US20170066035A1

US20170066035A1 - Method and Apparatus for Providing Metal Container with Lining

Info

Publication number: US20170066035A1
Application number: US15/356,288
Authority: US
Inventors: Alvin Widitora; Michael Gurka; Michael Richards; Dustin Lobner; Phil Frisella; Mitchell Cureton
Original assignee: Silgan Containers LLC
Current assignee: Silgan Containers LLC
Priority date: 2014-05-21
Filing date: 2016-11-18
Publication date: 2017-03-09
Also published as: WO2015179514A1

Abstract

Apparatuses configured to apply and methods for applying a lining element to an interior surface of a can and/or to a can end are provided.

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application is a continuation of PCT/US15/031771, filed May 20, 2015, which claims the benefit of and priority to U.S. Provisional Patent Application No. 62/001,490 filed May 21, 2014 and U.S. Provisional Patent Application No. 62/036,335 filed Aug. 12, 2014, all of which are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of metal containers. The present invention relates more specifically to a method and apparatus for providing a metal container with a lining.

SUMMARY OF THE INVENTION

One embodiment of the invention relates to an apparatus configured to apply a lining element to an interior surface of a can. The apparatus includes a core. The core extends from a first end to a second end along a longitudinal axis. The core includes a first protrusion and a second protrusion axially spaced apart from the first protrusion. The protrusions extend radially outwardly defining a channel therebetween. The core defines a bore having a first portion extending axially downwardly and a second portion extending radially outwardly from the first portion to an aperture defined between the first protrusion and the second protrusion. The bore and the channel are in fluid communication through the aperture. The apparatus includes a sleeve configured to be located around the core. The sleeve has a radially inner surface and a radially outer surface. The sleeve defines a plurality of bores extending from the radially inner surface to the radially outward surface. At least one of the bores is in fluid communication with the channel. The apparatus includes a first seal configured to extend between the first protrusion and the inner surface of the sleeve and to prevent fluid flow between the first protrusion and the inner surface of the sleeve. The apparatus includes a second seal configured to extend between the second protrusion and the inner surface of the sleeve and to prevent fluid flow between the second protrusion and the inner surface of the sleeve. The apparatus is configured to allow flow of pressurized fluid through the bore, through the aperture, into the channel, and through the at least one of the bores of the sleeve in fluid communication with the channel to move the lining element toward the interior surface of the can.
Another embodiment of the invention relates to an apparatus configured to apply a lining element to an interior surface of a can. The apparatus includes an upper portion. The apparatus includes a lower portion extending along a longitudinal axis from an upper surface to a lower surface. The apparatus includes a sleeve extending circumferentially around the lower portion. The sleeve has a radially inner surface and a radially outer surface and includes a plurality of bores extending from the radially inner surface to the radially outer surface. The apparatus includes a first seal. The first seal is configured to prevent fluid flow in a first direction between the lower portion and the sleeve. The apparatus includes a second seal configured to prevent fluid flow in a second direction opposite the first direction between the lower portion and the sleeve. The lower portion defines a first bore having a first portion extending from the upper surface axially downwardly and a second portion in fluid communication with the first portion and extending to an aperture in an outer surface of the lower portion located axially between the first seal and the second seal. The lower portion defines a second bore extending from the upper surface of the core to the lower surface of the core. The upper portion is configured to move the lower portion from a first position above the lining element and the can to a second position inside an interior of the can. The apparatus is configured to supply pressurized fluid through the first bore, through the aperture in the outer surface of the lower portion, and through the plurality of bores in the sleeve to the lining element to direct the lining element toward the interior surface of the can.
Another embodiment of the invention relates to an apparatus configured to apply a lining element to an interior surface of a can. The apparatus includes an upper portion. The apparatus includes a lower portion coupled to the upper portion. The lower portion includes a core extending along a longitudinal axis from an upper surface to a lower surface defining a cavity and a bore extending from the upper surface to the lower surface. The lower portion includes a redirection apparatus including a base and a projection projecting axially upwardly from the base, the projection configured to be received into the cavity and threadingly coupled to the core, the base defining an axially upwardly facing channel and a first bore extending from the channel to an aperture in an outer surface of the redirection apparatus. The lower portion includes a sleeve configured to extend circumferentially around the core, the sleeve defining a plurality of bores therethrough. The channel is configured to be in fluid communication with the bore of the core when the redirection apparatus is threadingly coupled to the core. The first bore of the redirection apparatus extends non-parallel to the bore of the core. The lower portion is configured to direct pressurized fluid through the bore of the core, to the channel, through the first bore of the redirection apparatus, and toward the lining element to apply the lining element to the interior surface of the can.
Another embodiment of the invention relates to an apparatus configured to apply a lining element to an interior surface of a can including a sidewall. The apparatus includes a liner insertion apparatus. The liner insertion apparatus is configured to displace a liner sheet into the interior of the can. The apparatus includes a can locator. The can locator is configured to locate the can relative to the liner insertion apparatus to receive the liner sheet therein. The can locator includes a sidewall defining a cavity in which the can is configured to be located. The liner insertion apparatus is configured to dispense pressurized fluid to move the liner sheet toward the sidewall of the can.
Another embodiment of the invention relates to a method of closing a can having a sidewall extending from a first open end to an end wall with a can end including a curl portion. The method includes applying a liner to an interior surface of the can, the liner including a first portion extending from the first open end of the sidewall to the end wall and a second portion extending from the first open end outside of the can. The method includes coupling the can end to the first open end of the sidewall with the second portion of the liner located in the curl portion which forms a hermetic seal between the sidewall and the can end.
Another embodiment of the invention relates to a method of making a can end. The method includes stamping a metal blank into a can end shape including a curl portion. The method includes providing a liner sheet including a central portion and a radially outer portion. The method includes reducing the thickness of the central portion of the liner sheet to a thickness less than the thickness of the radially outer portion. The method includes coupling the liner sheet to the stamped metal blank with the radially outer portion located in the curl portion.
Another embodiment of the invention relates to a method of making a can end from a metal sheet. The method includes coupling a liner sheet having a central portion having a first thickness and a radially outer portion having a second thickness greater than the first thickness to the metal sheet. The method includes punching the portion of the metal sheet with the liner sheet coupled thereto to form a can end with a curl from the metal sheet, with the radially outer portion of the liner sheet being located in the curl.
Another embodiment of the invention relates to a method of lining an interior surface of a metal can. The method includes drawing a vacuum to draw a liner sheet onto a mandrel. The method includes moving the liner sheet downwardly into an interior of a can located in a can locator. The method includes sealing an outer peripheral portion of the liner sheet to the can locator. The method includes drawing a vacuum to remove fluid from between the liner sheet and an interior surface of the metal can. The method includes expelling fluid from the mandrel to force the liner sheet against an interior surface of the metal can.
Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:

FIG. 1 illustrates an exemplary embodiment of a system for lining cans.

FIG. 2 is a side view of the system of FIG. 1.

FIG. 3 illustrates a portion of the system of FIG. 2 with a sectional view of the liner displacement mechanism shown partially displacing the lining element into a can.

FIG. 4 is a cross-sectional view of the can and a portion of the liner displacement mechanism as shown in FIG. 3 with the liner displacement mechanism forcing the lining element toward the end wall and sidewall of the can.

FIG. 5 is a perspective view of an exemplary embodiment of an arrangement and liner displacement mechanism which inserts an embodiment of a lining element to the interior of a container.

FIG. 6 is an exploded view of a portion of an exemplary embodiment of a displacement mechanism.

FIG. 7 is a perspective view of an exemplary embodiment of a core of a displacement mechanism.

FIG. 8 is a perspective view of the core of FIG. 7 rotated about its longitudinal axis relative to FIG. 7.

FIG. 9 is a cross-sectional view taken along the line 9-9 in FIG. 7.

FIG. 10 is a cross-sectional view taken along the line 10-10 in FIG. 8.

FIG. 11 is a cross-sectional view taken along the line 11-11 in FIG. 7.

FIG. 12 is a bottom view of an exemplary embodiment of a core.

FIG. 13 is a top view of an exemplary embodiment of a core.

FIG. 14 is a perspective view of an exemplary embodiment of redirection apparatus.

FIG. 15 is a cross-sectional view taken along the line 15-15 in FIG. 14.

FIG. 16 is a cross-sectional view taken along the line 16-16 in FIG. 14.

FIG. 17 is a perspective view of an exemplary embodiment of a portion of a displacement mechanism.

FIG. 18 is a cross-sectional view taken along the line 18-18 in FIG. 17.

FIG. 19 is a cross-sectional view taken along the line 19-19 in FIG. 17.

FIGS. 20-27 are partial cross-sectional views of the displacement mechanism illustrating an exemplary embodiment of a method of applying an embodiment of a liner sheet to the interior of an embodiment of a container using an embodiment of a liner displacement apparatus.

FIG. 28 is a perspective view of an exemplary embodiment of a shaped container within which a lining element can be inserted.

FIG. 29 is a perspective, schematic view of an embodiment of a system for lining cans according to an exemplary embodiment.

FIG. 30 is a perspective view of a can locator in an open configuration with a can located therein according to an exemplary embodiment.

FIG. 30A is a perspective view of the can locator of FIG. 30 with the can removed according to an exemplary embodiment.

FIG. 31 is a perspective view of a can locator in a closed configuration according to an exemplary embodiment.

FIG. 32 is a cross-sectional view taken along the line 32-32 in FIG. 31.

FIG. 33 is a perspective view of a can locator in an open configuration below a liner insertion apparatus according to an exemplary embodiment.

FIG. 34 is a rear perspective view of a can locator in an open configuration according to an exemplary embodiment.

FIG. 35 is a cross-sectional view of a can and a can end according to an exemplary embodiment.

FIG. 36 is a perspective view of a can end and a disk of liner sheet material according to an exemplary embodiment.

FIG. 37 is a cross-sectional view of liner sheet material with differential thickness according to an exemplary embodiment.

FIG. 38 is a cross-sectional view of a portion of liner sheet material with differential thickness coupled to a can end according to an exemplary embodiment.

FIG. 39 is a cross-sectional view of a can located in a can locator with a mandrel located in the can according to an exemplary embodiment.

FIG. 40 is a schematic view of a can being moved by a conveyor to a can locator according to an exemplary embodiment.

FIG. 41 is a schematic view of a star wheel system configured to apply a liner sheet to an interior of a can according to an exemplary embodiment.

DETAILED DESCRIPTION

Referring generally to the figures, various mechanisms and methods for providing various containers with lining are shown according to exemplary embodiments. Metal containers, e.g., cans, two-piece cans such as can bodies formed from a single sheet of metal to which a panel is attached to close the cans, three-piece cans such as a can body to which two panels may be connected to close each end, e.g., by a double seam, etc., may be provided with non-metal lining to prevent contamination and/or degradation of contents that may be added to and/or stored in the container. In one embodiment, panels may include features such as, for example, beads, countersinks, etc.
Referring to FIG. 1, an embodiment of a system 20 for lining cans 22 is illustrated. A roll 24 dispenses a lining element, shown as liner sheet material 26 to a heater, illustrated as an infrared heater 28, where the liner sheet material 26 is heated. The heated liner sheet material 26 passes from the heater 28 to a liner sheet holding mechanism 30.
With reference to FIGS. 1-4, the holding mechanism 30 is configured to hold and support the liner sheet material 26. The holding mechanism 30 has an open central portion 32. The holding mechanism 30 is configured to hold a portion of the liner sheet material 26 above a can 22. In one embodiment, the liner sheet material 26 is held by the holding mechanism 30 a height H1 above the upper peripheral edge of the can 22. In one embodiment, the sidewall of the can 22 has a height H2. In various embodiments, the ratio of height H1 to height H2 may provide thinning of the liner sheet material 26 to a desirable thickness for lining the can 22. In one embodiment, the open central portion 32 of the holding mechanism 30 has a diameter D1. In one embodiment, the sidewall of the can 22 has a diameter D2. In one embodiment, the ratio of diameter D2:height H2:diameter D1:height H1 is 3.0:4.5:5.5:2. In one embodiment, the ratio of diameter D2 to diameter D1 is between 0.55 and 1. In another embodiment, the ratio of diameter D2 to diameter D1 is between 0.75 and 1. In another embodiment, the ratio of diameter D2 to diameter D1 is between 0.9 and 1. In one embodiment, the ratio of height H2 to height H1 is between 2.25 and 200. In another embodiment, the ratio of height H2 to height H1 is between 4.5 and 100. In another embodiment, the ratio of height H2 to height H1 is between 9 and 100. In other embodiments, other suitable configurations may be used.
A liner displacement mechanism 34 is configured to move from a first location outside of the can 22 and above the holding mechanism 30 through the open central portion 32 into contact with the liner sheet material 26 and to displace and/or stretch the liner sheet material 26 into the can 22. Inside the can 22, as will be further described below, the liner displacement portion 34 forces the liner material 26 against the end wall 36 and sidewall 38 of the can 22, forcing air between the liner material 26 and the can 22 to exit the can. Excess liner material 26 is then removed, e.g., by a cutting die, etc. In one embodiment, a cutting head is provided concentric with the liner displacement mechanism 34. In another embodiment, a cutting die set is configured to punch out the remaining liner material 40. In another embodiment, a rotating head with blades configured to remove the remaining liner material 40. In other embodiments, other suitable mechanisms may be used. The remaining liner material 40 is moved to, e.g., rolled onto, a take-up core 42. In one embodiment, the remaining liner material 40 may be recycled.
In one embodiment, the cans 22 may be moved into position under the liner displacement mechanism 34, e.g., by a conveyor. The cans 22, upon being lined with liner material 26, may be moved away from the liner displacement mechanism 34. The lining element is stretched and/or thinned as it is displaced toward the end walls of the cans 22 by the liner displacement mechanisms 34.
In one embodiment, the outer surface of at least a portion of the liner displacement mechanism 34 includes a coating, e.g., TEFLON® coating available from DUPONT™, silicone coating, etc., configured such that the liner sheet will stretch over the liner displacement portion without sticking to the outer surface and will release from the outer surface of the liner displacement portion when air is discharged from the apertures 63. In another embodiment, the outer surface of the liner displacement portion of the liner displacement mechanism 34 is formed from suitable metal such that the liner sheet will release from the outer surface of the liner displacement portion when air is discharged from the apertures 63. In other embodiments, other suitable constructions of liner displacement portions may be used.
In one embodiment, adhesive is applied to the interior surface of the sidewall 38 and the end wall 36 before the liner sheet 26 is displaced into the can 22 to adhere the liner sheet 26 to the sidewall 38 and the end wall 36. In another embodiment, adhesive is applied to the side of the liner sheet 26 proximate the can 22 to adhere the liner sheet 26 to the sidewall 38 and the end wall 36. In another embodiment, the liner sheet 26 includes and is integrally formed with an adhesive that may be activated, e.g., thermally activated, thermoset, etc., to adhere the side of the liner sheet 26 proximate the can 22 to the sidewall 38 and the end wall 36. In other embodiments, any other suitable method of coupling the liner sheet 26 to the end wall 36 and the sidewall 38 may be used.
With reference to FIG. 5, in one embodiment, the sidewall 38 of the can 22 extends from a first open end 44 to a second end 46. The first open end 44 defines a central opening 48 through which the liner material 26 is inserted into the can 22. The second end 46 of the sidewall 38 is coupled to the end wall 36, e.g., by a double seam 50, with the end wall 36 closing the second end 46 of the can 22.
With further reference to FIG. 5, the liner material 26 has a lower side 52 proximate the can 22 and which is configured to contact the can 22 and an upper side 54 opposite the lower side 52. The liner material 26 has a thickness T1.
In one embodiment, the liner displacement mechanism 34 includes an upper portion and a lower portion 56 configured to contact the liner material 26 and to move with the liner material 26 into the interior of the can 22. In one embodiment, the upper portion is configured to move the lower portion 56 axially from a first location above the liner material 26 and the can 22 to a second location inside the can 22. Generally, in one embodiment, the liner displacement mechanism 34 is configured to draw a vacuum through apertures 63 in the lower portion 56 and move the lower portion 56 into contact with the liner material 26, which may be held at its radial periphery by a holding mechanism such as holding mechanism 30 illustrated in FIG. 1. While continuing to draw a vacuum, the lower portion 56 and the liner material 26 are moved into the can 22, through the central opening 48 and to the end wall 36. The vacuum is reversed and fluid is expelled from the portion of the lower portion 56 proximate the end wall 36 while a vacuum continues to be drawn through the portions of the lower portion 56 distal from the end wall 36. The reversal of the vacuum and fluid being expelled continues upwardly along the lower portion 56 until the liner material 26 has been moved against the end wall 36 and the sidewall 38 across the interior of the can 22.
With reference to FIG. 6, an embodiment of a lower portion 56 of a liner displacement mechanism 34 is illustrated in an exploded configuration. The lower portion 56 includes a core 58, a lower redirection apparatus 60 configured to be coupled to the core 58, a sleeve 62 configured to be located around the core 58, and a plurality of valves 64, 66, 68, 70, 72, 74, and 76. The lower redirection apparatus 60 is configured to direct pressurized fluid received from a bore in the core 58 in a direction non-parallel to the direction through which the pressurized fluid travelled through the core 58 toward the liner material 26. In one embodiment, the core 58 is generally cylindrical and extends from a first end 78 to a second end 80. The sleeve 62 defines a plurality of aperatures/bores 63. In one embodiment, the aperatures 63 are arranged in a plurality of columns extending around the circumference of the sleeve 62. In other embodiments, other suitable arrangements of bores may be provided.
With reference to FIGS. 6 and 7, the core 58 includes a plurality of projections 82, 84, 86, 88, 90, and 92 projecting radially outwardly. The projection 84 has a lower wall 94 and an upper wall 96 spaced apart from the lower wall 94 and extending generally parallel to the lower wall 94 radially outwardly. The lower and upper walls 94 and 96 define a radially outwardly facing channel 98 therebetween. A ring seal 100 is located in the channel 98. Similarly, the projection 86 includes a lower wall 102 and an upper wall 104. The lower and upper walls 102 and 104 define a radially outwardly facing channel 106 therebetween. A ring seal 108 is located in the channel 106. In one embodiment, the projections 88, 90, and 92 are structured similarly to the projections 84 and 86.
Referring to FIG. 9, the lower wall 94 of the projection 84 and the projection 82 define a radially outwardly facing channel 110 therebetween. The upper wall 96 of the projection 84 and the lower wall 102 of the projection 86 define another radially outwardly facing channel 112 therebetween. Similarly, the upper wall 104 of the projection 86 and the lower wall of the projection 88 define a radially outwardly facing channel 114 therebetween. The upper wall of the projection 88 and the lower wall of the projection 90 define a radially outwardly facing channel 116 therebetween. The upper wall of the projection 90 and the lower wall of the projection 92 define a radially outwardly facing channel 118 therebetween. The channels 110, 112, 114, 116, and 118 extend circumferentially around the core 58.
With reference to FIGS. 6-9, in one embodiment, the core 58 includes a plurality of bores 120, 122, 124, 126, 128, 130, and 132 extending axially downwardly from the second end 80 of the core 58. In one embodiment, the bores 130 and 132 are approximately the same diameter. In one embodiment, the bores 120, 122, 124, 126, and 128 are approximately the same diameter. In one embodiment the diameter of the bores 130 and 132 is less than the diameter of the bores 120, 122, 124, 126, and 128.
The bore 120 includes a first portion extending axially downwardly generally parallel with the longitudinal axis of the core 58 and a second portion extending from the first portion radially outwardly to an aperture 134 providing access to the channel 110. In one embodiment, the displacement mechanism 34 includes a fluid source configured to selectively supply pressurized fluid, e.g., compressed air, or to draw a vacuum through the valve 64, the bore 120, and the aperture 134 to provide pressurized fluid or vacuum to the channel 110.
With further reference to FIGS. 6-9, in one embodiment, the bore 126 includes a first portion extending from the second end 80 of the core 58 axially downwardly generally parallel with the longitudinal axis of the core 58 and a second portion extending from the first portion radially outwardly to an aperture 136 providing access to the channel 116. The fluid source of the displacement mechanism 34 is configured to selectively supply pressurized fluid or to draw a vacuum through the valve 70, the bore 126, and the aperture 136 to provide pressurized fluid or vacuum to the channel 116.
With reference to FIGS. 6, 8, and 10, in one embodiment, the bore 122 includes a first portion extending from the second end 80 of the core 58 axially downwardly generally parallel with the longitudinal axis of the core 58 and a second portion extending from the first portion radially outwardly to an aperture 138 providing access to the channel 112. The fluid source of the displacement mechanism 34 is configured to selectively supply pressurized fluid or to draw a vacuum through the valve 66, the bore 122, and the aperture 138 to provide pressurized fluid or vacuum to the channel 112.
With reference to FIGS. 6, 7, and 11, in one embodiment, the bore 124 includes a first portion extending from the second end 80 of the core 58 axially downwardly generally parallel with the longitudinal axis of the core 58 and a second portion extending from the first portion radially outwardly to an aperture 140 providing access to the channel 114. The fluid source of the displacement mechanism 34 is configured to selectively supply pressurized fluid or to draw a vacuum through the valve 68, the bore 124, and the aperture 140 to provide pressurized fluid or vacuum to the channel 114.
With further reference to FIGS. 6, 7, and 11, in one embodiment, the bore 128 includes a first portion extending from the second end 80 of the core axially downwardly generally parallel with the longitudinal axis of the core 58 and a second portion extending from the first portion radially outwardly to an aperture 142 providing access to the channel 118. The fluid source of the displacement mechanism 34 is configured to selectively supply pressurized fluid or to draw a vacuum through the valve 72, the bore 128, and the aperture 142 to provide pressurized fluid or vacuum to the channel 118.
In one embodiment, the apertures 134, 136, 138, 140, and 142 are circumferentially offset from one another around the core 58. In one embodiment, the apertures 134, 136, 138, 140, and 142 are each spaced apart by approximately 72° from the closest neighboring aperture.
As illustrated in FIGS. 9-11, extending axially upwardly from the first end 78 of the core 58 is a cavity 144. The core 58 includes a threaded portion 146 with threads extending radially inwardly into the cavity 144. Extending axially upwardly generally parallel with the longitudinal axis of the core 58 is a central bore 148. The first end 78 of the core 58 includes a radially outer annular wall 141 and an inner annular wall 143 defining a radially outer channel 145 therebetween. The first end 78 of the core 58 defines a second radially inner channel 147 located radially inwardly from the outer channel 145.
With reference to FIGS. 14-16, an embodiment of the lower redirection apparatus 60 is illustrated. The redirection apparatus 60 includes a generally disk-shaped base 150 and a threaded central projection 152 projecting axially upwardly from the base 150. The projection 152 is configured to be received and threadingly retained in the threaded portion 146 of the cavity 144. The base 150 includes a central portion 154, an inner annular wall 156, and an outer annular wall 158. The radial outer periphery of the central portion 154 and the radial inner periphery of the inner annular wall 156 define an inner channel 160 therebetween. In one embodiment, the inner channel 160 is circular extending around the projection 152. The radial outer periphery of the inner annular wall 156 and the radial inner periphery of the outer annular wall 158 define an outer channel 162 therebetween. In one embodiment the outer channel 162 is circular extending around the projection 152. The redirection apparatus 60 defines a central bore 164 extending axially downwardly from the axial upper periphery of the projection 152, through the projection 152, through the central portion 154 of the base 150, and to the axial lower periphery of the central portion 154 of the base 150.
With further reference to FIGS. 15 and 16, in one embodiment, extending radially outwardly from the central bore 164 through the central portion 154 of the base 150 are a plurality of bores 166. The bores 166 are spaced apart around the circumference of the central bore 164 and extend from the central bore 164 to the radial outer periphery of the central portion 154 allowing fluid communication between the inner channel 160 and the central bore 164. The redirection apparatus 60 also includes a plurality of bores 168 extending from the inner channel 160, e.g., from the inner radial periphery of the inner annular wall 156, through the inner annular wall 156, axially under the outer channel 162, through the outer annular wall 158, to the outer radial periphery of the outer annular wall 158.
With further reference to FIGS. 14 and 16, in one embodiment, the redirection apparatus 60 defines a plurality of angular bores 170. The angular bores 170 are spaced apart around the circumference of the redirection apparatus 60 and extend angularly downwardly and radially outwardly from the outer channel 162 to the radially outer axially lower periphery of the redirection apparatus 60. In one embodiment, the angular bores 170 are circumferential offset from, e.g., do not intersect with, the bores 168.
With reference to FIG. 18, the lower periphery of the core 58 includes an outer annular portion 172. The outer annular portion 172 defines a radially outer channel 174 configured to receive a seal, shown in FIG. 18 as a ring seal 174. The outer channel 174 is located radially between the bore 130 and a raised radially inner portion 178 of the lower periphery of the core 58. The outer annular portion 172 has a lower axial periphery that is axially lower than the lower axial periphery of the inner portion 178. The inner portion 172 defines a radially inner channel 180 configured to receive a seal, shown in FIG. 18 as a ring seal 182.
With further reference to FIG. 18, the projection 152 is inserted into the cavity 144 of the core 58 and threadingly coupled to the threaded portion 146. The bore 130 is aligned in fluid communication with the outer channel 162 of the redirection apparatus 60. The ring seal 176 prevents fluid flow radially inwardly. Fluid, e.g., fluid from the fluid source, travels through the bore 130 to the outer channel 162 and through the angular bores 170 (see FIG. 16) angularly outwardly from the redirection apparatus 60.
With reference to FIG. 19, the bore 132 is aligned in fluid communication with the inner channel 160 of the redirection apparatus 60. The ring seal 147 is configured to prevent fluid flow radially inwardly between the redirection apparatus 60 and the core 58. The ring seal 145 is configured to prevent fluid flow radially outwardly between the redirection apparatus 60 and the core 58. Fluid, e.g., fluid from the fluid source, travels through the bore 132 to the inner channel 160 and radially outwardly through the bores 168 out of the redirection apparatus 60.
With reference to FIGS. 20-26, an embodiment of a method of applying a lining element to an interior of a metal container is described. A lining element, illustrated in FIG. 20 as a liner sheet 26, provided proximate the first open end 44 of the can 22 generally perpendicular to the longitudinal axis of the sidewall 38. In one embodiment, the liner sheet 26 is generally round disk-shaped. In other embodiments, the liner sheet 36 may be any other suitable shape.
In one embodiment, the can 22 is heated prior to displacement of the liner sheet 26 into the can 22. In one embodiment, the can 22, and air located within the can 22, are heated, prior to displacement of the liner sheet 26 into the can 22. In one embodiment the can 22, and air located within the can 22, are heated to a temperature T. In one embodiment, the temperature T is greater than the maximum temperature to which the can 22 will be subjected to during processing (e.g., maximum temperature to which the can 22 is heated during lining of the can, filling of the can (e.g., hot fill, etc.), sealing of the can, heating or retort of the filled can, etc.). In another embodiment, the temperature T is approximately equal to the maximum temperature to which the can 22 will be subjected to during processing (e.g., maximum temperature to which the can 22 is heated during lining of the can, filling of the can (e.g., hot fill, etc.), sealing of the can, heating or retort of the filled can, etc.). In one embodiment, the can 22, and the air within the can 22, are heated, prior to displacement of the liner sheet 26 into the can 22, to a temperature below the temperature of reflow (e.g., below the melting point of the material from which the sidewall of the can is formed, etc.). In another embodiment, the can 22, and the air within the can 22, are heated, prior to displacement of the liner sheet 26 into the can 22, with the can 22 being heated to a temperature between approximately 200° F. and approximately 300° F. In another embodiment, the can 22, and the air within the can 22, are heated, prior to displacement of the liner sheet 26 into the can 22, with the can 22 being heated to approximately 265° F. In one embodiment, heating the can 22 may aid in adhesive flow-out and wetting.
In one embodiment, the liner sheet 26 is heated prior to deformation by a vacuum, as will be further described below, and prior to being located in the can 22. In one embodiment, the liner sheet 26 may be heated by infrared heating. In other embodiments, other suitable heating mechanisms and/or methods may be used to heat the liner sheet 26. In one embodiment, the liner sheet 26 is heated to a temperature above the glass transition temperature of the liner sheet 26.
Adhesive may be applied to the side of the liner sheet 26 proximate the can 22. In other embodiments, other suitable mechanisms which adhere the liner sheet 26 to the interior surface of the can end 22 and the interior surface of the sidewall 22 may be used. By way of example, the liner sheet material may be manufactured with thermo-activated adhesive which is activated when the film is heated at heating station 28.
With reference to FIGS. 5, 20, and 21, in one embodiment, the liner displacement mechanism 34 is configured to draw a vacuum through the bores 120, 122, 124, 126, 128, 130, 132, 148, and 164 as the lower portion 56 of the displacement mechanism 34 is moved towards the liner sheet 26 and moves along with the liner sheet 26 into the interior of the can 22 until the liner sheet 26 reaches the end wall 36 of the can 22. In one embodiment, the lower portion 56 of the liner displacement mechanism 34 creates a vacuum around itself, e.g., pulls air through the bores 120, 122, 124, 126, 128, 130, 132, 148, and 164 to create an area of lower than ambient pressure around the lower portion 56 of the displacement mechanism 34.
As the vacuum is created, the heated liner sheet 26, e.g., heated above its glass transition temperature, is pulled toward the lower portion 56 as the lower portion 56 is moved downwardly toward the can 22. In one embodiment, the radial outer periphery of the liner sheet 26 is stretched and pulled upwardly and radially inwardly toward the lower portion 56 until the liner sheet 26 generally surrounds at least a portion of the lower portion 56. In one embodiment, the liner sheet 26, upon being displaced and stretched around the lower portion 56, is thinner than prior to being displaced and stretched around the lower portion 56.
In one embodiment, the liner sheet 26 comprises a film, such as, for example, a high elongation film, e.g., film configured to be stretched without tearing and remain elongated without wrinkling, etc. In one embodiment, the film is one of a sheet, a tube, and a bag.
In one embodiment, adhesive in the liner sheet 26 is activated, e.g., heat activated, pressure activated, etc., and couples the liner sheet 26 to the end wall 36.
With reference to FIGS. 20 and 21, in one embodiment, the liner displacement mechanism 34 then discontinues drawing a vacuum through the bores 130, 148, and 164 and provides pressurized fluid flow through the bores 130, 148, and 164 while continuing to draw a vacuum through the bores 120, 122, 124, 126, and 128, and 132. Fluid flows through the bore 148 to bore 164 and axially out of the redirection apparatus 60 toward the liner sheet 26, forcing the liner sheet 26 against the end wall 36. Fluid also flows through the bore 130, through the bores 170, and angularly out of the redirection apparatus 60 toward the liner sheet 26, forcing the liner sheet 26 against the end wall 36 and the sidewall 38, including proximate the corner 55 where the end wall 36 and the sidewall 38 meet, and forcing air from between the liner sheet 26 and the end wall 36 and from between the liner sheet 26 and the sidewall 38.
With further reference to FIGS. 21-26, in one embodiment, the liner displacement mechanism 34 then discontinues drawing a vacuum through bore 132, maintains pressurized fluid flow through the bores 130, 148, and 164, begins providing pressurized fluid flow through the bore 132, and continues to draw a vacuum through the bores 120, 122, 124, 126, and 128. Fluid flows through the bore 132, through the bores 168, and out of the redirection apparatus 60 toward the liner sheet 26, forcing a lower portion of the liner sheet 26 against the sidewall 38 and forcing air from between the liner sheet 26 and the sidewall 38.
With reference to FIG. 22, in one embodiment, the liner displacement mechanism 34 then discontinues drawing a vacuum through the bore 120, maintains pressurized fluid flow through the bores 130, 132, 148, and 164, begins providing pressurized fluid flow through the bore 120, and continues to draw a vacuum through the bores 122, 124, 126, and 128. Fluid flows through the bore 120, out of the aperture 134, into the channel 110, and through the bores 63 in the sleeve 62 axially located between the projection 82 and the seal 100. The fluid forces a portion of the liner sheet 26 generally located axially between the projection 82 and the seal 100 radially outwardly toward the sidewall 38 and forces air from between this portion of the liner sheet 26 and the sidewall 38 with the adhesive of the liner sheet 26 being activated and the liner sheet 26 becoming coupled to the sidewall 38.
With reference to FIG. 23, in one embodiment, the liner displacement mechanism 34 then discontinues drawing a vacuum through the bore 122, maintains pressurized fluid flow through bores 120, 130, 132, 148, and 164, begins providing pressurized fluid flow through the bore 122, and continues to draw a vacuum through the bores 124, 126, and 128. Fluid flows through the bore 122, out of the aperture 138, into the channel 112, and through the bores 63 in the sleeve 62 axially located between the seal 100 and the seal 108. The fluid forces a portion of the liner sheet 26 generally located axially between the seal 100 and the seal 108 radially outwardly toward the sidewall 38 and forces air from between this portion of the liner sheet 26 and the sidewall 38 with the adhesive of the liner sheet 26 being activated and the liner sheet 26 becoming coupled to the sidewall 38.
With reference to FIG. 24, in one embodiment, the liner displacement mechanism 34 then discontinues drawing a vacuum through the bore 124, maintains pressurized fluid flow through bores 120, 122, 130, 132, 148, and 164, begins providing pressurized fluid flow through the bore 124, and continues to draw a vacuum through the bores 126 and 128. Fluid flows through the bore 124, out of the aperture 140, into the channel 114, and through the bores 63 in the sleeve 62 axially located between the seal 108 and the seal 184 located in the channel 186 of the projection 88. The fluid forces a portion of the liner sheet 26 generally located axially between the seal 108 and the seal 184 radially outwardly toward the sidewall 38 and forces air from between this portion of the liner sheet 26 and the sidewall 38 with the adhesive of the liner sheet 26 being activated and the liner sheet 26 becoming coupled to the sidewall 38.
With reference to FIG. 25, in one embodiment, the liner displacement mechanism 34 then discontinues drawing a vacuum through the bore 126, maintains pressurized fluid flow through bores 120, 122, 124, 130, 132, 148, and 164, begins providing pressurized fluid flow through the bore 126, and continues to draw a vacuum through the bore 128 (see FIG. 24). Fluid flows through the bore 126, out of the aperture 136, into the channel 116, and through the bores 63 in the sleeve 62 axially located between the seal 184 and the seal 188 located in the channel 190 of the projection 90. The fluid forces a portion of the liner sheet 26 generally located axially between the seal 184 and the seal 188 radially outwardly toward the sidewall 38 and forces air from between this portion of the liner sheet 26 and the sidewall 38 with the adhesive of the liner sheet 26 being activated and the liner sheet 26 becoming coupled to the sidewall 38.
With reference to FIG. 26, in one embodiment, the liner displacement mechanism 34 then discontinues drawing a vacuum through the bore 128, maintains pressurized fluid flow through bores 120, 122, 124, 126, 130, 132, 148, and 164 and begins providing pressurized fluid flow through the bore 128. Fluid flows through the bore 128, out of the aperture 142, into the channel 118, and through the bores 63 in the sleeve 62 axially located between the seal 188 and the seal 192 located in the channel 194 of the projection 92. The fluid forces a portion of the liner sheet 26 generally located axially between the seal 188 and the seal 192 radially outwardly toward the sidewall 38 and forces air from between this portion of the liner sheet 26 and the sidewall 38 with the adhesive of the liner sheet 26 being activated and the liner sheet 26 becoming coupled to the sidewall 38.
With reference to FIG. 27, in one embodiment, following the steps of FIGS. 20-26, air has been removed from between the liner sheet 26 and the end wall 36 and sidewall 38 of the can 22 out of the can 22 and the liner sheet 26 is coupled to the interior of the can 22 generally covering the interior surface of the can 22. In one embodiment, the lower portion 56 of the liner displacement mechanism 34 is removed from the interior of the can 22, e.g., with fluid still continuing to be provided through bores 120, 122, 124, 126, 128, 130, and 132.
With reference to FIGS. 20-27, the can 22 is illustrated with a generally planar end wall 36. In other embodiment, cans having various features defined in their end walls, e.g., countersinks, curls, etc., may be lined with liner sheets as described above. In one embodiment, the bottom profile of the redirection apparatus 60 may be configured to match the profile of the end wall 36.
In another embodiment, the liner displacement mechanism 34 is heated prior to and/or while displacing the liner sheet 26 into the can 22.
In one embodiment, each of the cans 22 is located in a locating mechanism, e.g., a nest, configured to move the cans 22 and locate the cans 22 appropriately relative to the liner displacement mechanism 34. In one embodiment, the nest is configured to heat the can 22. In another embodiment, the nest is configured to cool the can 22 after the liner sheet 26 has been applied to the interior surface of the can 22. In various embodiments, such cooling may allow the liner sheet 26 to set relative to the can 22, e.g., allow adhesive to cure, allow adhesive to set, etc. In one embodiment, the nest is configured to draw a vacuum proximate the open end of the can 22 to draw fluid from between the liner sheet 26 and the can 22 as the liner sheet 26 is being forced against the interior surface of the can 22. In one embodiment, the nest is configured with two shell halves configured to pivot relative to one another to open and close around the can 22. In other embodiments, other suitable nest configurations may be used.
In one embodiment, an excess portion of the liner sheet 26 outside of the can 22 is removed, e.g., cut away, removed by a die or other suitable removal mechanism, etc.
In one embodiment, as the can 20 cools, any air that may remain between the liner sheet 26 and the sidewall 38 and/or between the liner sheet 26 and the end wall 36, including air located proximate the corner 55, may reduce in volume thus creating a vacuum tending to urge the liner sheet 26 toward the sidewall 38 and the end wall 36. Additionally, in one embodiment, by heating the can 22 and/or the air inside the can 22 to a temperature greater than or equal to the highest temperature to which the can 22 will be subjected during processing (e.g., maximum temperature to which the can 22 is heated during lining of the can, filing of the can (e.g., hot fill, etc.), sealing of the can, heating or retort of the filled can, etc.) prior to placing the liner sheet 26 inside the can 22, any air that may remain trapped between the liner sheet 26 and the sidewall 38 and/or between the liner sheet 26 and the end wall 36 may not expand to a volume greater than the volume of the trapped air when the liner sheet 26 is applied to the sidewall 38 and the end wall 36.
In one embodiment, the system 20 includes a controller configured to control an actuator configured to move the liner displacement mechanism 34 as described above. In one embodiment, the controller is further configured to control drawing vacuum and providing pressurized fluid through the bores 120, 122, 124, 126, 130, and 132, as described above. In one embodiment, the system 20 includes an interface coupled to the controller, the interface being configured to receive input from a user to adjust the control parameters, e.g., adjust the movement of the liner displacement mechanism 34, adjust pressure, timing, etc., of drawing vacuum and providing pressurized fluid through the bores 120, 122, 124, 126, 130, and 132, etc., for example to apply a lining to cans of different sizes, dimensions, etc.
In various embodiments, controllers such as those disclosed above may generally be any electronic control unit or circuit suitable to provide the functionalities discussed herein. For example the controller may include one or more processing circuits having hardware (e.g., processors, memory, communication interfaces, etc.) and/or software configured to control the operation of the liner displacement mechanism 34 as discussed herein.
Containers discussed herein, and to the interiors of which lining elements may be applied by the embodiments of methods described above, may include containers of a wide variety of styles, shapes, sizes, etc. For example, the containers discussed herein may be shaped such that cross-sections taken perpendicular to the longitudinal axis of the container are generally circular. However, with reference to FIG. 28, in other embodiments the sidewall of the containers, such as can 320, may be shaped in a variety of ways (e.g., having other non-polygonal cross-sections, as a rectangular prism, a polygonal prism, any number of irregular shapes, etc.) as may be desirable for different applications and embodiments of mechanisms and methods described herein may be used to apply lining elements to containers having other non-polygonal cross-sections, as a rectangular prism, a polygonal prism, any number of irregular shapes, etc.
In various embodiments, the sidewall 322 of the can 320 may include one or more axially extending sidewall sections that are curved or angled radially inwardly or outwardly such that the diameter of the can is different at different locations along the axial length of the can, and such curved or angled sections may be smooth continuous curved sections.
With reference to FIG. 29, a perspective view shown schematically of an embodiment of a system for lining cans 400 according to an exemplary embodiment is provided. The illustrated embodiment includes many of the features of the previous embodiments. Therefore, differences from the previous embodiments are the focus of the description below. The system 400 includes a moveable support, shown as a conveyor 402, configured to move the cans 404 relative to the liner insertion apparatus 406, e.g., in the direction of arrow A. A can locator, shown as a nest 408, is coupled to the conveyor 402. The nest 408 is configured to locate, e.g., precisely locate, the can 404 relative to the liner insertion apparatus 406 to receive the liner sheet 410 into the interior of the can 404.
In one embodiment, a can locator is movable between a loading configuration in which a can may be located in the can locator and a closed configuration for locating the can relative to the liner insertion apparatus 406.
In one embodiment, the nest 408 is pivotable between a first, open configuration, illustrated in FIG. 30, and a second, closed, configuration, illustrated in FIG. 31. With reference to FIGS. 30-32, the two halves of the nest 408 in the closed configuration have a sidewall 412 defining a cavity 414 in which the can 404 is located. The nest 408 also includes an actuation mechanism, shown in the figures as a handle and latch mechanism 416, configured to selectively hold the halves of the nest 408 in the closed configuration and allow the halves of the nest 408 to move to the first, open configuration. In other embodiments, other suitable automated actuation mechanisms configured to open and close the nest 408 may be used.
In one embodiment, the nest 408 also includes a bottom plate 418, closing the lower end of the cavity 414. In one embodiment, the nest 408 includes a can cooling element. With reference to FIG. 32, the halves of the nest and the bottom plate 418 each include a plurality of bores 420. The bores 420 are configured to receive cooling fluid, e.g., liquid, gas, etc., from cooling fluid supply conduits 422 (see FIG. 33) and to pass the cooling fluid through the nest 408 and past the can 404 to cooling fluid outlets 423 (see FIG. 34, conduits from cooling fluid outlets 423 not shown for clarity) to cool the can 404. In one embodiment, the can 404 may be cooled after a liner sheet is located inside the can 404, covering the interior surface of the can 404, to promote setting and/or adhesive bonding and/or coupling between the liner sheet and the interior surface of the can 404.
In one embodiment, the nest 408 includes a can heater. With further reference to FIG. 32, in one embodiment, the halves of the nest 408 and the bottom plate 418 include heating elements 424. In one embodiment, the heating elements 424 are configured to heat the can 404 prior to and/or while the liner sheet is located inside the can 404. Heating the can 404 may promote activation of an adhesive of a liner sheet and/or promote coupling of the liner sheet to the interior surface of the can 404. The can heater may include bores through the halves of the nest and the bottom plate 418 through which hot fluid, e.g., hot liquid, hot gas, etc., is passed through the nest 408 and past the can 404 to heat the can 404. In another element, the can heater includes a resistive heater with, e.g., heating elements located in the nest 408. In another embodiment, the can heater includes an induction heater. In other embodiments, other suitable types of can heaters may be used.
With reference to FIG. 35, an embodiment of a can 504 lined with a liner sheet 506, e.g., by one of the methods and/or mechanisms described above, is provided. The liner sheet 506 has a first portion 508 and a second portion 510. The first portion 508 extends from the first open end 514 of the sidewall 512 to the end wall 516. The second portion 510 extends from the first portion 508, e.g., from the first open end 514 of the sidewall 512, outside of the can 504. In one embodiment, the second portion 510 is thicker than the first portion 508. In one embodiment, the second portion 510 has a thickness between approximately 0.01 inches and approximately 0.03 inches. In another embodiment, the second portion 510 has a thickness of less than 0.02 inches. In one embodiment, the first portion 508 has a thickness between approximately 0.001 inches and approximately 0.003 inches. In another embodiment, the first portion 508 has a thickness of less than 0.002 inches.
With further reference to FIG. 35, in one embodiment, upon filling the can 504, e.g., filling with foodstuffs, liquids, etc., a can end 518 may be provided to close the first open end 514 of the sidewall 512. The can end 518 includes an annular, radially outer, continuously curved portion shown as a curl 520. The curl 520 and the open end 514 of the sidewall 512 trap at least a portion of the second portion 510 of the liner sheet 506 therebetween, with liner sheet 506 material being located in the curl 520. The curl 520 and the sidewall 512 are coupled together, e.g., by double seaming. The second portion 510 of the liner sheet 506 located between the can end 518 and the sidewall 512 forms a hermetic seal between the can end 518 and the sidewall 512, closing the can 504.
In one embodiment, the second portion 510 of the liner sheet 506 being located in the curl 520 may allow for the can end 518 to be coupled to the sidewall 512 and hermetically seal the can 504 without addition of compound, e.g., solvent-based compound, water-based compound, compound including heptane, modified PET, etc., to the curl 520. In one embodiment, the second portion 510 is moved into the curl 520 of the can end 518 by double seaming.
With reference to FIG. 36, an exemplary can end 600, e.g., a can end formed by stamping a metal blank, etc., is illustrated. The can end 600 includes a curl 602. A liner sheet 604, e.g., laminate sheet, configured to be applied to the can end 600 is illustrated below the can end 600. With reference to FIG. 37, in one embodiment, the liner sheet 604 includes a central portion 606 and an annular radially outer portion 608. The central portion 606 has a thickness T2. The outer portion 608 has a thickness T3. The thickness T3 is greater than the thickness T2. In one embodiment, the thickness T2 is between approximately 0.001 inches and approximately 0.003 inches. In another embodiment, the thickness T2 is less than 0.002 inches. In one embodiment, the thickness T3 is between approximately 0.01 inches and approximately 0.03 inches. In another embodiment, the thickness T3 is between 0.01 inches and 0.02 inches. In another embodiment, the thickness T3 is less than 0.02 inches. In one embodiment, the liner sheet 604 is positioned relative to the can end 600 and pressed, e.g., by hard tooling, etc., against the can end 600, with the liner sheet 604 being coupled to the can end 600 by adhesive, e.g., heat-activated adhesive, pressure-activated adhesive, etc. The annular radially outer portion 608 is located in the curl 602. The thickness and/or configuration of the radially outer portion 608 in the curl 602 may allow for double seaming of the can end 600 to a sidewall of a container to form a hermetic seal without the addition of compound into the curl 602 after laminating of the can end 600, which may be desirable, e.g., reduced complexity, reduced compound, such as, for example, solvent or water borne gaskets, applied as liquids and composed of natural rubber and other polymeric compounds, DAREX SLC 9385HC-57, DAREX WBC 9000-63-1, etc., usage, reduction in number of process steps, etc.
In one embodiment, the liner sheet 604 with differential thickness may be formed by providing a liner sheet of generally uniform thickness T3, clamping an outer annular area of the liner sheet, and thinning a central portion of the clamped liner sheet. In one embodiment, the thinning may be accomplished by stretching, e.g., stretching with tooling, such as hard tooling, stretching by applying pressurized fluid, etc.
With reference to FIG. 38, in one embodiment, a liner sheet 704 with differential thickness may be formed by rolling the outer edge of a liner sheet 704 of generally uniform thickness radially inwardly to form a rolled portion 706. The liner sheet 704 may then be coupled to a can end with the rolled portion 706 located in the curl of a can end.
In another embodiment, a roll of metal sheet from which can ends will be formed is provided. Portions of liner sheet with thinner central portions and thicker annular radially outer portions are coupled to the roll of metal sheet. Can ends are then formed, e.g., stamped from the metal sheet such that the thicker annular radially outer portions of the liner sheet portions are located in the curl of the finished can ends, allowing the can ends to be coupled to a sidewall of a can to form a hermetic seal without addition of compound into the curl.
With reference to FIG. 39, another embodiment of a can locator 808 is illustrated. The can locator 808 defines a cavity in which a can 804 is located. The can 804 includes a sidewall 805 and an end wall 806 closing one end of the sidewall 805. The end wall 806 is profiled, e.g., includes a plurality of beads, a countersink, etc. The can locator 808 includes a lower portion 810 closing one end of the cavity. The upper surface of the lower portion 810 is profiled to match the profile of the end wall 806 of the can 804. A can liner locating mechanism 834 extends into the can 804 locating a liner sheet 826 in the can 804. The can liner locating mechanism includes a seal shown as an O-ring 817. The O-ring 817 is configured to seal the liner sheet 826, e.g., an outer peripheral portion of the liner sheet 826, against an upper portion 819 of the can locator 808. The can locator 808 is configured to draw a vacuum drawing fluid from between the liner sheet 826 and the can 804 (path of fluid drawn by vacuum shown by arrows 809).
In one embodiment, the can liner locating mechanism 834 is configured to draw a vacuum to draw the liner sheet 826 onto a mandrel of the can liner locating mechanism 834. The can liner locating mechanism 834 then moves the mandrel and the liner sheet 826 downwardly into the can 804 located in the can locator 808. The seal 817 seals the liner sheet 826 to an upper portion 819 of the can locator 808. The can locator 808 draws a vacuum pulling air from between the liner sheet 826 and the can 804. The can liner locating mechanism 834 then sequentially reverses the vacuum drawn through the mandrel as described with respect to embodiments above, blowing the liner sheet 826 against the interior surface of the can 804. The can locator 808 then discontinues pulling vacuum from between the liner sheet 826 and the can 804. The can locator 808 then begins heating the can 804 to activate adhesive between the liner sheet 826 (e.g., in one embodiment, an outer layer of the liner sheet 826 is an adhesive layer, in another embodiment, an adhesive layer is applied to at least one of the liner sheet 826 and the inner surface of the can 804 before the liner sheet 826 is located in the can 804). In one embodiment, the can 804 is heated by induction heating. In another embodiment, the can 804 is heated by hot air conducting heat to the can 804. In other embodiments, other suitable heating methods may be used. The can locator 808 then cools the can 804 using, e.g., cold air flow, cold liquid flow, etc.
With reference to FIG. 40, another embodiment of a can locator is illustrated. The can locator includes a first half 906 and an opposite second half 908 configured to move toward and apart from one another perpendicular to the movement of a can 904 on a conveyor 902. The first and second halves 906 and 908 move apart to allow the can 904 to enter the can locator. The halves 906 and 908 then move together to close around the can 904. A liner sheet may then be located in the can 904 by a liner sheet locating mechanism as described in various embodiments above. Accordingly, the can locator it preferably supported beneath the holding mechanism 30 and relative to conveyor 902 so that halves 906 and 908 open and close in coordination with the insertion of liner material into can 904.
With reference to FIG. 41, in another embodiment, a system 1000 for applying a liner sheet to the interior of cans 1002 is illustrated. The system 1000 includes a first wheel 1004 that includes a plurality of pockets in which cans 1002 are located. The cans 1002 may be heated while located in the pockets. The cans 1002 are moved around the first wheel 1004 to a second wheel 1006. While located in pockets of the second wheel 1006, liner sheets may be located inside the cans 1002, such as by can liner locating mechanisms as described above. The cans 1002 are moved around the second wheel 1006 to a third wheel 1008. While the cans 1002 are located in pockets of the third wheel 1008, the cans 1002 may be heated, e.g., to activate adhesive between the liner sheets and the interior surfaces of the cans 1002, and/or cooled, e.g., to set the adhesive.
In one embodiment, the liner sheets are formed from laminate, such as, for example, polyester, polypropylene, nylon, polymer blends utilizing these compounds, etc. In other embodiments, other suitable types of coated materials may be used.
For purposes of this disclosure, generally uniform thickness of a sheet of liner material, e.g., material for lining a can prior to undergoing processes and/or methods and/or treatments as described above, means a thickness that varies less than 0.001 inches in thickness across the liner sheet.
The cans may be of various sizes (e.g., 3 oz., 8 oz., 12 oz., 15 oz., 28 oz., etc.) as desired for a particular application. A lining element may be adhered to the interior surface of the can 320 by embodiments of any of the mechanisms and/or any of the methods described above. Additionally, in other embodiments, the cans may be two-piece cans, e.g., cans with integrally formed sidewall and end wall to which a can end is coupled to seal the end of the sidewall distal from the end wall.
In some embodiments, lining elements, such as liner sheets, have a layer configured to contact the interior of cans to be lined. In one embodiment, this layer is a layer configured to couple the liner sheet to the cans, e.g., a tie layer. In one embodiment, the tie layer is generally non-tacky at a lower temperature, e.g., room temperature. In one embodiment, when the liner sheet is heated, the tie layer is activated, e.g., the tie layer transitions into a state for application of the liner sheet to the can wall such that the tie layer will then couple the liner sheet to the can wall and maintain the liner sheet coupled to the can wall upon cooling of the tie layer. In one embodiment, the tie layer is activated at approximately 275° F.
Lining elements described above may be formed from various plastic materials. In one embodiment, lining elements are formed from thermoplastics. In one embodiment, lining elements include polyethylene. In another embodiment, lining elements include polyethylene terephthalate (PET). In one embodiment, lining elements include polyethylene terephthalate glycol-modified (PETG). In one embodiment, lining elements including PET copolymer. In another embodiment, lining elements include polypropylene.
In one embodiment, adhesive is provided on one side of lining elements such as lining sheets. The adhesive is configured to couple, e.g., bond, etc., the lining elements to the interior surfaces of the cans. In one embodiment, the adhesive is a heat-activated adhesive. In another embodiment, the adhesive is pressure-activated adhesive. In another embodiment, the adhesive is activated application of both heat and pressure.
In one embodiment, fluid sources disclosed above are sources of both pressurized fluid and of vacuum.
In some embodiments, when cans and liner sheets are heated prior to coupling the liner sheet to the can, as the can cools, any air that may remain between the liner sheet and the sidewall and/or between the liner sheet and the can end will reduce in volume as the temperature cools, thus creating a vacuum tending to urge the liner sheet toward the sidewall and the can end. In one embodiment, this vacuum will remain and will continue to urge the liner sheet toward the sidewall and can end as long as the temperature of the air remains below the temperature to which it was heated when the liner sheet was applied to the can. In one embodiment, the vacuum will continue to urge the liner sheet toward the sidewall and can end when the can is at ambient temperature and conditions, e.g., later when the can is being transported to, for example, retail stores, displayed, stored, etc.
In one embodiment, liner displacement portions are heated prior to contacting lining elements such as liner sheets.
Embodiments of liner sheets are described above as being coupled to cans with beaded sidewalls. In other embodiments, lining elements such as liner sheets are applied to cans with unbeaded sidewalls. In one embodiment, upon coupling a liner sheet to a can with an unbeaded sidewall, the sidewall of the can is then beaded.
Further, embodiments of container ends or can ends discussed herein may be a variety of suitable walls or closures (e.g., a closure, lid, cap, cover, top, end, can end, sanitary end, “pop-top”, “pull top”, convenience end, convenience lid, pull-off end, easy open end, “EZO” end, etc.). In one embodiment, a can end such as, e.g., an “EZO” convenience end, sold under the trademark “Quick Top” by Silgan Containers Corp, may be coupled to a sidewall to close the top open end of an embodiment of a container upon filing of the container.
Embodiments of the can ends discussed above are shown and/or described coupled to the sidewall via a “double-seam” formed from the interlocked portions of material of the can sidewall and the can end. However, in other embodiments, the can ends discussed herein may be coupled to the sidewall via other mechanisms. For example, can ends may be coupled to the sidewall via welds or solders. The container end may be made of metals, such as steel or aluminum, metal foil, plastics, composites, or combinations of these materials. In various embodiments, the can ends, double-seams, and sidewall of the container are adapted to maintain a hermetic seal after the container is filled and sealed.
As discussed above, the containers discussed herein are configured to hold various items. It should be understood that the can and lining elements discussed herein may be utilized in cans configured to hold edible items. For example, the containers and inserts discussed above may hold nuts, beverages, fruits, meats, vegetables, or any other suitable food, drink, pet food, fluid, milk-based product, etc. It should be understood that the phrase “food” used to describe various embodiments of this disclosure may refer to dry food, moist food, powder, liquid, or any other drinkable or edible material, regardless of nutritional value.
In various embodiments, the cans discussed herein are configured to contain foods at a negative internal pressure (e.g., cans that have an internal vacuum) and the negative internal pressure results in an inwardly directed force on the sidewall of the can. In various embodiments, the negative internal pressure results from hermetically sealing the can (e.g., via doubled-seamed can ends that are coupled to the top and bottom of the sidewall) while the contents of the can are hot and from the subsequently cooling of the can contents within the hermetically sealed can. In various embodiments, the cans discussed herein are configured to hold contents at an internal vacuum of at least 28 pounds/square inch (gauge) or “psig,” and in another embodiment, the cans discussed herein are configured to hold contents at an internal vacuum of at least 22 psig. In other embodiments, the cans discussed herein are filled with food located with the internal cavity of the can and the can is sealed and has an internal vacuum of at least 22 psig, in one embodiment, and at least 28 psig, in another embodiment.
In one embodiment, cans described above are formed from metal, e.g., steel, aluminum, alloys, etc., by any suitable mechanism.
In one embodiment, a lining element is generally provided in the shape of a sheet. In another embodiment, the lining element is provided as a bag, e.g., structure having a sidewall and an end wall closing one end of the sidewall, etc. In another embodiment, the interior surface of the can end is coated and a lining element is provided as a generally tube-shaped liner and adhered to the interior surface of the sidewall.
Embodiments of lining elements disclosed above may be formed from a suitable film, such as a Bisphenol A-free (BPA-free) film. The film may be located above cans by a suitable film mechanism. In one embodiment, lining elements are a thermoplastic. In another embodiment, lining elements are a suitable polyolefin. In another embodiment, lining elements include an adhesive on one side. In one embodiment, the adhesive is BPA-free. In another embodiment, the adhesive is thermally activated. In another embodiment, the adhesive is pressure activated. In another embodiment, adhesive is integrally formed with the lining element.
In one embodiment, a lining element may include multiple layers of lining material. For example, a lining element may include a layer including materials configured to absorb gas, such as oxygen. In one embodiment, the lining element includes a plastic layer including an oxygen absorber, e.g., iron. When the lining element is applied to a container, the container is filled and sealed. If the container is hermetically sealed, e.g., a metal container closed by an end wall, oxygen trapped inside the container may be absorbed by the plastic layer including the oxygen absorber, providing a reduced-oxygen environment for the contents of the container. Contents, e.g., foodstuffs, liquids, etc., stored in a reduced-oxygen environment may have a longer lifetime compared to similar contents stored in a higher oxygen environment, e.g., longer time between filling the container and spoilage of the contents. Additionally, contents, e.g., foodstuffs, liquids, etc., stored in a reduced-oxygen environment may have and/or maintain improved organoleptic properties compared to similar contents stored in a higher oxygen environment.
Container contents, e.g., food, etc., may be sensitive to oxygen, which may cause deterioration of food either directly or indirectly, e.g., food deterioration may be caused by oxidation reactions or by presence of spoilage aerobic microorganisms. In one embodiment, embodiments of lining elements may include layers including oxygen and ethylene scavengers, carbon dioxide scavengers and emitters, humidity controllers, flavor emitters or absorbers, or antimicrobial and/or antioxidant agents. In one embodiment, scavengers and controllers may be directly incorporated into a layer of a lining element, e.g., a film layer. In another embodiment, scavengers and controllers may be contained in a sachet or sticker coupled to a layer of a lining element. In one embodiment, a lining element configured to be coupled to an interior surface of a container includes oxygen scavenging polyethylene terephthalate. In one embodiment, a lining element includes at least one of iron powder, ascorbic acid, photosensitive polymers, and enzymes, configured to oxidize or combine with oxygen when the lining element is applied to the interior of a container and the container is filled and sealed to remove oxygen from the interior of the container. In one embodiment, a lining element with an oxygen absorber is configured to reduce oxygen levels in the interior of a container to between approximately 0.3% and approximately 0.005%. In another embodiment, a lining element with an oxygen absorber is configured to reduce oxygen levels in the interior of a container to below approximately 0.01%.
In one embodiment, oxygen scavengers and/or absorbers incorporated into a lining element are harmless to humans, e.g., potential consumers of contents of a container, are configured to absorb oxygen at an appropriate rate, are configured not to produce toxic substances or unfavorable gas or odor, to be compact, to exhibit consistent quality and/or performance, and to absorb large quantities of oxygen. In one embodiment, metal scavengers are used. In another embodiment, non-metal scavengers are used. In one embodiment, oxygen scavengers and/or absorbers may include ascorbic acid, ascorbate salts, catechol, or enzymatic oxygen scavenger systems using glucose oxidase and/or ethanol oxidase and/or catalase.
In one embodiment, a lining element configured to line and be coupled to an interior surface of a container as discussed above may include a first interior layer which does not include an oxygen absorber and/or scavenger and which is configured to be in contact with the contents of a container and a second layer including an oxygen absorber and/or scavenger configured to be located between the first layer and the sidewall and end wall of a container. In various embodiments, oxygen scavengers and/or absorbers may be imbedded into a solid, dispersed in a plastic, or included in lacquer, enamel, or adhesive layers. In another embodiment, polyunsaturated fatty acids, e.g., oleic, linoleic, or linolenic, may be included in a liner sheet and may act as an oxygen absorber and/or scavenger. In various embodiments, oxygen absorbers and/or scavengers may be activated e.g., by heat, such as during the retorting process to which a container may be subjected, light, such as UV light, presence of fluid, such as liquid, or any other suitable mechanism. In various embodiments, sulphites, such as potassium sulfite, antioxidants, such as butylated hydroxytoluene, natural antioxidants, such as vitamin E and vitamin C, a-Tocopherol, etc. In another embodiment, aerobic microorganisms, e.g., Kocuria varians, Pichia subpelliculosa, etc., may be entrapped in plastic, e.g., hydroxyethyl cellulose and polyvinyl alcohol, etc., to form an oxygen absorbing and/or scavenging liner sheet.
In various other embodiments, other oxygen absorbers and/or scavengers may be used in conjunction with and/or incorporated into liner sheets as described above, including, for example, AGELESS, available from Mitsubishi Gas Chemical Co., Ltd., FRESILIZER, available from Toppan Printing Co., Ltd., VITALON, available from Toagosei Chem. Ind. Co., SEAQUL, available from Nippon Soda Co., Ltd., SANSO-CUT, available from Finetec Co., Ltd., TOMATSU, available from Toyo Pulp Co., OXYGUARD, available from Toyo Seikan Kaisha Ltd., O-BUSTER, available from Dessicare Ltd., FRESHMAX, available from Mutlisorb Technologies Inc., FRESHPAX, available from Multisorb Technologies Inc., AMOSORB, available from Amoco Chemicals, SHELFPLUS O2, available from Ciba Specialty Chemicals, PURESEAL, available from W.R. Grace and Co., DAREX, available from W.R. Grace and Co., ZERO2, available from CSIRO/Southcorp packaging, OS1000, available from Cryovac Sealed Air Co., OXBAR, available from CMB Technologies, ATCO, available from Standa Industrie, OXYCAP, available from Standa Industrie, BIOKA, available from Bioka Ltd., etc.
In one embodiment, sidewalls of cans include beading (e.g., for strength, etc.) or other structures that result in different diameters of the sidewall along the longitudinal axis of the sidewalls. In one embodiment, embodiments of applying a lining element to the interior of cans are configured to apply the lining to all or substantially all of the interior surface of the sidewall of cans including structures such as, e.g., beading, sidewalls of varying diameter along their longitudinal axes, etc.
Generally, the arrows in the figures illustrate air flow within and out of embodiments of cans in various embodiments of providing a can with a lining. In other embodiments, air may flow in other directions within and out of embodiments of cans in various embodiments of providing a can with a lining.
In various exemplary embodiments, the relative dimensions, including angles, lengths and radii, as shown in the Figures are to scale. Actual measurements of the Figures will disclose relative dimensions, angles and proportions of the various exemplary embodiments. Various exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles and proportions that may be determined from the Figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the express dimensions set out in this description.
Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.
For purposes of this disclosure, the term “coupled” means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

Claims

What is claimed is:

1. An apparatus configured to apply a lining element to an interior surface of a can including a sidewall, the apparatus comprising:

a liner insertion apparatus configured to insert a liner sheet into the interior of the can; and

a can locator configured to locate the can relative to the liner insertion apparatus, the can locator including a sidewall defining a cavity which supports a sidewall of the can;

wherein the liner insertion apparatus is configured to dispense pressurized fluid to move the liner sheet toward the sidewall of the can.

2. The apparatus of claim 1, comprising a can heater configured to heat the can located in the cavity of the can locator.

3. The apparatus of claim 1, comprising a can cooler configured to cool the can located in the cavity of the can locator.

4. The apparatus of claim 1, wherein the liner insertion apparatus is configured to seal the liner sheet to the can locator and wherein the can locator is configured to draw a vacuum to draw fluid from between an interior surface of the can and the liner sheet.

5. The apparatus of claim 1, wherein the liner insertion apparatus is configured to draw a vacuum to draw the liner sheet to the liner insertion apparatus prior to displacing the liner sheet into the interior of the can.

6. The apparatus of claim 5, wherein the liner insertion apparatus comprises a mandrel.

7. The apparatus of claim 6, wherein the mandrel has first, second, and third fluid ports spaced apart axially along the length of the mandrel.

8. The apparatus of claim 7, wherein the mandrel is configured to reverse the vacuum through the first port and expel fluid through the first port while continuing to draw vacuum through the second and third ports.

9. The apparatus of claim 8, wherein the mandrel is configured to subsequently reverse the vacuum through the second port and expel fluid through the second port while continuing to expel fluid through the first port and draw vacuum through the third port.

10. The apparatus of claim 9, wherein the mandrel is configured to subsequently reverse the vacuum through the third port and expel fluid through the third port while continuing to expel fluid through the first port and the second port.

11. The apparatus of claim 1, wherein the locator is movable between an open configuration and a closed configuration.

12. The apparatus of claim 11, wherein the locator comprises an actuator configured to selectively open and close the locator.

13. A method of closing a can having a sidewall extending from a first open end to an end wall with a can end including a curl portion, the method comprising:

applying a liner to an interior surface of the can, the liner including a first portion extending from the first open end of the sidewall to the end wall and a second portion extending from the first open end outside of the can; and

attaching the can end to the first open end of the sidewall at a joint wherein the second portion of the liner is located between the can end and the sidewall at the joint to form a hermetic seal between the can end and the side wall.

14. The method of claim 13, wherein the coupling the can end to the first open end of the sidewall includes forming the joint in the form of a double seam between the can end and the sidewall.

15. A method of making a can end comprising:

providing a liner sheet including a central portion having a first thickness and a radially outer portion having a second thickness greater than the first thickness;

forming a can end having a curl portion;

wherein the liner sheet is attached to the can end such that the radially outer portion of the liner is located in the curl portion.

16. The method of claim 15, wherein the step of forming a can end having a curl portion comprises stamping a metal blank into a can end shape including a curl portion.

17. The method of claim 16, wherein the liner is attached to the stamped metal blank prior to forming the can end shape.

18. The method of claim 16, further comprising double seaming the stamped metal blank with the liner sheet coupled thereto to a sidewall of a can with the radially outer portion of the liner sheet forming a hermetic seal between the stamped metal blank and the sidewall.

19. The method of claim 15, wherein the thickness of the radially outer portion of the liner sheet is increased by rolling the radially outer portion of the liner sheet inwardly to reduce its radius and increase its thickness.

20. The method of claim 15, wherein the step of forming a can end having a curl portion comprises coupling the liner sheet to a metal sheet and punching the portion of the metal sheet with the liner sheet coupled thereto to form the can end.