Method and apparatus for producing replaceable cartridge

Abstract

A canister and replaceable and disposable cartridge for use in a dispenser for dispensing a dry, pourable material and method of producing the replaceable and disposable cartridge is disclosed. The dispenser comprises a canister body, a replaceable and disposable cartridge having flexible membrane seal received within the canister body, a pouring spout cap attached to an open end of the canister body, the pouring spout cap movable between an open position and a closed position wherein the pouring spout cap seals the open end of the canister body, a pouring spout, and a pierce pin depending from a lower surface of the pouring spout cap providing communication between the replaceable and disposable cartridge and the pouring spout via a discharge chamber. The replaceable and disposable cartridge is prefilled with a predetermined quantity of the dry, pourable material and is fabricated and sealed with biodegradable materials.

We claim: 
     
         1 . A method for producing a replaceable and disposable cartridge for use in a dispenser for dispensing a dry, pourable material, the dispenser comprising a canister body, a pouring spout cap attached to an open end of the canister body, the pouring spout cap movable between an open position and a closed position, wherein the pouring spout cap sealingly engages the open end of the canister body when the pouring spout cap is in the closed position, a pouring spout, and a pierce pin depending from a lower surface of the pouring spout cap in communication with the pouring spout, the method comprising the steps of:
 forming a tube and inserting the tube within a cavity in the canister body, the tube having an interior and a first end and a second end, wherein each end comprises an opening;   sealing the first end opening;   filling the second end of the tube with a predetermined quantity of the dry, pourable material; and   disposing a flexible membrane over and around the second end opening to seal the second opening, wherein the flexible membrane is pierced by the pierce pin when the pouring spout cap is moved to the closed position to provide communication between the interior of the tube and the pouring spout, and wherein both the tube and the flexible membrane are fabricated from a biodegradable material.   
     
     
         2 . The method of  claim 1 , further comprising the step of inverting the tube between the step of sealing the first opening and the step of filling the second end of the tube. 
     
     
         3 . The method of  claim 1 , wherein the flexible member is disposed on a feed tape having a first layer comprising the flexible member and a second layer comprising a peelable backing paper, wherein a first surface of the flexible membrane is coated with an adhesive in removable contact with the second layer. 
     
     
         4 . The method of  claim 3 , wherein the first layer of the feed tape is perforated into a plurality of flexible membranes having a starburst shape comprising a plurality of radially extending legs. 
     
     
         5 . The method of  claim 4 , wherein the second layer has a split seam along either side of the feed tape to form a central portion and two side edges of the second layer of the feed tape, wherein the method further comprises the step of peeling the central portion of the second layer of the feed tape to expose the adhesive coated on the first surface of the flexible membrane prior to disposing the flexible membrane over and around the second opening to seal the second opening. 
     
     
         6 . The method of  claim 4 , wherein the starburst shape comprises twelve radially extending legs. 
     
     
         7 . The method of  claim 1 , wherein the flexible membrane is formed from a cellulose acetate membrane. 
     
     
         8 . The method of  claim 1 , further comprising the step of moving a punch collar comprising an upper disk, an intermediate disk, and a lower disk over the second opening to form and affix the flexible membrane about the second opening to seal the second opening. 
     
     
         9 . The method of  claim 8 , wherein the first layer of the feed tape is perforated into a plurality of flexible membranes having a starburst shape comprising a plurality of radially extending legs. 
     
     
         10 . The method of  claim 9 , wherein the lower disk of the punch collar has a lower face comprising a plurality of downwardly depending and inclined fingers, each finger corresponding to a leg of the flexible membrane. 
     
     
         11 . The method of  claim 10 , wherein an inner diameter of the intermediate disk of the punch collar is provided with a plurality of corresponding raised steps, each step corresponding to a leg of the flexible membrane and a finger of the lower face of the lower disk. 
     
     
         12 . The method of  claim 11 , wherein the upper disk is provided with an inner diameter which, when brought about the tube of the replaceable and disposable cartridge, urges the flexible membrane into contact with an outer surface of the tube. 
     
     
         13 . The method of  claim 4 , wherein the feed tape is indexed to bring one of the plurality of flexible membranes into registration with second opening to seal the second opening. 
     
     
         14 . The method of  claim 13 , wherein the peelable backing paper is removed by a take-off roller prior to disposing the flexible membrane over and around the second opening to seal the second opening. 
     
     
         15 . The method of  claim 14 , wherein a punch collar is forced downwardly over and around the second opening of the tube after the flexible membrane is disposed over the second opening to seal the second opening. 
     
     
         16 . The method of  claim 15 , wherein the flexible membrane has a plurality of outwardly extending legs and a lower face of the punch collar has a corresponding plurality of downwardly extending fingers that engage the outwardly extending legs of the flexible membrane and brings the legs of the flexible membrane into close proximity with an outer wall of the tube. 
     
     
         17 . The method of  claim 16 , wherein an inner diameter of the punch collar has a plurality of raised steps that correspond with the plurality of legs of the flexible membrane that further push the legs of the flexible membrane into contact with the outer wall of the tube. 
     
     
         18 . The method of  claim 17 , wherein the inner diameter of the punch collar further presses the plurality of legs of the flexible membrane into contact with the outer wall of the tube. 
     
     
         19 . The method of  claim 15 , wherein the punch collar further comprises a vent intermediate an upper and a lower surface of the punch collar to allow the escape of air to provide flat and smooth application of the legs of the flexible membrane to the sidewalls of the tube. 
     
     
         20 . The method of  claim 15  where the punch collar is retracted upwardly for positioning above a second tube and a next flexible membrane of the plurality of sealing membranes. 
     
     
         21 . A method for producing a replaceable and disposable cartridge for use in a dispenser for dispensing a dry, pourable material, the dispenser comprising a canister body, a pouring spout cap attached to an open end of the canister body, the pouring spout cap movable between an open position and a closed position, wherein the pouring spout cap sealingly engages the open end of the canister body when the pouring spout cap is in the closed position, a pouring spout, and a pierce pin depending from a lower surface of the pouring spout cap in communication with the pouring spout, the method comprising the steps of:
 forming a first of a series of tubes adapted for insertion within a cavity in the canister body, the first tube having an interior and a first end and a second end, wherein each end comprises a first and second opening, respectively;   transporting the first tube to a first sealing station;   disposing a first flexible membrane over and around the first opening to seal the first opening of the first tube;   transporting the first tube to a filling station;   filling the second end of the first tube with a predetermined quantity of the dry, pourable material;   transporting the first tube to a second station; and   disposing a second flexible membrane over and around the second opening of the first tube to seal the second opening, wherein one of either the first flexible membrane or the second flexible membrane is pierced by the pierce pin when the pouring spout cap is moved to the closed position to provide communication between the interior of the tube and the pouring spout, and wherein both the tube and the flexible membrane are fabricated from a biodegradable material.   
     
     
         22 . An apparatus for the production of a replaceable and disposable cartridge fabricated from a biodegradable material for use in a dispenser for dispensing a dry, pourable material, the dispenser comprising a canister body, a pouring spout cap attached to an open end of the canister body, the pouring spout cap movable between an open position and a closed position, wherein the pouring spout cap sealingly engages the open end of the canister body when the pouring spout cap is in the closed position, a pouring spout, and a pierce pin depending from a lower surface of the pouring spout cap in communication with the pouring spout, the apparatus comprising:
 a roller for dispensing a feed tape having a first layer comprising a flexible member and a second layer comprising a peelable backing paper, wherein a first surface of the flexible membrane is coated with an adhesive in removable contact with the second layer, the first layer of the feed tape is perforated into a plurality of flexible membranes and the second layer has a split seam along either side of the feed tape to form a central portion and two side edges of the second layer of the feed tape;   a take-off roll for peeling away the central portion of the second layer of the feed tape to expose the adhesive coated on the first surface of the flexible membrane prior to disposing the flexible membrane over and around the second opening to seal the second opening;   a sealing station comprising a base portion which receives a tube having an open upper end in a fixed position and an upper head further comprising a punch collar attached to a platen vertically displaceable in an upwardly and downwardly direction to affix the flexible membrane over and around the second opening to seal the second opening; and   a take-up roller for rolling up the feed tape after the flexible membrane has been affixed over and around the second opening to seal the second opening.   
     
     
         23 . An apparatus of  claim 22 , wherein the platen is displaced by actuation of an air cylinder. 
     
     
         24 . The apparatus of  claim 22 , wherein the first layer of the feed tape is perforated into a plurality of flexible membranes having a starburst shape comprising a plurality of radially extending legs. 
     
     
         25 . The apparatus of  claim 24 , wherein the starburst shape comprises twelve radially extending legs. 
     
     
         26 . The apparatus of  claim 22 , wherein the flexible membrane is formed from a cellulose acetate membrane. 
     
     
         27 . The apparatus of  claim 22 , wherein the punch collar further comprises an upper disk, an intermediate disk, and a lower disk over the second opening to form the flexible membrane about the second opening to seal the second opening. 
     
     
         28 . The apparatus of  claim 24 , wherein a lower surface of the punch collar has a plurality of downwardly depending and inclined fingers, each finger corresponding to a leg of the flexible membrane. 
     
     
         29 . The apparatus of  claim 24 , wherein an inner diameter of the punch collar is provided with a plurality of corresponding raised steps, each step corresponding to a leg of the flexible membrane and a finger of the lower surface of the lower disk. 
     
     
         30 . The apparatus of  claim 24 , wherein a portion of the inner diameter of the punch collar, when brought about the tube, urges the flexible membrane into contact with an outer surface of the tube. 
     
     
         31 . The apparatus of  claim 24 , wherein a vent is provided intermediate the lower surface and an upper surface of the punch collar to allow air to escape and to promote the flat and smooth application of the legs of the flexible membrane to the sidewalls of the tube.