Apparatus for direct injection molded closure

A direct injection molding station for use on a form, fill and seal packaging machine for forming, filling and sealing a carton, the molding station being configured to mold a closure on a predetermined portion of the carton, the molding station comprising:

• a frame;
• a fixed mold tool carried by the frame, the fixed tool having cooling channels formed therein in flow communication with channels formed in the frame for supplying a coolant to the cooling channels;
• a movable mold tool carried by the frame, the movable mold tool being movable between a first position wherein the movable tool is disengaged from the fixed tool and a second position in which the movable tool is engaged with the fixed tool with the carton disposed therebetween;
• a polymer injection system including a polymer flow conduit for providing polymer from a location external of the carton to the fixed tool, wherein a closure is directly molded at the predetermined portion of the carton.

A mold tool set for directly molding a closure to a package material, the mold tool set being in flow communication with a polymer injection system for providing polymer to the mold tool set, the mold tool set being positioned within a frame in a form, fill and seal packaging machine, comprising:

• a fixed mold tool carried by the frame, the fixed tool having cooling channels formed therein in flow communication with channels formed in the frame for supplying a coolant to the cooling channels;
• and
• a movable mold tool carried by the frame, the movable tool being movable between a first position wherein the movable tool is disengaged from the fixed tool and a second position in which the movable tool is engaged with the fixed tool with the package material disposed therebetween,
• wherein when the fixed tool and the movable tool are engaged with one another a mold cavity is formed corresponding to the closure, and wherein the fixed mold tool has cooling channels formed therein in flow communication with a coolant source for supplying a coolant to the fixed tool.

A direct injection molded closure formed on a package material, the package material being in an open top and open bottom tubular form, the closure being formed on a top panel of the package material, the closure comprising:

• a base portion integrally molded to the package material, the base portion forming a connecting flange;
• a spout portion extending upwardly from the base portion;
• a cover configured to form a seal at the spout;
• and
• a tamper-indicating member formed integral with the cover, the tamper indicating member formed as a frangible member integral with the cover that is broken upon initial opening of the closure.

A method for forming a closure on a carton blank in a tubular form, the carton blank formed from a composite material having a polymer layer on at least one side thereof, the method comprising the steps:

• providing a fixed mold tool defining a portion of a mold cavity therein, the mold tool being in flow communication with a polymer injection system;
• positioning the carton blank adjacent and engaged with the internal tool, the carton blank being in an at least partially erected state having a tubular form;
• providing a movable tool defining another portion of the mold cavity therein, the fixed tool mold cavity and the movable tool mold cavity defining a desired closure configuration;
• engaging the movable tool with the carton blank on an opposing side of the carton blank from the internal tool to form the mold cavity;
• pressing the movable tool to the carton blank and the fixed tool;
• injecting a polymer into the mold cavity to form the desired closure;
• and
• releasing the closure from the mold cavity.