BACKGROUND
The present disclosure relates to a system for sealing a closure for a container. More particularly, the present disclosure relates to a lid sealing system for mounting the closure on a brim of the container.
SUMMARY
According to the present disclosure, a closure system is adapted to couple and seal a lid to a container formed to include a product-storage region and a brim bordering an opening arranged to open into the product-storage region. The closure system includes a container support fixture and a sealing head. The container support fixture is adapted to support the container. The sealing head is used to apply heat to the lid, which is mechanically coupled to the brim, to establish a chemical-bond sealed connection between the container and the lid to form a package.
In illustrative embodiments, the sealing head is located above the container support fixture and includes a head foundation, an annular lid pusher, a burp plug, and a heater band. The annular lid pusher is coupled to the head foundation in a fixed position relative to the head foundation and located between the container support fixture and the head foundation. The burp plug is coupled to the head foundation in a fixed position relative to the head foundation and the annular lid pusher and positioned to lie in radial spaced-apart relation to the annular lid pusher. The heater band is coupled to the head foundation in a fixed position relative to the head foundation and located between the annular lid pusher and the burp plug.
In illustrative embodiments, the closure system further includes a sealing-head mover coupled to the sealing head. The sealing-head mover is configured to provide means for moving the sealing head relative to the container support fixture. In illustrative embodiments, the sealing-head mover is configured to provide means for moving the sealing head relative to the container support fixture between an initial position in which the sealing head is located a first distance from the container support fixture, an engaged position in which the sealing head is located a relatively smaller second distance from the container support fixture and the sealing head engages and moves the lid relative to the container and the container support fixture to cause a mechanical bond to be established between the lid and the container, a wiping position in which the sealing head is located a relatively smaller third distance from the container support fixture and the sealing head engages and moves the lid relative to the container to cause the lid to wipe spilled food product off an upwardly facing surface of the brim, and a sealing position in which the sealing head is located a relative smaller fourth distance from the sealing head and forms a heat bond between the lid and the container.
Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description particularly refers to the accompanying figures in which:
FIG. 1 shows an illustrative container filling and closing process in accordance with the present disclosure in which a container is moved on a conveyor in a factory and suggesting that the process includes the steps of: (1) filling the container with food; (2) placing a lid on a brim of the container; (3) placing the lid and the container in a container-receiving support fixture arranged to lie under a movable sealing head; (4) moving the sealing head downwardly to engage the lid; (5) using the sealing head to apply a downward force to the lid as the lid engages the brim of the container to couple the lid mechanically to the brim as suggested in FIGS. 8A-8D and to wipe spilled food off the brim while the lid remains coupled to the brim as shown, for example, in FIGS. 9A-9C and using a heater provided in the sealing head to apply heat to the top of the lid while the lid remains mechanically coupled to the brim to establish a chemical-bond sealed connection therebetween as suggested in FIG. 10; and (6) discharging a sealed package configured to be delivered to a consumer as shown in FIG. 10;
FIG. 2A is an enlarged perspective view of the container of FIG. 1 before a lid is coupled to the brim of the container to close an opening into a product-storage region formed in the container and showing that the lid includes an annular brim-mount frame and a central plate coupled to an inner rim of the annular brim-mount frame;
FIG. 2B is an exploded perspective assembly view showing (from bottom to top) a portion of a container-receiving support fixture provided in the container filling and closing line, the container having the brim and the lid, the movable sealing head including an illustrative annular lid mover and a diagrammatic lid heater coupled to the annular lid mover, and a diagrammatic sealing-head mover configured to provide means for moving the movable sealing head downwardly toward the container-receiving support fixture to engage the lid while the brim-mount frame of the lid rests on the brim of a container received in the container-receiving support fixture;
FIG. 2C is a perspective view of a package in accordance with the present disclosure showing that the package includes the container and the lid coupled to the container;
FIG. 3 is a sectional view taken along line 3-3 of FIG. 2C showing the lid coupled to the brim of the container;
FIG. 4 is an enlarged partial sectional view of FIG. 3 showing an annular lid-retention lip coupled to an outer rim included in the lid and arranged to extend inwardly into an outwardly opening undercut space defined by the brim to lie under a downwardly facing surface of the brim to retain a portion of the lid in a stationary position in sealing engagement with the brim;
FIG. 5A is an enlarged sectional view of a portion of the lid taken along line 5A-5A of FIG. 2A;
FIG. 5B is an enlarged dead-section view of a portion of the lid shown in FIG. 5A showing that, in an illustrative embodiment, the lid is multi-layered and comprises, in series from top to bottom (or left to right), an outer bed comprising a layer made of a plastics material, a core comprising a polypropylene layer, and an inner bed comprising a peelable and resealable sealant layer adapted to bond chemically to the brim to establish the chemical-bond sealed connection between the top wall of the lid and the brim;
FIG. 6 is an enlarged perspective view of a section of the lid taken along line 6-6 of FIG. 1;
FIG. 7 is a view similar to FIG. 6 taken along line 7-7 of FIG. 2C after the lid has been mounted on the brim of the container and showing (1) mating engagement of a portion of the outer rim of the brim-mount frame and the outer peripheral surface of the brim when the annular lid-retention lip is arranged to extend under the brim and (2) mating engagement of the top wall of the lid and an annular upwardly facing surface of the brim (after the lid was heated as disclosed herein) to establish a chemical-bond sealed connection between the top wall of the lid and the brim of the container;
FIGS. 8A-8D are a series of views showing an illustrative process for moving the lid downwardly using the sealing head to establish a mechanical coupling between the lid and the brim;
FIG. 8A is a diagrammatic view showing the lid in a first engaged position on the brim during a lid-mounting step and showing that some of the food discharged toward the interior product-storage region of the container during an earlier container filling step (see, for example, STEP 2 in FIG. 1) landed on the brim of the container to form residual spilled food;
FIG. 8B is a view similar to FIG. 8A showing the lid in a subsequent second engaged position on the brim and showing that the residual spilled food on the brim has been compressed between the top wall of the lid and the brim as a result of downward movement of the lid relative to the brim;
FIG. 8C is a view similar to FIG. 8B showing the lid in a subsequent third engaged position on the brim in which the residual spilled food has been further compressed between the top wall of the lid and the brim as a result of downward movement of the lid relative to the brim;
FIG. 8D is a view similar to FIG. 8C showing the lid in a subsequent fourth engaged (coupled) position on the brim to establish a mechanical coupling between the lid and the brim and suggesting that a first portion of the residual spilled food located on the upwardly facing surface of the brim has been pushed radially outwardly to lie along an outer peripheral surface of the brim and a remaining second portion of the residual spilled food remains on the upwardly facing surface of the brim to provide a relatively thin layer of spilled food on the brim;
FIGS. 9A-9C are a series of views showing an illustrative process of wiping (i.e., squeegeing) the remaining thin layer of spilled food from the upwardly facing surface of the brim to allow such food to exit a space provided between the outer peripheral surface of the brim and the outer rim of the lid in response to further downward movement of the lid relative to the container to remove substantially all spilled food from the brim and thereby increase the surface contact area of the top wall of the lid on the brim;
FIG. 9A is a diagrammatic view showing the lid in a subsequent fifth engaged position on the brim of the container after an inner rim of the lid has engaged a surrounding inner peripheral surface of the brim so as to stretch the top wall of the lid further in a radially outwardly directed top-wall stretching direction to displace some of the thin layer of spilled food remaining on the upwardly facing surface of the brim and move it radially outwardly off the brim and then downwardly through an opening provided between the lid and the brim to increase the surface contact area between the top wall and the brim;
FIG. 9B is a view similar to FIG. 9A showing further stretching of the top wall of the lid as the lid reaches a subsequent sixth engaged position on the brim to stretch the top wall of the lid further so as to displace more spilled food and moved that displaced food off the brim to increase further the surface contact area between the top wall and the brim;
FIG. 9C a view similar to FIG. 9B showing still more stretching of the top wall of the lid in relation to the relatively stationary inner rim of the lid as the lid reaches a subsequent seventh engaged position on the brim to displace substantially all of the spilled food to increase still further the surface contact area between the wall and the brim;
FIG. 10 is view similar to FIG. 9C showing that the heater provided in the sealing head has been activated to heat the stretched top wall of the lid to establish a chemical-bond sealed-connection between the stretched top wall of the lid and underlying portions of the brim and shows diagrammatically that any minute quantity of residual spilled food remaining on the upwardly facing surface of the brim is gasified during exposure of heat to the stretched top wall of the lid from the heater and passed as a gas through the top wall of the lid to the surroundings;
FIG. 11 is a diagrammatic view of another embodiment of an illustrative sealing system in accordance with the present disclosure showing a package located within a container-receiving support fixture arranged under a moveable sealing head, the movable sealing head includes a head foundation, a lid pusher extending below the head foundation and forming an annular outer edge of the sealing head, a heater band extending annularly inward of the lid pusher and coupled to the head foundation, and a burp plug located radially inward of the heater band, and the sealing head is configured to perform the closing process shown in FIG. 1 to cause spilled food to be wiped off the brim of the container before establishing a chemical-bond sealed connection between a lid included in the package and the brim as suggested in FIGS. 8-10;
FIG. 12 is a diagrammatic view of a portion of the sealing system of FIG. 11 showing the movable sealing head in an engaged position in which the lid pusher has engaged the lid included in the package to cause the lid to move downwardly relative to the container included in the package to cause the lid to snap onto the container and be retained by a mechanical bond with the brim;
FIG. 13 is a view similar to FIG. 12 showing the movable sealing head in a wiping position in which the lid pusher has continued moving the lid downward relative to the container to cause the burp plug included in the movable sealing head to engage a membrane sheet included in the lid and cause the membrane sheet to be pulled tight over the brim;
FIG. 14 is a view similar to FIG. 13 showing the movable sealing head has moved from the wiping position of FIG. 13 to a sealing position in which both the lid pusher and the heater band have engaged the lid to cause the heater band to apply heat to the membrane sheet and the brim to establish a chemical bond between the container and the lid;
FIG. 15 is an enlarged view taken from the circled region of FIG. 13 showing the lid pusher engaged with an annular brim-mount frame of the lid and the header band spaced apart from the membrane sheet of the lid during the closing process of the sealing system prior to the wiping position and further showing the lid pusher is relatively spaced apart from the heater band by a gap such that the lid pusher does not physically connect with the heater band during the closing process; and
FIG. 16 is an enlarged view taken from the circled region of FIG. 14 showing the heater band engaged with a heater-contact surface of the membrane sheet of the lid to apply heated, downward pressure on the membrane sheet to bond the membrane sheet to the brim and the top wall of the lid is pulled taut by the burp plug to force any spilled food (not shown) located on the brim away from the brim and create a clean surface on the brim to establish a sealed chemical bond between the membrane sheet and the brim during the sealing process.
DETAILED DESCRIPTION
A first embodiment of a closure system 500 in accordance with the present disclosure is shown in FIGS. 1-10. A second embodiment of closure system 600 is shown in FIGS. 11-16. As shown in FIG. 1, a lid 14 is coupled to a brim 24 of a container 12 using downwardly directed force 220F and heat 220H from closure system 500 to provide a package 10 in a sequence of illustrative steps. A top wall 14T of lid 14 is moved by a movable sealing head 220 included in closure system 500 in a container filling and closing process as suggested diagrammatically in STEP 5 of FIG. 1, FIGS. 9A-9C, and FIGS. 11-13. Top wall 14T of lid 14 is moved relative to brim 24 to wipe any spilled product 306 (e.g., food) deposited inadvertently on brim 24 during filling of container 12 during STEPS 1 and 2 shown in FIG. 1 off brim 24 to maximize mating contact between an inner surface 14TI of top wall 14T and an upwardly facing surface 24U of brim 24.
An illustrative container filling and closing process used with closure system 500 is shown in FIG. 1. In STEP 1, a product 304 such as food is discharged from a food product supply 30 through a dispenser 302 into an interior product-storage region 26 formed in container 12 before lid 14 is coupled to brim 24 of container 12. In STEP 2, it can be seen that a portion of food product 304 landed inadvertently on brim 24 during STEP 1 to provide residual spilled product 306 on brim 24. In STEP 3, lid 14 is placed to rest on top of brim 24 of filled container 12. Lid 14 and container 12 are placed in a container support fixture 210 that is arranged to lie under movable sealing head 220 as suggested in FIGS. 2B and 11. Movable sealing head 220 includes a lid pusher 222 and a heater band 224. It is within the scope of this disclosure to place container 12 in container support fixture 210 before STEP 1.
In STEP 4, movable sealing head 220 is moved downwardly to cause lid pusher 222 to engage lid 14 while lid 14 is at rest on brim 24. In STEP 5, lid pusher 222 of movable sealing head 220 is moved by a sealing head mover 218 to apply downwardly directed force 220F to lid 14 as lid 14 engages brim 24 to couple lid 14 mechanically to brim 24 as suggested in FIGS. 8A-8D and 12. In STEP 5, heater band 224 included in movable sealing head 220 is used to apply downwardly directed heat 220H to top wall 14T of lid 14 while lid 14 remains mechanically coupled to brim 24 as suggested in FIGS. 10 and 16 to establish a chemical-bond sealed connection 101 between top wall 14T of lid 14 and brim 24. In STEP 6, sealed package 10 comprising container 12 and lid 14 is presented and ready to be delivered to a buyer.
The first embodiment of closure system 500 in accordance with the present disclosure is shown in FIGS. 1-10. As shown in FIG. 1, closure system 500 is arranged to provide package 10. Package 10 includes container 12 and lid 14 configured to mate with container 12 to close an opening 27 into an interior product-storage region 26 formed in container 12 as suggested in FIGS. 1-4. In illustrative embodiments, lid 14 comprises a brim-mount frame 14F configured to mate with annular brim 24 of container 12, as suggested in FIGS. 2-4, and a center plate 14P coupled to brim-mount frame 14F as suggested in FIGS. 2A.
In illustrative embodiments, closure system 500 includes container support fixture 210, sealing head 220, and sealing head mover 218 as shown in FIG. 1. Container support fixture 210 is configured to retain container 12 in a fixed position. Sealing head 220 is positioned above container support fixture 210 and moveable downward to engage with lid 14 when it is positioned on top of container 12 in container support fixture 210. Sealing head mover 218 is coupled to sealing head 220 to move sealing head 220 relative to container support fixture 210. Closure system 500 generally operates to perform Step 5 as shown in FIG. 1 to mate lid 14 with container 12 to close opening 27 into interior product-storage region 26 formed in container 12 by creating both a mechanical connection between lid 14 and container 12 and a chemical-bond sealed connection 101 between lid 14 and container 12.
Sealing head movers 220 illustratively includes a head foundation 200, annular lid pusher 222 coupled to head foundation 200 in a fixed position relative to head foundation 200, a burp plug 225 coupled to head foundation 200 in a fixed position relative to head foundation 200 and lid pusher 222, and heater band 224 coupled to head foundation 200 as shown in FIG. 8A. In one example, sealing head 220 is circular in nature. However, the sealing head may have any other suitable shape.
When sealing head mover 218 causes sealing head 220 to move downwardly toward container 12 in container support fixture 210, head foundation 200, annular lid pusher 222, heater band 224, and burp plug 225 all move together in a fixed manner toward container 12. Sealing head 220 is positioned above container 12 when container is retained by container support fixture 210. In one example, sealing head 220 has a circumferential diameter that is proportional to the circumferential diameter of lid 14 of package 10.
In illustrative embodiments, lid pusher 222 includes an annular inner side wall 518, an annular outer side wall 512 spaced apart from annular inner side wall 518, and an engaging face 510 positioned therebetween as shown in FIG. 8A. Engaging face 510 defines a lower boundary of lid pusher 222. Lid pusher 222 is located below head foundation 200 in sealing head 220 and positioned such that engaging face 510 defines a portion of a bottom surface of sealing head 220. Annular outer side wall 512 defines the radially outward boundary of lid pusher 222 and also defines a portion of an outer surface of sealing head 220. Annular inner side wall 518 defines the radially inward boundary of lid pusher 222. When sealing head 220 is moved toward container support fixture 210 by sealing head mover 218, engaging face 510 of lid pusher 222 moves toward and engages with a top wall 14T of lid 14 when lid 14 is resting on top of container 12 in container support fixture 210.
As illustrated in FIGS. 8A-10, lid pusher 222 comprises a lid-shaping indent 530 positioned between engaging face 510 and annular inner side wall 518. Lid-shaping indent 530 is shaped to mirror shape of an outer peripheral surface 24O of brim 24 such that lid 14 is formed to outer peripheral surface 24O when it is compressed between lid-shaping indent 530 and outer peripheral surface 24O during STEP 5 of FIG. 1. Lid 14 engages initially with engaging face 510, as illustrated in FIG. 9A, and the downward mechanical force applied to lid 14 from lid pusher 222 may force lid 14 into lid-shaping indent 530, as illustrated in FIGS. 9B, and 9C.
Burp plug 225 is formed with heater band 224 as illustrated in FIGS. 8A-10. Burp plug 225 may extend down below heater band 224 and include an annular forming wall 552 as shown in FIG. 8A. Annular forming wall 552 is configured to mirror an inner peripheral surface 24I of brim 24 of container 12. As burp plug 225 moves downward toward lid 14 resting on top of container 12 during the sealing process, annular forming wall 552 engages with an inner rim 14I of lid 14 to cause inner rim 14I to be mated with inner peripheral surface 24I of brim 24, as illustrated in FIG. 8A-10.
As illustrated in FIGS. 9B-9C, burp plug 225 defines a burping face 544. Burping face 544 engages with a center plate 14P of lid 14 when lid 14 is being moved further downward relative to brim 24 to move substantially all of the spilled product 306 extant on the upwardly facing surface 24U of brim 24 in a radially outward direction to cause upwardly facing surface 24U to be free of spilled product and to mate with a confronting companion portion of lid 14. Burping face 544 of burp plug 225 may be linear in nature, or may be concave to provide a pressure point along lid 14 when burp plug 225 is moved to engage lid 14.
In another example, burping face 544 engages with center plate 14P of lid 14 when lid 14 is being moved further downward relative to brim 24 to move substantially all of the spilled product 306 extant on the upwardly facing surface 24U of brim 24 in a radially inward direction to cause upwardly facing surface 24U to be free of spilled product and to mate with a confronting companion portion of lid 14. In another example, burping face 544 engages with center plate 14P of lid 14 when lid 14 is being moved further downward relative to brim 24 to move substantially all of the spilled product 306 extant on the upwardly facing surface 24U of brim 24 in both radially inward and outward directions to cause upwardly facing surface 24U to be free of spilled product and to mate with a confronting companion portion of lid 14.
Heater band 224 included in movable sealing head 220 is operated to apply heat 220H to the top wall 14T of lid 14 as suggested in STEP 5 of FIG. 1 and shown in FIG. 10 while lid 14 is coupled mechanically to brim 24. This applied heat 220H is sufficient to establish a chemical-bond sealed connection 101 between top wall 14T of lid 14 and brim 24 at a container filling and closing factory as suggested in FIG. 10. This chemical-bond sealed connection will be broken the first time a consumer removes lid 14 from container 12. In illustrative embodiments, applied heat 220H is high enough to cause any minute quantity of residual spilled product 306 extant on brim 24 and located in a space provided between top wall 14T of lid 14 and brim 24 to be gasified and pass as a gas 306G through top wall 14T of lid 14 into the surroundings as suggested diagrammatically in FIG. 10 so that no spilled product 306 remains on brim 24.
The configuration of heater band 224, lid pusher 222, and burp plug 225 may be arranged for a particular application or purpose. For instance, burp plug 225 may be integrally formed with and attached to heater band 224, as illustrated in FIGS. 1-10, or burp plug 225 may be spaced apart from heater band 224 a distance B2, as illustrated in FIG. 11. Similarly, heater band 224 may be directly adjacent to lid pusher 222, as illustrated in FIG. 8A, or heater band 224 may be spaced apart from lid pusher 222 a distance H2, as illustrated in FIG. 15. In one example, distance B2 may be about 0.15 inches and distance H2 may be about 0.10 inches. In another example, distance B2 may be about 0.1464 inches.
Lid 14 is heated by heat 220H generated by heater band 224 to establish the chemical-bond sealed connection 101 between top wall 14T of lid 14 and brim 24 during a lid-heating step included in the container filling and closing process as shown in FIGS. 1, 7, and 10. This chemical-bond sealed connection 101 is broken the first time that lid 14 is removed from container 12 by a consumer. In illustrative embodiments, lid 14 includes a barrier material that is configured to mate temporarily and repeatedly with brim 24 to establish a fluid seal therebetween whenever lid 14 is later mounted on brim 24 by the consumer.
In an illustrative embodiment, brim-mount frame 14F of lid 14 comprises an outer rim 14O, an inner rim 14I surrounded by outer rim 14O, a top wall 14T arranged to interconnect outer and inner rims 14O, 14I, and a center plate 14P as suggested in FIGS. 5A-6. Top wall 14T interconnects upper edges of outer and inner rims 14O, 14I. Lid 14 further includes a downwardly extending frustoconical finger-grip flange 14G arranged to lie under outer rim 14O as suggested in FIG. 6. Lid-retainer lip 14L is also included in lid 14 and arranged to interconnect outer rim 14O and finger-grip flange 14G as suggested in FIGS. 5A and 6. In this embodiment, heater band 224 is configured to engage with top wall 14T to provide heat 220H to top wall 14T to establish chemical-bond sealed connection 101 during the lid-heating step as illustrated in FIG. 10.
Center plate 14P includes a cover foundation 14P1 coupled to inner rim 14I and arranged to overlie interior product-storage region 26 and a cover 14P2 surrounded by cover foundation 14P1 and coupled to cover foundation 14P1 as shown, for example, in FIG. 6. Center plate 14P may be coupled to a lower edge of inner rim 14I in an illustrative embodiment as suggested in FIG. 6. It is within the scope of this disclosure to provide a monolithic lid. In illustrative embodiments, and as illustrated in FIG. 8A, center plate 14P may be a distance S1 away from top wall 14T of lid 14.
In an illustrative embodiment, brim-mount frame 14F is configured to mate temporarily in snapping relation with a portion of brim 24 overlying an outwardly extending undercut space formed in container 12 so that container lid 14 is removable and reclosable as suggested in FIGS. 4-10. Lid 14 further comprises lid-retention lip 14L that is coupled to outer rim 14O and arranged to extend radially inwardly under brim 24 to anchor brim-mount frame 14F mechanically to brim 24.
As illustrated in FIG. 8B, an engaging face 514 of burp plug 225 may be partially located in a first plane 520 that is closer to lid 14 when lid 14 is resting on top of container 12 than a second plane 522 defined by engaging face 510 of lid pusher 222 or a third plane 524 defined by an engaging face 516 of heater band 224. First plane 520 may be defined by the lowest point of engaging face 514 of burp plug 225. The distance between first plane 520 to second plane 522 is E1. The distance between second plane 522 and third plane 524 is A1 as illustrated in FIG. 8B. As sealing head 220 moves down toward lid 14, lid pusher 222, burp plug 225, and heater band 224 moves downward in uniform relation to each other, and distances E1 and A1 are maintained through the uniform movement.
Distances S1, E1, and A1 permit various components of sealing head 220 to interact with lid 14 in a staggered or sequential manner to perform the burping and sealing process as disclosed herein. As illustrated in FIGS. 8A and 8B, the distance E1 is be smaller than the distance S1 such that, as sealing head 220 moves downward, engaging face 510 of lid pusher 222 will engage with top wall 14T of lid 14 before engaging face 514 of burp plug 225 engages with lid 14 during the sealing process. In another embodiment as illustrated in FIGS. 11-12, a distance E2 is greater than a distance S2, such that, as sealing head 220 moves downward, engaging face 510 of lid pusher 222 will engage with upwardly-extending support flange 562 after engaging face 514 of burp plug 225 engages with lid 14 during the sealing process. Other iterations of comparison of distances S1, E1, and A1 are encompassed in the present disclosure.
In one example, distance E1 may be between about 0.09 and 0.13 inches. In another example, distance E1 may be between about 0.0937 and 0.1260 inches. In one example, distance A1 may be less than about 0.03 inches. In another example, distance A1 may be between about 0.0040 and 0.0263 inches. Other measurements for distances E1 and A1 are also encompassed in the present disclosure.
In an illustrative embodiment, lid 14 comprises multiple layers 321, 322, and 323 as shown, for example, in FIG. 5B. When formed as a multi-layer component in accordance with the present disclosure, lid 14 comprises an outer bed 321 having an outer surface 3210, an inner bed 323 having an inner surface 3231, and a core 322 interposed between and coupled to outer and inner beds 321, 323. Each of outer bed 321, core 322, and inner bed 323 is made of a different material in an illustrative embodiment. Outer bed 321 comprises polyester, polypropylene, or nylon. Core 322 comprises a barrier layer. Inner bed 323 comprises low-density polyethylene, polypropylene-based sealant, blends of polypropylene and polybutane, as well as EMA-EVA-based sealants. In illustrative embodiments, inner bed 323 comprises a material that can be heat-sealed to brim 24 of container 12 as disclosed herein. In illustrative embodiments, inner bed 323 comprises a composition configured to establish a fluid seal whenever lid 14 is coupled with annular brim 24 of container 12 after lid 14 is removed from container 12 for the first time.
Brim 24 of container 12 is annular in illustrative embodiments. Brim 24 comprises an outer peripheral surface 24O, an upwardly facing surface 24U, and an inner peripheral surface 24I as suggested in FIGS. 7 and 9. Inner peripheral surface 24I includes a lower segment 24LI coupled to a side wall 12S of container 12 and an upper segment 24UI arranged to interconnect upwardly facing surface 24U and lower segment 24LI. In illustrative embodiments, upper segment 24UI has an annular convex round shape and lower segment 24LI has an annular shape as suggested in FIGS. 7 and 8. Inner peripheral surface 24I of annular brim 24 provides a relatively stationary abutment engaging the inner rim 14I of lid 14 during radially outward stretching of top wall 14T of lid 14 in top-wall stretching direction 14TS as suggested in FIGS. 9A-9C.
In an illustrative embodiment, and as suggested in FIG. 7, after lid 14 is mounted on brim 24 of container 12 there is: (1) mating engagement of outer rim 14O of brim-mount frame 14F and an outer peripheral surface 24O of brim 24 when an annular lid-retention lip 14L is arranged to extend under the brim 24 and (2) mating engagement of top wall 14T of lid 14 and an annular upwardly facing surface 24U of brim 24 (after lid 14 was heated as disclosed herein) to establish a chemical-bond sealed connection 101 between the top wall 14T of lid 14 and brim 24 of container 12.
An illustrative process for moving lid 14 downwardly using movable sealing head 220 to establish a mechanical coupling between lid 14 and brim 24 is shown, for example, in FIGS. 8A-8D. As suggested in FIG. 8A, lid 14 is placed in a first engaged position on brim 24 during a lid-mounting step at a factory. A portion of food product 304 discharged through a dispenser 202 toward interior product-storage region 26 formed in container 12 during an earlier container filling step (see, for example, STEP 2 in FIG. 1) has landed on brim 24 of container 12 to form a residual spilled product 306. As suggested in FIG. 8B, the downwardly moving lid 14 has arrived in a subsequent second engaged position on the brim 24 to cause residual spilled product 306 located on brim 24 to be compressed between top wall 14T of lid 14 and brim 24 of container 12 as a result of downward movement of lid 14 relative to brim 24. As suggested in FIG. 8C, downwardly moving lid 14 has arrived in a subsequent third engaged position on brim 24 to cause further compression of the residual spilled product 306 between top wall 14T of lid 14 and brim 24 of container 12.
As suggested in FIG. 8D, downwardly moving lid 14 has arrived in a subsequent fourth engaged (coupled) position on brim 24 of container 12 to establish a mechanical coupling between lid 14 and brim 24. A small first portion 3061 of residual spilled product 306 located on upwardly facing surface 24U of brim 24 has been pushed radially outwardly to lie along an outer peripheral surface 24O of brim 24. A remaining second portion 3062 of residual spilled product 306 remains on upwardly facing surface 24U of brim 24 to provide a relatively thin layer 3062 of spilled food 306 on brim 24.
An illustrative process of wiping (i.e., squeegeing) the remaining thin layer 3062 of spilled food 306 from the upwardly facing surface 24U of brim 24 in response to further downward movement of lid 14 relative to container 12 is shown, for example, in FIGS. 9A-9C, to remove substantially all spilled food 306 from brim 24 and thereby increase the surface contact area of top wall 14T of lid 14 on brim 24 of container 12. As shown in FIG. 9A, downwardly moving lid 14 has arrived in a subsequent fifth engaged position on brim 24 of container 12. In arriving at the fifth engaged position, lid 14 causes an inner rim 14I of lid 14 to engage a surrounding inner peripheral surface 24I of brim 24 so as to limit radially outward movement of inner rim 14I relative to brim 24. As a result, top wall 14T of lid 14 is further stretched to displace some of thin layer 3062 of spilled food 306 remaining on upwardly facing surface 24U of brim 24 and move it in a radially outward direction off upwardly facing surface 24U to increase the surface contact area between top wall 14T of lid 14 relative to stationary inner rim 14I of lid 14 and brim 24.
Displaced food 3061 can exit a space 300 provided between lid 14 and brim 24 through a downward facing opening 301 as shown in FIGS. 9A-9C. As suggested in FIG. 9B, further stretching of top wall 14T of lid 14 relative to the stationary inner rim 14I of lid 14 takes place as downwardly moving lid 14 reaches a subsequent sixth engaged position on brim 24 to displace more spilled food 3062 and move displaced food 3062 off brim 24 to increase further the surface contact area between top wall 14T of lid 14 and brim 24. As suggested in FIG. 9C, still more stretching of top wall 14T of lid 14 relative to inner rim 14I takes place as downwardly moving lid 14 reaches a subsequent seventh engaged position on brim 24 to displace substantially all of spilled food 306 to increase still further the surface contact area between top wall 14T of lid 14 and brim 24.
A heater band 224 provided in movable sealing head 220 has been activated to apply downwardly directed heat 220H to stretched top wall 14T of lid 14 to establish a chemical-bond sealed connection 101 between stretched top wall 14T of lid 14 and underlying portions of brim 24 as shown in FIG. 10. In illustrative embodiments, any minute quantity of residual spilled food 3062 remaining on upwardly facing surface 24U of brim 24 is gasified during exposure of stretched top wall 14T of lid 14 to downwardly directed heat 220H from heater band 224 and passed as a gas 306G through top wall 14T of lid 14 to the surroundings so that no spilled product 306 remains on brim 24.
In illustrative embodiments, lid 14 comprises a peelable and resealable sealant material or layer that in illustrative embodiments is configured to engage brim 24 to provide means for establishing a fluid seal between lid 14 and container 12 when reclosable lid 14 is mated with brim 24 so that ingress of oxygen and other contaminants into product-storage region 26 formed in container 12 is blocked while lid 14 is mated to container 12. Lid 14 can be removed from container 12 and reclosed in one piece repeatedly by a consumer. In some embodiments, a fluid seal is formed between lid 14 and container 12 each time lid 14 is mated to container 12.
In illustrative embodiments, lid 14 may comprise at least a composition in accordance with the present disclosure that functions to establish a fluid seal between lid 14 and brim 24 each time the removable and reclosable lid 14 is mounted on container 12 in certain embodiments of the present disclosure. Thus, a fluid seal is created between lid 14 and container 12 that is opened easily by a consumer and that is later resealable.
In illustrative embodiments, in a container-filling process in accordance with the present disclosure, a product 304 (e.g., food) is deposited by a dispenser 302 into interior product-storage region 26 formed in container 12 as suggested in FIG. 1. Then lid 14 is mounted on container 12 to close an opening 27 into product-storage region 26 and to cause the peelable and resealable sealant layer established in lid 14 to mate with brim 24 of container 12 so that a mechanical seal is established as suggested in FIGS. 3, 4, 7, and 8D. Then, for example, the peelable and resealable sealant layer included in top wall 14T of lid 14 is welded to brim 24 using downwardly directed heat 220H applied by heater band 224 so that a chemical-bond sealed connection 101 is established. It is within the scope of the present disclosure to couple top wall 14T of lid 14 to brim 24 through heat 220H applied by conduction or transmission of ultrasonic or electromagnetic energy.
In an illustrative first embodiment, a process is provided in accordance with the present disclosure for coupling a lid 14 to a brim 24 of a container 12 to close an opening 27 into an interior product-storage region 26 formed in container 12 as suggested in FIGS. 1-10. The process comprises the steps of providing a lid 14 having an elastic top wall 14T made of an elastic material and moving elastic top wall 14T of lid 14 downwardly toward annular brim 24 of container 12 to cause a radially inner portion 14I of lid 14 to contact a surrounding inner peripheral surface 24I of annular brim 24 and to locate any spilled product 306 located on upwardly facing surface 24U of annular brim 24 under a downwardly facing surface 14TI of elastic top wall 14T of lid 14 as suggested in FIGS. 8A-8D.
In the illustrative first embodiment, the process further comprises the step of stretching the elastic top wall 14T of lid 14 in radially outward top-wall stretching direction 14TS relative to radially inner portion 14I of lid 14 during further downward movement of lid 14 relative to brim 24 of container 12 as suggested in FIGS. 9A-9C. Stretching elastic top wall 14T moves substantially all of spilled product 306 extant on upwardly facing surface 24U of annular brim 24 in a radially outward direction and causes substantially all of upwardly facing surface 24U of annular brim 24 to be free of spilled product 306 and to mate with a confronting companion portion of a downwardly facing surface 14TI of elastic top wall 14T of lid 14 therebetween. As a result, substantially all of the spilled product 306 formerly extant on upwardly facing surface 24U of annular brim 24 is wiped away as suggested in FIG. 10.
In illustrative embodiments, spilled product 306 wiped from annular brim 24 is deposited into a radially outer space 300 provided between lid 14 and outer peripheral surface 24O of annular brim 24 so that it can exit space 300 through an opening 301 provided between outer peripheral surface 24O of brim 24 and outer rim 14O of lid 14 as suggested in FIGS. 9A-9C and 10. Container 12 includes annular brim 24 arranged to surround an opening 27 into interior product-storage region 26 formed in container 12. Annular brim 24 includes inner peripheral surface 24I bounding opening 27, an outer peripheral surface 24O surrounding inner peripheral surface 24I, and an upwardly facing surface 24U lying between and interconnecting inner and outer peripheral surfaces 24I, 24O as suggested in FIGS. 7 and 8A.
In the illustrative first embodiment, the process further comprises the step of heating elastic top wall 14T of lid 14 to establish a chemical-bond sealed connection 101 between elastic top wall 14T of lid 14 and upwardly facing surface 24U of annular brim 24 of container 12 as suggested in STEP 5 of FIG. 1 and in FIG. 10. Heat 220H in excess of a selected temperature is applied to elastic top wall 14T of lid 14 during the heating step to cause any residual spilled product 3062 located on upwardly facing surface 24U of annular brim 24 can exit in a space provided between elastic top wall 14T of lid 14 and annular brim 24 of container 12 after the stretching step to be gasified and pass as a gas 306G from the space through elastic top wall 14T of lid 14 into the surroundings so that no spilled product remains on annular brim 24 of container 12 as suggested in FIG. 10.
In the illustrative first embodiment, a radially outwardly moving squeegeing action takes place along upwardly facing surface 24U of annular brim 24 and from inner peripheral surface 24I of annular brim 24 toward outer peripheral surface 24O of annular brim 24. This squeegeing action functions to wipe substantially all of spilled product 306 extant on upwardly facing surface 24U of annular brim 24 in a radially outward direction off annular brim 24 during movement of elastic top wall 14T of lid 14 on annular brim 24 during the stretching step.
In the illustrative first embodiment, the process further comprises the step of heating lid 14 using a heater band 224 after the stretching step as suggested in FIGS. 1 and 10. Downwardly facing surface 14TI of top wall 14T of lid 14 is configured to provide means for chemically bonding with upwardly facing surface 24U of annular brim 24 during the heating step, separating from upwardly facing surface 24U of annular brim 24 in response to application of an external peeling force to top wall 14T of lid 14 to disengage lid 14 from annular brim 24 of container 12, and mating temporarily and repeatedly with the upwardly facing surface 24U of annular brim 24 of container 12 to close opening 27 into the interior product-storage region 26 formed in container 12 each time lid 14 is coupled to container 12 by a consumer so that any product 304 stored in interior product-storage region 26 is retained in a chamber 100 defined by container 12 and lid 14 as suggested in FIG. 2C.
A process is provided for coupling lid 14 to brim 24 of container 12 to close opening 27 into interior product-storage region 26 formed in container 12 as suggested in FIG. 1. The process comprises the steps of filling interior product-storage region 26 formed in container 12 with product 304, placing lid 14 on brim 24 of container 12 to cover opening 27 into interior product-storage region 26, moving a sealing head 220 downwardly toward container 12 received in container support fixture 210 to apply downwardly directed force 220F to lid 14 while lid 14 is on brim 24 of container 12 to couple lid 14 mechanically to brim 24 and to move a top wall 14T or center plate 14P of lid 14 laterally relative to brim 24 to wipe any spilled product 306 off brim 24 while lid 14 remains coupled to brim 24, and using a heater band 224 associated with sealing head 220 to apply heat 220H to top wall 14T or center plate 14P of lid 14 while lid 14 remains mechanically coupled to brim 24 to establish a chemical-bond sealed connection 101 between top wall 14T of lid 14 and brim 24 of container 12.
Heater band 224 is operated to apply heat 220H in excess of a selected temperature to top wall 14T of lid 14. This causes any residual spilled product 306 located on brim 24 after the moving step to be gasified and pass as a gas 306G through top wall 14T of lid 14 to the surroundings.
It is unnecessary to attach a separate closure film or foil to container 12 on the filling line after container 12 has been filled and before lid 14 is mounted on container 12 when using a lid 14 in accordance with the present disclosure owing, in part, to the provision of a peelable and resealable sealant layer 323 in lid 14 disclosed herein. Packaging cost and complexity is thus minimized and the customer is provided with an easy-to-use product that is characterized by sustainability. The peelable and releasable sealant layer is peelable and resealable.
A package 410 in accordance with a second embodiment of the present disclosure is shown in FIGS. 11-16. The package 410 includes a container 412 and a lid 414 configured to mate with container 412 to close an opening 427 into an interior product-storage region 426 formed in container 412 as shown in FIG. 11. In illustrative embodiments, lid 414 may comprise a brim-mount frame 414F configured to mate with an annular brim 424 of container 412, as suggested in FIGS. 11-14, and a center plate 414P coupled to brim-mount frame 414F as suggested in FIGS. 14-15.
A second embodiment of closure system 600 includes a container support fixture 210A, a sealing head 220A, and a sealing head mover 218A as shown in FIG. 11. In illustrative embodiments, a container support fixture 210A is configured to retain container 412 in a fixed position. Sealing head 220A is moveable downward to engage with lid 414 when it is positioned on top of container 412 in container support fixture 210A. Sealing head mover 218A moves sealing head 220A relative to container support fixture 210A. Closure system 600 generally operates to perform Step 5 of FIG. 1 to mate lid 414 with container 412 to close opening 427 into interior product-storage region 426 formed in container 412 by creating both a mechanical connection between lid 414 and container 412 and a chemical-bond sealed connection 101 between lid 414 and container 412.
In illustrative embodiments, sealing head 220A includes a head foundation 200A, an annular lid pusher 222A coupled to head foundation 200A in a fixed position relative to head foundation 200A, a burp plug 225A coupled to head foundation 200A in a fixed position relative to head foundation 200A and lid pusher 222A, and a heater band 224A coupled to head foundation 200A as shown in FIGS. 11-16. When sealing head mover 218A causes sealing head 220A to move downwardly toward container 412 in container support fixture 210A, head foundation 200A, annular lid pusher 222A, heater band 224A, and burp plug 225A all move together in a fixed manner toward container 412. Sealing head 220A may be positioned above container 412 when container 412 is retained by container support fixture 210A. Sealing head 22A may have a circumferential diameter that is directly proportional to the circumferential diameter of lid 414 of package 410.
In illustrative embodiments, lid pusher 222A includes an annular inner side wall 618, an annular outer side wall 612 spaced apart from annular inner side wall 618, and an engaging face 610 positioned therebetween as shown in FIGS. 11 and 12. Engaging face 610 defines a lower boundary of lid pusher 222A. Lid pusher 222A is located below head foundation 200A in sealing head 220A and positioned such that engaging face 610 defines a portion of a bottom surface of sealing head 220A. Annular outer side wall 612 defines the radially outward boundary of lid pusher 222A and may also define a portion of an outer surface of sealing head 220A. Annular inner side wall 618 defines the radially inward boundary of lid pusher 222A. When sealing head 220A is moved toward container support fixture 210A by sealing head mover 218A, engaging face 610 of lid pusher 222A will move toward and engage with a top wall 414T of lid 414 when lid 414 is resting on top of container 412 in container support fixture 210A.
As illustrated in FIGS. 11-14, burp plug 225A includes a burping face 644. Burping face 644 engages with a center plate 414P of lid 414 when lid 414 is being moved further downward relative to brim 424 to move substantially all of the spilled product 306 extant on the upwardly facing surface 424U of brim 424 in a radially outward direction to cause upwardly facing surface 424U to be free of spilled product and to mate with a confronting companion portion of lid 414. Burping face 644 of burp plug 225A is illustratively concave to provide a pressure point along lid 414 when burp plug 225A is moved to engage lid 414.
Heater band 224A is operated to apply heat 220H to top wall 414T of lid 414 as suggested in STEP 5 of FIG. 1 and shown in FIG. 16 while lid 414 is coupled mechanically to brim 424. This applied heat 220H is sufficient to establish a chemical-bond sealed connection 101 between top wall 414T of lid 414 and brim 424. This chemical-bond sealed connection will be broken the first time a consumer removes lid 414 from container 412. In illustrative embodiments, the applied heat 220H is high enough to cause any minute quantity of residual spilled product 306 extant on brim 424 and located in a space provided between top wall 414T of lid 414 and brim 424 to be gasified and pass as a gas 306G through top wall 414T of lid 414 into the surroundings so that no spilled product 306 remains on brim 424.
In illustrative embodiments, the configuration of heater band 224A, lid pusher 222A, and burp plug 225A may be arranged for a particular application or purpose. For instance, burp plug 225A is spaced apart from heater band 224A a distance B2, as illustrated in FIG. 11. Similarly, heater band 224A is spaced apart from lid pusher 222A a distance H2, as illustrated in FIG. 15. In one example, distance B2 is about 0.1464 inches and distance H2 is about 0.10 inches. In one example, distance B2 is about 0.15 inches.
In an illustrative embodiment, lid 414 includes a brim-mount frame 414F a center plate 414P, and a lid-retainer lip 414L as shown in FIG. 11. Center plate 414P coupled to brim-mount frame 414F and is arranged to overlie interior product-storage region 426. It is within the scope of this disclosure to provide a monolithic lid. In an illustrative embodiment, brim-mount frame 414F is configured to mate temporarily in snapping relation with a portion of brim 424 overlying an outwardly extending undercut space formed in container 412 so that container lid 414 is removable and reclosable as shown in FIGS. 11-14. Lid-retention lip 414L is coupled to brim-mount frame 414F and is arranged to extend radially inwardly under brim 424 to anchor brim-mount frame 414F mechanically to brim 424.
Brim-mount frame 414F comprises an annular sheet support ring 660 coupled to center plate 414P, as suggested in FIGS. 11-15. Sheet support ring 660 is configured to mate temporarily in snapping relation with a portion of brim 424 overlying an outwardly extending undercut space formed in container 412 to help cause container lid 414 to be removable and reclosable. Lid-retention lip 414L is coupled to sheet support ring 660 and arranged to extend radially inwardly under brim 424 to anchor brim-mount frame 414F mechanically to brim 424.
Center plate 414P includes a cover film 658 coupled to sheet support ring 660 and arranged to overlie interior product-storage region 426 and a ring connection portion 656 surrounding and coupled to cover film 658 to connect center plate 414P to sheet support ring 660, as illustrated, for example, in FIGS. 14 and 15. Center plate 414P may be coupled to an inner edge of sheet support ring 660 in an illustrative embodiment as suggested in FIGS. 14-15. In such embodiment, heater band 224A is configured to engage with center plate 414P to provide heat 220H to center plate 414P to establish chemical-bond sealed connection 101 with brim 424 during the lid-heating step, as illustrated in FIG. 14.
Sheet support ring 660 may comprise an upwardly-extending support flange 662, a finger-receiving flange 664 arranged to lie below upwardly-extending support flange 662 and lid-retention lip 414L, and a support body 666 extending there between, as suggestion in FIGS. 14-15. Upwardly-extending support flange 662 extends upwardly above the other portions of lid 414 and is configured to align with, and provide a point of contact for, lid pusher 222A as it moves downward toward lid 414, as illustrated in FIGS. 11-13. In illustrative embodiments, upwardly-extending support flange 662 may extend above center plate 414P of lid 414 by a distance of S2, as illustrated in FIG. 15.
In illustrative embodiments, and as illustrated in FIGS. 13 and 15, an engaging face 614 of burp plug 225A may be partially located in a first plane 620 that is closer to lid 414 when lid 414 is resting on top of container 412 than a second plane 622 defined by engaging face 610 of lid pusher 222A or a third plane 624 defined by an engaging face 616 of heater band 224A. First plane 620 may be defined by the lowest point of engaging face 614 of burp plug 225A. The distance between first plane 620 to second plane 622 is E2. The distance between second plane 622 and third plane 524 is A2 as illustrated in FIGS. 13 and 15. As sealing head 220A moves down toward lid 414, lid pusher 222A, burp plug 225A, and heater band 224A move downward in uniform relation to each other, and distances E2 and A2 are maintained through the uniform movement.
Distances S2, E2, and A2 permit various components of sealing head 220A to interact with lid 414 in a staggered or sequential manner to perform the burping and sealing process as disclosed herein. As shown in FIGS. 11-12, the distance E2 is greater than the distance S2, such that, as sealing head 220A moves downward, engaging face 610 of lid pusher 222A will engage with upwardly-extending support flange 662 after engaging face 614 of burp plug 225A engages with lid 414 during the sealing process. Other iterations of comparison of distances S2, E2, and A2 are encompassed in the present disclosure.
In one example, distance E2 is between about 0.09 and 0.13 inches Distance A2 is less than about 0.03 inches. In another example, distance E2 is between about 0.0937 and 0.1260 inches and distance A2 is between approximately 0.0040 and 0.0263 inches. Other measurements for distances E2 and A2 are also encompassed in the present disclosure.
In illustrative embodiments, closure system 500, closure system 600, package 10, and package 410 include various measurements that may be related to each other by various ratios. The ratios may provide a determination of size, spacing, and other features of closure system 500, closure system 600, package 10, and package 410. In illustrative embodiments, closure system closure system 500, closure system 600, package 10, and package 410 may include several measurements, as illustrated in FIGS. 8B, 13, and 15. In the illustrative embodiment, the measurements have units of inches. In other embodiments, the measurements may have any other suitable unit.
A1 is a vertical distance from second plane 522 defined by engaging face 510 of lid pusher 222 to third plane 524 defined by engaging face 516 of heater band 224 as shown in FIG. 8B. In one example, A1 is less than about 0.03. In some examples, A1 is less than about 0.02. In some examples, A1 is less than about 0.01. In some examples, A1 is about 0.0263. In some examples, A1 is about 0.004.
A2 is a vertical distance from second plane 624 defined by engaging face 610 of lid pusher 222A to third plane 624 defined by engaging face 616 of heater band 224A as shown in FIG. 15. In some embodiments, A2 is less than about 0.03 inches. In some embodiments, A2 is less than about 0.02 inches. In some embodiments, A2 is less than about 0.01 inches. In some embodiments, A2 is about 0.03 inches. In some embodiments, A2 is about 0.026 inches. In some embodiments, A2 is about 0.0263 inches. In the illustrative embodiment, A2 is about 0.004 inches.
B2 is a horizontal distance between an inner-most plane 626 of heater band 224A and an outer-most plane 638 of burp plug 225A, if heater band 224A and burp plug 225A are spaced apart from each other as shown in FIG. 13. In some embodiments, B2 is less than about 0.2 inches. In some embodiments, B2 is less than about 0.1 inches. In some embodiments, B2 is less than about 0.05 inches. In some embodiments, B2 is about 0.15 inches. In some embodiments, B2 is about 0.146 inches. In some embodiments, B2 is about 0.1464 inches.
C1 is a horizontal distance between inner-most plane 526 of heater band 224 and an inner most point 528 of engaging face 510 of lid pusher 222 as shown in FIG. 8B. In some embodiments C1 is less than about 0.3 inches. In some embodiments C1 is less than about 0.2 inches. In some embodiments C1 is less than about 0.1 inches. In some embodiments C1 is about 0.22 inches. In some embodiments C1 is about 0.217 inches. In some embodiments C1 is about 0.2166 inches. In some embodiments C1 is about 0.2 inches. In some embodiments C1 is about 0.20 inches. In some embodiments C1 is about 0.198 inches.
C2 is a horizontal distance between inner-most plane 626 of heater band 224A and an inner most point 628 of engaging face 610 of lid pusher 222A as shown in FIG. 13. In some embodiments C2 is less than about 0.3 inches. In some embodiments C2 is less than about 0.2 inches. In some embodiments C2 is less than about 0.1 inches. In some embodiments C2 is about 0.2 inches. In some embodiments C2 is about 0.20 inches. In some embodiments C2 is about 0.198 inches. In some embodiments C2 is about 0.2166 inches. In some embodiments C2 is about 0.22 inches. In some embodiments C2 is about 0.217 inches. In some embodiments C2 is about 0.2166 inches.
D1 is a horizontal distance between a center contact-point axis 532 of heater band 224 and inner-most plane 526 of heater band 224 as shown in FIG. 8B. In some embodiments, D1 is less than about 0.14 inches. In some embodiments, D1 is less than about 0.13 inches. In some embodiments, D1 is less than about 0.12 inches. In some embodiments, D1 is less than about 0.11 inches. In some embodiments, D1 is about 0.12 inches. In some embodiments, D1 is about 0.120 inches. In some embodiments, D1 is about 0.1197 inches. In some embodiments, D1 is about 0.1 inches. In some embodiments, D1 is about 0.13 inches. In some embodiments, D1 is about 0.133 inches.
D2 is a horizontal distance between a center contact-point axis 632 of heater band 224A and inner-most plane 626 of heater band 224A as shown in FIG. 13. In some embodiments, D2 is less than about 0.14 inches. In some embodiments, D2 is less than about 0.13 inches. In some embodiments, D2 is less than about 0.12 inches. In some embodiments, D2 is less than about 0.11 inches. In some embodiments, D2 is about 0.13 inches. In some embodiments, D2 is about 0.133 inches. In some embodiments, D2 is about 0.12 inches. In some embodiments, D2 is about 0.120 inches. In some embodiments, D2 is about 0.1197 inches.
E1 is a vertical distance between second plane 522 defined by engaging face 510 of lid pusher 222 to first plane 520 defined by engaging face 514 of burp plug 225 as shown in FIG. 8B. In some embodiments, E1 is less than about 0.2 inches. In some embodiments, E1 is less than about 0.15 inches. In some embodiments, E1 is less than about 0.1 inches. In some embodiments, E1 is about 0.09 inches. In some embodiments, E1 is about 0.094 inches. In some embodiments, E1 is about 0.0937 inches. In some embodiments, E1 is about 0.13 inches. In some embodiments, E1 is about 0.126 inches.
E2 is a vertical distance between second plane 622 defined by engaging face 610 of lid pusher 222A to first plane 620 defined by engaging face 614 of burp plug 225A as shown in FIG. 13. In some embodiments, E2 is less than about 0.2 inches. In some embodiments, E2 is less than about 0.15 inches. In some embodiments, E2 is less than about 0.1 inches. In some embodiments, E2 is about 0.13 inches. In some embodiments, E2 is about 0.126 inches. In some embodiments, E2 is about 0.09 inches. In some embodiments, E2 is about 0.094 inches. In some embodiments, E2 is about 0.0937 inches.
F1 is a horizontal distance between center contact-point axis 532 of heater band 224 and a center axis 536 of burp plug 225 as shown in FIG. 8B. In some embodiments, F1 is greater than about 1 inch. In some embodiments, F1 is greater than about 1.2 inches. In some embodiments, F1 is greater than about 1.4 inches. In some embodiments, F1 is greater than about 1.6 inches. In some embodiments, F1 is greater than about 1.8 inches. In some embodiments, F1 is about 1.2 inches. In some embodiments, F1 is about 1.21 inches. In some embodiments, F1 is about 1.205 inches. In some embodiments, F1 is about 1.2051 inches. In some embodiments, F1 is about 1.7 inches. In some embodiments, F1 is about 1.69 inches. In some embodiments, F1 is about 1.685 inches.
F2 is a horizontal distance between center contact-point axis 632 of heater band 224A and a center axis 636 of burp plug 225A as shown in FIG. 13. In some embodiments, F2 is greater than about 1 inche. In some embodiments, F2 is greater than about 1.2 inches. In some embodiments, F2 is greater than about 1.4 inches. In some embodiments, F2 is greater than about 1.6 inches. In some embodiments, F2 is greater than about 1.8 inches. In some embodiments, F2 is about 1.7 inches. In some embodiments, F2 is about 1.69 inches. In some embodiments, F2 is about 1.685 inches. In some embodiments, F2 is about 1.2 inches. In some embodiments, F2 is about 1.21 inches. In some embodiments, F2 is about 1.205 inches. In some embodiments, F2 is about 1.2051 inches.
H2 is a horizontal distance between an inner-most plane 670 of lid pusher 222A and an outer-most plane 672 of heater band 224A as shown in FIG. 15. In some embodiments, H2 is less than about 0.02 inches. In some embodiments, H2 is less than or equal to about 0.01 inches. In some embodiments, H2 is less than about 0.005 inches. In some embodiments, H2 is greater than about 0.0 inches. In illustrative embodiments, H2 is about 0.01 inches.
S1 is a vertical distance between an upper-most plane 574 of top wall 14T and an upper-most plane 576 of center plate 14P as shown in FIG. 8A. In some embodiments, S1 is less than about 0.2 inches. In some embodiments, S1 is less than about 0.1 inches. In some embodiments, S1 is less than about 0.05 inches. In some embodiments, S1 is less than about 0.01 inches. In illustrative embodiments, S1 is about 0.12 inches. In some embodiments, S1 is about 0.01 inches.
S2 is a vertical distance between an upper-most plane 674 of top wall 414T and an upper-most plane 676 of center plate 414P as shown in FIG. 15. In some embodiments, S2 is less than about 0.2 inches. In some embodiments, S2 is less than about 0.1 inches. In some embodiments, S2 is less than about 0.05 inches. In some embodiments, S2 is less than about 0.01 inches. In illustrative embodiments, S2 is about 0.01 inches. In some embodiments, S2 is about 0.12 inches.
X1 is a vertical distance between first plane 520 defined by engaging face 514 of burp plug 225 and third plane 524 defined by engaging face 516 of heater band 224 as shown in FIG. 8B. In some embodiments, X1 is greater than about 0.1 inches. In some embodiments, X1 is greater than about 0.11 inches. In some embodiments, X1 is greater than about 0.12 inches. In some embodiments, X1 is greater than about 0.13 inches. In some embodiments, X1 is greater than about 0.14 inches. In illustrative embodiments, X1 is about 0.12 inches. In some embodiments, X1 is about 0.13 inches.
X2 is a vertical distance between first plane 620 defined by engaging face 614 of burp plug 225A and third plane 624 defined by engaging face 616 of heater band 224A as shown in FIG. 13. In some embodiments, X2 is greater than about 0.1 inches. In some embodiments, X2 is greater than about 0.11 inches. In some embodiments, X2 is greater than about 0.12 inches. In some embodiments, X2 is greater than about 0.13 inches. In some embodiments, X2 is greater than about 0.14 inches. In illustrative embodiments, X2 is about 0.13 inches. In some embodiments, X2 is about 0.12 inches.
Z1 is a horizontal distance between outer-most plane 538 of burp plug 225 and center axis 536 of burp plug 225 as shown in FIG. 8B. In some embodiments, Z1 is greater than about 1 inch. In some embodiments, Z1 is greater than about 1.1 inches. In some embodiments, Z1 is greater than about 1.2 inches. In some embodiments, Z1 is greater than about 1.3 inches. In some embodiments, Z1 is greater than about 1.4 inches. In some embodiments, Z1 is greater than about 1.5 inches. In some embodiments, Z1 is about 1.1 inches. In some embodiments, Z1 is about 1.09 inches. In some embodiments, Z1 is about 1.086 inches. In some embodiments, Z1 is about 1.4 inches. In some embodiments, Z1 is about 1.41 inches. In some embodiments, Z1 is about 1.406 inches.
Z2 is a horizontal distance between outer-most plane 638 of burp plug 225A and center axis 636 of burp plug 225A as shown in FIG. 13. In some embodiments, Z2 is greater than about 1 inch. In some embodiments, Z2 is greater than about 1.1 inches. In some embodiments, Z2 is greater than about 1.2 inches. In some embodiments, Z2 is greater than about 1.3 inches. In some embodiments, Z2 is greater than about 1.4 inches. In some embodiments, Z2 is greater than about 1.5 inches. In some embodiments, Z2 is about 1.4 inches. In some embodiments, Z2 is about 1.41 inches. In some embodiments, Z2 is about 1.406 inches. In some embodiments, Z2 is about 1.4061 inches. In some embodiments, Z2 is about 1.1 inches. In some embodiments, Z2 is about 1.09 inches. In some embodiments, Z2 is about 1.086 inches.
In illustrative embodiments, the measurements of closure system 500, closure system 600, package 10, and package 410 may include the following relative dimensions:
TABLE 1
|
|
Dimensional Measurements of the Closure Systems
|
First Embodiment
Second Embodiment
|
|
A1
0.03 inches
A2
0.004 inches
|
B2
0.15 inches
|
C1
0.22 inches
C2
0.2 inches
|
D1
0.12 inches
D2
0.13 inches
|
E1
0.10 inches
E2
0.13 inches
|
F1
1.21 inches
F2
1.69 inches
|
H2
0.01 inches
|
S1
0.12 inches
S2
0.01 inches
|
X1
0.12 inches
X2
0.13 inches
|
Z1
1.09 inches
Z2
1.41 inches
|
|
In addition to the measurements of the closure systems 500, 600, various measurements of the packages 10, 410 may be obtainable. In the first embodiment, brim 24 has a thickness T1, lid 14 has a thickness T2, and a side wall 580 has a thickness T3 as shown in FIG. 8B. In the second embodiment, brim 424 has a thickness T4, cover film 658 has a thickness T5, and side wall 680 has a thickness T6 as shown in FIG. 15. As an example, thickness T1 and thickness T4 may be between about 0.050 and about 0.065 inches. Thickness T2 and thickness T5 may be about 0.005 inches. Thickness T3 and T6 may be between about 0.030 and about 0.035 inches.
In illustrative embodiments, a range of various ratios may be derived from the measurements of the closure system 500, closure system 600, package 10, and package 410:
TABLE 2
|
|
Dimensional Ratios of the Closure Systems
|
First Embodiment
Second Embodiment
|
|
R1 = C1/A1
8.236
R1 = C2/A2
49.50
|
R2 = C1/E1
2.312
R2 = C2/E2
1.571
|
R3 = C1/X1
1.805
R3 = C2/X2
1.523
|
R4 = Z1/E1
11.590
R4 = Z2/E2
11.159
|
R5 = D1/C1
0.553
R5 = D2/C2
0.672
|
R6 = Z1/C1
5.014
R6 = Z2/C2
7.101
|
R7 = F1/Z1
1.110
R7 = F2/Z2
1.198
|
R8 = D1/X1
0.998
R8 = D2/X2
1.023
|
R9 = X1/A1
4.563
R9 = X2/A2
32.5
|
R10 = X1/T1
2.400
R10 = X2/T1
N/A
|
R11 = X1/T4
N/A
R11 = X2/T4
2.00
|
R12 = X1/E1
1.281
R12 = X2/E2
1.032
|
R13 = S1/A1
4.563
R13 = S2/A2
2.5
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In an illustrative embodiment, lid 414 comprises multiple layers. When formed as a multi-layer component in accordance with the present disclosure, lid 414 comprises an outer bed having an outer surface, an inner bed having an inner surface, and a core interposed between and coupled to outer and inner beds. Each of outer bed, core, and inner bed is made of a different material in an illustrative embodiment. Outer bed comprises polyester, polypropylene, or nylon. Core comprises a barrier layer. Inner bed comprises low-density polyethylene, polypropylene-based sealant, blends of polypropylene and polybutane, as well as EMA-EVA-based sealants. In illustrative embodiments, inner bed comprises a material that can be heat-sealed to brim 424 of container 412 as disclosed herein. In illustrative embodiments, inner bed comprises a composition configured to establish a fluid seal whenever lid 414 is coupled with annular brim 424 of container 412 after lid 414 is removed from container 412 for the first time.
An alternative embodiment for a container filling process is shown in FIGS. 11-15. In the alternative embodiment, lid 414 is mechanically coupled to brim 424 by downward force from lid pusher 222A onto upwardly-extending support flange 662 of sheet support ring 660. Burp plug 225A provides additional downward force on center plate 414P, as illustrated in FIGS. 11-13, to stretch top wall 414T of lid 414 relative to the stationary sheet support ring 660.
A first opened position is shown in FIG. 11. In the first opened position, sealing head 220A is spaced apart from lid 414. Lid 414 rests on top of container 412 and sheet support ring 660 of brim-mount frame 414F is not engaged with brim 424.
A second opened position is shown in FIG. 12. In the second engaged position, burp plug 225A of sealing head 220A engages center plate 414P of lid 414 and applies a downward pressure thereto. The downward pressure causes center plate 414P to bend inward toward product-storage region 426.
A third mechanical-coupling position is shown in FIG. 13. In the third mechanical-coupling position, lid pusher 222A of sealing head 220A engages and applies a downward pressure to upwardly-extending support flange 662 of sheet support ring 660. As a result, sheet support ring 660 mechanically couples to brim 424 as illustrated in FIG. 13. During the mechanical-coupling position, burp plug 225A continues to apply downward pressure to center plate 414P of lid 414.
A fourth wiping position is shown in FIG. 14. In the fourth wiping position, sealing head 220A continues to move downward to cause engaging face 616 of heater band 224A to engage with a sealing portion 668 of center plate 414P of lid 414 above upwardly facing surface 424U of brim 424. Sealing head 220A applies downward pressure on center plate 414P to cause spilled food 306 to be wiped away from upwardly facing surface 424U of brim 424. In addition, burp plug 225A continues to apply downward pressure to another portion of center plate 414P. As a result, sealing portion 668 is stretched and pulled toward upwardly facing surface 424U of brim 424 to create additional wiping action, as described above.
A fifth sealing position is shown in FIG. 14. In the fifth sealing position, heater band 224A is activated and applies downwardly directed heat 220H to stretched sealing portion 668 of center plate 414P of lid 414 to establish a chemical-bond sealed connection 101 between stretched center plate 414P and upwardly facing surface 424U of brim 424. In illustrative embodiments, any minute quantity of residual spilled food 306 remaining on upwardly facing surface 424U of brim 424 is gasified during exposure of stretched sealing portion 668 of center plate 414P of lid 414 to downwardly directed heat 220H from heater band 224A and passed as a gas 306G through top wall 414T of lid 414 to the surroundings so that no spilled product 306 remains on brim 424.
In illustrative embodiments, lid 414 may comprise a peelable and resealable sealant material or layer that in illustrative embodiments is configured to engage brim 424 to provide means for establishing a fluid seal between lid 414 and container 412 when reclosable lid 414 is mated with brim 424 so that ingress of oxygen and other contaminants into product-storage region 426 formed in container 412 is blocked while lid 414 is mated to container 412. Lid 414 can be removed from container 412 and reclosed in one piece repeatedly by a consumer. In some embodiments, a fluid seal is formed between lid 414 and container 412 each time lid 414 is mated to container 12.
It is unnecessary to attach a separate closure film or foil to container 412 on the filling line after container 412 has been filled and before lid 414 is mounted on container 412 when using a lid 414 in accordance with the present disclosure owing, in part, to the provision of a peelable and resealable sealant layer in lid 414 disclosed herein. Packaging cost and complexity is thus minimized and the customer is provided with an easy-to-use product that is characterized by sustainability. The peelable and releasable sealant layer is peelable and resealable.
Packages in accordance with the present disclosure are well-suited for use in hot-filled non-barrier containers. They may also be used in barrier, retortable containers. Sustainability is enhanced because the lid is made of like materials without the inclusion of metal rings or other non-plastics materials in illustrative embodiments.
Patent Application
20160152360
