Composite Containers for Bulk Solids, Related Systems, and Methods

Abstract

A container for holding a bulk solid, the container comprising a tubular body that at least partially extends around the interior of the container so as to form a tubular body having a top end and a bottom end, and at least one sealing member positioned within the container and spaced apart from each of the top end and the bottom end of the tubular body. The at least one sealing member is engagable to sealingly engage at least a portion of the tubular body, and a reclosable lid is attached to the top end of the tubular body to form a closed top end of the container, the reclosable lid comprising pulp fibers, and a bottom plate is attached to the bottom end of the tubular body to form a closed bottom end of the container, the bottom plate comprising pulp fibers.

Description

Technical Field

[0001] The present disclosure relates to a method of manufacturing a composite container such as a can and packaging bulk solids such as dry or wet articles in the composite can. The composite can disclosed herein comprises a carton body made from a carton-based laminate that may include one or more outer polymer layers in addition to a carton core layer. Further, the composite can includes a top sealing member, a bottom sealing member, a top rim, a reclosable lid, and optionally additional can components such as a bottom plate.

Background Art

[0002] Composite carton-based cans for packaging moisture- and air-sensitive particulate or granular articles such as baby food, coffee, tea, cereal, tobacco, etc. are well known in the art. In the field of packaging consumer goods, particularly as protective transport and storage containers on the retailer side and as storage and dispensing containers on the consumer side, in relatively rigid composite cans, the different functions of the composite cans can pose conflicting requirements for their design. For economic and environmental reasons, it is necessary to minimize the amount of material required to manufacture the composite can while still providing sufficient rigidity and shape stability to the composite can. On the retailer side, it is desired that the composite cans enable efficient and space-saving transport and storage and that they be stackable.

[0003] Carton-based cans generally have the drawback of low shape stability of the carton body, which has been found to be particularly problematic during the manufacture and filling of the can before it is finally sealed. In a filled and fully assembled composite can, sufficient shape stability and protection of the container contents are provided, but the relatively thin carton body material can be damaged when exposed to the forces exerted on the carton body during the manufacture and filling of the composite can. The tension incorporated in the stiff carton material causes the tubular body formed from a rectangular carton blank to deviate from the intended body shape, making it difficult to process the tubular body at high speed in a manufacturing machine. A tubular body that has deviated from the intended shape is more susceptible to damage by grippers, transporters, and other equipment in the manufacturing line. Such damage can result in an undesirably high rejection rate as damaged tubular bodies must be discarded. For example, when tubular bodies being conveyed on a conveyor belt accumulate on the conveyor, they may become crowded and pressed against each other, and the tubular body may assume a deformed configuration where the extension in the conveying direction becomes shorter and the extension perpendicular to the conveying direction becomes longer. A tubular body deformed in this way may become immobile within the machine or difficult to grip and reposition with a gripper. Furthermore, it may become difficult to attach elements such as a top sealing member, a bottom sealing member, a top rim, and a bottom plate without damaging the exposed edge portions of the tubular body. In order to minimize the risk of deforming or damaging the tubular body during manufacture, it may be necessary to reduce the manufacturing speed, resulting in a lower manufacturing efficiency of the composite can than is desirable.

Summary of the Invention

Problems to be Solved by the Invention

[0004] Therefore, there is a need for a low-cost and high-speed manufacturing process for composite cans made from commonly available materials that can be carried out with minimal waste in a manufacturing line.

[0005] The object of the present disclosure is to overcome or improve at least one of the drawbacks of the prior art, or to provide a useful alternative means.

Means for Solving the Problem

[0006] According to one aspect, the present disclosure generally relates to a container for holding a bulk solid, the container comprising a tubular body that at least partially extends around the interior of the container and forms a tubular body having a top end portion and a bottom end portion, at least one sealing member spaced apart from each of the top end portion and the bottom end portion of the tubular body and positioned inside the container, the at least one sealing member being sealably engageable with at least a portion of the tubular body, a resealable lid attached to the top end portion of the tubular body and comprising pulp fibers to form a closed top end portion of the container, and a bottom plate attached to the bottom end portion of the tubular body and comprising pulp fibers to form a closed bottom end portion of the container.

[0007] According to another aspect, the present disclosure generally relates to a method of forming a container for holding a bulk solid, the method comprising obtaining a body blank, positioning the body blank that at least partially extends around the interior of the container to form a tubular body having a top end portion and a bottom end portion, positioning at least one sealing member inside the container spaced apart from each of the top end portion and the bottom end portion of the tubular body, the at least one sealing member being sealably engageable with at least a portion of the tubular body, attaching a lid comprising resealable pulp fibers to the top end portion of the tubular body to form a closed top end portion of the container, and attaching a bottom plate comprising pulp fibers to the bottom end portion of the tubular body to form a closed bottom end portion of the container.

[0008] According to another aspect, the present disclosure generally relates to an assembly line for forming a container for holding a bulk solid, the assembly line including a supply section for a body blank, a sealing member, a reclosable lid, and a bottom plate including pulp fibers; a body forming station for bending at least partially the body blank from the supply section of the body blank around the interior of the container; a sealing station for attaching the sealing member from the supply section of the sealing member to the tubular body inside the container; a filling station for filling the bulk solid into the interior of the container through the bottom end portion of the tubular body; a bottom plate addition station for attaching the bottom plate from the supply section of the bottom plate to the bottom end portion of the tubular body to form a closed bottom end of the container; a lid attachment station for attaching the reclosable lid from the supply section of the reclosable lid to the top end portion of the tubular body to form a closed top end of the container; and a body plate addition station for attaching the bottom plate from the supply section of the bottom plate to the bottom end portion of the tubular body to form a closed bottom end of the container.

[0009] According to another aspect of the present disclosure, a method of manufacturing a composite can and packaging a dry or wet article in the composite can, the method comprising: removing a body blank from a pile of body blanks and transferring the body blank to a body forming station; bending the body blank and forming a tubular body by joining two opposing edges of the body blank at an end-to-end joint, the joint extending in the height direction of the tubular body; sealing the joint by welding a sealing strip over the joint on the inner surface of the tubular body, thereby forming an intermediate can; transferring the intermediate can to a top sealing station; sealing a top opening of the top end portion of the tubular body by welding a peripheral flange of a top sealing member to the inner surface of the tubular body at a distance from the top edge of the tubular body; transferring the intermediate can to a top rim addition station; transferring the intermediate can to a filling unit; Filling the intermediate can with the dry or wet article through the bottom opening of the tubular body; Transferring the filled intermediate can to a sealing unit, wherein the filled intermediate can is transferred to the sealing unit within a closed conveying system while maintaining a protective gas atmosphere; Sealing the bottom opening of the tubular body by welding the peripheral flange of the bottom sealing member to the inner surface of the tubular body at a distance from the bottom edge of the tubular body, wherein the sealing of the bottom opening is performed while maintaining the protective gas atmosphere; Adding a bottom plate 217 to the bottom end of the bottom-sealed intermediate cans 403, 503, wherein the bottom plate 217 covers the entire bottom opening, and the bottom plate 217 is a formed plate containing pulp fibers; Placing the bottom-sealed intermediate cans 403, 503 on the conveyor 2d with the bottom plate 217 placed on the conveyor 2d during the transfer of the intermediate cans 403, 503 to the lid attachment unit 7; Rotating the filled and bottom-sealed intermediate can to position the top end of the tubular body in the vertically upward position and transferring the intermediate can to the lid attachment unit; Attaching a reclosable lid to the top end of the tubular body with the inner surface of the reclosable lid in direct contact with the upper surface of the top rim; A method is provided that includes the above steps.

[0010] The bottom plate covers the entire bottom opening, thus minimizing, preventing, and / or stopping insects from nesting in the space between the bottom sealing member and the bottom end of the tubular body, and stabilizing the can at the same time.

[0011] The intermediate can can be subjected to a protective gas atmosphere during the filling of the intermediate can or by introducing the filled intermediate can into a vacuum chamber to evacuate air.

[0012] This enables prevention of air contact between the filled articles within the opened intermediate container until the article is safely enclosed in the composite can. A further technical effect is that since there is no need to remove air from the filled and opened container before sealing the container, the atmosphere in the sealing station and the sealing step can be extremely well controlled. This is known to be a great advantage because a pressure difference in the sealing step can cause a turbulent flow in the container filling material, which may have an adverse effect on the sealing process. Such turbulent flow can result in powder material being trapped within the seal, potentially compromising the airtightness of the seal.

[0013] According to another aspect, the present disclosure generally relates to transferring the intermediate can to a top rim addition station, adding a top rim to the intermediate can by inserting at least a lower portion of the top rim into the top opening above the top sealing member, welding or adhering the inserted portion of the top rim to the inner surface of the tubular body, transferring the intermediate can to a conveyor and arranging the intermediate can on the conveyor such that the top rim is placed on the conveyor and the bottom opening at the bottom end of the tubular body faces vertically upward, and relates to.

[0014] These are optional for composite cans having a top closure with a lid formed from paperboard components.

[0015] As disclosed herein, the longitudinal axis of the intermediate can can be arranged in a substantially vertical direction with the top end of the tubular body directed vertically upward during the transfer of the intermediate can from the top sealing station to the top rim addition station.

[0016] In the method disclosed herein, while adding and attaching the top sealing member and the top rim to the top opening of the tubular body, the top edge of the tubular body is directed vertically upward and the bottom edge of the tubular body is directed vertically downward. Thereafter, the intermediate can comprising the tubular body, the top sealing member and the top rim is turned upside down so that the top edge faces vertically downward and the bottom edge faces vertically upward. The intermediate can with the top rim attached can be rotated within the rim applicator or within a conventional rotating device downstream of the rim applicator.

[0017] By attaching the top rim to the tubular body and turning the intermediate can upside down before conveying the intermediate can to the filling unit, the intermediate can will be placed on the conveyor with a durable top rim during transfer to the filling unit.

[0018] By attaching the top sealing member before filling the can, the risk that particulate material contaminates the welding area and adversely affects the quality of the seal of the top sealing member, as well as the risk of finding residues of the container filling material outside the top sealing member at the upper end of the can, can be reduced or eliminated.

[0019] The top rim matches the container body wall to the contour of the top rim and provides a desired predetermined stable shape to the container body wall.

[0020] The weld seal between the top rim and the tubular body can be formed by any suitable method such as high-frequency induction welding. To achieve a tight seal, the weld seal is preferably a continuous seal extending around the top opening and creates a moisture-proof and preferably airtight seal. In the composite cans manufactured according to the method disclosed herein, high-frequency induction welding is the preferred method for attaching can components such as the body sealing strip, the top rim, the bottom plate, and the top and bottom sealing members.

[0021] By joining the top rim to the inner surface of the tubular body by welding, a tighter and thinner attachment of the top rim to the tubular body can be obtained than when using adhesive attachment, which was previously common in the art. As described herein, the welded top rim is preferably a formed fiber rim and is arranged to extend from the inner surface of the tubular body to the inner surface of the lid, parallel to the material within the tubular body. The top rim is more rigid than the carton base material within the tubular body, forms a shape-stable continuous or supplementary part at the upper end of the tubular body, and provides a first abutment surface that resists deformation when pressed against a second abutment surface on the inner surface of the reclosable lid. Thereby, the composite can is able to be repeatedly opened and closed with a high level of airtightness even after the first opening of the can by the consumer and after the breaking or removal of the top sealing member.

[0022] Accordingly, the top rim constitutes a rigid and shape-stable part at the top end of the tubular body that can form a tight seal against the inner surface of the lid.

[0023] The top rim is preferably welded to the inner surface of the tubular body such that the upper part of the top rim extends beyond the top edge of the tubular body.

[0024] The top rim can be an outer profile element with a circumferential flange extending outwardly from the upper edge of the lower part of the top rim, and the top rim is added to the intermediate can with the circumferential flange covering the upper edge of the tubular body. The circumferential flange constitutes a rigid protection of the carton material at the top edge of the tubular body.

[0025] The top rim attached to the tubular body with a part of it extending in the height direction of the tubular body from the top opening of the tubular body forms a rigid and wear-resistant shape-stable support on which the intermediate can can be placed after rotating the intermediate can 180 degrees and placing it upside down on the conveyor for transfer to the filling unit. The intermediate cans can form tightly packed rows or slide on the conveyor belt without causing deformation of the carton material within the tubular body or damage to the top edge of the tubular body.

[0026] The top rim can have any suitable cross-sectional outer shape as long as at least a part of the top rim inside the top opening can be fitted. The lower part of the top rim can have different thicknesses at different parts of the top rim. In some preferred cases, no part of the top rim is preferably arranged to extend downward on the outer surface of the body tube. A top rim having a substantially I-shaped or L-shaped outer shape may be preferred because it can be easily inserted into the top opening and can be attached to the inner surface of the tubular body by welding and applying a vertical pressure to the inner surface of the tubular body.

[0027] As described herein, the carton body is supported and protected by the top rim during subsequent process steps without the risk of damaging the exposed carton edge. The top rim provides support and protection for the intermediate can during process steps such as filling and sealing the bottom opening, degassing, etc., and these steps can be performed while the intermediate can is placed on the top rim.

[0028] The top rim enables filling the container from the bottom end after the top sealing member is added to the top opening. Instead, if the composite can is filled with contents in the form of particles or granules and then the top end sealing member is added, the turbulent flow generated when the top sealing member is pushed into the container body can cause some of the particles or granules to leak from the tubular body and reach outside the top sealing member within the space between the top sealing member and the top edge of the tubular body. A user who opens the composite can and discovers that the exposed top sealing member is contaminated by the container filling material will generally consider the can to be less hygienic than desired. Furthermore, a part of the container filling material is trapped within the weld seal between the top sealing member and the inner surface of the tubular body, which may make the seal less tight than desired and difficult to accurately control the strength of the seal.

[0029] The method disclosed herein is While transferring the intermediate can to the lid attachment unit, it can further include placing the intermediate can with the bottom sealed on the conveyor belt with the bottom plate placed on the conveyor belt.

[0030] The bottom plate can be added in the form of a closed loop extending within the bottom loop plane and having an outer contour, an inner contour, and a height in the height direction perpendicular to the bottom loop plane. The bottom plate has an upper rim portion and a lower rim portion in the height direction of the bottom reinforcing rim. The bottom plate is such that the lower edge of the bottom reinforcing rim is outside the container body or on the same plane as the bottom edge of the tubular body, and the top rim portion of the bottom plate and optionally the lower rim portion of the bottom plate are also inserted into the tubular body at the bottom edge, Attaching the bottom plate to the inner surface of the tubular body, which can be preferably done by welding such as high-frequency induction welding.

[0031] The advantages of providing a composite can with a bottom plate are similar to those obtained with the top rim. In an intermediate can filled from the bottom and sealed with a bottom sealing member, the bottom plate enhances the shape stability at the bottom end of the tubular body and protects the bottom edge of the carton material inside the tubular body from wear when the filled and bottom-sealed intermediate can is conveyed on the conveyor while standing on the bottom plate. In a fully assembled composite can, the bottom plate continues to be a support element that protects the carton material at the bottom end of the composite can from moisture that may be present on the countertop or other surface where the can is placed by the user. The bottom plate can further form a rigid and shape-stable support element that cooperates with the fitting stacking element on top of another composite can when stacking the composite cans on top of each other.

[0032] After adding the bottom sealing member to the filled intermediate can, the sealed and filled intermediate can can be rotated 180 degrees in the sealing unit or in a conventional rotating device downstream of the sealing unit.

[0033] The method disclosed in this specification can include two or more intermediate cans, such as four intermediate cans, being processed simultaneously during one or more process steps such as sealing the top opening, adding a top rim, welding or adhering the top rim, rotating the intermediate can 180 degrees, filling the intermediate can, sealing the bottom opening, rotating the filled and bottom-sealed intermediate can 180 degrees, and attaching a re-closable lid. According to another aspect, the present disclosure generally relates to an assembly line for manufacturing composite cans and filling the composite cans with dry or wet articles, for example, according to the method disclosed herein. The assembly line includes a plurality of mechanical units connected by a conveyor, and the mechanical units include

[0034] a body forming unit, a filling unit, a sealing unit, a lid attaching unit, and .

[0035] In the assembly line disclosed herein, a gas box can be disposed between the filling unit and the sealing unit.

[0036] The body forming unit of the assembly line can include a body blank extraction station, a body forming station, a top sealing station, a top rim adding station, and

[0037] The sealing unit of the assembly line can include a can sealing station and, optionally, a rim adding station.

[0038] Any mechanical unit of the assembly line can be arranged at least partially within the external housing. Further, any mechanical unit or part of a mechanical unit can be arranged to operate within a reformed gas atmosphere, also referred to herein as a protective gas atmosphere, within the external housing. As disclosed herein, the sealing unit can be arranged within the external housing and can be arranged to operate within the protective gas atmosphere within the external housing. In addition, any can component applicator disclosed herein can be arranged at least partially within an inner housing within the external housing.

[0039] The method disclosed herein can include a degassing step that is carried out in conjunction with the filling step. The degassing step can include supplying a protective gas to the flow of the product in the filling step. The protective gas can be nitrogen, carbon dioxide, or a mixture of nitrogen and carbon dioxide. The protective gas can be blown into the flow of the dry or wet product during the filling of the intermediate can before the flow of the product reaches the inner compartment within the intermediate can.

[0040] Alternatively, or in addition thereto, the sealing of the bottom opening can be carried out within a protective gas atmosphere. If the flow of the product is treated with a protective gas in the filling step, the filled intermediate can is preferably conveyed to the closing step in the sealing unit while maintaining the protective atmosphere, for example, by moving the intermediate can through a tunnel filled with a protective gas. Alternatively, the filled intermediate can can be introduced into a vacuum chamber to evacuate air, and then the filled intermediate can is subjected to a protected atmosphere and sealed.

[0041] The addition of can components such as a top sealing member, a bottom sealing member, a top rim, and a bottom plate can be carried out using an attachment unit comprising a welding unit such as a high-frequency induction welding unit configured to fix the components to the tubular body during the manufacture of the composite can. The welding unit can comprise an induction welding energy generator that softens or melts a weldable layer forming part of the tubular body and / or the added can components. The apparatus can further comprise conveying means configured to convey the flow of intermediate cans to and from the attachment unit. The conveying means can sequentially comprise a supply mechanism, a main conveyor member, and a movable gripping mechanism. The supply mechanism can be configured to continuously transfer the intermediate cans one by one to the main conveyor member, and the gripping mechanism can be configured to transfer the intermediate cans from the main conveyor member to the welding unit. The apparatus can be arranged such that during normal operation of the apparatus, the intermediate cans are aligned close to each other upstream of the supply mechanism, and the supply mechanism is configured to increase the supply speed of each individual intermediate can along the supply mechanism, thereby increasing the distance between adjacent intermediate cans supplied along the supply mechanism, so as to separate adjacent intermediate cans from each other in the supply direction. The main conveyor member can be configured to operate at a conveying speed that substantially corresponds to the discharge speed of the intermediate cans when they are sent out from the supply mechanism and is uniform with respect to the discharge speed, such that the intermediate cans transferred to the main conveyor member and along the main conveyor member remain separated. The movable gripping mechanism can be configured to grip at least two intermediate cans such as four intermediate cans and simultaneously transfer these intermediate cans from the main conveyor member to the attachment unit, and the attachment unit is preferably configured to simultaneously fix the can components to each of the intermediate cans transferred simultaneously.

[0042] The supply mechanism can comprise a supply screw member with an increasing pitch, whereby when the intermediate cans are conveyed by the supply screw member, the supply speed of the individual intermediate cans and the distance between adjacent intermediate cans increase corresponding to the increasing pitch. Such a supply screw member creates a defined distance between the intermediate cans, enabling controlled positioning and proper gripping of the intermediate cans.

[0043] The supply screw member enables a controlled supply speed at the inlet of the supply screw member. By adjusting this inlet speed relative to the speed at which the intermediate cans are conveyed towards the supply screw member, for example, by making the inlet speed slightly lower than the conveying speed of the conveyor belt arranged to convey the intermediate cans to the supply screw member, it is possible to prevent the filled and opened intermediate cans from colliding with the slow-moving line of intermediate cans at high speed, and the opened intermediate cans smoothly approach and merge with the upstream line of intermediate cans.

[0044] The supply screw mechanism preferably comprises two supply screw members arranged in parallel along each side of the flow of intermediate cans, with each intermediate can being adapted to be conveyed between the two supply screw members arranged to operate in cooperation with each other. This provides a reliable supply grip for the intermediate cans and reduces the risk of the intermediate cans slipping beyond their space within the supply screw.

[0045] The main conveyor member can include a sliding guide and a carrier bar. The sliding guide is configured to support the intermediate can when the intermediate can is transferred to the main conveyor member and to enable the intermediate can to slide in the conveying direction. The carrier bars are distributed at a predetermined distance along the moving and conveying portions of the main conveyor member so as to push the containers along the sliding guide. In this way, the intermediate cans are prevented from sliding relative to normal moving parts such as conveyor belts, which would result in a randomly varying distance between adjacent intermediate cans and cause problems in subsequent gripping steps. The use of the sliding guide and carrier bars described herein further improves the positioning of the intermediate cans before gripping because the distance between adjacent transferred intermediate cans delivered to the gripping mechanism is predefined and does not vary.

[0046] The conveying means can further include an inlet conveyor member configured to supply the containers to the supply mechanism. The inlet conveyor member can be configured to operate at a conveying speed that substantially corresponds to and is uniform with respect to the initial supply speed at the inlet side of the supply mechanism. This provides a smooth transition of the intermediate cans between the inlet conveyor member and the supply mechanism. Preferably, the inlet conveyor member also forms a support for the intermediate cans while they are being supplied along the supply mechanism. The inlet conveyor member can be configured to enable the intermediate cans to slide while being supported when the supply speed of the intermediate cans increases during supply along the supply mechanism. The inlet conveyor member can include an endless steel band for conveying and supporting the intermediate cans.

[0047] The attachment unit can comprise at least two sub-units, each sub-unit comprising a cavity adapted to receive at least an end portion of an intermediate can to which a can component such as a top sealing member, a bottom sealing member, or a rim is fixed. An induction welding energy generator such as a coil extends around the cavity so as to circumferentially surround the intermediate can disposed within the cavity along a distance corresponding to the periphery of the can component disposed at the intended fixing position of the intermediate can. Each unit further comprises a can component positioning device configured to position the can component at the intended fixing position.

[0048] The positioning device can take the form of a press plunger which positions the can component inside the tubular body of the intermediate can and then expands radially to exert a radially outward pressing force on the inserted can component and press a portion of the can component against the inner surface of the tubular body. The can component is held under pressure against the inner surface of the tubular body while the can component is welded to the tubular body.

[0049] The positioning device can comprise two parts axially movable relative to each other, namely, a base plate comprising or consisting of a rigid material, and an elastically deformable plunger skirt. The base plate is connected to the end of a first piston such that the footprint surface of the base plate is perpendicular to the axial direction. The plunger skirt is connected to the end of a second piston. The first piston and the second piston are configured to be axially displaceable in synchronization with and independently of each other. The end of the second piston is configured to be closer to the end of the first piston when the plunger skirt is in the expanded state as compared to the non-expanded state.

[0050]

[0051] ​When the can component is inserted into the mounting position within the tubular body, the first piston and the second piston are displaced axially in synchronization with each other and move together as a single unit. When the plunger skirt is deformed into an expanded state, the first piston and the second piston are displaced independently of each other such that the second piston is axially displaced relative to the first piston. Thereby, the plunger skirt is pushed down onto the base plate and flattened so that the outer periphery of the plunger skirt assumes an expanded state. The elastically deformable plunger skirt automatically returns to the unexpanded state when the pressure exerted on the plunger skirt from the first piston and the second piston ceases after the container element has been added to the desired position within the container body.

[0052] The base plate has a footprint surface with a peripheral edge, which includes a plurality of side edge portions connected by corners. The plunger skirt covers the surface of the base plate on the opposite side of the footprint surface.

[0053] As described herein, the plunger skirt is deformable between an unexpanded state and an expanded state. The plunger skirt has an outer periphery that, in the unexpanded state, is located at the peripheral edge of the footprint surface of the base plate and, in the expanded state, is located at least partially outside the peripheral edge of the footprint surface of the base plate.

[0054] The outer periphery of the unexpanded plunger skirt preferably has a shape corresponding to the shape of the peripheral edge of the footprint surface.

[0055] At least one of the side edge portions of the peripheral edge of the base plate can include a curved segment that curves in an inward direction from the peripheral edge of the footprint surface, and at least one corresponding side of the outer periphery of the plunger skirt can include a curved segment that curves in an inward direction from the outer periphery of the plunger skirt.

[0056] The plunger skirt is disposed on the base plate so as to cover the upper surface of the base plate on the side opposite to the footprint surface. When the plunger skirt is in the non-expanded state, the plunger skirt does not contact the can component or at least does not exert a force on the can component while inserting the can component into the mounting position within the tubular body. When the can component reaches the mounting position, the plunger skirt is radially expanded, thereby pressing the edge portion of the can component against the inner surface of the tubular body in the circumferential direction. In this expanded state of the plunger skirt, the cross-sectional area defined by the outer periphery of the plunger skirt is larger than that in the non-expanded state of the plunger skirt.

[0057] By providing at least one curved segment at the peripheral edge of the footprint surface of the base plate and at least one corresponding curved segment at the outer periphery of the plunger skirt, the positioning unit can be significantly reduced or eliminated when inserting the can component. The risk of colliding with the upper edge of the tubular body and thereby damaging the tubular wall of the tubular body.

[0058] During deformation to the expanded state, the plunger skirt is flattened and, if there are one or more segments curved inward, they are straightened simultaneously to the extent that at least the outer periphery of the plunger skirt extends beyond the peripheral edge of the footprint surface. Therefore, by carefully selecting the shape and / or material properties of the plunger skirt in the non-expanded state, the desired shape change during deformation can be obtained. The material used for the plunger skirt can be a natural or synthetic rubber material, for example, any useful elastically deformable wear-resistant and heat-resistant material known in the art such as polyamide, polyurethane, polyester, etc.

[0059] The method disclosed in this specification can be at least partially implemented using an apparatus having the above-described components. continuously transferring intermediate cans one by one from a supply mechanism to a main conveyor member; transferring the intermediate cans from the main conveyor member to the attachment unit by a movable gripping mechanism; increasing the supply speed of each individual intermediate can along the supply mechanism, thereby increasing the distance between adjacent intermediate cans supplied along the supply mechanism, and separating adjacent containers from each other in the conveying direction; operating the main conveyor member at a conveying speed that substantially corresponds to the discharge speed of the intermediate cans when the intermediate cans are sent out from the supply mechanism and is uniform with respect to the discharge speed, so that the intermediate cans transferred to the main conveyor member and along the main conveyor member remain separated; grasping at least two intermediate cans by a movable gripping mechanism and simultaneously transferring these intermediate cans from the main conveyor member to the attachment unit; simultaneously fixing can components to each of the simultaneously transferred intermediate cans; may include.

[0060] The movable gripping mechanism can include a first gripping element and a second gripping element configured to operate on both sides of the flow of the intermediate cans. The gripping elements are movable toward and away from each other to grip and release the intermediate cans respectively. The gripping elements are movable synchronously along the flow of the intermediate cans between the main conveyor member and the welding unit for the simultaneous transfer of two or more intermediate cans. Each gripping element includes at least two recesses, such as four recesses, to grip each side of the corresponding number of simultaneously gripped intermediate cans. The distance between the recesses of the gripping elements corresponds to the distance between the intermediate cans positioned on the main conveyor member during the operation of the device.

[0061] The movable gripping mechanism can be configured to grip four containers and simultaneously transfer these four intermediate cans from the main conveyor member to the welding unit. The welding unit is configured to simultaneously fix the can components to each of the four intermediate cans.

[0062] The supply mechanism can include a second movable gripping mechanism and an outlet conveyor member disposed downstream of the attachment unit, and the second movable gripping mechanism is configured to grip at least two intermediate cans and simultaneously transfer these intermediate cans from the attachment unit to the outlet conveyor member.

[0063] Sliding guides such as a stationary sliding plate can be arranged at the end of the outlet conveyor member so that the intermediate cans can slide on the sliding plate from the outlet conveyor member to a further conveyor member for transporting the intermediate cans to subsequent machine units of the production line. Such a sliding plate reduces the supply speed of the intermediate cans and reduces the distance between them. Thus, the intermediate cans are re-aligned in close proximity to each other in a continuous row in the same way as on the upstream side of the supply mechanism.

[0064] As described herein, the attachment unit can be disposed within the external housing, and the protective gas atmosphere can be generated inside the external housing. The outlet port for the intermediate can can be disposed on the external housing, and the size of the opening is adapted to the size of the intermediate can being processed. The outlet port can comprise a short tunnel disposed at the end of the outlet conveyor member, and the sliding plate constitutes the floor within the tunnel. The outlet conveyor presses the intermediate can against the stationary sliding plate, thereby forming a continuous row of intermediate cans passing through the outlet tunnel. Since the size of the outlet tunnel is adapted to the size of the intermediate can, the can fills the cross-section of the outlet tunnel, whereby the outlet port is relatively airtight during operation of the device without the need for additional equipment. By providing a stationary sliding plate within the outlet tunnel, there is always an intermediate can acting as a "plug" within the outlet tunnel, ensuring that the protective gas does not leak and air does not enter through the outlet from the external housing. In a corresponding manner, the size and shape of the inlet port having an inlet tunnel to the external housing can be adapted to the size and shape of the intermediate cans manufactured on the assembly line, as disclosed herein. However, since the inlet conveyor may already be disposed within the protective gas atmosphere, it is generally sufficient to provide a closable hatch at the inlet to the attachment unit in order to be able to close the inlet port as required.

[0065] When transporting intermediate cans that are filled but not yet sealed, it is desirable to maintain the protective gas atmosphere from its generation until the bottom of the intermediate can is closed over the filled contents. The protective gas atmosphere may already be generated during the filling stage, for example, by blowing the protective gas into the material stream before the material reaches the can. Alternatively, the filled intermediate can can be introduced into a vacuum chamber to evacuate the air, after which the can is subjected to a reformed gas atmosphere and the bottom sealing member is added.

[0066] In all cases, the filled cans are conveyed to the sealing unit in a closed conveying system while maintaining a protective gas atmosphere. To ensure that no protective gas leaks at the interface between the conveying system and the can sealing unit, as disclosed herein, closely fitting inlet and outlet tunnels can be arranged at the inlet and outlet of the sealing unit.

[0067] The method disclosed herein can include adding a spoon into a compartment formed between a top sealing member and a reclosable lid. The spoon is preferably added to the intermediate can after filling and before attaching the reclosable lid to the top end of the tubular body. The spoon can be added directly onto the top sealing member or can be placed within a spoon holder disposed above the top sealing member. The spoon holder can be formed as an integral part of the top rim or can be an additional part of the top rim. The spoon holder disposed on the top rim can include a scraper bar for scraping off excess contents scooped up from the head of the spoon. The head of the spoon and the spoon holder can have a matching shape such that the spoon can be arranged with the head of the spoon closely fitted within the spoon holder and the handle of the spoon held in a substantially horizontal position above the top sealing member. The head of the spoon and the spoon holder can be arranged such that, for example, the head of the spoon has one or more protruding elements such as one or more knobs or ridges, and when the head of the spoon is pushed into the spoon holder, it snaps into engagement with the spoon holder by snapping under the edge of the spoon holder. The snap-in engagement between the head of the spoon and the spoon holder ensures that after the top sealing member is removed by the user, the spoon remains firmly held in place within the spoon holder without rattling and without the handle of the spoon sinking into the contents of the composite can.

[0068] The resealable lid can have a ladle holder in the form of a clamp disposed on the inner surface of the resealable lid. The ladle holder on the inner surface of the resealable lid may be provided as an alternative to, or in addition to, the ladle holder on the top rim.

[0069] The ladle can be placed directly into the can or pre-packaged in a sanitary wrap such as a plastic or composite bag.

[0070] The barrier properties of the cans disclosed herein can be designed to meet different requirements for airtightness depending on the articles packaged in the cans. By way of example, for cans for dry chickpeas, a lower barrier level can be tolerated that is less sensitive to exposure to oxygen and moisture than, for example, cans for infant formula. The combination of an airtight gas gasket seal between the upper edge of the top rim and the inner surface of the resealable lid and an airtight welded seal between the top rim and the inner surface of the tubular body can provide a can with excellent barrier properties even after the top sealing member has been removed.

[0071] Cans manufactured by the method disclosed herein can preferably have barrier properties that remain substantially unchanged even after breakage or removal of the top sealing member. In other words, the contents of the closed can can be equally well protected, or almost equally well protected, regardless of whether the top sealing member is open or not. This also means that the seals formed between the resealable lid and the top rim and the welded seal between the top rim and the inner surface of the can preferably have barrier properties that provide the same level of protection for the packaged contents as an unbroken top sealing member.

[0072] As described herein, a welding process, particularly a high-frequency induction welding process, provides a highly controlled method of forming a joint having a predetermined level of airtightness between a top rim and a tubular body. The joining is done by supplying energy to heat one or more components within the formed fiber rim and / or on the inner surface of the tubular body, locally softening or melting them, and pressing the formed fiber rim and the tubular body together in a direction perpendicular to the inner surface of the tubular body. The material used to form the weld seal can be provided by the thermoplastic film or coating of the formed fiber rim, by the thermoplastic film or coating on the inner surface of the tubular body, or by both the thermoplastic film or coating of the formed fiber rim and the thermoplastic film or coating on the inner surface of the tubular body. In some embodiments, the formed fiber rim and the tubular body can be joined / sealed without using a plastic material. The formed fiber rim may preferably be made from a softwood pulp material. The formed fiber rim can be manufactured by any suitable formed fiber process known in the art, such as transfer molding or thermoforming (curing in a mold). By controlling the amount of energy supplied, the pressure applied, and the welding time, the welding process can be adapted to the materials being welded to obtain a weld seam having the required level of airtightness. Thus, the welding process is an efficient method that is accurate and predictable and produces a reliable seal having a predetermined level of airtightness.

[0073] After filling the can with the container-packed product, the bottom end is closed to seal the product within the internal compartment of the can. Closing of the bottom end is effected, as described herein, by attaching a bottom sealing member to the inner surface of the tubular body. The bottom sealing member is preferably attached at a slight inward distance from the bottom edge of the tubular body to provide stackability and / or facilitate the addition of a bottom plate to the bottom end of the tubular body. Insertion of the bottom sealing member can create a pressure slightly higher than the ambient pressure inside the sealed intermediate can. This overpressure has been found to cause a slight outward bulge in the top sealing member. In a two-layer top sealing member having a tear strip partially cut out of the upper outer layer of the sealing member, it has been found that a slight outward bulge in the top sealing member facilitates lifting the gripping end of the tear strip from the underlying layer. In this way, the gripping end is more easily gripped, thereby facilitating detachment of the top sealing member.

[0074] The bottom sealing member can be made from any suitable material such as carton, plastic, metal, and laminates of such materials, etc., and a carton-based bottom sealing member is generally preferred. The carton-based bottom sealing member can be made from a laminate material including a carton layer and a thermoplastic polymer layer disposed on the inner surface of the carton layer facing the inside of the container body. A further thermoplastic polymer layer can be disposed on the outer surface of the carton layer. In some embodiments, the carton-based bottom sealing member may not contain a plastic material. The bottom sealing member may be attached to the inner surface of the tubular body by welding such as high-frequency induction welding. The bottom sealing member is aligned with the inner surface of the tubular body before or during insertion into the bottom opening, and the peripheral edge is bent outward from the plane of the bottom sealing member so as to form a flange that can be welded to the inner surface of the tubular body. The weld seal between the bottom sealing member and the container body wall is much less sensitive to contamination by the container filling material than the weld seal between the top sealing member and the inner surface of the tubular body. The carton-based bottom sealing member is generally thicker, more compressible than the top sealing member, and can more easily form a tight seal between the bottom sealing member and the tubular body. The amount of container filling material that may leak from the intermediate can when the bottom sealing member is inserted into the bottom opening is extremely small. Since the bottom sealing member is inserted into the tubular body for only a very short distance, the insertion step generates only minimal turbulence on the surface of the container filling material. Thereby, the amount of material lost in the closing step is minimized. The material that becomes outside the bottom sealing member after the intermediate can is closed and sealed can be easily removed and the fully assembled composite can will not appear dirty.

[0075] Alternatively, the bottom end of the composite can can be closed by any suitable method known in the art, such as by bending and sealing the end of the container wall.

[0076] After sealing the bottom and optionally attaching the bottom plate to the bottom end of the composite can, the composite can can be conveyed to devices such as a code marking unit, a weighing unit, a leaflet inserter, a spoon inserter, etc. in a conventional manner.

[0077] The lid addition step of the method disclosed herein can further include adding a frame structure by mechanically attaching the frame structure to the top rim. The mechanical connection between the top rim and the frame structure can be achieved by providing mating contours on the top rim and on the frame structure. Such mating contours preferably include snap-fit features such as ridges and tracks that engage with each other, or protrusions and holes / cavities.

[0078] The frame structure can be configured to cooperate with a plug-in lid or a hinged lid to maintain the lid in the closed position with the inner surface of the lid in direct contact with the upper surface of the top rim. The frame structure can be added together with the lid.

[0079] The attachment between the frame structure and the top rim can be made by forming a snap-in connection between the frame structure and the top rim.

[0080] The mechanical connection between the top rim and the frame structure is preferably irreversible, which means that once the connection is established, it can only be broken by destroying or damaging the connected parts.

[0081] The frame structure can form part of the lid component, and the lid component further comprises a lid portion connected to the frame structure by a hinge. The lid portion can be a complete lid or only part of a lid that is assembled with one or more additional lid portions to form a container lid. By way of example, the lid portion can be an outer lid portion that defines the shape and size of the portion of the lid that is exposed on the outside of the composite can, which, within the container lid, cooperates with a corresponding abutment surface on the top rim to provide an abutment surface that forms a gasket seal between the lid and the top rim, in combination with an inner lid portion such as an inner sealing member. The inner sealing member can take the form of a flat disk and can be made from cardboard, plastic, or any suitable laminate, and can include an elastically compressible material such as a natural or synthetic foam material or other elastically compressible polymeric material that can contribute to a tight seal between the lid and the top rim. The inner sealing member can be attached to the outer lid portion by an adhesive or by welding. However, it may be preferred in some cases that the inner sealing member be mechanically attached to the outer lid portion, such as by snap-fitting into a groove that extends along the edge of the outer lid portion on its inner surface.

[0082] Since it has been found that an inner lid portion under tension has an enhanced sealing ability, it may be further advantageous to attach the inner sealing member to the outer lid portion under tension.

[0083] When the lid portion constitutes a complete lid, it is the inner surface of the lid that forms a seal against the abutment surface of the top rim. The inner surface of the lid can be coated with an elastically compressible material at least within the region corresponding to the abutment surface of the top rim, or can be provided with a layer of elastic material on the inner surface of the lid.

[0084] By providing the lid, frame structure, or lid component as a separate part from the top rim, these parts can be attached to the top rim after the intermediate can is filled and the bottom end is closed. The lid, frame structure, or lid component may have a three-dimensional outer shape with laminated features, decorative relief elements, locking elements, and other aberrations and irregularities. Further, the lid or lid portion may have a non-planar surface such as a rounded surface or a surface with irregularities. All such three-dimensional features can make it difficult to handle the intermediate composite can in the bottom filling process because the intermediate can may not be safely placed on the non-planar upper surface formed by the lid or lid component. Components with complex three-dimensional shapes are relatively expensive to manufacture and can be easily damaged during the process of transferring the intermediate can between different process stations, gripping and repositioning the can, attaching the can components, filling and closing the can. By adding the frame structure or lid component after the can is filled and closed, the number of cans that need to be damaged and discarded during the process can be reduced. The lids and upper closures with two-part rim / frame structures disclosed herein can function to maintain waste at a lower level than is possible with conventional single-part rim structures. The top rim disclosed herein has a simple shape without protruding features that can be damaged in the manufacturing process and can serve as a support and reinforcement element for the tubular body during the manufacturing and filling processes described herein. In the assembled composite can, the top rim contributes to stabilizing and shaping the carton-based body during transportation and storage.

[0085] The reclosable lid can be added to the upper end of the intermediate can after the inner packaging compartment within the tubular body is filled with the containerized product and the bottom end of the tubular body is closed.

[0086] The reclosable lid can be a separate part of the composite can that can be completely removed when opening the can. Alternatively, the lid may be attached to the frame structure by a hinge as described herein. The hinge can be a living hinge, i.e., a bendable connection between the lid and the frame structure. The living hinge can be formed integrally with the lid and / or the frame structure, or can be a separately formed element attached to the lid and the frame structure. Alternatively, the hinge can be a two-piece hinge having a first hinge portion disposed on the lid and a second hinge portion disposed on the frame structure. Alternatively, a two-piece hinge structure can be used to attach the lid directly to the top rim.

[0087] If the reclosable lid includes an outer portion and an inner sealing disk, the inner sealing disk is preferably attached to the outer portion of the reclosable lid portion before attaching the reclosable lid or lid component to the intermediate can. Although less preferred, the inner sealing disk may alternatively be attached to the outer portion of the reclosable lid after attaching the reclosable lid or lid component to the intermediate can.

[0088] In a composite can manufactured according to the method disclosed herein, the inner outer shape of the top rim defines the shape and size of the access opening, which is smaller than the top opening of the tubular body. The opening area of the access opening is preferably 85% to 99% of the area of the top opening of the tubular body, for example, 90% to 98% of the area of the top opening of the tubular body, or 94% to 97% of the area of the top opening of the tubular body. The top rim is preferably constructed as small as possible within the can opening such that the size of the access opening is maximized. The narrow top rim and large access opening facilitate easy access to the contents of the can and contribute to making it easier to scoop or pour out the contents from the can. The narrow inner top rim minimizes the risk of particulate material being trapped on the surface of the rim during scooping or pouring out the contents from the can, or when the closed can is moved or shifted during distribution. When the user opens the can and exposes the dirty top rim, the can is perceived as dirty and not as hygienic as desired. Generally, container-packed products are more likely to come into easier contact with the hands of the person opening the can and removing the contents through the access opening, so it is desirable to keep them away from the more contaminated access opening. Contaminated contents within the can trapped on the top rim may fall back into the can and then contaminate the remaining contents within the can.

[0089] If the packaging can comprises a frame structure mechanically connected to the top rim, it may be preferable for no part of the frame structure to extend into the access opening and reduce the area of the access opening. The frame structure can then serve to provide features such as lid hinges, means for covering the access opening and holding the lid in the closed position, locking elements, stacking elements, and the like.

[0090] The top rim or frame structure can be further configured to include means for holding the lid in the closed position with the inner surface of the lid in direct contact with the upper edge of the top rim. Such means can be constituted by snap-locking elements including mating ridges and grooves on the rim or frame structure and on the lid, female / male locking elements, etc., as are known in the art. In addition, the closing mechanism on the composite can preferably includes a locking mechanism.

[0091] The locking mechanism, if present, can include a first locking element disposed on the frame structure, on the tubular body or on the composite can, or on the top rim, and a second locking element disposed on the can lid. The first locking element and the second locking element can be mating locking elements such as female / male locking elements including hooks and other protrusions arranged to engage with ridges, hooks, tracks, holes, cavities, loops, etc.

[0092] The locking mechanism can include at least one locking flap permanently joined to the top rim or frame structure at the front edge portion and / or side edge portion, etc. of the access opening of the can. The locking flap has a free end portion extending in the height direction of the composite can towards the reclosable lid. The free end portion of the locking flap includes a first locking element arranged to engage with a second locking element on the outer surface of the reclosable lid. Preferably, the locking flap has an extension portion extending in the height direction of the composite can, and this extension portion enables the free end portion to reach a certain distance beyond the top of the outer lid surface so that the first locking element and the second locking element can be arranged to engage at the edge of the reclosable lid at the top of the outer lid surface. When the locking flap is in the closed position with the first locking element and the second locking element engaged with each other, the lid and the top rim or frame structure are clamped firmly together and maintained under tension. The locking flap is preferably hingedly connected to the top rim or frame structure, and preferably by a living hinge formed integrally with the top rim or frame structure and the locking flap.

[0093] The snap - grip area can be arranged on the outer lid surface at the top of the lid part. The snap - grip area is arranged at the free - end part of the locking flap and functions to provide access to the free - end part of the locking flap in a direction perpendicular to the height direction of the lid component. Thereby, any part of the locking flap in the closed position can be easily operated even if it does not extend in the height direction of the lid component beyond the outer lid surface at the top of the lid part.

[0094] Alternatively, although generally less preferred, the locking mechanism can be provided by a locking flap or a clasp closure comprising at least one locking element extending from an edge of the lid, such as the front edge of the lid, and fixed in or on a corresponding locking element on the top rim or frame structure.

[0095] The locking element is preferably designed to enable repeated opening and closing of the locking mechanism. The operation of the locking mechanism can be facilitated by a gripping device such as a finger grip, a friction - enhancing element, a pull tab, etc.

[0096] The single or multiple stacking members of the can opening can be arranged around the lid and / or around a frame structure connected to the top rim surrounding the access opening of the packaging can. The lid can comprise mating stacking members arranged on the upper outer surface and the inner lower surface of each lid, for example, enabling the lids to be stacked separately before being added to the intermediate can in the process of manufacturing the packaging cans disclosed herein. Similarly, a lid component comprising a lid part hinged to a frame structure can comprise mating stacking members enabling the lid components to be stacked separately.

[0097] The stacking members at the can opening can take the form of a peripheral ledge on the outer lid surface, or on the top rim, or on a frame structure connected to the top rim. When one can is stacked on top of another, the bottom edge or bottom plate of the first can is supported on the peripheral ledge.

[0098] The lid components for the composite cans disclosed in this specification have a lateral direction and a height direction perpendicular to the lateral direction, and include a lid portion and a frame structure. The lid portion includes a top portion and a side wall portion. The top portion has an outer lid surface, an inner lid surface opposite to the outer lid surface, and a peripheral edge portion surrounding the outer lid surface. The frame structure has an upper portion and a lower portion in the height direction and has a lower edge surface. The stacking member can be disposed on the outer lid surface, and the stacking member on the outer lid surface includes a lid component stacking step portion and a can stacking step portion. The can stacking step portion includes a first support surface disposed at a first level below the uppermost level of the outer lid surface in the height direction of the lid component. The lid component stacking step portion includes a first support surface disposed at a second level below the uppermost level of the outer lid surface and below the first level in the height direction of the lid component. The lid component stacking step portion is disposed at the peripheral edge portion of the outer lid surface closer to the outside of the can stacking step portion in the lateral direction of the lid component. The frame structure is adapted to fit into and be supported by the lid component stacking step portion. The can stacking step portion is adapted to receive and support the bottom edge portion of the composite can.

[0099] The lid portion and the frame structure of the lid components disclosed in this specification can be completely separable parts, partially separable parts, or completely inseparable parts. In a lid component having completely separable parts, the parts are separably and re-closably connected to each other in the closed configuration of the lid component. In a lid component having partially separable parts, the parts are connected to each other by a hinge and can move between the closed configuration and the open configuration of the lid component by pivoting around the hinge. A lid component having inseparable parts is a lid component in which the frame structure forms an integral continuous portion of the side wall portion of the lid portion.

[0100] As described in this specification, the bottom plate can be attached to the tubular body of the composite can at the bottom end of the tubular body. In a composite can provided with a stacking step portion on a re-closable lid or a lid component including a re-closable lid, the bottom plate is adapted for stacking cooperation with the can stacking step portion on the lid or the top of the lid portion.

[0101] In the composite can disclosed in this specification, the lower end surface of the bottom plate can be adapted for stacking cooperation with the first support surface of the can stacking step portion, and the inner wall of the bottom plate can be adapted for stacking cooperation with the second support surface of the can stacking step portion. When stacking the second can disclosed in this specification on the first can disclosed in this specification, the lower end surface of the bottom plate of the second can is placed on the first support surface of the can stacking step portion of the first can, and the second support surface of the can stacking step portion restricts the lateral movement of the second can relative to the first can.

[0102] As described in this specification, the stacking member is arranged on the outer lid surface of the lid component and includes a lid component stacking step portion and a container stacking step portion. The lid component stacking step portion is arranged laterally outward and downward of the can stacking step portion. By arranging the stacking member at the edge of the lid portion, the stacking member minimally intrudes into the top surface of the lid, and a large central region of the lid is available for display purposes, for example, to convey information, logos, and / or for design purposes. Since the stacking step portions are arranged at a level below the central region of the top surface of the lid portion, they are not prominent, and the technical features of their function as stacking members may not be immediately apparent to the end user of the composite can. The composite can can have a more attractive and "highly designed" appearance and be recognized as having fewer technical features, which can be beneficial when the can is placed in a visible location, such as on a user's kitchen countertop or on a store shelf.

[0103] When stacked together, the lid components with stacked steps disclosed herein are nested with each other. As a result, when the lid components are stacked, the height added by stacking is lower than that of the lid components, so that they can be stacked in a space-saving, efficient and stable manner. Therefore, the combined height of the stacked lid components is smaller than the sum of the individual heights of the lid components. The space-saving stacking configuration is advantageous not only during the manufacture of composite cans, but also for transportation and storage purposes. The magazine for lid components can accommodate more lid components and does not require frequent replenishment, so the space-saving stacking makes the supply of lid components in the manufacturing process more efficient.

[0104] Therefore, the two-stage configuration of the peripheral portion of the lid of the lid component provides stable and efficient stacking of the individual lid components as well as composite cans provided with the lid components. By providing separate stacking steps for the lid component and the composite can on the outer surface of the lid of the lid component, it becomes possible to dimension and configure each stacking step to be optimal for a specific stacking purpose.

[0105] The lid of the lid component includes two different and separate stacking members arranged as two substantially L-shaped stacking steps at the peripheral edge of the outer lid surface. The lid component stacking step is located outside the can stacking step in the lateral direction of the lid component and below the can stacking step in the height direction. When the second lid component is stacked on the first lid component, the lid component stacking step of the first lid component receives the lower part of the frame structure of the second lid component in a fitting manner so that the lower part of the frame structure fits into the lid component stacking step in an nested manner.

[0106] The lid component stacking step and the can stacking step can each include a second support surface.

[0107] The second support surface of the lid component stacking step portion can be arranged to support the inner wall at the lower part of the frame structure, that is, to support the second lid component in the lateral direction of the lid component. Therefore, when the lid components are stacked on each other on a horizontal plane, the first support surface and the second support surface can be arranged to absorb the forces in two substantially perpendicular directions corresponding to the vertical direction and the horizontal direction.

[0108] The lid component stacking step portion and / or the can stacking step portion can include one or more interruption portions, such as two interruption portions, three interruption portions, or four interruption portions. The interruption portions can be arranged as a pair of interruption portions at opposite positions along the peripheral edge of the outer lid surface, for example, at the opposite side portions of the peripheral edge of the outer lid surface. The interruption portions can be arranged only at the top of the lid portion or also on the frame structure of the lid component.

[0109] The interruption in one or both of the stacking steps can function as a separating means that facilitates the gripping and separation of individual lid components from the stack of lid components when adding the lid components to the intermediate can in the manufacturing process of the composite cans disclosed herein. Providing a separating means is particularly useful when stacking lid components that have very thin dividing lines between the stacked lid components and fit snugly together. Such closely fitting lid components form a compact stack with a smooth and regular shape, which is beneficial for the storage and transportation of the stacked lid components and the handling of the stack of lid components in a packaging machine. However, it has been found that the lid components tend to adhere closely to each other and are difficult to separate at high speeds required in the manufacturing process. In addition to facilitating the separation of the closely stacked lid components by inserting a gripping member into the interruption, the interruption counteracts the formation of a pressure lower than the atmospheric pressure in the space between the stacked lid components because the interruption acts as an air channel between the inside and the outside of the stack. The reduced air pressure in the internal space between the stacked lid components generates a suction force, which tends to hold the lid components firmly together. Conversely, if the pressure inside the stack is higher than outside the stack, it may tend to reduce the stability of the stack by forcing the lid components apart.

[0110] The stacking step can extend across a locking flap disposed at the edge of the lid, whereby the locking flap in the closed position forms a continuous portion of the sidewall portion of the lid part. At the same time, the portion of the stacking step disposed on the locking flap can contribute to improving the gripability of the locking flap and facilitating the operation of the locking flap between the open and closed positions.

[0111] The fitting and gripping area can be arranged on the outer lid surface at the top of the lid part. The fitting and gripping area is arranged at the free end part of the locking flap, and while providing access to the free end part of the locking flap, it plays a role in protecting the free end part of the locking flap from inadvertent opening. Thereby, even if any part of the locking flap in the closed position does not extend in the height direction of the lid component beyond the outer lid surface at the top of the lid part, the locking flap can be easily operated.

[0112] As an alternative to the continuous or discontinuous ledges or stacking steps arranged around the outer lid surface, the stacking member of the can opening can be provided as two or more support surfaces that cooperate with the corresponding stacking member at the bottom of the can. The stacking member at the bottom of the can can take the form of a bottom edge portion extending downward as described above, or can take the form of a knob or other protrusion that provides a desired spacing between the can bottom sealing member and the surrounding ledge or other support surface on which the single or multiple stacking members at the bottom of the can are placed when one can is stacked on top of another can.

[0113] The tubular body of the composite can disclosed in this specification can have four main body wall portions, namely, a front wall portion arranged opposite to the rear wall portion, and two opposing side wall portions extending between the front wall portion and the rear wall portion. The main body wall portions are connected by curved corners, providing a soft and slightly rounded appearance to the packaging can. Further, the shape of the main body wall portions can deviate from a flat shape such that one or more of the main body wall portions have an outward or inward curvature. When the tubular body has one or more outwardly curved main body wall portions, the curvature of any such main body wall portion is always smaller than the curvature of any curved corner, that is, the radius of curvature of the corner in the tubular body of the composite can disclosed in this specification is always smaller than the radius of curvature of any of the main body wall portions. The transition between the corner and the main body wall portion can be seen as a distinct change in curvature or as a continuous change in curvature.

[0114] Alternatively, the tubular body can be made without a separate body wall portion and can have any suitable footprint shape such as circular, oval, or elliptical.

[0115] In composite cans, there is a conflict between minimizing the amount of carton material used in the can and making the can sufficiently rigid to avoid, for example, the can being damaged or crushed during manufacture or when stacked for transport and storage. It has been found that by simply curving all the can walls slightly outward, the shape stability and rigidity of the composite can can be significantly improved compared to conventional packaging cans with flat walls. Therefore, the radii of curvature of the top and bottom edges of the tubular body that determine the curvature of the can wall portion are preferably selected such that the can wall portion has a substantially flat shape and is recognized as being flat to the naked eye.

[0116] The carton-based composite cans disclosed herein function as protective transport and storage cans on the retailer side and as storage and dispensing cans on the consumer side. In addition to an openable lid, the composite can is manufactured with a top sealing member attached inside the tubular body of the can at a distance from the top edge of the tubular body. The top sealing member keeps the contents fresh and protects them from contamination until the filled and sealed can is delivered to the consumer. When the top sealing member is broken or removed to access the contents of the can, the ability of the can to protect the contents from harmful environmental effects strongly depends on the ability of a reclosable lid that forms a seal at the access opening of the can. Composite cans for products such as powdered milk, coffee, tea, cereals, etc. typically contain more container-packed product than is used at each dispensing. Therefore, it is desirable that the product remaining in the can retain its characteristics such as flavor, aroma, scoopability, vitamin content, color, etc. for at least the time corresponding to the time it is expected to take the consumer to use up all the contents of the packaging can.

[0117] As described herein, by joining the top rim to the inner surface of the tubular body by welding such as high-frequency induction welding, it is possible to obtain an attachment having a better sealing ability than that generally achievable by adhesive attachment. The welded top rim is preferably a molded fiber rim, which connects the inner surface of the tubular body to the inner surface of the lid and contributes to forming a continuous barrier between the tubular body and the lid. The weld seal forms a first seal between the top rim and the inner surface of the tubular body, and the contact surface between the top rim and the lid forms a second seal between the top rim and the lid. The first seal is a permanent seal that always exists, and the second seal is a releasable seal that is effective only when the lid is closed over the can access opening and the inner surface of the lid is pressed against the top rim.

[0118] The lid or lid component can be added using a lid attachment unit, which is a device for automatically attaching the lid to the intermediate can. The lid attachment unit can comprise a rotatable unit with a lid holding member, a lid supply unit, and a lid addition unit. The apparatus can further comprise an article addition unit configured to add individual additional articles into the intermediate can, onto the top rim, or into a holder disposed inside the lid. The additional articles can be spoons or other utensils, toys, pamphlets, etc. Alternatively, the article applicator can be provided as a separate device from the lid attachment unit.

[0119] For example, after adding a lid in the form of a lid component, the assembled composite can can be conveyed in a conventional manner to further equipment on the packaging line, such as a case packer, a code marker, a weighing unit, and a palletizer. The packaging line usually ends with a palletizer.

[0120] Definitions The carton-based sheet material used to form the tubular body and the base sealing member is mainly made of cellulose fibers or paper fibers that form a carton layer within the paperboard material. The carton layer can be a single-layer or multi-layer material. The sheet material is a laminate that can include at least one thermoplastic polymer layer in the form of a film or coating in addition to the carton layer. The polymer layer can also be disposed on the surface of the sheet material that forms the outer surface of the composite container. In some embodiments, the carton-based sheet material may not include a plastic material. The sheet material may be subjected to coating, printing, embossing, etc., and can include fillers, pigments, binders, and other additives known in the art.

[0121] The term "tubular body" should be understood to mean any hollow tubular shape that the body blank assumes during the manufacture and filling of the composite cans disclosed herein, as well as the shape that the body has in the finally assembled and filled composite can. Thus, as used herein, the tubular shape can be a cylindrical shape, or any other useful cross-section such as a square, rectangular, or other polygonal cross-section, or a deformed polygonal cross-sectional shape with rounded corners. The tubular shape also includes any temporary shape that the tubular body can assume during the manufacturing process. By way of example, the cross-section of the tubular body can initially exhibit a teardrop appearance with a separate peak provided at the end-to-end joint between the edges of the body blank and a curved portion opposite the peak.

[0122] As used herein, the term "can component" refers to the tubular body of a composite can and any component intended to be attached to the tubular body to form an integral part of the composite can disclosed herein. Examples of can components that may be part of the composite can disclosed herein are the tubular body, body seal strip, top seal member, bottom seal member, top rim, reclosable lid and frame structure, lid components, bottom plate, spoon holder, and spoon. Only the tubular body, body seal strip, top seal member, bottom seal member, top rim, and reclosable lid are essential components of the composite can disclosed herein.

[0123] The top seal member and the bottom seal member are sheet-like components that are added inside the tubular body of the composite can so as to cover the cross-sectional area of the tubular body. The bottom seal member forms the bottom end closure of the composite can, and the top seal member forms the inner transfer seal of the composite can. The top seal member is usually at least sufficient to allow a top rim to be attached over the top seal member and may also be able to accommodate a spoon or other additional article in the space between the top seal member and the inner surface of the reclosable lid, and is attached to the access opening of the composite can at a distance from the opening edge. The fully or partially removable transfer closure can be airtight or gas permeable. An airtight closure can be manufactured from any material or combination of materials suitable for providing an airtight seal of the compartment delimited by the transfer closure, such as aluminum foil, silicon-coated paper, plastic film, or a laminate thereof. An airtight transfer closure is advantageous when the bulk solid stored in the packaging container is sensitive to air and / or moisture, and it is desirable to avoid contact between the container-packed bulk solid and the ambient air. Since the transfer closure is a removable closure, it does not affect the recyclability of the composite paperboard container.

[0124] The composite cardboard container may not include plastic components such as a plastic rim component, a lid component, or a bottom component. Thus, such a composite cardboard container enables a user to recycle the container without first separating the plastic component from the tubular body.

[0125] The lid 221, the lid component 231, the top rim 223, and the bottom plate 217 can have a density in the range of 0.2 kg / dm3 to 1.5 kg / dm3, optionally in the range of 0.2 kg / dm3 to 1 kg / dm3, and optionally in the range of 0.4 kg / dm3 to 0.8 kg / dm3.

[0126] The lid 221, the lid component 231, the top rim 223, and the bottom plate 217 according to the present disclosure may be molded and thus may need to have structural durability, preferably similar to that of a plastic rim. In the case of a rim component connected to additional rim parts such as an inner rim component and an outer rim component, the rim component should have a certain degree of flexibility and be structurally stable and structurally stabilizable.

[0127] As seen in a cross-sectional view, the rim can include a U-shaped or angled-edge U-shaped track portion having a first side wall section and a second side wall section that are opposing wall sections, and a bottom section facing the edge portion of the tubular body. The draft angle between the bottom section and the first side wall section can be in the range of 0 degrees to 10 degrees, optionally in the range of 0 degrees to 5 degrees. Since the tubular body wall is formed by a cardboard blank and thus has a thin rectangular cross-section, a draft angle in the range of 0 degrees to 10 degrees, or in the range of 0 degrees to 5 degrees, enables a tight fit between the tubular body, the bottom section, and the first side wall section. This promotes the durability of the container-packed articles and the safety of the packaging.

[0128] The top sealing member and the bottom sealing member can be made from paper, cardboard, plastic film, and laminates of such materials. Usually, the bottom sealing member is made from a laminate including a cardboard base layer. The bottom sealing member is generally coated with an outer layer of a thermoplastic polymer material. The top sealing member is generally a flexible component made from a laminate of layers of a thermoplastic polymer material. However, a cardboard-based top sealing member that does not include a plastic material can also be used with the embodiments described herein. The top sealing member is generally arranged to be partially or completely removed upon the first opening of the composite can and can be provided with opening means such as a tear strip, a grip tab, etc., as known in the art.

[0129] The top rim and the bottom plate can be made from a formed pulp fiber material such as a softwood pulp fiber material, which is added to the inner surface of the tubular body of the composite can with at least a part of the rim or the plate welded to the inner surface of the tubular body. The top rim and the bottom plate provide enhanced rigidity at the edge of the tubular body to the tubular body. Preferably, the formed rim and plate are sufficiently elastically deformable so as to withstand lateral deformation without breakage or permanent deformation, for example when inserted into the tubular body or when exposed to accidental shocks during use. The rim or the plate may also cover the edge of the tubular body and optionally extend onto the outer surface of the tubular body.

[0130] As used herein, an "intermediate can" is a can formed after bending a cardboard blank into a tubular shape and sealing the joined edges of the bent cardboard blank to form a tubular body. The processed can remains an "intermediate can" until the final components are added to complete the composite can. Generally, the composite can is fully assembled when a reclosable lid is added as the final component.

[0131] The composite cans disclosed in this specification are cans for dry or wet articles, often referred to as "bulk solids". Such products are non-liquid and are generally particulate materials that can be poured out of, scooped up from, or removed by hand from the can. The cans are generally disposable cans intended to be discarded when the contents are emptied.

[0132] "Particulate material" or "particulate article" should be broadly understood to include any material in the form of particles, granules, pulverized matter, plant fragments, short fibers, flakes, seeds, pieces, etc. Particulate articles suitable for packaging in the composite cans disclosed in this specification are generally free-flowing non-liquid articles that allow a desired amount of the article to be poured out of, scooped up from, or removed by hand from the composite can.

[0133] The composite cans disclosed in this specification can be cans for nutritional products or consumer products such as infant formula, coffee, tea, rice, wheat flour, sugar, rice, peas, beans, lentils, cereals, soup powder, custard powder, pasta, snacks, etc. Alternatively, the container-packed articles can be non-nutrients such as tobacco, detergents, dishwasher powder, fertilizers, chemicals, etc.

[0134] An openable or peelable top sealing member means a sealing member that can be completely or partially removed by the user to provide initial access to the internal compartment of the composite can by breaking the seal between the sealing member and the inner surface of the tubular body of the can, or by tearing or otherwise breaking the sealing member itself. A tearable sealing member can have one or more predetermined weakened portions such as perforations or cuts that partially penetrate the membrane, and can have a tear strip disposed therein to facilitate removal of the sealing member. A peelable top sealing member is usually provided with a grip tab that facilitates the initiation of separation from the inner surface of the tubular body and subsequent removal of the sealing member.

[0135] The top sealing member is preferably disposed at a distance from the upper edge of the tubular body of the composite can, whereby the top rim can be attached to the inner surface of the tubular body between the top sealing member and the top edge of the tubular body. Alternatively, the upward edge of the breakable sealing film can extend into the weld joint between the top rim and the inner surface of the tubular body. The distance between the top sealing member and the top edge of the tubular body can be about 10 millimeters to about 60 millimeters. When the top sealing member is disposed at a distance of 30 millimeters to 60 millimeters from the top edge of the tubular body, the space above the top sealing member can be used to accommodate a spoon or other article provided in the container-packed product. Examples of other articles that can be provided are leaflets, coupons, and / or clips, forks, or other utensils.

[0136] The weld seal between the top rim and the inner surface of the tubular body is preferably a sift-proof seal, more preferably a moisture-proof seal, and most preferably an airtight seal. A can having a volume of about 1 L can be considered airtight if it provides an oxygen barrier of about 0.006 cc or less per 24 hours at 23 °C and 50% relative humidity.

[0137] If the container-packed product is sensitive to moisture and / or tends to deteriorate when exposed to ambient air, a higher level of airtightness of any seals between the composite can and the can elements may be desirable. Also, the composite can may desirably be aroma-impermeable to preserve the flavor and aroma within the container-packed article and to prevent the container-packed product from absorbing flavor and aroma from outside the composite can. Thus, the composite can can function as a barrier in both the inward and outward directions.

[0138] In connection with the filling step, by subjecting the filled article in the open intermediate can to a protective gas atmosphere, the amount of air trapped in the can when the bottom closure is added can be minimized. Further, since the protective gas atmosphere is generated before the filled intermediate can reaches the sealing station, there is no need to remove air from the filled and open container before sealing the container, so that the atmosphere in the sealing station and the sealing step can be very well controlled. This is known to be a great advantage because the pressure difference in the sealing step can cause turbulence in the container filling material, which can adversely affect the sealing process. Such turbulence can cause powder material to be trapped in the seal and potentially compromise the airtightness of the seal.

[0139] The present invention will be further described below by way of non-limiting examples with reference to the accompanying drawings.

Brief Description of the Drawings

[0140]

Figure 1

Figure 2a

Figure 2b

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Best Mode for Carrying Out the Invention

[0141] The present invention is illustrated below by way of embodiments. The embodiments are included to explain the principles of the present invention and do not limit the scope of the present invention. Details from two or more embodiments can be combined with each other.

[0142] FIG. 1 shows an assembly line 1 that can be used to manufacture a composite can (broadly, a "container") and fill it with bulk solids according to the method disclosed herein. The assembly line 1 is configured to assemble a composite can by forming a tubular body and attaching can components to the tubular body in the flow of intermediate cans. FIGS. 2a and 3 show an exemplary can 201 that can be manufactured on the assembly line 1 of FIG. 1. The specific shape of the can 201 shown in FIG. 3 should not be considered as limiting the present invention, and the assembly line 1 is suitable for the manufacture and filling of cans of any useful shape or size and is suitable for the manufacture of composite cans without components as disclosed herein as optional.

[0143] The illustrated assembly line 1 includes a plurality of mechanical stations or units 3 to 10 connected by conveyors 2a, 2b, 2c, 2d. In order from the start of the assembly line 1, the mechanical units are a body forming station or unit 3, a filling station or unit 4, a gas box 5, a sealing station or unit 6, a washing station or unit 8, a can rotating station or unit 9, a spoon inserting station or unit 10, and a lid attaching station or unit 7. A further conveyor 2e is arranged at the end of the assembly line 1 and is arranged to convey the manufactured composite can from the lid attaching unit 7 to, for example, a packaging device (not shown).

[0144] The manufacture of composite cans on assembly line 1 is described below with reference to a single composite can. It should be understood that while assembly line 1 is in operation, multiple composite cans are continuously manufactured and exit the lid attachment unit 7 at the end of assembly line 1. As described herein, the mechanical units of assembly line 1, such as any can component attachment unit, can be configured to simultaneously process multiple intermediate cans, such as two, three, four, five, or six intermediate cans. Exemplary can component attachment stations or units 505 are shown in FIGS. 5, 6, and 7.

[0145] Accordingly, assembly line 1 can include, or be provided with, supply sections for a body blank, a sealing member, a reclosable lid, a rim, and a bottom plate, as further described herein.

[0146] The body forming unit 3 includes a body blank extraction station 11, a body forming station 12, a top sealing station 13, and a top rim addition station 14.

[0147] At the body blank extraction station 11, the body blank 16 is removed from the pile of body blanks 16 and transferred to the body forming station 12. At the body forming station 12, the tubular body is formed by bending the body blank 16 and joining two opposing edges of the body blank at an end-to-end joint, also known as a "butt joint". The joint extends in the height direction H of the tubular body between the top end and the bottom end of the tubular body, as shown in FIG. 2a. Next, the joint is sealed by a sealing strip welded to the inner surface of the tubular body, thereby forming an intermediate can. The sealing strip and the inner surface of the tubular body include a polymer layer weldable on adjacent surfaces. The sealing strip is preferably welded to the inner surface of the tubular body by high-frequency induction welding, as disclosed herein.

[0148] After forming the tubular body and adding the sealing strip, the intermediate can is transferred to the top sealing station 13 and sealed by attaching a top sealing member across the entire top opening of the top end of the tubular body. The top sealing member is attached by welding the peripheral flange of the top sealing member to the inner surface of the tubular body. As disclosed herein, the top sealing member can be a flexible component made from a laminate of one or more layers of a thermoplastic polymer material, and the peripheral flange is made by bending the edge portion of the top sealing member from the plane of the top sealing member to be aligned with the inner surface of the tubular body, although the top sealing member may not contain a plastic material without departing from the present disclosure. The top sealing member is removed from a magazine not visible in FIG. 1 and is added at a distance from the top opening edge to enable the attachment of a top rim over the top sealing member. If the composite can contains a spoon, leaflet, or other supplementary item, the top sealing member can be added at a sufficient distance from the top opening edge to enable the item to be accommodated in a space formed between the top sealing member and the inner surface of the reclosable lid.

[0149] After sealing the top opening, a top rim can be added. The intermediate can with the top sealing member added can then be transferred to the top rim adding station 14, where the top rim is added to the intermediate can by inserting at least the lower portion of the top rim into the top opening above the top sealing member. Preferably, the top rim is inserted into the tubular body such that the upper edge of the top rim remains outside the tubular body or lies in the same plane as the top edge of the tubular body, thereby protecting the vulnerable carton edge of the tubular body and forming a rigid placement surface for the intermediate can during subsequent process steps.

[0150] As shown in FIG. 1, the body forming unit 3 is surrounded by an outer housing 20. A can rotation configuration can be further arranged within the outer housing 20 such that the intermediate can with the top rim attached can be inverted vertically immediately after the rim addition. Alternatively, the intermediate can is rotated by a conventional rotating device arranged downstream of the top rim addition station 14. An example of a conventional rotating device is shown by a can rotating unit 9 located downstream of the body forming unit 3. The can rotating station or unit 9 operates by tipping the intermediate can on an inclined conveyor.

[0151] After adding the top rim and inverting the intermediate can, the intermediate can is transferred to the first conveyor 2a, and the top rim is placed and arranged on the conveyor 2a, and the bottom opening of the bottom end of the tubular body is placed with the opening facing vertically upward. The intermediate can is moved by the conveyor 2a to the filling unit 4, where the intermediate can is filled with dry or wet articles through the bottom opening of the tubular body.

[0152] Thereafter, the filled intermediate can is moved by the second conveyor 2b to the gas box 5 while still placed on the top rim, where the filled intermediate can is subjected to treatment with a protective gas while the intermediate can moves through the gas box 5. The gas box 5 is an optional part of the process equipment that executes the method disclosed herein, which can be used, for example, when the container-packed articles are sensitive to oxygen and / or moisture. Further, the generation of a protective gas atmosphere for the filled intermediate can can be performed by other means as described herein. After exiting the gas box 5, the filled intermediate can is transferred to a sealing unit 6 on the third conveyor 2c. The third conveyor 2c moves through a gas tunnel that fits tightly against the wall of the sealing unit 6 at the entrance to the sealing unit 6 in order to maintain the protective atmosphere generated within the gas box 5.

[0153] In the sealing unit 6, the bottom opening of the tubular body is sealed at the can sealing station 21 by attaching a bottom sealing member over the entire bottom opening, and this attachment is performed by welding the peripheral flange of the bottom sealing member to the inner surface of the tubular body at a distance from the bottom edge of the tubular body. Thus, the bottom sealing member is added in a manner corresponding to the method of the top sealing member by folding the peripheral portion of the bottom sealing member so as to be aligned with the inner wall of the tubular body and then welding the opposing surfaces of the bottom sealing member and the tubular body to each other. The sealing unit 6 preferably includes a bottom plate adding station 22 for adding a bottom plate after the bottom sealing member is inserted into the tubular body and welded in place.

[0154] As shown in FIG. 1, the sealing unit 6 is surrounded by an outer housing 23 similar to the outer housing 20 surrounding the body forming unit 3. By adapting the sizes and shapes of the inlet port 24 and the outlet port 25 of the outer housing 23 to the sizes and shapes of the intermediate cans manufactured on the assembly line 1, the ports 24, 25 can be kept in a substantially sealed state by the intermediate cans continuously passing through the ports 24, 25 during manufacturing. Thereby, it is possible to maintain a protective gas atmosphere inside the outer housing 23 during the bottom sealing operation.

[0155] After filling, sealing the bottom, and adding the bottom plate, the intermediate can is rotated again to a position where the top rim faces vertically upward.

[0156] Similar to the first rotation operation performed after the addition of the top rim, the can rotation mechanism can be made part of the sealing unit 6 such that the intermediate can is rotated immediately after bottom sealing and bottom plate addition. In the assembly line 1 shown in FIG. 1, the intermediate can is instead rotated in a conventional rotation unit 9 arranged downstream of the sealing unit 6.

[0157] In the example shown in FIG. 1, a cleaning unit 8 is disposed between the sealing unit 6 and the rotating unit 9. In the cleaning unit 8, product residues that may have leaked outside the intermediate can during previous process steps are removed by pressurized air. The cleaning unit 8 is optional with respect to the assembly line as disclosed herein and may be particularly useful when the container-filled article is a powder or particulate material having small-sized particles or containing fragments that can cause dusting.

[0158] As described herein, before finally closing the composite can by attaching the lid, a spoon or other item can be placed on the top sealing member. As shown in FIG. 1, the spoon insertion unit 10 and / or other item insertion unit can be disposed downstream in the process line at a position where the composite can is inverted with its top end facing upward. In the assembly line shown in FIG. 1, the spoon insertion unit 10 is disposed after the rotating unit 9.

[0159] The filled and sealed intermediate can is then conveyed to the lid attachment unit 7 on the conveyor 2d, and a reclosable lid is attached to the top end of the tubular body such that the inner surface of the reclosable lid is in direct contact with the upper surface of the top rim. As described herein, the reclosable lid may be added as part of a lid component, and the lid component further comprises a frame structure. Preferably, the lid component is mechanically attached to the upper rim by a snap-fit connection.

[0160] The assembly line can further include a quality control device and a device for removing incomplete intermediate composite cans and fully assembled composite cans from the flow of the composite cans. Such a quality control device can include a detection device for detecting defects in the intermediate cans or malfunctions of the machines during manufacturing, for example, a visual detection device, an X-ray device that can be arranged after the lid attachment unit 7, and the like. Further, the quality control device can include a can rejection station that is generally arranged after one or more of the body forming unit 3, the filling unit 4, the sealing unit 6, the spoon insertion unit 10, and the lid attachment unit 7 in order to ensure that incomplete composite cans are removed from the manufacturing line.

[0161] As disclosed herein, the composite can is filled with a dry or wet article in the form of particles or small pieces, granules, flakes, grains, etc. The article flows into the composite can under the influence of gravity.

[0162] The composite can 201 shown in FIGS. 2a and 3 can be manufactured on the assembly line 1 of FIG. 1 and includes a tubular body 203 having a tubular body wall 205. The body wall 205 extends in the height direction H of the can 201 from the bottom edge portion 207 of the bottom end portion of the tubular body 203 to the top edge portion 209 of the top end portion of the tubular body 203. The tubular body 203 has a top opening 211 at the top end portion and a bottom opening 213 at the bottom end portion.

[0163] The bottom sealing member 215 is positioned adjacent to the bottom end portion of the tubular body 203 and covers the bottom opening 213. In this regard, the bottom sealing member 215 is positioned inside the tubular body 203 and is sealingly engaged with the tubular body 203. The bottom sealing member 215 is spaced apart from the top end portion of the tubular body 203, the bottom end portion of the tubular body 203, and the top sealing member 227, respectively, as further described herein. The tubular body 203 is formed by joining the side edge portions of the body blank end to end and sealing the joint with a sealing strip 214 as described herein.

[0164] The bottom edge portion 207 is reinforced between the bottom sealing member 215 and the bottom edge portion 207 by a reinforcing bottom plate 217 added to the inner surface of the main body wall 205 and / or the peripheral flange 216 of the bottom sealing member 215. The bottom plate 217 is a formed plate containing pulp fibers such as softwood pulp fibers. In this regard, the bottom plate 217 may not contain a plastic material. The bottom plate 217 covers the entire bottom opening 213. In the illustrated embodiment, the bottom plate 217 has an outward flange 219 that covers the bottom edge portion 207 of the tubular body 203 and engages with the bottom end portion of the tubular body 203 to form the bottom edge portion of the can 201. The bottom plate 217 reinforces the bottom edge portion 207, stabilizes the shape of the tubular body 203, and protects the bottom edge portion 207 from mechanical deformation. The bottom plate 217 also functions as a protective barrier against water and other fluids that may be present on the surface on which the can 201 is placed. The bottom plate 217 defines a downward open space between the bottom sealing member 215 and the bottom edge portion of the can 201, and this space can be used to accommodate stacking elements arranged at the upper end portion of another can when two or more cans are stacked on top of each other.

[0165] The composite can 201 is provided with a closing configuration including a lid 221 and a top rim 223 extending along the edge of the top opening 211. The lid 221 can include a flat inner sealing disk that seals against the top rim 223 when the composite can 201 is closed, as shown in FIG. 3. The can 201 further includes a completely or partially removable top sealing member 227 sealed to the main body wall 205 along the peripherally folded flange 218. Thus, the top sealing member 227 is positioned inside the tubular body 203 and sealingly engages the tubular body 203, and the top sealing member 227 is spaced apart from each of the top end portion of the tubular body 203, the bottom end portion of the tubular body 203, and the bottom sealing member 215.

[0166] The top rim 223 can form a closed loop, as seen in FIG. 2a.

[0167] The top rim 223 and / or the bottom plate 217 can be attached to the end portion of the tubular body along the edge of the tubular body at the connection portion of the top rim 223 and / or the bottom plate 217. The connection portion of the top rim 223 and / or the bottom plate 217 has a distal edge. The tubular body can be made from a laminate sheet material including a carton substrate layer and a thermoplastic welding layer. In some embodiments, the tubular body may not include a plastic material and a welding layer.

[0168] The tubular body can have a thermoplastic welding layer with a basis weight of at least 15 g / m2 on the laminate sheet material, within a range such as 20 g / m2 to 160 g / m2, optionally 35 g / m2 to 140 g / m2, or 40 g / m2 to 120 g / m2. The inventors have found that such a basis weight of the thermoplastic welding layer enhances the welding with a rim containing pulp fibers. Conventionally, the rim is a plastic rim, and thus, the welding between the plastic rim and the paperboard container including the thermoplastic welding layer is facilitated. However, when the thermoplastic welding layer has such a basis weight, an improved seal with durability and moisture resistance between the tubular body and the rim according to the present invention can be achieved.

[0169] The thermoplastic welding layer can include or consist of a polyethylene layer.

[0170] The thermoplastic welding layer can include metal powder or metallized polymer dispersed therein.

[0171] The laminate body sheet material that can be used for the composite packaging container disclosed herein can include one or more layers in addition to the essential structural carton substrate layer and the inner thermoplastic welding layer disclosed below. Looking from the outside to the inside in order, the laminate sheet material has the following structure, that is, a) an optional polymer coating, such as lacquer, b) an optional printing and / or coloring layer, c) a carton substrate layer, d) Any polymer bonding layer, such as a polyethylene (PE) layer, and e) an inner thermoplastic welding layer such as a polyethylene (PE) layer, and It can have. The inner thermoplastic welding layer can consist of two or more sub-layers such as a polyethylene (PE) layer and a low-density polyethylene (LDPE) layer. The sub-layers may be co-extruded to form the inner polymer layer or formed as separate films laminated together.

[0172] The tubular body is connected to the top rim 223 and / or the bottom plate 217 by welding the ends of the tubular body to the connection portions of the top rim 223 and / or the bottom plate 217. The distal edge of the connection portion is located at a distance of at least 4 mm from the edge of the tubular body when viewed in the longitudinal direction of the tubular body.

[0173] The lid 221, the top rim 223, and the bottom plate 217 can each be a molded component containing pulp fibers. In this regard, one or more of the lid 221, the top rim 223, and the bottom plate 217 may not contain a plastic material. The molded component can be composed of 95% - 100% pulp fibers, such as softwood pulp fibers, optionally softwood pulp fibers, and optionally 98% - 100% pulp fibers. Examples of such materials developed for molded applications such as molded trays and blisters, molded or embossed boxes, etc. are, for example, manufactured by Billerud Gruvon and sold under the trademark Billerud FibreForm. A similar material is Advantage Formable paper available from Mondi.

[0174] The tubular body of the composite paperboard container can be made from a laminate sheet material including a carton base material layer and an inner thermoplastic welding layer. The composite paperboard packaging container related to the present disclosure is intended to store a hygroscopic bulk solid, but is not usually intended to be stored in a cooled space such as a refrigerator, and thus does not require an outer polymer resin layer such as polyethylene. However, the tubular body of this type of composite paperboard container often includes an outer coating composition such as varnish to improve wear resistance and provide an aesthetically pleasing packaging container.

[0175] It is desirable to provide packaging for sensitive products such as food with improved recyclability without sacrificing the durability of the containerized article or the safety of the packaging. However, since the top rim 223 is a molded rim containing pulp fibers, this structure has lower flexibility compared to conventional plastic rims and may have a more uneven surface, which may reduce the sealing airtightness between the rim and the tubular paperboard body. Thereby, there may be a risk of air and / or moisture penetrating into the space between the tubular body and the rim, which may reduce the durability of the containerized article or the safety of the packaging. However, surprisingly, the inventor has provided a rim having a connecting portion extending longitudinally at least 4 mm from the edge of the tubular body, and by welding the rim to the tubular body provided with the inner layer of the thermoplastic welding layer, it is possible to achieve a satisfactory sealing airtightness that enables packaging of sensitive products such as food while still providing a neat appearance on the bottom or upper container edge of the easily recyclable container. It has been found that a rim having a connecting portion extending longitudinally at least 4 mm, optionally 4 mm to 50 mm longitudinally from the edge of the tubular body, and optionally 5 mm to 40 mm longitudinally from the edge of the tubular body provides enhanced shape stability for the rim by the tubular body wall that provides support for the most vulnerable part of the rim, i.e., the single or plural connecting portions.

[0176] The rim can be an inner rim, and the composite paperboard container can further include a lid component. The lid component can be a formed lid component including pulp fibers such as softwood pulp fibers, and can be made from the same material and in the same manner as the inner rim. The lid component can include a lid portion and an outer rim portion, and the outer rim portion and the lid portion can be integrally formed and connected to each other via a hinge portion. The outer rim portion can be connectable to the inner rim. The outer rim component may be mechanically connected to the inner rim by a snap-on connection, a slide-in connection, or the like.

[0177] Alternatively, the rim can be part of the rim and the lid component, the rim portion and the lid portion of the rim and the lid component can be integrally formed, the rim portion is connected to the lid portion via a hinge portion, and the rim portion is welded to the tubular body.

[0178] The rim can be connected to either the inner surface or the outer surface of the tubular body via a first connection portion. The first connection portion is a circumferential connection portion extending over the entire circumference of the tubular body. The first connection portion is connected to the tubular body along the entire end portion, to the inner surface and / or the outer surface of the tubular body.

[0179] The rim can include a thermoplastic layer on the surface facing the tubular body. The thermoplastic layer provides a surface with fewer irregularities on the rim, thus strengthening the seal and improving the durability of the container-packed article or the safety of the packaging. The rim can be provided without such a thermoplastic layer without departing from the present disclosure.

[0180] The top rim 223 defines the perimeter of an access opening that is smaller than the top container body opening 211 defined by the top edge 209 of the tubular body 203.

[0181] As described in this specification, the top rim 223 is attached to the inner surface of the body wall 205 at the top opening 211. The top rim 223 has an extending portion in the height direction H of the composite can 201, and has a lower rim portion facing the bottom sealing member 215 and an upper rim portion facing away from the bottom sealing member 215. The top rim 223 extends around the entire circumference of the top opening 211. The upper part of the top rim 223 projects upward in the height direction H above the top edge portion 209, whereby a part of the top rim 223 is disposed above the top edge portion 209 in the height direction H of the composite can 201.

[0182] The top rim 223 can be joined to the inner surface of the body wall 205 by a welding seal extending around the top opening 211. The welding seal preferably extends continuously around the top opening 211, is a penetration-resistant welding seal, preferably also a moisture-proof welding seal, and most preferably an airtight welding seal.

[0183] As described herein, the weld seal between the top rim 223 and the body wall 205 can be formed by supplying energy to heat one or more thermoplastic components within a coating or film on the inner surface of the top rim 223 and / or the body wall 205 to locally soften or melt them, and by pressing the top rim 223 and the body wall 205 together in a direction perpendicular to the body wall 205. The temperature and pressure can be controlled and adjusted to form a strong and tight seal without damaging the welded components. The thermoplastic material used to form the weld seal can be provided by the partially thermoplastic top rim 223, by a thermoplastic film or coating on the inner surface of the body wall 205, or by thermoplastic materials from both the top rim 223 and the body wall 205. The top rim 223 is preferably made from molded pulp fibers. By way of example, the surface of the top rim or bottom plate welded to the container body may be formed from a polymer composition having a lower softening point and melting point than other parts of the rim. Further, the abutment surface on the top rim 223 may be formed from an elastic thermoplastic polymer. Any suitable welding technique can be used, such as ultrasonic welding or high-frequency induction welding, and as described herein, high-frequency induction welding is preferred.

[0184] The top rim 223 and the body wall 205 can be joined without using a thermoplastic material without departing from the present disclosure.

[0185] The lid 221 is an outer component having a three-dimensional shape that provides the upper outer surface of the lid 221. The lid can have an inner surface that includes a pattern of reinforcing ribs. The composite can can include a flat sealing disk that is added onto the inner surface of the lid 221. The sealing disk can be arranged to seal against the upper part of the top rim 223 when the composite can 201 is in the closed position as shown in FIG. 3. Alternatively, the inner sealing surface of the lid may be integrally formed with the lid. A further alternative for forming a sealing closure between the top rim 223 and the lid 221 is by placing a sealing ring on the inner surface of the lid 221 or by adding a sealing coating to a selected portion of the inner surface of the lid and / or the top rim 223.

[0186] The lid 221 is connected to the frame structure 230 by a hinge 229, and the lid 221 and the frame structure 230 together form a lid component 231. The hinge 229 is a live hinge that is integrally formed with the lid 221 and the frame structure 230 as a flexible connection between the lid 221 and the frame structure 230. As described herein, the illustrated hinge is intended only as a non-limiting example, and it should be understood that any other type of functional hinge can be used for the connection between the frame structure and the lid. Further, the lid can be of a removable type that is not permanently connected to the frame structure. The lid component 231 may be made of a molded pulp fiber material, preferably a softwood pulp fiber material.

[0187] The frame structure 230 is added to the composite can 201 at the top edge 209 and mechanically attached to the top rim 223 by a snap-on connection. The frame structure 230 is attached to the top rim 223 after the top rim 223 is welded to the inner surface of the body wall 205. The frame structure 230 is added to the top rim 223 by pushing the frame structure 230 down over the upper edge of the top rim 223 until the frame structure 230 is locked in place on the top rim 223 by the top rim 223 and mating snap-in features on the frame structure 230. Once the frame structure 230 is attached to the top rim 223, it can only be removed again by breaking or damaging the snap-in connection between the top rim 223 and the frame structure 230.

[0188] An internal compartment 208 for containing the containerized article is defined by a top sealing member 227 at the upper end of the tubular body 203 and a bottom sealing member 215 at the bottom end of the tubular body 203.

[0189] To gain access to the containerized article within the internal compartment 208, the user must open the lid 221 and expose the containerized article by completely or partially removing the top sealing member 227. The top sealing member 227 can be arranged to be peeled away from the wall 205 of the tubular body 203 or can be arranged with means for breaking the top sealing member 227, such that the top sealing member can be at least partially removed through the access opening. Such means can be in the form of one or more predetermined weakening portions such as perforations or cuts that partially penetrate the top sealing member 227. If the top sealing member 227 is of the tear-open type, the narrow edge of the top sealing member 227 may remain on the inner surface of the body wall 205. Any such remaining portion of the top sealing member 227 should preferably extend into and not be so large as to restrict the access opening defined by the inner circumference of the top rim 223.

[0190] When the top sealing member 227 is removed, it is sufficient to simply open the lid 221 to access the container-packed articles within the internal compartment 208 through the access opening. As seen in FIG. 2a showing the inside of the top rim 223, the area of the access opening is defined by the inner circumference or inner contour of the top rim 223. The top rim 223 is added to the inner surface of the body wall 205 and adds thickness to the body wall in the inward direction, so the area of the access opening is always smaller than the area of the top opening 211 of the tubular body 203.

[0191] When the composite can 201 is opened, a desired amount of the container-packed articles can be removed from the composite can 201 through the access opening either by means of a spoon or by pouring. The spoon can preferably be provided in the composite can 201. The spoon can first be placed on the top sealing member 227 and removably attached to the inner surface of the lid 221, the inner surface of which can be constituted by the above-described sealing disk. When placed on the top sealing member 227, the spoon can be packaged within a protective wrap such as a paper or plastic bag. As a further alternative, for example, as shown in FIG. 2a, the spoon can be attached to the top rim 223 by placing the head of the spoon within a spoon holder 240 provided on the top rim 223. In the illustrated embodiment, the spoon holder 240 also functions as a scraper bar for shaving off excess material scooped up by the spoon. An example of the spoon 280 is shown in FIG. 2b. The spoon 280 has a spoon head 281 and a spoon handle 282. Generally, the spoons 280 inserted into the intermediate can during the manufacture of the composite cans disclosed herein are stacked, for example, as shown in FIG. 2b, with the spoon heads 281 nested inside each other. To facilitate stacking of the spoons 280 having flat handles 282, the proximal end of the handle 282 can be provided with a stack stabilization configuration 284. The stack stabilization configuration 284 enables the same spoons 280 to be stacked inside each other, facilitates keeping the spoon stack 283 together, and simplifies the storage and handling of the spoons 280 and the loading of the spoons into the spoon insertion unit 10 as shown in FIG. 1.

[0192] Advantageously, the ladle head 281 has a tapered shape to enable the ladles 280 to fit snugly inside each other in an efficient and space-saving manner.

[0193] As an alternative to stacking the ladles 280 with the ladle heads 281 and the ladle handles 282 arranged in the same direction, the ladles 280 may be stacked alternately in opposite directions, as is known in the art.

[0194] It should be understood that the ladle 280 shown in FIG. 2b constitutes only an example of a suitable ladle configuration, and ladles having different-shaped ladle heads, different-shaped handles, different ratios between the ladle head and the ladle handle, etc. can be used in the composite cans disclosed herein. The ladle can further have means for improving additional stack stabilization and / or retention of the ladle 280 within the ladle holder. By way of example, the ladle head can comprise a thin snap-in ridge that functions to releasably lock the ladle head in a desired position within the ladle holder. Such additional securing elements for the ladle head can prevent the ladle head from inadvertently falling out of the ladle holder and can also serve to prevent the ladle handle from hanging down into the composite can.

[0195] The closure mechanism shown on the composite can 201 of FIGS. 1 and 2a having a top rim 223 directly attached to the inner surface of the body wall 205 and a lid component 231 comprising a lid 221 and a frame structure 230 provides a seal between the lid 221 and the tubular body 203. When the lid 221 is closed on the composite can 201, the upper edge of the top rim 223 can abut against the above-described sealing disk to form a seal between the top rim 223 and the lid 221.

[0196] In order to keep the lid 221 in the closed position fixed between the time of dispensing and the time of dispensing, the closing mechanism of the composite can 201 can further include a locking mechanism 245 as seen in FIGS. 2a and 3. The locking mechanism 245 can include a first mating locking element and a second mating locking element, for example, a female locking element such as a groove disposed on the lid 221 and a male locking element such as a rib disposed on a locking member 246 disposed on the frame structure 230. The locking member 246 is hingedly connected to the frame structure 230 by a live hinge 249 or the like integrally formed with the frame structure 230 and the locking member 246.

[0197] This type of locking mechanism 245 is closed by moving the locking member 246 above and inside the lid 221 until the locking elements are in a mating engagement position. The locking mechanism 245 is opened by pulling the locking member 246 until the connection between the locking elements is released and rotating the locking member 246 downward at the hinge 249. When the locking member 246 is in the closed position with the first locking element and the second locking element engaged with each other, the lid 221 and the frame structure 230 are firmly clamped together, whereby the top rim 223 is firmly sealed against the above-described sealing disk on the inner surface of the lid 221 or against a sealing ring or sealing surface disposed inside the lid 221.

[0198] As best shown in FIG. 3, the lid component 231 is provided with a lid component stacking step portion 251 and a can stacking step portion 252. As shown in the figure, the stacking step portions 251, 252 can extend across the entire locking member 246.

[0199] The lid component stacking step portion 251 is arranged to enable the lid components 231 to be stacked on top of each other to form a stack that can be loaded into the lid attachment unit. The can stacking step portion 252 is arranged to enable the composite cans 201 to be stacked on top of each other.

[0200] The snap-in gripping region 265 can be disposed within the lid 221 at the free end portion of the locking member 246 on the opposite side of the hinge 249. Thereby, easy access to the locking member 246 can be achieved, while the locking member 246 is protected from inadvertent release when in the closed position.

[0201] The composite can 201 as shown in FIGS. 2a and 3 can be manufactured and filled on the assembly line as shown in FIG. 1.

[0202] As described herein, the composite can disclosed herein is manufactured in the order of forming a tubular body, adding a top sealing member and a top rim to the tubular body, inverting the tubular body upside down, filling the tubular body with dry or wet articles through the bottom opening of the tubular body, closing the bottom opening of the tubular body, adding a bottom plate to the tubular body, rotating the sealed can so that the top sealing member is upward again, and finally adding a lid or lid component to the top end of the tubular body.

[0203] FIGS. 4-7 show equipment that can be used to add can components at the top sealing station 13, top rim adding station 14, sealing unit 6, and bottom plate adding station 22 of the assembly line 1 as shown in FIG. 1.

[0204] Referring to FIGS. 2a and 3, the bottom sealing member 215, bottom plate 217, top rim 223, and top sealing member 227 are examples of can components for which the equipment of FIGS. 4-7 can be used.

[0205] Referring to FIG. 4, a can sealing station or unit 401 that can be the sealing unit 6 of FIG. 1 is shown.

[0206] The intermediate can 403 is conveyed through the can sealing unit 401 in the traveling direction R. The conveying means 402 includes a supply mechanism 411 in the form of two supply screw members arranged on opposite sides of each of the intermediate cans 403 (only one of the supply screw members is visible in FIG. 4), a main conveyor member 413, a movable gripping mechanism 415, and an outlet conveyor member 419. The outlet conveyor member 419 is arranged downstream of the can sealing unit 401, and the stationary sliding plate 421 is arranged downstream of the outlet conveyor member 419 at the outlet of the can sealing unit 401. Further details of a useful conveying configuration are described in International Publication No. 2013 / 009226, which is hereby incorporated by reference.

[0207] The can sealing station 405' is located downstream of the supply mechanism 411, and the bottom plate addition station 405'' is located downstream of the can sealing station 405'. The movable gripping mechanism 415 moves the intermediate can 403 to the sealing station 405', where the bottom sealing member 427 is attached by welding inside the tubular body wall of the intermediate can 403 as shown in FIG. 8. Next, the intermediate can 403 is moved to the bottom plate addition station 405'', where the bottom plate 417 is added, for example, as shown in FIGS. 5 and 6. As shown in FIGS. 4 to 6, in order to increase the operating speed of the can sealing station 401, a plurality of bottom sealing members and the bottom plate 417 may be attached to a plurality of corresponding intermediate cans 403 simultaneously. In the illustrated embodiment, four bottom sealing members and four rims are attached to each intermediate can 403 simultaneously. Alternatively, the bottom sealing members, rims, or other can components disclosed herein may be attached simultaneously in any number other than four, for example, in groups of two, three, six, eight, or ten, or may be attached to the cans sequentially.

[0208] As shown in FIG. 1, the conveying means 402 and the can sealing station 401 can be accommodated within the external housings 20, 23. The external housings 20, 23 are adapted to protect the can sealing station 401 and / or to provide and maintain a protective gas atmosphere inside the can sealing station 401. The protective gas may be, for example, nitrogen, carbon dioxide, or a mixture of nitrogen and carbon dioxide.

[0209] As shown in FIG. 1, the degassing of the intermediate can can be carried out simultaneously with the filling of the intermediate can in the filling unit 4. Degassing can include supplying a protective gas to the flow of the material contained in the can during filling. The protective gas may be blown into the flow of the material before the material reaches the can. When the material is treated with the protective gas during filling, the intermediate can 403 is preferably conveyed to a can component applicator such as the can sealing station 401 disposed downstream of the filling unit 4 while maintaining a modified gas atmosphere, for example, by moving the can through a tunnel filled with the protective gas as shown by the covered conveyor 2c between the gas box 5 and the sealing unit 6 in FIG. 1. Alternatively, the filled intermediate can 403 can be introduced into a vacuum chamber to evacuate air, and then the can is subjected to a modified gas atmosphere and a bottom sealing member is added.

[0210] FIGS. 5 and 6 show an attachment station or unit 505 for attaching can components such as the bottom plate 517 to the intermediate can 503. The attachment station or unit 505 includes a holding device 523, a support device 525, a positioning device 528, and a transfer plate 529.

[0211] An example of the transfer plate 529 is shown in FIG. 7. The transfer plate 529 extends in a first direction x parallel to the running direction R of the can component applicator of which the attachment station or unit 505 forms part, and in a second direction y perpendicular to the first direction x. The transfer plate 529 has a cavity portion 531 with at least one through-transfer cavity 533, which is adapted to receive and hold the can component, in this case the bottom plate 517, while transferring the can component into alignment with the end of the intermediate can 503. The transfer cavity 533 has a first open area A1 and is sized and configured such that the can component can be fitted into and held therein during transfer into the intermediate can 503.

[0212] As a variant, particularly when the can component is a can component in sheet form, for example a top sealing member or a bottom sealing member, the transfer plate 529 may be omitted and the can component may be arranged directly on top of the holding device 523.

[0213] In order to fit and hold the can component in the transfer cavity 533, the shape of the transfer cavity 533 is made to correspond to the shape of the can component.

[0214] In the case of a can component that includes an edge portion that is folded to create a peripheral flange before or during insertion of the can component into the can, as in the case of a bottom sealing member or a top sealing member, the first open region A1 of the transfer cavity 533 can be made smaller than the surface area of the can component before folding. The area difference corresponds to the area of the portion of the can component that forms the peripheral flange. Such a folded flange can typically be band-shaped and can have a width in the range of 1 mm to 10 mm, for example, in the range of 2 mm to 5 mm. See FIG. 8. Thus, a folded peripheral flange on a sheet-shaped can component, such as a top sealing member or a bottom sealing member, can be created by pushing the can component through a transfer cavity 533 that has a cross-sectional area smaller than the can component and thereby forcibly folding the can component at the edge of the transfer cavity so that it is received within the first open region A1 of the transfer cavity.

[0215] The wall of the transfer cavity 533 can include a holding element 534 that is adapted to hold the can component within the transfer cavity 533. See FIG. 7. Such a holding element 534 is particularly useful for loop-shaped can components, such as a top rim, that do not cover the first open region A1 of the transfer cavity 533. If the can component is a sheet-shaped can component, the holding element 534 may be omitted.

[0216] In the embodiment shown in FIG. 7, there are four holding elements 534, each adapted to hold corresponding side portions of a loop-shaped can component having a substantially rectangular or square shape. In the illustrated embodiment, the holding elements 534 are arranged to hold the can component at the center of each side portion. It would be possible to use one, two, three, four or more such holding elements 534. The holding elements 534 can be made elastically compressible, for example due to material properties or by being biased by a spring. Alternatively or additionally, a can component such as a rim can be made elastically deformable by itself, for example due to material properties. The holding elements 534 can be utilized to compensate for tolerances regarding the dimensions of the can component and / or the transfer cavity 533. Further, the holding elements 534 may be used to temporarily press one or more side surfaces of the can component inwards, reducing the cross-section of the can component and thereby making it easier to insert into the intermediate can 503. This can eliminate or at least significantly reduce the risk of damaging the vulnerable carton edge of the tubular body of the intermediate can 503 during the insertion of a rim-type can component.

[0217] As shown in FIGS. 5, 6, and 7, the transfer plate 529 can include a cover portion 535 that is at least as large as, or substantially the same size as, the first open area A1 of the transfer cavity 533. The cover portion 535 is disposed adjacent to the cavity portion 531 as viewed from the second direction y. The cover portion 535 has a minimum extension y1 in the second direction y, which is at least 1.0 times, preferably at least 1.2 times, more preferably at least 1.4 times the maximum extension y2 in the second direction y of the area A1 of the transfer cavity 533. The use of the transfer plate having the cover portion 535 is advantageous for preventing excessive leakage of the protective gas from inside the can component applicator while the can component is disposed within the transfer cavity 533 and is being conveyed to be aligned with the intermediate can 503. If the can component is instead a component in sheet form, the can component can be taken out by a suction member and disposed in alignment with the opening of the intermediate can 503 into which the sheet-form can component is to be inserted. As described herein, the transfer plate 529 can be omitted and the sheet-form can component can be disposed directly on the holding device 523.

[0218] After being added to the intermediate can 503, the sheet-form can component covers the can opening and prevents gas from leaking through the intermediate can 503. When the can component applicator is operated without a protective atmosphere, or when some loss of the protective gas can be tolerated, a transfer plate without a cover portion can be used when adding the can component. Further, the attachment unit 505 can include an internal housing 547, as shown by the dashed-dotted line in FIGS. 5 and 6. The internal housing 547 is located inside the external housings 20, 23 as shown in FIG. 1 and is arranged to enhance protection against leakage of the protective gas from the space above the positioning cavity 537 of the holding device 523.

[0219] In order to facilitate the placement of can components into the transfer cavity 533 of the transfer plate 529, as shown in FIG. 7, a recess 536 can be provided. The recess 536 allows for space for gripping members 544a, 544b, 544c, 544d arranged to move the can components from the magazine 543 into the transfer cavity 533. See FIGS. 5 and 6. When the holding element 534 is provided on the transfer plate 529, the recess 536 is preferably positioned so as not to interfere with the holding element 534. Thus, the recess 536 may be located at a corner of the transfer cavity 533. Such gripping members 544a, 544b, 544c, 544d having their corresponding recesses 536 are particularly useful when the can components form a loop that includes an internal volume filled with a gas, such as air, like a bottom rim.

[0220] When the can component is a sealing member or a lid, the can component can instead be placed into the transfer cavity 533 by gripping means such as one or more suction cups. In such a case, the recess 536 may be omitted. However, suction cups are not suitable when the can component is loop-shaped such as a top rim.

[0221] In the illustrated embodiment, which may be the bottom plate addition station 22 of the assembly line 1 as shown in FIG. 1, there are four cavity portions 531 arranged in a row when viewed in the first direction x. Each cavity portion 531 includes its respective transfer cavity 533 and is arranged with its corresponding respective cover portion 535.

[0222] The holding device 523 holds the intermediate can 503 while a can component shown as a bottom plate 517 is attached to the intermediate can 503. The holding device 523 comprises at least one through positioning cavity 537 having a second open area A2 corresponding to the first open area A1 of the transfer cavity 533. The positioning cavity 537 is adapted to receive a portion of the intermediate can 503. When having a cover portion 535, the size and shape of the cover portion 535 of the transfer plate 529 are selected such that the cover portion 535 can cover or at least substantially cover the second open area A2 of the positioning cavity 537.

[0223] The support device 525 is arranged to support the intermediate can 503 and to position the intermediate can 503 within the holding device 523.

[0224] The positioning device 528 is arranged to position the can component within the intermediate can 503, as shown in FIGS. 5 and 6. Thus, the positioning device 528 is aligned with the positioning cavity 537 as seen in the vertical direction z. The positioning device 528 is vertically adjustable and allows the can component to be inserted into the intermediate can 503 to a desired pre-selectable attachment position. As described herein with reference to FIG. 8, the positioning device 528 can be radially expanded with respect to the positioning cavity 537 and press a vertically extending portion of the can component in a direction towards the wall of the positioning cavity 537, whereby the can component is pressed against the inside of the tubular wall of the intermediate can 503 disposed within the positioning cavity 537.

[0225] In the illustrated embodiment, the attachment unit 505 is arranged to process four intermediate cans 503 simultaneously. The transfer plate 529 comprises four cavity portions 531 arranged in a row as seen in the first direction x of the attachment unit 505. Correspondingly, the holding device 523 comprises four positioning cavities 537, and the support device 525 is adapted to support the four intermediate cans 503 and position the intermediate cans 503 within respective positioning cavities 537 of the holding device 523. In addition, the attachment unit 505 comprises four positioning devices 528 aligned with the positioning cavities 537 such that each positioning device 528 is associated with a respective positioning cavity 537. It should be understood that the attachment unit may be arranged to process any suitable number of intermediate cans simultaneously as described herein.

[0226] The transfer plate 529 is movable between a first position shown in FIG. 5 and a second position shown in FIG. 6. In the first position, the transfer plate 529 is moved in the y direction such that the transfer cavity 533 is shifted away from the holding device 525. In this position, the transfer plate 529 is arranged to receive can components within the transfer cavity 533. When the transfer plate 529 is provided with a cover portion 535 as shown in FIGS. 5-7, the cover portion 535 in the first position covers or substantially covers the second open region A2 of the positioning cavity 537 during the addition of can components within the transfer cavity 533 as shown in FIG. 5. Thereby, loss of protective gas through the positioning cavity 537 can be minimized or preferably eliminated.

[0227] In the second position, as shown in FIG. 6, the transfer plate 529 is moved in the y direction, whereby the transfer cavity 533 is aligned with the positioning cavity 537 of the holding device 523 and the positioning device 528 disposed above the positioning cavity 537. When the transfer plate 529 is in the second position, the positioning device 528 can push the can component located within the transfer cavity into the intermediate can. Can components such as the bottom plate 517 shown in FIGS. 5 and 6 pass through the transfer cavity 533 and are pushed from the transfer cavity 533 in the transfer plate 529 into the intermediate can 503 by downward movement of the can component in the z direction passing at least partially through the positioning cavity 537 of the holding device 523.

[0228] The holding device 523 can comprise a welding station or unit 539 as disclosed herein. The welding unit is preferably a high-frequency induction welding unit and is disposed around the positioning cavity 537. The welding station or unit 539 is adapted to weld the can component to the intermediate can 503 and includes a coil extending around the positioning cavity 537. As described herein, the positioning device 528 can be radially expanded in the positioning cavity 537 so that the can component can be pressed against the welding unit 539.

[0229] As shown in FIGS. 5 and 6, the bottom plate 517 or other can components can be placed within the transfer cavities 533 of the transfer plate 529 by an optional can component feeder 541 that includes at least one gripping station or unit 542. A stack of can components, such as the bottom plate 517, can be stored within a magazine 543. The number of stacks within the magazine 543 and the number of gripping units 542 correspond to the number of transfer cavities 533 within the transfer plate 529. The gripping unit 542 can grip a single can component, here the bottom plate 517, move it from an opening 545 within the magazine 543, and place it within the corresponding transfer cavity 533. As an example, four single can components are gripped simultaneously. The gripping unit 542 includes four gripping members 544a, 544b, 544c, 544d that grip the corners of the bottom plate 517. The positions of the gripping members 544a, 544b, 544c, 544d correspond to the positions of the depressions 536 in the transfer plate 529. Such gripping members 544a, 544b, 544c, 544d having their corresponding depressions 536 are particularly useful when the can component forms a loop, such as a top rim, rather than a sheet-like element such as a bottom sealing member, an internal sealing member, or a top sealing member.

[0230] FIG. 8 shows a positioning device 828 disclosed herein. The positioning device 828 can be used as the positioning device 528 of the attachment unit 505 as shown in FIGS. 5 and 6, or can be used for positioning a can component in any attachment unit used for attaching a can component inside a tubular can body. Thus, the positioning device can be used to place a can component within the tubular body regardless of the simultaneous use of a transfer plate.

[0231] FIG. 8 shows the top sealing member 827 in the process of being disposed within the intermediate can 803. As can be seen from FIG. 8, the top sealing member 827 has a cross-sectional area larger than the internal cross-sectional area of the intermediate can 803. When disposed within the intermediate can 803, the edge portion 833 of the top sealing member 827 is bent upwardly to conform to the inner surface of the can wall 805. The illustrated top sealing member 827 is a bendable member such as a laminate of plastic films, a plastic film, a paper sheet, a paper / plastic laminate, etc. Such a bendable member may not include a plastic material without departing from the present disclosure. The can components such as the top sealing member and the bottom sealing member may alternatively be pre-formed with a sealable edge portion extending perpendicular to the main plane of the can component. In this case, there is no need to bend the edge when inserting the can component into the tubular can body.

[0232] The positioning device 828 includes a base plate 849 including or consisting of a rigid material such as metal or composite material, and a plunger skirt 851 including an elastically deformable material, such as rubber or plastic. The plunger skirt 851 is located above the base plate 849 so as to at least partially cover the upper surface of the base plate 849, and its upper surface is on the opposite side of the bottom footprint surface 853 of the base plate 849.

[0233] The footprint surface 853 is configured to face the can component, here the top sealing member 827, during the addition of the can components in the intermediate can 803. The footprint surface 853 of the base plate 849 has a peripheral edge 855 that in the illustrated example has a substantially polygonal shape. However, it should be understood that the footprint surface can have any other suitable shape adapted to the cross-sectional shape of the composite can being manufactured. In the illustrated example, the substantially polygonal shape is a substantially square shape including four side edge portions connected by outwardly rounded corners. In the illustrated embodiment, each side edge portion is slightly curved inwardly. Thereby, the peripheral edge 855 of the footprint surface 853 of the base plate 849 having inwardly curved side edge portions does not deviate from the cross-sectional shape or footprint of the manufactured composite can. Alternatively, the base plate of the positioning device can have the same footprint as the footprint of the intermediate can 803 and have straight side edge portions between the curved corners.

[0234] It may be advantageous to dispose the curved side edge portion at least on the side of the base plate 849 that will face the sealing strip 814 covering the joint within the tubular body 805 during insertion of the can component. The sealing strip 814 locally thickens the tubular wall 805 of the intermediate can 803 and also constitutes a bending line where the tubular wall 805 tends to bend, deviating the tubular wall 805 from the desired flat or substantially flat shape. The slightly inwardly curved side edge portion of the peripheral edge of the footprint surface of the base plate allows the base plate to move along the joint without damaging the seal strip or the can body material when the positioning device 828 inserts the can component 827 into the intermediate can 803.

[0235] The plunger skirt 851 is deformable between a non-expanded state and an expanded state by relative movement with respect to the base plate 849.

[0236] In the non-expanded state of the plunger skirt 851, the shape of the outer contour of the plunger skirt 851 corresponds to the shape of the outer contour of the base plate 849. Therefore, in the non-expanded state, the plunger skirt 851 has the same or substantially the same footprint as the base plate 849.

[0237] Viewed with respect to the base plate 849, the outer periphery 861 of the plunger skirt 851 is located at or on the peripheral edge 855 of the base plate 849. Preferably, when the plunger skirt 851 is in the non-expanded state, the outer periphery 861 of the plunger skirt 851 coincides with the peripheral edge 855 of the footprint surface 853 of the base plate 849 or is located slightly inside the peripheral edge 855 of the footprint surface 853 of the base plate 849.

[0238] In the expanded state of the plunger skirt 851, the footprint defined by the outer periphery 861 of the plunger skirt 851 is larger than that in the non-expanded state of the plunger skirt 851.

[0239] During deformation to the expanded state, pressure is applied to the plunger skirt 851 from above. Thereby, the side edge portions of the plunger skirt 851 are stretched between the corners, whereby any curved side edge portions are made straight. By selecting the shape and material properties of the plunger skirt 851, a desired shape change can be obtained during deformation.

[0240] In the expanded state of the plunger skirt 851, the outer periphery 861 of the plunger skirt 851 is located at least partially outside the corresponding peripheral edge 855 of the base plate 849. By deforming the plunger skirt 851 to the expanded state, the plunger skirt can be brought into contact with the edge portion 833 of the top sealing member 827, and the edge portion 83 of the top sealing member 827 can be pressed against the inside of the body wall 805.

[0241] When the can component attachment unit includes a transfer plate 529 having a retaining element 534 disclosed herein that exerts an inward force on the can component, the plunger skirt 851 can contribute to radially pushing back the can component if the can component does not exhibit sufficient spring-back from the deformed configuration imparted to the can component by the retaining element 534.

[0242] The positioning unit shown in FIG. 8 includes a first piston 871 and a second piston 873 coaxial with the first piston 871. The pistons 871, 873 extend in an axial direction A that coincides with the vertical direction z of the attachment unit 505 (see FIGS. 5 and 6). The base plate 849 is attached to the end of the first piston 871 such that the footprint surface 853 is perpendicular to the axial direction A. The plunger skirt 851 is attached to the end of the second piston 873. The first piston 871 and the second piston 873 are configured to move in the axial direction A together as a single unit and independently of each other as separate elements.

[0243] During displacement of the positioning device 828 into the intermediate can 803, the plunger skirt 851 remains in a non-expanded state until the can component 827 moves to the attachment position. When the can component 827 reaches the attachment position, the end of the second piston 873 is brought closer to the end of the first piston 871, and the edge of the plunger skirt 851 is pressed radially outward to deform the plunger skirt 851 into an expanded state.

[0244] The outer periphery 861 of the plunger skirt 851 presses against the can component 827 against the inner side of the body wall 805 of the intermediate can 803 disposed within the positioning cavity. The edge portion of the outer periphery of the plunger skirt 851, which is arranged to contact the can component and exert pressure on the can component in the expanded state of the plunger skirt, can have a contact surface that is slightly inclined with respect to the vertical direction of the positioning device in the non-expanded state of the plunger skirt.

[0245] In order to further improve the contact between the can component at the corner and the can body material, the thickened corner can be disposed on the upper surface of the base plate, i.e., the surface opposite to the footprint surface of the base plate. The thickened corner forms a raised region on the upper surface of the base plate and functions to move the plunger skirt further outward, applying an increased pressure to the added can component and improving the contact between the can component and the tubular body. Thereby, the joint formed between the can component and the corner of the tubular can body can be improved. In particular, the increased pressure at the corner of the tubular body can help to form a tight seal between the body material and the sheet-like can component. The excess material present at the corner of the sheet-shaped can component such as the bottom sealing member or the top sealing member generally wrinkles at the corner of the can when the can component is bent and aligned with the tubular body wall. In such cases, the increased pressure generated at the corner of the tubular body compresses the wrinkles and contributes to the formation of a good functional bond such as heat welding between the body material and the sheet material within the can component. When using a heat welding process to bond the can component to the wall of the tubular can body, at least one, preferably both, of the can component and the tubular wall contain an amount of thermoplastic material sufficient to form a functional bond. However, as described herein, such a bond can be achieved without using plastic materials without departing from the present disclosure.

Claims

1. A container for holding a bulk solid, comprising: a tubular body that extends at least partially around the interior of the container and has a top end and a bottom end; at least one sealing member positioned within the interior of the container and spaced from each of the top end and the bottom end of the tubular body, the at least one sealing member being sealingly engageable with at least a portion of the tubular body; a resealable lid attached to the top end of the tubular body to form a closed top end of the container, the resealable lid comprising pulp fibers; a bottom plate attached to the bottom end of the tubular body to form a closed bottom end of the container, the bottom plate comprising pulp fibers; The container comprising the above components.

2. The container according to claim 1, wherein the bottom plate does not contain a plastic material.

3. The container according to claim 2, wherein the bottom plate defines an outward flange that engages with the bottom end of the tubular body.

4. The container according to claim 2, further comprising a rim attached to the top end of the tubular body above the sealing member such that the resealable lid contacts the rim.

5. The container according to claim 4, wherein the rim comprises pulp fibers and does not contain a plastic material.

6. The at least one sealing member is a top sealing member spaced from each of the top end of the tubular body and the bottom end of the tubular body, and the container further comprises a bottom sealing member positioned within the container and spaced from each of the top end of the tubular body, the bottom end of the tubular body, and the first sealing member. The method according to claim 4.

7. A method of forming a container for holding a bulk solid, comprising: obtaining a body blank; positioning the body blank so as to extend at least partially around the interior of the container to form a tubular body having a top end and a bottom end; positioning at least one sealing member within the interior of the container and spaced from each of the top end and the bottom end of the tubular body, the at least one sealing member being sealingly engageable with at least a portion of the tubular body; Attaching a resealable lid containing pulp fibers to the top end of the tubular body to form a closed top end of the container; Attaching a bottom plate containing pulp fibers to the bottom end of the tubular body to form a closed bottom end of the container, a method comprising. **Claim 8** The method according to claim 7, wherein the bottom plate does not contain a plastic material. **Claim 9** The method according to claim 8, wherein the bottom plate defines an outward flange, and attaching the bottom plate includes engaging the bottom end of the tubular body with the flange of the bottom plate. **Claim 10** The method according to claim 8, wherein attaching the resealable lid to the top end of the tubular body includes attaching a rim to the top end of the tubular body above the at least one sealing member such that the resealable lid contacts. **Claim 11** The method according to claim 10, wherein the rim contains pulp fibers and does not contain a plastic material. **Claim 12** The at least one sealing member is a top sealing member spaced from each of the top end of the tubular body and the bottom end of the tubular body, and the method further includes positioning a bottom sealing member within the container spaced from each of the top end of the tubular body, the bottom end of the tubular body, and the first sealing member, the bottom sealing member being sealingly engaged with the tubular body, the method according to claim 11. **Claim 13** Positioning the body blank at least partially extending around the interior of the container includes transferring the body blank to a body forming station, bending the body blank using the body forming station, and forming an intermediate container by joining two opposing edges of the body blank at an end-to-end joint using the body forming station, the at least one sealing member being a top sealing member, and positioning the top sealing member within the container includes transferring the intermediate container to a top sealing station and attaching the top sealing member to the tubular body using the top sealing station, the method according to claim 7. **Claim 14** transferring the intermediate container to a filling station and filling the intermediate container with bulk solid through the bottom end portion of the tubular body using the filling station to form a filled intermediate container, the method of claim 13 further comprising.

15. transferring the filled intermediate container to a bottom sealing station and removably attaching the bottom sealing member to the tubular body such that the bottom sealing member is spaced from the top sealing member, the method of claim 14 further comprising.

16. positioning the filled intermediate container on a conveyor and transferring the filled intermediate container to a lid attachment station, and attaching the reclosable lid includes attaching the reclosable lid to the top end portion of the tubular body using the lid attachment station, the method of claim 15 further comprising.

17. transferring the filled intermediate container to a top rim addition station and attaching the rim to the top end portion of the tubular body above the sealing member using the top rim addition station such that the reclosable lid is positioned in contact therewith, the method of claim 16 further comprising.

18. filling the intermediate can with bulk solid includes supplying a protective gas to the bulk solid, the method of claim 17 further comprising.

19. further comprising positioning a scoop between the top sealing member and the reclosable lid inside the container, the method of claim 18 further comprising.

20. an assembly line for forming a container for holding bulk solid, a supply section for a body blank, a sealing member, a reclosable lid, and a bottom plate, the bottom plate including a supply section containing pulp fibers, a body forming station for bending the body blank from the supply section of the body blank at least partially around the inside of the container, a sealing station for attaching the sealing member from the supply section of the sealing member to the tubular body inside the container, a filling station for filling the inside of the container with bulk solid through the bottom end portion of the tubular body, a bottom plate addition station for attaching the bottom plate from the supply section of the bottom plate to the bottom end portion of the tubular body to form a closed bottom end of the container, A lid attachment station that attaches the re-closable lid from the supply unit of the re-closable lid to the top end of the tubular body to form the closed top end of the container. A body plate addition station that attaches the bottom plate from the supply unit of the bottom plate to the bottom end of the tubular body to form the closed bottom end of the container. An assembly line comprising the above.

21. The assembly line according to claim 20, wherein the bottom plate of the supply unit of the bottom plate does not contain a plastic material.

22. The assembly line according to claim 21, wherein the re-closable lid of the supply unit of the re-closable lid contains pulp fibers.

23. The assembly line according to claim 20, further comprising a rim supply unit and a rim attachment station configured to add the rim from the rim supply unit to the top end of the tubular body.

24. The assembly line according to claim 23, wherein the rim of the rim supply unit contains pulp fibers and does not contain a plastic material.

25. The sealing member is a top sealing member, the sealing station is a top sealing station that attaches the top sealing member of the supply unit of the top sealing member to the tubular body inside the container, the assembly line further comprises a bottom sealing member supply unit and a bottom sealing station, and the bottom sealing station is configured to add the bottom sealing member of the supply unit of the bottom sealing member to the tubular body inside the container at a distance from the top sealing member.

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