System and method for application and sealing of end closures on containers

Abstract

The present disclosure relates to a system and method for hermetically sealing a closure to a container, the system comprising a mold assembly and a mandrel assembly. The mandrel assembly comprises an outer mandrel, an inner mandrel, and an ejector disposed within an inner circumference of the inner mandrel. At least the outer mandrel is configured to translate a first distance in a first time period, the inner mandrel and the ejector are configured to translate a second distance in a second time period, the inner mandrel is configured to retract a third distance in a third time period, and the ejector is configured to retract the third distance in a fourth time period.

Description

[0001] Cross-reference application

[0002] This application claims priority to U.S. Patent Application No. 63 / 071,076, filed August 27, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention generally relates to systems and methods for forming and sealing containers having closures. Background Technology

[0004] This disclosure generally relates to containers and methods of sealing such containers. Paper-based or composite material containers are commonly used for snacks and similar products. Such containers typically have a peelable / removable film sealed to the top edge of the container, a removable / replaceable outer cap or end cap covering the film, and a metal closure rolled to the bottom edge of the container. Typically, the film is first sealed to the top edge. The container is then filled with product through the open bottom end, and the metal closure is rolled to the bottom edge of the container.

[0005] The aforementioned process using a metal bottom interferes with the recyclability of the container because rolling the metal closure to the bottom makes it extremely difficult to separate the metal closure from the container itself after use. Without the ability to separate the paper-based body of the container from the metal bottom, the container assembly cannot enter the paper or metal recycling stream. This can lead to unnecessary waste and negative environmental impacts. There is a need for recyclable containers to increase the sustainability of the final product.

[0006] One solution to the need for recyclability is to produce containers with paper-based end closures instead of metal ends. However, existing equipment for winding metal ends to containers is specifically built for metal ends, and simply replacing metal closures with paper-based end closures is incompatible with current metal end winding processes because paper-based end closures introduce unique challenges not present in metal ends (e.g., closure flexibility, separating closures from closure stacks, feeding closures, folding closures, fusing non-metallic closures). Through ingenuity and hard work, the inventors have not only developed systems and methods for applying paper-based end closures to containers, but also systems and methods for operation at high speeds (e.g., more than 250 containers per minute). Summary of the Invention

[0007] In one embodiment, the invention includes a sealing tool kit for sealing the bottom to a container, the sealing tool kit having an integrated controlled ejector for retracting the mandrel from the bottom of the container (i.e., during the discharge process). In a particular embodiment, the present invention includes a method and sealing system for hermetically sealing a closure to a container, the sealing system comprising: a mold assembly including: a mold having a positioning portion configured to hold a disc and a mold opening adjacent to said positioning portion; and at least one sealing member configured to provide heat to seal the disc to the container; and a mandrel assembly including: an outer mandrel including an extension portion sized to fit within the inner circumference of said positioning portion; an inner mandrel configured to translate through the inner circumference of said extension portion of said outer mandrel and the mold opening; and an ejector disposed within the inner circumference of said inner mandrel, wherein at least said outer mandrel is configured to translate a first distance during a first time period, wherein said inner mandrel and said ejector are configured to translate a second distance during a second time period, wherein said inner mandrel is configured to retract a third distance during a third time period, wherein said ejector is configured to retract the third distance during a fourth time period, wherein each of said first distance, second distance and third distance is different from each other. In one embodiment, the outer mandrel, the inner mandrel, and the ejector extend, translate, and retract parallel to each other. In another embodiment, the outer mandrel extends and retracts vertically, the inner mandrel translates and retracts vertically, and the ejector translates and retracts vertically.

[0008] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate one or more embodiments of the invention and, together with the description, serve to explain the principles of the invention. Attached Figure Description

[0009] The complete and enabling disclosure of the invention is set forth in the description with reference to the accompanying drawings, which include the best mode of the invention for those skilled in the art, in which:

[0010] Figure 1 An exemplary sealing system according to an embodiment of the present invention is described;

[0011] Figure 2 An exemplary sealing system according to an embodiment of the present invention is described;

[0012] Figure 3 An exemplary sealing system according to an embodiment of the present invention is described;

[0013] Figure 4 An exemplary sealing system according to an embodiment of the present invention is described;

[0014] Figure 5 An exemplary sealing system according to an embodiment of the present invention is described;

[0015] Figure 6 An exemplary sealing system according to an embodiment of the present invention is described;

[0016] Figure 7 An exemplary sealing system according to an embodiment of the present invention is described;

[0017] Figure 8 An exemplary sealing system according to an embodiment of the present invention is described;

[0018] Figure 9 An exemplary sealing system according to an embodiment of the present invention is described;

[0019] Figure 10 An exemplary sealing system according to an embodiment of the present invention is described;

[0020] Figure 11 An exemplary sealing system according to an embodiment of the present invention is described;

[0021] Figure 12 An exemplary sealing system according to an embodiment of the present invention is described;

[0022] Figure 13 An exemplary sealing system according to an embodiment of the present invention is described;

[0023] Figure 14 An exemplary sealing system according to an embodiment of the present invention is described;

[0024] Figure 15 An exemplary sealing system according to an embodiment of the present invention is described;

[0025] Figure 16 An exemplary sealing system according to an embodiment of the present invention is described;

[0026] Figure 17 An exemplary sealing system according to an embodiment of the present invention is described;

[0027] Figure 18 An exemplary sealing system according to an embodiment of the present invention is described;

[0028] Figures 19 to 26 An exemplary sealing system according to an embodiment of the present invention is described; and

[0029] Figure 27A This illustration shows a top front view of an exemplary container body, top closure, and paper base disc according to some embodiments of the present disclosure.

[0030] Figures 27B to 27E According to some embodiments of this disclosure Figure 27A Cross-sectional views of the exemplary container body, top closure, and paper base disc;

[0031] Figure 28 A cross-section of an exemplary sealed container assembly according to some embodiments of the present disclosure is shown; and

[0032] Figure 29 The diagram illustrates a comparison of leakage detection curves in the paper bottom closure of the present invention compared to those in a metal bottom closure.

[0033] Reference numerals are used repeatedly in this specification and drawings to indicate the same or similar features or elements of the invention. Detailed Implementation

[0034] Reference will now be made in detail to embodiments of the invention, one or more of which are illustrated in the accompanying drawings. Each example is provided by way of explanation rather than limitation of the invention. In fact, those skilled in the art will understand that modifications and variations can be made to the invention without departing from the scope or spirit of the invention. For example, a feature that is illustrated or described as part of one embodiment may be used in another embodiment to produce other embodiments. Therefore, the invention is intended to cover such modifications and variations within the scope of the appended claims and their equivalents.

[0035] In embodiments, the present invention includes an apparatus and method for manufacturing high-barrier packaging for perishable products, such as airtight, closureable containers for packaging moisture- and oxygen-sensitive solid foods. Containers produced according to the apparatus and method described herein are capable of maintaining various atmospheric conditions when filled and closed. More specifically, airtight, closureable containers are suitable for maintaining the freshness of crumbly foods, such as, for example, potato chips, processed potato snacks, nuts, and the like. As used herein, the term "airtight" refers to the property of maintaining oxygen (O2) levels using, for example, a seal, surface, or container barrier.

[0036] In the embodiments, the systems and methods described herein can produce hermetically sealed containers with an all-paper, paper-based, or composite material bottom (though the methods described herein are not intended to be so limited and can be applied to polymers, metals, or other types of bottoms known in the art), which are formed and / or sealed (e.g., via a heated stamping tool) without causing pinholes, wrinkles, cuts, or cracks in the barrier layer, the closure container, and / or the bottom. Therefore, when solid, crumbly foods that are perishable upon exposure to humidity or oxygen are sealed in hermetically sealed containers with a lower probability of pinholes, wrinkles, cuts, or failures, the probability of product spoilage can be reduced. Thus, such hermetically sealed containers can contain a generally stable environment (i.e., oxygen, humidity, and / or pressure) without bulging and / or leakage.

[0037] Furthermore, such hermetically sealed containers can be transported worldwide via, for example, sea, air, or rail. Therefore, the containers are subject to varying atmospheric conditions (e.g., caused by changes in temperature, humidity, and altitude). For example, such conditions can lead to significant pressure differences between the inside and outside of the hermetically sealed container. Moreover, atmospheric conditions can cycle between relatively high and relatively low values, which can exacerbate existing manufacturing defects. Specifically, hermetically sealed containers can be subjected to strains that lead to defect growth, i.e., the size of pinholes, creases, cuts, or cracks, for example, caused by manufacturing processes, can increase. The systems and methods described herein for producing hermetically sealed containers can provide containers that can be transported and / or stored under a wide range of different climatic conditions (i.e., temperature, humidity, and / or pressure) without defect growth.

[0038] Furthermore, the systems and methods described herein can produce hermetically sealed containers with sufficient rigidity to resist deformation when subjected to varying atmospheric conditions. Specifically, when hermetically sealed containers containing high internal pressure are subjected to environmental conditions at relatively high altitudes (e.g., approximately 1,524 meters, 3,048 meters, or 4,572 meters above sea level), the pressure difference between the inside and outside of the hermetically sealed container can exert a force on the container (e.g., act to cause the container to bulge). Depending on the shape of the hermetically sealed container, any bulging can lead to deformation, which can result in unstable behavior on shelves (e.g., wobbling and rocking) and negatively impact purchasing behavior. In the embodiments described herein, the hermetically sealed containers can be formed from materials with sufficient strength, surface friction, and thermal stability for rapid manufacturing (i.e., high-cycle-output machine types and / or production lines).

[0039] As described herein, the hermetically sealed containers produced using the systems and methods described herein may include a paper-based composite bottom. Similarly, the container body may include a paper-based composite material, thereby allowing the entire container to be recycled in a single stream (e.g., in contrast to similar containers with metal bottoms). The bottom and / or container body of the present invention may include any paper known in the art, for example, fiber-based and / or pulpable materials, such as cardboard, paperboard, cupboard raw materials, paper cup paper, lithographic paper, or even molded fibers. In some embodiments, the bottom and / or container body of the present invention may be 100% paper. In some embodiments, the container assembly may have a paper content of about 90% by mass or greater. In some embodiments, the container assembly may have a paper content of about 95% by mass or greater. These percentages of paper content may advantageously limit the container assembly to a single material in certain countries, thereby allowing it to be accepted in recycling streams in most countries globally. In some embodiments, the term "single material" includes any material that can be collected and entered into waste management processes to obtain raw materials from the residue for various applications. In other embodiments, the bottom and / or container body of the present invention may be a composite material.

[0040] Sealing system

[0041] refer to Figures 1 to 11 The container described herein may be formed using the following sealing system 100 and / or according to the following methods. In one embodiment, the paper base may begin as a sheet or a disc. Although the paper base discussed herein is referred to as circular or disc, the invention should not be limited in this way. The paper base may include any shape known in the art and may be associated with the shape of the container. For example, if the container has a square, rectangular, triangular, or irregular cross-section, then the paper base may have a corresponding shape (square, rectangular, triangular, or irregular).

[0042] For example, a composite sheet or paper-based disc 50 can be formed into a composite container body 60 via a cooperating mandrel assembly 200, a mold assembly 300, and a container support assembly (not shown). The mandrel assembly 200 can be used to stamp or press the paper-based disc 50 to form it into a composite bottom 51 (e.g., ...). Figures 10 to 11 (As shown).

[0043] The mandrel assembly 200 may include an outer mandrel 210 (sometimes referred to as a "downholder" due to its purpose of holding the disc 50 downward against the mold assembly 300) and an inner mandrel 220 (sometimes referred to as a "sealing punch" due to its purpose of punching and pulling the disc 50 into the container 60 and sealing the disc 50 against the sidewall of the container 60). The outer mandrel 210 and the inner mandrel 220 may each move independently along the Y-axis. The inner mandrel 220 may translate relative to the outer mandrel 210 to form the paper-based disc 50 into a bottom closure 51. Furthermore, the mold assembly 300 may cooperate with the mandrel assembly 200 to form the paper-based disc 50 into the bottom closure 51, simultaneously or nearly simultaneously inserting the closure 51 into the bottom end 62 of the composite body 60. The mold assembly 300 may typically include a mold 80 having a top surface 97, a positioning portion 90, a mold opening 98, and a sealing member 40 (also referred to as a mold liner). The tube assembly can be configured to hold and move the composite material body 60 relative to the mandrel assembly 200 and the mold assembly 300. For example, the tube assembly can move the composite material body laterally so that the axis of the container body 60 is aligned with the axis of the mandrel assembly 200 and the mold assembly 300 and / or moves perpendicularly along the axis of the mandrel assembly 200 and the mold assembly 300.

[0044] In the embodiments, at least during the method described herein, the mandrel assembly 200, the mold assembly 300, and the container support assembly can be aligned along the Y-axis such that the paper base disk 50 can be pushed by the inner mandrel 220 through the mold opening 98 and inserted into the bottom end 62 of the composite body 60 held by the tube support member.

[0045] Mold assembly

[0046] The die assembly 300 can be configured to receive and hold the paper-based tray 50 before it is inserted through the die opening 98 and into the container body 60. In some embodiments, the tray 50 is received from a separate tray feed assembly (not shown). In embodiments, the die assembly 300 can be configured to mate with or otherwise align with the feed assembly. For example, the die 80 may include a notch, ridge, or other alignment feature 302 (see FIG. 27) on its upper end, which allows the die 80 to mate with, align with, or receive corresponding mechanical elements of the feed assembly. This allows for proper placement of the tray 50 within the die 80.

[0047] More specifically, the mold assembly 300 may include a mold 80 (i.e., a mold bushing) having a positioning portion 90 (i.e., a chuck) configured to receive and align the paper base disk 50 within the mold 80 prior to forming the disk 50 into a recessed end 51. The positioning portion 90 may be positioned adjacent to a mold opening 98 to align the paper base disk 50 with the mold opening 98.

[0048] The positioning portion 90 may include an inclined surface 96 that connects the top surface 97 of the mold 80 to the sidewall 94 of the positioning portion 90. The inclined surface 96 may be inclined downward toward the mold opening 98 and the mold assembly 300. In an embodiment, the inclined surface 96 may allow the disk 50 to be guided into the positioning portion 90.

[0049] In one embodiment, the sidewall 94 of the positioning portion 90 may be vertical or substantially vertical. In another embodiment, the sidewall 94 of the positioning portion 90 may be longer than the thickness of the disk 50. In yet another embodiment, the outer diameter of the sidewall 94 of the positioning portion 90 may be substantially similar to the diameter of the disk 50. In yet another embodiment, the outer diameter of the sidewall 94 of the positioning portion 90 may be slightly larger than the diameter of the disk 50.

[0050] In an embodiment, the inclined surface 96 of the positioning portion 90 may have a larger perimeter closest to the top surface 97 of the mold 80 and a smaller perimeter closest to the sidewall 94. In some embodiments, the circumference of the outer edge of the inclined surface 96 of the positioning portion 90 may be larger than that of the paper base disk 50. The inclined surface 96 may taper downwards to allow gravity-assisted alignment of the paper base disk 50 within the positioning portion 90. Once placed, the paper base disk 50 is positioned adjacent to the disk support surface 92 and the sidewall 94 of the positioning portion 90. In an embodiment, the disk support surface 92 and the sidewall 94 of the positioning portion 90 are connected at a 90-degree angle or substantially 90 degrees. In an embodiment, the disk support surface 92 may be horizontal or substantially horizontal. In an embodiment, the disk 50 is positioned such that its lower surface 54 (see Figure 2 The adjacent disk support surface 92 (i.e., placed on top of it) is used. In an embodiment, the placement disk 50 is positioned such that its thickness is adjacent to the sidewall 94 of the positioning portion 90.

[0051] In one embodiment, the inner circumference of the disc support surface 92 is smaller than the circumference of the disc 50. In another embodiment, the inner circumference of the disc support surface 92 is adjacent to the mold opening 98. In yet another embodiment, the disc support surface 92 is positioned adjacent to the inner surface 99 of the mold opening. In this embodiment, the inner surface 99 of the mold opening may be vertical or substantially vertical. In yet another embodiment, the disc support surface 92 is positioned at a right angle or nearly a right angle to the inner surface 99 of the mold opening.

[0052] In use, the disc 50 is inserted into the mold assembly 300, positioned within the positioning portion 90, and placed on the disc support surface 92. In an embodiment, a vacuum pressure can be applied to the paper-based disc 50 from below to align it within the positioning portion 90 of the mold 80.

[0053] Although the mold opening 98 is depicted as having a generally circular cross-section, the mold opening 98 may have a generally circular, triangular, rectangular, quadrilateral, pentagonal, hexagonal, or elliptical cross-section. In an embodiment, the mold opening 98 may be configured to receive the inner shaft 220, as described below. In an embodiment, the mold opening 98 may have a cross-section that is generally similar to the cross-section of the inner shaft 220.

[0054] mandrel assembly

[0055] As described above, the spindle assembly 200 may include an inner spindle 220 and an outer spindle 210. The inner spindle 220 and the outer spindle 210 may translate separately from each other. In an embodiment, the inner spindle 220 and the outer spindle 210 translate parallel to each other, which may be perpendicular, but is not necessarily perpendicular. For example, the system may provide an inner spindle 220 and an outer spindle 210 that translate horizontally or at an angle.

[0056] In one embodiment, the inner shaft 220 is movable by a first distance, and the outer shaft 210 is movable by a second distance, wherein the first and second distances are different from each other. Similarly, the inner shaft 220 is movable at a first time, and the outer shaft 210 is movable at a second time, wherein the first and second times are different from each other. In one embodiment, the inner shaft 220 and the outer shaft 210 can move concurrently during a first time period. In one embodiment, the inner shaft 220 may have a first extension length, and the outer shaft 210 may have a second extension length, wherein the first and second extension lengths are different from each other. In one embodiment, the outer shaft 210 can move concurrently with both the inner shaft 210 and the ejector 30 until the shaft assembly 200 contacts the mold assembly 300. In one embodiment, each of the outer shaft 210, the inner shaft 210, and the ejector 30 can simultaneously contact the mold assembly 300.

[0057] In this embodiment, the outer mandrel 210 may be generally cylindrical. In this embodiment, the container may be cylindrical. However, if the container is not cylindrical (i.e., square, triangular, rectangular, irregular cross-section, etc.), then the outer mandrel 210 may have a shape and configuration related to the shape and configuration of the container.

[0058] In another embodiment, the outer mandrel 210 may include a vertically extending (i.e., downward) portion 212 and a radially outwardly pointing flange 214. In some embodiments, the flange 214 may be absent (see [link to previous embodiment]). Figure 19 In an embodiment, the vertical extension 212 may be perforated and / or may have a through hole 216 disposed therein. In an embodiment, the vertical extension 212 and the radially outwardly pointing flange 214 may be joined at right angles or nearly right angles.

[0059] In one embodiment, the vertical extension 212 of the outer mandrel 210 can be adjusted in size to fit within the circumference of the positioning portion 90. In another embodiment, the vertical extension 212 of the outer mandrel 210 has a circumference larger than the mold opening 98, preventing it from extending into the mold opening. More specifically, the vertical extension 212 of the outer mandrel 210 can be adjusted in size and / or configured such that, when fully extended, it is positioned adjacent to the positioning portion sidewall 94 and the disc support surface 92 of the positioning portion 90. In another embodiment, the vertical extension 212 of the outer mandrel 210 can extend after the disc 50 is placed within the positioning portion 90 and can be configured to secure the disc 50 in place (see [link to relevant documentation]). Figure 4 ).

[0060] like Figure 12 As shown, the inner shaft 220 can be generally cylindrical. As described above regarding the outer shaft, the inner shaft 220 can be shaped and configured to relate to the shape and configuration of the container. For example, if the container has a square cross-section, then the inner shaft 220 can have a square shape and configuration.

[0061] In one embodiment, the inner shaft 220 can be adjusted in size to fit within the inner circumference of the vertical extension 212 of the outer shaft 210. In another embodiment, the inner shaft 220 can be configured to extend vertically lower than the vertical extension 212 of the outer shaft 210. In this embodiment, once the disk 50 is positioned within the positioning portion 90 and constrained by the fully extended vertical extension 212 of the outer shaft 210, the inner shaft 220 can continue to move vertically downwards, extending beyond the base of the vertical extension 212 of the outer shaft 210, and pushing / urging the disk 50 into the open end 62 of the container 60 (see [link to container 60]). Figure 6 ).

[0062] The inner spindle 220 may include a first spindle surface 222 adjacent to the second spindle surface 224, which together are configured to insert into and shape the paper base disk 50 (see...). Figure 12 In one embodiment, the first mandrel surface 222 may engage with the second mandrel surface 224 at an angle between approximately 92° and approximately 94°. In another embodiment, the first mandrel surface 222 may be horizontal or substantially horizontal and, when fully extended, may be positioned adjacent to the top surface of the disk 50. In another embodiment, the second mandrel surface 224 may be vertical or substantially vertical and may be configured to adjoin the inner surface of the vertical extension 212 of the outer mandrel 210 when the inner mandrel 220 passes through the outer mandrel 210. That is, the circumference of the second mandrel surface 224 may be smaller than the inner circumference of the vertical extension 212 of the outer mandrel 210. In another embodiment, the second mandrel surface 224 is parallel to the inner surface of the vertical extension 212 of the outer mandrel 210.

[0063] It should be noted that although the first mandrel surface 222 and the second mandrel surface 224 are depicted in the drawings as generally flat (horizontal and vertical), the first mandrel surface 222 and the second mandrel surface 224 may be curved, contoured, or shaped. The inner mandrel 220 may further include a shaped portion disposed between the first mandrel surface 222 and the second mandrel surface 224. The shaped portion may be curved, chamfered, or include any other contour. It should be noted that although the inner mandrel 220 is depicted as having a generally circular cross-section, the inner mandrel 220 may have a generally circular, triangular, rectangular, quadrilateral, pentagonal, hexagonal, or elliptical cross-section.

[0064] When the inner shaft 220 pushes the disk 50 into the container 60 (see...) Figures 5 to 6 The disc 50 is released from between the outer spindle 210 and the positioning portion 90 of the mold assembly 300. The central portion 56 of the disc 50 can be pushed downwards into the open end 62 of the container 60 through the mold opening 98, such that the central portion 56 (first deformable surface 53) remains flat or substantially flat (i.e., horizontal). In an embodiment, during insertion of the disc 50 into the container 60, the outer peripheral portion 58 of the disc 50 can be bent at a right angle or near a right angle, as shown. Figure 11 The second deformable surface 55 in the container 50. In this embodiment, the outer peripheral portion 58 of the disk 50 (becoming the second deformable surface 55) can be compressed adjacent to the second mandrel surface 224, thereby passing through the mold opening 98. The resulting second deformable surface 55 of the disk 50 (the previous outer peripheral portion 58) can be positioned vertically or nearly vertically at the open end 62, adjacent to the inner sidewall 66 of the container 60.

[0065] The disc 50 can be pushed into the container 60 to any practical distance within its domain. In an embodiment, the disc 50 becomes a recessed composite material bottom 51. Figure 11 In one embodiment, the outer peripheral edge 57 of the disc 50 is flush with the edge of the sidewall of the container 60. In another embodiment, the outer peripheral edge 57 of the disc 50 is positioned inside the edge of the sidewall of the container 60 relative to the container 60. In one embodiment, the first deformable surface 53 and the second deformable surface 55 are joined at right angles or near right angles within the container body 60.

[0066] In one embodiment, the mandrel heater may be configured to heat a first mandrel surface 222 and / or a second mandrel surface 224 of the inner mandrel 220. In another embodiment, the mandrel heater may be housed within the inner mandrel 220. In yet another embodiment, the inner mandrel 220 may further include an insulating portion formed of a heat-insulating material configured to mitigate heat transfer.

[0067] sealing components

[0068] (Several) sealing elements 40 may be configured to provide heat and pressure for heat sealing. (Several) sealing elements 40 may be positioned at the sealing location. Figures 1 to 6 ) and open position ( Figures 7 to 11 Between (a plurality of) sealing components 40. When in the sealed position, (a plurality of) sealing components 40 are in contact with the outer surface 64 of the container 60, and when in the open position, (a plurality of) sealing components 40 are not in contact with the container 60. In an embodiment, (a plurality of) sealing components 40 include segmented clamping supports (see generally the accompanying drawings).

[0069] In other embodiments, the sealing component includes a non-segmented clamping ring (see...). Figures 14 to 18 ). Figure 14 The present invention describes a system with a non-segmented clamping ring, wherein the system is in its initial state. Figure 15 In the process, the system moves to the position where the disk is clamped in the appropriate location. Figure 16 The system moves to the sealed position. Figure 17 This explains the removal of the sealing punch when the ejector supports the bottom of the paper in the appropriate position. Finally, Figure 18 The ejector is moved away from the container. In this embodiment, the sealing component may include a static mold liner. This type of sealing component can be particularly useful in ready-to-eat food processing equipment where food safety is a high concern.

[0070] In embodiments, such as the segmented clamping bracket embodiment, several sealing members 40 are rotatably coupled to the mold assembly 300. The several sealing members 40 may be complementaryly shaped such that when in the sealed position, they generally surround the workpiece in a jigsaw puzzle-like manner. In other embodiments, the sealing members 40 may comprise a single integral part (i.e., a closed loop) that surrounds the container body 60 when the container is in place. When the paper-based disc 50 is sealed to the composite body 60, the several sealing members 40 may compress the bottom end 62 of the composite body 10 along the generally complete outer circumference of the outer surface 64. When the composite body 60 has a generally circular cross-section, the circumference of the composite body 60 may be compressed generally uniformly by the several sealing members 40. In one embodiment, three sealing members 40 are present. In other embodiments, one sealing member 40 is present (i.e., a non-segmented clamping ring). However, it should be noted that any number of sealing members 40 may be used. For example, the sealing system may include from about one to about ten sealing elements 40. Furthermore, each of the sealing elements 40 may cover substantially equal segments of the composite material body, or may cover substantially unequal segments.

[0071] Several sealing components 40 can be used to compress and heat the container body to perform a heat sealing operation. Each sealing component 40 can provide conductive heating to the container body up to about 300°C. In addition, several sealing components 40 can apply pressure to the container body up to about 30 MPa. The sealing components 40 can be adjacent to each other.

[0072] When the sealing components 40 contact the outer surface 64 of the container body 60, the container body 60 and the composite material closure 51 can be compressed between the second mandrel surface 224 and the sealing components 40. After sufficient residence time has been applied with compression and heating, the sealing components 40 can move away from the bottom end 62 of the container body 60, so that the sealing components 40 do not contact the container body 60 after the residence time has expired. Figure 7 ).

[0073] Ejector

[0074] Once the sealing process is complete, in one embodiment, the mandrel assembly 200 is removed from the container body 60. In another embodiment, the outer mandrel 210 is released and translated away from the mold assembly 300 before the inner mandrel 220 moves. In other embodiments, both the outer mandrel 210 and the inner mandrel 220 are released and translated away from the mold assembly 300 simultaneously.

[0075] In one embodiment, the ejector 30 is positioned inside the inner spindle 220 to aid in the removal of the spindle assembly 200 from the container 60. In another embodiment, the ejector 30 may be spring-loaded. In yet another embodiment, the ejector 30 may be non-spring-loaded. In some embodiments, the inner spindle 220 may be spring-loaded or non-spring-loaded. In yet another embodiment, the outer spindle 210 may be spring-loaded or non-spring-loaded. In a particular embodiment, only the outer spindle 210 is spring-loaded.

[0076] The ejector 30 may have a circumference on its lower end 32 that is smaller than the circumference of the inner shaft 220. In this respect, the ejector 30 may be fitted within the inner circumference of the inner shaft 220 in its retracted position (e.g., Figure 12 (As shown). In an embodiment, the base of the ejector 30 may include a cylindrical cone. In this embodiment, the interior of the inner shaft 220 may include a cylindrical cone-shaped groove, allowing the ejector 30 to be fitted into the inner shaft 220. In an embodiment, the ejector 30 may be perforated and / or may have a through hole disposed therein, such as... Figure 20 and 28 As shown.

[0077] In another embodiment, the base of the ejector 30 may include multiple disk contact segments, each contacting the bottom closure 51 but separated from each other. For example, the ejector may include three or four tips that flatten at their contact surfaces with the closure 51 to avoid damaging the closure 51.

[0078] In one embodiment, the ejector has a bottom surface 34 designed to contact the bottom closure 51. In one embodiment, the ejector 30 may be solid across its bottom surface 34 from one side of the diameter to the other. In another embodiment, the ejector 30 may have a hollow internal portion, as shown in the figure. In this embodiment, the cross-section of the bottom contact surface 34 may be circular. In any embodiment, the bottom surface 34 of the ejector 30 may contact at least a portion of the first deformable surface 53 of the composite closure 51. In one embodiment, the first deformable surface 53 of the closure 51 may include a countersunk portion of the closure 51. In a particular embodiment, the bottom surface 34 of the ejector 30 is circumferential and, when in its extended position, is positioned near the second deformable surface 55 of the composite closure 51 (e.g., ...). Figure 13 (As shown in the image).

[0079] In one embodiment, when the ejector 30 is in its recessed position (e.g., in...), Figure 12 When shown in the diagram, the bottom surface 34 of the ejector 30 may be flush with the first (lower) surface 222 of the inner shaft 220. In another embodiment, the ejector 30 may be slightly recessed within the inner shaft 220 such that when the ejector is in its recessed position, the bottom surface 34 of the ejector 30 is higher than the first (lower) surface 222 of the inner shaft 220.

[0080] In an embodiment, the ejector 30 and the inner shaft 220 (and / or the outer shaft 210) can each translate in a parallel manner, optionally vertically, but separately from each other. That is, the inner shaft 220 can move a first distance, and the ejector 30 can move a second distance, wherein the first and second distances are different from each other. Similarly, the inner shaft 220 can move at a first time, and the ejector 30 can move at a second time, wherein the first and second times are different from each other. In an embodiment, the inner shaft 220 and the ejector 30 can move concurrently during a first time period. In an embodiment, the inner shaft 220 may have a first extension length, and the ejector 30 may have a second extension length, wherein the first and second extension lengths are different from each other.

[0081] In a particular embodiment, the inner mandrel 220 (and / or outer mandrel 210) is initially retracted vertically from the container 60, while the ejector 30 maintains the adjacent composite closure 51 in position. Figure 8 and 13(As shown), thereby holding the paper-based closure 51 within the container 60. In this embodiment, space can be provided between the outer circumference of the lower end 32 of the ejector 30 and the deformed portion 55 of the closure 51. This position ( Figure 8 and 13 This can be referred to as the extended position of the ejector 30. In this embodiment, once the inner shaft 220 retracts beyond the outer peripheral edge of the container 60, the ejector 30 then retracts vertically upwards back into the inner shaft 220.

[0082] In another embodiment (see...) Figure 27E After the sealing process is complete, the ejector 30 may extend further downward than it extended during the sealing process to aid in the removal of the container 60 from the mold assembly 300. That is, the ejector 30 may push the container 60 downward via pressure on the closure 51. Alternatively, the ejector 30 may not apply pressure to the closure 51, but may translate downward with the container 60 and the closure 51 in relation to the movement of the container assembly. In this embodiment, the ejector 30 may then retract from contact with the closure 51 and into the mandrel assembly 200.

[0083] In one embodiment, the ejector 30 includes a component for delivering a controlled jet of air guided toward the closure 51 simultaneously with or immediately before the ejector 30 retracts from the closure 51. In another embodiment, the delivery of pressurized air may include a nozzle mechanism disposed within the ejector 30. In yet another embodiment, the spindle assembly 200 includes an ejector coupling 201 and a spindle or sealing head coupling 202 (see [link to original document]). Figure 19 ).

[0084] The ejector 30 of this invention avoids problems caused by the standard mandrel retraction process. That is, standard mandrel retraction involves pulling the mandrel out of the container (or vice versa), resulting in friction between the mandrel and the paper-based closure. Any relative movement of the paper-based closure when the mandrel and container separate can cause folds, wrinkles, and / or air bubbles to form in the seal, thereby reducing or compromising the airtightness of the container. The ejector 30 of this invention allows for stable positioning of the paper-based closure within the container body during the mandrel removal process (i.e., during discharge). Throughout the entire cycle of the paper bottom sealing process, the ejector 30 helps ensure the airtightness of the seal between the closure 51 and the container 60.

[0085] After both the inner shaft 220 and the ejector 30 retract, the container can optionally be removed vertically downward from the mold assembly 300 and the shaft assembly 200. Figure 10 In one embodiment, the inner spindle 220 and outer spindle 210 may then optionally be retracted integrally from the mold assembly 300 completely vertically upwards. Figure 11In one embodiment, the mandrel assembly 200 and the mold assembly 300 are then positioned for another insertion, bottom closure formation, and sealing process.

[0086] Container support assembly

[0087] The container support assembly can be configured to retract and / or retain the composite body 60 and hold it in a desired position. The container support assembly may include a tube support member shaped to receive the composite body 60. In an embodiment, the tube support member can vertically lift the container 60 to meet the mold assembly 300 and the mandrel assembly 200.

[0088] In one embodiment, the container 60 is inserted into the mold assembly by being lifted upwards, and is secured in a vertical position within the mold assembly by contacting the edge or rim of the container 60 with the lower surface of the mold opening 98 (see [link]). Figures 2 to 3 When the inner shaft 220 moves into and out of the container assembly, the container 60 will be in a fixed position to prevent relative vertical movement of the container 60.

[0089] Closure

[0090] like Figure 2 As shown, in one embodiment, the paper-based disk 50 may have an upper surface 52 and a lower surface 54 defining the sheet thickness. In another embodiment, the paper-based disk 50 may include a layered structure, namely a fiber layer, an oxygen barrier layer, and a sealant layer. The paper-based disk 50 may include a central portion 56 and an outer peripheral portion 58. In another embodiment, the central portion 56 and the outer peripheral portion 58 may be generally flat. For example, the paper-based disk 50 may be cut or shaped into a circular disk. In other instances, the paper-based disk 50 may be cut or shaped into an arched disk (not depicted) such that the central portion 56 is offset from the outer peripheral portion 58 along the Y-axis.

[0091] After formation, the paper base disk 50 becomes the bottom closure 51. Figure 11 The bottom closure 51 may have a first deformable surface 53 and a second deformable surface 55. In one embodiment, the first deformable surface 53 may be generally horizontal. In another embodiment, the first deformable surface 53 includes the central portion 56 of the paper base disk. In another embodiment, the second deformable surface 55 may be generally vertical and / or may include the outer peripheral portion 58 of the paper base disk. In one embodiment, the first deformable surface 53 may be adjacent to the inner cavity of the container 60, and the second deformable surface 55 may be adjacent to the inner surface 66 of the sidewall of the container 60.

[0092] method

[0093] In use, the sealing system 100 receives the disc 50 and places it within the positioning portion 90 of the mold assembly 300, optionally using vacuum pressure to properly position the disc. In one embodiment, the container 60 is then lifted toward the mold assembly 300 via a lifting plate until the outer peripheral edge of the container 60 contacts the lower surface of the mold 80. In this embodiment, the inner sidewall 66 of the container may be flush with the mold opening 98. In another embodiment, the outer mandrel 210 is then translated vertically downward toward the disc 50 until it contacts the outer peripheral portion 58 of the disc 50, thereby holding it in place. The downward movement of the outer mandrel 210 may occur in conjunction with (i.e., as a whole) the movement of the inner mandrel 220 and the ejector 30.

[0094] Once the outer mandrel 210 is positioned adjacent to the disk 50 on top of the disk support surface 92, the inner mandrel 220 and ejector can continue to translate vertically downward toward the disk 50. The inner mandrel 220 and ejector then contact the disk 50 and push it downward through the mold opening 98 until the disk 50 deforms, resulting in a flat central portion and deformed sidewalls 55 adjacent to the inner sidewall 66 of the container 60. In one embodiment, pressure can be applied to the disk via the first mandrel surface 222 and / or the second mandrel surface 224 of the inner mandrel 220 (e.g., by actuating the inner mandrel 220 in the Y direction).

[0095] Next, the composite closure 51 can be hermetically sealed to the container body 60. Specifically, compression and heat can be applied to the composite closure 51 and / or the container body 60, causing their respective sealant layers to form an hermetically sealed layer. In an embodiment, heat is provided at least via several sealing members 40. Similarly, several sealing members 40 and the second spindle surface 224 of the inner spindle 220 can provide opposing pressure to the outer surface 64 of the container 60 and / or the deformable sidewall 55 of the closure 51.

[0096] According to this disclosure, the hermetic seal can be formed by the sealing member 40 at a temperature greater than about 90°C, for example, from 120°C to about 280°C or from about 140°C to about 260°C. A suitable hermetic seal can be formed by holding the sealing member(s) 40 in contact with the bottom end 62 of the composite body 60 for any dwell time (e.g., less than about 5 seconds, from about 0.8 seconds to about 5.0 seconds, or from about 1 second to about 4 seconds) sufficient to heat the sealant layer to a temperature suitable for forming a hermetic seal. The bottom closure 51 and the bottom end 62 of the composite body 60 can be compressed between the sealing member 40 and the inner shaft 220 at any pressure less than about 30 MPa (e.g., from about 1 MPa to about 22 MPa).

[0097] After sufficient compression and / or heat have been applied and a sufficient residence time has elapsed, the sealing member 40 may be moved away from the bottom end 62 of the container 60, such that the sealing member 40 does not come into contact with the composite material body 10 after the residence time has elapsed. Figure 7 Next, the inner shaft 220 retracts from the closure 51, while the ejector 30 remains in place. Once the inner shaft 220 has at least passed the outer peripheral edge of the container 60, the ejector 30 then retracts, optionally accompanied by pressurized airflow to aid a smooth retraction process. The ejector 30 then retracts completely into the interior of the inner shaft 220. Then, before, during, or after the mandrel assembly 200 has fully retracted from the mold assembly 300, the container 60 moves away from both the mold assembly 300 and the mandrel assembly 200.

[0098] In some embodiments, multiple composite containers may be formed by a system or apparatus suitable for simultaneously processing multiple paper-based discs, bottom closures, and composite containers. For example, a manufacturing system may include multiple mandrel assemblies, multiple mold assemblies, and multiple tube support assemblies operating in a coordinated manner. Specifically, a turreted apparatus with multiple sub-assemblies can simultaneously or synchronously receive and process discs, each sub-assembly including a mandrel assembly, a mold assembly, and a tube assembly. Depending on the complexity of the turreted apparatus, hundreds of individual composite containers can be manufactured in a coordinated manner per cycle. Therefore, any of the processes described herein can be performed simultaneously. For example, when each sub-assembly operates synchronously, each of the following can be performed simultaneously: a first paper-based disc can be positioned above a mold opening; a second paper-based disc can be constrained between a mandrel assembly and a mold assembly; a third paper-based disc can be formed as a first bottom closure by insertion into a first composite body; and the third bottom closure can be hermetically sealed to a second composite body. Alternatively, any of the operations described herein can be performed simultaneously, for example, by an apparatus with multiple sub-assemblies.

[0099] In one embodiment, the system and method of the present invention allow the sealing system to operate at high speeds (e.g., more than 300 containers per minute). In another embodiment, the system and method of the present invention allow the sealing system to operate at a rate of at least 400 containers per minute. In yet another embodiment, the system and method of the present invention allow the sealing system to operate at a rate of at least 500 containers per minute.

[0100] It should be understood that this disclosure provides hermetically sealed containers for packaging moisture-sensitive and / or oxygen-sensitive solid foods (e.g., for example, crunchy carbohydrate-based foods, salted foods, crispy foods, potato chips, processed potato snacks, nuts, and the like). Such hermetically sealed containers can provide hermetically sealed operation under a wide range of climatic conditions, including high and low temperatures, high and low humidity, and high and low pressure. Furthermore, the hermetically sealed containers can be manufactured according to the methods described herein via a process involving conductive heating technology with relatively low environmental pollution. The hermetically sealed containers described herein exhibit high structural stability at low weight and are suitable for recycling.

[0101] Example

[0102] In the following examples, various properties of the paper-bottomed container (composite material container, paper bottom, membrane cap, and outer cap) of the present invention are tested. The paper bottom of the tested container comprises a paper layer (195 g / m²). 2 The flexible board (i.e., paper cup board) with a thickness of 0.3 mm, a bonding layer, an aluminum foil (8 μm) as a barrier layer, and an ionomer layer (32 g / m²) as a sealant layer. 2 In some containers, a PET layer is included to protect the aluminum barrier layer. In other embodiments, an aluminum barrier layer is not included. All versions have been tested as indicated below.

[0103] Example 1

[0104] In the high-altitude test, the container of the present invention is placed in a sealed chamber, and the pressure inside the chamber is increased to at least 11 inHg over a period of approximately 10 minutes. If the container can withstand up to 10 inHg (simulating atmospheric pressure when the container crosses the Rocky Mountains) for at least 10 minutes, then the container passes the test. Otherwise, the container is classified as “fail.” As used herein, “observed bottom bulge” refers to the membrane and / or paper bottom arching due to overpressure conditions during vacuum chamber confinement, which is normal under such conditions. After removal from the container, the arch returns to a neutral position. Arching can be the membrane or paper bottom moving outward from the inside of the container such that it extends beyond the relevant cut edge of the container. Failure or failure includes leakage, peeling of the membrane or paper bottom, retention of distortion after pressure release, seam cracking or delamination, membrane or paper bottom bursting, and / or another failure that will prevent the container from meeting the airtightness standard. If the membrane or paper bottom arches inward into the canister upon pressure release, this may indicate a leakage failure. The test results are stated below.

[0105] Table 1a. Results of the High Altitude Test ("HAT").

[0106]

[0107]

[0108] The test results indicate a success rate of 99.4% for the paper bottom described in this article, which is acceptable.

[0109] Table 1b. High-altitude test results

[0110]

[0111]

[0112] The test results, as described in this article, indicate a success rate of 98% for the standard laminate and 100% for the lightweight paper bottom, which is acceptable.

[0113] Example 2

[0114] In this example, the container of the present invention underwent a helium leak test. Helium can be used as a tracer gas to detect leaks because it constitutes only about 5 ppm in the atmosphere, resulting in a very low background level. Helium also has a relatively low mass, making it mobile, and is completely inert / non-reactive. The sealed container of the present invention was placed in a sealed vacuum chamber, and then the vacuum chamber was overflowed with 130 mbar of helium. A sniffer / leak detector was connected to the container so that a sample of the gas from inside the container could be extracted and passed through a mass spectrometer to read the increase in the background reading of the helium content in the container. In this example, the helium leak limit is 2.3 x 10⁻⁶. -4 mbar*l / sec. A success rate of 99.8% was observed. This result is acceptable.

[0115] Table 2. Results of Helium Leakage Test ("HLT")

[0116]

[0117] Example 3.

[0118] In this example, the container of the present invention underwent a container integrity test. The container was placed in a vacuum chamber at a pressure of 200 mbar, and the vacuum decay was measured over a 20-second period. The method uses pressure change measurements to indirectly determine the flow from the container into the fixed-volume chamber. Mass extraction variant measurements were used to measure the flow required to maintain the vacuum at a fixed level (ASTM F2338 and ASTM F 3287). If the container leaks, it will reduce the expected vacuum within the vacuum chamber. The vacuum drop or decay was measured per second. The success / failure threshold was set to 42 Pa / s. A success rate of 98.6% was observed. This result is acceptable.

[0119] Table 3. Container Integrity Test ("CIT") Results

[0120]

[0121]

[0122] Example 4.

[0123] In this embodiment, the container of the present invention undergoes a container periodic test interval (“PTI”) test. The container is placed in a vacuum chamber at a pressure of 700 mbar, and the vacuum decay is measured over a 20-second period. The vacuum decrease or decay per second is measured. The success / failure threshold is set to 20 Pa / s. A success rate of 96% was observed. This result is acceptable.

[0124] Table 4. PTI Test Results

[0125] batch# Batch size PTI (700mbar, 20sec) Observe the bottom protrusion Failure Types 1 26 containers 1 failed none none 2 25 containers 1 failed none none

[0126] Example 5.

[0127] In this example, the inventors analyzed the simulated shelf life of the container of the present invention. The container was filled, sealed, and stored with a residual oxygen content of 0.0%. The residual oxygen content of the container was then tested after 6 months and 9 months. During these time periods, the success / failure threshold was set to be less than or equal to 2.0% residual oxygen (a threshold of 4.0% to 4.5% may be acceptable after approximately 18 months). A success rate of 92% was observed. This result is acceptable.

[0128] Table 5. Simulated storage period results

[0129]

[0130] Example 6.

[0131] In this embodiment, the inventors used the vacuum decay method described herein to compare the leakage of a container with the paper-bottom closure of the present invention and a container with a metal-bottom closure. Pressure drop in the containers was measured in Pa / s. The "blue" and "green" containers are paper-bottom containers, while the "reference with metal end" includes metal-bottom containers. It is evident that the paper-bottom container exhibits a smaller overall pressure drop during vacuum decay compared to the container with a metal bottom. Figure 29 The results are illustrated in the graph. Overall, the paper bottom of this invention is superior to the metal bottom in terms of consistency in preventing leakage.

Claims

1. A sealing system for hermetically sealing a closure to a container, comprising: Mold assembly, comprising: A mold having a positioning portion configured to hold a disc and a mold opening adjacent to said positioning portion; and At least one sealing element configured to provide heat to seal the disc to the container; and Mandrel assembly, comprising: An outer spindle includes an extension portion that is sized to fit within the inner circumference of the positioning portion; An inner shaft configured to translate through the inner circumference of the extension of the outer shaft and the mold opening; and The ejector is positioned within the inner circumference of the inner shaft. At least the external mandrel is configured to translate a first distance within a first time period. The inner axis and the ejector are configured to translate a second distance during a second time period, and the inner axis is configured to retract a third distance during a third time period. The ejector is configured to retract the third distance during a fourth time period, and Each of the first distance, the second distance, and the third distance is different from the others.

2. The sealing system according to claim 1, wherein the closure element is paper-based.

3. The sealing system of claim 1, wherein the sealing element is configured to provide pressure to the outer surface of the container.

4. The sealing system according to claim 1, wherein the sealing component is disposed below the mold.

5. The sealing system of claim 1, wherein the extension portion of the outer mandrel has a circumference larger than the mold opening.

6. The sealing system according to claim 1, wherein the outer mandrel is spring-loaded.

7. The sealing system according to claim 1, wherein the first distance is less than the second distance.

8. The sealing system of claim 1, wherein the inner core shaft, the outer core shaft, and the ejector are translated integrally during the first time period.

9. The sealing system of claim 1, wherein the inner shaft and the ejector are configured to translate the second distance integrally during the second time period.

10. The sealing system of claim 1, wherein each of the first time period, the second time period, the third time period, and the fourth time period is different from each other.

11. The sealing system of claim 1, wherein the ejector includes a component for delivering a controlled jet of air guided toward the closure.

12. The sealing system of claim 1, wherein the outer mandrel, the inner mandrel, and the ejector extend, translate, and retract in parallel with each other.

13. The sealing system according to claim 1, wherein: The outer mandrel extends vertically; The inner axis is vertically translated; and The ejector is vertically translated.

14. A method for hermetically sealing a closure to a container, comprising: Provide mold assembly, which includes: A mold having a positioning portion configured to hold a disc and a mold opening adjacent to said positioning portion; and At least one sealing element configured to provide heat to seal the disc to the container; and Provide a mandrel assembly comprising: An outer spindle includes an extension portion that is sized to fit within the inner circumference of the positioning portion; An inner shaft configured to translate through the inner circumference of the extension of the outer shaft and the mold opening; and The ejector is positioned within the inner circumference of the inner shaft. At least the external mandrel should be translated a first distance within the first time period. The inner axis and the ejector are translated a second distance during the second time period. The inner axis retracts by a third distance within the third time period. The ejector retracts to the third distance during the fourth time period, and Each of the first distance, the second distance, and the third distance is different from the others.

15. The method of claim 14, wherein the sealing member is configured to provide pressure to the outer surface of the container.

16. The method of claim 14, wherein the extension portion of the outer mandrel has a circumference larger than the mold opening.

17. The method of claim 14, wherein the outer mandrel is spring-loaded.

18. The method of claim 14, wherein the first distance is less than the second distance.

19. The method of claim 14, wherein the inner core shaft, the outer core shaft, and the ejector are translated integrally during the first time period.

20. The method of claim 14, wherein the inner axis and the ejector are configured to translate the second distance integrally during the second time period.

21. The method of claim 14, wherein each of the first time period, the second time period, the third time period, and the fourth time period is different from one another.

22. The method of claim 14, wherein each of the first time period, the second time period, the third time period, and the fourth time period is a consecutive time period.

23. The method of claim 14, wherein the ejector delivers a controlled jet of air guided toward the closure during retraction from the closure.

24. The method of claim 14, wherein the outer mandrel, the inner mandrel, and the ejector extend, translate, and retract in parallel with each other.

25. The method of claim 14, wherein: The outer mandrel extends vertically; The inner axis is vertically translated; and The ejector is vertically translated.

26. The method of claim 14, wherein the closure is paper-based.

Images