Expandable press plunger, attachment unit for attaching a container element to a container body, and method for sealing a packaging container

Abstract

A radially expandable plunger (2) having an axis a1 extending in an axial direction (A) perpendicular to the radial direction (R) has a base plate (8) and first and second tools (9, 10) movable axially relative to each other. The first tool has an inclined plane (15) disposed with a first end (15') axially closer to the base plate than a second end (15''). Each inclined plane of the first tool inclines away from the axis a1 from the first end to the second end. The second tool includes an inclined plane (16) corresponding to the inclined plane of the first tool. Each inclined plane of the second tool has a first end axially farther from the base plate than the second end. Each inclined plane of the second tool inclines toward the axis from the first end to the second end. Each inclined plane of the first tool contacts and applies pressure to a corresponding inclined plane of the second tool when the plunger is in a radially expanded state. A mounting unit for mounting a container sealing element to a container body and a method for mounting a container sealing element to a container body are also disclosed.

Description

[Technical Field]

[0001] The present disclosure relates to a radially expandable press plunger having a plunger axis extending in an axial direction perpendicular to the radial direction. The press plunger includes a base plate, a first expansion tool, and a second expansion tool. The first expansion tool and the second expansion tool are axially movable relative to each other. The base plate has a bottom surface and a top surface opposite the bottom surface, the top surface facing the first expansion tool in the axial direction. The second expansion tool has upper and lower ends, and includes an expansion tool sidewall extending from the upper end to the lower end and having inner and outer surfaces. The expansion tool sidewall includes a periphery at the lower end of the second expansion tool, and the periphery of the second expansion tool is disposed radially outward of the first expansion tool. The second expansion tool is deformable between an unexpanded state and a radially expanded state under influence from the first expansion tool.

[0002] The present disclosure also relates to a mounting unit for attaching a container closure element to a container body, and a method for sealing a packaging container using the mounting unit. [Background technology]

[0003] When packaging consumer goods, particularly dry, flowable consumer goods, it is common to use rigid paperboard packaging containers that serve as protective shipping and storage containers at the retail end and as storage and dispensing containers at the consumer end. Such paperboard containers typically have a retractable lid. Patent Document 1 (U.S. Pat. No. 6,444,499) discloses an expandable-type lid welding piston comprising two piston portions, a forming portion and an expanding portion, that are axially movable relative to each other. The expanding portion is operable to provide peripheral expansion of a section of the piston when the two portions move together, and the expanding portion comprises an expanding disk made of a deformable material. The forming portion comprises a base plate having an upper surface that supports and guides at least a portion of the bottom surface of the expanding disk. The outer peripheral surface of the base plate has the same shape as the outer peripheral edge of the expanding disk. The expanding disk is typically cup-shaped, and the bottom plate has at least the same size as the outer peripheral edge of the expanding disk in its normal, unexpanded state. The forming portion and the expanding portion are positioned such that axial movement of these portions toward each other flattens the expanding disk from its cup shape and moves the outer peripheral edge of the expanding disk so that it extends beyond the periphery of the bottom plate. The lid welding piston can be used as a component in an apparatus for manufacturing packaging containers, and serves to introduce and position an inner flexible lid into a container tube and press the edge of the flexible lid against the inner wall of the container tube during a welding operation to attach the inner flexible lid to the container wall. The lid welding piston is introduced into the container tube with the expansion disk in an unexpanded or normal state. When the flexible lid is placed in the intended position within the container tube, the piston parts move together, thereby deforming the expansion disk into an expanded state, and the peripheral edge of the expansion disk extends beyond the peripheral edge of the base plate, thereby pressing the edge of the flexible lid against the inner wall of the container tube.

[0004] Patent Document 2 discloses a device similar to that in Patent Document 1. Thus, Patent Document 2 discloses a radially expandable press plunger having two main parts, namely, a forming part and an expanding part, which are movable relative to each other. The expanding part is arranged to provide at least a partial expansion of the press plunger when the main parts are moved together. The expanding part comprises a cup-shaped expanding body, and the forming part is designed with a forming surface and adapted so that at least a portion of the expanding body slides against the forming surface when the forming part and the expanding part are moved axially toward each other. The expanding part is composed of two distinct parts: an outer pressing part for performing the actual radially outward contact pressure of the press plunger and made of a wear-resistant, temperature-resistant, and elastic material, and an inner carrier part made of a relatively hard, elastic material that supports the pressing part.

[0005] Patent Document 3 discloses an apparatus and method for sealing cardboard-based containers. The apparatus includes a welding unit configured to secure a lid to the container, the welding unit including an induction welding energy generator for melting weldable layers forming part of the container and / or the lid, and transport means configured to transport a stream of containers to and from the welding unit. The transport means includes a feeder, a main conveyor member, and a movable gripper, in order of the container stream. The feeder is configured to transfer the containers one by one sequentially to the main conveyor member, and the gripper is configured to transfer the containers from the main conveyor member to the welding unit. Patent Document 3 also discloses a method for operating this type of apparatus. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] European Patent No. 247986 [Patent Document 2] U.S. Patent No. 4,989,394 [Patent Document 3] International Publication No. 2013 / 009226 [Patent Document 4] International Publication No. 2017 / 180056 Summary of the Invention [Problem to be solved by the invention]

[0007] While these known configurations for attaching a sealing member to a container have been found to be suitable for their purpose, there is still room for further improvement. Accordingly, it may be an object of the present disclosure to provide a versatile, expandable press plunger with improved functionality. A further object of the present disclosure may be to provide a versatile attachment unit with improved functionality. Yet another object of the present disclosure may be to provide an improved method of attaching a sealing member when manufacturing paperboard containers.

[0008] The general object of the present disclosure is to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

[0009] One or more of the above objects may be achieved by the subject matter of independent claims 1, 19 and 22. Embodiments are set out in the accompanying dependent claims, the following description and drawings.

[0010] Disclosed herein is an expandable press plunger having a plunger axis extending in an axial direction perpendicular to the radial direction. The expandable press plunger is radially expandable and includes a base plate, a first expansion tool, and a second expansion tool. The first expansion tool and the second expansion tool are axially movable relative to each other. The base plate has a bottom surface and an upper surface opposite the bottom surface, and the upper surface faces the first expansion tool and the second expansion tool in the axial direction. The second expansion tool has upper and lower ends and includes an expansion tool sidewall with an inner and outer surface. The expansion tool sidewall extends from the upper end to the lower end of the second expansion tool. The expansion tool sidewall includes a periphery at the lower end of the second expansion tool, and the periphery of the second expansion tool is disposed radially outward of the first expansion tool. The periphery of the lower end of the second expansion tool is also referred to as the terminal periphery of the lower end of the second expansion tool. The peripheral edge may be limited in its extension above the bottom end, for example. For example, the peripheral edge may be limited to 10% or even 5% of the expansion tool sidewall of the second expansion tool. The second expansion tool is deformable between an unexpanded state and a radially expanded state. The first expansion tool has one or more inclined planes, each having a first end and a second end, the first end being axially closer to the base plate than the second end. The one or more inclined planes of the first expansion tool are inclined away from the plunger axis (ai) from the first end to the second end. The second expansion tool has one or more inclined planes, each inclined plane of the second expansion tool corresponding to the inclined plane of the first expansion tool. Each inclined flat surface of the second expansion tool has a first end and a second end, the first end being axially farther from the base plate than the second end, and each inclined flat surface of the second expansion tool is inclined toward the plunger axis from the first inclined flat surface to the second inclined flat surface, and when the expandable press plunger is in a radially expanded state, each inclined flat surface of the first expansion tool contacts and applies pressure to a corresponding inclined flat surface of the second expansion tool.

[0011] The inclined plane of the second expansion tool may be disposed on the inner surface of the sidewall of the second expansion tool. The inner surface of the sidewall of the second expansion tool may further include a first section extending axially, i.e., extending axially, or in other words, extending substantially without inclination toward the plunger axis. The first section of the inner surface is disposed between the upper end and the inclined plane. In other words, the inclined plane of the second expansion tool is disposed closer to the lower end than the first section of the inner surface of the sidewall of the expansion tool. In one example, the first section can extend a distance in the range of 40 to 70% of the height of the second expansion tool measured axially from the lower end to the upper end of the sidewall of the expansion tool.

[0012] In the expandable press plunger disclosed herein, one or more inclined planes of the first expansion tool may be inclined away from the plunger axis at an angle α in the axial direction from the first end of each inclined plane to the second end of each inclined plane, and each inclined plane of the second expansion tool may be inclined toward the plunger axis at an angle β relative to the axial direction from the first end of the inclined plane to the second end of the inclined plane. The angle β is greater than the angle α by a differential angle γ. The differential angle γ may be in the range of 1 to 3 degrees. By arranging the inclined planes on the first and second expansion tools at a small differential angle, the expansion effect can be enhanced.

[0013] The transformation of the second expansion tool, and thereby the expandable press plunger, from the unexpanded state to the expanded state is accomplished by moving the first expansion tool toward the base plate. The first expansion tool is moved downward inside the sidewall of the second expansion tool until a first end of each inclined flat of the first expansion tool contacts a corresponding first end of a corresponding inclined flat of the second expansion tool. For example, the first end of each inclined flat of the first expansion tool may contact a corresponding first end of a corresponding inclined flat of the second expansion tool on a radially extending plane. Continued downward movement of the first expansion tool causes one or more inclined flats of the first and second expansion tools to gradually come into contact with each other as the one or more inclined flats of the first expansion tool slide against the corresponding one or more inclined flats on the second expansion tool until the inclined flats of the first expansion tool are fully aligned with the inclined flats of the second expansion tool. If a different angle γ exists between the angles α and β of the inclined planes on the first and second expansion tools, aligning the inclined planes on the first and second expansion tools gradually reduces the angle γ until it completely disappears when the expandable press plunger is in its fully expanded state. The force applied by the first expansion tool to the sidewall of the second expansion tool deflects the sidewall radially outward, thereby increasing the length of the peripheral portion of the second expansion tool, i.e., increasing the circumference of the second expansion tool at least at the lower end of the second expansion tool. For example, the circumference of the second expansion tool is larger at the lower end of the second expansion tool. Because the lower end of the second expansion tool is deflected more than other portions of the second expansion tool, such as the first section and the upper portion of the inclined planes, the pressure on the container is highest at the lower end, including the peripheral edge, which is beneficial for forming a good seal at the peripheral edge.

[0014] The second expansion tool is made of a material, such as a polymeric material, that can be repeatedly bent and / or stretched without breaking. The material in the second expansion tool is preferably elastically flexible and / or stretchable so that it returns to its unexpanded shape when the expansion force from the first expansion tool is removed. The second expansion tool disclosed herein is a cup-shaped element disposed radially outside the first expansion tool. For example, the cup-shaped element may have a hollow cup shape without a bottom or handle to accommodate the first expansion tool within the cup-shaped element. The cup-shaped element may be thin relative to its other dimensions, such as its height and width. The first expansion tool is axially movable inside the second expansion tool during the transformation of the expandable press plunger to its expanded state and during the return of the expandable press plunger to its unexpanded state. Furthermore, the second expansion tool is preferably made, for example, by injection molding, as a single, integral piece of the same material. In other words, the second expansion tool is preferably formed as a single, integral piece of the same material. The sidewall of the second expansion tool above the inclined plane and the material that can be repeatedly bent and / or stretched without breaking allow the second expansion tool to be repeatedly deflected radially outward below the first end of the inclined plane of the second expansion tool to direct the force from the press plunger primarily toward the periphery.

[0015] In the expandable press plunger disclosed herein, each inclined flat surface of the second expansion tool may be disposed on a wedge-shaped protrusion disposed on an inner surface of a sidewall of the second expansion tool.

[0016] The cross section of the second expansion tool in a plane parallel to the radial direction may have a modified polygonal shape having at least three wall portions connected by at least three corner portions. A wedge-shaped protrusion having an inclined flat surface may be disposed at each corner of the second expansion tool. At least one wedge-shaped protrusion having an inclined flat surface may be disposed on each wall portion of the second expansion tool. Depending on the size of the wall portion, two or more wedge-shaped protrusions may be used on the wall portion. Providing separate wedge-shaped protrusions on the corner portion and the wall portion allows for different degrees of expansion at the corner and between the corners. High pressure applied to the material to be sealed at the corner of the container body may be beneficial for sealing operations, as the corner may require a higher sealing pressure than the wall portion to achieve comparable sealing quality at the corner. When a flat element such as a sealing disk is bent, inserted into the container body, and deflected to align the sealing edge with the inner surface of the container body wall, excess sealing disk material may form wrinkles and unevenness at the corner portion. To flatten out such wrinkles and irregularities and create a seal between the sealing disc and the container body, a higher sealing pressure may be required than for wall portions where the materials to be sealed lie flat against each other.

[0017] Here, a modified polygon, such as a modified triangle, rectangle, pentagon, or hexagon, refers to a shape with sides that have rounded corners. The sides may be straight or may have a curvature that is less than the curvature of the corners. In the expandable press plunger disclosed herein, each inclined plane of the first expansion tool may be disposed on a wedge-shaped protrusion on the first expansion tool. When both the inclined plane of the first expansion tool and the inclined plane of the second expansion tool are disposed on the wedge-shaped protrusion, each wedge-shaped protrusion of the first expansion tool is disposed to align and interact with the corresponding wedge-shaped protrusion of the second expansion tool.

[0018] The wedge-shaped protrusions on the first expansion tool taper downward, i.e., toward the base plate of the expandable press plunger, and the wedge-shaped protrusions on the second expansion tool taper upward, i.e., away from the base plate of the expandable press plunger.

[0019] When multiple wedge-shaped protrusions are disposed on the sidewall of the second expansion tool, the wedge-shaped protrusions are spaced apart from one another circumferentially around the sidewall of the second expansion tool. This allows different portions of the sidewall of the second expansion tool carrying the wedge-shaped protrusions to move more freely relative to one another when the second expansion tool is transformed from an unexpanded state to a radially expanded state. Furthermore, the separation between the wedge-shaped protrusions allows different portions of the sidewall of the second expansion tool to expand to different degrees. As described herein, portions of the sidewall that form corners of the second expansion tool may be positioned to achieve greater expansion than portions of the sidewall that are disposed between the corners.

[0020] To facilitate radial expansion of the second expansion tool, at least one expansion slit may be disposed in the expansion tool sidewall of the second expansion tool, the expansion slit extending axially in the expansion tool sidewall. If two or more wedge-shaped protrusions are disposed in the sidewall of the second expansion tool, the expansion slits may preferably be disposed to separate the wedge-shaped protrusions from each other and allow them to move independently of each other.

[0021] The one or more expansion slits may be disposed from the upper end of the second expansion tool all the way to the lower end of the second expansion tool, or only in a selected portion of the wall of the second expansion tool between the upper and lower ends. Although generally less preferred, the expansion slits may be disposed so as not to penetrate the peripheral portion of the second expansion tool. The expansion slits may divide the peripheral portion of the second expansion tool and extend axially from the peripheral portion toward the upper end of the second expansion tool. Each expansion slit may terminate at an end opening in the side wall of the second expansion tool. The end opening may have any suitable shape, such as a circle, an ellipse, or a modified polygon, as described herein. When multiple expansion slits are disposed in the side wall of the second expansion tool, the slits may terminate in end openings disposed at the same level along the circumference of the side wall of the second expansion tool. The end openings facilitate bending of the portion of the side wall located between the two end openings along a hinge line formed between the end openings.

[0022] The second expansion tool disclosed herein has an axial height, and the one or more expansion slits may extend in the expansion tool sidewall a distance in the range of 40% to 100%, preferably 40% to 70%, or most preferably 45% to 60% of the height of the second expansion tool.

[0023] In the expandable press plunger disclosed herein, a plurality of expansion slits may extend from the circumferential edge portion of the second expansion tool toward the upper end, the expansion slits dividing the circumferential edge into a plurality of edge segments.

[0024] Each expansion slit in the second expansion tool may terminate in an end opening, preferably located on a hinge line extending circumferentially around the second expansion tool and perpendicular to the axial direction.

[0025] In the expandable press plunger disclosed herein, the base plate may include a deformation control member arranged to limit radially inward deformation of the peripheral portion of the second expansion tool, the deformation control member preventing the peripheral portion of the second expansion tool from moving radially inward beyond a limit created by the deformation control member.

[0026] The deformation control member can take the form of a stop wall disposed on the upper surface of the base plate, the stop wall being inset from the periphery of the bottom surface of the base plate, the stop wall preventing a circumferential edge portion of the second expansion tool from moving radially inward beyond the stop wall.

[0027] The second expansion tool may include a sealing ridge extending circumferentially on the outer surface of the second expansion tool sidewall along all or part of the circumference of the second expansion tool sidewall.

[0028] The second expansion tool may comprise a deformation tool that protrudes radially from an outer surface of the second expansion tool sidewall. The deformation tool may comprise or consist of an elongated bulge that extends circumferentially around the second expansion tool sidewall, the elongated bulge extending around all or part of the circumference of the second expansion tool sidewall.

[0029] The peripheral portion of the second expansion tool sidewall may comprise or consist of the deformation tool. Thus, the peripheral portion may constitute the deformation tool.

[0030] The expandable press plunger disclosed herein may include a sealing ridge and a deformation tool, and the sealing ridge may be disposed above the deformation tool as viewed axially from the lower end of the second expansion tool toward the upper end of the second expansion tool. The expandable press plunger including the sealing ridge and the deformation tool may be used both to generate deformation in the container wall and to attach the sealing disk to the container body.

[0031] The deformation tool can be configured to form a mating locking bulge in a closed configuration within a packaging container, such as the packaging container disclosed in U.S. Patent No. 5,623,499. U.S. Patent No. 5,623,499 discloses a paperboard packaging container for bulk solids. The paperboard packaging container includes a tubular paperboard container body, a container bottom, and a container lid. The container body extends longitudinally of the packaging container from a lower end of the container body to a container opening. The container body includes a container body abutting edge at the container opening. The container body has an inner surface facing toward an interior compartment within the packaging container and an outer surface facing away from the interior compartment. The container lid includes a lid collar having an abutting edge adapted to abut the container body abutting edge, and a lid insert. The lid insert has a side that extends longitudinally and faces the interior surface of the container body when the container lid is in the closed position. The lid insert further includes a major surface that is located a distance from the container body abutting edge when the container lid is in the closed position. The lid collar is made from the same material as the container body, and is separated from the container body by a slit or a weakened means extending along the periphery of the container body to allow the lid collar to be completely or partially separated from the container body at the abutting edge. The shape of the container opening is stabilized by (i) a paperboard package including a partially removable shipping closure attached to the inner surface of the container body and forming a roof over the interior compartment, and / or (ii) a container body including a multi-layer paperboard material including one or more layers of polymer film, coating layer, and / or metal foil. The paperboard package further includes a locking device for holding the container lid in a closed position. The locking device includes a first locking element in the form of a recess on the inner surface of the container body and a second locking element in the form of a protrusion on a side of the lid insert, the first and second locking elements being mating locking elements. The first and second locking elements are positioned so that the protrusion engages the recess when the container lid is in the closed position.

[0032] The container lid and insert of a paperboard packaging container are co-formed from a single sheet of paperboard material during manufacturing. Therefore, the lid collar forms a contiguous continuation of the container body wall, and the insert functions as a plug that fits tightly against the inner surface of the container body and securely fits into the container opening. The interlocking locking elements of the locking mechanism ensure that the container remains closed after closure. Closing the container requires the user to press the lid insert downward in a fairly consistent and forceful manner to overcome the resistance that arises when the protrusion of the second locking element is moved over the edge of the container wall. Thus, the abutting edge of the top member contacts the abutting edge of the container body with increased force, thereby providing the consumer with an enhanced closure indication, such as a sensory snap-in indication and an audible signal in the form of a click, that informs the user that the container is properly closed. This improves the user experience regarding the perception of a properly sealed container.

[0033] The container lid may be closed by pushing the insert into the container opening until the projection snaps into the recess and the lid collar abutting edge closes against the container body abutting edge, which may be indicated to the user by the sensation of slight resistance that must be overcome when pushing the lid into place; an audible signal such as a snap-in or slide-in sensation and / or a click, squeak, or scrape is generated when the lid is closed on the container body. It may generally be preferred that the closure indication be provided as a distinct sensation or sound, or a combination of distinct sensations or sounds, and such a signal may be perceived as providing a more distinct confirmation of proper closure than an imprecise sensation or sound. An example of a distinct sensation is a snap-in sensation, although a click or pop can provide a distinct sound sensation.

[0034] The expandable press plunger disclosed herein, in which the second expansion tool includes both a sealing ridge and a deformation tool, can be used to apply the inner sealing member and form the interengaging locking elements in the locking configuration, as disclosed in, for example, U.S. Patent No. 6,277,999. Thus, applying the inner sealing member, welding it to the inner wall of the container body tube, and forming the locking configuration can be performed in the same process operation when manufacturing a packaging container. The application of the inner sealing member and the formation of the locking configuration may occur simultaneously or sequentially. If performed sequentially, the application of the inner sealing member and the formation of the locking configuration may occur with or without overlap. It is also possible that the duration of the application of the inner sealing member and the formation of the locking configuration may differ. For example, a longer process time may be required to properly set the packaging material in the deformed configuration within the area of ​​the locking mechanism.

[0035] The expandable press plunger disclosed herein may include a first piston and a second piston, the first piston and the second piston extending in an axial direction, the second piston being coaxial with the first piston, a base plate connected to the first piston such that a bottom surface of the base plate extends perpendicular to the axial direction, a first expansion tool connected to the second piston, and the second expansion tool connected to the first piston, the first piston and the second piston being arranged to be simultaneously movable in the axial direction as a unit and to be independently movable in the axial direction.

[0036] Also disclosed herein is a mounting unit for mounting a container closure element to a container body, the mounting unit comprising: an expandable press plunger as disclosed herein; and a holding device adapted to hold the container body, the holding device comprising at least one through positioning cavity adapted to receive and hold a portion of the container body, the positioning cavity of the holding device having a cross-sectional area defining a footprint area of ​​the container body. The expandable press plunger is axially movable between a mounting position inside the positioning cavity of the holding device and a rest position outside the positioning cavity of the holding device.

[0037] The holding device may include a welding unit, such as a welding unit with an induction coil, which may preferably be arranged around the positioning cavity.

[0038] The positioning cavity of the holding device may include a recess disposed in the wall of the positioning cavity, the recess corresponding to a deformation tool protruding radially from the outer surface of the second expansion tool sidewall, the deformation tool positioned to nest inside the recess when the expandable press plunger is in the attached position. The outer surface of the second expansion tool sidewall may include a single deformation tool or multiple deformation tools, and the positioning cavity may include a single recess or multiple recesses that fit the one or more deformation tools on the outer surface of the second expansion tool sidewall. The cooperating deformation tools and recesses may be used to create any desired shape of deformation in the container wall, such as elongated ridges / grooves, discrete protrusions / recesses, etc.

[0039] The cross-sectional area of ​​the positioning cavity may include a plurality of sides connected by corners, and the bottom surface of the base plate and the peripheral edge of the first expansion tool in an unexpanded state each include a corresponding plurality of sides connected by corners.

[0040] A method of sealing a packaging container using a mounting unit having an expandable press plunger disclosed herein includes the following. - placing the container body in a positioning cavity of the holding device with the body wall of the container body aligned with the wall of the positioning cavity; - applying a container closure element to the bottom surface of the base plate, the attachment boundary extending radially outwardly of the periphery of the bottom surface; - moving the container closure element in the axial direction of the mounting unit by means of an expandable press plunger into a mounting position in the container body, while simultaneously deflecting the mounting boundary of the container closure element into alignment with the body wall of the container body; - gradually deforming the expandable press plunger from a non-expanded state to a radially expanded state by moving the first expansion tool axially toward the upper surface of the bottom plate and sliding the inclined flat surface of the first expansion tool against the inclined flat surface of the second expansion tool, wherein the side wall of the second expansion tool is subjected to a biasing force that moves the side wall of the second expansion tool away from the plunger axis of the expandable press plunger and presses the attachment interface of the container closure element radially against the body wall of the container body; - welding the attachment boundary of the container closure element to the body wall of the container body; Includes:

[0041] The mounting boundary of the container closure element may be pressed against the body wall of the container body by a sealing ridge disposed on the second expansion tool, the sealing ridge extending circumferentially on the outer surface of the expansion tool side wall along the circumference of the expansion tool side wall of the second expansion tool. The welding of the mounting boundary of the container closure element to the body wall of the container body is performed along the sealing ridge. The sealing ridge is preferably disposed so as to extend around the entire circumference of the expansion tool side wall.

[0042] The second expansion tool may include a deformation tool protruding radially from the outer surface of the expansion tool sidewall, and the positioning cavity of the holding device may include a corresponding recess disposed in the wall of the positioning cavity, and the method further includes deforming the attachment interface of the container closure element and the body wall of the container body by radially forcing the deformation tool into the recess in the wall of the positioning cavity. This process step may result in a locking configuration as disclosed herein, or may be a method of providing a container wall with a shape that deviates from the original planar shape of the packaging material. The deformed portion of the container wall may be provided to provide a technical function, such as a locking element or a stiffening element, and / or may have a decorative or informational purpose, such as a decorative relief pattern, text, logo, etc.

[0043] In the methods disclosed herein, multiple container closure elements may be simultaneously inserted and positioned into multiple corresponding container bodies by multiple mounting units, each mounting unit inserting and positioning a closure element into a corresponding container body, which may then be simultaneously attached to the corresponding container bodies by welding, as described herein.

[0044] The invention will now be further described by way of non-limiting examples with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0045] [Figure 1] 1 illustrates a cross-sectional view of an expandable press plunger as disclosed herein. [Figure 2] 2 illustrates a side view of a first expansion tool within the expandable press plunger of FIG. 1. [Figure 3] 3 shows a top view of the first expansion tool shown in FIG. 2. [Figure 4] 2 illustrates a side view of a second expansion tool within the expandable press plunger of FIG. 1. [Figure 5] 5 shows a top view of the second expansion tool shown in FIG. 4. [Figure 6]1 shows a schematic cross-sectional view of a first expansion tool and a second expansion tool. [Figure 7] 2 shows a side view of the base plate of the expandable press plunger of FIG. 1. [Figure 8] 2 shows a cross-sectional view of a mounting unit disclosed herein including the expandable press plunger of FIG. 1. [Figure 9] 8 shows a detailed cross-sectional view of the mounting unit of FIG. 7 used in the methods disclosed herein. [Figure 10] 2 shows a package that can be made using the mounting unit shown in FIG. 1. The package is shown in a closed state. [Figure 11] 10 shows the packaging container of FIG. 9 in a closed state and in a partial cross-sectional view of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0046] Referring to FIG. 1, an expandable press plunger 2 is shown. The expandable press plunger 2 has a plunger axis a1 extending in an axial direction A perpendicular to the radial direction R. The expandable press plunger 2 is expandable in the radial direction R and comprises a base plate 8, a first expansion tool 9, and a second expansion tool 10. The first expansion tool 9 and the second expansion tool 10 are movable together as a unit and relative to each other in the axial direction A. The base plate 8 has a bottom surface 11 and a top surface 14 opposite the bottom surface 11. The base plate 8 is positioned such that the top surface 14 faces the first expansion tool 9 and the second expansion tool 10 in the axial direction A.

[0047] 4 and 5, the second expansion tool 10 has an upper end 20 and a lower end 21, and includes an expansion tool sidewall 22 having an inner surface 23 and an outer surface 24, the expansion tool sidewall 22 extending from the upper end 20 to the lower end 21 of the second expansion tool 10. The expansion tool sidewall 22 includes a periphery 25 at the lower end 21 of the second expansion tool 10, the periphery 25 of the second expansion tool 10 being radially outwardly disposed relative to the first expansion tool 9. The second expansion tool 10 is transformable between an unexpanded state and a radially expanded state, as further described with reference to FIGS. 7 and 8. As shown by the cross-section of the second expansion tool in FIG. 1, the expansion tool sidewall 22 may be thin relative to other dimensions, such as its height.

[0048] The second expansion tool 10 includes one or more inclined planes 16. More specifically, the inclined planes 16 may be disposed on the inner surface 23 of the expansion tool sidewall 22. The inner surface 23 of the expansion tool sidewall 22 may further include a first section 23-1 extending in the axial direction A, i.e., extending substantially without inclination toward the axial direction A. The first section 23-1 of the inner surface 23 is disposed between the upper end 20 and the inclined planes 16. The sidewall 22 of the second expansion tool 10 may also include a first section 22-1, which may be disposed between the upper end 20 and the inclined planes 16 and may extend in the axial direction A, i.e., extend substantially without inclination toward the axial direction A. Additionally, the outer surface 24 may include a first section 24-1 extending in the axial direction A, i.e., extend substantially without inclination toward the axial direction A.

[0049] As shown in FIGS. 2 and 3 , the first expansion tool 9 includes multiple inclined planes 15. The inclined planes 15 are positioned facing the inner surface 23 of the expansion tool sidewall 22 of the second expansion tool 10. Accordingly, each inclined plane 15 of the first expansion tool 9 has a first end 15′ and a second end 15″, with the first end 15′ being closer to the base plate 8 than the second end 15″ in the axial direction A. The inclined planes 15 are inclined away from the plunger axis a1 from the first end 15′ of the inclined plane 15 to the second end 15″ of the inclined plane 15. The inclined planes 15 may also be inclined away from the inner surface 23 of the sidewall 22 of the second expansion tool 10 in the axial direction A. More specifically, the inclined planes 15 may also be inclined away from the first section 23-1 of the inner surface 23 of the sidewall 22 of the second expansion tool 10 in the axial direction A.

[0050] The first expansion tool 9 may further include a plurality of second surfaces 26 that may extend in the axial direction A along the plunger axis a1. Thus, in some embodiments, the second surfaces 26 are not inclined with respect to the plunger axis a1 and, therefore, are not inclined from the first section 23-1 of the inner surface 23 of the side wall 22 in the axial direction A. Each second surface 26 may be positioned farther from the base plate 8 in the axial direction A than the inclined plane 15. For example, as shown in FIG. 2 , each second surface 26 may extend between an upper end 27 of the first expansion tool 9 and the inclined plane 15. The second surfaces 26 may be flat.

[0051] In the illustrated example, the first expansion tool 9 has eight inclined flat surfaces 15, each positioned on a wedge-shaped protrusion 17, 18, or 19. The wedge-shaped protrusions 17, 18, or 19 and the inclined flat surfaces 15 are positioned to face the inner surface 23 of the expansion tool sidewall 22 of the second expansion tool 10 when the first expansion tool 9 is inserted into the second expansion tool 10. The first expansion tool 9 shown in FIGS. 2 and 3 is configured for use in inserting and attaching a container closure element to a container body having a modified rectangular cross-section with four sidewalls connected by four rounded corners. Four wedge-shaped protrusions 17 are positioned on the corners of the first expansion tool 9, a first pair of opposing wedge-shaped protrusions 18 are positioned on a first pair of sidewalls of the first expansion tool 9, and a second pair of opposing wedge-shaped protrusions 19 are positioned along a second pair of sidewalls of the first expansion tool 9. In the example shown in FIGS. 2 and 3, the wedge projections of the first pair of wedge projections 18 have a greater expansion in the circumferential direction of the first expansion tool 9 than the wedge projections of the second pair of wedge projections 19 .

[0052] During the process of inserting and attaching the container closure element to the container body, the wedge-shaped protrusions 17, 18, and 19 on the first expansion tool 9 are positioned on the corresponding wall portions of the container body. Thus, the wedge-shaped protrusions 17 positioned at the corners of the first expansion tool 9 are positioned on the corresponding corners of the container body. The wedge-shaped protrusions 18 positioned on the long sides of the first expansion tool 9 are positioned on the long sidewall portions of the container body, and the wedge-shaped protrusions 19 positioned on the short sides of the first expansion tool 9 are positioned on the short sidewall portions of the container body. As described herein, the expandable press plunger is not limited to being an expandable press plunger for use in manufacturing packaging containers having a modified rectangular cross-section. The expandable press plungers disclosed herein can be used in manufacturing packaging containers having any useful shape, including circular, elliptical, and polygonal. It should be understood that the number and position of the wedge-shaped protrusions bearing inclined flat surfaces on the first expansion tool should be adapted to the configuration of the specific packaging container to be manufactured.

[0053] The inclined planes 15 of the first expansion tool 9 are inclined at an angle α with respect to the axial direction A toward the plunger axis a1 from the second end 15″ of each inclined plane 15 to the first end 15′ of each inclined plane 15.

[0054] 4 and 5 has a modified rectangular cross-sectional shape corresponding to the shape of the first expansion tool 9 so that the first expansion tool 9 can be inserted and fitted inside the second expansion tool 10. The second expansion tool 10 has two long wall portions 22wl and two short wall portions 22ws, which are connected by four corner portions 22c.

[0055] The second expansion tool 10 includes eight inclined planes 16 corresponding to the eight inclined planes 15 of the first expansion tool 9. Each of the inclined planes 16 of the second expansion tool 10 has a first end 16' and a second end 16'', with the first end 16' disposed farther from the base plate 8 in the axial direction A than the second end 16''. As seen in FIG. 9 , the inclined planes 16 of the second expansion tool 10 are inclined toward the plunger axis a1 by an angle β relative to the axial direction A from the first end 16' of the inclined plane to the second end 16'' of the inclined plane, where the angle β differs from the angle α by an angle γ, which is in the range of 1 to 3 degrees. As disclosed herein, a difference in inclination between the inclined planes 15 on the first expansion tool 9 and the corresponding inclined planes 16 on the second expansion tool 10 is not a requirement for the expandable press plunger 2 as disclosed herein.

[0056] The inclined flat surface 16 of the second expansion tool 10 is disposed on the inner surface 23 of the expansion tool side wall 22 and is disposed on wedge-shaped protrusions 47 , 48 , 49 that protrude radially inward from the inner surface 23 of the expansion tool side wall 22 .

[0057] The second expansion tool 10 includes a first set of wedge-shaped protrusions 47, each having an inclined plane 16 and arranged at a corner 22c of the second expansion tool 10. The second expansion tool 10 further includes a second wedge-shaped protrusion set 48 having two wedge-shaped protrusions 48 arranged on each of the opposing long walls 22wl, and a third wedge-shaped protrusion set 49 having one wedge-shaped protrusion 49 arranged on each of the short walls 22wl. Thus, each inclined plane 16 arranged on each long wall 22wl is divided into two partial surfaces by the partition between the two wedge-shaped protrusions 48 on each long wall 22wl.

[0058] As seen in FIG. 4 , the expansion slit 35 is disposed in the expansion tool sidewall 22 of the second expansion tool 10. The expansion slit 35 extends in the axial direction A from the peripheral edge 25 of the second expansion tool 10 at the expansion tool sidewall 22, dividing the peripheral edge 25 into multiple edge segments. In the example shown in FIG. 4 , the expansion slit 35 extends approximately 50% of the distance from the lower end 21 to the upper end 20 of the second expansion tool 10. Such placement of the expansion slit 35 is not a prerequisite for the expandable press plunger 2 disclosed herein. The expansion slit 35 may extend in the expansion tool sidewall 22 a distance ranging from 40% to 100% of the height of the second expansion tool 10, as measured between the upper end 20 and the lower end 21 of the second expansion tool 10. It may be preferable for the expansion slit 35 to extend less than the total height of the second expansion tool 10, for example in the range of 40% to 70%, or most preferably in the range of 45% to 60%, of the height of the second expansion tool 10 measured in the axial direction A from the lower end 21 to the upper end 20.

[0059] The arrangement of the expansion slits 35 may be different from that shown in Figure 4, for example, there may be only one or more than two expansion slits 35 arranged in the long wall portion 22I of the second expansion tool 10. Furthermore, the expansion slits 35 may have different lengths and / or widths. As shown in Figure 4, the expansion slits 35 preferably have the same length and terminate at the same height to provide a hinge function along a hinge line HL formed between the ends of the expansion slits 35.

[0060] The expansion slits 35 are disposed between wedge-shaped protrusions 47, 48, 49 disposed on the inner surface 23 of the expansion tool sidewall 22. Each expansion slit 35 terminates in an end opening 37 in the sidewall 22 of the second expansion tool 10. The end openings 37 may have any suitable shape, such as circular, oval, square, triangular, etc. By locating the end openings 37 at the same level along the periphery of the sidewall 22 of the second expansion tool 10, the end openings 37 serve to enhance the hinge effect along the hinge line HL formed between the ends of the expansion slits 35 by facilitating bending of the portion of the sidewall located between the two end openings 37 along the hinge line HL.

[0061] FIG. 6 is a schematic diagram of how the wedge-shaped protrusion 17 with the inclined flat surface 15 belonging to the first expansion tool 9 relates to the wedge-shaped protrusion 47 with the inclined flat surface 16 belonging to the second expansion tool 10. As the first expansion tool 9 moves downward in the axial direction A, as indicated by arrow A1, the inclined flat surface 15 on the first expansion tool 9 slides against the corresponding inclined flat surface 16 on the second expansion tool 10, exerting pressure on the second expansion tool 10 in the radial direction R, as indicated by arrow R1. This causes the side wall 22 of the second expansion tool 10 to bend at the hinge line HL, and the peripheral edge 25 of the second expansion tool 10 to move radially outward. As described above, the first section 23-1 of the inner surface 23 and the first section 22-1 of the side wall 22 are positioned between the upper end 20 (not shown in FIG. 6) and the inclined flat surface 16. As shown in FIG. 6 , the inclined plane 16 of the second expansion tool 10 is positioned below the first section 23-1 of the inner surface 23 of the expansion tool sidewall 22. That is, the inclined plane 16 is positioned axially closer to the lower end 21 than the first section 23-1. The inclined plane 16 may be positioned between the hinge line HL and the lower end 21. In some embodiments, such as the embodiment of FIG. 6 , the first sections 22-1, 23-1 extend somewhat below the hinge line HL. For example, the first sections 22-1, 23-1 may extend below the hinge line HL by 0 to 40% of the distance between the lower end 21 and the hinge line HL. In another example, the first section 22-1 of the expansion tool sidewall 22 extends from the lower end 21 to the upper end 20 in the axial direction A by a distance in the range of 40 to 70% of the height of the second expansion tool 10. Correspondingly, the first section 23-1 of the inner surface 23 can extend on the inner surface 23 of the expansion tool sidewall 22 a distance in the range of 40 to 70% of the height of the second expansion tool 10, measured in the axial direction A from the lower end 21 to the upper end 20. Preferably, the first section 23-1 may extend within the expansion tool sidewall 22 a distance in the range of 60 to 70% of the height of the second expansion tool 10. Thus, only the lower portion of the first section 23-1 of the inner surface 23 is shown in Figure 6.

[0062] The second expansion tool 10 further comprises a sealing ridge 41 extending circumferentially on the outer surface 24 of the second expansion tool sidewall 22 along the outer periphery of the second expansion tool sidewall 22. The sealing ridge 41 preferably extends along the entire circumference of the second expansion tool sidewall 22, although it is contemplated that the second expansion tool 10 may have a sealing ridge that extends along only a portion of the circumference of the second expansion tool sidewall 22.

[0063] The second expansion tool 10 further comprises a deformation tool 42 that protrudes in the radial direction R from the outer surface 24 of the second expansion tool sidewall 22. In the illustrated example, the deformation tool 42 comprises an elongated bulge that forms part of the periphery 25 of the second expansion tool sidewall 22 and extends circumferentially along the entire circumference of the second expansion tool sidewall 22. It should be understood that the deformation tool 42 may be positioned a distance from the periphery 25 of the second expansion tool sidewall 22 and / or the deformation tool 42 may extend only along part or more of the circumference of the second expansion tool sidewall 22.

[0064] As can be seen in the figure, the sealing ridge 41 is disposed above the deformation tool 42 in the axial direction A from the lower end 21 of the second expansion tool 10 towards the upper end 20 of the second expansion tool 10 .

[0065] Transformation of the second expansion tool 10, and thus the expandable press plunger 2, from the unextended state to the expanded state is accomplished by moving the first expansion tool 9 toward the base plate 8. The first expansion tool 9 moves downward in the axial direction A inside the side wall 22 of the second expansion tool 10 until the first end 15' of each inclined plane 15 of the first expansion tool 9 contacts the corresponding first end 16' of the inclined plane 16 of the second expansion tool 10. Continued downward movement of the first expansion tool 9 causes the inclined planes 15, 16 of the first and second expansion tools 9, 10 to gradually come into contact as the inclined planes 15 of the first expansion tool 9 slide against the corresponding inclined planes 16 of the second expansion tool 10, until the difference angle γ between the inclined planes is eliminated and the inclined planes 15 of the first expansion tool 9 are fully aligned with the inclined planes 16 of the second expansion tool 10. Aligning the inclined planes 15, 16 on the first and second expansion tools 9, 10 applies a radially outward force from the first expansion tool 9 to the sidewall 22 of the second expansion tool 10, deflecting the corresponding portion of the sidewall 22 of the second expansion tool 10 radially outward, thereby increasing the length of the periphery 25 of the second expansion tool 10. As the inclined plane 15 of the first expansion tool 9 moves downward in the axial direction A, the sidewall 22 of the second expansion tool 10 gradually deflects radially outward, gradually reducing the difference angle γ between angles α and β. When the first expansion tool 9 moves to the inner end position of the second expansion tool 10, the first inclined plane 15 and the second inclined plane 16 are fully aligned and in contact with each other.

[0066] During expansion of the second expansion tool 10, the segments of the side wall 22 located between the expansion slits 35 are forced to bend radially outward along the hinge line HL formed between the end openings 37. Thus, the segments of the side wall 22 between the expansion slits 35 can flex outward independently of each other. By selecting the angles α and β, the degree of bending, and therefore the degree of expansion, can be different in different portions of the second expansion tool 10. For example, it may be desirable for the second expansion tool 10 to be more expandable at the corners of the side wall 22 than at the walls connecting the corners.

[0067] When the press plunger 2 and second expansion tool 10 are in a fully expanded state, any features on the outer surface 24 of the side wall 22 of the second expansion tool 10, such as the sealing ridge 41 and / or the deformation tool 42, can be used to form a seal between the container body wall and a sealing member inserted into the container body and / or to deform a portion of the container body wall as described herein.

[0068] FIG. 7 shows a base plate 8 provided with a deformation control member 40. The deformation control member 40 is arranged to limit the radially inward deformation of the peripheral edge 25 of the second expansion tool 10 by preventing the peripheral edge 25 from being moved too far towards the plunger axis a1. The deformation control member 40 as shown in FIG. 7 is provided in the form of a stop wall arranged on the upper surface 14 of the base plate, which is inset from the peripheral edge 12 of the base plate. The stop wall limits the radially inward movement of the peripheral edge 25 of the second expansion tool 10, as can be seen in FIG. 9.

[0069] 8 shows two mounting units 1 arranged side by side, each mounting unit 1 comprising an expandable press plunger 2 and a retaining device 4 with a through locating cavity 6. Each mounting unit 1 is configured to attach a container closure element 29 to a container body 3 and form a mating locking means by deforming a selected portion of the container body. The locating cavity 6 is adapted to receive and hold a portion of the container body 3 in place during processing of the container body 3 in the mounting unit 1. The locating cavity 6 of the retaining device 4 has a cross-sectional area that defines a footprint area of ​​the container body 3 to be inserted into the locating cavity 6.

[0070] The expandable press plunger 2 includes a first piston 30 and a second piston 31, both of which extend in an axial direction A, with the second piston 31 being coaxial with the first piston 30. A base plate 8 is connected to the first piston 30 with a bottom surface 11 of the base plate 8 extending perpendicular to the axial direction A. A first expansion tool 9 is coupled to the second piston 31, and the second expansion tool 10 is coupled to the first piston 30. The first and second pistons 30, 31 are configured to be moved simultaneously as a single unit in the axial direction A to enable the expandable press plunger 2 to be positioned within the container body, and are independently movable relative to each other to enable expansion of the second expansion tool 10 by moving the first expansion tool 9 toward the base plate 8, as described herein.

[0071] The illustrated mounting unit 1 is configured to form a packaging container having a modified rectangular cross-sectional area. The cross-sectional area may also be referred to as the footprint area of ​​the packaging container. The cross-sectional areas of the first and second expansion tools 9, 10, the bottom surface 11 of the base plate 8, and the positioning cavity 6 also each have a modified rectangular cross-sectional area with sidewall portions interconnected by rounded corners. It should be understood that the modified rectangular shape shown in the drawings is provided only as a non-limiting example of a useful shape, and that any useful cross-sectional or footprint shape, such as a circle, an ellipse, or a modified polygon, is contemplated. As used herein, a modified polygonal shape, e.g., a modified rectangular shape, refers to a shape having sides connected by rounded corners. The sides may be straight or may have a curvature that is less than the curvature of the corners.

[0072] The expandable press plunger 2 is axially movable between an attachment position inside the positioning cavity 6 of the holding device 4 and a rest position outside the positioning cavity 6 of the holding device 4. Figure 8 shows the attachment unit 1 inserted into the positioning cavity 6 after the expandable press plunger 2 has returned from the extended state and before being removed from the positioning cavity 6 after completion of the welding and vessel wall deformation operation.

[0073] 9, the deformation control members 40 on the base plate 8 are provided in the form of stop walls located on the upper surface 14 of the base plate 8. The deformation control members 40 are arranged to limit the radially inward movement of the peripheral edge 25 of the second expansion tool 10. Thus, the stop walls prevent the peripheral edge 25 of the second expansion tool 10 from being pressed radially inward.

[0074] 8 and 9, the sealing ridges 41 on the outer surface 24 of the second expansion tool sidewall 22 extend along the entire circumference of the second expansion tool sidewall 22. While such a configuration is generally preferred as it creates a continuous seal along the circumference of the second expansion tool 10, it should be understood that intermittent sealing ridges and sealing ridges that extend only along a portion or portions of the circumference of the second expansion tool may also be used within the scope of the present invention.

[0075] In the second expansion tool 10 shown in FIGS. 4, 8, and 9, the deformation tool 42 on the outer surface 24 of the second expansion tool 10 is formed by the peripheral edge 25 of the second expansion tool sidewall 22 as a thickened portion of the expansion tool sidewall. While the deformation tool 42 is shown in FIG. 4 as extending around the entire circumference of the second expansion tool 10, it should be understood that the deformation tool 42 may extend around only a portion(s) of the outer circumference of the second expansion tool 10, may be located elsewhere on the outer surface 24 of the expansion tool sidewall 22, and / or may have other shapes, as described herein. The deformation tool 42 is used to deform material within the packaging container wall to create features within the container wall that deviate from the original planar shape of the packaging material. The packaging material is preferably a laminate having a base layer of paper-based packaging material, such as a carton, and one or more additional layers, such as plastic or aluminum foil, laminated to the base layer. Such materials are readily deformable in the processes disclosed herein.

[0076] The holding device 4 of the mounting unit 1 as shown in Figures 8 and 9 comprises a high frequency induction welding unit 55 with an induction coil 56. The high frequency induction welding unit 55 surrounds the positioning cavity 6 at a level corresponding to the position of the sealing ridge 41 on the second expansion tool 10 when the expandable press plunger 2 is brought to the mounting position in the positioning cavity 6 as shown in Figures 8 and 9.

[0077] The positioning cavity 6 of the retaining device 4 includes a recess 57 disposed in the wall of the positioning cavity 6. The recess 57 is arranged to receive the deformation tool 42 on the second expansion tool 10, and the deformation tool 42 is arranged to nest inside the recess 57 when the expandable press plunger 2 is in the attached position.

[0078] When the expandable press plunger 2 is inserted into the container body 3 in the positioning cavity 6 and reaches a fully expanded state, the deformation tool 42 is pressed into the recess 57. The wall material of the container body 3 and the attachment interface 28 of the container closure element 29 are located between the outer surface 24 of the side wall 22 of the second expansion tool 10 and the wall of the positioning cavity, as can be seen in Figure 9. By pressing the deformation tool 42 into the recess 57 in the wall of the positioning cavity 6, the container body material and the attachment interface 28 of the container closure element 29 are also pressed into the recess 57, deforming and creating a bulge in the wall material.

[0079] Welding of the attachment interface 28 of the container closure element 29 to the container body wall is performed along the sealing ridge 41 by activating the induction coil 56 of the high frequency induction welding unit 55. It should be understood that the method as disclosed herein is not limited to high frequency induction welding, and other types of welding, such as thermal welding or ultrasonic welding, may also be used.

[0080] As described herein, the cross-sectional area of ​​the positioning cavity 6 of the mounting unit 1 is adapted to the shape and size of the container body into which the container closure element will be installed. The positioning cavity 6 of the mounting unit 1 shown in Figure 8 is configured for mounting the container closure element 29 in a container having a modified rectangular cross-sectional shape, with sides connected by corners that correspond to the generally rectangular cross-sectional shape of the bottom surface 11 of the base plate 8.

[0081] Regardless of the shape of the cross-sectional area of ​​the positioning cavity 6 of the mounting unit 1, the cross-sectional area of ​​the positioning cavity 6 of the mounting unit 1 is always larger than the cross-sectional area of ​​the second expansion tool 10, which allows the unexpanded press plunger 2 to be inserted into the positioning cavity 6 without damaging the container body placed in the positioning cavity 6.

[0082] The mounting unit shown in Figures 8 and 9 may be used in a method for sealing a packaging container, the method comprising: - placing the container body 3 in the positioning cavity 6 of the holding device 4 with the body walls of the container body 3 aligned with the walls of the positioning cavity 6; - attaching to the bottom surface 11 of the base plate 8 a container closure element 29 having an attachment boundary 28 extending radially outwardly of the periphery 12 of the bottom surface 11; - using the expandable press plunger 2 to move the container closure element 29 in the axial direction A of the mounting unit into a mounting position in the container body 3, while simultaneously deflecting the mounting boundary 28 of the container closure element 29 into alignment with the body wall of the container body 3; - gradually deforming the expandable press plunger 2 from a non-expanded state to a radially expanded state by moving the first expansion tool 9 in the axial direction A towards the upper surface 14 of the bottom plate 8 and causing the inclined planes 15 of the first expansion tool to contact and slide against the corresponding inclined planes 16 of the second expansion tool, the side walls 22 of the second expansion tool being subjected to a biasing force that moves the side walls 22 of the second expansion tool 10 away from the plunger axis a1 of the expandable press plunger 2 and presses the attachment boundary 28 of the container closure element 29 in the radial direction R towards the body wall of the container body 3; - attaching the attachment boundary 28 of the container closure element 29 to the body wall of the container body 3 by pressing the attachment boundary 28 of the container closure element 29 against the body wall of the container body 3 by means of a circumferentially extending sealing ridge 41 on the outer surface 24 of the expansion tool side wall 22 of the second expansion tool 10 and welding the attachment boundary 28 of the container closure element 29 to the body wall of the container body 3 along the sealing ridge 41; - deforming the body wall of the container body 3 by forcing the deformation tool 42 on the second expansion tool 10 radially into the recess 57 in the wall of the positioning cavity 6, with the attachment boundary 28 of the body wall of the container body 3 and the container closure element 29 being positioned between the deformation tool 42 on the second expansion tool 10 and the recess 57 in the wall of the positioning cavity 6.

[0083] The mounting unit 1 having the press plunger 2 disclosed herein can be used in forming the paperboard packaging container 100 shown in Figures 10 and 11 and described herein.

[0084] Figures 10 and 11 show the paperboard package 100 in the closed position, with a portion of the container wall broken away in Figure 11 to show a cross section of the closure mechanism of the package 100.

[0085] The paperboard packaging container 100 comprises a tubular paperboard container body 103, a container bottom 104, and a container lid 105. The container body 103 extends in the longitudinal direction L of the container 100 from a lower end 110 of the container body 103 to a container opening 107. The container body 103 comprises a container body abutment edge 118 at the container opening 107. The container body 103 has an inner surface 112 facing toward an interior compartment 114 of the packaging container 100 and an outer surface 113 facing away from the interior compartment 114.

[0086] The container body 103 has a modified rectangular shape. The paperboard container has a narrow front wall 136, a narrow rear wall 137, wide side walls 138, 139, and curved corners 140 connecting the walls 136-137. The curved corners 140 may have a radius of curvature of 15-30 mm. As described herein, it should be understood that the container body shapes shown in Figures 10 and 11 are non-limiting examples only, and that the container body may have any useful shape as described herein.

[0087] The front and rear walls 136, 137 may be flat or may have an outwardly curved shape with a radius of curvature between 30 and 1000 mm. Similarly, the side walls 138, 139 may be substantially flat or may have a curvature, as desired. The radii of curvature of the front wall 136, rear wall 137, side walls 138, and side walls 139 are always greater than the radii of curvature of the corners 140.

[0088] The container lid 105 includes a peripheral lid collar 108 having a lid abutment edge 119 adapted to abut against a container body abutment edge 118, and a lid insert 115. The container lid 105 also includes a grip tab 128.

[0089] The insert 115 extends in the longitudinal direction L and has a side surface 116 that faces the inner surface 112 of the container body 103 when the container lid 105 is in the closed position. The insert 115 further comprises a major surface 117 that is positioned within the container body 103 and spaced apart from the container body abutment edge 118 when the container lid 105 is in the closed portion, such that the insert 115 forms a plug that extends downwardly toward the container bottom 104.

[0090] The paperboard packaging container 100 further includes a locking arrangement for improving retention of the container lid 105 in the closed position after the lid 105 is closed. The locking arrangement shown in Figure 11 includes a first locking element 121 in the form of a recess on the inner surface 112 of the container body 103 and a second locking element 122 in the form of a mating protrusion on the side surface 116 of the lid insert 115. However, the first locking element 121 may alternatively be in the form of a protrusion and the second locking element 122 in the form of a recess, the protrusion and recess matching together such that the protrusion projects into the recess when the container lid 105 is in the closed position.

[0091] The first and second locking elements 121, 122 are positioned so that the protrusions engage with the recesses when the container lid 105 is in the closed position, i.e., the first locking element 121 provided on the inner surface 112 of the container body 103 is located at the same distance from the container body abutment edge 118 as the second locking element 122 provided on the side surface 116 of the insert portion 115.

[0092] 10 and 11 have the form of an elongated continuous protrusion and an elongated continuous recess, respectively, provided along substantially 100% of the circumference of the inner surface 112 of the container body 103 and the side surface 116 of the insert 115. Alternatively, the locking elements may be provided only on one or more selected portions of the periphery of the inner surface 112 of the container body 103 and the side surface 116 of the insert 115, such as on the front wall 136 of the container body 103.

[0093] The packaging container 100 may be provided with two or more locking mechanisms, with two or more first locking elements 121 and two or more second locking elements 122 arranged in parallel, spaced apart in the longitudinal direction L of the packaging container 100, continuously or discontinuously along the periphery of the inner surface 112 of the container body 103 and along the periphery of the side surface 116 of the insert portion 115, respectively.

[0094] The container body abutting edge 118 and the lid abutting edge 119 in the packaging container 100 shown in FIGS. 10 and 11 are perpendicular to the wall of the container body 103 and have flat surfaces.

[0095] The container lid 105 is opened by pivoting about a hinge 127 provided between the container lid 105 and the container body 103. The hinge 127 is provided on the rear wall 137. In the example shown in FIGS. 10 and 11, the rear wall 137 forms the short side of the packaging container 100. Alternatively, as shown in FIGS. 10 and 11, the hinge may be provided on the rear wall formed from the long side of a rectangular packaging container. For packaging containers having other shapes, such as circular, oval, or other polygonal cross-sectional shapes, the hinge may be located at any suitable position around the container opening. A further alternative is for the lid to be a fully separable lid that can be completely removed from the container body.

[0096] 11, the lid collar 108 is separated from the container body by a separation line 120, formed by, for example, one or more cuts or perforations, which extends along at least 55% of the container body periphery, thereby allowing the lid collar 108 to be fully or partially separated from the container body at abutment edges 118, 119. The non-separated portion of the lid collar may function as a hinge 127 between the lid and the container body.

[0097] In the packaging container 100 disclosed herein, the lid 105 can be positioned to be completely removed when the container 100 is opened. If the container lid 105 is a completely removable lid, the container lid 105 has no permanent connection to the container body 103. For the lid collar 108, and therefore the container lid 105, to be completely separable from the container body, the separation line 120 should extend around the entire circumference of the container body 103. However, prior to the first opening of the packaging container 100, the lid collar 108 may be connected to the container body by small protrusions that remain between the cuts or perforations that form the separation line 120. The paperboard packaging container 100 shown in FIGS. 10 and 11 includes a fully or partially removable shipping closure 129 that is attached to a shipping closure peripheral flange 135 on the inner surface 112 of the container body 103. The shipping closure 129 is removed by a user to gain initial access to the packaged contents. The transport closure 129 can be completely removed by peeling the peripheral flange 135 from the inner surface 112 of the container body 103. Alternatively, the transport closure 129 can be partially removed, leaving at least the peripheral flange 135 still attached to the inner surface 112 of the container body 103. The remaining peripheral flange 135 and any other portions of the transport closure 129 that are not removed can act as reinforcement for the container opening 107 and stabilize the shape of the container opening 107. The stabilizing remaining portions of the transport closure 129 contribute to maintaining a clear and well-fitting closure even after the container 100 has been opened and closed multiple times. The transport closure 129 is provided at a sufficient distance from the container body abutment edge 118 at the container opening 107 to allow the container lid 105 with the insert 115 to be in the closed position, which means that this distance should be equal to or greater than the height of the insert 115.

[0098] 11, the container bottom 104 is in the form of a bottom disk provided at the lower end 110, the bottom disk having a peripheral flange bent in the longitudinal direction L toward the lower end 110. The flange can be attached by gluing or welding, for example, by high frequency induction welding, to the inner surface 112 of the container body 103. The bottom edge is folded inward over the bottom disk flange.

[0099] Further modifications of the invention are possible within the scope of the appended claims. Accordingly, the invention should not be considered limited by the embodiments and drawings described herein. Rather, the full scope of the invention should be determined by the appended claims, with reference to the description and drawings.

Claims

1. An expandable press plunger (2) for attaching a container closure element to a container body, comprising: The expandable press plunger (2) has a plunger axis (a1) extending in an axial direction (A) perpendicular to a radial direction (R), and the expandable press plunger (2) is expandable in the radial direction (R). The expandable press plunger (2) comprises a base plate (8), a first expansion tool (9), and a second expansion tool (10), and the first expansion tool (9) and the second expansion tool (10) are movable relative to each other in the axial direction (A). The base plate (8) has a bottom surface (11) and a top surface (14) opposite the bottom surface (11), and the top surface (14) faces the first expansion tool (9) and the second expansion tool (10) in the axial direction (A). the second expansion tool (10) has an upper end (20) and a lower end (21), the second expansion tool (10) comprises an expansion tool sidewall (22) having an inner surface (23) and an outer surface (24), the expansion tool sidewall (22) extending from the upper end (20) to the lower end (21) of the second expansion tool (10), the expansion tool sidewall (22) comprising a peripheral portion (25) at the lower end (21) of the second expansion tool (10), the peripheral portion (25) of the second expansion tool (10) being positioned outward of the first expansion tool (9) in the radial direction (R), the second expansion tool (10) being deformable between a non-expanded state and a radially expanded state, The first expansion tool (9) comprises one or more inclined planes (15), each inclined plane (15) of the first expansion tool (9) having a first end (15') and a second end (15''), the first end (15') being disposed closer to the base plate (8) in the axial direction (A) than the second end (15''), the one or more inclined planes (15) of the first expansion tool (9) being inclined away from the plunger axis (a1) from the first end (15') of each inclined plane (15) to the second end (15'') of each inclined plane (15), and the second expansion tool (10) comprises one or more inclined planes (16), each inclined plane (16) of the second expansion tool (10) being inclined away from the inclined plane (a1) of the first expansion tool (9). each inclined plane (16) of the second expansion tool (10) has a first end (16') and a second end (16''), the first end (16') being positioned farther from the base plate (8) in the axial direction (A) than the second end (16''); each inclined plane (16) of the second expansion tool (10) is inclined toward the plunger axis (a1) from the first end (16') of the inclined plane (16) to the second end (16'') of the inclined plane (16); each inclined plane (15) of the first expansion tool (9) contacts and applies pressure to the corresponding inclined plane (16) of the second expansion tool (10) when the expandable press plunger (2) is in the radially expanded state; the second expansion tool (10) is transformable between a non-expanded state and a radially expanded state by moving the first expansion tool (9) downwardly toward the base plate (8) inside the expansion tool sidewall (22) of the second expansion tool (10) until the first end (15') of each inclined plane (15) of the first expansion tool (9) meets a corresponding first end (16') of the inclined plane (16) of the second expansion tool (10), and by continued downward movement until the inclined plane (15) of the first expansion tool (9) is fully aligned with the inclined plane (16) of the second expansion tool (10); the second expansion tool (10) is made of a material that can be repeatedly bent and / or stretched without breaking; the one or more inclined planes (15) of the first expansion tool (9) are inclined at an angle α with respect to the axial direction (A) away from the plunger axis (a1) from the first end (15') of each inclined plane (15) to the second end (15'') of each inclined plane (15); and each inclined plane (16) of each second expansion tool (10) is inclined at an angle β with respect to the axial direction (A) towards the plunger axis (a1) from the first end (16') of each inclined plane (16) to the second end (16'') of each inclined plane (16), the angle β being greater than the angle α by a difference angle γ in the range of 1 to 3 degrees.

2. 2. The expandable press plunger (2) of claim 1, wherein each inclined plane (16) of the second expansion tool (10) is positioned on a wedge-shaped protrusion (47, 48, 49) on the inner surface (23) of the expansion tool side wall (22).

3. The expandable press plunger (2) according to claim 2, characterized in that the cross section of the second expansion tool (10) parallel to the radial direction (R) is a modified polygon in which at least three wall portions (22wl, 22ws) are connected by at least three corner portions (22c), and the inner surface (23) of the expansion tool side wall (22) at each corner portion (22c) of the second expansion tool (5) is provided with a wedge-shaped protrusion (47) having an inclined flat surface (16).

4. The expandable press plunger (2) according to claim 3, characterized in that at least one wedge-shaped protrusion (48, 49) having an inclined plane (16) is arranged on the inner surface (23) of the expansion tool side wall (22) of each wall portion (22wl, 22ws) of the second expansion tool (10).

5. 5. The expandable press plunger (2) according to any one of claims 1 to 4, characterized in that each inclined plane (15) of the first expansion tool (9) is arranged on a wedge-shaped protrusion (17, 18, 19) on the first expansion tool (9).

6. 6. The expandable press plunger according to claim 1, wherein an expansion slit (35) is arranged in the expansion tool side wall (22) of the second expansion tool (10), and the expansion slit (35) extends in the axial direction (A) in the expansion tool side wall (22).

7. 7. The expandable press plunger (2) of claim 6, wherein the second expansion tool (10) has a height in the axial direction (A), and the expansion slit (35) extends into the expansion tool side wall (22) a distance in the range of 40% to 100% of the height of the second expansion tool (10).

8. 8. The expandable press plunger (2) of claim 7, wherein the expansion slit (35) extends into the expansion tool side wall (22) a distance in the range of 40% to 70% of the height of the second expansion tool (10).

9. 8. The expandable press plunger (2) of claim 7, wherein the expansion slit (35) extends into the expansion tool side wall (22) a distance in the range of 45% to 60% of the height of the second expansion tool (10).

10. 10. The expandable press plunger (2) of claim 6, wherein a plurality of expansion slits (35) extend from the peripheral portion (25) of the second expansion tool (10) towards the upper end (20) and divide the peripheral portion (25) into a plurality of edge segments.

11. 11. The expandable press plunger (2) of claim 10, wherein each of the expansion slits (35) of the plurality of expansion slits (35) terminates in an end opening (37), the end opening being positioned on a hinge line (HL) extending in a circumferential direction of the second expansion tool (10) perpendicular to the axial direction (A).

12. 12. The expandable press plunger (2) according to any one of claims 1 to 11, characterized in that the base plate (8) is provided with a deformation control member (40), the deformation control member (40) being arranged to limit radially inward deformation of the peripheral portion (25) of the second expansion tool (10).

13. 13. The expandable press plunger (2) according to claim 12, characterized in that the deformation control member (40) is provided in the form of a stop wall (40) arranged on the upper surface of the base plate (14), the stop wall (40) being inserted from the peripheral portion (12) of the base plate (8).

14. 14. The expandable press plunger (2) of claim 13, wherein the second expansion tool (10) comprises a sealing ridge (41) extending circumferentially on the outer surface (24) of the expansion tool side wall (22) along all or part of the outer periphery of the expansion tool side wall (22).

15. 15. The expandable press plunger (2) of claim 14, wherein the second expansion tool (10) includes a deformation tool (42) that protrudes in the radial direction (R) from the outer surface (24) of the expansion tool sidewall (22).

16. 16. The expandable press plunger (2) of claim 15, wherein the deformation tool (42) comprises or consists of an elongated bulge extending circumferentially on the expansion tool side wall (22), the elongated bulge extending over all or part of the circumference of the expansion tool side wall (22).

17. 16. The expandable press plunger (2) according to claim 15, characterized in that the peripheral portion (25) of the expansion tool side wall (22) comprises or consists of the deformation tool (42).

18. 18. The expandable press plunger (2) of any one of claims 15 to 17, characterized in that, when viewed in the axial direction (A) from the lower end (21) of the second expansion tool (10) towards the upper end (20) of the second expansion tool (10), the sealing ridge (41) is positioned above the deformation tool (42).

19. 19. The expandable press plunger (2) according to any one of claims 15 to 18, characterized in that the expandable press plunger (2) comprises a first piston (30) and a second piston (31), the first piston (30) and the second piston (31) extending in the axial direction (A), the second piston (31) being coaxial with the first piston (30), the base plate (8) being connected to the first piston (30) with the bottom surface (11) of the base plate (8) extending perpendicular to the axial direction (A), the first expansion tool (9) being connected to the second piston (31), and the second expansion tool (10) being connected to the first piston (30), the first piston (30) and the second piston (31) being arranged to be simultaneously movable together in the axial direction (A) and to be movable independently of each other in the axial direction (A).

20. 20. A mounting unit (1) for mounting a container closure element (29) to a container body (3), the mounting unit (1) comprising an expandable press plunger (2) according to any one of claims 15 to 19 and a holding device (4), the holding device (4) being adapted to hold the container body (3), the holding device (4) comprising at least one through-positioning cavity (6) adapted to receive and hold a portion of the container body (3), the through-positioning cavity (6) of the holding device (4) having a cross-sectional area defining a footprint area of ​​the container body (3), the expandable press plunger (2) being axially movable between a mounting position inside the through-positioning cavity (6) of the holding device (4) and a rest position outside the through-positioning cavity (6) of the holding device (4).

21. 21. Mounting unit (1) according to claim 20, characterized in that the holding device (4) comprises a welding unit (55) with an induction coil (56), the welding unit (55) being arranged around the through-positioning cavity (6).

22. 22. The mounting unit (1) according to claim 20 or 21, characterized in that the through-positioning cavity (6) of the holding device (4) comprises a recess (57) arranged in the wall of the through-positioning cavity (6), the recess (57) corresponding to the deformation tool (42) protruding radially from the outer surface (24) of the expansion tool side wall (22), the deformation tool (42) being arranged so as to nest inside the recess (57) when the expandable press plunger (2) is in the mounting position.

23. A method for sealing a packaging container using a mounting unit (1) according to any one of claims 20 to 22, said mounting unit (1) comprising an expandable pressing plunger (2) according to any one of claims 1 to 19, placing the container body (3) in the through-positioning cavity (6) of the holding device (4) of the mounting unit (1) with the body wall of the container body (3) aligned with the wall of the through-positioning cavity (6); Attaching to the bottom surface (11) of the base plate (8) of the expandable press plunger (2) a container closure element (29) having an attachment boundary (28) extending radially outward of the peripheral edge (12) of the bottom surface (11); moving the container closure element (29) in the axial direction (A) of the mounting unit (1) by the expandable press plunger (2) to a mounting position in the container body (3), while simultaneously deflecting the mounting boundary (28) of the container closure element (29) to align with the body wall of the container body (3); gradually deforming the expandable press plunger (2) from the unexpanded state to the radially expanded state by moving the first expansion tool (9) in the axial direction (A) toward the top surface (14) of the base plate (8) and sliding the inclined plane (15) of the first expansion tool (9) against the inclined plane (16) of the second expansion tool (10), wherein the expansion tool side wall (22) of the second expansion tool (10) is subjected to a biasing force that moves the expansion tool side wall (22) away from the plunger axis (a1) of the expandable press plunger (2) and presses the attachment boundary (28) of the container closure element (29) in the radial direction (R) toward the body wall of the container body (3); welding the attachment boundary (28) of the container closure element (29) to the body wall of the container body (3); A method comprising:

24. 24. The method according to claim 23, wherein the attachment boundary (28) of the container closure element (29) is pressed against the body wall of the container body (3) on the outer surface (24) of the expansion tool side wall (22) of the second expansion tool (10) by the sealing ridge (41) extending circumferentially along the entire circumference of the expansion tool side wall (22) of the second expansion tool (10), and the welding of the attachment boundary (28) of the container closure element (29) to the body wall of the container body (3) is performed along the sealing ridge (41).

25. 25. The method according to claim 23 or 24, characterized in that the second expansion tool (10) comprises a deformation tool (42) protruding radially from the outer surface (24) of the expansion tool side wall (22), and the through-positioning cavity (6) of the holding device (4) comprises a corresponding depression (57) arranged in the wall of the through-positioning cavity (6), the method further comprising the step of deforming the body wall of the container body (3) by radially pressing the deformation tool (42) into the depression (57) in the wall of the through-positioning cavity (6) while the body wall of the container body (3) is positioned between the deformation tool (42) on the second expansion tool (10) and the depression (57) in the wall of the through-positioning cavity (6).

26. 26. A method according to any one of claims 23 to 25, characterized in that a plurality of container closure elements (29) are simultaneously positioned in a plurality of container bodies (3) by a plurality of mounting units (1).

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