container

Abstract

A container is provided having an outer shell and an inner pouch made from a paperboard material. The outer shell includes a sidewall and a bottom element, the sidewall including an elongated cylindrical body portion having a first larger diameter, an elongated cylindrical neck portion having a second smaller diameter, and a tapered or curved shoulder portion extending between the neck portion and the body portion. The inner pouch is secured to a fitment to form a pouch assembly and is supported within the outer shell by a fitment that engages the neck portion of the outer shell such that the inner pouch extends within the body portion of the outer shell. The sidewall is formed from a blank that is wrapped around a former during manufacture, the blank being formed from a flat sheet of paperboard and including a body panel that forms the overlapping cylindrical body portion of the outer shell and a plurality of neck panels that form the cylindrical neck portion of the outer shell.

Description

[Technical field]

[0001] The present invention relates to an apparatus for manufacturing a container and the container. In particular, the present invention relates to a container / bottle including a paperboard outer shell and an inner liner or pouch and an apparatus for manufacturing the same. [Background technology]

[0002] There is a general desire and need to reduce the amount of waste produced, and a drive to reuse as much as possible. One particular area that has received a lot of attention is food and drink packaging.

[0003] Traditionally, wine has been stored and sold in glass bottles. The glass used is relatively heavy, typically accounting for about 40% of the weight of a bottle filled with wine. This means that transportation costs are high. Furthermore, glass breaks relatively easily, for example when the bottle is dropped. The bottles typically risk breaking into sharp shards that can injure the consumer.

[0004] It is known to make bottles with a pulp-molded paperboard outer shell and a blow-molded inner plastic lining. These containers, although offering reduced weight compared to glass bottles, have a number of disadvantages. The shelf life of the wine in the bottle is reduced compared to glass bottles, and it is difficult to apply printing to the exterior of the bottle.

[0005] It is also known to produce bottles having an outer shell and an inner liner or pouch made of paperboard, where the shell is formed from a flat sheet of material that is pressed to form the three-dimensional shape of the shell. Such a bottle is disclosed in WO 2015 / 150794. By forming the bottle shell from a flat sheet of paperboard, the paperboard can be pre-printed prior to the manufacture of the bottle, thereby significantly improving the aesthetics of the bottle as compared to pulp-molded bottles.

[0006] Commercial considerations mean that it is desirable for any alternative bottle containing a paperboard shell to be able to be produced in a cost-effective manner as quickly, in similar volumes, and with the same reliability and consistency as existing glass bottles.

[0007] SUMMARY OF THE DISCLOSURE It is therefore an object of the present invention to provide a machine for producing containers / bottles and containers / bottles which can run reliably and at high speed. Summary of the Invention

[0008] A first aspect of the present disclosure provides an apparatus for use in the manufacture of a bottle, the bottle including an inner pouch and an outer shell made of paperboard, the shell being made from two sheet blanks, each including a body panel, a first neck panel and a second neck panel, the apparatus comprising: a former having a cavity for receiving the pouch; first and second clamping elements configured to fit the body panel around a body section of a former, each of the clamping elements including a partially cylindrical surface; a pair of inner neck press assemblies configured to fit the first neck panel around a neck section of a former, each of the inner neck press assemblies including a first partially cylindrical press surface and a second double curvature press surface; and a plurality of clamping units configured to fit the second neck panel around a neck section of a former, each clamping unit including a first curved press surface and a second flat press surface.

[0009] Preferably, the apparatus further includes a control device configured to cause the first and second clamping elements to conform the body panel around a former, simultaneously cause the neck press assembly to conform the first neck panel around the former, and simultaneously cause the multiple clamping units to conform the second neck panel around the former.

[0010] The blank may form the side walls of a shell that partially surrounds the pouch. In some implementations, it may be preferred that the pouch is fully enclosed, and in these embodiments, it may therefore be preferred to secure a bottom element to the side walls of the shell. Thus, the apparatus preferably further includes an assembly configured to secure a bottom element to the blank to form the bottom of the shell.

[0011] The shape of the sidewall formed by the blank and pouch may mean that it is necessary to offset a portion of the pouch relative to the sidewall in order to secure the base element to the sidewall. The apparatus may therefore include a mechanism for offsetting a portion of the pouch relative to a portion of the blank. The mechanism may include an expansion system configured to inflate the pouch. The mechanism may additionally include a member provided for applying a force to a portion of the inflated pouch.

[0012] To allow the flat-sheet paperboard blank to be more easily conformed around the former, a preferred embodiment of the apparatus includes an assembly for applying moisture to the blank. The assembly is preferably configured to apply a greater level of moisture to the first and second neck panels than to the body panel.

[0013] In a preferred method of forming a bottle, two sheet blanks are fitted around a former and glued together. Thus, in a preferred embodiment, the apparatus further includes an applicator configured to apply adhesive to a first surface of at least one blank. The adhesive is preferably applied to selective areas of the blank, and thus the applicator is preferably configured to apply adhesive in a predetermined two-dimensional pattern on the surface of the blank.

[0014] The apparatus may include a first heating element configured to apply heat to a first region of the adhesive. The first heating element may include an infrared heating element. Alternatively, the first heating element may be heated by a source of heat flow, e.g., hot air.

[0015] The apparatus may include a second heating element configured to apply heat to a second region of the adhesive. The second heating element may include an infrared heating element. Alternatively, the second heating element may be heated by a heat flow, e.g., a source of hot air.

[0016] Since the apparatus may be configured to sequentially form different portions of the blank around the former, it may be necessary to activate or reactivate adhesive applied to any portion of the blank. Furthermore, in embodiments in which the paperboard moisture content of the blank is increased prior to blank formation, it may be necessary to provide additional moisture to a portion of the blank during the blank forming process. Thus, the apparatus preferably includes an assembly for selectively increasing the moisture content of only a portion of the at least one blank. The assembly preferably includes a delivery nozzle for directing a combined stream of hot air and dry steam to a selected portion of the at least one blank. The assembly preferably further includes a shroud, sheath, or heat-resistant plate configured to prevent interaction between the combined stream of hot air and dry steam and a second portion of the at least one blank.

[0017] In a preferred embodiment, the pouch is secured to the fitment, with the pouch and fitment together forming a pouch assembly. The pouch assembly is preferably configured to hold and dispense liquid. During manufacture of the bottle, a portion of each of the first and second neck panels may be formed to fit around a portion of the fitment. Thus, in a preferred embodiment, the apparatus includes a stopper for insertion into the aperture of the fitment. The stopper is preferably cylindrical. The stopper is preferably configured to seat over the portion of the fitment.

[0018] A second aspect of the present disclosure provides an apparatus for use in the manufacture of a bottle, said bottle including an inner pouch and an outer shell made of paperboard, said shell being made from two sheet blanks, and said apparatus comprising: a former having a cavity for receiving the pouch; a first blank holder disposed on a first side of the former for holding a first of the two sheet blanks; a second blank holder disposed on a second side of the former for holding a second of the two sheet blanks; a first clamping element having a partially cylindrical clamping surface facing a first side of the former and movable along a first axis between a retracted position and a clamped position, the movement from the retracted position to the clamped position being in the former direction; a second clamping element having a partially cylindrical clamping surface facing a second side of the former and movable along the first axis between a retracted position and a clamped position, the movement from the retracted position to the clamped position being toward the former; and a pair of overlapping clamping elements, each movable along a second axis between a retracted position and a clamped position, transverse to the first axis, with movement from the retracted position to the clamped position being in the former direction.

[0019] The former is preferably a split former including two halves defining a cavity therebetween. The two halves of the former may be separated by a gap.

[0020] The former is preferably positioned between the first and second blank holders such that the plane of each of the first and second blank holders is substantially perpendicular to the plane of the gap between the two halves of the former.

[0021] In the clamping position, the first clamping element is configured to clamp a portion of a first one of the two sheet blanks between a clamping surface of the first clamping element and a portion of the former. In the clamping position, the second clamping element is configured to clamp a portion of a second one of the two sheet blanks between a clamping surface of the second clamping element and a portion of the former.

[0022] The overlapping clamping elements are preferably configured such that, in the clamping position, each of the overlapping clamping elements is disposed between a portion of the first clamping element and a portion of the second clamping element, and further configured such that, in the clamping position, each of the overlapping clamping elements is configured to apply a force to an overlap region between the two sheet blanks.

[0023] In a preferred embodiment, the apparatus further includes a heating element, preferably an infrared heating element, configured to apply heat to the adhesive area on the first surface of one of the blanks.

[0024] In some embodiments, the apparatus further includes a first infeed assembly for holding a first stack of two sheet blanks and a second infeed assembly for holding a second stack of two sheet blanks. The first transfer assembly is preferably provided for transferring one blank from the first infeed assembly to the first blank holder. The second transfer assembly is preferably provided for transferring one blank from the second infeed assembly to the second blank holder. Each of the first and second transfer assemblies preferably includes a separation element configured to separate one blank from the stack of blanks at each of the first and second infeed assemblies. The separation element may include a suction cup.

[0025] In embodiments in which the apparatus includes a heating element, the second transfer assembly is preferably configured to transfer a blank from the second feed assembly to a position adjacent an adjacent heating element and subsequently transfer the blank from the position adjacent the adjacent heating element to the second blank holder.

[0026] The apparatus preferably includes a controller configured to operate the first clamping element to move between a retracted position and a clamped position, the second clamping element to move between a retracted position and a clamped position, and the overlapping clamping element to move between a retracted position and a clamped position. Preferably, the controller is configured to move the first clamping element to its clamped position, subsequently move the second clamping element to its clamped position, and simultaneously move the overlapping clamping element to its clamped position.

[0027] In embodiments including first and second transfer assemblies, the controller may additionally be configured to operate the first transfer assembly to transfer one blank from the first feed assembly to the first blank holder and to operate the second transfer assembly to transfer one blank from the second feed assembly to the second blank holder.

[0028] In an embodiment additionally including a heating element, the controller may: i) operating a first transfer assembly to transfer one blank from the first infeed assembly to a first blank holder; ii) operating a second transfer assembly to transfer one blank from the second infeed assembly to a position adjacent the heating element; iii) operating the first clamping element to move the first clamping element to its clamping position; iv) operating a second transfer assembly to transfer the blank from adjacent the heating element to a second blank holder; v) operating the second clamping element to move the second clamping element to its clamping position; and vi) may be configured to manipulate the overlapping clamping element to move the overlapping clamping element to its clamping position.

[0029] Operations (i) and (ii) may be carried out in either order or simultaneously. Operations (iii) and (iv) may be carried out in either order or simultaneously.

[0030] A third aspect of the present disclosure provides an apparatus for use in the manufacture of a bottle, the bottle including an inner pouch and an outer shell made of paperboard, the shell being made from a sheet blank including a body panel, a first neck panel and a second neck panel, the apparatus comprising: a former having a cavity for receiving the pouch, the former including a body section, a neck section, and a shoulder section extending between the body section and the neck section; at least two neck press elements, each neck press element including a press surface facing and aligned with at least a portion of the neck section of the former, and each neck press element movable to a clamping position to clamp a portion of one of the neck panels between the neck press element and the neck section of the former; and At least two shoulder press elements, each including a press surface facing and aligned with at least a portion of the shoulder section of the former, and each shoulder press element movable to a clamping position to clamp a portion of one of the neck panels between the shoulder press element and the shoulder section of the former.

[0031] Preferably, the press surface of the shoulder press element is a curved press surface. Preferably, each of the neck press elements includes a curved press surface.

[0032] Preferably, the apparatus includes a pair of neck press elements disposed on opposite sides of the former, and a pair of shoulder press elements disposed on opposite sides of the former.

[0033] Preferably, the former body section is substantially cylindrical, the former neck section is substantially cylindrical, and the diameter of the former body section is greater than the diameter of the former neck section.

[0034] The apparatus preferably further includes a heating assembly. The heating assembly is configured to heat an area of ​​the first neck panel to activate the adhesive on a surface of the first neck panel. The heating assembly preferably includes an annular heating element. The heating element is preferably heated by a supply of a thermal fluid, preferably hot air. The heating element is preferably movable between a release position and an engagement position. Movement of the heating element from the release position to the engagement position includes movement of the heating element toward the former.

[0035] In a preferred embodiment, the inner pouch is secured to a fitment that includes a pair of lugs. Each of the first neck panels includes an aperture sized to receive one of the pair of lugs. During manufacture of the bottle, the first neck panels are formed such that the lugs protrude through the apertures to allow the fitment to engage the shell of the bottle.

[0036] In a preferred embodiment, to ensure precise alignment of the first neck panel and the lugs, the apparatus includes a pair of alignment fingers movable between a retracted position in which the ends of the alignment fingers are spaced from the former and an insertion position in which each alignment finger extends through an aperture in a respective first neck panel.

[0037] Each of the alignment fingers preferably includes an elongated member, the longitudinal axis of which is preferably aligned with a portion of the neck section of the former.

[0038] Each neck press element preferably includes a pair of arms extending substantially parallel to one another, a gap is preferably defined between the arms, and each neck press element may include two curved press surfaces, one provided at a distal end of each arm.

[0039] The distance between the arms, i.e. the width of the gap, is preferably slightly greater than the width of the aperture in the first neck panel such that when the neck press element is in the clamped position, the arms contact adjacent opposite areas of the aperture in the first neck panel.

[0040] In embodiments including alignment fingers, each alignment finger is preferably disposed in a gap between the arms of one of the respective neck press elements.

[0041] In a preferred embodiment, the apparatus further includes a pair of push rods, each of which is aligned with a portion of the shoulder section of the former, and each of which is movable between a retracted position and an extended position, and in the extended position, each of which applies a force to a respective first neck panel to deflect at least a portion of the first neck panel toward the neck section of the former.

[0042] Each of the push rods may be elongate. Each of the push rods may include an end face transverse to a longitudinal axis of the push rod. An angle between the plane of the end face and the longitudinal axis may be between 30° and 80°.

[0043] Each of the push rods may extend through an aperture in each of the shoulder press elements.

[0044] The curved press surface of each shoulder press element preferably includes an upper portion having a partially cylindrical shape with a first radius of curvature, and a lower portion having a partially cylindrical shape with a second radius of curvature, the second radius of curvature being greater than the first radius of curvature.

[0045] The curved press surface of each shoulder press element may further include a middle portion disposed between the upper and lower portions. The middle portion of the curved press surface preferably has a double curvature. The two planes of the main curvature are preferably perpendicular to each other. The lower, middle and upper portions preferably form a continuous press surface.

[0046] The apparatus preferably includes a controller configured to operate the pair of neck press elements to move the pair of neck press elements between the release position and the clamped position, and to operate the pair of shoulder press elements to move the pair of shoulder press elements between the release position and the clamped position.

[0047] In embodiments including a heating element, the controller is preferably configured to operate the heating element to move the heating element between the disengaged and engaged positions.

[0048] In embodiments including alignment fingers, the controller is preferably configured to manipulate the alignment fingers to move them between their retracted and inserted positions.

[0049] In embodiments including a push rod, the controller is preferably configured to operate the push rod to move the push rod between its retracted and extended positions.

[0050] In a preferred embodiment, the control device comprises: (i) operating the heating element to move the heating element to an engaged position; (ii) after a predetermined time, operating the heating element to move the heating element to a release position; (iii) manipulating the alignment fingers to move the alignment fingers to their insertion position; (iv) operating the push rods to move the push rods to their extended positions; (v) operating the pair of neck press elements to move the pair of neck press elements to a clamping position; and (vi) may be configured to operate the pair of shoulder press elements to move the pair of shoulder press elements to the clamping position.

[0051] Operations (v) and (vi) may be carried out in either order, or simultaneously.

[0052] A fourth aspect of the present disclosure provides an apparatus for use in the manufacture of a bottle, the bottle including an inner pouch and an outer shell made from a sheet blank including a body panel, a first neck panel and a second neck panel, the apparatus comprising: a former having a cavity for receiving the pouch, the former including a body section, a neck section, and a shoulder section extending between the body section and the neck section; and and a plurality of clamping units, each clamping unit including a curved press surface and a flat press surface, each clamping unit movable to a clamping position for clamping a first portion of one of the second neck panels between the curved press surface and a shoulder section of the former and for clamping a second portion of one of the second neck panels between the flat press surface and a neck section of the former.

[0053] Preferably, the clamping units are provided in a substantially circular array around the former.

[0054] The apparatus preferably includes between 8 and 16 clamping units. More preferably, the apparatus includes 14 clamping units. The clamping units are preferably spaced around the former.

[0055] Each of the clamping units preferably includes a shoulder press element including a curved press surface and a neck press element including a flat press surface, and the neck press element may additionally include a second curved press surface.

[0056] The neck press element is preferably pivotally connected to a shoulder press element, which is preferably pivotally connected to the support arm.

[0057] Each clamping unit preferably includes an actuator. The actuator is preferably arranged to move the neck press element relative to the shoulder press element about the pivotable connection. The actuator is further arranged to move the shoulder press element about the pivotable connection relative to the support arm. The actuator is preferably connected between the support arm and the neck press element. The actuator may be pivotally connected to the support arm. The actuator may be pivotally connected to the neck press element. The actuator is preferably a linear actuator.

[0058] The shoulder press element and the neck press element are preferably arranged such that movement of the clamping unit to the clamping position causes a curved press surface of the shoulder press element to apply a force to the second neck panel and subsequently a flat press surface of the neck press element to apply a force to the second neck panel.

[0059] The apparatus preferably further comprises at least two alignment plates, a first set of neck press elements or a first set of clamping units connected to a first alignment plate of said alignment plates, and a second set of neck press elements or a second set of clamping units connected to a second alignment plate of said alignment plates, said alignment plates being movable in a direction towards the former. Each alignment plate preferably comprises a radially inner curved surface, the radius of curvature of the radially inner curved surface being substantially the same as the radius of curvature of the neck section of the former.

[0060] A fifth aspect of the present disclosure provides an apparatus for use in the manufacture of a container, said container being made of paperboard and formed from at least two elements bonded together, and the apparatus comprising: a first inlet connected to a source of dry steam; a second inlet connected to a source of hot air; a mixing chamber in which the first inlet and the second inlet are fluidly connected such that the dry steam flow from the first inlet mixes with the hot air flow from the second inlet; a delivery nozzle fluidly connected to the mixing chamber and configured to direct a combined flow of the hot air and dry steam to at least a portion of one of the elements.

[0061] In a preferred embodiment, the first inlet is fluidly connected to a mixing chamber downstream of the second inlet.

[0062] The first inlet is preferably connected to a steam generator. A separator for removing condensate from the steam is preferably disposed between the steam generator and the first inlet. The separator preferably comprises a cyclone separator.

[0063] The delivery nozzle may include an end face or edge surrounding the aperture. The device may further include a sealing plate. In these embodiments, the delivery nozzle is preferably movable between a first position in which the delivery nozzle does not contact the sealing plate and a second position in which the end face or edge of the delivery nozzle contacts the sealing plate.

[0064] The apparatus preferably further includes a heating assembly adapted to apply heat to a portion of the delivery nozzle. The heating assembly is preferably located proximate or adjacent to the delivery nozzle. The heating assembly may include a heating zone or heater jacket surrounding a portion of the delivery nozzle.

[0065] The delivery nozzle preferably includes an outlet for the combined flow of hot air and dry steam.

[0066] In a preferred embodiment, the device includes a protective sheath arranged to prevent or inhibit interaction between the mixed flow of hot air and dry steam and at least one second portion of said element. The protective sheath may be connected to the delivery nozzle. The protective sheath may be disposed in an interior volume of the delivery nozzle. The protective sheath may be supported in the interior volume of the delivery nozzle to define an annular flow path around the protective sheath. The protective sheath preferably includes a tubular sidewall.

[0067] The apparatus preferably includes a diverter disposed downstream of the first inlet. The diverter is fluidly connected to the exhaust conduit. The diverter preferably has a delivery configuration and an exhaust configuration. In the delivery configuration, the dry steam flow from the first inlet mixes with the hot air flow in the mixing chamber and flows into the delivery nozzle. In the exhaust configuration, the dry steam flow from the first inlet is directed to flow through the exhaust conduit. In this manner, a continuous flow of dry steam enters the apparatus through the first inlet, and the diverter may be set in the delivery configuration when the dry steam is directed to the portion of the at least one element, and placed in the exhaust configuration to redirect the dry steam flow away from the delivery nozzle. The diverter may include a bypass valve.

[0068] A sixth aspect of the present disclosure is mixing the dry steam stream with the hot air stream; and directing the mixed stream to flow over a surface containing a layer of adhesive.

[0069] A seventh aspect of the present disclosure provides a method for inserting a bottom element into a tubular sidewall element of a container, the method comprising: forming a limiting protrusion on an inner surface of the sidewall element spaced from an end of the sidewall element; and inserting the base element into the tubular sidewall element until an edge region of the base element contacts the limiting projection.

[0070] In a preferred embodiment, the step of forming the limiting protrusion on the inner surface of the sidewall element includes applying a curable polymer composition to a portion of the inner surface. Preferably, the curable polymer composition is applied along a line extending circumferentially around the inner surface. The curable polymer composition may be applied in a continuous line. Alternatively, the curable polymer composition may be applied as a plurality of discrete dots or droplets. The curable polymer composition may be an adhesive.

[0071] In other embodiments, forming the limiting protrusion on the inner surface of the sidewall element may include embossing or recessing an area of ​​the sidewall element, hi other embodiments, forming the limiting protrusion on the inner surface of the sidewall element may include folding back a portion of the sidewall element.

[0072] An eighth aspect of the present disclosure provides an apparatus for use in the manufacture of a container having a base element and a tubular sidewall element, the apparatus including a nozzle configured to dispense a curable polymer composition along a line extending circumferentially around an inner surface of the tubular sidewall element.

[0073] The nozzle may be configured to dispense the curable polymer composition to apply the curable polymer composition in a continuous line. Alternatively, the nozzle may be configured to dispense the curable polymer composition to apply the curable polymer composition as a plurality of discrete dots or droplets. The curable polymer composition may be an adhesive.

[0074] The apparatus may further include an assembly for rotating the nozzle. Alternatively, the apparatus may further include an assembly for rotating the tubular sidewall element.

[0075] A ninth aspect of the present disclosure provides a sheet paperboard blank for forming a container, the blank including a body panel and a neck panel extending from the body panel, the neck panel having a moisture content greater than a moisture content of the body panel.

[0076] A tenth aspect of the present disclosure provides a method of treating a sheet paperboard blank to form a container, the method comprising: applying moisture to a body panel of the blank such that the moisture content of the body panel is at a first level; and applying moisture to the neck panel of the blank such that the moisture content of the body panel is at a second level, said second level being greater than said first level.

[0077] An eleventh aspect of the present disclosure provides an apparatus for treating a sheet paperboard blank to form a container, the apparatus including at least one nozzle configured to apply moisture to a body panel of the blank such that a moisture content of the body panel is raised to a first level, and to apply moisture to a neck panel of the blank such that a moisture content of the neck panel is raised to a second level, the second level being higher than the first level.

[0078] Preferred and / or optional features of each aspect and embodiment described above may be used alone or in any suitable combination in the other aspects and embodiments. [Brief description of the drawings]

[0079] Embodiments of the invention will now be further described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] FIG. 1 is a side view of a bottle including an outer paperboard shell and an inner pouch. [Diagram 2] FIG. 2 is a further side view of the bottle of FIG. 1, perpendicular to the view of FIG. [Diagram 3] FIG. 3 is a cross-sectional view taken along line III-III in FIG. [Figure 4] 4 and 5 illustrate an embodiment of a blank used to form the first and second sidewall elements of the outer shell of the bottle of FIG. [Diagram 5]4 and 5 illustrate an embodiment of a blank used to form the first and second sidewall elements of the outer shell of the bottle of FIG. [Figure 6] FIG. 6 shows a second sidewall element of a partially formed shell formed from the blank of FIG. [Figure 7] FIG. 7 illustrates the complete sidewall of the shell, including the body portion and the neck portion. [Figure 8] FIG. 8 is a schematic diagram of a machine for producing bottles according to a preferred embodiment of the present invention. [Figure 9] FIG. 9 is a perspective view of a first station (Station A) of a machine for producing bottles according to a preferred embodiment of the present invention. [Figure 10] 10 is an enlarged perspective view of the pouch insertion mechanism of the first station of FIG. [Figure 11] 11 is an enlarged perspective view of a pouch rail of the infeed assembly of the first station of FIG. 9; [Figure 12] FIG. 12 is a perspective view of a split former according to an embodiment of the present invention. [Figure 13] FIG. 13 is a perspective view of the split former of FIG. 12 showing the pouch assembly inserted between the body portions of the former in an open configuration. [Figure 14] FIG. 14 is a perspective view of the second station (Station B) of the machine for producing bottles according to a preferred embodiment of the present invention. [Figure 15] 15 is a cross-sectional view of the second station of FIG. 14 taken along a plane containing line XV-XV of FIG. [Figure 16] 16 is a cross-sectional view of a portion of the second station of FIG. 14, taken along a plane containing line XVI-XVI of FIG. [Figure 17] 17 is a cross-sectional view of a portion of a second plane of FIG. 14, taken at a plane containing line XVII-XVII of FIG. 14, showing the heating assembly of the second station. [Figure 18]18 is a further cross-sectional view of the heating assembly of FIG. [Figure 19] FIG. 19 is a cross-sectional view of a portion of the second station of FIG. 14, taken along a plane containing line XIX-XIX of FIG. [Figure 20] FIG. 20 is a perspective view of the third station (Station C) of the machine for producing bottles according to a preferred embodiment of the present invention. [Figure 21] FIG. 21 illustrates a portion of a first sidewall element of a partially formed shell showing the three neck panels of the sidewall element. [Figure 22] FIG. 22 illustrates the method step of pressing a central neck panel of a sidewall element to form part of the neck portion of the shell sidewall (the two sidewall elements are shown separated for clarity). [Diagram 23] FIG. 23 is a perspective view of a portion of the third station of FIG. 20 with some elements removed to show the alignment fingers of the third station. [Figure 24] FIG. 24 is a perspective view of a portion of the third station of FIG. 20, specifically showing the push rod of the third station. [Diagram 25] FIG. 25 is a perspective view of a portion of the third station of FIG. 20, specifically showing the press element of the third station in an open configuration. [Figure 26] 26 is a perspective view of a portion of the third station of FIG. 20, showing the press element of FIG. 25 in a closed configuration. [Figure 27] FIG. 27 is a first side view of the fourth station (Station D) of a machine for producing bottles according to a preferred embodiment of the present invention. [Figure 28] FIG. 28 is a second side view of the fourth station, orthogonal to the view of FIG. [Figure 29] FIG. 29 is a cross-sectional view taken along line XXIX-XXIX in FIG. [Diagram 30]FIG. 30 is a side view of the steam application assembly of the fourth station of FIG. 27, showing the steam application assembly in a raised position. [Diagram 31] FIG. 31 is a cross-sectional view taken along line XXXI-XXXI in FIG. [Diagram 32] FIG. 32 is a side plan view of the steam application assembly of FIG. 30, showing the steam application assembly in a lowered position. [Diagram 33] FIG. 33 is a cross-sectional view taken along line XXXIII-XXXIII in FIG. [Diagram 34] 34 is a perspective view of the second neck press assembly of the fourth station of FIG. 27; [Diagram 35] FIG. 35 is a side view of the second neck press assembly of FIG. [Diagram 36] FIG. 36 is a cross-sectional view taken along line XXXVI-XXXVI of FIG. [Figure 37] FIG. 37 illustrates the method step of pressing the outer neck panels of the sidewall elements to form the neck portion of the shell sidewall (the two sidewall elements are shown separated for clarity). [Figure 38] 38 is a perspective view of a portion of the second neck press assembly of FIG. 34; [Figure 39] FIG. 39 is a cross-sectional view taken along line XXXIX-XXXIX of FIG. [Diagram 40] FIG. 40 is a plan view of four matching units of the fifth station (Station E) of a machine for manufacturing bottles according to a preferred embodiment of the present invention. [Diagram 41] FIG. 41 is a perspective view of the molding unit of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0080] Figures 1 to 3 illustrate a container in the form of a bottle (2) comprising an outer shell (4) of paperboard or cardboard and an inner pouch (6).

[0081] The container or bottle (2) includes an outer shell (4) made of paperboard or paperboard material. The outer shell (4) is generally cylindrical and has an elongated cylindrical body portion (8) having a first, larger diameter, and an elongated cylindrical neck portion (10) having a second, smaller diameter. The neck portion (10) extends from a first end of the body portion (8), and a tapered or curved shoulder portion (12) of the shell (4) of the bottle (2) extends between the neck portion (10) and the body portion (8).

[0082] The inner pouch (6) is supported within the shell (4) by a fitment (14). The fitment (14) is secured to the pouch (6) and engages the neck portion (10) of the shell (4) such that the pouch (6) is partially suspended from or supported by the fitment (14) and extends downwardly into the body portion (8) of the shell (4). The lower end (7) of the pouch (6) is supported or rests on the bottom of the shell (4). The pouch (6) and fitment (14) together form a pouch assembly (16). The pouch (6) and fitment (14) are each preferably made of a plastic material. The pouch (6) may be a metallized pouch.

[0083] The shell (4) is formed from three separate elements that are joined together. The shell (4) includes a first sidewall element (18), a second sidewall element (20), and a third bottom element (22). The first and second sidewall elements (18, 20) each include a portion of the neck portion (10) of the shell (4) and a portion of the body portion (8) of the shell (4), as illustrated in FIG. 6. When the first and second sidewall elements (18, 20) are joined, a portion of the first sidewall element (18) overlaps a portion of the second sidewall element (20) to form a complete and continuous sidewall (24) of the shell (4), as illustrated in FIG. 7.

[0084] The base element (22) is formed from a circular disc of paperboard or paperboard and includes a flat central region (26) and a peripheral skirt portion (28) that extends entirely around the periphery of the central region (26). The skirt portion (28) includes a circular edge region that is pressed to extend at an angle relative to the flat central region (26). Thus, the first surface (27) of the base element (22) has a substantially concave shape.

[0085] The first, second and third elements (18, 20, 22) of the shell (4) are all made from flat sheets of 100% paperboard that are pressed to form the required three-dimensional shape.

[0086] The blanks (30, 32) used to form the first and second sidewall elements (18, 20) are shown in Figures 4 and 5, respectively. The first sidewall blank (30) is used to form the first sidewall element (18), and the second sidewall blank (32) is used to form the second sidewall element (20). Each of the first and second sidewall blanks (30, 32) includes a body panel or portion (34), a central neck panel or portion (36), and an outer neck panel or portion (38). In each of the sidewall blanks (30, 32), the central neck panel (36) and the outer neck panel (38) extend from a first end of the body panel (34), and a plurality of bottom tabs (35) extend from an opposite second end of the body panel (34).

[0087] The second sidewall blank (32) further includes a sidewall tab (33) and a neck tab (37). The sidewall tabs (33) extend from each side edge of the body panel (34). The neck tabs (37) extend from the outer edge of each outer neck panel (38).

[0088] 8 is a schematic diagram of a machine (40) for manufacturing containers, in accordance with a preferred embodiment of the present invention. The machine (40) is preferably configured to manufacture bottles, and more specifically, wine bottles. Thus, although the following description illustrates the machine (40) for use in manufacturing bottles, it will be understood that aspects of the machine may be employed to manufacture any suitable container.

[0089] At a first station (42, Station A) of the machine (40), the pouch assembly (16) is inserted between two halves of a separated former (94). The machine (40) preferably includes an infeed assembly (44) configured to store a plurality of pouch assemblies (16) and deliver them to the first station (42). At a second station (46, Station B) of the machine (40), two sidewall blanks (30, 32) are formed around the former (94) to create the body portion (8) of the shell (4). As noted above, the sidewall blanks (30, 32) used to form the complete sidewalls (24) of the shell (4) are different. Accordingly, the machine (40) preferably includes a first blank feed assembly (48) for feeding a first one of the sidewall blanks (30) to the second station (46), and a second blank feed assembly (50) for feeding a second one of the sidewall blanks (32) to the second station (46). At station B, the first sidewall blank (30) is wrapped around a first portion of the former (94), and the second sidewall blank (32) is then wrapped around a second portion of the former (94), such that an edge region of the second sidewall blank (32) overlaps an edge region of the first sidewall blank (30). The second sidewall blank (32) is secured to the first sidewall blank (30) by an adhesive.

[0090] At a third station (52, station C) of the machine (40), the central neck panels (36) of each of the two sidewall blanks (30, 32) are formed around a former (94). At a fourth station (54, station D) of the machine (40), the outer neck panels (38) of each of the two sidewall blanks (30, 32) are formed around the former (94) to create the neck portion (10) of the shell (4). It is desirable to activate the adhesive applied to the neck panels (38) of the blanks (30, 32) at this stage to bond the outer neck panels (38) to the central neck panel (36) and to each other. Thus, in a preferred embodiment, the machine (40) includes means (56) for activating or reactivating the adhesive disposed on the neck panels (38) of the blanks (30, 32). It is understood that in forming the neck panels (36, 38) about the former (94), both the neck region (10) and the shoulder region (12) of the shell (4) are formed.

[0091] At a fifth station (58, Station E) of the machine (40), the neck portion (10) and shoulder portion (12) of the shell (4) are hot pressed. At a sixth station (60, Station F) of the machine (40), the neck portion (10) and shoulder portion (12) of the shell (4) are cold pressed and the stopper (88) is removed from the fitment (14) of the pouch assembly (16).

[0092] At the seventh station (62, station G) of the machine (40), the side wall (24) of the shell (4) is removed from the former (94) and the pouch (6) is expanded in preparation for the insertion of the base element (22).

[0093] At an eighth station (64, station H) of the machine (40), a limiting feature (350) is applied to the inner surface (25) of the sidewall (24) adjacent the bottom tab (35).

[0094] At a ninth station (66, station I) of the machine (40), the bottom element (22) is inserted into the end of the side wall (24) and contacted with the limiting feature (350). The machine (40) preferably includes an infeed assembly (68) adapted to receive a number of bottom elements (22) and feed them to the ninth station (66).

[0095] At a tenth station (70, Station J) of the machine (40), adhesive is applied to the bottom tab (35). At an eleventh station (72, Station K) of the machine (40), the bottom tab (35) is folded and pressed into contact with the bottom element (22). At a twelfth station (74, Station L), the adhesive on the bottom tab (35) is activated and then the bottom region of the shell (4) is cold pressed to bond the bottom tab (35) to the bottom element (22).

[0096] Optionally, a length of tape or label may be wrapped around the neck portion (10) of the bottle (2) before the bottle (2) is removed from the machine (40). A final drying process is then applied to the bottle (2) to remove any excess moisture from the paperboard of the shell (4).

[0097] The operation of a preferred embodiment of the machine (40), and the preferred configuration of each of the stations (Stations A through L) will now be described.

[0098] In the following description, references to up, down, top, and bottom refer to the orientation of the bottles (2) such that the bottoms of the bottles (2) are at the bottommost and the necks of the bottles (2) are at the topmost, i.e., the bottles (2) stand on their bottoms. The vertical axis is that which extends between the tops of the bottles (2) at the ends of their necks and the bottoms of the bottles (2). It is understood that one or more stations of the machine (40) may be oriented such that the bottles (2) are not standing or oriented vertically, and references to up, down, top, and bottom should be interpreted accordingly.

[0099] Station A The first station (42) is shown in Figures 9-11 with an infeed assembly (44) coupled thereto. The infeed assembly (44) includes a rail (80) configured to support a plurality of pouch assemblies (16). Each pouch assembly (16) includes a pouch (6) that is attached to a fitment (14), as shown most clearly in Figure 13. Typically, the pouch (6) is heat welded to the lower portion (13) of the fitment (14). The upper portion (15) of the fitment (14) preferably includes threads for engagement with a tip or cap (not shown) of the bottle (2). It is understood that in a preferred embodiment, the pouch (6) is made of a flexible polymeric material and the fitment (14) is made of a rigid polymeric material. As illustrated in Figure 11, in this embodiment, the flanges of the upper portion (15) of the fitment (14) seat on and slide along the guide projections of the rail (80).

[0100] The feed mechanism (82) is configured to transfer one pouch assembly to an end region (84) of the rail (80) in preparation for insertion and transfer into a former (94).

[0101] A formed insert or stopper (88) is inserted into the open end of the top (15) of the fitment (14). The stopper (88, shown most clearly in FIG. 12) is generally cylindrical and includes a first portion (90) having a first diameter and an axially aligned second portion (92) having a second diameter, the second diameter being smaller than the first diameter. The stopper (88) engages the fitment (14) such that a portion of the first portion (90) of the stopper (88) seats in the top portion (15) of the fitment (14). An end of the first portion (90) of the stopper (88) protrudes beyond the end of the fitment (14). The second portion (92) of the stopper (88) extends through the bottom portion (13) of the fitment (14) and into the pouch (6).

[0102] Stopper 88 is configured to prevent or minimize distortion of fitment 14 during manufacture of bottle 2, as described below. Thus, the outer dimensions of stopper 88 are preferably substantially the same as or similar to the inner dimensions of fitment 14. Stopper 88 is preferably made of a suitable metallic material.

[0103] At a first station (42) of the machine (40), the pouch assembly (16) along with the stopper (88) is inserted into a former (94). As shown most clearly in Figures 12 and 13, the former (94) has two halves (96). Each half (96) of the former (94) includes a body section (98), a neck section (100), and a shoulder section (102) disposed between the body section (98) and the neck section (100). When the two halves (96) of the former (94) are in a closed configuration, the body sections (98) are adjacent to one another and the outer surfaces (104) of the pair of body sections (98) define a surface around which the body portion (8) of the outer shell (4) is formed. Similarly, when the two halves (96) of the former (94) are in the closed configuration, the neck sections (100) are adjacent to one another and the outer surfaces (106) of the pair of neck sections (100) define a surface around which the neck portion (10) of the outer shell (4) is formed. When the two halves (96) of the former (94) are in the closed configuration, the shoulder sections (102) are adjacent to one another and the outer surfaces (108) of the pair of shoulder sections (102) define a surface around which the shoulder portion (12) of the outer shell (4) is formed. Thus, the former (94) is effectively split vertically in two to allow for insertion of the pouch assembly (16) between the two halves (96) of the former (94).

[0104] The interior of the former (94) defines a cavity (110) for receiving at least a portion of the pouch assembly (16). Specifically, as illustrated in FIG. 13, when the two halves (96) of the former (94) are in an open configuration, the pouch assembly (16) is insertable between the two halves (96). The pouch assembly (16) is inserted such that the lower portion (13) of the fitment (14) is received in a portion of the cavity (110) between the two neck sections (100) and the pouch (6) is received in a portion of the cavity (110) between the two body sections (98) of the former (94). The upper portion (15) of the fitment (14) preferably protrudes from the former (94).

[0105] It is understood that the two halves (96) of the former (94) are movable between an open configuration and a closed configuration. Thus, in this embodiment, the first station (42) has a mechanism for moving the two halves (96) of the former (94) away from each other to an open configuration, and for moving the two halves (96) towards each other to a closed configuration. In the closed configuration, the two halves (96) of the former (94) may not contact each other, and there may still be a gap between the two halves (96). However, the gap in the closed configuration is smaller than the gap between the two halves (96) in the open configuration.

[0106] In this embodiment, each of the two halves (96) of the former (94) is mounted on a respective sliding plate (112) of the carriage assembly (114). The sliding plates (112) are arranged such that they are slidable in a first direction toward one another and in a second direction away from one another. The sliding plates (112) may be biased to move in a first direction such that the two halves (96) of the former (94) are biased to a closed configuration. In this embodiment, the first station (42) includes an opening mechanism (116) arranged to engage the carriage assembly (114) and move the sliding plate (112) in the second direction against a biasing force. The pouch assembly (16) is then inserted between the two halves (96) of the former (94) in the open configuration as described above.

[0107] After insertion of the pouch assembly (16), the opening mechanism (116) is disengaged from the carriage assembly (114). The biasing force then automatically moves the slider plate (112) in a first direction such that the two halves (96) of the former (94) move to a closed configuration around the pouch assembly (16). In the closed configuration, the neck sections (100) of the two halves (96) of the former (94) grip the lower portion (13) of the fitment (14). The neck sections (100) of the two halves (96) of the former (94) also or alternatively grip at least a portion of the second portion (92) of the stopper (88). A side edge of the pouch (6) may protrude through the gap between the two halves (96) of the former (94). This protrusion may assist in maintaining alignment of the pouch assembly with the former 94. Additionally, in embodiments in which the pouch assembly fitment includes lugs 17, the lugs 17 may also protrude through the gap.

[0108] To apply a biasing force to the sliding plate (112), the carriage assembly (114) includes a biasing element (118), which in this embodiment is preferably a spring (118).

[0109] With the former (94) remaining mounted on the carriage assembly (114), the carriage assembly (114) carries or transports the former (94) and pouch assembly (16) to the second station (46) of the machine (40). It will be appreciated that a biasing force is continuously applied to the two halves (96) of the former (94) such that the two halves (96) remain in a closed configuration and the pouch assembly (16) remains engaged with the former (94) during formation of the shell (4) of the bottle (2).

[0110] Station B The second station (46), along with its associated feed assembly (48, 50), is shown in Figures 14 to 19.

[0111] The first feed assembly (48) is configured to hold a number of first sidewall blanks (30) which form the first sidewall elements (18) of each of the shells (4) and feed them to the second station (46). The second feed assembly (50) is configured to hold a number of second sidewall blanks (32) which form the second sidewall elements (20) of each of the shells (4) and feed them to the second station (46).

[0112] Each of the first and second feed assemblies (48, 50) includes a holder (120, 122) and a biasing push plate (124, 126). In use, a stack of blanks (30, 32) is loaded into each respective holder (120, 122) with each blank (30, 32) vertically oriented. The associated push plates (124, 126) maintain the blanks (30, 32) in a vertical orientation and apply a force to the stack to urge the stack toward the leading edge of each respective holder (120, 122).

[0113] Moisture is applied to each of the blanks (30, 32) before the blanks (30, 32) are loaded into the holders (120, 122). Moisture is applied to the blanks (30, 32) so that the moisture soaks into the fibers of the paperboard. Preferably, the moisture is applied such that the neck panels (36, 38) of the blanks (30, 32) have a higher moisture content than the body panels (34) of the blanks (30, 32). Increasing the moisture content of the paperboard makes it easier to form. As explained below, conforming the neck panels (30, 32) to form the neck portion (10) and shoulder portion (12) of the shell (4) requires a higher degree of forming (areas having smaller radii of curvature and double curvature) than conforming the body panels (34) to form the body portion (8) of the shell (4). Each of the blanks (30, 32) includes a two-dimensional pattern of adhesive applied to a first surface of the blank (30, 32) that, once formed, becomes part of the interior surface of the shell (4) of the bottle (2). It will be appreciated that the adhesive applied to the blanks (30, 32) is not activated, i.e., it has no adhesive strength, such that the blanks (30, 32) do not adhere to one another in the stack while stored in the first and second feed assemblies.

[0114] In this embodiment, the second station (46) includes an upper infeed section (128), a lower infeed section (130), and a forming section (132). The first infeed assembly (48) is coupled to the lower infeed section (130). A first transfer assembly (134) extracts a blank (30) from the front of the stack of blanks (30) at the front edge of the holder (120). The first transfer assembly (134) is provided to transfer the blank (30) to the forming section (132). The first transfer assembly (134) may be of any suitable design, as described below, but should be configured to separate a single blank (30) from the stack of blanks (30) in the first infeed assembly (48) and then carry or transfer the blank (30) to another portion of the second station (46). In this embodiment, the first transfer assembly (134) includes a plate (136) having a number of suction cups (138) attached thereto. In use, the suction cups (138) engage the blank (30) and apply a force to the blank (30) to separate the blank (30) from the stack of blanks (30) in the first infeed assembly (48). The suction cups (138) then maintain or hold the blank (30) allowing it to move through the second station (46). The plate (136) of the first transfer assembly (134) is coupled to a suitable mechanism for moving the first transfer assembly (134) forward and backward relative to the infeed assembly (48) along a first axis in the lower infeed section (130) and along a second axis through the forming section (132). In this embodiment, the second axis is perpendicular to the first axis.

[0115] The second infeed assembly (50) is coupled to the upper infeed section (128). The second transfer assembly (140) extracts a blank (32) from the front of the stack of blanks (32) at the leading edge of the holder (122). The second transfer assembly (140) is provided to transfer the blank (32) to the forming section (132). The second transfer assembly (140) may be of any suitable design, but should be configured to separate a single blank (32) from the stack of blanks (32) in the second infeed assembly (50) and thereafter convey or transfer the blank (32) to another portion of the second station (46), as described below. In this embodiment, the second transfer assembly (140) includes a plate (142) having a plurality of suction cups (144) attached thereto. In use, the suction cups (144) engage the blanks (32) and apply a force to the blanks (32) to separate them from the stack of blanks (32) in the second infeed assembly (50). The suction cups (144) then maintain or hold the blanks (32) and allow them to move into the lower infeed section (130) and forming section (132) of the second station (46). The plate (142) of the second transfer assembly (140) is coupled to a suitable mechanism for moving the second transfer assembly (140) forward and backward relative to the second infeed assembly (50) along a first axis in the upper infeed section (128), as well as along a second axis through the lower infeed section (130) and forming section (132). In this embodiment, the second axis is perpendicular to the first axis.

[0116] During use of the machine (40), the carriage assembly (114) moves with the former (94) and pouch assembly (16) to the forming section (132) of the second station (46). The carriage assembly (114) is oriented so that the plane of the gap between the two halves (96) of the former (94) is substantially perpendicular to the plane of each of the blanks (30, 32) in the stack of blanks.

[0117] 15 and 16, the first transfer assembly (134) carries one first sidewall blank (30) to the forming section (132) and engages the blank (30) with a first blank holder (146) disposed on a first side of the former (94). The blank holder (146) holds the blank (32) so that the blank (32) is precisely aligned with the former (94), i.e., the body panel (34) is adjacent the body section (98) of the former (94) and the neck panels (36, 38) are adjacent the neck section (100) of the former (94). The plane of the blank holder (146) is substantially perpendicular to the plane of the gap between the two halves (96) of the former (94). The blank holder (146) preferably holds the blank (32) such that the central neck panel (36) is aligned with the cavity in the former (94).

[0118] The first clamping element (148) of the second station (46) includes a block having a concave, partially cylindrical clamping surface (150), as shown most clearly in FIG. 19. The radius of curvature of the clamping surface (150) is substantially the same as the radius of curvature of the outer surface (104) of the body section (98) of the former (94). In an initial retracted position, the first clamping element (148) is disposed on a first side of the first blank holder (146) such that the blank (30) is disposed between the first clamping element (148) and the former (94). The first clamping element (148) is configured to move in a first direction toward the former (94) to a clamping position such that the body panel (34) of the blank (30) is pressed and applied around the body section (98) of the former (94).

[0119] The circumferential width of the concave, partially cylindrical clamping surface (150) is less than the width of the first sidewall blank (30) between the opposing side edges of the body panel (34). Thus, when the first clamping element (148) presses the blank (30) against the former (94), a central section of the body panel (34) of the blank (30) is disposed and clamped between the first clamping element (148) and the former (94), and side edge regions of the body panel (34) of the blank (32) extend beyond the edges of the first clamping element (148).

[0120] The second transfer assembly (140) carries one second sidewall blank (32) to the heating device, as shown in Figures 17 and 18. In this embodiment, the heating device is located in the lower infeed section (130). The heating device (152) includes a pair of heating elements (154). In this embodiment, the heating elements (154) are infrared (IR) heating elements (154), preferably including IR lamps. When the second sidewall blank (32) engages the heating device (152), the blank (32) is positioned such that the sidewall tabs (33) of the blank (32) are adjacent the heating elements (154) and a first surface of the blank (32) faces the heating elements (154). The heating elements (154) apply sufficient heat to the blank (32) to activate the adhesive applied to each of the sidewall tabs (33). In a preferred embodiment, a strip of adhesive extends along each of the sidewall tabs (33) and each of the heating elements (154) is elongated to apply heat evenly along the sidewall tabs (33).

[0121] In a preferred embodiment of a method for manufacturing a bottle (2) using the machine (40), the second sidewall blank (32) is heated by a heating device (152) to activate the adhesive while the first clamping element (148) presses and fits the first sidewall blank (30) around the body section (98) of the former (94).

[0122] As soon as the adhesive on the sidewall tabs (33) of the second sidewall blank (32) is activated by the heating device (152), the second transport assembly (140) carries the second sidewall blank (32) to the forming section (132) and engages the blank (32) with a second blank holder (156) located on the second side of the former (94). The blank holder (156) holds the blank (32) so that it is precisely aligned with the former (94), i.e., with the body panel (34) adjacent the body section (98) of the former (94) and the neck panels (36, 38) adjacent the neck section (100) of the former (94). The plane of the blank holder (156) is substantially perpendicular to the plane of the gap between the two halves (96) of the former (94). The blank holder (156) preferably holds the blank (32) so that the central neck panel (36) is aligned with the cavity in the former (94).

[0123] The second clamping element (158) of the second station (46) includes a block having a concave, semi-cylindrical clamping surface (160). The radius of curvature of the clamping surface (160) is substantially the same as the radius of curvature of the outer surface (104) of the body section (98) of the former (94). In a start position, the second clamping element (158) is disposed on a first side of the second blank holder (156) such that the blank (32) is disposed between the second clamping element (158) and the former (94). The second clamping element (158) is configured to move in a first direction toward the former (94) to a clamping position such that the body panel (34) of the blank (32) is pressed to fit around the body section (98) of the former (94).

[0124] The circumferential width of the concave partially cylindrical clamping surface (160) is less than the width of the second sidewall blank (32). Thus, when the second clamping element (158) presses the blank (32) against the former (94), a central section of the body panel (34) of the blank (32) is disposed and clamped between the second clamping element (158) and the former (94), and the sidewall tabs (33) of the blank (32) extend beyond the edges of the second clamping element (158).

[0125] The second clamping element (158) fits the second sidewall blank (32) around the former (94) so ​​that the sidewall tabs (33) overlap the side edge regions of the body panel (34) of the first sidewall blank (30).

[0126] As shown most clearly in Figure 19, when the first and second clamping elements (148, 158) are in their respective clamping positions, there are gaps between the first and second clamping elements (148, 158) on opposite sides of the former (94). The overlapping portions of the first and second sidewall blanks (30, 32) are disposed in these gaps (162) such that at least one outer surface of each of the sidewall tabs (33) is exposed.

[0127] The second station (46) further includes a pair of overlapping clamping elements (164). Each overlapping clamping element (164) includes a curved clamping surface (166). The radius of curvature of the clamping surface (166) is substantially the same as the radius of curvature of the outer surface (104) of the body section (98) of the former (94). Further, the width of each of the overlapping clamping elements (164) is substantially the same as or slightly less than the width of each of the gaps (162) between the first and second clamping elements (148, 158) when they are in the clamped position.

[0128] After both blanks (30, 32) have been wrapped around former (94) as described above, overlapping clamp element (164) moves into position in gap (162) to press sidewall tab (33) against the side edge region of body panel (34) of first sidewall blank (30). Overlapping clamp element (164) is preferably configured to apply a force to sidewall tab (33) for a time sufficient to allow adhesion of sidewall tab (33) to the side edge region of first sidewall blank (30).

[0129] In this embodiment, the second station (46) therefore includes a mechanism (168) for moving the overlapping clamping elements (164) to the correct position relative to the first and second clamping elements (148, 158) to apply the required force to the blanks (30, 32). The mechanism (168) is configured to move each of the overlapping clamping elements (164) in a first direction toward the former (94) and in a second direction away from the former (94). In this manner, the mechanism (168) is configured to move each of the overlapping clamping elements (164) between an alignment position, in which the overlapping clamping elements (164) are aligned with the gaps (162) but do not apply force to the blanks (30, 32), and a clamping position, in which the overlapping clamping elements (164) apply force to the blanks (30, 32) to bond the sidewall tabs (33) to the side edge regions of the first sidewall blank (30).

[0130] The mechanism (168) may be further configured to move each of the overlapping clamp elements (164) to a third, retracted position. In this third position, illustrated in FIG. 19, the overlapping clamp elements (164) are not aligned with the gaps (162). In some embodiments, such as the illustrated embodiment, the carriage assembly (114) moves along direction E to enter the second station (46). Specifically, the carriage assembly (114) moves along direction E to position the former (94) between the first and second blank holders (146, 156). The direction E is preferably substantially parallel to the plane of each of the first and second blank holders (146, 156).

[0131] To allow this movement of the carriage assembly (114) and former (94) to the second station (46), the overlapping clamp elements (164) are preferably held in a third position such that the overlapping clamp elements (164) do not impede movement of the carriage assembly (114) and former (94). The mechanism (168) may thus be configured to move each of the overlapping clamp elements (164) between the retracted position and the aligned position in a third and fourth direction. The third and fourth directions may be substantially perpendicular to the first direction of movement of the overlapping clamp elements (164).

[0132] In some embodiments, a separate mechanism (168) may be coupled to each of the overlapping clamping elements (164). In these embodiments, the second station (46) may be configured such that both mechanisms (168) are actuated simultaneously.

[0133] After the sidewall tabs (33) are adhered to the side edge regions of the first sidewall blank (30), the first clamp element (148), the second clamp element (158), and the overlapping clamp element (164) are all moved away from the former (94) so ​​that they no longer apply force to the blanks (30, 32). The carriage assembly (114), along with the former (94), pouch assembly (16), and partially formed sidewall elements (18, 20), are then released and exit the second station (46) and move to the third station (52) of the machine (40).

[0134] Station C The third station (52) is shown in Figure 20. At the third station (52), the central neck panels (36) are fitted around a former (94) and a portion of each of the central neck panels (36) is adhered to the pouch assembly (16).

[0135] The third station (52) includes a heating assembly (170) and a pair of inner neck press assemblies (180). When the carriage assembly (114) enters the third station (52), the carriage assembly places the former (94) with the pouch assembly (16) and the partially formed sidewall elements (18, 20) between the two inner neck press assemblies (180). The heating assembly (170) is positioned above the former (94). In FIG. 20, the partially formed sidewall elements (18, 20) are represented by a cylindrical outline around the former (94). Details of the partially formed sidewall elements (18, 20), including the neck panels (36, 38), are not shown in FIG. 20. FIG. 21 illustrates one embodiment of the neck panels (36, 38) of the partially formed sidewall element (18).

[0136] The heating assembly (170) includes an annular heating element (172). The diameter of the radially inner surface of the heating element (172) is greater than the outer diameter of the fitment (14) or greater than the maximum dimension of the fitment (14) perpendicular to the longitudinal axis of the fitment (14). The maximum diameter of the radially outer surface (174) of the heating element (172) is substantially equal to or slightly less than the diameter of the cylindrical surface defined by the inner surfaces of the neck panels (36, 38) of the partially formed sidewall elements (18, 20). It will be appreciated that after the formation of the blank at the second station (46) described above, the neck panels (36, 38) have a tendency to bow slightly radially inward, so that the diameter of the opening defined by the upper edges of the neck panels (36, 38) is less than the inner diameter of the body panels (34) of the partially formed sidewall elements (18, 20). For this reason, the radially outer surface (174) of the heating element (172) is preferably tapered or sloped so that the diameter of the radially outer surface (174) is smaller toward the bottom or tip of the heating element (172).

[0137] The heating element (172) is preferably heated by a thermal fluid, in this embodiment by hot air. Thus, the heating assembly (170) preferably includes one or more pipes (176) for supplying hot air to the heating element (172).

[0138] The heating assembly (170) further includes a mechanism for moving the heating element (172) between a released position and an engaged position. In the released position, the heating element (172) is spaced apart from the former (94) and the partially formed sidewall elements (18, 20). In the engaged position, the heating element (172) is disposed between at least a portion of the central neck panel (36) of the partially formed sidewall elements (18, 20).

[0139] In a preferred embodiment, the heating element (172) is spaced apart from the former (94) in the released position. The mechanism is then configured to move the heating element (172) downwardly to a position between the central neck panels (36) of the partially formed sidewall elements (18, 20). As the heating element (172) moves to the engaged position, a tapered radially outer surface (174) of the heating element (172) may push radially outward against the neck panels (36, 38).

[0140] Heat from the heating element (172) activates or reactivates the adhesive applied to the first surface of each of the neck panels (36, 38) of the blanks (30, 32). In some embodiments, the heating element (172) may only activate the adhesive applied to the central neck panel (36). The heating element (172) remains in the engaged position for an appropriate dwell time sufficient to activate the adhesive. The heating element (172) then returns to the released position.

[0141] Following adhesive activation of the neck panels (36, 38), the two inner neck press assemblies (180) apply force to the central neck panel (36) to conform and shape the central neck panel (36) around the neck section (100) of the former (94) and a portion of the fitment (14). Specifically, the inner neck press assemblies (180) are configured to conform the central neck panel (36) such that the central neck panel (36) is formed as illustrated in FIG. 22. One embodiment of the inner neck press assemblies is shown in FIGS. 23-26 (180). Each inner neck press assembly (180) is provided to form a corresponding one of the central neck panels (36). As the carriage assembly (114) enters the third station (52), the former (94) is preferably oriented so that the central neck panel (36) of the partially formed sidewall elements (18, 20) is aligned with the inner neck press assembly (180).

[0142] In a preferred embodiment, the outer shell (4) of the bottle (2) is held in at least partial engagement or cooperation with the pouch assembly (16) using lugs (17) that project radially outward from the fitment (14). The fitment (14) preferably includes a pair of lugs (17) disposed on opposite sides of the fitment (14), i.e., the lugs (17) are directly opposite one another. The central neck panel (36) of each of the blanks (30, 32) preferably includes apertures (39). Each aperture (39) is sized and shaped to receive a respective one of the lugs (17). As will be further described below, when the central neck panel (36) is fitted around the former (94) and the fitment (14), each of the lugs (17) projects through a respective aperture (39). Thus, the fitment (14) is engaged with the shell (4) by the projection of the lugs (17) through the apertures (39). This prevents rotation of fitment 14 relative to shell 4, and therefore prevents rotation of pouch assembly 16. Engagement of lugs 17 through apertures 39 also supports pouch assembly 16 within shell 4.

[0143] In this embodiment, each of the inner neck press assemblies (180) includes an alignment pin or finger (182), as shown most clearly in FIG. 23. During operation of the inner neck press assembly (180), each of the alignment fingers (182) moves from an initial retracted position a distance from the former (94) to an insertion position where each of the alignment fingers (182) extends through a corresponding one of the apertures (39) in the central neck panels (36). In the insertion position, the alignment fingers (182) ensure that the central neck panel (36) is precisely aligned with the fitment (14), and in particular with respect to the lugs (17) of the fitment (14).

[0144] Each of the alignment fingers (182) preferably comprises an elongated member. Each alignment finger (182) extends along an axis of the member to a free end (184) of the alignment finger (182). The dimension of the member perpendicular to the axis is such that the alignment fingers (182) can extend through apertures (39) in the central neck panel (36). There is preferably minimal clearance between each member and the edges of the apertures (39) such that insertion of the alignment fingers (182) through the apertures (39) serves to accurately locate and align the central neck panel (36).

[0145] Each inner neck press assembly (180) includes a push rod (186), as best seen in FIGS. 24 and 25, for performing an initial fitting step in the method of fitting the central neck panel (36). Each push rod (186) includes an elongated member terminating in a free end (188). The axis of each push rod (186) is preferably parallel to, but offset from, the axis of the corresponding alignment finger (182). Specifically, the alignment finger (182) is aligned with an aperture (39) near the top edge of the central neck panel (36), while the push rod (186) is aligned with a portion of the shoulder section (102) of the former (94). The push rods (186) are oriented such that the axis of each push rod (186) extends radially toward the longitudinal axis of the former (94) and the free end (188) is radially inwardly most.

[0146] The free end (188) of each push rod (186) includes an end face (190). The end face (190) may be flat or curved. The face of the end face (190) is transverse to the axis of the push rod (186). Preferably, the angle between the face of the end face and said axis is acute and is less than 90°. Preferably, the angle between the face of the end face and the longitudinal axis may be between 30° and 80°. Thus, the push rod (186) may have the shape of a cylindrical wedge. The inclination of the end face (190) is oriented such that the vertically upper portion of the free end (188) of the push rod (186) is closer to the vertical axis of the former (94) than the vertically lower portion of the free end (188).

[0147] With the alignment fingers (182) remaining in the inserted position, the push rods (186) of each of the inner neck press assemblies (180) are moved from a retracted position to an extended position. In the retracted position, the push rods (186) are spaced from the formers (94) such that the free ends (188) are not engaged with the partially formed sidewall elements (18, 20). To move each of the push rods (186) from the retracted position to the extended position, the free ends (188) are moved radially inward in a direction parallel to the axis of the push rods (186). In the extended position, an end face (190) of each of the push rods (186) contacts a portion of a corresponding one of the central neck panels (36) in an area of ​​the neck panel (36) adjacent the shoulder section (102) of the formers (94). Movement of the push rod (186) to the extended position presses the central neck panel (36) toward the shoulder section (102) and neck section (100) of the former (94).

[0148] With the alignment fingers still in the inserted position (182), when the push rods (186) reach the extended position, a first portion of each of the central neck panels (36) is placed in contact with the shoulder section (102) of the former (94) and a second portion of each of the central neck panels (36) is placed in contact with the neck section (100) of the former (94).

[0149] As shown most clearly in FIG. 25, the inner neck press assembly (180) further includes press elements (192, 194) configured to press and fit the central neck panel (36) around the former (94) and fitment (14).

[0150] The upper neck press element (192) is aligned with the top of the central neck panel (36) near the top edge of the central neck panel (36). The upper press element (192) is configured to press and form the area of ​​the central neck panel (36) around the aperture (39). In this embodiment, the upper press element (192) includes a pair of arms (196).

[0151] Each arm (196) includes an elongated member terminating in a free end (198). Each pair of arms (196) extend parallel to but spaced apart from one another such that there is a gap (200) between the elongated members. In this embodiment, alignment fingers (182) extend through and along the gap (200) between arms (196).

[0152] The free end (198) of each arm (196) includes a curved press surface (202) and a finger (204) extending from the distal end of the arm (196). The curved press surfaces (202) of the pair of arms (196) are concave partial cylindrical. The radius of curvature of the curved press surface (202) is preferably substantially the same as or slightly greater than the radius of curvature of the exterior surface of the neck section (100) of the former (94). The press surfaces (202) of each arm (196) of the pair of arms face inwardly toward one another to define a contacting partial cylindrical surface.

[0153] Each pressing surface (202) extends along the depth of the arm (196) between an upper surface (206) and an opposing lower surface of the arm (196). The fingers (204a) of a first arm (196a) of the pair of arms extend from a distal end of the arm (196a) adjacent to the upper surface (206) of the arm (196a). The fingers (204a) do not extend along the entire depth of the arm (196a). Preferably, the fingers (204a) extend approximately halfway through the depth of the arm (196a). The fingers (204b) of a second arm (196b) of the pair of arms extend from a distal end of the arm (196b) adjacent to the lower surface of the arm (196b). Fingers 204b do not extend along the entire depth of arm 196b. Preferably, fingers 204b extend approximately halfway through the depth of arm 196b. An inner surface 208 of each of fingers 204 is continuous with press surface 202.

[0154] The third station (52) includes a pair of upper press elements (192), one on each side of the former (94). Thus, the third station (52) includes a first pair of arms (196) on a first side of the former (94) and a second pair of arms (196) on a second side of the former (94). The upper press elements (192) are preferably identical. Thus, with the upper press elements (192) positioned opposite each other, a first arm (196a) of a first one of the upper press elements (192) faces a second arm (196b) of a second one of the upper press elements (192).

[0155] Each of the upper press elements (192) is movable between a retracted position and an extended or clamped position. In the retracted position, the upper press elements (192) are spaced from the former (94) such that the arms (196) are not engaged with the partially formed sidewall elements (18, 20). In a later step in the process of forming the central neck panel (36), the upper press elements (192) are moved from the retracted position to the clamped position. The upper press elements (192) are moved in a direction parallel to the axis of the arms (196) such that the arms (196) move toward the neck section (100) of the former (94). During this movement, the press faces (202) and the inner surfaces (208) of the fingers (204) are in contact with an upper region of each of the central neck panels (36). The upper press elements (192) apply force against the central neck panel (36), and the press faces (202) and the inner surfaces (208) of the fingers (204) conform the central neck panel (36) around the neck section (100) of the former (94) and a portion of the fitment (14). In the clamped position, an upper region of each central neck panel (36) is clamped between the neck section (100) of the former (94) and a corresponding one of the upper press elements (192).

[0156] The fingers (204) extend around the former (94) such that a first finger (204a) of a first arm (196a) of a first of the upper press elements (192) of the upper press elements (192) overlaps with a second finger (204b) of a second arm (196b) of the second of the upper press elements (192) of the upper press elements (192), as shown in Figure 26. In this manner, the central neck panel (36) is formed completely around the neck section (100) of the former (94) and the fitment (14).

[0157] With the upper press element (192) in the clamped position, each lug (17) of the fitment (14) protrudes through a corresponding one of the apertures (39). At this point, the alignment fingers (182) may be returned to their initial retracted position.

[0158] It will be appreciated that during this forming of the central neck panel (36), at least a portion of the upper press element (192) presses against or clamps around a portion of the fitment (14). The stopper (88) extending through the fitment (14) prevents or minimizes distortion of the fitment (14) during this process. It is important that the shape of the fitment (14) be maintained so that any screw cap or other closure device of the bottle (2) to be secured to the fitment (14) can engage the fitment (14) and properly seal the bottle (2).

[0159] The third station (52) includes a pair of lower shoulder press elements (194), one on each side of the former (94). Each lower press element (194) is aligned with a lower portion of a respective central neck panel (36). Each lower press element (194) is configured to press and conform an area of ​​the central neck panel (36) around the neck section (100) and shoulder section (102) of the former (94).

[0160] In this embodiment, each lower press element (194) includes a press block or jaw plate (210) that includes a press surface (212). Each jaw plate (210) is movable between a release or retracted position and a clamped position. In the retracted position, the lower press element (194) is spaced from the former (94) such that the jaw plate (210) is not engaged with the partially formed sidewall elements (18, 20). In the clamped position, the press surface (212) of each of the jaw plates (210) is in contact with a respective central neck panel (36), and a lower portion of the central neck panel (36) is clamped between the jaw plate (210) and the former (94).

[0161] Each jaw plate (210) includes an upper section (214), a lower section (216), and a middle section (218) extending between the upper section (214) and the lower section (216). The upper section (214) of the jaw plate (210) terminates at an upper surface (220) of the jaw plate (210), and the lower section (216) terminates at a lower surface (222) of the jaw plate (210). An axis extending between the upper surface (220) and the lower surface (222) defines a vertical axis of the jaw plate (210).

[0162] The upper section (214) of the jaw plate (210) includes an upper portion (224) of a press surface (212). The upper portion (224) of the press surface (212) has a concave semi-cylindrical shape. The radius of curvature of the upper portion (224) of the press surface (212) is substantially the same as the radius of curvature of the outer surface of the neck section (100) of the former (94). The axis of curvature of the upper portion (224) of the press surface (212) is substantially vertical. The lower section (216) of the jaw plate (210) includes a lower portion (226) of a press surface (212). The lower portion (226) of the press surface (212) has a concave semi-cylindrical shape. The radius of curvature of the lower portion (226) of the press surface (212) is substantially the same as the radius of curvature of the outer surface of the body section (98) of the former (94). The axis of curvature of the lower portion (226) of the pressing surface (212) is substantially vertical.

[0163] The middle section (218) of the jaw plate (210) includes a middle portion (228) of the press surface (212). The middle portion (228) of the press surface (212) has a double curvature. The middle portion (228) of the press surface (212) has two planes of basic curvature, and these planes are perpendicular to each other. The first axis of curvature is substantially vertical, and the second axis of curvature is substantially horizontal. Thus, the middle portion (228) of the press surface (212) has a half-dome shape or a truncated half-dome shape.

[0164] The upper (224), lower (226), and middle (228) portions of the press surface (212) are continuous with one another to form a continuous press surface (212) of the jaw plate (210).

[0165] In use, the lower press element (194) is moved from the retracted position to the clamped position. The lower press element (194) is moved in a direction perpendicular to the vertical axis of the jaw plate (210), causing the jaw plate (210) to move toward the neck section (100) and shoulder section (102) of the former (94). During this movement, each of the press surfaces (212) contacts a respective one of the central neck panels (36). The lower press element (194) applies a force against the central neck panel (36), and the press surfaces (212) are configured to conform the central neck panel (36) around the neck section (100) and shoulder section (102) of the former (94). Specifically, the upper portion (224) of the press surface (212) conforms a portion of the central neck panel (36) around the neck section (100) of the former (94). In the clamped position, a portion of the central neck panel (36) is thus clamped between the upper section (214) of the jaw plate (210) and the neck section (100) of the former (94). The middle section (228) of the press surface (212) fits a portion of the central neck panel (36) around the shoulder section (102) of the former (94). In the clamped position, a portion of the central neck panel (36) is thus clamped between the middle section (218) of the jaw plate (210) and the shoulder section (102) of the former (94). The lower section (216) of the jaw plate (210) fits a proximal portion of the central neck panel (36) around the body section (98) of the former (94) and ensures a smooth transition and fit between the body portion (8) of the shell (4) and the shoulder portion (12) of the shell (4). In the clamped position, a portion of the central neck panel (36) is thus clamped between the lower section (216) of the jaw plate (210) and the body section (98) of the former (94).

[0166] It will be appreciated that the push rods (186) are aligned with a portion of the shoulder section (102) of the former (94) and that the lower press element (194) extends around and over a portion of the shoulder section (102) of the former (94). Thus, in a preferred embodiment, each of the jaw plates (210) of the lower press element (194) includes an aperture or hole (230) through which a corresponding one of the push rods (186) extends. The dimensions of each aperture (230) preferably provide clearance between the push rods (186) and the surface of the hole (230).

[0167] In a preferred embodiment, the upper portion (224) of the press surface (212) has a concave substantially semi-cylindrical shape, while the lower portion (226) of the press surface (212) has a concave partial cylindrical shape (i.e., less than a semi-cylindrical). Thus, when the lower press element (194) is in the clamped position, the upper section (214) of the jaw plate (210) extends around almost the entire circumference of the neck section (100) of the former (94), while the lower section (216) of the jaw plate (210) extends around only a portion of the circumference of the body section (98) of the former (94). This is because the lower section (216) of each of the jaw plates (210) is configured to press a proximal end region of the central neck panel (36) where the neck panel (36) abuts the body panel (34). Thus, the lower section (216) of each jaw plate (210) is limited to span only the width of the central neck panel (36) in this area, so that the jaw plate (210) does not apply force to the outer neck panels (38) on either side of the central neck panel (36). In contrast, the upper section (214) of each jaw plate (210) may extend between the outer neck panels (38) and may completely fit or wrap the central neck panel (36) around the neck section (100) of the former (94).

[0168] In a preferred method of forming the central neck panel (36), the heating elements (172) are moved from a released position to an engaged position to activate the adhesive applied to the central neck panel (36). The heating elements (172) then return to the released position. The alignment fingers (182) then move from their initial positions to an inserted position to properly align the central neck panel (36) with the lugs (17) of the fitment (14). With the alignment fingers (182) remaining in the inserted position, the push rods (186) are moved from a retracted position to an extended position to press the central neck panel (36) against the shoulder section (102) and neck section (100) of the former (94).

[0169] With both alignment fingers (182) in the insertion position and the push rod (186) in the extended position, the upper press element (192) and the lower press element (194) are moved from their respective retracted positions to their respective clamping positions to conform the central neck panel (36) around the neck section (100) and shoulder section (102) of the former (94). Thereafter, with the upper and lower press elements (192, 194) in the clamping positions, the alignment fingers (182) may be moved back to their initial positions, and the push rod (186) may be moved back to their retracted positions.

[0170] After a predetermined dwell time, the upper press element (192) and the lower press element (194) are returned to their respective retracted positions.

[0171] The carriage assembly (114) then moves the former (94), along with the partially formed bottle (2), to the fourth station (54).

[0172] Station D The fourth station (54) is shown in Figures 27-39 with an associated means (56) for activating the adhesive on the outer neck panels (38) of the blanks (30, 32). At the fourth station (54), the outer neck panels (38) are fitted around a former (94) and a portion of each of the outer neck panels (38) is adhered to the central neck panel (36).

[0173] In this embodiment, the means (56) for activating the adhesive disposed on the outer neck panel (38) of the blank (30, 32) includes a device (232) for delivering dry steam to the outer neck panel (38). This steam delivery device (232) is most clearly shown in Figures 30-33.

[0174] The steam delivery device (232) includes a hot air inlet (234), which in this embodiment is provided at a first end of an elongated delivery conduit (236). The hot air is preferably supplied by one or more hot air blowers (not shown). However, the stream of hot air may be supplied from any suitable system or device that is fluidly connected to the hot air inlet (234). The hot air supply preferably provides a continuous stream of hot air to the hot air inlet (234).

[0175] The steam delivery apparatus (232) further includes a steam inlet (238). In this embodiment, the steam inlet (238) is connected to an elongated delivery conduit (236) downstream of the hot air inlet (234). A constant flow of steam is preferably produced and supplied by a suitable steam generator (not shown). The steam produced by the steam generator is wet steam, and this wet steam is preferably supplied to a suitable separation device (not shown) for removing condensate or water droplets from the wet steam stream. The separation device may be in the form of a cyclonic separator. The output from the separation device is in the form of a stream or flow of dry steam. This continuous flow of dry steam is supplied to the steam inlet (238). The dry steam is preferably low pressure steam.

[0176] A stream of dry steam entering the steam delivery device (232) through the steam inlet (238) is mixed in a mixing chamber (240) with a stream or flow of hot air entering the steam delivery device (232) through the hot air inlet (234). In this embodiment, the mixing chamber (240) is a section of the elongated delivery conduit (236) downstream of the steam inlet (238).

[0177] The combined stream of hot air and dry steam then proceeds to a delivery nozzle or chamber (242). In this embodiment, the delivery nozzle (242) is disposed at the second end of the elongated delivery conduit (236). The delivery nozzle (242) comprises a length of tubing having an inner diameter or internal dimension that is larger than the outer diameter of the body portion (8) of the bottle (2). The distal end of the delivery nozzle (242) is open and includes an annular end face (244).

[0178] The delivery nozzle (242) further includes a protective sheath (246) disposed in an interior volume (248) of the delivery nozzle (242). In this embodiment, the protective sheath (246) includes a tubular sidewall (250) extending between first and second ends to define a cylindrical bore (252). A cap (254) is disposed on the first end of the sidewall (250), thereby closing the first end of the bore (252). The second end of the bore (252) is open. The inner diameter of the tubular sidewall (250) is greater than the maximum dimension of the fitment (14) perpendicular to the longitudinal axis of the fitment (14). The outer diameter of the tubular sidewall (250) is less than the outer diameter of the body section (98) of the former (94). Preferably, the outer diameter of the annular sidewall (250) is less than the outer diameter of the cylindrical surfaces defined by the inner surfaces of the neck panels (36, 38) of the partially formed sidewall elements (18, 20).

[0179] The protective sheath (246) is mounted in the interior volume (248) of the delivery nozzle (242) such that the longitudinal axis of the protective sheath (246) is substantially parallel to the longitudinal axis of the delivery nozzle (242). The outer diameter of the protective sheath (246) is smaller than the inner diameter of the delivery nozzle (242). In this manner, an annular flow passage is defined around the tubular sidewall (250) of the protective sheath (246) through the delivery nozzle (242).

[0180] In addition, protective sheath (246) is mounted in the interior volume (248) of delivery nozzle (242) such that the second end of protective sheath (246) is in a plane that is spaced from a plane containing end face (244) of delivery nozzle (242). A lower region of delivery nozzle (242) is defined between the second end of protective sheath (246) and the distal end of delivery nozzle (242).

[0181] The protective sheath (246) may be attached or suspended in the interior volume (248) of the delivery nozzle (242) using any suitable device. The protective sheath (246) is preferably attached or suspended such that there is no relative movement between the protective sheath (246) and the delivery nozzle (242).

[0182] A heating assembly (not shown) is preferably coupled to a portion of the delivery nozzle (242). The heating assembly is disposed at a distance from the distal end of the delivery nozzle (242) to apply heat to the portion of the delivery nozzle (242). The heat is preferably applied to a portion of the delivery nozzle (242) that coincides with at least a portion of the protective sheath (246), and in particular to a portion of the delivery nozzle (242) that coincides with a portion of the sidewall (250) of the protective sheath (246). The heating assembly is configured to provide heat to the delivery nozzle (242) to maintain the temperature of the interior volume of the delivery nozzle (242) at a predetermined operating temperature. The operating temperature may be selected to remove any remaining condensate larger than a certain droplet size from the mixed stream of hot air and dry steam. The heating assembly may include a heating zone that extends around the complete circumference of the delivery nozzle (242).

[0183] Delivery nozzle (242) further includes an outlet (256) disposed in a lower region of delivery nozzle (242). Outlet (256) is preferably disposed proximate or adjacent to the distal end of delivery nozzle (242). In this embodiment, outlet (256) is fluidly connected to a pressure balancing conduit or pipe (258).

[0184] The vapor delivery device (232) further includes a sealing plate. The sealing plate (260) is an annular plate that extends around the body portion (8) of the shell (4). In this embodiment, the sealing plate (260) extends around the body portion (8) of the shell (4) approximately midway between the bottom tab (35) of the shell (4) and the shoulder portion (12) of the shell (4). Thus, the inner radius of the annular sealing plate (260) is substantially the same as the outer radius of the body portion (8) of the shell (4). The outer radius of the annular sealing plate (260) is greater than the outer radius of the annular end face (244) of the delivery nozzle (242).

[0185] The closure plate (260) preferably includes two semi-annular portions, each of which is movable from a separated position to an abutting position, in which the distance between the two portions of the heat-resistant plate (260) is such that the former (94) and the associated shell (4) can be positioned between the two portions, and in the abutting position, the two portions abut against each other to form a complete annular closure plate (260) extending around the complete circumference of the body portion (8) of the shell (4).

[0186] In this embodiment, the closure plate 260 includes a support plate 262 and a heat-resistant layer 264. The heat-resistant layer 264 may include a foam material.

[0187] The diverter (266) is disposed downstream of the steam inlet (238). In this embodiment, the diverter includes a conduit (268) having a first end (270) disposed downstream of the steam inlet (238) within the elongated delivery conduit (236). A second end of the diverter conduit (236) is fluidly connected to a waste or exhaust conduit (272). The diverter conduit (236) may be continuous with the exhaust conduit (272). The diverter (266) has a delivery configuration and an exhaust configuration. In the delivery configuration, a stream of dry steam entering the steam delivery device (232) through the steam inlet (238) mixes with the hot air stream and travels through the steam delivery device (232) to the delivery nozzle (242).

[0188] In the exhaust configuration, the dry steam stream flows into a diverter conduit (268) and into an exhaust conduit (272). The dry steam stream then flows from the exhaust conduit (272) and is discharged to a waste tank or other suitable storage space (not shown).

[0189] In a preferred embodiment, the diverter (266) includes a valve, which may be a bypass valve. The valve may be a swivel valve.

[0190] In operation, the shell (4) and pouch assembly (16) associated with the former (94) are placed between two portions of the closure plate (260) that are in a separated position, and the two portions are then moved to an abutting position to enclose the shell (4).

[0191] Initially, the diverter (266) is in an exhaust configuration, and a constant flow of dry steam entering the steam delivery device (232) through the steam inlet (238) is exhausted to a waste tank. The delivery nozzle (242) is moved until the annular end face (244) of the delivery nozzle (242) contacts the surface of the sealing plate (260, and particularly the heat-resistant layer (264)). Preferably, the annular end face (244) contacts the surface of the sealing plate (260) to form a pressure seal between the delivery nozzle (242) and the sealing plate (260, and particularly the heat-resistant layer (264)).

[0192] With the delivery nozzle (242) against the closure plate (260), the protective sheath (246) is positioned about the fitment (14) of the pouch assembly (16). Because the outer neck panel (38) has not yet been formed, the outer neck panel (38) extends outside of the protective sheath (246). Specifically, the outer neck panel (38) is positioned within an annular passage defined about the tubular sidewall (250) of the protective sheath (246) through the delivery nozzle (242). The shoulder portion (102) of the former (94) is positioned at a lower region of the delivery nozzle (242) between the second end of the protective sheath (246) and the distal end of the delivery nozzle (242).

[0193] Once a pressure seal is established between the delivery nozzle (242) and the closure plate (260), the diverter (266) is moved to the delivery configuration. The stream of dry steam then mixes with the stream of hot air and flows to the delivery nozzle (242). The dry steam mixed with the hot air flows from the delivery nozzle (242) through an annular passage or gap defined around the tubular side wall (250) of the protective sheath (246). In this manner, the outer neck panel (38) of the shell (4) is exposed to the stream of dry steam and hot air.

[0194] The seal plate (260) substantially prevents the dry steam and hot air from leaking through the distal end of the delivery nozzle (242). The dry steam and hot air mixture then flows through the outlet (256) of the vapor delivery device (232). In this embodiment, the dry steam and hot air mixture flows through a pressure balancing conduit (258) and into a waste tank or other suitable storage space (not shown).

[0195] Exposing the outer neck panel (38) of the shell (4) to the dry steam and hot air stream acts both to reactivate the adhesive applied to the outer neck panel (38) and to increase the moisture content in the paperboard of the outer neck panel (38) so that the outer neck panel (38) is more easily formed.

[0196] The protective sheath 246 surrounds the fitment 14 to protect it from hot air and dry steam. The fitment 14 will typically be made of a polymeric material that may bend or distort if exposed to a mixture of hot air and dry steam. In addition, the center neck panels 36, already formed at the third station 52 of the machine 40, are also surrounded and protected by the protective sheath 246. This means that the center neck panels will not be exposed to the hot air and dry steam 36, but will retain their shape and remain adhered to the fitment 14.

[0197] After a sufficient predetermined steam application time, the diverter (266) is returned to the exhaust configuration. The delivery nozzle (242) is then moved away from the closure plate (260). The outer neck press mechanism (274) of the fourth station (54) then forms the outer neck panel (38) to fit around the former (94).

[0198] The outer neck press mechanism (274) of the fourth station (54) is most clearly shown in Figures 34-39.

[0199] The outer neck press mechanism (274) includes a plurality of clamping units (276) provided for pressing and fitting the outer neck panel (38) of the shell (4) around the neck section (100) of the former (94). As best seen in FIG. 36, the clamping units (276) are provided in a generally annular array about the former (94). As best seen in FIG. 38, each clamping unit (276) includes a support arm (278), a lower shoulder press element (280), an upper neck press element (282), and an actuator (284).

[0200] In this embodiment, the outer neck press mechanism (274) includes four sets of clamping units (276). Each set of clamping units (276) is attached to a support plate (286). Each support plate (286) has a quarter-circular shape and has a radially inner edge (288), a radially outer edge (290), and two edges (292). The radius of curvature of the radially inner edge (288) is substantially equal to the radius of curvature of the outer surface of the body portion (8) of the shell (4).

[0201] Each set of clamp units (276) includes a plurality of clamp units (276), three or four clamp units (276) in this embodiment. A support arm (278) of each of the clamp units (276) is attached to an upper surface of a respective support plate (286). The support arms (278) are spaced apart between two edges (292) around the circumference of the support plate (286). A first end (294) of each of the support arms (278) is disposed on the support plate (286), and the support arms (278) project radially outward from the support plate (286), such that a second end (296) of each of the support arms (278) has a distance from the support plate (286).

[0202] The lower press element (280) is pivotally fixed to the first end (294) of each support arm (278). Each lower press element (280) includes a press surface (298). In this embodiment, the lower press element (280) is in the form of a plate, and the press surface (298) is provided by an edge of the plate. The press surface (298) has a curved shape with a contour that substantially matches the contour of a first portion of the shoulder section (102) of the former (94). This first portion of the shoulder section (102) is preferably a lower portion of the shoulder section (102) and is adjacent to the body section (98) of the former (94).

[0203] The upper press element (282) is pivotally fixed to the lower press element (280). The axis of the pivot connection between the support arm (278) and the lower press element (280) is preferably parallel to, but spaced apart from, or offset from, the axis of the pivot connection between the upper press element (282) and the lower press element (280). The upper press element (282) includes a press surface (300). In this embodiment, the upper press element (282) is in the form of a plate, and the press surface (300) is provided by an edge of the plate. The press surface (300) includes a first substantially straight or flat portion (302) and a second curved portion (304). The curved portion (304) has a contour that substantially matches the profile of the second portion of the shoulder section (102) of the former (94). This second portion of the shoulder section (102) is preferably an upper portion of the shoulder section (102) and is adjacent to the neck section (100) of the former (94).

[0204] The actuator (284) is connected between the support arm (278) and the upper press element (282). In this embodiment, the actuator (284) is a linear actuator. A first end of the actuator (284) is pivotally connected to a second end of the support arm (278), and a second end of the actuator (284) is pivotally connected to the upper press element (282). An axis of the pivotal connection between the actuator (284) and the upper press element (282) is preferably parallel to but spaced apart or offset from an axis of the pivotal connection between the upper press element (282) and the lower press element (280). The actuator (284) is provided to move the upper and lower press elements (282, 280) between a first configuration and a second configuration.

[0205] The outer neck press mechanism (274) further includes a plurality of alignment plates (302). Each alignment plate (302) has a quarter-circular shape and has a radially inner edge (304), a radially outer edge (306), and two edges (308). In this embodiment, the radius of curvature of the radially inner edge (304) is substantially smaller than the radius of curvature of the radially outer edge (306). Furthermore, the radial distance between the radially inner edge (304) and the radially outer edge (306) of the alignment plate (302) is preferably greater than the radial distance between the radially inner edge (288) and the radially outer edge (290) of the support plate (286). The radius of curvature of the radially inner edge (304) is substantially equal to the radius of curvature of the outer surface of a portion of the fitment (14).

[0206] A link (310) extends between and connects each alignment plate (302) of the plurality of alignment plates (302) to a corresponding one of the plurality of support plates (286). In this embodiment, link (310) includes a rod member (312). A first end of rod member (312) is secured to alignment plate (302) near its radially outer edge (306) and a second end of rod member (312) is secured to support plate (286) near its radially outer edge (290).

[0207] In this embodiment, the coupling portion (310) further includes an upper arm (314) extending radially outward from the radially outer edge (306) of the alignment plate (302) and a lower arm (316) extending radially outward from the radially outer edge (290) of the support plate (286).

[0208] A main actuator is connected to each of the links (310) and is provided to move the alignment plate (302) and the support plate (286) between the released and engaged positions. In this embodiment, a first upper main actuator (318) is connected to the upper arm (314) and a second lower main actuator (320) is connected to the lower arm (316). The first and second main actuators (318, 320) act in cooperation to move the alignment plate (302) and the support plate (286) between the released and engaged positions.

[0209] Thus, each alignment plate (302) is coupled to an associated set of support plates (286) and clamp units (276). Each coupled set of alignment plates (302), support plates (286), and clamp units (276) forms an outer neck press assembly (322). In this embodiment, there are four outer neck press assemblies (322).

[0210] The first outer neck press assembly (322a) of the outer neck press assembly is pivotally connected to the second outer neck press assembly (322b) of the outer neck press assembly. In particular, the first alignment plate (302a) is pivotally connected to the second alignment plate (302b), and the first support plate (286a) is pivotally connected to the second support plate (286b). The pivotal connection between the first alignment plate (302a) and the second alignment plate (302b) is proximate to the first edge (308) of the first alignment plate (302a) and the second edge (308) of the second alignment plate (302b). Furthermore, the pivotal connection between the first alignment plate (302a) and the second alignment plate (302b) is proximate to the radially outer edge (306) of the alignment plate (302). Similarly, the pivot connection between the first support plate (286a) and the second support plate (286b) is proximate a first edge (292) of the first support plate (286a) and a second edge (292) of the second support plate (286b). Additionally, the pivot connection between the first support plate (286a) and the second support plate (286b) is proximate a radially outer edge (290) of the support plate (286).

[0211] In a similar manner, the third outer neck press assembly (322c) of the outer neck press assemblies is pivotally connected to the fourth outer neck press assembly (322d) of the outer neck press assemblies.

[0212] The pivotal connection between the first and second outer neck press assemblies (322a, 322b) facilitates movement of the first and second outer neck press assemblies (322a, 322b) between open and closed configurations upon actuation of the first and second main actuators (318, 320) connected to the outer neck press assemblies (322a, 322b). Similarly, the pivotal connection between the third and fourth outer neck press assemblies (322c, 322d) facilitates movement of the third and fourth outer neck press assemblies (322c, 322d) between open and closed configurations upon actuation of the third and fourth main actuators (318, 320) connected to the outer neck press assemblies (322c, 322d).

[0213] In the open configuration, the distance between the radially inner edges (304) of the pivotally connected alignment plates (302) is greater than the distance in the closed configuration. Similarly, in the open configuration, the distance between the radially inner edges (288) of the pivotally connected support plates (286) is greater than the distance in the closed configuration.

[0214] The first and second outer neck press assemblies (322a, 322b) together form a first outer neck press system (324), and the third and fourth outer neck press assemblies (322c, 322d) together form a second outer neck press system (326). In this embodiment, each of the first and second outer neck press assemblies (322a, 322b) includes seven clamp units (276). Three clamp units (276) are attached to the first and third support plates (286a, 286c), respectively, and four clamp units are attached to the second and fourth support plates (286b, 286d), respectively.

[0215] The outer neck press mechanism (274) further includes a drive mechanism (328) connected to each of the first and second outer neck press systems (324, 326). The drive mechanism (328) is configured to move the first and second outer neck press systems (324, 326) away from one another to a retracted position and towards one another to an engaged position.

[0216] In use, the carriage assembly (114) and former (94) are positioned between the two outer neck press systems (324, 326) with the outer neck press systems (324, 326) in the retracted position. The steam delivery device (232) is then actuated to apply hot air and dry steam to the outer neck panel (38) as described above. Following retraction or movement of the steam delivery device (232) away from the former (94), the drive mechanism (328) is actuated to move the first and second outer neck press systems (324, 326) toward the former (94) and into the engaged position.

[0217] The main actuators (318, 320) of the first outer neck press system (324) are actuated to move the first and second outer neck press assemblies (322a, 322b) to the closed configuration. The main actuators (318, 320) of the second outer neck press system (326) are actuated to move the third and fourth outer neck press assemblies (322c, 322d) to the closed configuration. Preferably, the main actuators (318, 320) of the first outer neck press system (324) and the main actuators (318, 320) of the second outer neck press system (326) are actuated simultaneously. In the closed configuration, the radially inner edge (304) of the alignment plate (302) abuts a portion of the fitment (14), and the radially inner edge (288) of the support plate (286) abuts the outer surface of the body portion (8) of the shell (4).

[0218] Contact between the alignment plate (302) and the fitment (14), and contact between the support plate (286) and the body portion (8) of the shell (4), maintain the former (94), shell (4), and fitment (14) in a fixed position and in precise alignment with the clamping unit (276). Stops (88) located on the fitment (14) prevent distortion of the fitment (14) due to the force applied against the fitment by the alignment plate (302).

[0219] With the first and second outer neck press systems (324, 326) in the engaged position and the first, second, third, and fourth outer neck press assemblies (322) in the closed configuration, a first edge (308) of the first alignment plate (302a) is adjacent to and substantially aligned with a second edge (308) of the second alignment plate (302b) and a first edge (308) of the second alignment plate (302b) is adjacent to and substantially aligned with a second edge (308) of the third alignment plate (302c). The first edge (308) of the third alignment plate (302c) is adjacent to and substantially aligned with the second edge (308) of the fourth alignment plate (302d), and the first edge (308) of the fourth alignment plate (302d) is adjacent to and substantially aligned with the second edge (308) of the first alignment plate (302a). In this manner, the alignment plates (302) extend around the entire periphery of the fitment (14). Similarly, with the first and second outer neck press systems (324, 326) in the engaged position and the first, second, third, and fourth outer neck press assemblies (322) in the closed configuration, a first edge (292) of the first support plate (286a) is adjacent to and substantially aligned with a second edge (292) of the second alignment plate (286b), and the first edge (292) of the second support plate (286b) is adjacent to and substantially aligned with a second edge (292) of the second alignment plate (286b). The first edge (292) of the third support plate (286c) is adjacent to and substantially aligned with the second edge (292) of the fourth alignment plate (286d), and the first edge (292) of the fourth support plate (286d) is adjacent to and substantially aligned with the second edge (292) of the first alignment plate (286a). In this manner, the support plates (286) extend around the entire periphery of the body portion (8) of the shell (4).

[0220] When the outer neck press assembly (322) is moved to the closed configuration, the clamping unit (276), and particularly the upper and lower press elements (282, 280), are in their first configuration in which the upper and lower press elements (282, 280) are not engaged with the outer neck panel (38) of the partially formed sidewall elements (18, 20).

[0221] The actuators (284) of each of the clamping units (276) are then actuated to move the upper and lower press elements (282, 280) to their second configuration. As the upper and lower press elements (282, 280) are moved toward their second configuration, the upper and lower press elements (282, 280) engage the outer neck panel (38) and press the outer neck panel (38) toward and against the shoulder portion (102) and neck portion (100) of the former (94). A clamp unit (276) attached to the first support plate (286a) engages with a first one of the outer neck panels (38) of the first sidewall element (18), a clamp unit (276) attached to the second support plate (286b) engages with a second one of the outer neck panels (38) of the first sidewall element (18), a clamp unit (276) attached to the third support plate (286c) engages with a first one of the outer neck panels (38) of the second sidewall element (20), and a clamp unit (276) attached to the fourth support plate (286d) engages with a second one of the outer neck panels (38) of the second sidewall element (20).

[0222] In the second configuration, a lower portion of the outer neck panel (38) is pressed or clamped between the lower press element (280) and the shoulder section (102) of the former (94), and an upper portion of the outer neck panel (38) is pressed or clamped between the upper press element (282) and the neck portion (100) of the former (94).

[0223] A pivotal connection between the actuator (284) and the upper and lower press elements (282, 280) is preferably provided such that during movement of the upper and lower press elements (282, 280) to the second configuration, the lower press element (280) applies a force against the first outer neck panel (38) to deform the outer neck panel (38) about the shoulder section (102) of the former (94) and toward the neck section (100). The upper press element (282) then applies a force against the outer neck panel (38) to conform the outer neck panel (38) to the entire periphery of the shoulder section (102) and neck section (100) of the former (94).

[0224] As illustrated in Figure 37, the outer neck panels (38) of each of the sidewall elements (18, 20) overlap the respective central neck panels (36). Additionally, the neck tabs (37) of the outer neck panel (38) of the second sidewall element (20) overlap the outer neck panel (38) of the first sidewall element (18, not shown in Figure 37) to form the complete neck portion (10) of the shell (4). Thus, the actuators (284) of each of the clamping units (276) may be actuated in a particular order rather than simultaneously. The actuation sequence of the actuator (284) may be such that the outer neck panel (38) of the first sidewall element (18) is pressed first, followed by the outer neck panel (38) of the second sidewall element (20) such that the neck tab (37) of the outer neck panel (38) of the second sidewall element (20) overlaps the outer neck panel (38) of the first sidewall element (18).

[0225] In this embodiment, when the outer neck press systems (324, 326) are in the engaged position and the outer neck press assembly (322) is in the closed configuration, the fourth clamp units (276d) attached to the second and fourth support plates (286b, 286d) are positioned directly opposite one another. Each of the fourth clamp units (276d) attached to the second and fourth support plates (286b, 286d) is also aligned with a respective edge of each of the outer neck panels (38) of the first sidewall element (18) and with each of the neck tabs (37) of the second sidewall element (20) when the outer neck panel (38) is being pressed to form the neck portion (10) of the shell (4).

[0226] Thus, in a preferred sequence of operations: (i) all of the clamp units (276) of the first outer neck press assembly (322a), all of the clamp units (276) of the second outer neck press assembly (322b), and the fourth clamp unit (276d) of the fourth outer neck press assembly (322d) are actuated and moved to the second configuration to press and conform the outer neck panel (38) of the first sidewall element (18) such that the outer neck panel (38) of the first sidewall element (18) is adhered to the central neck panel (36) of the first sidewall element (18); (ii) the fourth clamp unit (276d) of the second outer neck press assembly (322b) and the fourth clamp unit (276d) of the fourth outer neck press assembly (322d) are returned to the first configuration, while the clamp unit (276) of the first outer neck press assembly (322a) and the remaining three clamp units (276) of the second outer neck press assembly (322b) are maintained in the second configuration to continue applying a force against the outer neck panel (38) of the first sidewall element (18); (iii) all of the clamp units (276) of the third outer neck press assembly (322c), all of the clamp units (276) of the fourth outer neck press assembly (322d), and the fourth clamp unit (276dc) of the second outer neck press assembly (322d) are actuated and moved to the second configuration to press and conform the outer neck panel (38) of the second sidewall element (20) such that the outer neck panel (38) of the second sidewall element (20) is adhered to the overlapping area of ​​the central neck panel (36) of the second sidewall element (20) and the outer neck panel (38) of the first sidewall element (18).

[0227] Thus, in a first step of the sequence, the fourth clamping unit (276d) applies a force against the outer neck panel (38) of the first sidewall element (18), and in a third step of the sequence, the fourth clamping unit (276d) applies a force against the neck tabs (37) of the outer neck panel (38) of the second sidewall element (20) so that the neck tabs (37) overlap, are pressed and adhered to the outer neck panel (38) of the first sidewall element (18).

[0228] After a predetermined dwell time sufficient to allow bonding between the outer neck panel (38) and the central neck panel (36) to occur, the clamping units (276) return to the first configuration, the outer neck press assemblies (322) then return to their open configuration, and the outer neck press systems (324, 326) return to their retracted positions.

[0229] The carriage assembly (114) then moves the former (94), along with the partially formed bottle (2), to the fifth station (58).

[0230] Station E At a fifth station (58), the central neck panel (36) and the outer neck panels (38) are hot pressed. This results in further conformity of the central neck panel (36) and, in particular, the outer neck panel (38) to the final shape of the neck portion (10) of the bottle (2).

[0231] The fifth station (58) includes an adaptor assembly (330) that contains four adaptor units (332). The four adaptor units (332) are shown in Figures 40 and 41. In this embodiment, the adaptor units (332) are identical.

[0232] Each of the matching units (332) includes a matching block (334) that includes a matching surface (336). The matching surface (336) includes a first upper portion (338) having a concave partial cylindrical shape and a second lower portion (340) having a partial dome shape or a truncated partial dome shape. The second lower portion (340) extends from and is continuous with the first upper portion (338) to form the matching surface (336). The first upper portion (338) corresponds in shape and contour to the shape and contour of a portion of the neck portion (10) of the bottle (2). The second lower portion (340) corresponds in shape and contour to the shape and contour of a portion of the shoulder portion (12) of the bottle (2). The matching block (334) is preferably made of a suitable metal material.

[0233] The four adapting units (332) are arranged such that the first adapting unit (332a) faces the second adapting unit (332b) and the adapting surface (336a) of the first adapting unit (332a) faces the adapting surface (336b) of the second adapting unit (332b), and the third adapting unit (332c) faces the fourth adapting unit (332d) and the adapting surface (336c) of the third adapting unit (332c) faces the adapting surface (336d) of the fourth adapting unit (332d). The first top 338 of the mating surface 336a of the first mating unit 332a faces and is aligned with the first top 338 of the mating surface 336b of the second mating unit 332b. The first top 338 of the mating surface 336c of the third mating unit 332c faces and is aligned with the first top 338 of the mating surface 336d of the fourth mating unit 332d. The second lower portion (340) of the mating surface (336a) of the first mating unit (332a) faces the second lower portion (340) of the mating surface (336b) of the second mating unit (332b) and is aligned with the second lower portion (340) of the mating surface (336b) of the second mating unit (332b). The second lower portion (340) of the mating surface (336c) of the third mating unit (332c) faces the second lower portion (340) of the mating surface (336d) of the fourth mating unit (332d) and is aligned with the second lower portion (338) of the mating surface (336d) of the fourth mating unit (332d).

[0234] Each of the adapting units 332 further includes a mechanism 342 for moving the adapting block 334 between the retracted position and the extended position. In this embodiment, the mechanism 342 includes a linear actuator.

[0235] Each of the matching units (332) further includes a heating element (not shown) for heating the matching block (334).

[0236] In use, the matching blocks (334) are initially in their retracted positions so that there are gaps between each of the matching blocks (334). The carriage assembly (114) enters the fifth station (58) and positions the former (94, and associated partially formed shell (4)) centered between the four matching blocks (334). The matching blocks (334) are aligned with the neck panels (36, 38) of the shell (4).

[0237] The conforming blocks (334) are then moved to an extended position. In the extended position, each of the conforming blocks (334) contacts and applies a force to a portion of the shoulder and neck regions (12, 10) of the shell (4). Specifically, a first upper portion (338) of each conforming surface (336) contacts and applies a force to a portion of the neck region (10) of the shell (4), and a second lower portion (340) of each conforming surface (336) contacts and applies a force to a portion of the shoulder region (12) of the shell (4). In the extended position, adjacent conforming blocks (334) may contact each other to completely surround the neck and shoulder regions (10, 12) of the shell (4).

[0238] The heat and contour of the conforming surface (336) of the conforming block (334) further presses and conforms the neck panels (36 and 38) of the shell (4) to form the final shape of the neck region (10) of the bottle (2).

[0239] After a predetermined amount of time, the matching blocks (334) are returned to their retracted positions, and the carriage assembly (114) then moves the former (94) along with the partially formed bottle (2) to the sixth station (60).

[0240] Station F At a sixth station (60), the central neck panel (36) and the outer neck panels (38) are cold pressed, which ensures that the outer neck panels (38) are firmly adhered to the central neck panel (36) and that the central neck panel (36) and the outer neck panels (38) retain their final shape.

[0241] The sixth station (60) includes an adaption assembly that includes four adaption units. The four adaption units are substantially identical to the adaption units (332) of the fifth station (58), except that the four adaption units of the sixth station do not include heating elements. Thus, the adaption blocks of the four adaption units of the sixth station (60) remain at ambient temperature. All other characteristics of the four adaption units are substantially identical to the adaption units (332) of the fifth station (58).

[0242] In use, the matching blocks are initially in their retracted positions so that there are gaps between each of the matching blocks. The carriage assembly enters the sixth station (60) and positions the former (94) and associated partially formed shell (4) centrally between the four matching blocks. The matching blocks are aligned with the neck panels (36, 38) of the shell (4).

[0243] The conforming blocks are then moved to an extended position, in which each of the conforming blocks contacts and applies a force to a portion of the shoulder and neck regions (12, 10) of the shell (4). Specifically, a first, upper portion of a conforming surface of each conforming block contacts and applies a force to a portion of the neck region (10) of the shell (4), and a second, lower portion of each conforming surface contacts and applies a force to a portion of the shoulder region (12) of the shell (4). In the extended position, adjacent conforming blocks may contact each other to completely surround the neck and shoulder regions (10, 12) of the shell (4).

[0244] The neck panels (36, 38) are pressed together for a predetermined amount of time to ensure that the adhesive on the neck panels (36, 38) is cured and sufficient heat has been removed from the neck panels (36 and 38). After the predetermined amount of time, the mating blocks are returned to their retracted positions.

[0245] The sixth station (60) preferably further includes a mechanism for removing the stopper (88) from the fitment (14) of the pouch assembly (16). The mechanism may include means for gripping or otherwise engaging the stopper (88) and means for applying a force to the stopper (88) to remove it from the fitment (14).

[0246] The carriage assembly (114) then moves the former (94), along with the partially formed bottle (2), from the sixth station (60).

[0247] Station G At the seventh station (62) of the machine (40), the side wall (24) of the shell (4) is removed from the former (94) and prepared for the insertion of the base element (22).

[0248] In a preferred embodiment, the former (94) is separated and includes two halves (96) as described above. Furthermore, in the closed configuration, the two halves (96) of the former (94) preferably do not contact each other such that a gap remains between the two halves (96). Referring now to FIG. 12, the carriage assembly (114) may include a spacer member (344) disposed on a bottom (346) of the former (94). In the closed configuration, the two halves (96) of the former (94) contact the spacer member (344) such that the spacer member (344) is disposed in a space between the two halves (96) and maintains and defines the width of the space in the closed configuration.

[0249] To remove the fully formed sidewalls 24 of the shell 4 from the former 94, the spacer members 344 are preferably movable relative to the former 94 to a removal position. In the removal position, the spacer members 344 no longer maintain a spacing between the two halves 96 of the former 94. The two halves 96 of the former 94 are preferably biased (e.g., using the biasing element 118) to move toward one another, thereby decreasing the spacing between the two halves 96. The movement of the two halves 96 of the former 94 toward one another creates a gap between the outer surface of the former 94 and the inner surface of the sidewalls 24. The sidewalls 24 can then be slid or pulled out of the former 94.

[0250] It will be appreciated that following removal of the stopper (88) at the sixth station (60), the neck sections (100) of the two halves (96) of the former (94) are free to move toward one another to an ejection position. This movement to the ejection position may result in a small deformation of the lower portion (13) of the fitment (14), which deformation is preferably elastic, such that the lower portion (13) of the fitment (14) returns to its original shape following removal of the side wall (24) and pouch assembly (16) from the former (94).

[0251] The seventh station (62) further includes an apparatus for inflating the pouch (6). Preferably, a nozzle is inserted into the fitment (14) and air is supplied to the nozzle to inflate the pouch (6). In other embodiments, another suitable gas, such as an inert gas, may be supplied to the nozzle to inflate the pouch (6).

[0252] The expansion of pouch (6) causes a decrease in the distance between the end of pouch (6) farthest from fitment (14) (the lower end of pouch (6)) and fitment (14). Thus, the lower end of pouch (6) moves within side wall (24) and away from bottom tab (35) in a direction toward fitment (14). In this manner, a lower region of inner surface (25) of side wall (24) adjacent and adjacent to bottom tab (35) is exposed.

[0253] Station H The eighth station (64) preferably includes a mechanism for flaring the bottom tabs (35). The mechanism is preferably configured such that each of the bottom tabs (35) is pressed or forced into a flared position in which the bottom tabs (35) extend radially outwardly from the body panel (34) at an angle from the body panel (34). Flaring the bottom tabs (35) in this manner allows the bottom element (22) to be more easily inserted into the ends of the side walls (24).

[0254] The eighth station (64) preferably further includes an apparatus for applying a limiting feature (350) to the inner surface (25) of the sidewall (24) adjacent the bottom tab (35). In this embodiment, the limiting feature (350) includes a line of adhesive that extends circumferentially around a lower region of the inner surface (25) of the sidewall (24) proximal to but at a distance from the bottom tab (35). Thus, the apparatus includes an applicator for applying the line of adhesive. The apparatus may include a mechanism for rotating the applicator while the sidewall (24) remains stationary, or alternatively, the apparatus may include a mechanism for rotating the sidewall (24) while the applicator remains in a fixed position.

[0255] The line of adhesive dries or hardens to form a substantially rigid protrusion extending inwardly from the inner surface (25) of the sidewall (24). The line of adhesive does not have to extend completely around the circumference of the sidewall (24).

[0256] In other embodiments, the limiting feature (350) may be of any suitable type that provides a substantially rigid protrusion extending inwardly from the inner surface (25) of the sidewall (24). For example, in some embodiments, a line of a hardenable composition other than an adhesive may be applied to the inner surface (25) of the sidewall (24). The composition may be a suitable polymeric composition. In other embodiments, the adhesive or other composition may be applied as a series of discrete beads or lines that extend circumferentially around the inner surface (25) of the sidewall (24).

[0257] In further embodiments, the limiting feature (350) may be provided by embossing or recessing an area of ​​the side wall (24), or the limiting feature (350) may be provided by folding over a portion of the side wall (24). Importantly, the limiting feature (350) provides a substantially rigid protrusion extending inwardly from the inner surface (25) of the side wall (24) to limit insertion of the bottom element (22) into the lower end of the side wall (24), as will be further described below.

[0258] Station I At a ninth station (66) of the machine (40), the bottom element (22) is inserted into the end of the side wall (24).

[0259] In this embodiment, a plurality of bottom elements (22) are held in an in-feed assembly (68) associated with the ninth station (66). The in-feed assembly (68) includes a mechanism for feeding a single bottom element (22) to the ninth station (66) when needed.

[0260] In a preferred embodiment, each of the base elements (22) is preformed to include a flat central region (26) and a peripheral skirt portion (28) that extends completely around the circumference of the central region (26).

[0261] The ninth station (66) includes an apparatus for positioning the base element (22) against the ends of the side walls (24) and inserting the base element (22) into the opening defined by the ends of the side walls (24). The base element (22) is inserted such that the first surface (27) of the base element (22) faces away from the neck portion (10) of the shell (4).

[0262] The bottom element (22) is inserted until the skirt portion (28) of the bottom element contacts or abuts the limiting feature (350), which thus ensures that the bottom element (22) is in the correct position relative to the bottom tab (35) for the subsequent molding process.

[0263] Station J The tenth station (70) includes an apparatus for applying adhesive to each of the bottom tabs (35) of the side walls (24). In this embodiment, a bead or spot of adhesive (352) is applied to each bottom tab (35).

[0264] When adhesive is applied to the bottom tab 35, there is an obvious advantage to applying the same adhesive to the inner surface 25 of the side wall 24 as that used to form the limiting features 350. It is desirable if the adhesive that forms the limiting features 350 cures or dries quickly. Thus, the same adhesive applied to the bottom tab 35 also dries or sets quickly.

[0265] Station K An eleventh station (72) of the machine (40) includes an apparatus for folding the bottom tabs (35) back into contact with the skirt portion (28) of the bottom element (22). The apparatus may include a plurality of fingers configured to fold each of the bottom tabs (35). In other embodiments, the apparatus may include an annular element provided for engaging an outer surface of the bottom tabs (35). The annular element may be provided for folding the bottom tabs (35) radially inward to reduce their diameter.

[0266] In a further embodiment, eleventh station (72) may include a mandrel or former having a contoured surface such that when bottom tab (35) is placed in contact with the surface, the shape of the surface causes bottom tab (35) to fold inwardly.

[0267] During this process of folding and forming the bottom tab (35), the adhesive applied to the bottom tab (35) preferably does not tack or provides only limited adhesion.

[0268] Station L Twelfth station (74) of machine (40) preferably includes a heating element configured to activate or reactivate the adhesive on bottom tab (35). The heating element may be annular or circumferential. The twelfth station (74) further includes a press block containing a press surface. The press surface has a shape corresponding to the shape of the first surface (27) of the bottom element (22). The press surface thus includes a central planar region and an edge region extending around the periphery of the central region. The edge region extends at an angle from the flat central region. The press block is preferably made of a suitable metallic material.

[0269] In some embodiments, the press block is at ambient temperature. In other embodiments, the twelfth station (74) includes means for cooling the press block to a temperature below ambient temperature.

[0270] In a preferred embodiment of the method for manufacturing a bottle (2) using machine (40), the shell (4) of the bottle (2) is positioned against a press surface, specifically, the shell is positioned so that the bottom tab (35) is against the press surface.

[0271] A force is applied to the bottom tab (35) by the press block to hold the bottom tab (35) against the skirt portion (28) of the bottom element (22). The force is applied to the bottom tab (35) for a predetermined length of time sufficient to ensure that the adhesive on the bottom tab (35) cures.

[0272] The shell (4) of the bottle (2) is now completely formed.

[0273] In an optional further step in the process of manufacturing the bottle 2, a label is wrapped around the neck 10 of the bottle 2. The label preferably surrounds and covers at least a portion of the neck panels 36, 38. The label may be in the form of a paper label with an adhesive layer or in the form of a length of tape.

[0274] The finished bottles (2) may then be removed from the machine (40).

[0275] The bottles (2) may undergo a further drying step to remove excess moisture from the paperboard shells (4). Thus, the bottles (2) may pass through a heater station containing heating elements. The heater station may be in the form of a heater tunnel through which the bottles (2) are conveyed.

[0276] Additionally, a cap or other closure device may be attached to fitment (14). In a preferred embodiment, top (15) of fitment (14) includes threads for engagement with a screw cap of bottle (2).

[0277] In the preceding description, each of stations A through L of machine 40 has been described as a separate station. However, it will be appreciated that in some embodiments, the processes or method steps of one or more stations may be combined into one station. Alternatively, the method steps or processes described above for one station may be provided by one or more stations in other embodiments.

[0278] Machine 40 may include one or more controllers configured to operate one or more stations of machine 40. Machine 40 may include one controller configured to centrally coordinate and control the operation of all stations. In other embodiments, each station of the machine may include a separate controller.

[0279] While in the above descriptions and embodiments, the bottle shell includes sidewalls formed from two blanks, in other embodiments, the sidewalls are formed from a single blank that is wrapped around the former with one overlap. The single blank includes multiple neck panels extending from a single body panel. The single blank may include six neck panels extending from the body panel such that the neck panels assume the configurations described above when the blank is wrapped around the former. In still further embodiments, the shell sidewalls may be formed from more than two blanks, each blank preferably including at least two neck panels.

[0280] Other modifications and variations not expressly disclosed above may be contemplated without departing from the scope of the invention as defined in the appended claims.

Claims

1. A container comprising: an outer shell made of a paperboard material, the outer shell including a sidewall and a bottom element, the sidewall including an elongated cylindrical body portion having a first larger diameter, an elongated cylindrical neck portion having a second smaller diameter, and a tapered or curved shoulder portion extending between the neck portion and the body portion; an inner pouch secured to a fitment to form a pouch assembly, the inner pouch supported within the outer shell by the fitment engaging the neck portion of the outer shell such that the inner pouch extends into the body portion of the outer shell; The sidewalls are formed from a single blank that is wrapped around a former during manufacture, the blank being formed from a flat sheet of paperboard and including a single overlapping body panel that forms a cylindrical body portion of the outer shell, and a plurality of neck panels extending from the body panel that form the cylindrical neck portion of the outer shell. A container characterized by:

2. The container of claim 1 , wherein the container is a bottle.

3. 3. A container according to claim 1 or 2, wherein the inner pouch is made of a plastic material.

4. The container of any one of claims 1 to 3, wherein the pouch assembly is retained in engagement with the outer shell by lugs projecting radially outwardly from the fitment.

5. 5. The container of claim 4, wherein the fitment includes a pair of lugs disposed on opposite sides of the fitment, each of the lugs projecting through an aperture in a respective one of the neck panels.

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