Reduced Force Capping for Lightweight Metallic Bottles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for sealing metallic bottles with Roll-On Pilfer Proof (ROPP) closures apply excessive force, leading to deformation, failure, or substandard sealing, particularly in high-speed production environments, and are inadequate for lightweight metallic bottles.
Innovation Solution
A novel capping apparatus and method that apply reduced simultaneous forces, with independent control of topload and sideload forces, allowing for a cumulative force of less than 320 pounds, and include rotating the ROPP closure and bottle to enhance sealing efficiency and reduce torque required for closure removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing capping methods apply sufficient force to ensure sealing, then sealing reliability is improved, but bottle deformation occurs and lightweight bottles fail
Solution Approach 1:
The capping process is divided into multiple sequential stages: positioning the closure, applying topload to create a channel, forming threads, and securing the pilfer band. Each stage applies force independently and sequentially rather than simultaneously, allowing the closure to be formed step-by-step without exceeding the bottle's structural limits.
Solution Approach 2:
The capping apparatus dynamically adjusts and controls the timing of force application. The topload and sideload forces are applied at different times during the capping sequence, with independent control mechanisms that can timing-adjust the application of each force component to match the bottle's structural capacity during formation.
2Strength
If high force is applied during capping to ensure secure sealing, then sealing strength is improved, but production speed decreases due to increased processing time
Solution Approach 1:
The capping process maintains continuous productive action by overlapping operations. The topload is applied first to create the channel, then threads are formed while maintaining reduced topload, and finally the pilfer band is secured. This continuous sequence without idle time ensures sealing strength is achieved through efficient force utilization rather than prolonged high-force application.
3Manufacturing precision
If sufficient topload is applied to form closure channel, then closure formation is improved, but cumulative force exceeds safe limits for lightweight bottles
Solution Approach 1:
The channel formation is performed as a preliminary action before thread formation. By creating the channel first with controlled topload, the closure structure is partially formed and stabilized. Subsequent thread formation then proceeds with reduced force requirements since the base channel structure is already in place, preventing cumulative force from exceeding safe limits.
4Manufacturing precision
If high sideload is applied to form closure threads, then thread formation is improved, but bottle deformation increases
Solution Approach 1:
Thread formation is segmented into multiple passes with reduced sideload in each pass. Rather than applying full sideload force in a single operation, the thread rolling process progresses through incremental passes, allowing the metal to deform gradually and form threads without causing overall bottle deformation.
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 solution effectively seals metallic bottles with reduced force, preventing deformation and ensuring a reliable seal, while enabling the use of lightweight bottles without compromising sealing integrity or increasing production costs.
Implementation Method 1
a pressure block ejector that applies a predetermined first topload to a top portion of the ROPP closure to at least partially press a liner within the ROPP closure against a curl positioned on an upper portion of the threaded neck of the bottle
Implementation Method 2
a pressure block that applies a predetermined second topload to a top portion of the ROPP closure to form a channel with a predetermined depth in an outer radial edge of the ROPP closure
Implementation Method 3
at least one thread roller configured to apply a predetermined first sideload to an exterior surface of a body portion of the ROPP closure to form closure threads on the body portion
Implementation Method 4
at least one pilfer roller configured to apply a predetermined second sideload to a pilfer band of the ROPP closure, wherein the bottle is sealed by the ROPP closure
Implementation Method 5
the capping apparatus is configured to rotate at least one of the ROPP closure and the bottle around a longitudinal axis of the bottle to drive the curl further into the liner
Data Source
AI summary
Methods of sealing a metallic container are provided. More specifically, the present invention relates to methods that reduce the amount of force applied to a metallic bottle to seal the metallic bottle with a ROPP closure. The methods include use of a capping apparatus that may include more thread rollers than known capping apparatus. Optionally, the thread rollers may use more forming passes to form threads on the ROPP closure. The capping apparatus may also rotate one or more of the ROPP closure and the metallic container in a closing direction before the metallic container is discharged. In one embodiment, the thread rollers form the closure threads before or after a pilfer roller applies a sideload to the ROPP closure.