System and method for high speed application of paper end closures to composite containers

Abstract

The system for assembling a container and a closure includes an expanding collet having a plurality of pivoting collet segments configured to simultaneously pivot radially outward about a pivot point. The collet includes a lip engageable with a rim at the open end of the container and an angled tip positioned radially inward from the lip and shaped to press a countersunk portion of the closure against the inner wall of the container as the collet segments pivot radially outward. When the container and chuck are mated, the rim engages the lip of the collet segment, causing the angled tip of the collet segment to pivot outward toward the inner wall of the container, thereby pressing the countersunk portion of the closure against the inner wall of the container.

Description

[Technical Field]

[0001] SUMMARY The present disclosure relates to a system and method for quickly adding paper end closures to composite containers.

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 125,013, filed December 14, 2020, and U.S. Provisional Patent Application No. 63 / 030,959, filed May 28, 2020, the entire disclosures of both of which are incorporated herein by reference. [Background technology]

[0003] The present disclosure generally relates to containers and methods for sealing such containers. Cylindrical paper or composite containers are often used for snack foods and similar products. Such containers often have a membrane sealed to the top rim of the container, an overcap or end cap that covers the membrane, and a metal closure bonded to the bottom rim of the container. Typically, the membrane is first sealed to the top rim, and then the end cap is added to the container. The container is then filled with product through the open bottom end, and then the metal closure is bonded to the bottom rim of the container. The container may be flushed or evacuated during the bottom bonding process to preserve the stored product for a longer period of time.

[0004] The above-described process using a metal bottom end can hinder the recyclability of certain containers because, once the metal closure is bonded to the bottom of the container, it becomes very difficult to separate the metal closure from the container itself. If it is not possible to separate the paper body of the container from the metal bottom, the container assembly may not be eligible for either the paper or metal recycling stream, depending on the configuration. This can result in unnecessary waste and adverse environmental impacts. Recyclable containers are needed to increase the sustainability of the final product.

[0005] One solution to the need for recyclability is to manufacture containers with paper end closures rather than metal ends. However, simply substituting a metal closure for a paper end closure is not compatible with current metal end joining processes because existing equipment for joining metal ends to containers is built specifically for metal ends, and paper end closures present unique challenges that do not exist with metal ends (e.g., closure flexibility, separation of a closure from a stack of closures, feeding the closure, folding the closure, and fusing non-metallic closures).

[0006] Through ingenuity and diligent research, the inventors have not only developed a system and method for applying paper end closures to containers, but also developed a system and method that operates at high speeds (e.g., over 300 containers per minute). Additionally, in certain embodiments, certain aspects of the disclosed system and method can be used to retrofit existing metal end connectors (e.g., Angelus 60L), thereby saving the cost of new equipment. Summary of the Invention

[0007] In some embodiments, an assembly module for assembling the container and closure can be provided. The container and / or closure can be made of paper. The container can have an open end surrounded by a rim. The assembly module can include a chuck, an expanding collet, and an actuator. The chuck can be configured for axial alignment with the container, and the actuator can be configured to axially align the container and the chuck. In some embodiments, the chuck can be configured to be axially stationary. The expanding collet can engage with the chuck and can include pivoting collet segments. The collet segments can be configured to simultaneously pivot radially outward about a pivot point. The collet segments can include a lip and an angled tip. Each lip of the collet segment can be positioned around the expanding collet to be engaged by the rim of the open end of the container. The angled tip of each collet segment can be positioned radially inward from the lip and can be shaped to press a countersink portion of the closure against an inner wall of the container when the collet segment pivots radially outward. When the container and chuck are axially aligned by the actuator, the rim of the container engages the lip of the collet segment, causing the angled tip of the collet segment to pivot outward toward the interior wall of the container, thereby forcing the closure into the open end of the container and compressing the countersink portion of the closure between the angled tip of the collet segment and the interior wall of the container. The pivot point of each collet segment can be located where the expanding collet engages the chuck. As the collet segments pivot radially outward about the pivot point, the diameter of the expanding collet can increase. In some embodiments, the diameter of the expanding collet can increase by approximately 5% of the overall diameter of the expanding collet. When the diameter of the expanding collet increases to its maximum diameter (e.g., in a fully expanded state), the outer diameter of the angled tip of the collet segment can be approximately equal to the inner diameter of the container. The length of the angled tip can correlate to the depth of the countersink of the closure within the open end of the container upon assembly.The angled tip can have an end proximal to the lip and a distal end, and can be angled such that the expanding collet has a diameter at the proximal end of the angled tip that is larger than the diameter at the distal end of the angled tip. In some embodiments, the lip can include a generally horizontal surface configured to engage the rim of the container. In some embodiments, the expanding collet can be formed from a non-metallic material.

[0008] In some embodiments, the expanding collet can further include an expandable retainer. The expandable retainer can be configured to pivot the collet segments radially inward. The rim at the open end of the container can have a hoop strength greater than the biasing force of the retainer through a given expansion.

[0009] In some embodiments, the assembly module can further include a compressible backstop positioned to resist pivoting of the collet segments after a predetermined pivot distance. The assembly module can also include a secondary backstop positioned to prevent pivoting of the collet segments after a predetermined secondary pivot distance. The predetermined secondary pivot distance can occur before the predetermined compression.

[0010] In some embodiments, the assembly module can further include an assembly rod concentrically positioned within the chuck and the expansion collet. The assembly rod can be configured to move axially to compress a central portion of the closure into the open end of the container when the container and chuck are axially aligned. The assembly rod can include a centering disk that contacts the center of the closure as the closure is compressed into the open end of the container.

[0011] In some embodiments, the assembly module may further include a circumferential sleeve surrounding the chuck and the expansion collet. The circumferential sleeve may be configured to fold the peripheral skirt of the closure over the rim and around the outer wall of the container. The circumferential sleeve may have an inner diameter greater than the outer diameter of the container. The circumferential sleeve may further include an inner edge having a gripping surface texture configured to contact the folded peripheral skirt of the closure. The circumferential sleeve may be formed from a non-metallic material. The assembly module may further include an O-ring positioned between the chuck and the circumferential sleeve, the circumferential sleeve being rotationally and laterally movable along the O-ring relative to the chuck. The circumferential sleeve may be stationary in the axial direction.

[0012] In some embodiments, the assembly module can further include a roller. The roller can be configured to move laterally relative to the chuck and press the circumferential sleeve against a portion of the folded circumferential skirt of the closure. The container can be configured to rotate axially relative to the roller. The expanding collet can resist the pushing action of the roller. The circumferential sleeve can be configured to shift eccentrically relative to the chuck when pushed by the roller.

[0013] In some embodiments, the assembly module can further include a membrane disposed around the lip and angled tip of the expansion collet to prevent the ingress of debris between the expansion collet. The membrane can be formed from silicone and / or rubber.

[0014] Having thus generally described the present disclosure, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. [Brief explanation of the drawings]

[0015] [Figure 1] 1 is a cross-sectional side perspective view of an exemplary container (e.g., a rigid composite can) and closure (e.g., a paper end closure) according to some embodiments of the present disclosure.

[0016] [Figure 2A] 1 is a cross-sectional view of an exemplary closure prior to application to a container, according to some embodiments of the present disclosure. FIG.

[0017] [Figure 2B] 2B is a cross-sectional view of the closure of FIG. 2A after being applied to a container, according to some embodiments of the present disclosure.

[0018] [Figure 2C] 1 is a cross-sectional view of a closure after being applied to a container according to some embodiments of the present disclosure.

[0019] [Figure 2D] 1 is a cross-sectional view of a closure and a container according to some embodiments of the present disclosure.

[0020] [Figure 3] 1 is a bottom perspective image of an exemplary container assembly formed by adding a closure to a container according to some embodiments of the present disclosure.

[0021] [Figure 4] FIG. 1 is a top view of a splicing system diagram including a conveyor that transports containers through various modules (e.g., a separation and feeding module, an assembly module, a fusion module) according to some embodiments of the present disclosure.

[0022] [Figure 5] FIG. 10 is a top side view of an exemplary assembly module and fusion module above a rotating turntable configured to rotate and transport containers and closures through modules in a joining system, thereby producing a container assembly, according to some embodiments of the present disclosure.

[0023] [Figure 6]FIG. 10 is a top side view of an example separation and delivery module configured to use vacuum cups attached to a spindle device to each remove an individual closure from a stack of closures and transfer the individual closures to a pocketed turret that rotates and deposits the closures onto the open ends of containers, according to some embodiments of the present disclosure.

[0024] [Figure 7] FIG. 10 is a bottom side view of an example assembly module including a chuck and an expansion collet in an unexpanded state, according to some embodiments of the present disclosure.

[0025] [Figure 8] FIG. 8 is an underside view of the assembled module of FIG. 7 in a fully expanded state according to some embodiments of the present disclosure.

[0026] [Figure 9] FIG. 9 is a bottom view of the assembled module of FIGS. 7 and 8 in an unexpanded state in which the collet segments that together form the expansion collet are not pivoted, according to some embodiments of the present disclosure.

[0027] [Figure 10] FIG. 10 is a cross-sectional side view of the assembled module of FIGS. 7-9 in a partially expanded state, just after the front stop of the collet segment has been pivoted away from the front stop of the chuck, in accordance with some embodiments of the present disclosure.

[0028] [Figure 11] FIG. 11 is a cross-sectional side view of an example container and closure engaged with the assembly module of FIGS. 7-10 in a partially expanded state caused by an upward force on the rim of the container acting on the collet segment to pivot the collet segment from the front stop toward the rear stop of the chuck, according to some embodiments of the present disclosure.

[0029] [Figure 12]FIG. 10 is a cross-sectional top side view of an example container and closure engaged with an assembly module including a lateral movement roller, a circumferential sleeve, a chuck, and an expansion collet, with the container in a partially expanded state with the collet segments pivoted away from the front stop of the chuck and abutting against a compressible rear stop, according to some embodiments of the present disclosure.

[0030] [Figure 13] FIG. 13 is a cross-sectional top side view of the container, closure, and assembly module of FIG. 12 in a fully expanded state with the container having fully pivoted the collet segments so that the rear stops of the collet segments abut against the hard rear stops of the chuck, according to some embodiments of the present disclosure.

[0031] [Figure 14] FIG. 10 is a cross-sectional side view of an example container and closure moving upward toward an assembly module, including lateral movement rollers, a circumferential sleeve, a chuck, and an expanding collet in an unextended state with the collet segments abutting the front stop of the chuck, according to some embodiments of the present disclosure.

[0032] [Figure 15] FIG. 15 is a cross-sectional side view of the container, closure, and assembly module of FIG. 14 in a fully expanded state in which the container has pivoted the collet segments away from the front stop and abutted against the rear stop of the chuck due to the rollers moving laterally toward the chuck, in accordance with some embodiments of the present disclosure.

[0033] [Figure 16] 16A and 16B are cross-sectional side views of the container, closure, and assembly module of FIGS. 14 and 15 in a fully expanded state with the closure's peripheral skirt sandwiched between the container and a peripheral sleeve eccentrically shifted relative to the chuck by lateral movement of the rollers, according to some embodiments of the present disclosure.

[0034] [Figure 17]FIG. 10 is a cross-sectional underside view of an exemplary container and closure below an assembled module including a circumferential sleeve, a chuck, an expansion collet, and an expandable membrane surrounding the expansion collet, according to some embodiments of the present disclosure.

[0035] [Figure 18] 1 is a cross-sectional side view of an exemplary container and closure in an assembled module with an exemplary fusion module, according to some embodiments of the present disclosure. [Figure 19] 1 is a cross-sectional side view of an exemplary container and closure in an assembled module with an exemplary fusion module, according to some embodiments of the present disclosure. [Figure 20] 1 is a cross-sectional side view of an exemplary container and closure in an assembled module with an exemplary fusion module, according to some embodiments of the present disclosure. [Figure 21] 1 is a cross-sectional side view of an exemplary container and closure in an assembled module with an exemplary fusion module, according to some embodiments of the present disclosure. [Figure 22] 1 is a cross-sectional side view of an exemplary container and closure in an assembled module with an exemplary fusion module, according to some embodiments of the present disclosure. [Figure 23] 1 is a cross-sectional side view of an exemplary container and closure in an assembled module with an exemplary fusion module, according to some embodiments of the present disclosure.

[0036] [Figure 24] FIG. 1 illustrates an exemplary embodiment of a fusion module, according to some embodiments of the present disclosure. [Figure 25] FIG. 1 illustrates an exemplary embodiment of a fusion module, according to some embodiments of the present disclosure. [Figure 26] FIG. 1 illustrates an exemplary embodiment of a fusion module, according to some embodiments of the present disclosure. [Figure 27] FIG. 1 illustrates an exemplary embodiment of a fusion module, according to some embodiments of the present disclosure. [Figure 28]FIG. 1 illustrates an exemplary embodiment of a fusion module, according to some embodiments of the present disclosure. [Figure 29] FIG. 1 illustrates an exemplary embodiment of a fusion module, according to some embodiments of the present disclosure. [Figure 30] FIG. 1 illustrates an exemplary embodiment of a fusion module, according to some embodiments of the present disclosure. [Figure 31] FIG. 1 illustrates an exemplary embodiment of a fusion module, according to some embodiments of the present disclosure. [Figure 32] FIG. 1 illustrates an exemplary embodiment of a fusion module, according to some embodiments of the present disclosure. [Figure 33] FIG. 1 illustrates an exemplary embodiment of a fusion module, according to some embodiments of the present disclosure. [Figure 34] FIG. 1 illustrates an exemplary embodiment of a fusion module, according to some embodiments of the present disclosure.

[0037] [Figure 35] FIG. 10 is a top view of a circumferential sleeve according to some embodiments of the present disclosure.

[0038] [Figure 36] FIG. 1 is a perspective view of a circumferential sleeve according to some embodiments of the present disclosure.

[0039] [Figure 37] 1 is a cross-sectional view of a separation and supply module according to some embodiments of the present disclosure. [Figure 38] 1 is a cross-sectional view of a separation and supply module according to some embodiments of the present disclosure. [Figure 39] 1 is a cross-sectional view of a separation and supply module according to some embodiments of the present disclosure. [Figure 40] 1 is a cross-sectional view of a separation and supply module according to some embodiments of the present disclosure.

[0040] [Figure 41]1 is a cross-sectional view of a fusion module of the present invention, according to some embodiments of the present disclosure. [Figure 42] 1 is a cross-sectional view of a fusion module of the present invention, according to some embodiments of the present disclosure.

[0041] [Figure 43] 1A-1C illustrate an exemplary finished container and paper end, according to some embodiments of the present disclosure.

[0042] [Figure 44] FIG. 2 illustrates an exemplary induction coil according to some embodiments of the present disclosure.

[0043] [Figure 45] FIG. 1 illustrates an exemplary concentrator used in connection with an induction coil, according to some embodiments of the present disclosure.

[0044] [Figure 46A] 1A and 1B show an exemplary concentrator used in accordance with some embodiments of the present disclosure, from an angle. [Figure 46B] 1A and 1B show an exemplary concentrator used in accordance with some embodiments of the present disclosure, from an angle. [Figure 46C] 1A and 1B show an exemplary concentrator used in accordance with some embodiments of the present disclosure, from an angle. [Figure 46D] 1A and 1B show an exemplary concentrator used in accordance with some embodiments of the present disclosure, from an angle.

[0045] [Figure 47] 1A-1C illustrate three-dimensionally printed examples of assembly modules according to some embodiments of the present disclosure.

[0046] [Figure 48] 1A-1C illustrate embodiments of a separation and supply module, an assembly module, and a sealing module according to some embodiments of the present disclosure.

[0047] [Figure 49] 1 illustrates an embodiment of a cross-sectional top side view of a container, closure, and assembly module in a fully expanded state.

[0048] [Figure 50] 1 illustrates an embodiment of a cross-sectional top side view of a container, closure, and assembly module in a fully expanded state. DETAILED DESCRIPTION OF THE INVENTION

[0049] While the present disclosure may be embodied in many forms, one or more embodiments have been shown in the drawings and are described in detail herein, with the understanding that the disclosure is to be considered as an exemplification of the principles of the disclosure and is not intended to limit the disclosure to the embodiments illustrated.

[0050] rigid composite container Rigid, paper composite containers are used to package a variety of products, such as snacks and other food products. These containers often comprise a rigid, cylindrical or molded body that is typically manufactured with open top and bottom ends. Composite containers can include rigid cans made from rolled sheet materials, such as cardboard and / or paperboard. In one embodiment, the containers can be spirally rolled. The bottom closure is usually permanently affixed to the container, while the top closure is often designed for easy removal by the consumer (i.e., a removable overcap and / or peelable membrane).

[0051] FIG. 1 is a cross-sectional side perspective view of an exemplary container 202. 13Container 202, also shown in FIG. 1, can comprise a rigid cylindrical body having a sidewall 206 that terminates in a rim 205 at an open end 203. In this embodiment, open end 203 can comprise the bottom end of container 202. In some embodiments, open end 203 can be sealed with a closure 204 (e.g., a paper end closure). In some embodiments, container 202 can further have a second open end (e.g., a top end) opposite open end 203 that can be sealed with a flexible membrane or other closure.

[0052] The open end 203 of the container 202 may be surrounded by a rim 205 formed by the terminal edge of a sidewall 206 that forms the body of the container 202. The sidewall 206 may include an inner surface 207 that faces the inside of the container 202 and an outer surface 208 that faces the outside of the container 202. The inner surface 207 may be the product-facing side of the sidewall 206 of the container 202. In some embodiments, the product(s) may be food products, and the inner surface 207 may include a food-safe layer and / or coating that helps protect the integrity of the food(s) contained within the container 202. The outer surface 208 may include printing or other applied graphics for labeling and / or advertising the product(s) contained within the container 202.

[0053] In some embodiments, the rigid sidewall 206 of the container 202 can comprise multiple layers of paper, metal foil, and / or sealant. For example, the sidewall 206 can comprise, from the exterior surface 208 inward, an outer layer of paper (white) coated with a sealant, two sandwiched layers of paper (e.g., brown cardboard or paperboard), and an inner lining of metal foil (e.g., approximately 0.0003 inch thick aluminum). The metal foil lining and sealant layers can advantageously aid in the induction heating process and seal the closure 204 to the container 202. Any combination of container layers (paper, metal, and / or sealant) can be utilized in the present invention.

[0054] In some embodiments, the inner surface 207 and / or outer surface 208 can have a layer of sealant at the open end 203 of the container 202, which can melt and seal the assembled closure 204 to the container 202. In some embodiments, the layer of sealant can be disposed over the entire inner surface 207 and / or outer surface 208 of the container 202, or can be disposed only along the edge(s) of the open end 203 of the container 202. However, in other embodiments, no separate sealant material is used.

[0055] Paper end closures In some embodiments, the closure 204 of the present disclosure can be a paper end closure. In one embodiment, the closure 204 can be a generally flat circle or disk sized to fit around the open end 203 of the container 202. In one embodiment, the closure 204 can be a generally flat circle or disk sized to be recessed around the open end 203 of the container 202. In another embodiment, the closure 204 can be pre-punched, as shown in FIG. 1 . In either case, the rotational / circumferential orientation of the closure 204 relative to the container 202 can be ignored if the container 202 and closure 204 are uniform across all rotational angles. However, other shapes (e.g., rectangle, polygon with elongated sides) are possible.

[0056] As discussed herein, the upper side 204a and / or lower side 204b of the closure 204 are referred to in the context of the orientation of the closure 204 when applied to the open end 203 of the container 202. Here, as shown in Figure 1, the container 202 is oriented relative to the closure 204 with the rim 205 of the open end 203 of the container 202 facing upward so that the upper / upper side 204a of the closure 204 faces upward and first contacts the lower / lower / underside / inner side 204b of the closure 204, which faces downward. Thus, in embodiments in which the open end 203 of the container 202 is the bottom of the container 202, the upper side 204a of the closure 204 faces downward when the container assembly 406 (shown in Figure 3) is oriented upright. While other orientations not depicted in this disclosure are possible for attaching the closure 204 to the container 202, it should be understood that the upper / top side 204a of the closure 204 may face outward when assembled as part of the final product container assembly 406, and the lower / bottom / directly below side 204b will face the product(s) inside the container 202 when assembled as part of the final product container assembly 406.

[0057] In some embodiments, the closure 204 can be pre-punched and / or pre-formed with particular structural features (see FIG. 1). The punching and / or pressing process can include feeding flat closure material into a die press (e.g., a stamping press) and compressing the material between opposing dies.

[0058] The closure 204 can be made primarily from paper and other fibrous materials, but can also include non-fibrous barrier layers made from metal and / or plastic. In some embodiments, the closure material can comprise multiple layers of paper, metal, and / or sealant. For example, the closure can comprise two layers of paper (e.g., white) on the top side and / or a sealant-coated metal foil layer (e.g., aluminum approximately 0.0003 inches thick) on the bottom side 204b. The sealant-coated metal foil layer can advantageously be used in conjunction with induction heating to seal the closure 204 to the container 202. In some embodiments, the sealant can be applied to the bottom side 204b of the closure 204 only around the perimeter where the closure 204 is configured to contact the container 202. In other embodiments, the sealant can be applied to the entire bottom side 204b of the closure 204.

[0059] 2A-2C show cross-sectional views of an embodiment of a preformed closure 204 both before and after assembly with a container 202. Before assembly, the preformed closure 204 can have a central, generally flat central portion 240, an annular chuck wall 242 radially surrounding the central portion 240 and extending vertically at an angle from the central portion 240, and (optionally) a peripheral skirt 209 extending radially outward from the chuck wall 242. The peripheral skirt 209 can also be disposed vertically at an angle. As noted above, in other embodiments, the entire closure 204 can be generally flat or flat and disk-shaped prior to insertion into the container 202.

[0060] In some embodiments, the central portion 240 of the closure 204 may be generally flat and horizontal, but may include one or more convex protrusions 240a, 240b rising from an upper side of the central portion 240. The one or more convex protrusions 240a, 240b may advantageously provide additional material and / or surface area for the closure 204 within the central portion 240 that may be stretched when the closure 204 is expanded within the open end 203 of the container 202 (e.g., when the chuck wall 242 is pressed against the inner surface 207 of the sidewall 206 of the container 202). In some embodiments, the one or more convex protrusions 240a, 240b may additionally provide flexibility within the closure 204 to minimize any damage and / or distortion to the container assembly 406 and its seals (e.g., airtightness) due to varying pressure differentials between the outside and inside of the sealed container assembly 406. In this manner, the convex protrusions 240a, 240b formed in the closure 204 can help ensure the integrity of the product(s) contained therein. In other embodiments, the central portion 240 of the closure 204 can include one or more concave protrusions or a combination of concave and convex protrusions.

[0061] 2A , in some embodiments, the central portion 240 can include a dome 240a at the center of the closure 204, with the dome 240a resting on a flat portion 240b that surrounds the dome 240a. In one embodiment, the radially outer edge of the flat portion 240b can form an obtuse angle with a generally horizontal, flat annular ring 240c that surrounds the flat portion 240b and forms the lowest portion of the closure 204 on the upper side 240a of the closure 204 (and the highest shelf of the closure 204 on the lower side 204b of the closure 204). In other words, the annular ring 240c can be the farthest point from the outer edge of the skirt 209 before the closure 204 is applied to the container 202. In certain embodiments, the annular ring 240c can be generally U-shaped.

[0062] Further radially outward from and adjacent to the annular ring 240c, a chuck wall 242 may be preformed and / or stamped into the closure body 204. The chuck wall 242 may form an obtuse angle with the annular ring 240c. In this manner, the diameter of the lower portion of the chuck wall 242 adjacent the annular ring 240c may be smaller than the diameter of the upper portion of the chuck wall 242 adjacent the circumferential skirt 209.

[0063] The chuck wall 242 can be configured to press against the inner surface 207 of the sidewall 206 of the container 202 when inserted into the open end 203 of the container 202, thus forming a countersink 244 (as shown in FIGS. 2B and 2C, which depict cross-sectional views of various closures 204 after assembly to the container). The length / height of the chuck wall 242 can correlate to a predetermined countersink depth 246 of the countersink 244 of the closure 204 within the open end 203 of the container 202 when assembled.

[0064] In some embodiments, the peripheral skirt 209 can extend generally horizontally adjacent and further radially outward from the chuck wall 242. The peripheral skirt 209 can be configured to fold over the rim 205 of the sidewall 206 of the container 202 at the open end 203 of the container 202. In some embodiments, the length of the peripheral skirt 209 can be long enough so that the peripheral skirt 209 extends far enough beyond the rim 205 of the container 202 and folds around the rim 205 to contact the outer surface 208 of the sidewall 206 of the container 202. In some embodiments, the peripheral skirt 209 can further press and seal against the outer surface 208 of the sidewall 206 of the container 202. In this manner, the closure 204 can advantageously form two seals with the container 202 (e.g., against the inner surface 207 and against the outer surface 208). Providing a double seal between the container 202 and the closure 204 can help maintain an airtight seal. In some embodiments, the closure 204 can form a single continuous seal with the container 202 through the countersink 244, over the rim 205, and through the peripheral skirt 209.

[0065] 2C and 2D, the closure 204 can be configured such that the peripheral skirt 209 is recessed within or positioned inside the body of the container 202. In this embodiment, the peripheral skirt 209 can be folded around the rim 205 so that it does not contact the exterior surface 208 of the sidewall 206 of the container. In one embodiment, the top surface 204a of the closure 204 can be spaced from (e.g., recessed within) the bottom peripheral edge 205 of the container 202 body. The closure 204 can be recessed a predetermined recess distance "D r " can be retracted into the container body 202. r " may be measured from the bottom periphery or rim 205 of the container body 202 to the face 204a of the bottom closure 204. In some embodiments, the setback distance "D r" can be in the range of about 0.2 cm to 2 cm (about 0.08 inches to 1.2 inches). For example, the setback distance "D r " can be about 0.7 cm (about 0.275 inches). r " may be configured to minimize any protrusion of the face 204a of the bottom closure 204 beyond the bottom peripheral edge or rim 205 of the container body 202 when the container assembly is exposed to a higher pressure differential between the container interior and the external environment. For example, the setback distance "D r " can ensure that the bottom closure 204 does not over-expand beyond the bottom periphery or rim 205 of the container body 202 at pressure differentials exceeding about 10 inHg (about 34 kPa). In this manner, the setback distance "D r ", combined with the integrity of the hermetic seal, can help prevent the closure from expanding beyond the periphery or rim 205 of the container body 202, rocking of the container body 202 when the container body 202 is positioned upright, and / or other problems with the bottom closure 204.

[0066] The inventors surprisingly discovered that in this embodiment, the airtightness of the bottom closure relative to the inner surface 207 of the container body 202 can be maintained using a retractable closure 204 secured only to the inner surface 207 of the container body 202. As disclosed herein, the closure 204 can be retracted into the container body 202 any distance practical in the art. In some embodiments, the closure 204 is a retracted bottom. In some embodiments, the peripheral edge of the closure 204 is flush with the edge or rim 205 of the sidewall 206 of the container body 202 (see FIG. 2D ). In other embodiments, the peripheral edge of the closure 204 is disposed inwardly relative to the peripheral edge or rim 205 of the sidewall 206 of the container body 202.

[0067] The closure 204 can be recessed inside the container body 202 to form a first deformed surface 204c of the closure 204 that is spaced from (e.g., recessed within) the bottom peripheral edge 205 of the container body 202. The first deformed surface 204c can include a central portion of the closure 204. In one embodiment, the first deformed surface 204c can be flat, substantially flat, horizontal, or substantially horizontal. During insertion of the closure 204 into the container body 202, as will be described, in some embodiments, the peripheral skirt 209 of the closure 204 can be bent at a right angle or a near-right angle, as shown as the second deformed surface 204d in FIG. 2D . The resulting second deformed surface 204d (formerly the peripheral skirt 209) of the closure 204 can be positioned vertically or near-vertically adjacent the inner surface 207 of the container body 202 at the open bottom end 203.

[0068] system In some embodiments, the present invention includes a system for applying and sealing a closure (e.g., a paper end closure) to a container body (e.g., a composite can). In one embodiment, the system of the present disclosure can include at least a separating and dispensing module 100, an assembling and pressing module 200, and a sealing module 300. The various modules can be utilized separately and / or as part of an overall system.

[0069] The system can include a conveyor that transports the container bodies through the modules. The conveyor can also include different sections that move the container bodies in different ways through the system. In some embodiments, the conveyor can include a rotary turntable 32 that transports the container bodies in a rotating path through one or more modules.

[0070] 4, the conveyor can include an infeed conveyor 44 that transports the container bodies 202 to the module. The infeed conveyor 44 can include a feed screw 46 or any other suitable type of mechanism for transporting the container bodies into the system. The feed screw 46 can feed the container bodies into a pocketed turret device 52. The turret device 52 can transport the container bodies through the separation and feeding module 100.

[0071] The container bodies may then be fed from turret 52 to transfer turret 58. Transfer turret 58 may advance the container bodies one at a time into assembly module 200.

[0072] In some embodiments, the rotary turntable 32 can include a chamber 34. The rotary turntable 32 can support a plurality of chambers spaced about its periphery. Each chamber essentially comprises a cylindrical tube into which a container body with a closure thereon can be loaded. The bottom of the chamber can comprise a lift plate.

[0073] In some embodiments, as shown in FIG. 5 , one or more assembly modules 200 and / or fusion modules 300 can be mounted above the turntable 32. The turntable can include lift plates. Each lift plate can be vertically movable relative to the assembly module 200. A cam can be mounted below the turntable 32, and the cam can engage an elevator attached to the lift plate. As the turntable 32 rotates about its axis, the elevator can move vertically following the profile of the cam to raise and lower the lift plate, thereby raising and lowering the container body, to perform various operations involving the assembly and pressing module 200.

[0074] Separation and Supply In some embodiments, the present disclosure includes novel systems and methods for separating and dispensing individual closures (e.g., paper end closures) from a closure supply onto individual containers (e.g., rigid, cylindrical composite cans) (see FIG. 6). In some embodiments, as the containers (e.g., composite cans) are conveyed through the system, closures 204 (e.g., paper end closures) can be placed onto the open ends 203 of the containers 202. Prior to placing the closures 204 onto the containers 202, the closures 204 can be separated from the stack of closures 204 and dispensed individually onto each container 202. Accordingly, the separation and dispensing module 100 will now be described.

[0075] In some embodiments, the separating and feeding module 100 may be capable of separating a single closure 204 from a stack of closures 204 and feeding the closure 204 to the feed screw assembly at a rate of at least 200 closures / minute. In other embodiments, the separating and feeding module 100 may be capable of separating a single closure 204 from a stack of closures 204 and feeding the closure 204 to the feed screw assembly at a rate of at least 300 closures / minute. In some embodiments, the separating and feeding module 100 may be capable of separating a single closure 204 from a stack of closures 204 and feeding the closure 204 to the feed screw assembly at a rate of at least 400 closures / minute. In yet another embodiment, the separating and feeding module 100 may be capable of separating a single closure 204 from a stack of closures 204 and feeding the closure 204 to the feed screw assembly at a rate of at least 450 closures / minute. In one embodiment, the separation and delivery module 100 can be considered a high speed separation and delivery system.

[0076] figure 37 ~Figure 40, generally speaking, the closures (e.g., die-cut paper edges) 204 can be provided in a stacked configuration. For example, the closures 204 can be provided to the system via a gravity-feed closure infeed track 105. The infeed track 105 can accommodate a plurality of stacked closures 204. The infeed track 105 can generally have a size, shape, and configuration similar to or identical to the closures 204. For example, if the closures 204 are generally disk-shaped, the infeed track 105 can be generally cylindrical and can enclose a stack of closures 204 within the cylindrical portion. In one embodiment, the infeed track 105 can have an accordion configuration so that it can bend, rotate, or twist as needed by the system. In one embodiment, the infeed track 105 can be arranged so that the closures 204 are stacked vertically or nearly vertically, with the openings 122 of the infeed track 105 then depositing the closures 204 face down or nearly face down. Alternatively, the infeed track 105 can be arranged horizontally or nearly horizontally. Any configuration can be utilized.

[0077] In one embodiment, the closures 204 can be placed in the infeed track 105 with the non-product-facing surface 116 facing the opening 122 in the separation and feeding module 100. In one embodiment, the infeed track can include clips 120 on the open end 122 that hold or secure each closure 204 within the track 105 until it is removed. The clips 120 can take any form or shape that holds the closures 204 in place within the track 105 but allows sufficient deformation of the closures 204 to allow them to be removed from the infeed track at the appropriate time. In one embodiment, the clips 120 are positioned partially around the open end 122 of the infeed track 105. Alternatively, the open end 122 can have an integral feature that holds the closures 204 within the infeed track 105 until they are removed by the system.

[0078] In one embodiment, the separation and delivery module 100 can remove closures 204 one at a time from the stack of closures and deliver the closures 204 to a servo-driven screw, screw conveyor, or other device known in the art. The screw conveyor can be driven by any known mechanism, such as a belt, gear, chain, or other system. In one embodiment, the screw can rotate continuously. In another embodiment, the screw can stop and start, with the stopping of the screw correlated to the placement of the closure 204 within the screw. For example, the screw can rotate at a continuous speed and stop when the screw is positioned below the displacement position of the closure 204. In yet another embodiment, the screw can rotate at a continuous speed and slow down when the screw is positioned below the displacement position of the closure 204. In one embodiment, the screw can be timed relative to the separation and delivery module 100. 39 and Figure 40 Note that in FIG. 1, multiple closure bodies 204 are shown vertically aligned below the displacement position of the system 100. In one embodiment, a closure body 204 will be transported horizontally before another closure body 204 is placed into the screw. Thus, in one embodiment, the closure bodies 204 will not be vertically aligned at the same time.

[0079] In some embodiments, the separation and delivery module 100 can include a servo-driven transfer dial 111 with four heads 113, each having a vacuum cup 114 attached to a spindle device. That said, any number of heads is contemplated herein. In one embodiment, the system includes a two-axis servo system.

[0080] figure 39, removal of the closure 204 from the infeed track 105 is shown. In one embodiment, the closure 204 is removed from the infeed track 105 by the vacuum cup 114. In one embodiment, the vacuum cup 114 is mounted on the head 113 and rotates around the transfer dial 111 in a clockwise or counterclockwise motion about an axis of rotation designated as X1 that is in the center of the transfer dial 111. Similarly, the vacuum cup 114 can rotate around the head 113 in a clockwise or counterclockwise motion about an axis of rotation designated as X2 that is within the post that supports the head 113. Thus, it can be seen that the vacuum cup 114 can rotate about axes X1 and X2 simultaneously. In one embodiment, the rotations about axes X1 and X2 are in the same direction (i.e., clockwise or counterclockwise).

[0081] As the vacuum cup 114 approaches the open end 122 of the infeed track 105, the vacuum cup 114 is rotated to align with the open end 122 of the infeed track 105. The vacuum cup 114 is forced into the closure 204 at the front of the open end 122 of the infeed track 105. The closure is temporarily secured to the vacuum cup 114 using suction created by the shape of the vacuum cup 114 and / or forced vacuum air drawn inward through line 110. As the dial 111 and / or head 113 rotates, the vacuum cup 114 is moved away from the infeed track 105. The suction / vacuum force holds the closure 204 on the vacuum cup 114 and moves with it (see FIG. 39 1. The closure 204 is capable of deforming slightly to pass through the clip 120 when removed from the infeed track 105.

[0082] In some embodiments, the separation and delivery module 100 can include a vacuum manifold having a blow-out port 112. In this embodiment, the vacuum function can hold the closure 204 on the vacuum cup 114 during transport, and the blow-out port can apply a jet of pressurized air to remove the closure 204 from the vacuum cup 114 upon delivery to the screw 125. Thus, in this embodiment, the vacuum function can be activated until the blow-out function is triggered. In one embodiment, the blow-out port can use room air or a reservoir.

[0083] In some embodiments, the vacuum cup engages the outside 204a of the closure (i.e., the non-product-facing side 116). In other embodiments, the vacuum cup engages the inside 204b of the closure (i.e., the product-facing side). In certain embodiments, the vacuum cup 114 only contacts the surface 116 of the closure 204 that will ultimately face outward on the container. That is, the vacuum cup 114, in one embodiment, may not contact the food or product-facing side 118 of the closure 204. This can provide a more hygienic application process, especially for containers that hold food, beverages, medicines, or other similar products.

[0084] In some embodiments, the rotational movement of each head 113 may be coupled to the movement of the transfer dial via a timing belt. In some embodiments, the system can feed the closure body 204 into one or more delivery screw assemblies 124. In one embodiment, the system 101 drops the closure body 204 vertically into the screw. The delivery screw assembly 124 can transfer the closure body 204 to a rotary dial. In one embodiment, the rotary dial can rotate continuously around the system 100. The rotary dial can then, optionally in conjunction with a main body turret, transport the closure body to the container 202. In some embodiments, the delivery screw includes one or more (in some cases, three) feed screws, which can also be servo-driven and can be coupled to each other and to the transfer dial. In other embodiments, the vacuum cup 114 rotates the closure body 204 adjacent to or directly onto the container 202. In some embodiments, the closure body 204 can be positioned above the container 202 by the system 100.

[0085] 4 and 6, the separation and delivery module 100 may be associated with the pocketed turret 54. In this embodiment, the conveyor turret assembly 52 may transport containers to the pocketed turret 54. The separation and delivery module 100 may be configured to deliver and deposit closures 204 into each pocket of the turret 54.

[0086] In any embodiment, the closure 204 may then be loosely placed, optionally in a vacuum chamber, onto the container 202. In one embodiment, the container 202 and closure 204 may then be transported to an assembly and pressing module.

[0087] Assembly and pressing In some embodiments, the system 100 can include an assembly module 200 that assembles a container 202 (e.g., a composite can) and a closure 204 (e.g., a paper end closure). The assembly process of the container 202 and closure 204 can include adding the closure 204 to the open end 203 of the container 202 and folding and compressing certain portions of the closure 204 to seal (e.g., hermetically close) the container 202.

[0088] Figure 7~Fig. 17 2, the assembly module 200 can include a chuck 220 that is engaged with an expanding collet 210. Generally, the chuck 220 and expanding collet 210 of the assembly module 200 can be configured to provide a controlled, repeatable pressing and folding action on the closure 204 during assembly with the container 202. In this manner, the chuck 220 and expanding collet 210 can insert the closure 204 into the open end 203 of the container 202, press the closure 204 against the open end 203 of the container 202, and fold the closure 204 around the open end 203 of the container 202. More specifically, the expanding collet 210 can be configured to be partially inserted into the open end of the container 202 (adjacent the closure 204) and then expanded outward to press the closure 204 against the inner surface 207 of the container 202. In various embodiments, the closure 204 can also be pressed onto the rim 205 of the side wall 206 of the container 202 and against the outer surface 208 of the container 202 simultaneously or sequentially (e.g., by a peripheral sleeve 230, as discussed herein).

[0089] Turning now to specific embodiments, in some embodiments, the chuck 220 can be configured such that the chuck 220 does not move vertically (i.e., is vertically stationary) relative to the vessel 202. That is, the chuck 220 does not move up and down vertically. For clarity, while the chuck 220 can be vertically stationary, the chuck 220 can spin continuously about its axis and / or rotate about the machine's turret center.

[0090] In such embodiments, the container 202 is lifted upward to align with the chuck 220 and collet 210. In such embodiments, the system 100 may include a lift plate that lifts the container 202 to pneumatically or otherwise contact the chuck 220 and the extending collet 210. The lift plate may be configured to axially align the rim 205 of the container 202 with a particular portion of the extending collet 210 before lifting the container 202 to engage the container rim 205 with the closure 204, chuck 220, and / or extending collet 210. In other embodiments, a bell guide may align the closure 204, container 202, and chuck 220.

[0091] Additionally, the lift plate can be configured to rotate the container 202 (e.g., rotate about a central longitudinal axis of the container). In some embodiments, the rotational speed of the container 202 can be at least 1000 revolutions per minute (RPM). In other embodiments, the rotational speed of the container 202 can be at least 2000 RPM. In some embodiments, the rotational speed of the container 202 can be in the range of about 1000 RPM to about 2000 RPM.

[0092] Additionally, the lift plate can be configured to translate the container 202 (e.g., horizontally along a path). In some embodiments, the translation path can be circular or semicircular. In some embodiments, the translation speed of the container 202 can be at least 50 RPM. In other embodiments, the translation speed of the container 202 can be at least 100 RPM. In some embodiments, the translation speed of the container 202 can be in a range of about 50 RPM to about 100 RPM.

[0093] As will be appreciated, the rotation and translation of the container 202 can assist in fusing the closure 204 to the container 202 and / or pressing the closure 204 against the outer surface 208 of the sidewall 206 of the container 202. In one embodiment, translation and rotation of the container 202 at such a rate allows for commercial application of the closure 204 to the container 202 at a rate of at least 400 or 420 containers per minute ("CPM"). In another embodiment, translation and rotation of the container 202 at such a rate allows for commercial application of the closure 204 to the container 202 at a rate of at least 500 CPM. In yet another embodiment, translation and rotation of the container 202 at such a rate allows for commercial application of the closure 204 to the container 202 at a rate of at least 600 CPM.

[0094] One or more additional components of the assembly module 200 can be configured to rotate synchronously with the lift plate and / or the container 202. For example, the chuck 220 and / or the expansion collet 210 can rotate at substantially the same rotational speed as the lift plate and the container 202 during assembly of the container 202 and closure 204 to minimize frictional forces due to relative movement between the container 202, the chuck 220, the expansion collet 210, and / or other components of the assembly module 200.

[0095] Additionally or alternatively, system 100 can lower chuck 220 and expanding collet 210 onto rim 205 of open end 203 of container 202 and apply closure 204. In either case, the pressure of container 202 against collet 210 or collet 210 against rim 205 of container 202 can be between approximately 10 and 30 pounds of pressure. In certain embodiments, the pressure can be approximately 20 pounds.

[0096] zipper As described above, the assembly module 200 may include a chuck 220 engaged with the expanding collet 210. In one embodiment, the chuck 220 may be generally cylindrical with notches formed and / or cut into its periphery to form recesses that engage with the expanding collet 210. In one embodiment, the chuck 220 may include an upper portion 220a and a lower portion 220b. In one embodiment, the upper portion 220a may have a larger diameter than the lower portion 220b. In one embodiment, the lower portion 220b of the chuck 220 may be the portion that engages with the collet 210. In one embodiment, the chuck 220 may further include a neck portion 220c disposed above the upper portion 220a. The neck portion 220c may have a smaller diameter than the upper portion 220a and / or the lower portion 220b.

[0097] In some embodiments, the center of the chuck 220 can include a central hollow portion (eg, a through-hole or bore) with internal threads that attach the chuck 220 to a cooperating threaded portion of the system 100 .

[0098] Expanding Collet The extension collet 210 can surround a generally cylindrical lower portion 220b of the chuck 220. In one embodiment, the extension collet 210 can also be generally cylindrical and can include a plurality of individual collet segments 212. A portion of the extension collet 210 can be inserted into an indentation and / or recess in the lower portion 220b of the chuck 220, providing engagement between the extension collet 210 and the chuck 220.

[0099] In some embodiments, the expansion collet 210 can be configured to pivot axially upward and / or radially outward when the rim 205 of the open end 203 of the container 202 moves axially toward the chuck 220 and engages the expansion collet 210.

[0100] The expanding collet 210 can have different expanded states. For example, as shown in FIG. 7, the expanding collet 210 can have a rest or unexpanded state in which the collet segments 212 are not initially pivoted. In the unexpanded state, the expanding collet 210 can have a smallest diameter and / or circumference compared to other expanded states. As shown in FIG. 8, the expanding collet 210 can have a fully expanded state in which the collet segments 212 cannot further pivot. In the fully expanded state, the expanding collet 210 can have a largest diameter and / or circumference compared to other expanded states.

[0101] As collet segments 212 pivot radially outward about pivot point 213, the overall diameter and / or circumference of expanding collet 210 can increase. In some embodiments, the diameter of expanding collet 210 can increase by approximately 5% of the overall diameter (e.g., widest diameter) of expanding collet 210. In one embodiment, the diameter of expanding collet 210 can increase by approximately 5% at maximum collet rotation (i.e., when the collet is in an expanded state having its widest diameter).

[0102] In some embodiments, the expanding collet 210 operates similarly to a Hoberman sphere, expanding to the desired final shape of the expanding collet 210 with a single actuation. In some embodiments, the expanding collet 210 can be configured such that actuation from an unexpanded state to a fully expanded state occurs solely due to the force of the container 202 acting on the collet segments 212 of the expanding collet 210. In this manner, the assembly module 200 may not require a separate drive to actuate or expand the expanding collet 210 to perform the pushing and / or bending action. Rather, actuation is integrated into the structure of the system 100. When the container 202 and chuck 220 are mated, the axial force of the container / chuck can be translated into a radially applied force and / or a specific force applied to a specific portion of the closure 202. This can advantageously save power and / or wear on the expanding collet 210 because the collet 210 will not expand when the system 100 is utilized without the container 202 in place. In some embodiments, the expanding collet 210 can only expand when the container 202 is pressed against the collet segment 212 .

[0103] In some embodiments, the action of the expanding collet 210 is resisted by the hoop strength of the container 202. In some embodiments, actuation and / or action of the expanding collet 210 against the chuck 220 may be caused by an upward force of the rim 205 of the container 202 against a particular portion (e.g., lip 215) of the expanding collet 210. In some embodiments, the resistance of the expanding collet 210 to this upward force can be tailored to the hoop strength of the container 202. The hoop strength of the container 202 may vary based on, for example, the thickness of the sidewall 206, the diameter of the container 202, and / or the height of the container 202.

[0104] In some embodiments, the expanding collet 210 can be formed from a non-metallic material (e.g., plastic, ceramic, resin). For example, the collet segments 212 can be formed from nylon (e.g., nylon 12) or a combination of nylon and glass. The collet segments 212 can be individually formed using a three-dimensional (3D) printer and then assembled into the expanding collet 210 through engagement with the chuck 220 and / or retainer 211. Forming the expanding collet 210 from a non-metallic material can aid in fusing the closure 204 to the container 202 in embodiments where induction heating is utilized. In this manner, the non-metallic material can be prevented from being heated by induction heating.

[0105] figure 17 As shown in FIG. 1, in some embodiments, the assembly module 200 can include a membrane 260 disposed around the expanding collet 210 to prevent debris from entering between the collet segments 212 as the expanding collet 210 expands, creating small gaps between the collet segments 212. For example, the membrane 260 can be formed from silicone, rubber, and / or any other expandable material. In some embodiments, the membrane can be a sleeve that fits tightly over the expanding collet 210.

[0106] In certain embodiments, the expansion of the expanding collet 210 creates small gaps between the collet segments 212, and as the individual collet segments 212 are pressed against the interior wall of the container, ridges may form between the collet segments 212 within the closure 204. It should be understood that these ridges within the closure 204 do not pose a problem from an airtight standpoint; the ridges are simply compression marks on the actual paper. However, the membrane 260 can additionally function to reduce or eliminate ridges that form on the closure 204 because the pressure from the individual collet segments 212 is more evenly distributed when the membrane 260 is in place.

[0107] Collet segment As described above, the expanding collet 210 can include multiple pivoting collet segments 212, the pivoting of which results in the expansion of the expanding collet 210. Any number of pivoting collet segments 212 is encompassed within the present disclosure. In some embodiments, the expanding collet 210 includes approximately 20 to 40 pivoting collet segments 212. In some embodiments, the expanding collet 210 includes at least 20 pivoting collet segments 212. In some embodiments, the expanding collet 210 includes 32 pivoting collet segments 212. Other quantities of collet segments 212 are possible (e.g., 2, 4). A greater number of pivoting collet segments 212 allows for smaller spaces or gaps between the segments, which is an advantage described herein.

[0108] As shown in FIG. 10 , a portion of each collet segment 212 can be inserted into a segment recess 222 formed in the periphery of the lower portion 220b of the chuck 220. The segment recess 222 can be configured to be larger than the collet segment 212, thereby allowing the collet segment 212 to move within the segment recess 222. In some embodiments, each collet segment 212 can have an individual segment recess 222 within the chuck 220. For example, the chuck 220 can include 32 segment recesses 222 formed in the lower portion 220b of the chuck 220. In some embodiments, the number of segment recesses 222 formed within the chuck 220 can be fewer than the number of collet segments 212 within the extending collet 210, such that multiple collet segments 212 share one segment recess 222.

[0109] Each segment recess 222 may include radially oriented sidewalls that separate the segment recess 222 from adjacent segment recesses 222. In this manner, the sidewalls of the segment recesses 222 may form spokes emanating from the central axis of the chuck 220. Having sidewalls for the segment recesses 222 may help prevent each collet segment 212 from moving circumferentially relative to the chuck 220 as the chuck 220 rotates. In this manner, the sidewalls of the segment recesses 222 may aid in the engagement of the expanding collet 210 with the chuck 220.

[0110] In addition to the side walls, each segment recess 222 may include a lower ledge or front stop 229a, an upper ledge or rear stop 229b, and a rear wall 229d. The rear wall 229d may be disposed radially inward toward the central axis of the chuck 220. The rear wall 229d may include a curved entrance 229c that engages the curved tip of the collet segment 212 due to the pivot point 213 about which each collet segment 212 pivots.

[0111] Each collet segment 212 making up the generally cylindrical expanding collet 210 may be generally wedge-shaped, having two planar sides 212a and a circumferential surface 212b that wraps around the collet segment 212. The collet segments 212 may be oriented relative to the chuck 220 such that the planar sides 212a are parallel or generally parallel to the radial direction of the chuck 220 (and / or the side walls of the segment recesses 222) and the circumferential surface 212b is generally perpendicular to the radial direction of the chuck 220, as shown in FIG.

[0112] Each collet segment 212 may have separate portions around the periphery 212b, such as a closure contour surface 212c, a pivot portion 214a (which may engage with a segment recess 222 in the chuck 220 to form a pivot point 213), a front stop 214b (configured to contact a front stop 229a on the chuck 220 in an unextended state (unextended state shown in FIG. 7)), a rear stop 214c (configured to contact a hard rear stop 229b on the chuck 220 in a fully extended state, as shown in FIG. 8), and / or a side stop 214d (configured to contact a side stop 238 on the circumferential sleeve 230 when the roller 250 pushes against the circumferential sleeve).

[0113] In some embodiments, the collet segments 212 may each include additional portions or elements within each portion, such as a compression protrusion 214e (configured to contact and compress an O-ring (e.g., compressible rear stop 227) before the rear stop 214c hits the hard rear stop 229b of the chuck 220), and / or a retainer lead-in 214f ​​(configured to receive the retainer 211 therein so that the collet segment 212 is held in engagement with the chuck 220).

[0114] Closure contour surface Advantageously, the collet segments 212 can be shaped such that certain portions of the peripheral surfaces 212b (e.g., closure contour surfaces 212c) configured to contact (e.g., press and / or push) the closure 204 are shaped in a manner that mimics or reflects the desired final contour of the closure 204 on the container 202 upon assembly. In this manner, at least a portion of the closure 204 can be formed into the shape desired for the final product during fusion when the collet segments 212 are fully pivoted and the expanding collet 210 is in a fully expanded state. For example, the closure contour surface 212c, in one embodiment, comprises three surfaces (e.g., two generally horizontal surfaces 215, 216b and one generally vertical surface 216a therebetween) that form two generally right-angle angles.

[0115] Other contours of the closure contour surface 212c are possible, such as a horizontal plane (horizontal may be useful as a first surface orientation to ensure stability of the container assembly 406 when inverted) followed by a longer angled surface that meets another horizontal plane. As another example, the contour of the closure contour surface 212c may include a horizontal plane followed by a long arcuate surface, such that the closure forms a dome shape on the underside of the container assembly 406. In yet another example, the contour of the closure contour surface 212c may include a sloped surface followed by another sloped surface that meets at an acute or other angle in a repeating pattern, such that the underside of the bottom of the container assembly 406 forms a ridge for better seating on an uneven surface. In some embodiments, surfaces within the contour of the closure contour surface 212c may include outwardly extending ridges and / or other surface textures that are desirably incorporated into the configuration of the closure on the container assembly 406.

[0116] It may be advantageous to minimize the gap between fully pivoted collet segments 212 because the closure contour surfaces 212c of the collet segments 212 form at least a portion of the desired final profile of the closure 204 in the final product when the collet segments 212 are fully pivoted and the extended collet 210 is in a fully extended state. To minimize the gap, in some embodiments, the extended collet 210 may include a greater number of collet segments 212 (e.g., at least 24) to reduce the gap / gap closure profile between adjacent collet segments 212. In this manner, minimizing the space between the collet segments 212 may provide a more uniform pressing surface against and / or around the sidewall 206 of the container 202. For example, as shown in FIG. 8, the gap 290 between the 32 collet segments 212 may be approximately 0.025 inches. In some embodiments, the gap 290 can range from about 0.01 inches to about 0.25 inches.

[0117] lip Within the closure contour surface 212c, each collet segment 212 may include a lip 215 positioned to be engaged by the rim 205 of the open end 203 of the container 202. Alternatively, in some embodiments, such as when the closure 204 is configured to be fully assembled within the open end 203 of the container 202 (e.g., when no portion of the closure 204 is folded over the rim 205 of the container 202), the lip 215 may be located elsewhere on the peripheral surface 212b, outside of the closure contour surface 212c.

[0118] The lip 215 can be configured to receive the upward force of the rim 205 when the container 202 contacts the chuck 220 and collet 210 engagement mechanisms. In some embodiments, the lip 215 can be slightly angled so that the generally horizontal surface of the lip 215 is slightly angled toward the central axis of the extension collet 210. In other words, the more radially outer end of the generally horizontal surface of the lip 215 (e.g., the end most distal from the central axis of the extension collet 210) is lower than the radially inner end of the generally horizontal surface of the lip 215. In this manner, when the rim 205 of the container 202 pivots the collet segment 212, the generally horizontal surface of the lip 215 can be tilted closer to 0 degrees horizontal. Orienting the lip 215 at 0 degrees horizontal can assist in applying the upward force of the flat, horizontal rim 205 onto the lip 215 by spreading the force over a larger surface area of ​​the entire rim 205. In other words, because both the rim 205 and the lip 215 are horizontal and flat, the pressure exerted by the upward force of the container 202 can be spread across the entire engagement area between the rim 205 and the lip 215. For example, in embodiments where the surface area of ​​the lip 215 is equal to or greater than the surface area of ​​the rim 205, the upward force can be spread across the entire surface area of ​​the rim 205 where both the lip 215 and the rim 205 are oriented at 0 degrees horizontal when engaged. Otherwise, if the lip 215 were angled away from 0 degrees horizontal to more fully engage the inside or outside of the sidewall 206 of the container 202, the upward force would be more concentrated at the inside or outside corners of the rim 205. Additionally, by initially tilting the lip 215 slightly so that the outer portion of the lip 215 points slightly downward, any portion of the closure 204 that extends beyond the rim of the container (e.g., the peripheral skirt 209) is forced downward over and / or around the rim to the outer wall of the container.

[0119] The lips 215 of the collet segments 212 can form the radially outermost portion of the expanding collet 210 such that when an upward force on the rim 205 is applied, the distance of each lip 215 from the respective pivot point 213 of the collet segments 212 allows the upward force to apply maximum torque to each collet segment 212. Applying a force (e.g., a constant upward force) against the lips 215 provides the necessary torque on the collet segments 212, causing them to pivot at the pivot points 213. In one embodiment, the lips 215 are located distal to the pivot points 213. Advantageously, the structural configuration of the collet segments 212 can be optimized to translate the upward force of the container 202 into the necessary compressive force to assemble the closure 204 into and / or fold the closure 204 around the container 202.

[0120] In some embodiments, the length of the generally horizontal plane of the lip 215 of the collet segment 212 can be approximately similar to and / or slightly greater than the thickness of the sidewall 206 of the container 202. The extending collet 210 can be configured such that the outer periphery of the lip 215 is approximately equal to the circumference of the container 202. In some embodiments, the inner diameter of the lip 215 can be smaller than the diameter of the inner surface 207 of the container 202, and the outer diameter of the lip 215 can be larger than the diameter of the outer surface 208 of the container 202. When the container 202 is axially aligned with the extending collet 210, the engagement of the rim 205 of the container 202 with the lip 215 of the extending collet 210 and the upward force that the rim 205 of the container 202 exerts on the lip 215 of the extending collet 210 cause all of the collet segments 212 to pivot radially outward simultaneously.

[0121] Adjacent the generally horizontal surface of the lip 215 toward the central axis of the expansion collet 210, each collet segment 212 can include a generally vertical, radially outwardly facing surface 216a as part of the closure contour surface 212c. The generally vertical, radially outwardly facing surface 216a can be part of the angled tip 216 of the collet segment 212.

[0122] In some embodiments, each collet segment 212 may include an angled tip 216. The angled tip 216 may be positioned radially inward from and adjacent to the lip 215.

[0123] In some embodiments, before the collet segments 212 are pivoted and / or when the expansion collet 210 is in an unexpanded state, the radially outwardly facing generally vertical surface 216a of the angled tip 216 can be angled away from the inner surface 207 of the container 202 and radially inward toward the center of the expansion collet 210. In other words, the radially outwardly facing generally vertical surface 216a of the angled tip 216 can be angled such that the diameter of the top of the radially outwardly facing generally vertical surface 216a of the angled tip 216 proximate the lip 215 is greater than the diameter of the bottom of the radially outwardly facing generally vertical surface 216a of the angled tip 216 distal from the lip 215. In this manner, the combined radially outwardly facing generally vertical surfaces 216a of all of the collet segments 212 can form a conical cross section when the expansion collet 210 is in an unexpanded state.

[0124] In some embodiments, the radially outwardly facing generally vertical surface 216a of the angled tip 216 can be configured to press the inner chuck wall 242 of the closure 204 against the inner surface 207 of the container 202 when the collet segment 212 pivots radially outward due to torque applied to the lip 215 by an upward force on the rim 205 of the container 202. As the collet segment 212 pivots, the radially outwardly facing generally vertical surface 216a of the angled tip 216 can rotate and become increasingly closer to vertical (e.g., approaching 90 degrees) until the radially outwardly facing generally vertical surface 216a is parallel to the inner surface 207 of the container 202. In this manner, when the collet segment 212 is pivoted, the radially outwardly facing, generally vertical surface 216a of the angled tip 216 pivots outward toward the inner surface 207 of the container 202, thereby pressing the inner chuck wall 242 of the closure body 204 against the inner surface 207 of the container 202 and forming the countersunk portion 244 (as shown in Figures 2B, 2C, and 3).

[0125] Actuation of the expansion collet 210 can convert the pre-formed chuck wall 242 of the closure 204 into a countersink 244 through a series of pushing, stretching, and / or compressing actions.

[0126] The length of the generally vertical surface 216a facing radially outward of the angled tip 216 may be equal to or approximately equal to the predetermined countersink depth 246 of the countersink portion 244 of the closure 204 within the open end 203 of the container 202 when assembled.

[0127] The engagement of the collet segments 212 of the expanding collet 210 with the chuck 220 allows the upward force of the container 202 to press the inner chuck wall 242 of the closure 204 against the inner surface 207 of the container 202. This pressing action can assist in forming a seal between the closure 204 and the container 202 during the fusion process.

[0128] Collet segment 212 can be configured such that when the diameter of expanded collet 210 is at its largest diameter in a fully expanded state (e.g., as shown in FIG. 8 ), the generally vertical radially outwardly facing surface 216 a of collet segment 212 and / or the outer diameter of angled tip 216 are approximately equal to the inner diameter of container 202 (e.g., the diameter measured across inner surface 207 of container 202). For example, the inner diameter of container 202 and the widest allowable diameter of angled tip 216 can be approximately 2.88 inches.

[0129] The collet segments 212 can be configured such that when the diameter of the expanding collet 210 is at its largest diameter in a fully expanded state (e.g., as shown in FIG. 8 ), the generally vertical radially outwardly facing surfaces 216 a of the collet segments 212 and / or the outer diameter of the angled tip 216 are approximately equal to the inner diameter of the container 202 (e.g., the diameter measured across the inner surface 207 of the container 202). This ensures intimate contact between the collet segments 212, the container 202, and the closure 204 in preparation for sealing. In this embodiment, some small stretching / expansion of the container diameter may occur within the elastic limits of the material comprising the container.

[0130] Further radially inward along the closure contour surface 212c, adjacent to the generally vertical, radially outward facing surface 216a, the angled tip 216 may include a generally horizontal, generally downward facing end surface 216b located at the portion of the angled tip 216 that is vertically furthest from the lip 215. The end surface 216b may be configured to contact the closure 204 and press and / or pierce into the corner formed by the bottom of the closure 204 and the countersink portion 244.

[0131] The generally horizontal surface of the lip 215 in combination with the generally vertical radially outwardly facing surface 216a and end surface 216b of the angled tip 216 can form a closure contour surface 212c of the collet segment 212. Advantageously, the closure contour surface 212c can substantially outline a desired bottom / end profile of a final product or container assembly 406 having the closure 204 and container 202 assembled together. When taken together in the expanded state of the expanded collet 210, the contour surfaces of the collet segments 212 (e.g., the closure contour surface portion 212c) form the desired shape of the closure 204 inserted into the container 202. For example, in some embodiments, the closure contour surface 212c can include specific radii of curvature between various configured surfaces that are angled and / or curved as desired. In some embodiments, the desired bottom / end contour of the container assembly 406 may not be uniform around the circumference of the closure 204, and therefore the collet segments 212 may vary from one another to form specific recesses and protrusions (e.g., logos, notches, stabilizing shapes) within the closure 204.

[0132] In some embodiments, the angled tip 216 can include an inwardly facing surface 216c located radially inward of and adjacent to the generally horizontal, generally downwardly facing end surface 216b of the angled tip 216. In some embodiments, the inwardly facing surface 216c can be approximately vertical when the expansion collet 210 is in an unexpanded state, as shown in FIG. 7. In a fully expanded state of the expansion collet 210 (e.g., as shown in FIG. 8), the inwardly facing surface 216c can form an approximately 45-degree angle with respect to the axial and transverse planes.

[0133] Extending radially inward and axially upward along the collet segment 212, the inwardly facing surface 216c may transition to a retainer lead-in 214f. The retainer lead-in 214f ​​may be a generally semicircular cylindrical recess or a downwardly facing U-shaped (as viewed in cross section) portion of the circumferential surface 212b of the collet segment 212. The retainer lead-in 214f ​​may be configured to allow for the insertion of a retainer 211 (e.g., an O-ring).

[0134] In some embodiments, the expanding collet 210 can include a retainer 211 that engages with the collet segments 212 within the retainer lead-in 214f. For example, the retainer 211 can be an O-ring (e.g., an oil-resistant Buna N O-ring having a 3 / 16 fractional width, a 70A durometer hardness, and an inner diameter of approximately 1.6 inches). The retainer 211 can be configured to bias the collet segments 212 to pivot radially inward such that the expanding collet 210 is in an unexpanded state (e.g., as seen in FIG. 7 ) having a minimum circumference and / or diameter. Thus, the retainer 211 can maintain the expandable collet 210 in an unexpanded state without the upward force of the container 202 being applied to the expanding collet 210 to overcome the resisting force of the retainer 211.

[0135] In some embodiments, the retainer 211 can be expandable and can comprise a material with elastic or resistive properties, such as rubber. The resistance of the expandable retainer 211 can be tailored to the hoop strength and / or upward force of the container 202. The resistance or biasing force of the expandable retainer 211 through a given expansion can be less than the hoop strength of the container 202.

[0136] In some embodiments, the assembly module 200 can be configured so that the expandable retainer 211 is expanded by pivoting the collet segments 212 through a predetermined range of pivot angles, thus increasing the resistance force of the expandable retainer 211. The collet segments 212 can be shaped so that the resistance force of the expanded retainer 211 resulting from engagement with the expanding collet 210 within the retainer lead-in 214f ​​reduces the pressing force of the generally vertical radially outwardly facing surface 216a of the chuck wall 242 of the closure 204 against the inner surface 207 of the open end 203 of the container 202. By reducing the pressing force of the collet segment 212 and the closure body 204 against the inner surface 207 of the container 202 while maintaining the upward force of the rim 205 of the container 202 acting on the peripheral skirt 209 of the closure body 204 and the lip 215 of the collet segment 212, full insertion of the closure body 204 into the open end 203 of the container 202 can be facilitated before the chuck wall 242 of the closure body 204 is fully clamped against the inner surface 207 of the container 202.

[0137] In some embodiments, assembly module 200 can be configured such that engagement of retainer 211 with expanding collet 210 at retainer lead-in 214f ​​does not allow retainer 211 to resiliently expand as collet segment 212 pivots due to the shape of collet segment 212 and / or retainer lead-in 214f. In such embodiments, retainer lead-in 214f ​​can be eccentrically shaped and / or can act as a cam so that retainer 211 maintains the same circumference and / or diameter as collet segment 212 is pivoted about pivot point 213. In such embodiments, collet segment 212 can be configured to pivot back to their limit in the unexpanded state by gravity and / or other timed actuation of the system at the smallest circumference and / or diameter of expanding collet 210 (e.g., as seen in FIG. 7 ).

[0138] In some embodiments, in the unexpanded state of the expansion collet 210, the retainer lead-in 214f ​​can be aligned (radially) with the front stop 229a of the chuck 220. The radially inner wall 214h of the retainer lead-in 214f ​​can extend downwardly, opposite the inward-facing surface 216c of the angled tip 216 (e.g., as shown in FIG. 10 ). The retainer lead-in 214f ​​can include a protruding surface 214g on its radially inner wall 214h that protrudes toward the inward-facing surface 216c of the angled tip 216. The protruding surface 214g of the radially inner wall 214h of the retainer lead-in 214f ​​can provide resistance to unintentional displacement of the retainer 211 from within the expansion collet 210. In some embodiments, the protruding surface 214g of the radially inner wall 214h can comprise a ridge, bump, retention arm, extension, protrusion, or the like.

[0139] Front stop Further radially inward from and adjacent to retainer lead-in 214f, peripheral surface 212b of collet segment 212 can include front stop 214b. Front stop 214b can contact the vertical (or near-vertical) and / or horizontal (or near-horizontal) surfaces of front stop 229a of chuck 220 when expansion collet 210 is in an unexpanded state (e.g., as shown in FIG. 7). As shown in FIG. 10, front stop 214b can be shaped as a right angle (or near-right angle), and front stop 229a can be shaped like a disk (optionally with a square apex corner) around the base of chuck 220, forming a lower ledge of segment recess 222.

[0140] At rest in the unextended state, the collet segments 212 of the expanding collet 210 can pivot fully to their limit, which may be provided by the front stop 214b of the collet segment 212 contacting the front stop 229a of the chuck 220 (e.g., the lower ledge of the segment recess 222). In the unextended state, the collet segments 212 may be at a minimum pivot angle (e.g., 0 degrees).

[0141] In some embodiments, the generally inwardly facing surface of front stop 214b can be generally vertical. In some embodiments, the generally inwardly facing surface of front stop 214b can contact the vertical (or generally vertical) surface of front stop 229a of segment recess 222 when expansion collet 210 is in an unexpanded state.

[0142] In some embodiments, the generally downwardly facing surface of front stop 214b can be generally horizontal, and in some embodiments, the downwardly facing surface of front stop 214b can contact the horizontal (or generally horizontal) surface of front stop 229a of segment recess 222 when expansion collet 210 is in the unexpanded state.

[0143] Pivot The expanding collet segments 212 can each be configured to pivot about a pivot point 213 such that the expanding collet 210 changes diameter as the collet segments 212 pivot between expanded states. As shown in FIG. 11 , in some embodiments, the pivot point 213 can be centered within the radially innermost portion of the collet segment 212 and adjacent to the chuck 220 (e.g., at the rear wall 229d of the segment recess 222). In this manner, the pivot point 213 can be located at the radially innermost portion of the expanding collet 210 that engages with the chuck 220 (e.g., at the curved entrance 229c).

[0144] 10, each collet segment 212 can have a curved tip (e.g., pivot portion 214a) formed at its radially innermost portion. In some embodiments, the terminal end of pivot portion 214a can have a circular radius of curvature. In some embodiments, the terminal end of pivot portion 214a can have a semicircular cylindrical shape. The curved tip (e.g., pivot portion 214a) can be inserted into a cooperating curved entrance 229c of chuck 220 having approximately the same radius of curvature. In this manner, the interface between the curved tip (e.g., pivot portion 214a) and the cooperating curved entrance 229c creates a pivot point 213 for each collet segment 212.

[0145] Rear stop Further radially outward from and adjacent to the pivot portion 214a, the collet segment 212 may include a collet backstop 214c. The collet backstop 214c may be configured to abut a chuck backstop 229b (e.g., an upper ledge of the segment recess 222) of the chuck 220 when the extending collet 210 is in a fully extended state (e.g., as shown in FIG. 8). As shown in FIG. 13, the collet backstop 214c comprises a substantially vertical, substantially horizontal, or obtuse-angled (nearly right-angled) portion that contacts a vertical surface, a horizontal surface, and / or a corner of the chuck backstop 229b of the chuck 220 when the collet 212 is expanded. For example, in one embodiment, a corner of the collet backstop 214c may contact a corner of the chuck backstop 229b in an aligned manner to stop further expansion of the collet 212.

[0146] In some embodiments, the generally inwardly facing surface 219a of the rear stop 214c can be approximately vertical (FIG. 10). In some embodiments, when the expansion collet 210 is in a fully expanded state, the inwardly facing surface 219a of the rear stop 214c can contact the vertical (or generally vertical) surface or rear wall 229d of the rear stop 229b of the chuck 220. However, this contact is not required.

[0147] In some embodiments, the generally upwardly facing surface of rear stop 214c can be generally horizontal, and in some embodiments, the upwardly facing surface of rear stop 214c can at least partially contact a horizontal (or generally horizontal) surface of rear stop 229b of chuck 220 (e.g., an upper ledge of segment recess 222) when expansion collet 210 is in its fully expanded state.

[0148] In the fully extended state, the collet segments 212 of the extension collet 210 can pivot fully to their limit, which may be provided by rear stop 214c of the collet segment 212 contacting rear stop 229b of the chuck 220 (e.g., the upper ledge of segment recess 222). In the fully extended state, the collet segments 212 may be at their maximum pivot angle (e.g., approximately 45 degrees).

[0149] In this manner, the widest allowable diameter of the angled tip 216 (e.g., the extending collet 210) can be controlled by the shape of the collet segment 212 and the engagement of the collet segment 212 of the extending collet 210 with the chuck 220. For example, the backstop 229b of the chuck 220 can prevent the collet segment 212 from further pivoting after the maximum pivot angle. The chuck 220, and thus the backstop 229b, can comprise a rigid, incompressible material.

[0150] In some embodiments, between the generally upwardly facing surface 217a of the rear stop 214c and the pivot portion 214a, the peripheral surface 212b of the collet segment 212 can include a generally vertical surface 219a as part of the rear stop 214c. The generally upwardly facing surface 217a and the generally vertical surface 219a can form a substantially right angle. In some embodiments, the corner 219b formed between the generally vertical surface 219a and the generally upwardly facing surface 219a of the rear stop 214c can be configured to contact the rear wall 229d of the segment recess 222 of the chuck 220 when the extension collet 210 is in its fully expanded state. This contact can be in addition to or in place of the generally inward-facing and / or generally upward-facing surfaces of rear stop 214c contacting the vertical, horizontal, and / or corners of rear stop 229b of chuck 220 when extension collet 210 is in a fully extended state (e.g., when collet segment 212 is pivoted to its maximum pivot angle).

[0151] Further radially outward from and adjacent to the generally inwardly facing surface of rear stop 214c, peripheral surface 212b of collet segment 212 can include a generally upwardly facing surface. The generally upwardly facing surface can form a generally perpendicular angle with the generally inwardly facing surface of rear stop 214c. The generally inwardly facing surface and the generally upwardly facing surface of rear stop 214c can together form compression protrusion 214e.

[0152] In some embodiments, the compression protrusion 214e can be configured to abut a compressible backstop 227 in the chuck 220 when the expansion collet 210 is in a partially expanded state (e.g., as shown in FIG. 12 ). The assembly module 200 can include a compressible backstop 227 positioned between the upper portion 220a of the chuck 220 and the expansion collet 210. More specifically, the compressible backstop 227 can be disposed or fitted within a backstop recess 227a. The backstop recess 227a can be formed below a wide, disk-shaped protrusion in the upper portion 220a of the chuck 220. In some embodiments, the backstop recess 227a can comprise a semicircular cylindrical recess or a downwardly facing U-shape.

[0153] In some embodiments, the compressible rear stop 227 can have a retention bead 227b formed in a radially inward-facing surface 227c of the rear stop recess 227a. The radially inward-facing surface 227c can have a generally vertical radial cross-section (e.g., circular when viewed in cross section), while the retention bead 227b can form a quadrant when viewed in radial cross-section (e.g., as shown in FIG. 10 ). The retention bead 227b can protrude from the radially inward-facing surface 227c of the rear stop recess 227a toward the radially outward-facing surface 227d of the rear stop recess 227a (e.g., toward the central axis of the chuck 220). Like the radially inward-facing surface 227c, the radially outward-facing surface 227d of the rear stop recess 227a can have a generally vertical radial cross-section (e.g., circular when viewed in cross section). The radially outward facing surface 227d can be an extension of the generally vertical radially outward facing surface of the upper ledge or backstop 229b of the chuck 220. The retention bead 227b can be configured to hold the compressible backstop 227 in place within the backstop recess 227a. In some embodiments, the retention bead 227b of the backstop recess 227a can include a ridge, bump, retention arm, extension, protrusion, or the like.

[0154] When the expansion collet 210 is in an unexpanded state (e.g., as shown in FIG. 7), the compressible backstop 227 can be positioned vertically above the collective compression ledges 214e of the expansion collet 210 such that a space or distance is provided between the compressible backstop 227 and the collective compression ledges 214e of the expansion collet 210. In this unexpanded state, the compressible backstop 227 can be uncompressed.

[0155] When the expansion collet 210 is in a partially expanded state (e.g., as shown in FIG. 12 ), the compressible backstop 227 can be positioned adjacent to the collective compression lobes 214 e of the expansion collet 210. In some embodiments, the compression lobes 214 e of the expansion collet 210 rotate upward toward the compressible backstop 227 through the space or distance between the compressible backstop 227 and the collective compression lobes 214 e until the compressible backstop 227 contacts the compressible backstop 227. In this partially expanded state (e.g., as shown in FIG. 12 ), the compressible backstop 227 may be uncompressed or at least partially compressed.

[0156] The compressible backstop 227, in some embodiments, can be configured to resist pivoting of the collet segment 212 after the collet segment 212 has pivoted through a predetermined pivot angle (or a predetermined distance above the container 202), such that when the compression protrusion 214e compresses the compressible backstop 227, the pressing force of the angled tip 216 on the chuck wall 242 of the closure 204 against the inner surface 207 of the open end 203 of the container 202 is reduced. By reducing the pressing force of the closure 204 against the inner surface 207 of the container 202 while maintaining the upward force of the rim 205 of the container 202 against the lip 215 of the closure 204 and collet segment 212, full insertion of the closure 204 into the open end 203 of the container 202 can be encouraged before allowing the inner chuck wall 242 of the closure 204 to be fully clamped against the inner surface 207 of the container 202.

[0157] The pressing force of the closure 204 against the inner surface 207 can provide a better seal of the closure 204 against the container 202. In some embodiments, the compressible backstop 227 can prevent the angled tip 216 of the collet segment 212 from applying so much pressure against the container inner surface 207 that the inner surface 207 is distorted. In one embodiment, the pressing force of the closure 204 against the inner surface 207 can be approximately 400 to 500 pounds of pressure. In certain embodiments, the pressing force can be approximately 475 pounds. In one embodiment, the pressing force of the container 202 into the collet 210 or the pressing force of the collet 210 into the rim 205 of the container 202 can be approximately 20 pounds of pressure, which can translate to a total pressing force of approximately 475 pounds of the closure 204 against the inner surface 207 (e.g., approximately 1000 PSI). In one embodiment, the present invention provides a converted pressure of approximately 23 to 24 times the applied pressure. In one embodiment, each of the collet segments 212 can press against the container 204 with approximately 14 to 15 pounds of pressure.

[0158] In some embodiments, the compressible backstop 227 can be an O-ring made from foam, rubber, silicone, and / or another compressible material. For example, the compressible backstop 227 can be an oil-resistant Buna-N O-ring having a 3 / 16 fractional width, a 70A durometer hardness, and an inner diameter of approximately 1.6 inches. The resistance or compressibility of the compressible backstop 227 through a given compression or compression pivot angle can be tailored to the hoop strength and / or lift force of the container 202. The resistance of the compressible backstop 227 through a given compression or compression pivot angle can be kept lower than the hoop strength of the container 202, so that the upward force of the rim 205 on the lip 215 of the collet segment 212 pivots the collet segment 212 and compresses the compressible backstop 227 without damaging the sidewall 206 of the container 202.

[0159] As shown in Figures 11-13, when the rim 205 of the container 202 engages the lip 215 of the collet segment 212, the upward force of the rim 205 allows the collet segment 212 to pivot a predetermined pivot angle before the generally upwardly facing surface of the compression protrusion 214e contacts the compressible rear stop 227, and then pivot a compression pivot angle while compressing the compressible rear stop 229 before the rear stop 214c contacts the hard rear stop 229b at a predetermined maximum pivot angle.

[0160] In some embodiments in which the retainer 211 reduces the pressure on the generally vertical surface 216a facing radially outward through a predetermined pivot angle range, the assembly module 200 may not include the compressible backstop 227 and / or the compression protrusion 214e. Alternatively, the assembly module 200 may have a compression protrusion 214e with a different configuration.

[0161] Although collet segments 212, chuck 220, and compressible backstop 227 are described with specific reference to the drawings, it should be understood that any shape and / or geometry that would achieve the characteristics described herein is encompassed by the present disclosure.

[0162] Side stop 10, the side stop 214d can include two surfaces angled in different radially outward directions: an upper surface 241a and a lower surface 241b. In the unexpanded state of the extension collet 210 (e.g., when the collet segment 212 is not pivoted and abuts the front stop 229a of the chuck 220), the upper surface 241a of the side stop 241d can be positioned to be contacted by the side stop 238 of the circumferential sleeve 230. In the fully expanded state of the extension collet 210 (e.g., when the collet segment 212 is pivoted against the rigid rear stop 229b of the chuck 220), the lower surface 241b of the side stop 214d can be positioned to be contacted by the side stop 238 of the circumferential sleeve 230.

[0163] 7, in some embodiments, the side stops 212d and / or one or both planar sides 212a of each collet segment 212 can include nesting lugs 218a and cooperating nesting recesses 218b. The nesting lugs 218a and recesses 218b can aid in assembling the individual collet segments 212 together in the proper orientation / alignment, particularly while the retainer 211 is positioned within the retainer lead-in 214f ​​of the collet segment 212 and / or while the pivot portion 214a of the collet segment 212 is inserted into the cooperating curved entrance 229c of the chuck 220. In some embodiments, the nesting lugs 218a and recesses 218b can assist in approximately uniform expansion of the expansion collet 210 when a defective rim 205 on the container 202, for example, one that is uneven, torn, bent, or otherwise does not simultaneously engage all of the lips 215 of the expansion collet 210.

[0164] 11 , the assembly module 200 can include an assembly rod 235. In some embodiments, the assembly rod 235 can position and initially insert the closure 204 into the container 202 when the container 202 is lifted toward the chuck 220 and the extension collet 210 (or when the chuck 220 and the collet 210 are moved toward the container 202). The assembly rod 235 can be cylindrical and can be positioned concentrically within the hollow center of the chuck 220. The assembly rod 235 can be configured to move axially to ensure proper positioning of the closure 204 relative to the container 202. Specifically, the assembly rod 235 can be configured to press the center portion 240 of the closure 204 into the open end 203 of the container 202 when the container 202 is lifted toward the chuck 220. The assembly rod 235 can be integral with and / or further include a centering disk 236. The centering disk 236 may be generally cylindrical and may be wider than the assembly rod 235. The centering disk 236 may be configured to initially contact the center portion 240 of the closure 204 as the closure 204 is forced into the open end 203 of the container 202.

[0165] In some embodiments, assembly rod 235 can include helical threads on its outermost surface that can engage with corresponding helical threads on the inner surface of chuck 220. Similarly, in some embodiments, centering disk 236 can include helical threads on its innermost surface that are configured to correspond to the helical threads on the outer surface of assembly rod 235. In some embodiments, centering disk 236 can be axially movable separately from the assembly rod. In other words, assembly rod 235 can have a maximum extension length, and centering disk 236 can extend axially further than the maximum extension length of assembly rod 235.

[0166] In some embodiments, the assembly rods 235 and centering disks 236 can aid in the removal of the assembled module 200 from the closure body 204. That is, after assembly is complete, the assembly rods 235 and / or centering disks 236 can remain in place after the chuck 220 is moved away from the container assembly 406 and / or the container assembly 406 is moved away from the chuck 220. The assembly rods 235 and / or centering disks 236 can hold the positioning of the closure body 204 and then finally release from the surface of the closure body 204.

[0167] Circumference sleeve 12 (and various other figures), the assembly module 200 can include a peripheral sleeve 230 that surrounds the chuck 220 and the expansion collet 210. The peripheral sleeve 230 can be configured to fold the peripheral skirt 209 of the closure 204 over the rim 205 and around the outer surface 208 of the sidewall 206 of the container 202. 49 and Figure 50 2 illustrates an alternative configuration of circumferential sleeve 230 that operates in the same manner as described herein.

[0168] The circumferential sleeve 230 may be generally cylindrical in nature and may extend vertically from at least the top of the chuck 220 to approximately the base of the chuck 220 and the expansion collet 210. 49 and Figure 50 In the illustrated embodiment, the circumferential sleeve 230 can include a neck portion 230a that is narrower in diameter than the body portion 230b. The neck portion 230a can be integral with and / or disposed above the body portion 230b. A shoulder portion 230c can connect the neck portion 230a and the body portion 230b.

[0169] When the expansion collet 210 is in a retracted / rested non-expanded state (e.g., FIGS. 7, 10, and 11, and 1412 ), the edge 237 of the circumferential sleeve 230 can be positioned adjacent to the radially outward facing side stop 214d of the collet segment 212. When the extension collet 210 is in a partially expanded state (e.g., as shown in FIG. 12 ), the edge 237 of the circumferential sleeve 230 can be positioned vertically below the lip 215 of the collet segment 212. In these embodiments, the circumferential sleeve 230 may not move vertically. Instead, the lip 215 of the collet segment 212 is pivoted upward by the rim 205 of the container 202 to change position. In this manner, as the peripheral skirt 209 of the closure body 204 moves upward together with the lip 215 of the expansion collet 210 and the rim 205 of the container 202, the peripheral skirt 209 is folded over the rim 205 of the container 202 and pressed or clamped between the peripheral sleeve 230 and the outer surface 208 of the side wall 206 of the container 202.

[0170] An inner edge surface 237a of the circumferential sleeve 230 is disposed inward of the edge 237 and can be configured to contact the folded circumferential skirt 209 of the closure 204. The inner edge surface 237a can include a knurled or gripping surface texture to grip the circumferential skirt 209 of the closure 204 and minimize any slippage that may occur due to the rotating parts.

[0171] In another embodiment, the inner edge surface 237a need not be knurled or have a gripping texture. In this embodiment, the skirt 209 may tend to buckle and fold / wrinkle as it is folded and forced into a smaller circumference, occupying a smaller area. In yet another embodiment, a knurled inner edge surface 237a may cause these wrinkles to have a pattern with a repeatable frequency and amplitude, making them more likely to appear intentionally manufactured.

[0172] In some embodiments, the circumferential sleeve 230 can be formed from a non-metallic material (e.g., plastic, resin). For example, the circumferential sleeve 230 can be formed from nylon (e.g., nylon 12) or a combination of nylon and glass. Forming the circumferential sleeve 230 from a non-metallic material can aid in fusing the closure 204 to the container 202 in embodiments where induction heating is utilized.

[0173] In some embodiments, the inner diameter of the circumferential sleeve 230 can be larger than the outer diameter of the container 202 .

[0174] In some embodiments, assembly module 200 may include one or more O-rings (e.g., O-rings 232, 234, 238) positioned between chuck 220 and circumferential sleeve 230. In some embodiments, O-rings (e.g., O-rings 232, 234, 238) may be made from foam, rubber, silicone, and / or another compressible material. For example, each O-ring (e.g., O-rings 232, 234, 238) may be an oil-resistant Buna N O-ring having a 3 / 16 fractional width, a durometer hardness of 70A, and an inner diameter of approximately 1.6 inches. In some embodiments (see FIG. 49 and Figure 50 ), many of the O-rings may be optional, for example, ring 211 may be provided while other O-rings may be omitted.

[0175] The circumferential sleeve 230 may be rotationally and laterally movable relative to the chuck 220 along the O-rings 232, 234. The circumferential sleeve 230 may be configured to remain axially stationary relative to the chuck 220. For clarity, although the circumferential sleeve 230 may be axially stationary, the circumferential sleeve 230 may be continuously spinning about an axis and / or may rotate about the turret center of the machine.

[0176] figure 36 and Figure37 In the embodiment shown in FIG. 1, the circumferential sleeve 230 can include a plurality of teeth 231 on its inner axial surface. In one embodiment, these teeth 231 can replace one or more O-rings in the system. For example, O-ring 232 can be replaced by teeth 231. In one embodiment, the teeth 231 can extend radially inward from an inner surface 233 of the sleeve 230. In one embodiment, the teeth 231 need not extend the entire vertical distance of the sleeve 230. The teeth 231 can be positioned at discrete circumferential locations within the inner surface of the sleeve 230. For example, in FIG. 36 In contrast, the teeth 231 may not extend to the upper surface 239 of the sleeve, and may be positioned vertically lower than the upper surface 239 .

[0177] The teeth 231 can be oriented axially inward, can be positioned at a straight angle, and / or can have a non-zero radius of curvature. In one embodiment, the teeth 231 are arranged in a spiral pattern. Multiple teeth 231 can be provided. In some embodiments, each of the teeth 231 has the same angle or radius of curvature. In some embodiments, some of the teeth 231 can have different or alternating angles or radii of curvature.

[0178] In one embodiment, the teeth 231 can engage the chuck 220. The teeth 231 can extend from the sleeve 230 to contact the outer surface 223 of the neck 221 of the chuck 220 (see FIG. 12). In this embodiment, the neck 221 of the chuck 220 can be narrower than the remainder (or a portion) of the chuck 220. The tips of the teeth 231 can contact the neck 221 of the chuck 220 when the sleeve 230 is in the neutral position (FIG. 12). This teeth 231 / neck 221 contact can maintain the sleeve 230 in the neutral position unless an external force is applied. This contact between the teeth 231 and the neck 221 can provide the necessary spacing between the sleeve 230 and the collet segment 212 so that the closure 204 and container rim can be inserted between the sleeve 230 and the collet segment 212. Without teeth 231 (or a similar mechanism also encompassed herein), sleeve 230 could accidentally move laterally prior to insertion of the container rim, preventing proper insertion of the container rim and closure 204 and potentially jamming the system. Therefore, it is essential that sleeve 230 be maintained in a neutral position until it contacts roller 250, and then returned to the neutral position after contact with roller 250 ceases. Teeth 231 ensure this positioning.

[0179] The teeth 231 may bias the circumferential sleeve 230 to a laterally neutral and / or rest position (i.e., FIG. 12), but the teeth 231 may flex somewhat to allow the circumferential sleeve 230 to move laterally when pressure is applied by the rollers 250. 。 Thus, when roller 250 is pressed against the outer surface of sleeve 230, teeth 231 adjacent to at least the portion of sleeve 230 under pressure may flex inward, allowing sleeve 230 to move axially (laterally) inward. As roller 250 and / or sleeve 230 rotate, adjacent teeth 231 correspondingly flex inward. Similarly, when tension is released from a circumferential portion of sleeve 230, circumferentially corresponding teeth 231 may relax to their neutral position. This process repeats throughout the rotation.

[0180] In one embodiment, the teeth 231 provide a spring-like mechanism. In certain embodiments, the teeth 231 can prevent rotational movement of the circumferential sleeve 230 in a direction opposite to a desired direction. For example, FIG. 35 The teeth 231 shown in FIG. 1 may allow the sleeve 230 to rotate in a counterclockwise direction, but may prevent clockwise rotation. Thus, the teeth may bend in one direction, but not the other, preventing such rotation. In other embodiments, the sleeve 230 may be rotated in either direction, but the angle / curvature of the teeth is directionally related to the rotation of the sleeve 230. For example, FIG. 35 The teeth 231 shown in can be designed for the sleeve 230 to rotate in a counterclockwise direction, even if they do not prevent clockwise rotation.

[0181] Figure 13 to As shown, O-ring 234 can be positioned within a downwardly facing O-ring recess formed in the downwardly facing surface within circumferential sleeve 230. The upwardly facing surface of upper portion 220a of chuck 220 can be positioned below the downwardly facing O-ring recess to hold O-ring 234 in place. O-ring 232 can be positioned within an inwardly facing O-ring recess formed in the top and inwardly facing surface of circumferential sleeve 230. The radially outward facing surface of neck portion 220c of chuck 220 can be positioned adjacent to and within O-ring 232, which can help maintain O-ring 232 within the inwardly facing O-ring recess. The downwardly facing O-ring recess and the inwardly facing O-ring recess can have a simple U-shaped cross section with somewhat square corners.

[0182] As the sleeve 230 moves laterally relative to the chuck 220, the O-ring 234 can slide along the upwardly facing surface of the upper portion 220a of the chuck 220. In some embodiments, as the sleeve 230 moves laterally relative to the chuck 220, the O-ring 232 can contact the radially outwardly facing surface of the neck portion 220c of the chuck 220, thereby resisting lateral movement of the sleeve 230 and acting as a compressible side stop.

[0183] In other embodiments, one or more of the O-rings (232, 234, 238) may be replaced with a lightweight corrugated spring steel insert in place. In such embodiments, the spring steel insert is less susceptible to compression set and may better re-center the sleeve 230 after it is driven eccentrically. Additionally, in other embodiments, one or more of the O-rings (232, 234, 238) may be replaced with multiple small springs laterally to the axis.

[0184] Laura Figure 12~Fig. 13 and Figure 50 , the assembly module 200 may include a roller 250 configured to press laterally against the peripheral sleeve 230, thereby pressing a portion of the folded peripheral skirt 209 of the closure 204 against the outer surface 208 of the sidewall 206 of the container 202. Pressing the peripheral skirt 209 against the outer surface 208 of the sidewall 206 may aid in the fusing process, which will be discussed in more detail herein.

[0185] In some embodiments, FIGS. 13 As shown in FIG. 1, the roller 250 can press laterally against the body portion 230b of the circumferential sleeve 230. 50 , the roller 250 can press laterally into the neck 230a and / or shoulder 230c of the circumferential sleeve 230. In either case, the pressing and compressing action of the circumferential sleeve 230 works in the same way.

[0186] The roller 250 can be configured to move laterally relative to the chuck 220 and use a pushing force to push against the circumferential sleeve 230. The circumferential sleeve 230 can be configured to eccentrically shift relative to the expansion collet 210 and / or chuck 220 when pushed by the roller 250. In this manner, when the roller 250 applies a pushing force to the circumferential sleeve 230, the pushing force causes the circumferential sleeve 230 to eccentrically shift, sandwiching a portion of the folded circumferential skirt 209 of the closure 204 between the inner edge surface 237a of the circumferential sleeve 230 and the outer surface 208 of the container 202.

[0187] Figure 12~Fig. 13 As shown in FIG. 1, the radially outwardly facing surface of roller 250 can include one or more roller O-rings. The roller O-rings can fit snugly into curved grooves formed around (e.g., around) the radially outwardly facing surface of roller 250. In some embodiments, the roller O-rings are expandable and can stretch to fit into the curved grooves in the outwardly facing circumference of roller 250. This allows the contraction force of the roller O-rings to help maintain the roller O-rings in place within the grooves. In some embodiments, the roller O-rings are made from foam, rubber, silicone, and / or another compressible material. As roller 250 moves laterally relative to circumferential sleeve 230 and chuck 220, the roller O-rings can be positioned to contact the generally vertical radially outwardly facing surface of circumferential sleeve 230. The lateral force of roller 250 against circumferential sleeve 230 can at least partially compress the roller O-rings. The at least partially compressed roller O-ring can help provide a controlled pressing action of the roller 250 against the peripheral sleeve 230, and thereby a controlled pressing action of the peripheral skirt 209 of the closure 204 and the outer surface 208 of the container 202.

[0188] As the rollers 250 move the circumferential sleeve 230 laterally relative to the chuck 220, the O-rings 232, acting as compressible side stops, can resist the pushing force of the rollers 250 against the circumferential sleeve 230. The pushing force of the rollers 250 can cause the radially inward-facing surfaces of the inward-facing O-ring recesses to compress the O-ring 232 against the radially outward-facing surfaces of the neck portion 220c of the chuck 220. In this manner, the O-rings 232 can help minimize any damage to the chuck 220 caused by the circumferential sleeve 230. Additionally, the resistance of the O-rings 232 can aid in the controlled pressing of the circumferential sleeve 230 against the peripheral skirt 209 of the closure 204 and the outer surface 208 of the container 202.

[0189] Additionally, the rollers 250 can be configured to rotate freely. In this manner, when the rollers 250 contact the circumferential sleeve 230, which is rotating substantially synchronously with the rotational speed of the container 202, the rollers 250 can also rotate in a manner that minimizes any damaging or retarding frictional forces between the rollers 250 and the circumferential sleeve 230.

[0190] The expanding collet 210 can be configured to resist the pushing action of the roller 250 through engagement with the chuck 220. In one embodiment, the hoop strength of the container can act to further resist the pushing action of the roller and retain the manufactured diameter. In some embodiments, the assembly module 200 can include side stops 238 (e.g., compressible O-rings) positioned between the circumferential sleeve 230 and the expanding collet 210 to minimize any damage that may be caused by the pushing action of the roller 250 shifting the circumferential sleeve 230 relative to the expanding collet 210, particularly in the absence of the closure 204 and / or container 202 to pivot the collet segments 212 of the expanding collet 210. Alternatively, in some embodiments, the expanding collet 210 can be timed and / or otherwise synchronized with a system such that the collet segments 212 of the expanding collet 210 automatically shift without requiring an upward force from the container 202.

[0191] After assembly, the closure 204 is countersunk vertically downward against the rim 205 of the container 202 to form a bottom and countersink portion 244. The countersink portion 244 includes a chuck wall 242 that is folded and pressed against the inner surface 207 of the open end 203 of the container 202. The bottom includes a central portion 240 that extends across and is inserted into the open end 203 of the container 202. The bottom and countersink portion 244 can each extend below the rim 205 of the container 406 (e.g., as shown in FIG. 3 ). In some embodiments, after assembly, the closure 204 can form an outer envelope that includes a peripheral skirt 209 that is pressed and / or folded over (and around) the rim 205 of the container 202. The outer envelope may also include a peripheral skirt 209 that presses against the outer surface 208 of the side wall 206 of the container 202 .

[0192] As depicted, the chuck 220 and expansion collet 210 of the assembly module 200 are positioned above the container 202, although it should be noted that other orientations are possible. For example, the chuck 220 and expansion collet 210 can be axially aligned horizontally, with the container 202 being transported sideways past and moved from the left and / or right toward the chuck 220. As another example, the chuck 220 and expansion collet 210 can be mounted facing downward and sideways at a 45-degree or other angle, while the container 202 is transported to the chuck 220 and expansion collet 210 at a substantially equal angle, thereby axially aligning each container 202 with the expansion collet 210 during assembly of the container 202 and closure 204.

[0193] Although a rigid, paper composite container and paper end closure are disclosed, the container 202 and closure 204 used with the assembled module 200 can be made from other materials (e.g., plastic, metal, pulp, resin).

[0194] figure 14 ~Figure 16 As shown in FIG. 1, operation of the assembly module can initially include the expanding collet in an unexpanded state where the collet segments rest on the chuck without being pivoted. As the container moves axially toward the chuck, the rim of the container actuates the expanding collet, causing the collet segments to pivot about their respective pivot points until the expanding collet reaches a fully expanded state where the structure of the chuck prevents the collet segments from further pivoting. In some embodiments, the chuck and / or the expanding collet can include resistance features (e.g., compressible backstops 227) that resist pivoting of the collet segments at some point before they reach their maximum pivot angle. The resistance features can allow the expanding collet to provide a controlled pressing action of the closure against the interior surface of the container as the container continues to move axially toward the chuck.

[0195] In embodiments in which the closure 204 is a concave closure (see FIG. 2D ), the pressure of the expanding collet against the closure 204 and the interior sidewall 207 of the container 202 is sufficient to seal the second deforming surface 204d of the closure 204 against the interior sidewall 207 of the container 202. In this embodiment, there is no portion of the closure 204 (i.e., a skirt) that folds over the rim 205 of the container. In one embodiment, an advantage of the expanding collet system described herein is that it can be utilized with containers having various diameters and thicknesses (i.e., of the sidewalls) and with closures having various diameters and thicknesses. The system can close and seal one set of containers and then may later be used to close and seal a different set of containers having different container sidewall thicknesses, different container diameters, different closure thicknesses, and / or different closure diameters. This provides a dynamic system that can be utilized with more than one container type. In one embodiment, the expanding collet system can effectively close and seal containers and closures having a thickness of 0.010 mm within a tolerance of ±0.25 mm, which can represent as much as 25% of the total assembled wall thickness. This is a significant improvement over devices known in the art that require significantly less material thickness variation.

[0196] However, in other embodiments, while the container is moved axially toward the chuck to actuate the chuck to its fully extended state, the rim 205 of the container 202 pushes the closure's peripheral skirt 209 over the edge 237a of the peripheral sleeve 230, thereby folding the closure's peripheral skirt 209 around the container's rim 205 between the inner edge surface of the peripheral sleeve and the container's outer surface 208.

[0197] In some embodiments, after the expansion collet is fully expanded (e.g., when the container has fully actuated the expansion collet and is no longer moving axially toward the chuck), the roller O-ring presses against the outside of the circumferential sleeve as the roller moves laterally toward the chuck. The lateral pushing force of the roller shifts the circumferential sleeve eccentrically relative to the central axis of the chuck, thereby pressing the folded circumferential skirt of the closure between the inner edge surface of the circumferential sleeve and the outer surface of the container. The roller can then move laterally away from the chuck and return to its initial position, allowing the circumferential sleeve to re-center itself relative to the central axis of the chuck. In embodiments in which the closure 204 is recessed within the container body 202 as shown in FIG. 2D , the roller and circumferential sleeve can move against the outer wall 208 of the container without any intervening part of the closure (i.e., the skirt). In another embodiment, where the closure 204 is recessed within the container body 202, as shown in FIG. 2D, the roller and circumferential sleeve may not be present and / or may not be operable.

[0198] After the closure is fully assembled with the container 202 into the container assembly 406, the container assembly can be moved axially away from the chuck 220. As the container assembly 406 moves axially away from the chuck 220, the collet segments 212 can rest on the terminal ends of the container assembly as they pivot back to their unextended position.

[0199] figure 41 and Figure 42 2 shows an alternative embodiment of the configuration of the roller 250 and the circumferential sleeve 230. In this embodiment, rather than the roller 250 pressing against the side wall 249 of the circumferential sleeve 230 (see FIG. 14Instead, rollers 250 press against neck 247 of sleeve 230. Thus, in this embodiment, neck 247 of sleeve 230 is circumferentially narrower than the remainder of sleeve 230. The radially inward pressure exerted by rollers 250 on neck 247 of sleeve 230 is sufficient to cause the effects described herein. Additionally, this configuration can provide more space for the fusion module, described below. This configuration allows the fusion module to be positioned adjacent the sealing edge of the container (outside of sleeve 230).

[0200] Fusion Module In another embodiment, the system can include a fusion module 300 that fuses the closure 204 (e.g., a paper end closure) to the container 202 (e.g., a rigid composite can). In some embodiments, the fusion module 300 can be integrated with the assembly module 200, and the closure 204 can be fused to the container 202 simultaneously with the assembly and pressing method. In some embodiments, the fusion module 300 can include an induction coil 302 physically integrated with the assembly module 200, and the closure 204 can be fused to the container 202 using a combination of the assembly and pressing method and the induction coil 302. As described above, the fusion module 300 can fuse the closure 204 to the container 202 using induction heating techniques. In such embodiments, the fusion module 300 can include at least one induction coil 302.

[0201] In some embodiments, the induction heater can include a coil. A high-frequency alternating current is passed through the coil to generate a high-frequency alternating electromagnetic field. The metal layer of the closure 204 and / or container 202 is exposed to this alternating electromagnetic field, inducing eddy currents (also called Foucault currents) in the metal, causing Joule heating due to the metal's resistance. This heating of the metal layer then causes heat transfer by conduction to anything in contact with the metal, including any heat-sealable material(s) on the closure and / or sidewalls.

[0202] In one embodiment, the composite conductor 304 can be used to concentrate or focus the inductive energy of the coil(s) 302 towards the container 202 / closure 204. 41 and Figure 42 As shown in FIG. 1, the composite conductor 304 may have a curved body that directs and reflects energy and magnetic field lines from the coil 302 toward the container 202 / closure 204. The particular curvature of the composite conductor 304 may be based on the design of the coil 302. For example, in some embodiments, the composite conductor 304 may include a half-moon, U-shape, or C-shape. In some embodiments, the composite conductor 304 may have one or more sections that may be continuous or discontinuous. For example, if there are two coils 302, two separate composite conductors 304 may be utilized.

[0203] The composite conductor 304 may include a ferrous material suspended in a composite material that is then fired and hardened to the desired form. However, the composite conductor 304 may include any conductor known in the art. In one embodiment, the composite conductor 304 may be attached to an induction coil 302. The coil 302 may further be adjacent to a circumferential sleeve 230.

[0204] In one embodiment, the closure 204 can include at least one metal or metallized layer and at least one heat sealable layer. In one embodiment, the container sidewall 206 can include at least one metal or metallized layer and at least one heat sealable layer. When the metal layer(s) are heated by induction heating, the heat sealable layer(s) are heated by conduction, which softens or melts the heat sealable material.

[0205] In some embodiments, induction heating of the joint, followed by cooling (which occurs rapidly in response to cessation of the electromagnetic field or movement of the container away from the coil), can result in two heat-sealed regions between the closure 204 and the sidewall 206 of the container 202. An inner seal can exist between the inner surface 207 of the sidewall 206 and a portion of the chuck wall 242 that is parallel to and in intimate contact with the sidewall 206, and an outer seal can exist between the outer surface 208 of the sidewall 206 and a portion of what was previously the peripheral skirt 209 of the closure 204 prior to assembly. Similarly, in a concave embodiment such as that shown in FIG. 2D , the induction heating system can heat-seal only the second deformation 204d to the inner surface 207 of the container 202.

[0206] In one embodiment, the induction coils can be positioned in a manner that optimizes the sealing function of the system. An example of such a coil position is shown in FIG. 18 ~Figure 34 In some embodiments, the induction coil may comprise a single turn coil. In one embodiment, the coil configuration is a hairpin coil. In some embodiments, 44 The coil may comprise a flat coil, such as a coil having a rectangular cross section, as shown in FIG.

[0207] In some embodiments, the induction coil applies heat for about 0.1 seconds to 1.0 seconds, hi other embodiments, the induction coil applies heat for about 0.3 seconds to 0.6 seconds.

[0208] In some embodiments, the chuck 220 and / or the expansion collet 210 of the present disclosure are not made of metal (e.g., they comprise a polymeric material) to avoid overheating / overheating of these elements. In some embodiments, after induction sealing, the container 202 is sealed and ready to be released from the chamber.

[0209] Many variations and other embodiments of the subject matter of the present disclosure described herein will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the accompanying drawings. It is to be understood, therefore, that the disclosure is not limited to the particular embodiments disclosed, and that variations and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. In order to maintain the disclosure of the present application as originally filed, the contents of claims 1 to 29 as originally filed are added below. (Claim 1) An assembly module for assembling at least one container and at least one closure, comprising: a chuck configured to axially align with the container, the container having an open end surrounded by a rim; an expanding collet engaged with the chuck and including a plurality of pivoting collet segments, each of the pivoting collet segments configured to simultaneously pivot radially outward about a pivot point; a lip positioned to be engaged by the rim of the open end of the container; an angled tip positioned radially inward from the lip and shaped to press the countersink portion of the closure against the interior wall of the container when the collet segments pivot radially outward; an expansion collet comprising: an actuator configured to axially align the container and the chuck; Equipped with an assembled module, wherein when the container and the chuck are axially aligned, the rim engages the lip of the collet segment, causing the angled tip of the collet segment to pivot outward toward the interior wall of the container, thereby forcing the closure into the open end of the container and compressing the countersunk portion of the closure between the angled tip of the collet segment and the interior wall of the container. (Claim 2) 10. The assembly module of claim 1, further comprising a peripheral sleeve surrounding the chuck and the expansion collet and configured to fold a peripheral skirt of the closure over the rim and around an outer wall of the container. (Claim 3) 3. The assembled module of claim 2, wherein the circumferential sleeve has an inner diameter that is greater than an outer diameter of the container. (Claim 4) 3. The assembly module of claim 2, wherein the circumferential sleeve further comprises an inner edge having a gripping surface texture configured to contact the folded circumferential skirt of the closure. (Claim 5) The assembled module of claim 2 , wherein the circumferential sleeve is formed from a non-metallic material. (Claim 6) further comprising at least one O-ring positioned between the chuck and the circumferential sleeve; 3. The assembly module of claim 2, wherein the circumferential sleeve is rotationally and laterally movable along the O-ring relative to the chuck. (Claim 7) 3. The assembly module of claim 2, further comprising at least one roller configured to move laterally relative to the chuck and press the circumferential sleeve against a portion of the folded circumferential skirt of the closure. (Claim 8) The assembly module of claim 7 , wherein the container is configured to be rotated axially relative to the at least one roller. (Claim 9) The assembly module of claim 7 , wherein the expanding collet resists the pushing motion of the roller. (Claim 10) 8. The assembly module of claim 7, wherein the circumferential sleeve is configured to shift eccentrically relative to the expansion collet and the chuck when pushed by the at least one roller. (Claim 11) 10. The assembly module of claim 1, further comprising an assembly rod positioned concentrically within the chuck and the expansion collet and configured to move axially to push a central portion of the closure into the open end of the container when the container and the chuck are axially aligned. (Claim 12) 12. The assembly module of claim 11, wherein the assembly rod further includes a centering disk that contacts the center of the closure when the closure is forced into the open end of the container. (Claim 13) The assembly module of claim 1 , wherein the diameter of the expanding collet increases as the plurality of collet segments pivot radially outward about the pivot point. (Claim 14) 14. The assembly module of claim 13, wherein the diameter increases by about 5% of the overall diameter of the collet. (Claim 15) 15. The assembly module of claim 14, wherein when the diameter of the expanding collet increases to the maximum diameter of the collet, the outer diameter of the angled tips of the plurality of collet segments is approximately equal to the inner diameter of the container. (Claim 16) The assembled module of claim 1 , wherein the container is made of paper. (Claim 17) 10. The assembled module of claim 1, wherein the closure is made of paper. (Claim 18) The assembly module of claim 1 , wherein the chuck is axially stationary. (Claim 19) The assembly module of claim 1 , wherein the sleeve is axially stationary. (Claim 20) The assembly module of claim 1 , further comprising a compressible backstop positioned to resist pivoting of the plurality of collet segments after a predetermined pivoting distance. (Claim 21) a secondary backstop positioned to prevent pivoting of the plurality of collet segments after a predetermined secondary pivot distance; 21. The assembled module of claim 20, wherein the predetermined secondary pivot distance occurs before a predetermined compression. (Claim 22) 10. The assembled module of claim 1, wherein the length of the angled tip correlates to the depth of the countersink of the closure within the open end of the container when assembled. (Claim 23) the expanding collet further includes an expandable retainer configured to bias the plurality of collet segments to pivot radially inward; 10. The assembly module of claim 1, wherein the rim at the open end of the container has a hoop strength greater than the biasing force of the retainer through a predetermined expansion. (Claim 24) The assembly module of claim 1 , wherein the pivot point of each of the collet segments is located where the expanding collet engages the chuck. (Claim 25) The assembly module of claim 1 , wherein the expansion collet is formed from a non-metallic material. (Claim 26) 10. The assembly module of claim 1, further comprising a membrane disposed around the lip and the angled tip of the expansion collet to prevent ingress of debris between the expansion collets. (Claim 27) 27. The assembled module of claim 26, wherein the membrane is formed from at least one of silicone and rubber. (Claim 28) The assembled module of claim 1 , wherein the lip comprises a generally horizontal surface configured to contact the container rim. (Claim 29) 2. The assembly module of claim 1, wherein the angled tip has an end proximal to the lip and an end distal to the lip, and the expanding collet is angled such that the expanding collet has a diameter at the proximal end of the angled tip that is larger than the diameter at the distal end of the angled tip.

Claims

1. An assembly module for assembling at least one container and at least one closure, comprising: a chuck configured to axially align with the container, the container having an open end surrounded by a rim; an expanding collet engaged with the chuck and including a plurality of pivoting collet segments, each of the pivoting collet segments configured to simultaneously pivot radially outward about a pivot point; a lip positioned to be engaged by the rim of the open end of the container; an angled tip positioned radially inward from the lip and shaped to press the countersink portion of the closure against the interior wall of the container when the pivoting collet segment pivots radially outward; an expansion collet comprising: an actuator configured to axially align the container and the chuck; Equipped with an assembled module, wherein when the container and the chuck are axially aligned, the rim engages the lip of the pivoting collet segment, causing the angled tip of the pivoting collet segment to pivot outward toward the interior wall of the container, thereby forcing the closure into the open end of the container and compressing the countersink portion of the closure between the angled tip of the pivoting collet segment and the interior wall of the container.

2. 10. The assembly module of claim 1, further comprising a peripheral sleeve surrounding said chuck and said expansion collet and configured to fold a peripheral skirt of said closure over said rim and around an outer wall of said container.

3. The assembled module of claim 2 , wherein the circumferential sleeve has an inner diameter that is greater than an outer diameter of the container.

4. 3. The assembly module of claim 2, wherein the circumferential sleeve further comprises an inner edge having a gripping surface texture configured to contact the folded circumferential skirt of the closure.

5. The assembled module of claim 2 , wherein the circumferential sleeve is formed from a non-metallic material.

6. and at least one O-ring positioned between the chuck and the circumferential sleeve. The assembly module of claim 2 , wherein the circumferential sleeve is rotationally and laterally movable along the O-ring relative to the chuck.

7. The assembly module of claim 2 , further comprising at least one roller configured to move laterally relative to the chuck and press the circumferential sleeve against a portion of the folded circumferential skirt of the closure.

8. The assembly module of claim 7 , wherein the container is configured to be rotated axially relative to the at least one roller.

9. The assembly module of claim 7 , wherein the expanding collet resists the pushing action of the roller.

10. The assembly module of claim 7 , wherein the circumferential sleeve is configured to shift eccentrically relative to the expansion collet and the chuck when pushed by the at least one roller.

11. 2. The assembly module of claim 1, further comprising an assembly rod concentrically positioned within the chuck and the expansion collet and configured to move axially to push a central portion of the closure into the open end of the container when the container and the chuck are axially aligned.

12. 12. The assembly module of claim 11, wherein the assembly rod further includes a centering disk that contacts the center of the closure when the closure is forced into the open end of the container.

13. The assembly module of claim 1 , wherein the diameter of the expanding collet increases as the plurality of pivoting collet segments pivot radially outward about the pivot point.

14. 14. The assembly module of claim 13, wherein the diameter increases by up to 5% of the diameter of the expanding collet.

15. 15. The assembly module of claim 14, wherein when the diameter of the expanding collet increases to a maximum diameter of the expanding collet, an outer diameter of the angled tips of the pivoting collet segments is equal to an inner diameter of the container.

16. The assembled module of claim 1 , wherein the container is made of paper.

17. 2. The assembled module of claim 1, wherein the closure is made of paper.

18. The assembly module of claim 1 , wherein the chuck is axially stationary.

19. The assembly module of claim 2 , wherein the circumferential sleeve is axially stationary.

20. The assembly module of claim 1 , further comprising a compressible backstop positioned to resist pivoting of the plurality of pivoting collet segments after a predetermined pivoting distance.

21. a secondary backstop positioned to prevent pivoting of the plurality of pivoting collet segments after a predetermined secondary pivot distance; 21. The assembly module of claim 20, wherein the predetermined secondary pivot distance occurs before the compressible backstop.

22. 2. The assembled module of claim 1, wherein the length of the angled tip correlates to the depth of the countersink of the closure within the open end of the container when assembled.

23. the expanding collet further includes an expandable retainer configured to bias the plurality of pivoting collet segments to pivot radially inward; 2. The assembly module of claim 1, wherein the rim at the open end of the container has a hoop strength greater than the biasing force of the retainer through a predetermined expansion.

24. The assembly module of claim 1 , wherein the pivot point of each of the pivoting collet segments is located where the expanding collet engages the chuck.

25. The assembly module of claim 1 , wherein the expansion collet is formed from a non-metallic material.

26. The assembly module of claim 1 , further comprising a membrane disposed around the lip and the angled tip of the expansion collet to prevent ingress of debris between the expansion collets.

27. 27. The assembled module of claim 26, wherein the membrane is formed from at least one of silicone and rubber.

28. The assembled module of claim 1 , wherein the lip comprises a horizontal surface configured to contact a rim of the container.

29. 2. The assembly module of claim 1, wherein the angled tip has an end proximal to the lip and an end distal to the lip, and the expanding collet is angled so that it has a larger diameter at the proximal end of the angled tip than at the distal end of the angled tip.

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