Paper-Based End Closure Sealing System for Recyclable Containers
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Solution Overview
Problem
The existing metal end seaming process for containers is not compatible with paper-based end closures, leading to recyclability issues and environmental impact due to the difficulty in separating the paper-based container body from the metal bottom.
Innovation Solution
A sealing system comprising a die assembly, a mandrel assembly, and a gas evacuation assembly is used to apply and seal paper-based end closures to containers, allowing for high-speed operation and recyclable container production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal end closures are used and seamed to containers, then sealing reliability is improved, but recyclability deteriorates due to difficulty in separating metal from paper-based container body
Solution Approach 1:
The closure system is divided into separable components: a paper-based end closure that can be easily detached from the container body, allowing the container to be recycled separately without the metal closure interfering with the paper recycling stream
Solution Approach 2:
The metal closure is extracted/removed from the container assembly, replacing it with a paper-based closure that matches the container material, thereby enabling the entire container to be recycled together without contamination
2Adaptability or versatility
If paper-based end closures are used instead of metal, then recyclability is improved, but manufacturing complexity increases due to incompatibility with existing metal end seaming equipment and processes
Solution Approach 1:
The sealing system is designed to handle both metal and paper-based end closures using the same equipment and process, eliminating the need for separate manufacturing lines and reducing overall system complexity
Solution Approach 2:
The sealing process parameters (temperature, pressure, time) are adjusted to be compatible with paper-based materials while maintaining reliability, allowing existing equipment to process paper closures without requiring complete system redesign
3Adaptability or versatility
If paper-based end closures are applied to containers, then environmental sustainability is improved, but sealing reliability may deteriorate due to differences in material properties compared to metal closures
Solution Approach 1:
The paper-based end closure uses composite material structures with specialized sealing layers and adhesive formulations that provide sealing performance comparable to metal closures while maintaining recyclability
Solution Approach 2:
The sealing process uses controlled temperature and pressure parameters that optimize bond strength for paper-based materials, ensuring reliable seals that meet or exceed metal closure performance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively seals paper-based end closures to containers without causing doming of the membrane seal, enabling stable container handling and easy recycling, thus enhancing sustainability.
Implementation Method 1
at least one sealing member configured to provide heat to seal the disc to the container
Implementation Method 2
a means for suctioning gas from the interior of the die, the at least one channel opening, and the at least one channel to an exterior of the die
Data Source
AI summary
The invention is directed to a system and method for sealing a closure to a container comprising a die assembly, a mandrel assembly, and a gas evacuation assembly. The mandrel assembly comprises an outer mandrel and an inner mandrel. The outer mandrel is configured to vertically translate and constrain a closure in position. The gas evacuation assembly, which comprises at least one interior channel within the die and one or more channel openings into the interior of the die, suctions gas from the interior of an aligned container when the closure is constrained in position. The inner mandrel translates vertically to insert the closure into the container and a sealing member seals the closure in place.