The present invention relates to a method and apparatus for applying a cap to a container.
Screw caps for containers having a threaded neck portion have been known in the art for a very long time.
Usually, both the screw cap and the neck portion are made of polymer material, comprising one or more complementary threaded portions for screwing the cap onto the neck.
In the food packaging industry, containers and especially packaging containers with a bottle-like shape, having a body portion of a packaging material laminate and a top portion of polymer material including a threaded neck part are well known. Examples of such packaging containers are Tetra Top™, Tetra Evero™ and Tetra Evero Aseptic™ wherein the latter additionally comprises an oxygen barrier in the form of an aluminium foil as part of the packaging material laminate for longer storage time of the foodstuff contained in the packaging container.
After a web of paper material is laminated with several outer polymer materials, folded and spliced to form a hollow packaging container body, a top portion comprising threaded neck part is injection moulded onto the body, which may be of different material than the top portion as evident from the packaging containers mentioned in the previous paragraph. In the next step, a cap application unit screws a threaded cap usually made of polymer material onto threaded neck portion of the packaging container comprising complementary threads. In the ensuing step, the hollow side of the packaging container is filled with the foodstuff to be contained whereafter the hollow end of the container is folded and sealed. It should be mentioned, that in one possible and known implementation of the capping process, the hollow packaging container body including the injection moulded top portion is fed into a rotating drum and rotated to face a screw cap holder while at a distance a screw cap is fed to the screw cap holder. While both the packaging container and the screw cap holder are locked in their radial positions, the screw cap is rotatingly moved towards the top portion of the packaging container and screwed onto its neck portion.
Experience shows that a small percentage of the thus capped package containers display a misalignment between the cap and the neck part of the container. However, the problem exists also for other types of containers, where the top and the body portion are made of the same material, such as a polymer material. Such misalignment has the effect of not sufficiently sealed container, damaged threaded portions on the neck part and the cap itself or too easy opening of the container. Containers with these deviations need to be discarded.
It can be shown that besides reasons mentioned and dealt with in a pending application filed by the applicant, one reason for the misalignment problem lies in the path length the cap has to travel before it hits the start of a thread on the threaded neck portion of the container. Especially in the case when at least one of the threads in the cap may hit the start of either one of two threads on the threaded part of the container neck, obliquely applied or tilted caps are likely to occur.
One solution according to the present invention is given by independent claim 1.
The solution is a method for applying a cap to a container, comprising arranging a first cap in relation to the neck portion of a first container, such that a threaded portion of the first cap faces a complementary threaded neck portion of the first container and such that a symmetry axis of the first cap and a symmetry axis of the neck portion of the first container are aligned. Then the first cap is rotated around its symmetry axis to a pre-recorded initial angular position. Thereafter, the first cap is applied to the neck portion by moving it towards the threaded neck portion or vice versa along their symmetry axes and by rotating the first cap in a direction of engagement with the threaded neck portion. Then the path length of the first cap is recorded in relation to its initial angular position after which it has completely engaged the complementary threaded neck portion and reached a bottom part of the neck portion. In case the recorded path length of the first cap deviates from a predefined threshold value, the relative angular position of a second cap is adjusted to a new relative angular position.
In this way, if the path length is changing from decreasing trend to increasing path lengths, this is a sign that a certain critical value has been reached for a certain relative angle and that this relative angle should be adjusted a safe angular distance from this critical area. Using the solution according to the method of the present invention the percentage of discarded containers due to obliquely applied caps can be reduced.
Preferred embodiments are listed in the dependent claims 2-7.
Another aspect of the solution according to the present invention is presented in independent claim 8.
This solution is given by an apparatus for applying a cap to a container, which comprises a holder configured for arranging a first cap in relation to neck portion of a first container, such that a threaded portion of the first cap faces a complementary threaded neck portion of the first container, and such that a second symmetry axis of the holder and a symmetry axis of the neck portion of the first container are aligned. The apparatus also comprises a drive unit configured for rotating the holder and thus the first cap around its second symmetry axis to pre-recorded initial angular position, where the drive unit is further configured to apply the first cap to the threaded neck portion of the first container by instructing the holder to move the first cap in a direction of engagement with the threaded neck part. Also, the apparatus comprises a processing unit configured for recording a path length of the first cap in relation to its initial angular position after which the first cap has completely engaged the threaded neck portion of the first container and reached a bottom part of the neck portion. Furthermore, the processing unit configured for instructing the drive unit to adjust the relative angular position of the holder for a second cap to a new relative angular position in case the recorded path length of the first cap deviates from a predefined value.
Thus, using the apparatus according to the present invention, a notable decrease in discarded containers due to the cap application problems mentioned earlier can be achieved.
Preferred embodiments of the apparatus are listed in the dependent claims 9-15.
Embodiments of the present invention will be described in more detail below with reference to the accompanying drawings in order for those skilled in the art to be able to carry out the invention. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Ultimately, the present invention is only limited by the appended patent claims. Furthermore, the terminology used in the detailed description of the particular embodiments illustrated in the accompanying drawings is not intended to be limiting for the invention.
This position of the cap 230 may be set as its initial angular position, where the angle λ1 is measured as the angle in the X-Y-plane between the start of the cap thread and the X-axis. In the case depicted in
Thus using the relative starting angle λR1=0° we will get a first path length φ1.
In
In
In
At step 600 the cap application apparatus, such as the apparatus 100 in
Thereafter, at step 610, a cap application routine is started involving several sub-steps. These sub-steps are for convenience described in a summary way, since they are not an essential part of the present invention. It should also be mentioned here, that the cap application method is not limited to one specific apparatus only, since the generally principles of the invention as defined in the appended claims may be implemented on any cap application apparatus where alignment between the threads of the cap and a threaded neck portion of the container to which the cap is to be applied, is an issue.
Returning to the application routine mentioned in step 610, a cap holder, such as the cap holder 150 in the apparatus 100 in
This position at step 620 is defined as the relative initial angular position λR1=0° of the cap. What is unknown in this position is the angular position of the threads on the cap in relation to the threads on the neck portion of the container onto which the cap is to be applied.
Although, this angular position is not determined directly a path length the cap has to travel until it hits the bottom of the neck portion of the container is readily measurable. This path length depends on the position at which the cap threads hit the start of the complementary threads on the threaded neck portion of the container.
Furthermore, as already described in
In order to detect that critical relative start angle, the processing unit instructs the apparatus to apply a certain number of caps with the same relative start angle λR=0°.
Thus, at step 630, the processing unit instructs the apparatus to apply 10 caps using the initial angular position or relative initial start angle λR=0° and to determine the path length φ, i.e. the angular distance the cap has to travel in order reach the bottom of the neck portion of the container. This is practically calculated by the processing unit as the standard deviation for the path length at that relative start angle λ. However, other calculation methods may also be possible.
At step 640 the processing unit compares the registered path length φ with a predefined threshold value. This threshold value may vary for different types of caps and from machine to machine and may be set by the operator. In this specific example, the threshold value is selected as the threshold standard deviation and set to φT=60° (a path length difference of 120° for two consecutive start angles). In order to have a safe margin from the jump in path length which occurs for relative start angles λR somewhere between 60° and 70°, the safe relative angle is chosen to be 45°. If the path length difference in this example is determined to be longer than 45° the processing unit instructs the drive unit to rotate the cap holder and thus the cap away from this critical area to a start angle that is safe, i.e. to a start angle which eliminates or minimizes containers with tilted caps.
In this specific example, the processing unit instructs the drive unit at step 650 to rotate the cap holder and thus the cap by −60° from the previous relative start angle to be on the safe side. For other cap sizes and types and for other machines this value may be different.
However, if the processing unit at step 640 has determined that the path length φ is less than the threshold value, then it instructs the drive unit at step 645 to rotate the cap holder by a certain angle increment in order to determine which starting angle is the closest to the problematic are. In this example, the angle increment is 10°.
Thereafter, the apparatus applies the next 10 caps to the corresponding neck portions of containers and checks again if the standard deviation of the path length is higher that the predefined threshold value.
The example method in
However, this may also be done automatically by the apparatus under instruction form the processing unit, which may have a data base of threshold path lengths for each cap size and type in order to account for cap size and type changes. Also, the angle increments and the number of caps having the same starting angle may be modified an operator depending on the application.
It should be stated here that the present invention should be interpreted as being limited by the example embodiments described herein which only serve as illustrative examples only. The present invention is ultimately only limited by the scope of the appended claims.
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