underlayed or shingled beneath each o-ther by the pre-feeder conveyor such that the leading edge of each trailing carton blank underlays the trailing edge of the previously entered carton blank 100 (illustrated in Figure 21~ Additionally, as will become more apparent below, the leading carton blank 100 of each foursome group is overlapped upon the preceding foursome group so that the leading edge of the leading carton blank overlaps the trailing edge of the last carton blank in the preceding group~
Disposed in this shingled orientation, the carton blanks 100 are transported as a foursome group across the top surface of the forming mandrels 304 by the shingling conveyor 302. The blanks 100 are then collated and each loosely wrapped around an individual mandrel 304 and separated from the conveyor transport 302. Subsequentlys each of four carton blanks 100 is simultaneously formed into a square tubular configuration around ~Id conforming ~1~82~

to the shape o the forming mandrels 30~ by the wrapping and creasing mechanism 360.
After having their side wall sect.ions permanently creased to form a square tubular configuration, all four of the carton blan~s 100 are pushed off or ejec-ted from the forming mandrels 304, and transferred to Work Station III
(Seam and End Closure Bonding Appara-tus). Thus, as will become more apparent from the disclosure below, upon completion of their travel through Work Station XI, the carton blanks 100 are formed into a square tubular configuration as shown in Figure 29 r with the straw element 220 and tape length 230A sealed thereon.
- Referring now to Figures 20 through 28, the detailed construction and operation of the apparatus comprising Work Station II (Carton Blank Wrapping and Folding Apparatus) will be disclosed. As shown in Figure 20, the shingling conveyor transport 302 and pre-feeder conveyor 300 both include a conveyor belt, 314 and 301, respectively, which are moun-t~d at one end in a conventional manner by two pulley pairs 310 and 311. Both of the pulley p~irs 310 and 311 are carried by a common shaft 312 with the pulley pairs 310 being rigidly mounted to the shaft 312 and the pulley pair 311 being rotatably mounted upon the shaft 312 by a suitable bearing 357.
As shown in Figures 1 and 16, the belts 301 of the pre-feeder conveyor 300 are held taut between the pulleys 311 and an additional pair of pulleys 313 which are r.igidly mounted to a shaft 317, connected, as by a gear transmission (not shown), to the main drive system (not shown) of the.
heat seal and alignment drum 146~ Similarly, as shown in Figure 5, the conveyor belts 314 of the conveyor transport 302 extend to an additional pair of pulleys 319~
As will be recognized, by such an arrangement, the pre-feeder conveyor 300 is driven by the shaft 317 (shown in Figure 16 while the shingling conveyor transport 302 is drive~ by the shaft 312 s In the preferred e~bodimen-t, the -travel o both the pre-feeder conveyor 300 and shinglin~ conveyor transport 302 are synchronous, ~ith the speed of the pre-feeaer S conveyor 300 being faster than that of the shingling conveyor 302. As will be explained in more detail below,-this speed differential permits the carton blanks 100 en-tering the pre-feeder conveyor 300 to be arranged in ~roups of four, and shingled or underlayed beneath each other prior to their engagement with the stacking conveyor transport 302.
Each of the belts 31~ and 301 of the conveyor transport 302 and the pre-feeder conveyor 300 are additionally provided with plura]. pairs of registry tabs 316 and 315, respectively, which extend normal to the surface of the belts 31~ and 301, and are spaced at predetermined intervals along the entire length of both beltsr As previously described in relation to the tabs 206 and 27~ of the rotating drum 146 and disc element 262, respectively, the space between 2djacent -tabs 316 and 315 of each tab pair is sized to receive the end closure panels 112 and 11~ of the carton blanks 100 (shown in Figure 3)~
Further, as shown, the tabs 316 on the conveyor transport 302 are formed substantially longer than -the tabs 315 on Z5 the pre-feeder conveyor. As will become more apparent below, this extended length of the tabs 316 permits the conveyor transport 302 to engage the carton blanks 100 upon the pre-feeder conveyor 300 in a manner which compensates for the speed differential between the conveyors 300 and 302.
As best shown in Figure 20, the pre~feeder conveyor 300 is pre~erably oriented at an angular inclination to the shingling conveyor 302 and is disposed slightly above an inclined plate member 309 which extends bet~leen the carton blank pivo-t mechanism 152 (shown in Fi~ure 1~) and the shingling conveyor transport 302 (as shown in Figu.re 20). This inclined plate member 309 is pivotally mounted adjacent its upper end and communicates with a cam drive 321 ~hich rotates -to intermitently raise and lower the plate member 309 about its pivot. The plate member 309, in addition, preferably includes a pair of side members 309A which extend vertically upward from the ma~n-planar surface of the member 309~ As will he e~plained in more detail below, this plate member 309 provides a lower support for the carton blank 100 traveling along the pre-feeder conveyor 300 and additionally permits the ~arton blanks to be arranged into groups of four and partially underlapped beneath each other prior to their entry into the shingling conveyor transport 302.
Disposed beneath the plane of the conveyor belts 314 and equidistantly spaced along t~e length o-f the con~eyor transport 302, are four forming mandrels 30~ which are rigidly attached to the housing 320 at one end thereo. As shown, these mandrels 304 are preferably formed having a generally square cross-section and include a concave channel 322 and a pair of recesses 324 formed along their top and two side surfaces, respective~y, which extend partially throuyhout their lenyth, (better shown in Figure 22). The concave channel 322 receives the straw element 220 attached to the carton blank 100 during the olding process, whereas the recess 324 facilitates the ejection or transfer of the carton blan~ 100 from the mandrel 304.
Cooperating with each mandrel 304 and mounted adjacent one side thereof, is a separator plate apparatus designated generally by nume,ral 326 which forms a portion of the wrapping and creasing mechanism 360~ As shown in Figure 20, the separator plate apparatus 326 includes a slider plate 328 havin~ raised side walls 330, and a pair of rigid elongate stops 332, all of which are mounted to a sha-t 334. The shaft 334 is supported adjacent one 3~ end thereof by a support arm 336 haviny a bearing aperture 338 the.rethrouyh which allows the sha~t 334 to be rota-ted therein. ~11 four of the shafts 33~ axe additionally connected at one end thereof to a common drive mechanism 3~0 which may typically include a linkage drive such that all o:E the shafts 33n can be rotated simul-taneously.
During the operation of ~-~ork Station II, each of the carton blanks 100 (sho~n in Figure 16) is transported.
from the carton pivot mechanism 152 of l~lork Station ~ by the pre-feeder conveyor 3no ~rhich receives -the end closure panels 112 and 11~ of each of the carton blanks 100 between its registrY tabs 315 in a ~nanner previously described. During this transfer, the car-ton hlan]cs 100 are transported between the lower conveyor loop OL the pre Eeeder conveyor 300 and -the top surEace of the inclined plate member 309 ~as sho~n in Figure 20) and -travel to~Jard the shaft 312 of the shingling conveyor transport 302 As best shown in Figure 21, during this transport, the end closure panels 112 and 114 ride along the top surface of the raised side panels ~09a of the plate member 309. As such, the trailing edge of each carton blan}~ 100 r 20 is slightly elevated by the side walls 309A ~hile the leading edge of the carton blank 100 resides dircctly against the rnain planar surface of -the plate member 309.
As illustrated in Figure 21, this differing elevation of the carton blanks 100 upon the inclined plate 309, allows 25 consecutive carton blanks lOOA, lOOB, 100~, and l.OOD of each foursome to be group oriented along the plate member 309 such that the leading edge o-f the follo~in~ carton blanks lOOB, lOOC, and lOOD (indicated by the phan-torn lines referenced by numerals 3~4B, 3~4C, and 34aD, respectively) 30 lies beneath the trailing edge of the preceding carton blanks lOOA, lOOB, and lOOC. As such, consecutive carton blanks 100 are underlayed or shingled alon~ the inclined plate member 309 for subsequent entry into the shingling conveyor transport 302.
This shingling along the inclined member 309 permits consecu-tive carton blanks lOOA, 100B, lOOC, and 100~ to be wrapped around an individual forming mandrel 304, even though the mandrels 30~ axe spacecl closer to one anothex than the leng~h of the blanks 100. Further, this arrangemen t permits the compact arrangement of the mandrels 304 and the succeeding equipment stages, and is an important factor in permitting the present apparatus to occupy very limited floor space.
In addition to the shingling procedure, the inclined plate member 309 (as previously mentioned) arranges the 10 incoming carton blanks 100 in-to groups oE four for subsequent travel across the four forming mandrels 304.
In the preferred embodiment, this grouping procedure is provided by the upward pivoting (in a coun tercloc~ Jise direction as viewed in Figure 21) of the plate member 309 15 caused by the rotation oE the cam 321.
In operation, as every four-th carton blank 100 travels do~m the inclined plate member 309 toward the conveyor transpor-t 302, the lobe of the cam 321 causes the plate member to pivo-t upward. This upward pivoting o E
20 the plate member 309 causes the leading edge 344 of ever~
fourth carton blank 100 to be disposed above the trailing edge of the preceding carton blank (i.e., overlapped upon the other foursome group) upon the inclined plate` member 309. Subsequentl~ r the cam 321 continues its ro-tation, 25 so that the plate member 309 is again disposed in its lower, normal operating position.
As such, the next three entering carton blanks 100 are underlayed in the manner previously described, wherein the frontal edge 344 of each carton blank 100 lies beneath 30 the trailing edge of the preceding carton hlank upon the plate member 309. As will be explained in more detail infra, this particular foursome grouping of the carton blanks 100 permi ts the fixst four carton blanks lOOA through ~OOD to be creased into a square tubular configuration 35 about the forming mandrels 304 while a second group of four carton blanks 100 are simultaneously transported by the shingling transport conveyor 3û2 toward the individual forming mandrels 30~. Hence, the creasing and forming cycles of the apparatus are superimposed with -the transport and collating cycles oE the apparatus, as will become more apparent infra.
During the shingling procedure upon the inclined plate member 309, the registry tabs 316 of the shing~in~
conveyor transport 302 begin receiving the end closure panels 112 and 11~ of the consecutive carton blanks lOOA
throu~h 100D. Due to the pre-feeder conveyor 300 transporting the carton blanks 100 at a speed faster than travel of the conveyor transport 302, it is necessary to avoid accumula-tion and cloggincJ of the carton blanks 100 upon the inclined plate 309. Thus, the conveyor transport 30~ must remove the consecutive carton blanks lOOA throu~h lOOD
from the inclined plate member 309 at a speed greater than the actual traveling speed of the conve~or transpor-t 30~.
In the preferred embodiment, this increased removal speed on the inclined plate ~ember 309 is provided by the increased len~th and radial spaciny of the registry tabs 316 of the conveyor transport 302 engaging the end panels 112 and 11~ of the carton blan~s 100.
As will be recognized, by engaying the carton blanks lOOA through lOOD at a point adjacent the extreme outer radial end of the registry tabs 316, the effective diameter of the pulley pairs 310 is increased and thus the surface speed of travel about the pulleys 310 is increased. In the preferred embodiment, the length of the tabs 316 (and thus their radial spacing~ is formed such thatr upon engagemen~
with the carton blanks lOOA through lOOD, the effective diameter of the pulleys 310 in conjunction with the rotation of the shaft 312 exceeds the speed of travel of the pre-feeder conveyor 300. Thusl by such an arrangement/
consecutive carton blanks lOOA through lOOD are rapidly stripped from the pre-feeder con~eyor 300 at a speed equal to the speed of the pre-feeder conveyor 300 and subsequently transported hori~ontally at a slower speed by the transport conveyor 302 toward the forming mandrels 30~

,t' ~,~

~8~1Z7~

Since the width across the raised edges 330 of the slider plate 328 is slightly less than the length of the carton seyments 102 through 108, of the car-ton blank 100 (shown in Figure 3) during this -transport by the shingling conveyor 302 toward the formi.ng mandrels, the undersurface of the carton blanks 100 rest upon and are supported by the raisea edges 330 of the slider pla-tes 328. As such, consecutive car-ton blanks lOOA, lOOB, lOOC, and lOOD upon the conveyor 302 may travel unrestricted across all four of the forming mandrels 304.
As the leading edges 344 of each consecutive carton blank lOOA, lOOB, lOOC, and lOOD, carried by the conveyor 302 (Figure 21), approachetheir respective formi.ng mandrels 30~}, the drive mechanism 340 of the ~rapping and creasing mechanisrn 360 is momentarily activated, causing each-shaft 334 to rotate through a short arc in a cloc]cwise direct.ion~
- This short arcuate rotation causes the xigid stops ~32 and the slider plates 328 to pivot about the shafts 334 and raise vertically upward along their leading edges.
The carton blanks lying directly above the slider plates 328 (such as lOOA shown in Figure 21) during activation will be slightly lifted, while the leading edge 344B of : the following carton blank (such as lOOB shown in Figure 21) is deflected do~nward by the plate 328 to travel - beneath -the slider plate 328~ As will be recognized, the fifth carton blank which was previously overlayed upon the previous carton blank lOOD by the pivoting of the inclined plate ~.ember 309, will additionally be slightly lifted during this pivoting of slider plate 328 such that the fifth carton blank 100 will not entex the creasing mechanism 360 at this time.
After entry of the leading edge 344 beneath the slider plate 328, the drive mechanism 340 is deacti~ated such that the slider plate 328 and the rigid stops 332 pivot back to their lowered position (i.e., the position indicated in Figure 20)v Thus, the activation and deactivation o .

the separator plate apparatus 326 effectively separates or collates the individual carton blanks lOOA, lOOB, :LOOC, and lOOD ad-jacent each *ormin~ mandrel 304. Further, since the slider plates 328 are returned to their initial planar orientation, the subsequent group of four carton blanks 100 may be transported in the same manner by the shingling conve~or 302 toward the respective forming mandrels 30~.
Subsequent to the activation ancl deactivation of the separator plate apparatus 326, the end closure panels 112 and 114 of the c~rton blank 100 are still engaged with the conveyor transport 302 such that each of the carton blanks lOOA, lOOB, lOOC, lOOD continue their horizontal -travel lS beneath the slider plates 328 whereby the leading edge 344 of the carton blanX 100 contacts the creasing mechanism 360 as shown in Figures 22 and 23~
The cxeasiny mechanism 360 includes a hinged member 362 having a reciprocating vertical wall 364 and an L-shaped pivoting, clamping jaw 366. As clearly shown in Figures 23 and ~4, the vertical wall 364 is rigidly mounted to an elonga-te sleeve member 368 which is clamped at one end into a support rail 372. The sleeve member 368 suppoxts a rotatable shaft 370 ~7hich extends beyond both ends thereof and includes an end cap 374 which is securely mounted t~
the shaft 370~
The L-shaped clamping jaw 366 is rigiclly connected to thi.s end cap 374 such that, as the shaft 370 is rotated in a clockwise direction, the jaw member 366 rotates towara the vertical wall 364. ~s will be~ome more apparent, -this rotation of the jaw member 366 toward the vertical wall 364 imparts a permanent crease or fold to the carton blank 100, thereby formin~ the carton blank 100 into a square tube con:Ei~uration. The inside surfaces of the vertical wall 364 and the L-shaped clampiny jaw 366 are each provided wi.th a pair of spring pla-tes 378 preferabl~ formed from Teflon (a r.e~istered trademark of E~ I. DuPont de Numour) %~

~hich effectivel~ presses the carton blank 100 a~ainst the mandrel 304 duri.ng the folding process. Additionall~, a deElector ~inger 279 is provided which is rigidly attached -to the vertical wall 3~ and extencls in an angular segmented arcuate manner between the spring plates 378 of the vertical clam~ing ~aws 36~ and 366, respectively.
~ s shown in Figure 22, the creasi.ng mechanism 360 is positioned below the separator plate apparatus 32~
and disposed adjacent the side and bottom surfaces of the forming mandrel 304. In this position, -the creasing mechanism 360 ~orms a barrier to deflect the horizontal travel of the carton blank 100 belo~ the slicler plate and is free to operate wi-thou-t interference from the separator plate apparatus 326 and shingling conveyor transport 302.
The operation of the creasing mechanism 360 is illustrated in Figures 22-27. As previously mentioned, during actuation of the separator plate apparatus 326, ~ the leading edge of the carton blan~ 100 passes beneath the slider plate 323. After further movement caused by the conveyor belts 314, the leading edge 344 of the blank 100 contacts the deflec-tor finger 279 disposed on the inside surface of the ~ertical wall 364 of the creasing mechanism 360 (better shown in Fiyure 23).
This contact with the deflector finger 279 de:Elects the leading edge 344 of the carton blank 100 in a do~nward direction, and with the continued horizontal transport of the car-ton blank 100 by the shingling con~eyor transport 302, causes the elongate section of the carton blank 100 (formed by the segments 102 108) to cam against the finger 279 to loosely wrap around the forming mandrel 304, as shown in Figure 2S.
Duriny this same horizontal transport, the leading edge of the end closure panels 112 and 114 of the carton blank 100 approach the forming mandrel 304, ancl contact the base of the elongate stops 332 oE the separator plate . .

apparatus 326, Since the ends of the stop 332 are ben-t in an up~ard inclination, the end closure panels 112 and 114 slide beneath the lower sur:Eace of the stops 332, bu-t above the top su.rface of the forming mandxel 304.
Continued horizontal travel of the carton blank 100 by the shingling conveyor transport 302 causes the leading edge of the end closure panels 112 and 114 to contact or abut the shoulder 380 at the base of the stops 332, This direct abutment with the shoulder 380 effectively stops the horizon-tal travel of the carton blan~ 100 on the shingling conveyor t.ranspor-t 302 and registers the carton blank 100 on the mandrel 304 such that the end closure panels 112 and 114 and the carton segment 108 (as shown in Figure 3) lie exclusively on the top surEace of -the mandrel 304 and the straw element 220 is disposed within the concave channel 322.
It will be recognized that during the entry of the carton blank 100 into the creasing mechanism 360 beneath ~0 the stop 332, -the carton blank 100 is con-tinuously being pulled in a downward direction from the conveyor transpor-t 302 by the stop 332. This pulling causes the end closure panels 112 and 114 during the wrapping pxocess to slowly slide down the length of the registry tabs 316 away from the belts 314 so that the panels 112,114 engage the tabs adjacent their lo~ler end. Referring to Figure 207 the frontal edge of the tabs 316 is preferably formed having a beveled or angular configuration which permit the carton blank 100 to readily be disenga.ged from the conveyor transport 302 upon confronting a substantial resistance to movemen-t. As such, upon abutment with the shoulder 380, the increased resistance to the horizontal travel of -the carton elernent 100 along the conveyor transport 302 causes the registry tabs 316 to comple-tely disengage from the end 35 panels 112 and 114 and slide harmlessly over the trailing edge of the carton blank 100. In this manner, the carton blank 100 is maintained upon the forming mandrel 304 f ~;

Z'75 and is disengaged from the conveyor transport 302 without damaginy or permallently creasing the end closure panels 112 and 114 of -the carton blank 100.
Upon disengagement of -the carton blank 100 :Erom the conveyor transport 302, the creasing mechanism 360 is ac-tivated to begin the carton folding or creasing process~ The progression of operations perfo.rmed by the creasing mechanism 360.1s illustrated schematically in Figures 25 through 27.
In its initial position (Fic3ure 25~, the creasing mechanism 360 partially surrounds the forrning mandrel 304, and earries the car-ton blank 100 adjacent the deflector finger 279 along its inside surfaces. As shown in Figures 25 -through 27, each of the Eorming mandrels 304 is preferably formed having a slightly inclined kop surface and includes a small blocking memher 381 extendînc3 a shor-t distance above its top surface and rigidly mounted adjacent one side. As ~7ill be recognized due to this short 20 pro-trusion above the top surface of the m~ndrel 304, the carton blank 100 is free to s:Lide over the blocklng member 381 during the above-described wrapping process and reside slightly beyond the blocking member 381 as depicted in Figures 25 through 27. As such, the trailing edge of the carton blank 100 la~s flat upon the slightly inclined -top sur~ace of the forming mandrel 304 and is prevented from movement laterally away from the creasing mechanism 360 by the blocking member 381.
Subsequently, the entire creasing mechanism 360 is reciprocated toward and abutted against the side surface of the forming mandrel 304 (shown in Figure 26) hy the transverse movement of the rail 372 as indicated by the arrow in Fic,~ure 23. By this movement, a corner 382 ~shown in Figure 26) is permanently formed or creased into the carton blank 100 along the upper sur:Eace o:E the mandrel 30~ with the stop men~er 381 preventing the carton blank 100 from slidincf across the top of the mandrel 304. The formation 2~

of this corner 382 is aided by the indentation or scoring line 110 registered along the edge of the mandrels 304 and formed on the carton blank 100 (as shown in Figure 3) which significantly reduces the resistance to folding.
With the vertical wall 364 of the creasing mechanism 360 remaining in its abutted relationship with -the mandrel 304 (as shown in Figure 26), the L-shaped ja~7 member 366 is rotated in a clockwise direction whereby the spring plate 378 urges the remaining segments (102-106) of the carton blank 100 against the forming mandrel 304 (shown in Figure 27) In the preferred embodiment, the ~ovement of the L-shaped jaw member 366 is accomplished by the rapid rotation of the shaft 370 through a short arc. Upon closing, the jaw member 366 permanently creases the carton blank 100 adjacent the lower edges of the carton blank 100 (as shown in Figure 27) thereby forming corners 384 and 386. As previously mentioned in relation to the corner 382, the formation of these edges 384 and 386 occurs at the scoring lines 110 formed along the carton blank 100.
Since the spring clips 378 contact the carton blank 100 adjacent the corners of the forming mandrel 304, during closure of the jaw member 366, the carton member 100 is moderately stretched against the flats of the mandrel 304 to eliminate the possibility of sagging of the carton blank intermediate of -the edges 384 and 386. Further, during closing of the jaw member 366, the deflector fingers 279 extend through the open slot 281 (shown in Figure 23) formed in the jaw member 366 to extend beneath the jaw member 366 as shown in Figure 27. As such~ the carton ~lank 100 is tightly creased about the mandrel without any interference from the deflector finger 279 Thus, as may be recognized, by the dual movemen-t of the creasing mechanism 360, firs-t toward the mandrel 304/ and then upward against the bottom and side surface of the mandrel 304, the carton blank 100 is permanently folded into a square tubular configuration.

2~S

~fter the creasing mechanism 360 has permanen-tly folded the carton blank 100 around the mandrel 304, the carton blanl; 100 must be removed from the forming mandrel 304 and inser-ted upon the crossbar mandrel 400 (as shown in Figure 30) which forms part of Work Station I~ Seam and End Bonding Station). However, prior to this transfeic of the carton blank 100 into Work Station III, the sealing tab 120 (as sho~m in Figure 27) which e~tends above the top surface of the n~lndrel 304 mus-t be folded over and permanen tly creased upon the -top surface of the mandrel 304. Additionally, this sealing tab 120 must be folded over in a manner so as to be positioned beneath the lower surface of the carton segment 108 (i.e., the carton segmen-t 108 overlays the sealing tab 120).
In the preferred embodimen-t~ this folding of the sealing tab 1~0 is accomplished in a simple yet effective manner and occurs during the transfer of the carton blank 100 from the forming mandrel 304 to Work Station III.
Referring to Figure 24, the apparatus for bending or folding ~.r ' over the sealing tab 120 and for transferring the carton ; blank 100 from the forming mandrel 304 to Work Station III
is shown~ ~or purposes of illustration, it will be noted that, in Figure 24, the carton blank 100 has been removed from between the forming mandrel 304 and -the creasing mechanism 360. ~s shown, the vertical wall 364 and one ~f the legs of the L~shaped jaw 366 of the creasing mechanism 360 include a tab 388 at one end thereof, which extends inwardly toward the side surfaces of the forming mandrel 304O
As may be recognized, these tabs : ride within the recess channels 324 formed along both side surfaces of the s~andrel 30~ whereby the creasing mechanism 360 may slide foxward along the length of the mandrel 304.
~isposed adjacent one end of the forming mandrel 304 35 and closely positioned to the top surface thereof is a folding block 339 which is rigidly mounted to the housing ~not shown)~ The front edge of the block 390 is pxovided with an enlargecl radius 399 c~2d is inwardly tapered to provide an entry camminy surface, whereas the side wall 392 is beveled so that only a reduced thicXness of the block 3~9 extends across the width at the top surface of the forming mandrel 304. As will be explained r in more detail below, positioned in such a manner the block 389 directly contacts the sealing -tab 120, but only s]igh-tly liEts the carton segment 108 during transfer of the carton segment 100 from the forming mandrel 304 to Work Station III.
The sealing tab folding operation and the transfer of the carton blank 100 from the mandrel 304 to Work Station III may now be described. With the creasing mechanism 360 ]-5 maintained in its closed position and the carton blank 100 formed into a substan-tially square tubul~r con-fiyuration as sho~n in Fi~ure 27, the tabs 388 of the creasing mechanism 360 contact the rear edge of the carton blank 100. The entire creasing mechanism 360 then reciprocates fol~ard or slides along the length of the forming mandrel 304 toward Work Station III. In the preferred embodiment, this sliding movement is accomplished by the travel of the rail 372 in a direction indicated by the arrow in Figure 23. However, othex embodiments wherein only the jaw members 364 and 366 travel along the mandrel 304 may be utili~ed.
As this sliding movement is initiated, the carton blank 100 passes beneath the stops 332 (as shown in Figure 20~ and is thereby released from the biasing force of the stops 332 which previously held the end closure panels 114 and 112 and the carton segment 108 against the inclined top sur~ace of the mandrel 304.
Due to the subtly inclined top surface of the mandrel 304 as well as the moderate memory properties of ~he carton blank 100, during this sliding movement and upon release from the stops 332, the end closure panels 114 and 112 and the carton segment 108 tend to sliyh-tly spring upward off the top surface of the mandrel 7~

304 to lie in an inclined orientation. This inclined orien-tation aids in the trans:Eer process and additionally in the seali.ng tab fold-over process b~ allowing the end closure panels 114 and 112 and the carton segment 108 to slide past the folding block 389 whi.le the sealing tab 12D
is forced beneath the block 389. Thus, during the forward travel of the car-ton blank 100 along the mandrel 304, the end panels 114 and 112 and the carton segment 108 harmlessl~ ride against the upper beveled edge 392 of the block 389 and pass beyond the block 389. However, the sealing tab 120 directly abuts the camming eclge 390 of the block 389 and is -thereby bent in a downward direction toward the top surface of the mandrel 304.
As best shown in Fiyure 28~, the upper left corner of the mandrels 304 (as well as the mandrels 402 of the crossbar mandrel 400 of Figure 30) are provided with a small notch 383, the depth of which is sized slightly greater than the thic~ness of carton blank 100. The notch 383 prefe~ably extend partially across the top surface of the mandrels 304 through a length slightl~ greater than the width of the sealing tab 120. As such, the notch or po~ket 383 is adapted to receive the sealing tab 120 during -the fold-over process.
It will be recognized that the fold-over process of the tab 120 is aided b~ the spring plate 378 which maintains -the carton blank 100 tigh-tly against the side surface of the mandrel 304 and the scoxing line 110 (as sho~n in Figure 5) which weakens the carton blank 100 at a point adjacent -the edge of the forming mandrel 304. As such, during the transfer of the carton blank 100 onto the crossbar mandrel gO0 (of Work Station III), the sealing tab 120 is bent over and forced be-tween the bot-tom surEace of the block 389 and the top surface of the Eorming manclrel 35 304 to reside with the notch 383 (as shown in Figure 28A).
Referring to Figure 28, the completion of the transfer of the carton blank 100 from the forming mandrel 30~ onto the crossbar mandrel 400 (of Work Sta-tion III) is i illustrated. As may be seen, the forming mandrel 304 and the crossbar mandrel 400 are aligned in an end-for-end orientation such that, as the car-ton blank 100 is pushed off the end oE the forming mandrel 304, it is inserted onto the crossbar mandrel 400. Aaditionally, both ~he mandrels 304 and individual mandrels 402 oF the crossbar -mandrel ~00 include a concave channel 322 and 422 which receives the straw element 220 during the forming and transfer pro~esses, respectively.
Upon completion of the transfer of the carton blank 100 to the crossbar mandrel 400 (of Work Station III), the sealing tab 120 ~indicated in phantom lines) contacts the top surace of the crossbar mandrel 400 and lies beneath the carton segment 108 of the carton blank 100.
Thus, from the above description, it will be recognized that, upon completion of its travel through Work Station II, the carton blank 100 is permanently creased or folded into a s~uare tubular configuration, having its sealing tab 120 placed beneath the lower surface of the caaton , 20 segment 108 as shown in Figure 29, and aclditionally has been transferred to the crossbar mandrel 400 of Work Station III.
Following this -transfer of the carton blanks 100 to the crossbar mandrel 400, the rail 372 reciprocates back to its initial position and the creasing mechanism 3~0 returns to its initial position adjacent the forming mandrels 304 (as indicated in Figure 22) and is disposed to receive the subsequent group of four carton blanks 100 which were simultaneously being transported by the stacking conveyor 302 during the creasing process.
For illustration purposes, the description as to the operations occurring at Work Station II has been presented in relation to a single carton blank 100 being formed around a single mandrel 304. EIowever, it will be recognized that the same procedure described for the single carton blank 100 occurs si.multaneously at the other three forming mandrels 304. ~ddi.tionally; it will be recognized that, although in the preferred embodiment, our mandrels are utilized at this station, fewer or additional forming mandrels 304 wit~ their respective ~olding and creasing mechanisms 360 may be utilized ana the pivoting oE the plate member modified to group the carton blanXs accordingly, without departing from the spirit oE this invention.
~ork Statlon III - Seam and End ~ondinq Apparatus Subsequent to the previously described transfer of the carton blank 100 from the forming mandrel 304, the carton blank 100 is subjected to a series of operations which occur at Work Station III wherein the carton blank 100 is permanentl~ sealed along one edge to maintain the square tubular configuration and one of the end closure panels 112 is bonded to the carton blank 100 to provide a lic~uid-tight seal. In the preferred embodiment/ all o~ the processes occurring at ~ork Station III are performed on the crossbar mandrel 400 (as shown in Figure 30) thereby eliminating the complex transfer systems associated in the prior art devices.
~, 20 Basically, a-t Work Station III the carton blan~ 100 is initially sealed by the side sealin~ apparatus 430 along the previously overlapped edge at the junction 120,108, formed duxing the wrapping process in Woxk Station II
. described above. Subsec~uently, the carton bla~k 100 is 25 moved radially outward along the individual mandrel 402 o~ the crossbar mandrel 400 such that the sealing tabs 120 formed along the edge of the carton blank 100 extend partiall~ beyond the end of the mandrel 402. In this position, the sealing tabs 120 are contacted by a folding 30 apparatus 440 which folds the sealing tabs 120 tightly against the end of the mandrel 402.
Subse~uently, the crossbar mandrel ~00, with the carton blank 100 thereon~ is rotated upward through a 90 arc. During this rotation~ the end closure panel 35 112 contac-ts a roller 446 which bencls the end closure panel 112 over the end of the individual mandrel ~02~ At the end of the 90 rotation, the individual mandrel 402 ~82~5 extends in a ver-tical orientation wherein an ultrasonic sealing die or horn 450 i.s p.ressed over the end of the carton blank 100 and mandrel 402 to seal the end closure panel 112 to the sealing tabs 120.
After the sealing of the end of the ca:rton blank 100, the crossbar mandrel. 400 rotates through an additional 90 arc to align the carton blank lOa for removal from the individual mandrel 402 and entry into Work S-tation IV
~the Car-ton Rotating ~pparatus). Thus, through the processes occurring at Wor~ Station I~I the carton blan~
100 is provided with a liquid-tigh-t seal along its side and one end thereof>
Referring again to Figure 30 r the detailed construction and operation of -the componen-t systems oE Work Station III
is illustra-ted. ~s sho~7n, the crossbar mandrel 400 :~ includes four individual mandrels 402 which are each preferably welded at one end to a mounting plate 404.
These mounting plates 404 are attached across the fla-ts of a square arbor 408 by a plurality of fasteners 406.
The free end of each individual mandrel 402 is p~ovided with a die ~12 secured to the mandrel 402 by a pair of socket head machine screws al4. ~s shown in Figure 31, the edges of the die 412 are ~ormed having a raised land section 416 which includes four recessed pockets 418 formed on respective cor.ners. As will be explained below, the raised lands 416 provide a hardened surface area which aids in the subsequent end bondîng process, whereas the recesses 418 rel:ieve the stresses formed in the corner areas of the carton blank 100 and additionally allow the excess car-ton material which overlaps at ~he carton corners to be main-tained beneath the outer surface of the lands 416 during bonding. The die 412 adaitionally includes a concave channel 420 which extends across one edge thereof and is aligned with a similar channel 422 which ex-tends partially throughou-t the length of each oE the crossbar mandrels ~02 -to recei.ve the stra~J 220~

~3132~5 ~ stop ~llO is mounted proximal one edge of the crossbar mandrel 400 and is connected to a mechanical linkage 411 which selec-tively reciprocates in a direction S indicated b~ the arrow in Figure 30. The stop 410 is biased tightly against one edge of the individual mandrel 402 by a spring 413 and is formed having a shou:Lder 415 intermediate its lèngth~ As will be described below, this stop registers the carton blank 100 on the individual mandrels 402 and additionally, when actuated, moves the carton blan~ 100 radially outward along the leng-th of -the individual mandrel 402 for contact with the folding apparatus 440. The lower edge (not shown) of the stop 415 is preferably rounded, so thatr as the ar~or 408 rotates, the stop ~15 may cam into spring~biased contac~ wi-th each of the mandrels 402.
Aligned with and located verticall~ above one edge of the mandrel 402 is a side sealiny apparatus 430 of the present inven-tion which welds the carton segment 108 to , 20 the sealing tab 120, thereby permanently maintaining the square tubular configuration of the carton blan~ 300 As sho~n, the side sealing apparatus 430 includes an ultrasonic sealing horn 432 having an elongate section which terminates having an end 434 formed to grab or cam the extreme edge of the carton blank 100~ As shown in ~igure 28A, in the preferred embodiment, the end 43~
is formed having a substantially planar portion 434A
and a curvilinear portion 434B which protrudes downward below the por-tion 434A to extend over the corner of the carton blank 100. At the intersection between the portions 434A and 434B, a sharp edge 434C is formed which as will become more apparent below, forms a camming means which pulls the carton segment 108 toward the corner of the mandrel 402.
The sealing horn 432 is mounted to the piston 436 of a pneumatic cylinder 438 which selectively extends and retrac-ts the sealing horn 432 to contac-t the mandrel 402.

'75 The p~ ma-tic cylinder 438 is secured to the housing ~nok shown) and is located inbc,ard and at an angle with the mandrel 402, such that, when re-tracted (as shown S in Figure 33) the individual mandrel 402 of the crossbar mandrel 400 is free to rotate upward through a 90 arc.
In addition, the sealing hoxn 432 is moun-ted by means (not sho~m) to permit sligh-t freedom of movement in a direction parallel to the length of the horn 432 but restricted from movement in a plane perpendicular to the length of the horn 432. As such, the horn 432 is self-aligning with the mandrel 402 to effectuate a proper bond or seal during operation~
Disposed adjacent one end of the mandrel 402 c~nd mounted proximal thereto, is the folding apparatus 440 which permanently bends the sealing tabs 120 formed along the ends of the carton blank 100 against the lands 416 o~ the die 412~ The apparatus 440 preferably includes a T-shaped jaw 442 disposed beneath the lower 20 surface of the mandrel 402 and a pair of side jaws 4~4 ~ which are mounted adjacent bo-th sides of the mandrel 402.
: Each of these jaws is connected to an appropriate linkage (not shown), typically being cam actuated, such that the T-shaped jaw 442 reciprocates in a vertical directionr whereas the side jaws 444 reciprocate in a horizontal direction as indicated by the respective arrows of Figure 30.
Sprin~ loaded and disposed vertlcally above the individual mandrel 402 and in a common plane therewith is a roller assembly 446 illustrated schematically in Figure 30 30. Basically, the roller 446 includes a relieved cylinder 448 having a reduced diameter section 449. The width of the section 449 is preferably sized to equal the wid-th of the end closure panel 112 with the angular transition 451 between the reduced diameter section 449 and the main diameter of -the roller 448 sized to tightly abu-t the sides of the carton blank 100. As shown, -the roller 446 is xotatably mounted to a shaft 450 connectecl as by way of i ~

springs (not shown) to the housi.ng (not shown).
The roller 446 is accurately positioned radlally ou-tward from -the mandrel 402 such tha-t, as the i.ndividual mandrel 402 rotates upward through a 90 arc, the reduced diameter section 449 of the cylinder 448 contacts and ro~ls across the end closure panel 112 of the carton blank 100 at a poin-t tangent to the raised lands ~16 of the die 412.
As may be easily recognized, by contac~ing the end closure panel 112 during the rotation of the mandrel 402, -the roller apparatus 446 folds the end closure panel 112 over the end of the die 402.
With -~he struckure dæfined, the operation of -the component sys-tem.s of Work Station ~II may be described.
As shown in Fiyure 30~ the carton blank lO0 is transferred tQ th~ ;n~ a~ rel.402 at the nine o'clock position ol ci~ c-l~s'~-ar m~ dLel 400 in a mannex previousl~
described with one edge of -the blank 100 contac-ting the shoulder 415 of the stop A10. The stop 410 is initially ~r 20 spaced from the ena of the die 412 an appropriate distance selected so that, upon abutment with the shoulder 415, the en-tire length of each of the car-ton segments 102 through 1.08 lies slightly radially inward of the land sections 416D
While in this position, the pneumatic cylinder Z5 operator 438 is energized, causing the sealing horn 432 to extend in a downward direction and contact the carton blank 100 adjacent one edge of the mandrel 402. While in this extended position, the end 434 of the sealin~
horn 432 extends partially on both sides of the edge and firmly presses the carton secti.on 108 ayainst the sealing tab 120. Due to the end 434 having the particular configuration shown in Figure 28A, upon contacting the carton blank 100, the carton section 108 is grabbed and pulled tightly toward the co.rner of mandrel 402 by the sharp edge 234C and curved protrusion 434B t.hereby forming a tight corner. The horn 432 is then energized by well known driving apparatus r and the sealing tab 120 is bonded 2~5 to the carton segment 10~ by an ul-trasonic ~7eld.ing process which is well known in the art, however, alternative methods of forr,linc3 the bond, such as heat sealing, may be utilized.
~hus, by this ultrasonic weldiny process, a liquid-tight seal is formed along the edge of the carton blank 100 which permanently maintains the square tubular configuration of the carton blank 100.
Subsequent to this ultrasonic ~Jelding process, the pneumatic cylinder 438 is de-activated to retract the sealing horn 432 into a stored position as indicated in Figure 33O Since, as previously described, the pneuma-tic cylinder operator 433 is mounted inboard and at an angle with the plane of the crossbar mandrel 400l upon retraction, the crossbar mandrel 400 is clear to rotate in a clockwise direction as indicated in Figure 33. Prior to this rotation of the crossbar mandrel 400, ho~ever, the sealing tabs 120 located adjacen-t the outer end of the individual manarel 402 must be ~olded over the end of the die 412.
In the preferred embodiment, this folding procedure is accomplished quickly and easily by the folding apparatus 440. With the sealing horn ~32 retracted from the edge of the car~on blank 100, the caxton blan~ 100 is maintained on the mandrel ~02 only by frictional forces and~ therefore, may be easily positioned along the length of the mandrel 402. To expose the sealing tabs 120 beyond the end of the die 412, for the subsequent folding operation, the stop 410 driven by the linkage 411 moves radially outward from its initial position ~as shown by the phantom lines in Figure 33~, thereby pushing the carton blank 100 partially off the end of the mandrel 402. Upon movement through this : short distance, the scoring lines 122 formed adjacent the edges of the carton se~ments 102 through 106 of the carton blank 100 (as shown in Figure 3) are alignea with the outside edge of the lands 416 of the die 412. ~s previously men-tioned, these scoring lines 122 weaken the carton blank material, thereby insuri.ny that the fold will occur at the desired position along the car-ton blank 100 .
The sequence of operations performed by the folding apparatus ~40 is illustrated schema-tically in Fîgures 32A-through 32C. With the sealing tabs 120 extending over the edge of the lands 416, -the T-shaped jaw 442 of the folding apparatus 440 reciproca-tes in an upward vertical direction to a height slightly .above the lower surface of the mandrel 402 (as shown in Figure 32A) During this movement, the jaw ~42 contacts the sealin~ tab 120 along its top edge and crimps the tab 120 tightly against the land section 416 of the die 412.
Subsequently, the side jaws 444 are activated and move partially inward from their initial position shown in Figure 32A to the position shown in Figure 32B, wherei.n : their leadiny edye ex-tends to the vertical plane of the side edges of the die 412. During this partial lnward movement, the eage of each of the side jaws 444 contacts the lower corners of the sealing tabs 120, causing the lower corners to be tightly creased between the T-shaped jaw 442 and the side jaw 444. Due to the T-shaped jaw ~42 remaining in its extended position above the lower edge of the mandxel 402, the sealing tab 120 is prevented from springing away from the die 412 thereby insuring an accurate corner folding of the sealing tab 120.
Subse~uently, the T-shaped jaw 442 reciprocates slightl~ downward to a position wherein its relieved corners 442A are aligned with the lower corners of the die 412 and the side jaws 444 reciprocate fully inward across the frontal plane of the die 412 as shown in Figure 32C~
As previously described in relation to the T-shaped jaw 442, upon their full inward travel, the side jaws ~44 contact the sealing tabs 120 of -the carton blank 100 and thereby tightly crimp or fold the sealing tabs 120 over the lands 416 of -the die 412. Thereaf-ter, the side jaws 2~

7~
44fi are similarly reciprocated back to their original position as shown in Figure 30. As best shown in Figures 32A, 32B, and 32C, the right side jaw member 444 is formed sligh-tly shor-ter in length than the lef-t side jaw member 444~ The applicant has Eound this lenyth dif:Eeren-tial is desirable to eliminate the possibility of the sealing tab 120 -tearing in the vicinity of the upper corner due to its integral intersection (sho~n in Figure 3) ~7ith the 10 end panel 112. As such, during the seali~g tab fold-over process, the portion of the sealing tab in the upper right-hand corner is not tiyhtly creased against the face of the die 412 but rather is only urged against the die 412 for subsequent creasing by the roller apparatus 15 4~6 Thus, upon completion o~ the movement of the T-shaped jaw 442 and the side jaws 444, the sealing tabs 120 are folded over the end o~ the die 412 and are oriented within the square tubular configuration oi the car-ton blank . 20 100 as shown in Figure 32~ Additionally, it will be recognized that, due to the V--shaped scoring notches 124 formed on the cart.on blank 100 (shown in Figure 5), the corners of the sealing tabs 120 will consistently be folded flush with the carton segments 102-108 (any excess 25 material lying within the square cross-section o~ the carton blank 100), thereby being properly positloned for the end closure sealing and bonding operation~
Wi-th the sealing tabs 120 folded over the end of the die 412r the crossbar mandrel 400 subsequentl~ rotates in 30 a clockwise direction through a 90 arc as indicated by the arrows in Figure 33 During this rotation, -the carton blank 100 passes beneath and contacts -the roller apparatus 446, thereby causing the end closure panel 112 to be folded down over the end of the die 412.
Referxing jointly to Fiyures 33 and 34, the det.ailed operation oE this rolling procedure is illustrated While the carton blank 1.00 is carried by the individual ~3 51;Z75 n;andrel 402 in the nine o'clock position, the end panel 112 extends beyond the end OL the die 412 with the scoring line 11~ ~shown in Figure 3) being aligned with the top edge of the land section 416. As the individual mandrel 400 rotates from the nine o'clock to twelve o'clock positiont the ou-ter edges of the lands 416 pass closely beneath the cylinder 4~8 of the roller apparatus 446, whereby the end closure panel 112 contacts the reduced diameter section 449 of the cylinder 4~8. ~his contact forces the end closure panel 112 in a downward direction (from its initial position indicated by the phantom lines in Figure 34) tightly against the top surface of the die 412.
~he cylinder ~48 presses the end closure panel 112 tightly against the land sec-tions 416 of the die 412 and rotates across -the end of the clie in a direction indicated by the arrow in Figure 34. As the cylinder 448 rolls across the end of the die 412, the angular transition 451 between the reduced diameter section 44~ and the main diameter of the roller 448 tightly mates with the sides of the carton blank 100, thereby preventing the sides as well as the sealing tabs 120 o~ tne carton blank from springing outward from the mandrel 402~ Further, during this rolling process, the excess carton blan]c material disposed in the corners o:E the square tube (as previously mentioned and shown in Figure 32) is forced within the recess pockets 418 of the die 412 (as shown in Figure 31) such that the corners of the sealing tabs 120 are maintained within a common plane with the remainder of the sealing tab 120, contacting the land section 416 o~ the die 412. Thus, upon passing benea-th the roller apparatus 446, one end of the carton blank.100 is folded and positioned upon the die 412 for subsequent bonding~
Upon completion of the 90 rotation of the crossbar mandrel 400/ the carton blank 100 carried by the mandrel : 402 is oriented in a ver-tical twelve o'clock posi-tion as shown in Figure 33 and is registered or ali.gned beneath L8~

the sealing die or horn 450. While in this twelve olclock position, the sealing horn 450, which had been retracted in a stored posi.-tion vertically above the end oE the mandrel 5 402 taS shown in Figure 30) is lowered directly upon the end closure panel 112 (as shown in Figure 33). In the preferred embodiment, this downward travel of the sealing horn 450 is provided by a pneumatic ylinder (not shown), which is mounted by means (not shown) to permit the horn 450 to move slightly in a plane parallel to the top surface of the die 412 thereby self-aligning itself with the mandrel 402. The bottom surface of -the sealing horn 450 preferably includes a shallow pocket (not shown) formed having a cross-sectional area slightly greater than -that of the end panel 112 so that the sealing horn 450 may extend -partial.ly down over the end of the carton blank 100 when contacting the end closure panel 112.
In this lowered or extended position/ the sealing horn 450 presses firmly against the end closure panel 112, thereby el.iminating any raising of the end closure panel 112 from the sealing tab 120 caused by the memory proper-ties (previously described) of the carton blank material and eliminating a misalignment with the mandrel 402~
Subsequently, ultrasonic energy is applied to the horn 450, from sui-table driving means (not shown), thereby bondiny the end panel 112 to the sealing tab 120, and ~orming a liquid tight seal along the end of the carton blank 100.
After this bonding process, the sealing horn 450 is retracted vertically to its stored position above the end of the mandrel 402 by activation of the pneumatic cylinder (not shown).
Having sealed the end closure panel 112 to the sealing tabs 120, the crossbar mandrel 400 rotates through an additional 90 arcl to position the individual mandrel 402 carrying the carton blank 100 in alignment for transfer to the carton rotator and conveyor transfer apparatus of Work Station IV.

~l f Although for illustra-tion purposes, a single carton element 100 was described passing -through the processes of Work Station IIII it will be recognized that, upon each 90 rotation of -the crossbar mandrel 400, an additional carton blank 100 is transferred to the individual mandrel 402, such that three carton blanks axe carried by a respective three mandrels 402 of the crossbar mandrel 400 at most times. Additionally, it will be recognized that, sirice in the preferred embodimen-t, there are four crossbar mandrels aoo attached to the arbor 408 (as shown in Figure 5), four individual carton blanks are being formed simultaneously by the apparatus of the present invention. Each of these mandrels ~00 moves intermittently through the 90 arcs described, pausing ln sta-tionary positions at the quadrant loca-tions for the described operations.
~ork Station IV - Carton Rotator and Conveyor Transfer Apparatus Follo~Jing the sealing operation performed at Work Station III, the carton blank 100 is transferred to the horizontal conveyor belt 550 which carries the carton blank 100 -through the remaining Stations of the apparatus of the present invention. However, as may be recognized 25 from Figure 33, if the carton blank 100 were transferred in its present orientation upon the crossbar m~ldrel 400 directly to the conveyor 550, the other end closure panel 114 which extends beyonA the length of the carton segments 102 through 108 would lie perpendicular to the horizontal travel of the conveyor 550, thereby obstructing the operations to be performed at Work Stations V, VI, and VII. Thus, to eliminate the obstruction problems associa-ted with the end closure panel 114 r pricr to the transfer of the car-ton blank 100 onto the conveyor 550~
the carton blank :L00 is rotated 90 about its horizontal axis such that the end closure panel 114 lies in a parallel planar orientation with the travel of the conveyor 550~

Referrinc~ to Figure 35, there is shown the carton blank rota-tor mechanism designated generally as 480 which transfers the carton blank 100 from the crossbar mandrel 400 (of Work Station III) -to the horizontal conveyor 550 and rota-tes the carton blank 100 through a 90 axial arc.

_- - .. .. _ _ ., ... ._ ... _ ... ~ .. .. ___~, 27~i Although for illustration purposes only a single carton blank rotator 480 is shown r it will be recognlzed thatl in the preferred embodiment, there are four carton blank ro-tators 480, each positi.oned adjacent the end of the respective crossbar mandrel 40Q.
As shown in Figure 35, the carton blank ro-tator 480 includes a transfer and ejector mechanism designated generally by 482 and a rotating fix-ture apparatus 4~4 which cooperate with each other in transferrincJ and rotating the carton blank 100 from -the crossbar mandrel.
400 to the conveyor loader 550.
The transfer and ejector mechanism 482 preEerably includes a transfer arm 486 and an ejector arm 488 whlch are each rota-tably mounted to a slider mount 490 and 492, respec-tively~ The slider mounts 490 and 492 are spaced vertically apar-t and are each reciprocally mounted to a guide pin 494 and spline shaft 496 which extend between a pair of support columns ~98. These guide pins 494 are rigidly 2Q mounted to the support columns 498, whereas the spline shafts 496 are rotatably mounted thereto, and extend through one of the support columns 498 at one end. The spline shafts 496 addi-tionally engage the transfer and ejector an~s 486 and 488, respectively, such that rotation of the shafts 496 cause a corresponding pivotal movement of both arms 486 and 488.
As shown in Figure 35, the spline shafts ~96 are both provided with gear drives 500 and 502 which are interconnected by a timing belt 504 to rotate both spline shafts 496 simultaneously. Additionally, the diameter of the gear 500 is preferably greater than the diameter of the year 502 such that the ejector arm 488 pivots through a greater arc for any given rotation of the transfer arm ~86.
~ounted on the rear surface of the support columns 498 is a chain drive 506 which is connected in a conventional manner at one end to a ~echanical 2~

drive to power ~he chain 506 back and forth repea-tedl~.
Each of the slider mounts 490 and 432 are securely attached to this chain drive 506 so that, as the motor (not shown) powers the chain drive 506, the slider mounts travel horizon-tally between the support columns 498 along the -~uide pins 494 and spline shafts 496. Since -the slider mounts 490 and 492 are initially connected to the chain drive 506 while positioned adjacent opposite support columns 498, and since the moun-t 490 is connected to the top of the chain 506 loop while the mount 492 is connected to the bottom of the loop, it will be recoynized that, upon movement of the chain drive 50~, the slider mounts 490 and 492 travel between the columns 498 in opposed directions, i.e., as the slider moun-t 490 moves from left to ri~ht as indicated by the arro~J in Figure35, the slider pla-te 492 moves from right to left. As will become more apparent below, this opposed movement allows the carton blank rotator 482 to begin transferring the carton blank 100 Erom l~lork Sta-tion III, while simultaneously depositin~ the carton blank 100 into the horizontal conveyor 550.
As shown, the transfer arm 486 includes an ~-shaped extension 508 which terminates in a substantially rectangular head member 510. Both the extension 508 and head 510 are preferably formed having a hollow interior aperture (not shown) which is connected to a vacuum source ~not shown).
The frontal face of the head member 510 is additionally provided with a plurality of vacuum aper-tures 512 which extend into an interior aperture ~not shown) of the head 510 and extension 508 such that the vacuum source is exposed at the por-ts 512 to -the front surface of the head 510.
Located in a parallel plane and adjacent to the transEer e3ector mechanism 482 is the ro-tatin~ fixture apparatus 484 which is securely mounted to the housin~
514. The fixture apparatus 484 incluaes a hollow f r 7~

~ 1 rectanguLar fix-ture 516, prefer~bly formed of a sta.inless steel sheet material, having an open sicle wall configuration.
The fixture 516 is connected at its ends -to a pair of cylindrical bearing plates 518 which are rot,atably mounted to the support posts 520. The fix-ture 516 additionally includes a bracke-t 522 moun-ked on its lower surface ~shown in Figure 37~ which is connec-ted to a linkage 524. As will be described below, movement of the 1~ linkage 524 causes the fixture 516 to rotate in a counter-cloc]cwise direction as viewed in Figure 35 such that its open side is orien-ted with or faces the transfer and ejector mechanism 482.
The sequence of operations performed by the carton blan~ ro-tator 480 (Work S-tation IV~ is illustrated in . Figures 35~38. As shown in Figure 36 r the ro-ta-ting fixture apparatus 484 (Figure 35) is aligned with and spaced from the end of ro-tating crossbar mandrel 400 o Work Station III. While in this position~ the transfer arm 486 is ~r 20 extended into its extreme fon~ard position and vertically lowered r whereby the face of the rec-tangular head 510 contacts the closed end panel oE the car-ton hlank 100 (as shown by the phantom line in Figure 35)O Upon contact kherewi-th, the vacuum source acting through the apertures 512 on the face of the head member 510, pull -the carton blank 100 tightly against -the face of the head member 510 such -that the car-ton member 100 rnay be carried exclusively by the arm 486.
It will be recognized tha-t the lowering of -the transfer arm 486 to the position illustrated in Figure 35 was initiated by the clockwise rotation of the upper spline shaft 496O Further, since both spline shafts 496 are connected by the timing belt 504, this clockwise ro-tation causes a similar lowering of the ejector arm 488 from its posi-tion shown in E'igure 35, to the position illustrated in Figure 36~ Lowered in this position, the ejector arm 488 is inboard oE -the support post 520 of the rotating ,!

;27~

~2 fixture apparatus 484 r and may subsequently travel in a horizontal direction across the length of the rotating fixture apparatus 484 without ohstruction.
With the transfer arm 486 and the ejector arm 488 disposed adjacent opposite support posts 498 (shown in Figure 35) the chain drive mechanism 506 is activated, causing the sl.ider mounts 490 and 492 to travel hori~ontal].y along the guide pins 494 and the spline shafts 496 in opposed directions, as indicated by the arrows in Figure 36.
Since the carton blan~ 100 is maintained against -the head S10 of the transfer arm 486 by vacuum, during this horizontal movement, the ca ton blank 100 is removed from the crossbar mandrel 400 and drawn into the hollowr square fixture 516.
The square fixture 516 is sized to have a slightly larger cross-sectional area than that of the carton blank 100 and the head 510, such that insertion within the square fixture can be accomplished easily with minimurn friction.
Further~ it will be recognized that, auring this placement of the blank 100 into the square fix-ture 516, the L-shaped extension 508 of the transfer arm 486 lies within -the open side of the square fixture 516 and may travel throughout the lenyth of the square fixture 516.
The opposed horizontal travel of the transfer arm 486 and the ejector arm 488 continues until the slider mounts 490 and 492, respectively, are adjacent the support posts 498 (as shown in Figure 37). In this position, the carton blank 100 lies completely w.ithin the square fixture 516 and is aligned to be rotated in a counter~
clockwise direction throuyh a 90 arc by the rotating fixture apparatus 484.
In the preferred embodirnent, this 90 rotation is facilitated by the actuation of the linkage 524 in a ; . direction indicated by the arrow in Figure 37. By this ~ . movement of the linkage 524, the ~ixture 516 rotates abo~t ~ 3 the cyli.ndrical bearing plates 518 mounted within the suppor-t posts 520, whereby the open side o the fixture 51~ (as shown in Figure 35) faces the transfer and 5 - ejection mechanism 482 and is aligned for the subsequent tra.nsfer of the carton bl.ank 100 into the conveyor 550.
Followiny this rotation of the carton blank 100 and square ~ixture 516, the spline sha-f-ts 496 are rotated in a cou~lterclockwise direc-tion, as indicated by the arrows in Figure 3a ~ thereby pivotiny -the trans:Eer arm 486 and the ejector arm 488 vertically upward into their posi.tions illustrated in Figure 38. Raised in this position, ~he ejector arm 488 is aligned with the open side of the square fixture 516, having its tab 518 extending to abut the end of -the carton blank 100 while the transfer arm 48~ extends vertically above the axial plane of the fixture 516.
Subsequently, the gear drive 506 ~as shown in Figure 35) is activated in a reverse c~irection from its previous travel, causing the slider mount 492 and the ejector arm 488 to travel in a direction indicated by the arrow in Figure 38, ~hile the slider mount ago of the transfer arrn 48~ simultaneously travels in an opposed direction. Thus, the tab 518 of the ejector arm 488 contac-ts the edge of the carton blank 100 and pushes the carton blank 100 through the length of the square fixture 516. As the carton blank 100 is pushed out from the square :Eixture 516, it is supported by an LYshaped bracket 520 which aligns the end of the carton blank 100 for entry into the horizontal conveyor 550.
Thus, from the above, it ~7ill be recognized that, by use of the carton blank rotator 480 of the present invention, the carton blank 100 is transferred from Work Station III to the conveyor transport 550 and is rotated through a 90~ rotation such that the end closure panel 114 of the carton blank 100 is disposed in a plane parallel to the travel of the conveyor 550. ~dcli-tionally, it will be noted that, subsequent -to -the completed horizontal '~ .

27~ii travel of ~he ejec-tor arm 488 s~herein the carton blallk 100 is deposited upon the conveyor 550, the transfer arm 486 has moved to an extreme forwara position and may be 5 rotated in a dos~n~7ard direction for a repetition o:E the cycle previously described. Similarly, upon transfer of the carton blank 100 into the conveyor 550, the linkage 524 is activated to return to its initial position as shos~n in Figure 35, such that the open side .
of the square fixture 51h faces upward in a vertical dixection.
Semi-Rigid Transport Conveyor Referring now to Figure 39, the detailed construc-tion of the conveyor 550 and the entry o:E the carton blan}~ 100 therein may be described. As shown, the conveyor 550 is .
preferably composed of a plurality of elongate bar members 552 which are arranged in pairs and oriented in a parallel configuration with each other. Each pair of the bar members 552 is rigidly attached (preferably by a r' 20 fillet weld) at both ends to a connector rod 554 which maintains the parallel orientation of each pair of bar members 552. Consecutive pairs of the bar members 552 are then formed into a continuous conveyor length by plural link members 556 which are rotatahly mounted to both adjacent connector rods 554 and secured thereto by fasteners 558. Each of these fasteners additionally mounts a roller bearing 55~ s~hich meshes with a gear drive 561 ana supporks the conveyor 550 upon a pair of horizontal rails 563. By such construction, the conveyor 550 pxovides a semi-rigid structure s~hich has sufficient strength to adequately support the carton blanX 100 through the subsequent formation, filling and bonding processes, yet flexible enough to form a conveyor transport.
Disposed on each pair of bar members 552 and rigidly attached thereto, are four U-shaped anvils or yoXes 560 preferably formed from hardened tool steel which are constructed to tightly conform with the outside surfaces of the carton blank 100. The upper surface of anvil 560 adjacent the interior ~alls thereof is provided with a beveled edge 562 t~'nich is preferably formed at a 45 angle and includes an enlargecd radius at each o:E its interior corners. As will be explained i.n more detail infra, this beveled edge 562 coopera-tes with the pre-form apparatus of Work Station V to prepare the carton blank 100 for the end closure process, and additionally mates with an ultrasonic horn (Wor~ Station VII) ~Jhich forms a liquid-tight seal across the open end oE -the carton blank 100.
To ensure the rigid mounting of the anvil 560 to the bar members 552, a support plate 564 possessing the same general shape but making an opening sligh-tly greater than the anvil 560, is ali~ned ~itn the anvil 560 ancl rigidly attached to the ~ndersurface of -the bar members 552.
Pre-Eerably, a series of fasteners (not sho~n) are inserted through all three members, i.e., the support plate 56~, the bar members 552 and the anvil 560 from the undersurface of the conveyor 550 such that any relative movement between - 20 these elements is eliminated.
As will be recognized, the conveyor 550 is held taut between two pairs of gear drives 561 (one of which is shown in Figure 39) located at opposite ends of the conveyor and mounted to a shaft 565 ~hich is connected in a ~5 conventional manner to the main hydraulic drive system (not shown). In the preferred embodiment, the gear teeth oE
the drive engage the conveyor 550 intermediate adjacent pairs oE roller bearincJs 558 and driv2 the conveyor 550 in an intermittent, cy~lic manner (indicated hy the arrows in 30 Figure 39) such that each anvil 560 is momenkarily stationary at pre-determined intervals along the length of the conveyor travel. As tlill become more evident belo~, -khis stationary period allot~/s the appara-tus oE 17Or~ S-tations V khrough VIII to operate on the carton blank 100~
To support the bar members 552 intermediate their ends, a plurality of pairs of rigid support tabs or ears 557 preferably formed of Delrin (a hard plastic ma-terial possessing high ~ear characteristics), are located beneath the conveyor 550 positioned at eaeh of the Work Stations V through VIII. As shown in FicJure 39~, tlle support plates 564 rigidLy connec-ted to the undersurface of the anvils 560, rest against the ears 557, thereby preventing any downward deflection of the bar members 552 and anvil 560 during operation. In addition to the support ears 557 positioned at the Work Stations, the eonveyor 550 incluaes a pair of rigid bars 567 which extend throughou-t the length of the conveyor 550. As sho~m in FLgure 3gA, the rigid bars 567 are spacecl from one another at a aistanee slightly greater than the wid-th across each oE the car-ton segments 102-108 and varied in their vertical distance from the anvils 560 such -that they may maintain the carton blank 100 in a vertical orientation while being earried by the conveyor 550.
Located intermediate each pair of rigid bars 567 and 20 disposed substantially below the plane of the conveyor 550 is a lower support bar 569 which is connected to a hydraulic actuator (not shown~. As illustrated in Figure 39A, the lower support member 569 contacts the lower end of the earton blank 100 thereby maintaining the vertical heigh~
25 of the earton blank 100 upon the conveyor 550. Additionally, as indicated by the phantom lines in Figure 39A, the lower support member 569 is movable in a vertical direction by aetuation oE the hydraulic opera-tor (not shown), thereby accommodating the differing sized containers (1/2 pint and 30 1/3 quart) of the present invention.
Side-Loader Mechanism ~ . ...
Disposed beneath the conveyor 550 and located tangentially adjacent one end thereof, is a side loader mechanism 570 which is ver-tically aligned with the plural 35 carton blanks 100 as they are transEerred from the carton blan~. rotators 480 (oE Work Station IV and sho~n in Figure 38), In the preferred embodiment, this side loader ,, !' mechanism 570 simultaneously loads the ~our sepaxate carton blanks 100 received from the carton blank rotators 480 direc-tly upon the conveyor 550.
As better shown in Figures 40 and 40A, the side loader mechanism 570 preferably includes a plurality o~ C shaped fixture plates 572 which are spaced from one another along a mounting beam 575 at a distance slightly greater than the distance across parallel flats of the carton blank 100~
10 This relative spacing permits a single carton blank 100 to be received between adjacen-c fixtures 572 along the : mounting beam 575.
As shown, the vertically e~tending sidewalls 577 of each fixture pla-te 572 are formed havi.ng a tapered top 15 edge ~ich in the preterred embodiment is formed with an acute angle of less than 45. The fixtures 572 are each rigidly at-tached to the mounting beam 575 which is in turn connected to a linkc~ge 573~ Upon activation of the linkage 573, the beam 575 ancl thus the fixtures 572 move in a 20 horizontal transverse direction toward the open end of the anvil 560. This horizontal movement of the fixtures 572 enters and accurately positions the plural carton blanks 100 within the anvil 560~ As will be explained in more detail infra, the tapered top edge of the sidewalls 577 25 of each of the fixtures 572 permits the return transverse movement oE the fixtures 572 within the interior of the conveyor 550 without contacting the car~on blanks previously loaded and carried by the conveyor 550.
The detailed operation of the transfer of the carton 30 blank 100 from the carton rotator and conveyor transfer apparatus 480 (of Work Station IV) to the conveyor 550 is illustrated in ~igure 40. In the position shown in Figure 40, it will be recognized that the conveyor 550 is momentarily s-tationary in a tangential position aligned 35 with the carton blank rotato.r and the transfer apparatus 480, ~7hereby the frontal planes of ~he anvil. 560 and the C-shaped fixture 572 are perpendicular to the travel of -the ejector arm ~88.

~' f While in this posi~ion, the space between adjacent C-shaped fixtures 572 is registered and aligned with the carton blank 100 such that the blank 100 mav be directly transferred from -the carton blank rotator and conveyor transfer mechanism 480. AS the ejector arm 488 extends toward the conveyor 550 in a manner previously described, the carton blank 100, contacting the tab 518 of the ejec~or arm 488, is transferred to and received between the C-shaped fix-tures 572~ Since the space between the C-shapea fixtures 572, as well as the distance between the bar members 552, is slightly greater than the outside dimensions of the carton blank 100, the carton blank 100 is easily received between adjacent fixtures 572 without an~ bending or deformation of the carton blanlc 100 itself.
Once received between the fixtures 572 r the ejector arm 488 retracts and rotates in a downward direction (as previously descr;bed) and the carton blank 100 i5 carried by the mounting beam 575. Subsequently, the linkage 573 attached to the beam 575 is activatedr causing the fixtures 572 and the carton blank 100 carried ~h~orebetween to move traverse1y toward the open end of the anvil 560.
As shown in Figure 40, during this traverse movement toward the anvil 560, the car-ton blank 100, extending substantially beyond the leading edge of -the fixture 572, enters into the open end of the anvil 560 with the interior surfaces of the anvil 560 contacting the flats of the carton blank 100. It will be recognized that, slnce the fixtures 572 are p~sitioned beneath the conveyor 550, during the traverse movement, the leading edge of the fixture 572 will travel behind the lower surface of the anvil 560 thereby allowing the carton blank 100 to enter unobstructed into the anvil 560.
The C-shaped fixtures 572 continue their t.ransverse travel until -the leading edge 574 of the carton blank 100 contacts or abu-ts the in-terior wall of the anvil 560. As previously men-tioned, since -the interior dimension of the anvi]. 560 is sized to ti~h-tly recelve the tubular configuration of the carton blank lO0, the carton blank lO0 is thereby slightly press-fit into the anvil 560.
Subsequently the conveyor 550 begins its intermittent travel, whereby the carton blank lO0, maintained within the anvil 560, moves arcuately upward with the conveyor 55 to an approximate 45 orientation as shown by the nu~eral lOOA in Figure 39. B.y this travel of the conveyor 560, the ca.r-ton blank lO0 is removed from between adjacent C~-shaped fixtures 572 and is carried exclusively by the anvil 560. Fur-ther, since the sidewalls 577 oE the : fixture 572 are formed having a tapered top edye, subse~uen-t to the travel of the conveyor, the mounting beam 575 and C-shaped fix-tures 572 may _eturn to their initial position for repetition of an additional loadlng cycle, wh~rein another set of four carton blanks lO0 may be t~ansferred from the carton blank rota-tor and conveyor transfer apparatus 4~0 (of 1~1Ork Station IV) .~ 20 It will be recognized that the particular transverse movement of the car-ton lO0 into the anvil 560 in a direction parallel to the plane of the anvil 560 allows the open end of the side panels of the blank lO0 to moderately yield, allowin~ a close fit within the anvil 560.
25 If the carton ~7ere inserted closed-end first, the previously welded corners would resist any yieldingr and cartons would be crushed entering the anvils 560 Further, by transferrin~ the carton blank lO0 to the conveyor in the manner previously describedr 30 the carton blank lO0 is continuously supported by the two sides of the C-shaped fixture 572 as well as the mounting beam 575 during the carton blank's lO0 entry into the anvil 560. The applicant has found that this support of the carton blank lO0 durlng the entry into ~he 35 anvil 560 is preferable to insure against any deformati.on of the square tubular configuration of the :~L8~2~S
-so-carton blank 100 caused by a slight interference fit between the carton blank 100 and the interior walls of the anvil 560.
E'urther, the applicant has found that this side entry process, positively positions th~ carton blank 100 in its desired location within the anvil 560, thereby insuring the accuracy of the subsequent processes performed on the carton blank 100 while carried by the conveyor 550.
Referring again to Figure 39, it may be seen that, while carried by the conveyor 550, the top edge of the carton blank 100 is positioned slightly above the top surface of the anvil 560, and the end closure panel 114 is disposed in a parallel plane to the travel of the carton blank 100 on the conveyor 550. This positioning and orientation of the carton blank 100 upon the conveyor 550 facilitates the subsequent pre-forming, filling and sealing operations performed at Work Stations V through VIII, respectively.
Work Station V - End Section 'Pre-Form 'Apparatus .
With the carton blank 100 positioned upon the conveyor transport 550 and carried within the opening of the anvil 560, the continued cyclic or intermittent hori~ontal movement of the conveyor 550 transports the carton blank 100 to Work Station V (End Section Pre-Form Station). At this station, the end closure panel 114 as well as the top edges of the open end of the carton blank 100 are creased or folded by a discrete three-phase operation into a desired configuration, suitable for the subsequent end closure bonding and sealing process, which occurs at Work Station VII. As will become more apparent below, the apparatus of Work Station V
accomplishes the variety of folding and creasing operations without the benefit of interior mandrels to work against, i.e., all operations occur without the use of supporting means or forming mandrels positioned on the interior of the carton blank.

E~owever, the apparatus for producing such a configuration is substantially modified in the present invention, and therefor is disclosed herewith.
Referring to Figure 41, the overall construction and operation of Work Station V may be seen. Work Station V
includes a pre-form apparatus designated generally by the Numeral 600, which is mounted to a frame member 602 and located vertically above the conveyox 550. The pre-form apparatus 600 preferably includes a housing 604 which supports a mounting plate 606, xigidly attached thereto.
Three die bases 608, 610, and 612 are securely mounted to the undersurface of the mounting plate 606 and are horizo~tally spaced at intervals equal to the distance between anvils 560 ~ounted upon the con~eyor 550.
The dies 608, 610 include a plurality of plate operators (shown in Figures 43 and 45, respectively) whi.ch, during operation of the pre-form apparatus 600, contact the carton blank 100 and cooperate with the die bases 608~ 610 to permanently crease the carton blank 100 into its desired configuration. These operator plates are activated by pneumatic mechanisms 614 and 616 (represented schematically in Figure 413 which are mounted to the top surface of the mounting plate 606 and disposed within the housing 604, each having an apporpriate linkage (not shown) extending through the mounting plate 606. As will be explained in more detail below, each of the die bases 608, 610, and 612 per~orm an operational phase of the pre-foxm apparatus 600 and, upon engagement with the carton blank 100, folds or creases the carton blank 100 in a particular manner, whereby, upon completion of the travel of the carton blank 100 through each of these phase ~ 2-; operations, the carton blank 100 is permanently folded ~ into the particular configuration ind.icated in Figure 51A.
Further, it will be recognized that, although for illustration purposes only one series of the die bases ~ 5 608, 610, and 612 are shown and described, in the preferred ~ embodiment there are four of each of the die bases 608, 61C, and 612, similarly mounted to the plate 606 and positioned so as to register with the respective four anvils 560 carried by each pair of conveyor bars 552.
. 10 ~s shown in ~igure 41, the housing 604 of the pre-form apparatus 600 is slidingly mounted adjacent its corners by four posts 620, which cooperate with four bushings 622 rigidly mounted to the housing 604. Each of these posts 620 extends at one end substantially into the housing 604 and is rigidly attached at the other end to the frame 602. A pair of push rods Ç03 (shown in Figure 1) located outboard of the conveyor 550 are rig.idly connected to the housing 604 and are : engaged with the main transport drive (not shown~ of the con-veyor 550, to reciproc~te in a vertical direction. As may be recognized, by such an arrangement, the housing 604, as well as the die bases 608, 610, and 612 carried thereon, is raised and lowered in a vertical direction indicated by the arrows . in Figure 41. In operation, these push rods 603 synchronize ~ the travel of the pre-form apparatus 600 with the travel j. 25 of the conveyor 550, thereby insuring the proper formation steps are conducted on each carton blank 100.
` Although for illustration purposes, in Figure 41, the - housing 604 is illustrated disposed substantially above the ` ~ level of the anvil 560, it should be recognized that, during - 30 actual operation, the housing 604 only reciprocates upward through a short distance (approximately 1 to 1-1/2 inches) such that, while in its lo~ered position, the bottom surface of the die bases 608, 610, and 612 lie slightly beneath the top su~face of the anvil 560, and in its elevated position, '' the bot-tom surface o:E the die bases 60~, 610, and 612 lie slic~htly above the top surface of the anvil 560~ but below the top ed~e oE the end closure panel 112 of the carton blank 100. The applicant has found -that this short vertical travel of the pre-l'orm apparatus housing 60~
significantly reduces the time required for actuation of the pre-form apparatus 600 and additionally substantially eliminates any registry problems associated with extended ~ravel of the apparatus.
The sequential operation of the die bases 608, 610, and 612 of the pre-form apparatus 600 may now be described.
To help illustra-te tlle progression of opera-tions being performed by the pre-form apparatus 600, -the carton blank is designated in Figure 41 by the numerals lOOA, lOOB, and ,- lOOC, representing the three separate operational phases occurriny at the respective die bases 60~, 610, and 6l.2~
With the pre-form apparatus 600 reciprocated to its initial raised position, as shown in Figure 41, the conveyor 'r 20 550 carrying the carton blanks 100 -thereon, intermitently travels horizontally in the direction indicated by the arrow in Figure 41 and positions the carton blank lOOA beneath the - die base 608. Since, as previously mentioned, the horizontal travel of the conveyor 5S0 is cyclic or intermi-ttent in 25 nature, upon positioning of the carton blank lOOA beneath the die base 60~, the conveyor 550 momentarily stops its travel, thereby facilitating the operation of the pre-form apparatus 604 upon the carton blank lOOA.
While in this position, the housing 604 is lowered : 30 onto the carton blank lOOA and the anvil 560 by the push rods 603, wherehy the first phase operation of the pre-form apparatus 600 is performea upon the carton blank lOOA~ By this first operation, the carton blan}~ lOOA is accurately positioned within the anvil 560, positively seated upon the 35 lower support member 569 and permanently creased along the free edcJes of the end closure panel lL~ to form three beveled surfaces 632 (as shown in FicJure ~2).

9~
Re:Eerriny to Figures ~3 and 44, the detailed cons-truction oE the die base 608, and the first phase operation of the pre-form apparatus is illustrated. As shown in Figure 43, the die base 608 is formed having a generally square cross-sec-tion sized slightly greater than the carton blank lOOA, thereby ex-tending across three edges thereo-f~ The bottom surface of the die base 608 includes a recess 621 formecl adjacent three edges -thereof. This recess forms a boss 623 which is received within the interior of the carton blank lOOA during operation while a shoulder 625 formed by the recess 621 contacts the upper edge of the carton blank lOOA. The back surface (as viewed from Figure 41) of the die bases 608, includes a shallow central cavity 634 (Figure 43) havi.ng tapered angular walls formed at approximately 45 angles r Disposed outwardly from the back wall of the die base 608 is an operator plate 630 which is pivotally connected by linkages 631 and 633 to the die base 608 and ~neumatic operator un.it 20 6i4 (shown in Figure ~1), respectively, being movable both toward and away from the back wall of -the die base 608 as illus-trated by the arrow in Figure 43. The operator plate 630 is additiunally formed having a projection 636 7 the configuration of which is a mirror image of the concave cavity 634 formed on the back surface of -the die base 608 During the lowering of the pre~form apparatus 600 toward the conveyor 560, the operator plate 630 is initially spaced outwardly from the die base 608 (as shown in Figure 43) such that the end closure panel 114 30 may be received between the interface of the operator plate 630 and clie base 608. As such, the continued lowering of the apparatus 600 allows the boss 623 to en-ter into the interior of the carton blank lCO while the shoulder 625 formed on the bottom surf~ce of the aie base 608 contacts the top edges of the carton blan~ lOOA and firmly presses or seats the carton blan~ lOOA against the lower suppor-t member 56 (silo~/n in Figure 41). As may be reco~nized, -this seatiny positively re~isters the carton blank lOOA within the anvil 560, thereby insuring the accuracy of the subsequen-t creasing and ~olding operations being performed by the appara-tus 600.
Wi-th the die base 608 lowered a~ainst the top edges of the carton blank lOOA, the pneumatic operato~ 61~ is activated causing the operator plate 630 via the lin~ages 633 and 631 ko move toward the die base 60~. In the preferred em~odiment, this movement of the operator plate 630 is very rapid, thereby imparting a high velocity to the operator pla-te 630 such that the end closure panel 114 is creased between the cavity 634 and the extension 636.
lS This creasing action causes the end closure panel 11~ to be forced into and permanently assume the shallow, recessedJ
angular cornered shape of the cavity 634. Suhsequen-tly, the hydraulic operator 63~ is deactiva-ted, causing the operator pla-te 630 to move back to its initial position `r 20 spaced from the die base 608. The housing 604 and thus the die base 608 is then raised back to its elevated position.
Thus, from the above, it will be understood that, by the operations occurring at the first phase of the pre-form apparatus 600, the carton blank lOOA is properly seated in the anvil 560 and creased in-to a con~iguration illustrated in Figure 42, having three beveled surfaces 632 forming a picture-frame-like shape along the edges o~ the end closure panel 114.
Subsequent to completion of -the first operational phase 30 of the pre-form apparatus 600 (i.e., -the carton blank lOOA
being correctly seated within the anvil 560 and having its end closure panel 114 creased by the die base 608), the conveyor 550 continues its intermit-tent horizontal motion, causing the carton blank lOOB to be posi-tioned and 35 registered beneath the second phase die base 610~
Basically, by this second phase of pre~form apparatus 600, the two corners of the car-ton blank lOOB located furthest from the end closure panel 114, are stress-relieved by bein~ dimpled and pushed ~7ithin the interior of the carton blank (shown in Figure 46A). Additionally, the sealing tabs 120 formed adjacent the top three edges of the carton blank lOOB are bent or folded within the interior of the carton blank lOOB to be disposed in a plane normal to the end closure panel 114 ~shown in Figure 48~
The operations occurrin~ on the carton blank lOOB
and the respective a~paratus of-this second phase of the pre-form apparatus 600, are illustrated in Figures 45-48~
As shown in Figure 45, the die base 610 preferably includes three plate operators 650 which are pivotall~ mounted at one end to the die base 610 by pins 6~1 and are connected at the other end to the respecti~re ~ne~atic operator 616 by linkages 653 and cross-head 655~ As will be explained in more detail. below, these operator plates 650 pivot in an inward direction towards the in-terior of -the carton blank 100 ~Jhen actuated, thereby folding over the sealing tabs 120 of the carton blank lOOB, which extend slightly above the surface of the anvil 560 ~better shown in Figure 47).
Disposed adjacent the two for~ard corners of the die : base 610 ~as viewed in Figure 413 are two creasing pins 652 having their respective pneumatic R~M operators 654 securely mounted to the bottom surface of the support plate 606.
As best shown in Figures 46 and 46~, these creasing pins are aligned diayonally with the fon~ard corners of the carton blank lOOB and angularly oriented in a downward direction such 30 that the pins 652, upon actuation, extend slightly within the interior of the carton blank lOOB~
The detailed operations occurring at the second phase of the pre-form apparatus 600 may no~J he described. With the carton lOOB ali~ned under the die hase 610, the housing 604 carryin~ the die base 610 thereon is lowered (as previously described in relation to the first phase of the pre-form) onto the car-ton blank loos. As shown in - -~88275 FicJures ~7, when the die base 610 is ex-tended to its Eully lowered position, the ~hree operator pla-tes 650 pivotally connec-ted to the die base 610 reside partially outboard ~f the edges of the carton blank lOOB and are angularly oriented such tha-t their top edges extend within the interior oE the plane of the carton blank lOOB while -their lower edges lie partially within the beveled edge 562 of the anvil 560. Further~ disposed in this lowered position the operator plates 650 lightly touch the top edge of the sealing tabs 120 extending upon the three sides of the open carton blank lOOB, thereby causing the sealing tabs 1~0 to flip slightly inward toward the interior of the carton blank lOOB, as shown in Figure 47.
This particular slight flexing has been found to substantially increase the rigidity of the forward corners of the sealing tabs 120 and aid in the subsequent corner creasing operation performed in the second phase of the car-ton pre-form.
Subsequently the pneumatic R~ operators 65~ ~f the cxeasing pins 562 are ac-tuated, causing the creasing pins 562 to extend and travel in a direction indica-ted by the arrow in Figure ~6, thereby contacting the two forward corners of the carton blank lOOB. As previously mentioned, since the sealing tabs 120 are rigidified b~
the operator plates 650 a-t their top edge, upon contact therewi-th, the corners of the carton blank lOOB readily collapse or deform and are pushed within the interior of the carton blank lOOB as well as in a slicJht dow.nward direction. Due to the carton blank lOOB being formed with the V-shaped scoring notches 12~ (as shown in Figure 5) located at these respective fo~ard corners, the corners consistently collapse into a V-shaped orienta~ion as shown ; in Figure ~6A~ As will be recognized, this V-shaped orientation relieves any stresses in the corners of -the car-ton blan]c lOOB during the folding operations and effectively miters the forward corners of the carton blan~ lOOB for the subsequent sealing tab 120 fold-over operation.
Having the corners of the carton blank lOOs relieved in such a manner, the creasing pins 652 are retracted back to their storea position ~sho~n in Figure 46A) and theoperator plates 650 are activated by their respective pneumatic mechanism 616 to contact and fold over the sealing tabs 120. This particular fold-over operation is illustrated schematically in Figure 47, wherein -the operator plates 650 are shown in their initial position placed over the carton blank lOOB with the sealing tabs 120 adjacent their lower surfaces. From their ini-tial position, the operator plates 650 are pivoted downward within the .~ interior of the carton blank lOOB in a direction indicated by the arrows to assume a position illustrated by the phantom lines in Figure 47. As will be recognized, during this downward pivoting of the operator plates 650, the sealing tabs 120 are folded over to reside exclusively within the interior of the carton blank lOOB. As in the previous sealing tab fold-over operations, the consistency and accurate location of the fold is insured by the scoring lines 122 (shown in Figure 3) formed on the carton blank 2S lOOB, which substantially weaken the reslstance to the fold at a precise location on the carton blank lOOB.
As sho~Jn in.Figure 47, the operator plates 650 pivot through an arc substantially greater than 90 such that, during the folding operation, the top edge of the sealing tab 120 initially extends downward wi-thin the interior of the carton hlank lOOB~ This extended fold-over o~ the sealing tab 120 compensates for thc slight memory property of the carton blank material ~as previously described) so that, when the operator plates 650 return to their initial position, the sealing tabs 120 will spring slightly upward, but remain in a plane normal to the exterior walls of the carton blank lOOB.

3;Z75i As will be recognized, in the ideal situation, the lower pivot point 651 of the plate members 650 should be loca-ted a-t the bend point (i.e., the scoring lines 122) oE -the carton blank lOOB thereby insuring a pure and consistent bending force being appliea to ~he sealing -tab-120. However, since all three sealing tabs 120 must be concurrently folded over, the operator plates 650 must be spaced from the scoring lines 122 and from one another to provide suf~icien-t s~inging room during the pivoting procedure. The outboarcl pivot point 651 of the present invention provides a suitable compromise structure wherein the opera-tor plates 650 are spaced from one anothex to freely pivot simultaneously without contacting each other and which the applicant has Eound to yielcl consistent results. As such, during the pivoting of the plate members 650, the sealing tabs 120 not only pivot downward, but additionally slides or cams again~-t the lower surface of the plate members 650. This slicding motion tends to force the 10~7er portion of the sealing tab 120 to -flex outward into the beveled recess 562 of the anvil 560.
Hos~7ever, due to the scoring lines 122 weakening the sealing tab and forming, in effect, a preferential fold line, this outward fle~ure is held to a minimum and does not detrac-t from the overall effectiveness of the fold down operation.
Subsequently, the pneumatic mechanism 616 is de-activated, returning the operator plates 650 to their oriyinal position as shown in Figure ~6, and the housing 60~ of the pre-formed apparatus 600 is vertically raised, therehy removing the die base 610 as well as the creasing pins 652 carried thereon from the carton blank :lOOB. Thus, as may be easily recogrlized, by the operation of the seconcl phase of the pre-form apparatus 600, the carton blank lOOB is formed into the configuration shown in Figure ~8 with the sealing tab 120 folded within the in-~erior of the carton blank lOOB, and lyiny in a plane normal thereto with the two forward conlers rorming a miter-like corner interface.

Upon completion of -thc second phase oE the pre-form appara-tus 600 operation, the conveyor 550 again begins its inter~ittent horizon-tal travel, thereby positioning 5 -the caxton blank lOOC ~eneath the die base 612 for the third operational phase of the pre-foxm apparatus (shown in Figure 41). At this third phase, the top edges oE the carton blank lOOC are beveled out~ard to ex-tend sligh-tly be~vond the sidewall sections of the carton blank lOOC
10 and the forward corners are stretched outward or e~panded, to provide a suitable surface for end sealing, as sho~
in Figure 51~ and described in detail below. In the preferred embodiment, this procedure is accomplished effectively and easily by the die base 612 (shown in ~igure 15 49~ being lowered firmly upon the top edge of the carton blank lOOC.
Referring to Figure 49, i-t may be seen that the aie base 612 is formed into a generally square configuration and includes a chamfer 660 along its lower edges. In the r 20 preferred embodimen-tr this chamfer is formed at approximately a 45D angle to the bot-tom surface of the die base 612 such tha-t it mates with the beveled surfaces 562 formed on the anvil 560 (shown in Figure 50). As shownr the beveled surfaces 562 of the anvil 560 is provided with a series 25 of circumferentially ex~nding serrations 563 which (as will be explained in de-tail infra) form a gripping surface for the anvil 560 during the subsequent end sealing procedure of Work Station VII.
: The two Eorward corners (as viewed from Figùre 41) 30 Of the die base 612 slightly protrude from the flats of the die base 612 and are formed into a conical coni~uration 662 ~he outside diameter of this conical protrusion 662 is a mirxor image of the enlarged radii formed at the respective corners of the anvil 560 (shown in Figure 50).
35 Thus, the lo~er edges of the die base 612 are formecl to tightl~ mate with the he~eled surface 562 of the anvil 560 such that the die base 612 and anvil 560 cooperate to form a mold-like ixture.

As previously described in ~elation to the first two phases oE the pre-form apparatus 600, in operation the die base 612 is lowered to~ard the conveyor 550 to contact the -top edges of the carton blank lOOC. Extended to its fully lowered position, the die base 612 contacts the sealing tabs 120 (previously foldecl over -to lie ~.7ithin a plane normal to the flats of -the carton blank lOOC) and forces the sealing tabs 120 in a do~mward direction against the adjacent lower portion of the carton blank lOOC (sho~n in Figure 51).
The continued clo~nward pressure of the die base 612 ; ~orces the carton blank lOOC and its sealing tab 120 to reside between the beveled surfaces 562 of the anvil 560 and the chamrered edges 660 of the die base 612. As such, the top edges of the carton blan~ lOOC are beveled outward Ir and e~-tend sli.~htly beyond the vertical planes of the carton seyments 102-108 oE the carton blank lOOC (as shown in Figure 51) and the serrations 563 are pressed slightly -, 20 into the lo~7er surface of the top edges of the carton blank lOOCo It will aclditionally he recognized that, during this procedure, the forward corners of the carton blank lOOC
are stretched to conform to the conical corners 662 of the 25 die base 612 and the enlarged radii formed in the anvil 560. Thus, the for~7ard corners of the carton blan~ lOOC
are formed having an outer enlarged radius as clearly sho~n in Figure 51A
: Subsequently, the die base 612 is raised in a vertical 30 direction by -the push rods 6~2 tFigure 1) in a manner . previously described, ~7hereby the sealing tabs 120 spring upward tdue to the moderate memory properties of the carton blank material) slightly.
Thus, from the above, it may be recognized that, upon 35 completion of its travel through the pxe-form apparatus 600 and its three--stage operation, the upper or open edges of the carton blank lOOC are pre-formed into a configuration -~8~ S

suitable to the subsequent end sealing and bonding operationp without the use of forming mandrels or the like being inserted ~7ithin the interior of the carton hlank 100 during operation. Further, by the pre-forming process, the upper edges of the carton blank 100 are formed in an up~ard-facing picture-Erame-like structure which mates with the configura-tion of ~he end closure panel 114.
Additionally, it will be recognized that each of the three phases previously described in -reference to the pre-form apparatus 600, occurs simultaneously for each lo~ering of the pre-form apparatus 600 aown upon the carton blan~s lOOA, lOOB, and lOOC.
Work Station VI - Filllng Sta-tion Following the pre-form apparatus operation, the car-ton blanks 100 are transported by the conveyor 550 to l~ork Station VI ~the Filler Station). At this station, the car~n blanks 100 are filled with a desired liquid by a two-stage operation ~lerein, at the first stage, a pre-fill nozzle supplies a slight majority ~approximately 60%) of the liquid to the carton blank and, at the second stage, a topper nozzle accurately fills the carton to the precise liquid level. In the preferred embodiment, both of the nozzles, i.e., the pre-fill and topper nozzles, are 2S constructed in the same manner, with the differences in the quantity of liquid delivered into the carton being controlled by the ad~ustable displacement of a metering pump positioned on each of the nozzles.
As will be reco~lized, to fully utilize the space reduction made possible by the rectanyular configuration of the container 12 (shown in Figure lA), the carton blank 100 must be filled with the desired liquid to a level proximal the open end of the carton blank 100. As such, the container 12 of the present invention is highly s~sceptible to spillage durinc; the filling operation. Further, since~
in the preferred embodiment, the end closure bonding and ~8~32~5 sealing operation (occurring at l~ork Station VII) is accomplished wi-th an ultrasonic ~elding process, it is desirable that, duri.ng the filling operation, liquid does not splash ~r ~oam Gn~o the seali-~g tabs 120 formed at the open en~ of tlie ca~ton blank 100.
To facilitate bo-th of these ohjectives, a novel filling nozzle and metering pum.p app~ratus is utilized which, in the preferred e~bodiment, are combined into a single integral unit providing a positive liquid displacement, a high volume, low velocity discharge, and an accurate discharge shu-t-o-Ef which significan-tly reduces the possibility of accidental over-fill and splashing o the liquid during filling. Further, an alternative nozzle device is disclosed ~hich includes all of -the above performance features and is specifically adapted for 1~
use with a cons-tant volume and cons-tant pressure pump wherein li~uid metering is accomplished exclusively by an internally reciprocating spool.
Additionally, a novel pump and valve operating and timing mechanism is disclosed ~hich synchronizes the operation of the me-tering puTnp and nozzle with respect to the motion of the carton blanks upon the conveyor and provides an automatic and manual no-fill mode which prevents fluid discharge when a carton blan~ 100 is no-t positioned under the nozzle or when desired by the operator.
Referring to Figure 52, the detailed construction of the nozzle 700 and metering pump 740 of the present invention is shown. The nozzle 700 is formed having a yenerally cylindrical configuration and is preferably fabricated ~rom stainless steel such that the corrosive effects of the liquid passing therethrough are minimal.
A large central aperature 702 extends substantially through the length of the nozzle 700 and communicates with an enlarged torroidal cavi-ty 704 formed concentric therewith.
Adjacent the closed end o-E the aper-ture 702 is an aperture port 706 which extends radially in~ard from -the exterior 3Z~5 of the nozzle 700 into the upper end of the aperture 702.
The aperture 702 is enlarged at its lower end to form a discharge cavity 708 having a beveled or conical inside diameter 710. As will be explained in more detail below, this beveled diameter 710 provides a valve seat for a nozzle spool 712 and additionally directs the liquid passing through the end of the nozzle 700 inward towards its own center line.
Disposed within and slidingly received by the aperture 702 is a noæzle spool 712, preferably formed in a closed end tubular configuration~ the length of which is less than the length of the aperture 702. The spool 712 includes a plurality of elongated channels 714 which extend along the Qute~ diameter thereof and are located such that, when the-lower end of the spool 712 is seated against the beveled diameter 710, the top edge o each of the channels ~ 714 reside slightly below the lower surface of the eniarged torroidal cavity 704.
The lowex end of the spool 712 is proyided with a 20 ~ e cap 716 including a beveled edge 718 which mates with . the beveled diameter 710 formed on t~e end of the nozzle 700.
In the preferred embodiment~ this valve cap 7~6 if formed of ~ELRI~, a relatively hard plastic material, possessing a slight resiliency which, when pressed against the b~veled diameter 710, provides a positive shut-off for the noz.zle 700.
The upper end of the spool 712 is preferably formed having a closed end 720, the outside diameter of which is slidingly ~eceived within the aperture 702 and is provided wit~ ~n. ~-ring seal 721 which forms a liquid-tight seal between the spool 712 and the aperture 702. As shown, the O-ring 721 is disposed within an annular recess 723 ~ormed in the spool 712 and travels with the spool 712 during xeciprocation within the aperture 702.
The upper closed end 720 is provided with an upward projection 722 having a generally conical shape which *Txademark 7~ii serves as a bumper for the internally moving spool 712 as it slides in ~n upward direction within the aperture 702. As shown, the upper end 720 prefe~ably includes an arm linkage 711 which is rotatably mounted in a ball and socket arrangement 713 at one end~ and extends horizontall~
through an aperture 70~ formed in the upper portion of the nozæle 700. The linkage 711 is pivotally mounted intermediate its length about a pin 715 which is rigidly connected to the frame (not shown~ of the apparatus 10. The opposite end of the linkage 711 is adjustably connected to a push rod 717 which communicates with a linkage drive (not shown). As will be recognized, by vertically moving the push rod 717 in the direction of the arrows in Figure 52, the spool 712 reciprocates within the cen-tral aperture 702.
The inlet to the nozzle 700 is formed by a vertical : . aperture 724 ~^7hich extends from the upper surface 726 of the nozzle into the enlarged torroidal cavity 704. The 20 upper end of -the inlet aperture 724 is tapered in diameter, Eorming a beveled shoulder 728 which, in the preferred embodiment, cooperates with a ball check valve 730. The check valve 730 is supported on its lower surEace by a spider cylinder 731 having a plurality of radially exkenaing webs 733 which slidingly engage the cylindrical walls of the aperture 724. Both the spider cylinder 731 and check valve 730 are biased against the shoulder 728 in a conventional manner by the spring 732. This ball check valve 730 permits flow into the inlet aperture 724 but ;30 prevents any reverse flo~ therefrom :During operation, the spool 712 ver-tically reciprocates within the aperture 702 and functions both as a sh~t-off valve for positively sealing the discharge end of the nozzle, and a flow control valve for met~ring the passage of liquid through the nozzle The particular flow con-trol properties o~ the spool 712 are made possible by the design of the channels 714.

i, ~ . .. .

2~S

These channels 71~ are designed such that the ratio of the flow cross-section o~ the channels 71~ to the outle-t flow cross-sec-tion 70~ is essentially a constant value throughout the opening and closing o-f -the nozzle 700, with the outlet.flow cross~section being considerably greater than the channel flow cross-section. As such, as the liquid travels through the channels 714, it is free to flow into the larger discharge cross-sectional area 708, thereby dissipating fluid pressure and attenuating fluid velocity. Thus, the liquid exits the nozzle 700 at a substantially reduced velocity which yields laminar flo~, thereby allowing the carton blan~.
100 ~o be ~illed without the possibiliky of ~plash-over.
Additionally, slnce the nozzle 700 of the present invention utilizes an internally moving spool 712, ra~ner than an externally moving spool as utilized extensively ; in the prior art, upon discharge from the nozzle, the liquid is directed by the beveled diameler 710 inward, . 20 to~Jards the center line of the nozæle. This inward directed flow allows the diameter of the nozzle discharge to be formed as large as the open end of the carton blank 100 into which the liquid is being deliVered, thereby facilitating a high volume liquid flow rate. Further, the internally reciprocating spool 712 of the present invention specifically eliminates the entrapment of air under the nozzle dlscharge whicn occurs in the prior ar~
nozzles~ -thereby greatly reducing foam generated during the filling process~ In Figure 52C, a conventional pr.ior art nozzle "N" is shown, having a spool "S" outwardly reciprocable (in a direction indicated by the arrow in Figure 52C) to valve the discharge !'D". Typically9 ~he spool "S" is normally closed by a spring biasing arrangement (not shown) which permits the outward movement of the spool "S" (i.e., opening of the nozzle) in response to incoming fluid pressure. Such an arrangement always results in a minimum discharge opening for a glven liquid 27~i flow ra-te which yields a maximum discharge velocity. ~s shown, during opera~ion, the conventional nozzle "N"
discharges liquid over the end of the spool "S"
creating an umbrella-like flow configuration. This umbrella configuration entraps air beneath the spool "S"
and above the rising liquid level which generates substantial foam formation in the liquid "L". The genera-tion of foam adversely effects filling accuracy and additionally promotes splash-over during the filling operation. Additionally, although some prior art nozzles have attempted to alle~-iate the air entrap~ent problem by ven-tiny the air through a central aperture (not sho~) formed axially through the spool "S", such attempts have proven incapable of pro~iding a complete solutlon. In contradistinction to the conventional prior art nozzle, the internally reciprocating spool 712 of the present invention comple..ely eliminates the air entrapment problem associated duriny -the filling operation. As , 20 shown in Figure 52D, during filling, the spool 712 reci.procates upward, allowing the liquid to flow througn the discharge 708 in a conveying flow configuration.
~5 such, the umbrella of the prior art is eliminated with its attendant air entrapment and foam generation being ~5 eliminated. Thus, due to the high volume, low velocity flow rate through the nozzle, filling of the car-ton blank 100 occurs rapidly~ wi-thout the possibility of li~uid splashing onto the top edge of the carton blank 100.
By reference to ~igure 52f the detailed operation of the 30 nozzle 700 of the present invention may be easily recognized~ In the preferred embodiment, the spool 712 is reciprocated vertically within the aperture 702 of the nozzle 700 by the downward reciprocation of the push rod 717 which is transmitted to the spool 712 35 via the linkage arm 711. During this movement~ -the spool is drawn upwara toward the closed end of the aperture ~38~75 702 until the protrusion 722 of the closed end 720 contacts the upper wall of the aper-ture 702. With the spool 712 raised to this elevated position, the channels 714 co~municate with the e~larged cavity 704 and the lower DELRIN cap 718 is removed from the seat 710, such that the nozzle 700 is opened, and -the liquid flows through the inlet aperture 724, channels 714, and discharge cavity 70~ oE the nozzle 700.
Alternatively, the nozzle ?oo may be closed or shut off by reciprocating the push rod 717 in an upward vertical direction, whereby the spool 712 is forced in a downward direction wi-thin the aperture 702, isolating the channels 714 from the enlarged aperture 704 and : 15 simultaneously seating the DELRI~ cap 71~ tightly against~
the beveled diame-ter 710 of the noz.zle 700. This tight `~
sealin~ of the cap 718 positively shuts off flow through.:
the nozzle 70Q and eliminates any dripping of liquid fxom :~ the end thereof.
t 20 Although, in the preferred embodiment, this reciprocation of the spool 712 within the aperture 702 i.s accomplished by the reciprocation of the push rod 717, it should be recognized that, alternatively~ the uppex end of the aperture 702 may include a vacuum port 25 (not shown) which extends radially outward in the vicinity of the port 706 and ls connected to an alternating vacuum-pressure supply. In this regard, a three-way solenoid operated valve (not shown) may be mounted to the vacuum port ~not shown), and connected to both a constant 30 pressure line and a constant vacuum line (not shown3 which, by the operation of the solenoid, may be alternatively ~ exposed to the vacuum port to facilitate the rapid : reciprocation of the spool 712 ~7ithin the aperture 702 The amount of liquid passing through -the nozzle 700 35 is controlled by the metering pump 740 of the present invention which is preferably rigidly mounted to the top .

9L~81~Z75 surface of the noz~le 700. As shown in Fiyure 52, the metering pump 740 includes a bell-shaped cylinder housin~
742 having an aper-ture 744 e~tending throughout i-ts length Adjacent the lo~er end of the housing 742, this aperture 7~4 is enlarged to form a pumping chamber 746 which communicates directly with the inlet aperture 724 of the nozzle 700.
To prevent any leakage between the metering pump 740 and the nozzle 700, an O-ring 748 is provided along the periphery of the interface between the metering pump 740 and nozæle 700 and is clamped and maintainea in position by a collet 750 which extends arotmd the exterior diameter of both the metering pump 7~0 and noæz1.e 700.
Disposed within the chamber 746 is a purnp piston 752 having an elongate upper section 754 and a lower head member 756~ The diameters of the elongate sec-tion 754 and the head memher 756 are sized slightly less than the .~ diameters of the aperture 744 and pump chamber 746, respectively, such that the piston 752 may slide vertically within the housing 742. Additionally, both the elongate section 754 clnd the head me~ber 756 are provided with O-ring seals 758 and 760, respectively, which prevent leakage of liquid between the piston diameters and the housing apertures.
An elongate aperture 762, preferably formed concentric with the piston 752 and extending throughout its length~
provides a liquid inlet for the metering p~p 740~ As sho~m in Figure-52~the inlet aperture 762 includes a valve 764 biased in a closed position by a spring 766 and re~istered within the aperture 762 adjacent both ends by a plurali~y of guide projections 768. As will be recogniæed, the valve - 764 allows liquid passage into the pumping chamher 746 but prohibits any flow of liquid in a reverse direction through the inlet aper-ture 762.
In operation, the pump piston 752 is initially raised upward through the lenyth of the pumping chamber 746 by a 2~7~

rigid linkage 780 (shown schematically in Figures 53~55) attached to the upper end of the elongate section 754 During this up~ard travel, the pressure of the incominy l.iquid within the inl.et aperture 762 (produced by the static head of liquid cont.ained in storage reservoir 763, shown in Figure 1) causes the valve 764 to move off its seat or open/ thereby allowing liquid to fill the volume of the chamber 746. The pressure within the aperture 762 and within the chal~ber 746 rapidly equalizes at the end of this stroke, so that, due to the biasing :Eorce of the spring 766, the check valve 764 closes or sea-ts against the bottom surEace of the piston 752.
Subsequently, the piston 754 is forced in a do~mward direction b~ the rigid linkage 780 (shown in Figures 53-55), thereby displacing the liquid contained in the pumpinq chamber 746 through the ball check valve 730 of the nozzle 700. During this do~1nward travel or pumping stroke of the metering pump 740, the spool 712 of the nozzle 700 must be vertically raised within the structure 702 (in -the manner previously described) such that the channel 714 communicates with the inlet aperture 724. As such, upon reciprocation of the piston 754, the entire volume o-E l.iquid contained within the pumping chamber 746 flows through the nozzle 25 700 and is deposited within the carton blank 100.
Subsequently, upon completion of the pumping stroke~ the spool 712 of the nozzle 700 moves verticallv downward, seating against the beveled diameter 712, thereby providing a positive shut-off for the noæzle 700~
It will be recognized that, in basic principle, the metering pump 7~0 of the present invention is conventional in design in that it simply provides a posi-tiv~ displ~cement piston pump includin~ an inlet and outlet check valve.
However, since in the present invention the metering pump 35 740 is combined ~ith the nozzle 700 to form a single in-tegral unit, the mechanism provides siynifican-t improvements over the prior art designs.

g~5 sesides the obvious size and weigh-t reduc-tion benefits made possible b~ such a design, the present invention significantly reduces -the volume of the liquid passages on the outlet siae of the metering pump 740, thereby greatly reducing the possibility of air ingestion into the liquid-in the event that the spool 712 is not precisely timed to open and close at the beginning of the pump piston 752 travel. Further, since the lower surface of the piston 752 bottoms out directly against the top surface oE the nozzle 700 at the end of the pumping strol~e, the en-tire volume contained within the pumping chamber 746 is displaced through the nozzle 700, such that an~ air entering the system is swept out during each successive pumping cycle and will not accumulate in the pumping chamber. As will " be reco~ized, this lac~ of air accumulation significantly ~ increases the accuracy of the liquid quantity being ; delivered on each pumping cycle. Additionally, since the inlet to the pumping chamber 7~6 is concen-tric with the , 20 piston 752, any leakage through the valve 764 during the pumping cycle is substantially eliminated by the positive seating of the valve 764 caused by the increased PressUre developed by the downward movement of the piston 752.
An al-ternative embodiment of a filler nozzle suitable for use in the present invention as well as many other filling applications is shown in Figure 52A. The alternative nozzle 950 includes a generally cylindrical-shaped body configuration formed of an upper and lower housing portion 952 and 954, respectively. As with -the nozzle 700 of Figure 52, the nozzle 950 includes a central aper-ture 956 which extends in an axial orientation substantially throughou-t -the length of both the upper and lower housing portions 952 and 954. Adjacent cpposite ends of the lower housing portion 954, the central aperture 956 is enlarged to form two flow cavities 958 and 960. As shown, the upper flow cavity 958 co~municates with the nozzle inlet 962, whereas the lower flow cavity 960 forms the outlet 964 of the nozzle 950.

Disposecl wi-thin the cen-tral aperture 956 is-a spool 966, the outside diameter of which is sl.ightly less than the diameter of the aperture 956 such that the spool 966 may reciprocate. The spool 966 may be provided with a~
end cap 968 rigidly attached aajacent one end thereof which .
is preferably fabricated of DELRIN and formed to -tightly ma-te with the beveled circumference o:E the nozzle outlet 96~ As will be recognized, when this cap 968 is seated upon the outlet 964, the nozzle is valved with all flow through the outlet 964 being prohibited.
Intermediate the length of the spool 966, a plurality of flow channels 970 are formed which are spaced symme-trically about the circum-ference of the spool 966~
As with the emboaiment of Figure 52, these flow channels 970 selectively communicate bet~een -the uPper and lower flow cavities 958 and 960 thereby forming a meteriny passageway for liquid flowing through the noz~le 950.
At the intersection between the upper and lower housing portions 352 and 954, respectively, a cap seal assembly 972 is provided which provides a Liquid-tight seal between the housing portions 952 and 954 as well as a low friction seal around the circumference o~ khe spool 966. As best sho~m in Figure 52B, the cap seal assembly 972 resides in an annular recess 974 formed in the lower housing portion 954 and includes an O-ring 976 and C-shaped seal 978. The C-shaped seal 978 is constantly biased against the periphery of the spool 966 by the O-ring 976 and is compressed between the u~per and lower housing portions 952 and 954 to prevent leakage between the housing portions 952 and 954 In the preferred embodiment, the seal 978 is fabricated from a moderately stiff yet resilient elastomeric material which effectively forms a liq~lid-~iyht seal with the spool 966 yet possessing a small coefficient of friction to allow -~he spool 96~ to readily reci.procate within -the aperture 956. As will be explained in more detail belowJ this low friction stationary ~ap seal configuration elimi.nates any ~8!32~5 liquid displacement duri.ng the closing of the nozzle caused by the piston effect oE a sealiny member (such as the O-ring 721 of -the nozzle 700 of Figure 52) reciprocating with the spool 970 within the aperture 956.
The upper housing portion 952 is pre-ferabl~ provided with a control chamber 980 which com~unicates with the upper end of the central aperture 956 and accommoda-tes the bumper portion 982 o:E the spool 966. As shown, the control chamber 980 communicates with a vacuum pressure port g86 which may be connected to a vacuum and pressure source (not shown)~ As will be recognized, due to the cap seal assembly 972 being disposed between the housing portions 952 and 954 and tightly sealing against the spool 966, the control chamber 980 and upper portion of the central aperture 956 are isolated from liquid passing through the nozzle. As such, the control chamber 980 may be utilized to raise and lower the internal reciprocati.ng - spool g66 within the central aperture 956. In response to ~ 20 the alternative application of vacuum or pressure to the port 986~ Further, in the preferred emhodiment, an additional port 984 is provided which may be provided with an air switch (not shown) or other similar device for sensiny when -the nozzle 700 is in its open and closed position.
In operationt the nozzle 950 is pre-erably connectea to a constant pressure liquid supply (such as the elevated liquid reservoir 763 of Figure 1) which is connected to the inlet 962 of the nozzle 950 by means of the conduit 988. To permit liquid to flow through the nozzle 950, vacuum is selectivel~ applied -to the vacuum port 986 which causes the spool 966 to reciprocate upward within the aperture 955, thereby unseating the end cap 968 from the outlet 964. Liquid enterina the inlet 962 then flows through the flow channels 970 in-to the enlarged cavity 960 and through the outlet 96~.
In the preferred embodiment, the effective area of the :Elow channels. 970 is formed to be less than the area 11~
oE the lowex cavity 960 such tha~ the incoming liquid pressure may be dissipated and velocity attenuated through the valve 950 (as previously described in relation to the nozzle 700 of Figure 52). Additionally, the nozzle 950, due to its in~ernally reciprocating spool 966 and angularly beveled discharge 964 proviaes an a~ially converging liquid discharge which, as previously mentioned, eliminates air entrapment beneath the nozzle discharge and foam generation during the filling operation.
To discontinue the flow of liquid through the nozzle 950, the vacuum to the port 986 is terminated and pressure is applied thereto, thereby causing the spool 966 to reciprocate downward toward the outlet 964. Due to the cap seal 972 remaining stationary during this reciprocation process, it will be recognized tha-t the effective area of the spool 966 remains constant during closing. This same effective area prevents any displacement during the closing operation which would be present with the O-ring seal moving with the spool 966, and thereby eliminates the piston effect which causes a portion of the liquid contained within the aperture 956 to rapidly squirt from the discharge 964 during closing.
~urther, in the preierred embodiment, the flow channels 970 are formed to provide a substantially constant ratio bet~een the cross-sectional flow area of the channels 970 to the outlet 964 throughout opening and closing of the nozzle 950. As such, the rluid velocity remains at a constant value during closing of the valve thereby yielding laminar flow.
Thus, the flow channels 970 perform a metering effect which~ in combination with the cap seal asseI~ly 972, provides an effective shut-off nozzle which eliminates ~8~7~i any pi.s-ton effec-t during closing and effectively opexates with only one movincJ part, i.e., the spool 966.
Referring now to Figure 53, the opera-ting and timing mechanism 780 of the present inven-tion for synchronizing and adjusting -the operation oE the filler nozzles with respec-t to -the motion of the carton blan~s 100 carried by the ~onveyor 550 will be described. It should be noted that, for illustration purposes, the operating and 10 timing mechanism 780 are described in relation to the nozzle 700 and metering p~np 740 assembly of Figure 52.
However, the same operating and timing mechanism 780 ; may be modified for use with the alternative nozzle 750 of Figure 52A without departing Erom the spirit of the.
15 present invention.
As shown in Figure 53, the operating and timing mechanism 780 comprises a mechanical linkage driven by a cam operator 788 which is powered by a constantly rotating shaft 790 synchronized with the drive system ~not shown) .~ 20 Of the conveyor transport 550. The cam 788 converts the rotation of the shaft 790 in-to a reciprocating motion which drives a cross-head 792 via a vertical push rod 794 As will be recognized, the cross-head 792 is rigidly attached to this vertical push rod 794 such tha-t the ~5 vertical push rod 794 and the cross-head reciprocate as an integral unit in a vertical direction in response to the rotation of the cam 788.
Opposite ends of the cross-head 792 are con~ected to adjacent metering pumps 740 by way of a drive l.inkage 796 30 having one end thereof pivotally mounted to the cross~head 792 and the other end thereof pivotally connected to a rocker arm 798~ As shown, the rocker arms 798 are rotat.ably : mounted intermediate their len~th to the piston 754 of the metering pump 740 to form a central pivot, and are additionally 35 provided with an adjus-tahle pivot 800 at their opposite ends. This adjustable pivot 800 connects one end of the ~8~7~

rocker ~rm to ~1 air or hyclraulic cylinder 802 which is pivo-tally mounted -to the machine frame 804.
Since the metering pump 740 and nozzle 700 are additionally riyidly mounted to the machine frame 804, it will be recognized that, upon the vertieal reciproeated travel of the cross-heads 792, caused ~y the rotation of eam 788, the pis-tons 754 of the metering pumps 740 are raised and lowered ~i.e., comprising the pump stroke of the me-tering pump 740) by means of the vertical l;n}~aqe 796 and rocker arms 798.
ReFerrinc3 now -to Figures 53 through 55~ the aetailed operation of the ~.echanism 780 may be described~ In Figure 53, the mechanism 780 i5 sho-.~m in its normal operating position, having previously completed a pump stroke and filling operation, wherein the piston 754 is extended to its lo~Jer-most position against the top surface of the nozzle 700 (as shown in Figure 52). In this normal position r the pneumatic or hydraulic cylinders 802 are , 20 retracted to their upper-mos-t position, therehy providing a rigid structure for -the pivot point 800 of the rocker arm : 798.
Referring now to Figure 5a, the operation of the mechanism. 780 duriny the normal intake stroke of the metering pumps 740 is illustrated. In normal operation, the pneumatic eylinders 802 are pressurized to eonstantly remain retracted to their upper-most posi-tion as shown in Figure 53 whereby the rotation of the cam 788 causes the eross-head 792 to raise in a vertical direction~ Upon this vertical travel of the cross-head 792, the rocker arms 798 pivot about the points 800, which are rigidly maintained in a stationary position by pressure exerted upon -the cylinders 802, thereby raisincJ the pump pistons 754. As previously described, during this upward pump piston 754 travel, the incoming liquid opens the chec]~ valve 764 and fills the pumpiny cham~er 746 (shown in FicJure 52~ of the pumps 7~0.
Continued rotation of the cam 788 eauses the cross-head 792 to reciprocate downward, thereby forcing the pump ~L8~27S

pistons 754 of the metering pump 740 in a downward direction, discharging the liquid contained therein through both nozzles 700.
It will be recognized that, since the vertical travel of the pistons 75~ is dependent upon the ratio of the distances between each of the rocker arm end pivots ~00 to the central pivots r minor adjustments on the pump stroke, and -thus the pump displacement, can be indep~ndently facilitated by the limited travel o~ the adjustable pivot 800 along the respective rocker arm 798. As such, the displacement of each of the metering pumps 740 may be finely adjusted during operation simply by manually turning a respective thumb screw 805 positioned on the end ~5 of the rocker arms 798. Further, it will be recognized that to accommodate substantial differences in the metering ~: pump 740 displacement, the cam 788 may be replaced with a larger cam having a greater degree of eccentricity.
~eferring now to Figure 55, the operation of the mechanism 780 in a no-fill mode is illustrated. To provide a no-~ill mode for one or both of the metering pumps 7~0, upon completion of the pumping stroke of the metering pump 740 and prior to initiating the intake stroke of the metering pumps 740, the air pressure maintaining one or both Of the air cylinders 802 in a retracted position is discontinued, and nominal air pressure is applied to the reverse side of the air cylinders 802. By this nominal xeverse pressure, the air cylinders 802 function in a manner analogous to a shock absorber being biased and extending in a downward direction proportionately to the upward travel of the cross-head 792 and causiny the pivot point 800 of the respective rocker arm 798 to kravel vertically downward. By this downward vertical trav~l of the pivot point 800, the pump piston 75~ does not rise with the cross-head 7~2, but rather is positively maintained at the bottom of its stroke against the top surface of the nozzle 700 (shown in Figure 52). As such, the piston 754 fails to complete its inta~e stroke and fails to receive . ~

382~

liquid for its discharge stroke. Subsequently, upon completion of the discharge stroke of the cross-head 792, the hydraulic cylinder 802 may be selectively pressured in a manner previously described and raised to its normal opera-ting position for the continued pumping and discharge cycle.
In Figure 55, this no-fill mode of the mechanism 780 is aepicted wherein the right metering pump 740 is placed in a no-fill position (i~e., with the air cylinder 802 being ~iased in a downward direction) and the left metering pump 7~0 is placed in the normal position (iDe., with the air cylinder 802 retracted to its upper-most position). During the r~tation of the cam 788 and the 15 upward travel of -the cross-head 7~2, the left metering pump 740 raises through its normal intake stroke whereas the right metering pump 740 is inhibited from moving upward by the proportional downward extension of the air cylinder 802. As such, only the left metering pump 740 , 20 recelves a liquid charge during the inta~e stroke.
Further, upon the subsequent pumping stroke, the downwara travel of -the cross-head 792 overcomes the nominal reverse pressure exerted in the right air cylinder 802 thereby causing the right air cylindè~ 802 to raise 25 upward propor-tiona-tely to the downward trav~l of the cross-head 792. ~hus, the right metering pump 740 is main-tained in its bottomed position against the top surface of the right nozzle 700~ while the left metering pump 740. discharges liquid through its respective nozzle 700 in a mann~r previously described. Thus, by reversing the pressure on a respecti~e air cylinder 802, at the end of the preceaing pumping stroke~
the operator may selectively prohibit the subsequent filling opera-tion occurring in individual nozzles 700 without effecting the operation of the remaining nozzle 700 connected to the mechanism 780.
It will be recognized that the cylinders 802 may ~e advantageously provided with a simple valving arrangement 3f~75 to actuate their operation which may be incorparated by a switch located on the operator's panel (not shown~. Thusr the selective activation of the cylind2rs 8Q2 may be easily accomplished by manually tripping the switch. Fur-ther, in the preEerred embodiment, the mechanism 780 is connected to a carton blank electronic sensing device (not sho~) provided on the conveyor 550. Thi~ electronic sensorJ
upon detecting the absence of a carton blank 100 upon the conveyor 550, automatically reverse pressurizes the air cylinder 802 such that the no-fill mode of a respective noæzle 700 is actuated.
In the preferred embodiment, both the pre-fill nozzles and the topper nozzles (shown in Figure 1) are provided with their own operating and timing mechanism 780, with the topper nozzle having a cam 788 substantially smaller than the cam of the pre-fill no~zle such tha-t the amount of liquid delivered through the toppex nozzle is much less than the amount of liquid delivered through the pre-~ill nozzles. Further/ it will be recognized that~
since in the preferred em~odiment, there are four pre-fill nozzles and four topper nozzles, there will be two operating and timing mechanisms 780 for bo-th the pre-fill and topper nozzles. Additionallyl although in the preferred embodiment a mechanical operating and timing mechanism 780 is shown, it will be recognized that al-ternatively a hydraulic or pneumatic actuator connected to each of the pump pistons 50 including an appropriate metering valve system may be utilized without departing ~rom the teachings of the present invention.
Work Station VII - End Closure and Bonding Apparatus Subsequent to the filling operation occurring at Work ~ation ~I, the carton blank 100, carried by the conveyor 550, is transported to Work Sta-tion VII, the End Closure and Bonding Station. At this station, the end closure panel 114 which heretofor has been extending yl z~

. 120 vertically above the surface or the anvil 550, is folded over the open end of the carton blank 100, a~d then bonaed and sealed to the sealing tabs 120 (sho~Jn in Figure 3) to produce the sealed container 12 sho~Jn in Figure 1~.
In the preferred embodiment, this bonding operation is facilitated by an ultrasonic welding process (previously describecl in reference to Work Station III), which signiEicantly eliminates the production of vapors emitted from the polyethylene film ~rhich could contaminate the liquid contained within the carton blank 100 an~
addi-tionally settles the adjacent sealing surfaces OL the carton blank 100 into perfect alignment thereby insurin~
. a positive seal.
Referring now to Figures 56 through 60, the apparatus ; comprising Work Station VII, the end closure and sealing apparatus, is illustrated As shown in Figure 56, the apparatus includes a can~ing plate 8S0 which is rigidly - . mounted to a lin~age 852 and disposed slightly above the top ~ r 20 surface of the anvil 560. Thk plate 850 is preferably formed of Teflon (a registered trademark of E. I~ DuPont de Nemours) having a rectangular configuration, one edge 854 : of which is tapered to provide a beveled or camming surface.
Although, for illustration purposes, only one camming : 25 plate 850 is depicted in Figure 56, it will be recog-nizedthat, in the preferred embodiment, four plates 850 are utilized being interconnected by -the linkage 852, each being disposed adjacent a respective anvil 560 of the conveyor 550.
In operation, the carton blank 100 is transported by the intermittent cyclic drive of the conveyor 550 to a position, indicated in Figure 56, wherein the anvil 560 resides adjacent the camming p].ate 850. In this position, the linkage 852 is activated, causing this linkage 852 to reciprocate in the direction sho~m by the arrow in Figure 56, whereby the beveled ed~e 85~ of the camming- plate 850 contacts and extends over the end closure panel 114 of the i carton blank 100 adjacent the top surface of the anvil 560.

~., , , :

During -this con-tact, the end closure panel 114 is ur~ed in a downward direction as illustrated by the arrow in Figure 57, whereby the end closure panel 114 is folded over between the lower surface of the plate 850 and the anvil 560 to reside sligh-tly beneath the top surface of the anvil 560 (with the beveled panel 114 a~utting the picture-frame-like sealing tabs 120.
As will be recognized, since the end closure panel 114 was previously creased by the pre-form apparatu~ of Work Station V to include a picture~frame-like beveled edge, during th s fold~over process, the end closure panel 114 mates with the sealing tabs 120 of the carton blank 100 maintained against the beveled surfaces S62 formed along the top surface of the anvil 560. However, . due to the moderate memory properties of the caxton blank material, the end closure panel 114 tends to spring slightly upward away frorn the sealing tabs 120 after the operation of the camming plate 850, as depicted in phantom lines in - 20 Figure 57. Thus, upon completion of the travel of the camming plate 850 across the end closure panel 11~, the end closure panel 114 is substantially folded down upon the open end o~ the carton blank 100 and is pre-positioned for the subsequent sealing and bonding process.
~ubse~uently, the conveyor 550 continues its intermittent travel, thereby positioning the carton blank 100 beneath a sealing die or horn 860 (shown in Figure 59) which, in the preferred embodiment, seals the perimeter of the end closure panel 114 onto the sealing tabs 120 of the carton 30 blank 100. As best shown in Figure 58, the sealing horn 860 is formed having a substantiall~ square cross-sectional configuration and includes a beveled edge 862 formed ad~acen-t its bottom surface, as well as a large radius 86A formed along its two fron-tal corners. The beveled surface 862 and the enlarged corner radii 864 tigh-tly mate with the complementary surfaces 562 of the anvil 560 such that, hen the horn 860 is lowered upon the anvil 560, the edges z~

of the end closure p~nel 114 ana the sealing tabs 120 are pressed tiyhtly between the horn 860 and the anvil 560.
Referring to Figure 59, the horn 860 is supported by a slider plate 861 disposed above the plane of the conve~or 550. The slider plate 861 is fabricated from two plate segments 861A and 861B which are maintained toyether by plural ball bearings (not shown) to permit the plate segments 861A and 861B ~o sligh-tly move relati~e one another in a common plane. As shown, the horn 860 is mounted on the lower plate member 861B and is connected to an ultrasonic yenerator 866 ~Ihich in turn is rigidly mounted to the lower plate member 861B. The slider plate : 861 includes a pair of bushings 863 extending throughout the height of the slider plate 861 adjacent both ends thereof, which receive a pair of inclined posts 865~ As shown, these posts 865 are rigidly mounted adjacent one end to a pair of support beams 867 extending trans~ersely across the plane of the conveyor 550, and are angularly oriented to the vertical plane of the anvil 560. This angular orientation causes the die 860 to be located inboard of the end closure panel 114 o the carton blank 100 when maintainea in its stored position, above the plane of the conveyor 550, as indicated in Figure 59.
~ he slider plate 861 is additionally pro~ided with a rigid extension 869 which protrudes adjacent the rear edc~e thereo~, onto which is mounted a hydraulic or pneumatic actuator 871 connected to the housing of the apparatus (not shown3~ As will be recognized, by activating the hydraulic cylinder 871, the slider plate 861 reciprocates along the posts 865 in a direction sho~n by the arrows in Figure 59, thereby lowering and raising the sealiny horn 860 onto the end closure panel 114 of the carton blank 100~
In operation, the sealing horn 860 is lo~ered onto the end closure panel 114 or the carton blank 100, in an angular direction as indicated in Figure 60. Due to the angular orientation of the posts 865 wîth respect to :
.~

the anvil 560, upon contac-tin~ the end closure panel 114, the die base urges or ca~s the end closure panel 11~
downward and toward the closed end of the anvil 560 such 5 that the end closure panel 114 is properly seated upon the sealing tabs 120 of the carton blan~ 100 (as indicated in Figure 58). As will be recognized, the sealing horn 860, being free to move in a plane normal to the inclined posts 865 due to the bearing interface of the slider plate 1~ segments 861A and 861B, self aligns itself with all ~hreeof the beveled recesses 562 of the anvil 560 thereby causiny a wedging efFect between end closure panels 114 and the sealing tabs 120.
While in this position, the heveled ed~es 862 and the enlarged corner radii 864 of the die 860 firmly press the r peripheral edges of the end closure panel 114 tightly against the sealing tabs 120 of the carton blank 100 which are supported from their undersur:Eace by the beveled ed~es .~ of the anvil 560. Subsequently, the ultrasonic yenerator 866 is activated, causing the sealing die 860 to rapi.dly vibrate. This severe vibration results in the settling of the end closure panel 114 and the sealing tabs 120 in-to proper alignment with the small discontinuities or inconsistencies between the interfacing sealing surfaces being eliminated. Since the anvil 560 is maintained in stationary position along the conveyor 550 and the lower surface oE the sealing tabs 120 is gripped by the serrations 563 ormed on the beveled recess 562 of the anvil 560 (sho~7n in Figure 50), this rel.ative vibra-tion o~ the sealing horn 860 against the anvil 560 generates heat exclusively along the peripheral edges of the sealing tab 120 and the end closure panel 11~. This heat causes the polyethylene coating on the c~rton blank 100 to firmly bond the end closure panel114 -to the sealing tabs 120, thereby producing a liquid-tight seal for the carton blank 100, as illustrated in Figure 58.
As previously men-tioned, this ultrasonic ~elding process occurs in a matter of fractions of a second, 3Z~5 12~
whereupon, af-ter the sealiny of the end closure panel 114 to -the sealing tabs 120 of the carton blank 100, the hydraulic cylinder 871 is deac-tivated, causing the slider plate 861 ~nd the horn 860 to move angularly upward along -the posts 865 and back to its initial position.
It will be recognized that alternative methods of sealing the end closure panel 114 to the sealing tab 120 may be utilized in the present invention. However, the applicant has found that, by use of the ultrasonic welding process, the liberation of fumes from the polyethylene substances is significantly eliminated and the polyethylene is heated exclusively adjacent the periphery o~ the end closure panel 114 , thereby eliminating any possible damage : 15 to the coating on the remainder of the carton blank 100.
Similarly, due to the severe vibration of the ultrasonic welding process, the tab 120 and end panel 114 is consistently aligned in proper position with voids or air pockets between the sealing surfaces being comp-)etely eliminated.
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~L18~275 Work Station VIII - Filled Carton Ejector With the liquid sealed within the carton blank 100, the final step to be performed on the apparatus 10 of the present invention is the ejection o~ the carton blank 100 from the conveyor 550. In the pre~erred embodiment, this ejec-tion is accomplished in a simple yet e~ec-tive manner at Work Station VIII (the Ejector Apparatus) wherein the ~illed and sealed carton blan} 100 is expelled from the apparatus 10 through an aperture 901 for;ned in the housing 14 (as shown in FicJure l)o Referring to Figures 61, 62, and 63, the ejector apparatus 900 of the present invention is illustrated.
The apparatus 900 basically comprises a U~shaped rixture 902 which is rigidly mounted at one end to a linkage 90~.
As will be recognized, in the preferred embodiment four U-shaped ,ixtures 902 are symmetrically spaced along the linkage 90~ such that all four of the ~illed and sealed carton blan~.s 100 contained on the conveyor 550 may be simultaneously ejec-ted ~rom the apparatus.
The common linkage 904 is rigidly attached to ~ cam plate ',05 having a subs-tantially J-shaped cam run 9~7 formed therein, which cooperates with a cam follower 909 rigidly attached to the housing ~not shown) o~ the apparatus 10. The side walls of the U-shaped fixture 902 are preferably Eormed having differing lengths 901 and 903 and are spaced sufficiently apart from one another to slidingly receive a carton blank 100 therein. As will be recognized, the apparatus 900 is positioned beneath the upper horizontal surface of the conveyor 550 and is disposed proximal one end thereoi to cooperate with the carton blan~s 100 as the conveyor 550 begins its downward travel over the gear drive 561 tsimilar to the gear 561 snown in Figure 39) and as it subsequently returns toward l~or~ S-tation IV.
As shown in its stored position in Figure 6:L (this position corresponding to the phantom line of Figure 63) when t'ne conveyor 550 begins its downward travel over the gear drive 561, the U-shaped fixture 902 is aligned with , ~

12~
the anvil 560 and carton bl~n~ 100 con-tained therein.
As such, the carton blank 1()0 is receivecl between the differing length side walls 901 and 903 of the U-shaped fixture 902. ~his downward movement of the conveyor 550 continues until the carton blank 100 is disposed in a parallel plane with the U-shaped fixture 902 (as indicated in Figure 61) wherein the conveyor 550 momentarily remains s-tationary in the manner previously described While in this stationarY position~ the drive mechanism ~not shown) connected to -the li-nkage 904 is activated, causing the linkage 904 and -the U-shaped fi~ture 902 to begin its outward movemen-t toward the carton blank. lOQ in a direc-tion indicated by the arrow in Fiyure 61. ~s will lS be recognized, during this initial movement~ the cam follower 909 travels through the short straight section of the cam run 907, thereby imparting only an outward co~ponent to the travel of the U-shaped fixture 902 (i.e., toward the anvil 560), which facilitates abutment oE the rear panel 906- Of the U-shaped fi~ture 902 against the lower end of the carton blank 100.
Further outward travel of the linkage 904 causes the U-shaped fiY.ture 902 (following -the cam run 907~ to move further outward toward the anvil 560 and to simultaneously move transversely or horizontally across the plane of the anvil 560 (i.e./ from right to left as viewed in Figure 61), thereby causing the carton blank 100 to ~lide toward the open end of the anvil 560. This continued diagonal movement (i.e., outward and transverse) of the linkage 904 causes the carton ~lank 100 to be pushed forward through the anvil 560 and outward past the open end of the anvil into the position shown in Figure 62. As will be recognized, this diagonal movement avoids interference be-tween the re]atively rigid carton corners and the anvil 560.
In this position, the car-ton blank 100 is no longer maintained in the slight interference fit of the anvil 560 and, due to the interior dimensions of the U-shaped 1~7 fix-ture ~0~ being slightly greater than the distance across the carton segments 102 through 108 of the carton blank 100, the carton 100 may drop Erom the U-shaped fixture 902 and be carried away by an auxiliary packaging conveyor (not shown3.
As will be recognized, by use of the ejector apparatus 900, the sides or carton blank segments 102 through 108 of the carton blank 100 are supported as they are pushed outtJard and through the anvil 5600 The applicant has found that this support of the carton blank 100 during the ejection process eliminates any possibility of bending or deforming of the carton blank 100 ~Jhich would occur during direct out~7ard e~ection of the carton blan]c 100 through the anvil opening S60. Further, -the ejector apparatus 900 of ,~ the present invention automatically accommodates the differing sized containers produced by the apparatus 10 : (i.e., lJ2 pint and 1/3 quart~, with the decreased length of the smaller 1/3 quart container being compensated r 20 by the initial travel of the U-shaped fixture 902 being exclusively in an outwara direction which properly enters the carton within the fixture 902~
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In summary, it will be recognized, that the apparatus and method of the present invention provides a significant improvement over the prior art apparatus by providing the increased versatility of Producing dual-sized cartons without requiring drastic modification -to the apparatus. In particular, to change from the one-half 30 pint -to one~third quart size container, the only modifications necessitated by the presen-t invention are (1) the adjustment ;~ of the L-shaped aliynment block 167 to tightly contact the smaller length of the car-ton blank segments 102 through 108, . (2~ the initial pre-loadin~ of the differin~ sized carton blanks onto the conveyor loader 140 (of Figure 5), (3) the pre-position of the stop 410 further outt7ard u~on the length 27Si 12~
of -the ~vil 402 to accommodate the shorter leng-th of the car-ton segmen-ts 102 throu~h 108 (as shown in Figure 22~, ~4) the raising of the lower support members 569 of the conveyor 550 to the position indica-ted in Figure 39, and (5) the adjustment of the pivot 800 of the tir~ing and metering r~chanism 800 to decrease the quan-tity of liquid discharged through -the nozzle 700 (as shown in Figure 41).
As will he recognized, all of these minor adjustments may be accomplished in a matter of minutes, thereby easily facilitating the rrodification of the apparatus and method of the present invention to produce differing sized containers 12.
Further, it will he recognized tha-t the present invention significantly eliminates the space, reliability, versatility, and output deficiencies associated in the prior ar-t apparatus which heretofore have prevented the widespread use and adoption of -the straw bearing cartons disclosed h~rein.
'r 20 The significant reduction in required floor space was specifically addressed in each Work Station I - VIII of the present invention. In particular, the application of the straw elemen-t to the carton blank, as ~ell as the sealing oE the -tape length to the carton blank, has been 2~ consolidated to be performed in sequential operation upon a single rotating drum. Additionally, -the carton blank has been rotated through a 180 orien-tation upon completion of its travel through Work Station I, and returned to a - position proximal its initial orientation upon the aPparatus.
Further, the mechanisms for collating, wrapping, and creasing the carton blank about the forming mandrels have been corrbined into a single mechanism with the plural forming mandrels being spaced from one another at a dis-tance less than the effective length of the carton blan~s 100.
Additionally, this combined mechanism allows the collating and creasing of the carton blank to occur simultaneously~

~1l382~5 By use of the crossbar mandrel 400 of Work Sta-tion III r the carton blanks have been sealed upon their side and one end without the use of a plurality o transport mechanisms.
In addition, once the carton blanks have been inserted upon the conveyor transport 550, the remaining forming, filling, and sealing operations occur without relocating or transferring -the carton blanks to a difEerent support system.
The reliability benefits made possible by the present invention are additionally evident throughout each of the major sub-systems of the apparatus. In Work Stations I and II, the carton blank 100 has been continuously engaged by a pair of regis-try tabs adjacent the end panels 11~ and 114, thereby insuring the proper alignment of the carton blank 100 upon the apparatus. As such, the sealing of the stxaw element and tape leng-th to the car-ton blank, as well as the accuracy of the creasing and folding of the carton blank, has been maintained within positive limits. Further/ the , 20 use of the conveyor transport 550 throughout Work Stations III~VIII significantly limits the possibility of misalignment through the remainder of the apparatus.
The significant increased output of the present invention over the prior art apparatus has been made possible by the use o~ both a serial and parallel trac~.c transport system which advantageously coincides the particular serial and parallel transport system with those operations which require -the least and most operational time, respectively. Further, since the number of transfer mechanisms have been maintained to a minimum, the overall cycle time of the carton blanks through the apparatus of ~- the present invention has been si~nificantly reduced.
In addition, it should be noted that J throughout the disclosure, reference has been made to a main or common driving mechanism of the apparatus of the present invention to which all of the major sub-systems are synchronlzed~

~8~275 Although the details of this drive system have not been disclosed, it is well ~ithill the ~nowledg~ of one skilled in the art to install such a system and synchronize the operation of each of the various component systems clisclosed herein with such a main drive.

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Claims (15)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A high volume, low velocity shutoff discharge nozzle for filling containers with fluid comprising:
a housing having an inlet cavity, an outlet cavity and an aperture connecting said inlet cavity to said outlet cavity; a spool reciprocable in said aperture, channel means defining a flow path through said aperture between said inlet and outlet cavities; a valve seat adjacent said outlet cavity; and a valve member formed on one end of said spool, said valve member co-operating with said valve seat for opening and closing said nozzle in response to the position of said spool in said aperture, the flow cross section of said valve seat with the valve member in its open position being substantially larger than the cross section of said flow path defined by the channel means.

2. A discharge nozzle as claimed in Claim 1 wherein:
said channel means comprises a plurality of grooves formed on the periphery of said spool.

3. A discharge nozzle as claimed in Claim 1, wherein said channel means provides a constant cross-sectional area ratio between said flow path defined by the channel means and said outlet cavity, irrespective of the position of said spool within said aperture.

4. A discharge nozzle as claimed in Claim 1, wherein the flow cross-sectional area of said outlet cavity is formed substantially larger than the cross-sectional area of said flow path defined by the channel means, said larger outlet area dissipating pressure and attenuating the velocity of fluid passage through said nozzle.

5. A discharge nozzle as claimed in Claim 2, wherein the flow cross-sectional area of said outlet cavity is formed substantially larger than the cross-sectional area of said flow path defined by the channel means, said larger outlet area dissipating pressure and attenuating the velocity of fluid passage through said nozzle.

6. A discharge nozzle as claimed in Claim 1, 2 or 3, wherein said valve seat comprises a bevelled circumference which is formed adjacent said outlet chamber to direct fluid passing through said nozzle inwardly towards the centreline of said valve seat.

7. A discharge nozzle as claimed in Claim 1 or 2, in which said channel means is isolated from said inlet cavity when the valve member is in its closed position.

8. A discharge nozzle as claimed in Claim 4 or 5, m which said channel means is isolated from said inlet cavity when the valve member is in its closed position.

9. A discharge nozzle as claimed in Claim 1 in which said valve member opens in a direction opposite to the direction of fluid flow.

10. A discharge nozzle as claimed in Claim 1 in which said inlet cavity comprises an enlarged toroidal cavity which is formed concentric with said aperture.

11. A discharge nozzle as claimed in Claim 1, further including a check valve permitting fluid to pass only in one direction through the nozzle.

12. A discharge nozzle as claimed in Claim 1, further comprising means for reciprocating said spool in said cavity.

13. A discharge nozzle as claimed in Claim 1 which further comprises a mechanism for timing the discharge of the nozzle with the position of a carton carried upon a transport mechanism, said mechanism comprising: an arm member reciprocable in response to driving means co-ordinated with the travel of said transport mechanism;
a rocker arm pivotally mounted intermediate its length to said filler nozzle and connected adjacent one end to said arm member; means pivotally connected adjacent said other end of said rocker arm for providing a fulcrum for said rocker arm; and means for maintaining said fulcrum stationary when said carton is present beneath said nozzle, thereby providing a rigid fulcrum for said rocker arm so that reciprocation of said arm member causes a corresponding reciprocation of said filler nozzle, said means permitting reciprocating movement of said fulcrum when a carton is not present beneath said nozzle so that said fulcrum is free to reciprocate in an inverse direction and at a proportional rate to said reciprocation of said arm member so that said filler nozzle remains stationary.

14. A discharge nozzle as claimed in Claim 13, wherein said means for maintaining said fulcrum stationary comprises a pressure actuated cylinder having a reciprocable piston pivotally connected at one end to said rocker arm.

15. A discharge nozzle as claimed in Claim 13 or 14, further comprising a metering pump to supply a desired quantity of liquid to said nozzle, said reciprocation of said arm member causing said metering pump to sequentially intake and discharge a quantity of liquid for subsequent passage through said nozzle.