Rotary Thread Lug Forming System for Reclosable Containers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing container end structures for liquids and powdered materials face challenges in efficiently forming integral thread lugs for reclosable caps, particularly in maintaining product pressure or vacuum conditions, and require simplified and faster production methods.
Innovation Solution
A system employing progressive tooling in a rotary or reciprocating press to form thread lugs as an integral part of the container neck, using a unique feeding mechanism adaptable to various container heights, allowing for efficient and commercially viable production of containers with integral thread lugs for secure cap attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If progressive tooling in a reciprocating press is used to form thread lugs, then manufacturing precision is improved, but productivity is reduced due to sequential processing
Solution Approach 1:
The forming process is divided into multiple stations around a rotary drum, with each station performing a specific forming operation on different container ends simultaneously. This parallel processing approach maintains precision through dedicated tooling at each station while dramatically increasing productivity by processing multiple containers in one rotation cycle.
Solution Approach 2:
The invention transitions from linear sequential processing in a reciprocating press to circular parallel processing on a rotary drum. By arranging forming stations around the perimeter of the drum, the system adds a spatial dimension to the manufacturing process, allowing simultaneous formation of thread lugs on multiple container ends at different angular positions.
2Productivity
If a rotary forming system is used, then productivity is improved through parallel processing, but device complexity increases
Solution Approach 1:
The rotary drum serves multiple functions: it holds and rotates container ends, positions them at different forming stations, and synchronizes the forming operations. The indexing mechanism provides universal positioning capability for multiple stations, while the modular tooling design allows each station to be independently adjusted for different container types and lug configurations.
Solution Approach 2:
The system uses dynamic indexing to rotate the drum to precise angular positions, allowing the forming tools to engage container ends only when properly positioned. The indexing mechanism transitions the drum between stationary positions for forming operations and rotating positions for transferring containers, optimizing both productivity and control.
3Reliability
If thread lugs are formed as an integral part of the container neck, then reliability is improved for cap attachment, but manufacturing complexity increases
Solution Approach 1:
The thread lug formation process is merged with the container end forming process, creating the lugs as an integral part of the container neck in a single operation. The forming tools directly shape the metal of the container end to create both the neck structure and the threaded lugs simultaneously, eliminating separate manufacturing steps and ensuring reliable cap attachment.
Data Source
AI summary
Thread lug forming systems form thread lugs (36) on container necks or necked end domes. A continuously rotating cam system (100) has multiple sets of thread lug forming tools (135) which are driven to recirculate about stationary cams (130). The cams actuate inner and outer forming tools (150, 152) of the tool sets as they progress around the cams to form the thread lugs. A second system uses generally the same tool sets in a multiple-station reciprocating press (203), and the container bodies are indexed through the tool stations (252) in which the thread lugs are formed.