This application claims the priority of Swiss patent application 1221/06, filed Jul. 27, 2006, the disclosure of which is incorporated herein by reference in its entirety.
The invention relates to a method for the manufacture of a sequence of objects with a sealed seam and in particular a sequence of lids or covers, respectively, each provided with a tear off foil connected to the lid or cover, respectively, by said sealed seam. The invention further relates to an apparatus for manufacturing a sequence of objects with a sealed seam and in particular of a sequence of lids or covers, respectively, each provided with a tear off foil.
Covers or lids, respectively, made of metal and provided on packages and mainly on containers in the form of cans or boxes, respectively, are known as covers or lids being permanently fixed to the container and being provided with an opening in said cover or lid, respectively. Said opening is closed and sealed by a tear-off foil, and in particular a tear-off metal foil, up to the first use of the contents of the package. The foil is fixed to the cover or lid by a sealed seam or heat-sealed joint, respectively. An additional plastic cover that is arranged over the metal cover or lid, respectively, provides a reclosure for the package during the consumption time of the contents of the package. Known methods and apparatus for making such covers or lids, respectively, are shown in prior art
With a manufacturing cycle of 200 objects per minute only a very short time is available for the quality test by testing the air-tightness with a pressure difference.
It is an object of the present invention to provide a method and an apparatus to overcome this drawback.
Now, in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the method of making objects, and in particular covers or lids, respectively, which are provided with a tear-off foil attached by heat-sealing during manufacturing of the object within a heat-sealing station comprises the steps of taking a thermographic image or heat image, respectively, within the sealing station or within a neighbouring station following said sealing station, and analysing said image.
The object is met as well by an apparatus for making objects with heat-sealed seams, and in particular covers or lids, respectively, with a tear-off foil, said apparatus comprising a conveying means for said objects and a plurality of working stations arranged along the conveying path including a heat-sealing station and comprising a device for taking a thermographic or heat image, respectively, of said object at said sealing station or at a working station downstream of said heat sealing station.
By thermographically viewing the sealed seam, which is still hot, at or in the sealing station or at or in a following station and by analysing said viewed image or picture, respectively, and thus analysing the temperature around the seam, it can be detected in a simple and swift manner whether the seam has been sealed correctly and thus whether the seam is tight. Accordingly, a time consuming pressure test can be omitted. A seam that has been correctly sealed exhibits an essentially unitary temperature along its length, which leads to a corresponding heat picture or image, respectively. Parts of the seam that have become too hot during sealing or parts of the seam that have not been heated enough look differently in said image or picture, respectively, compared to the parts or sections of the seam treated with correct temperature in said sealing station and thus exhibiting an essentially uniform temperature in the image. Accordingly, the parts or sections with a temperature too high or with a temperature that is too low can be detected as parts or sections of the seam that are potentially defective and not tight and the object can be discarded.
The viewing of the seam to form the image, be it in the form of a picture of the seam or by recording the temperature gradient, is preferably done within the sealing station and is preferably done right after the sealing tool has been opened after the sealing has been done. Light guides and in particular optical fibres arranged above and along the seam may be provided for receiving and taking up heat radiation by the seam. Their ends can be bundled together and recorded by an infrared sensitive camera, so that a single heat picture or image, respectively, of the seam is provided. Another embodiment will take several pictures or images, respectively, each of a part of said seam. In another embodiment several infrared sensitive sensors or thermometers can be arranged so that they view a temperature image of the sealed seam by recording a temperature graph along the seam. In yet another embodiment a heat picture or image, respectively, is taken by optical fibres that are led directly through the sealing disc toward the seam.
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings, wherein:
It is referred again to the description already given above in connection with the prior art and FIGS. 1 to 9 for the making of can lids with tear-off foils. The present invention is now described as well with regard to the making of lids or covers with tear-off foils, respectively, for can-like containers. But it can be used for other containers or objects with hot-sealed seams as well.
FIGS. 10 to 12 show a first embodiment of a hot sealing station 40 which is used according to the present invention for making objects and in particular lids or covers 20, respectively, with a hot sealed seam. In the hot sealing station a tear-off foil is sealingly fixed to an annular lid or cover, respectively. The tear-off foil can be a multilayer foil comprising plastic layers and one or several aluminium layers. For example it may comprise a layer of polypropylene (PP) on the side facing the cover or lid, which is covered by a layer of PET (polyethylene terephthalate) followed by a layer of aluminium which is topped by another PET-layer to form the upper surface of the tear-off foil. A printing may be arranged below said last PET-layer. A further example may comprise a layer of a hot sealing lacquer facing the cover or lid and thus the contents of the can, followed by an aluminium layer and the top layer made of PET. Further examples are known to the person skilled in the art and can be used as well. Multilayer foils need usually their correct sealing temperature range prescribed by the foil manufacturer. If the temperature is too high a delamination may occur which is as well possible if the temperature difference between the upper sealing disk and the lower sealing disc is too high. It is further known that a sealing temperature that is too low may lead to a fixation of the tear-off foil on the cover or lid that is not airtight. According to the invention a thermal or heat view, respectively, is taken of the object at or within the sealing station or in a following station as long as the hot sealed seam is still hot as a result of the sealing process. Incorrectly sealed and thus faulty areas of the seam can be detected on such a thermographic image since these areas of the seam are too hot or too cold in comparison with the correctly sealed areas of the seam. The thermographic or heat image or picture, respectively, is taken or viewed in the sealing station where the sealing is performed. A presealing station may be present which provides a first fixing of the tear-off foil but does not finish the seam. It is not intended to provide a thermal view at this presealing station. Instead of taking an image or picture or viewing the seal in the sealing station such a step may occur in a station that follows downstream of the the sealing station, preferably in a station that follows directly to the sealing station. This station must be reached by the object while the temperature of the seam is still high enough so that a meaningful thermal view can be taken. And this station must be reached so fast that the temperature difference between defective areas and correctly sealed areas is still great enough to be analysed in the thermographic view. For these reasons it is preferred to view the seam directly in the sealing station.
FIGS. 10 to 12 show an embodiment for taking a thermal view within a sealing station 40. The construction of the sealing station itself can be done in conventional manner and is thus known to the person skilled in the art; accordingly it can be different to the example shown in the drawings with regard to the conventional parts. An upper sealing head 41 is provided with a thermally insulating layer 42 and carries an upper sealing disc 43 with electrical heating windings 43″ which heat the sealing surface 43′ of the sealing disc 43. This is done by a conventional temperature control that provides the selected sealing temperature that is suitable for the tear-off foil used in the manufacturing process of the objects. In the example shown the upper sealing head is a stationary head. The lower sealing head 45 is movable upwardly and downwardly to provide the closing distance and the opening distance d, respectively. This head 45 carries the lower sealing disc 44, separated by another thermal insulating layer 42, said disc 44 being provided with electrical heating windings 44″ and with the sealing surface 44′. This sealing station 40 is shown in
To this end light guiding means 49, 49′ are provided in this example. A camera 60 (shown only schematically as a box) views the whole area of the sealed seam of cover 20 through these light guiding means while the sealing tool is in its open state. An adapter part 46 is arranged at the sealing station which takes up the light guides in such a way that they are “looking” to the hot sealed seam. This is depicted in the FIG. by annularly arranged light guiding parts 49′ which are adapted to the shape of the hot sealed seam of cover 20. At their one free end the light guiding parts take up the heat radiation of the heated seam; an optical device 48 may be provided to focus the radiation to the receiving surface of the light guides. The beam of the radiation viewed is shown with lines and referenced with reference numeral 47. The heat radiation or infrared radiation, respectively, emitted by the hot seam is thus received by the light guiding means 49′ so that the radiation from the whole seam is received at the same time. The other free end 49 of the light guiding means at which the radiation viewed is emitted again is arranged so that it can be received by camera 60 which is an infrared sensitive camera as available on the market. This camera therefore takes in this embodiment a single picture which shows the whole hot sealed seam taken up in the infrared range. This picture is then analysed in an analysing means 61, usually a computer running image analysis software, as will be explained below. Light guiding means, such as optical fibres, are generally known and need not be explained here in greater detail. As mentioned already above cameras for taking thermographic images or infrared images, respectively, are known as well.
The light guiding means 49, 49′ can be constructed in different ways known to the person skilled in the art and can be selected as suitable for the special construction of the heat sealing station and its function.
After the viewing or recording, respectively, of a single or several thermographic or heat images, respectively, as described, the object 20 is moved away by the conveying means and the next object to be treated is placed into the sealing station 40 by the conveying means and is hot sealed therein after closing the tool as shown in
The contour of the sealed seam can be round, oval, or rectangular as is known and usually corresponds to the shape of the object or cover, respectively. These contours can be handled with all embodiments shown.
When the heat image of the sealed seam has been provided as described above, be it as a single image, as a sequence of images or as a temperature curve over the length of the seal taken with infrared sensors, it can be detected in a simple manner whether the seam has been correctly sealed or not. This can be done by an evaluation of the image or the images or the temperature curve; by this evaluation of the heat image or the temperature curve it can be detected whether the temperature of the sealed seam is within a predetermined range that is the known correct range for the seam temperature. This range of the correct temperature is known to the person skilled in the art and depends on the used heat sealing materials. A corresponding sealing temperature has to be selected for the sealing tool as is known to the person skilled in the art. Upon evaluation of the image it is possible to analyse the image by known image analysing techniques. Since it has only to be detected whether the section of the view of the seam actually evaluated is too hot or too cold with regard to the correct temperature range, the evaluation can be done by a simple comparison of the imaged temperatures with this correct range. The image can be evaluated for example line by line or as a whole. The image analysis can be done by a computer program suitable for image analysis; such programs are available on the market. If areas of the image or parts of the temperature curve exhibit temperatures that are too hot or temperatures that are too cold in comparison with the correct temperature range, the viewed seam is defective and thus the object or can cover is defective. Such parts of the image are shown in a heat image as parts that are too bright or parts that are too dark what can be detected by a very simple image analysis and is known to the person skilled in the art. Objects or covers or lids, respectively, thus identified as defective are sorted out. This can be done by different exits at the end of the apparatus as has been shown in
Instead of or in addition to a simple analysis of a viewed temperature or temperature curve with an upper and lower limit it is as well possible, in particular with an image, to provide a more detailed analysis and to try to assign a cause of the defect to the viewed defective parts of the seam. As well it can be detected whether defects are found due to a temperature that is too high or a temperature that is too low, whether the defects occur often or always at the same location of the seam, how large the defective areas of the seam are etc.
A method and an apparatus are thus provided for taking heat images of heat sealed seams. Such seams are made in heat sealing stations and in particular when making covers or lids, respectively, for containers, being provided with a tear-off foil that closes the container up to the first use of its contents. For ascertaining the air-tightness of the heat sealed seam during manufacturing a heat image of the seam is taken while the seam is still hot. By evaluating the image it can be detected whether the temperature of the seam is within a range that assures a correct seam or has exceeded an upper or lower limit for the temperature which is indicative of a defective heat sealed seam. Defective objects can then be discarded based on the evaluation of the heat image. This test of the correctness of the heat sealing is much faster than a pressure differential test testing the actual air tightness of the seam and can thus be used in high speed manufacturing apparatus for covers or lids, respectively.
While there are shown and described presently preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously embodied and practised within the scope of the following claims.
Number | Date | Country | Kind |
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1221/06 | Jul 2006 | CH | national |