U.S. patent application number 11/164262 was filed with the patent office on 2006-03-02 for vial with hinged cap and method of making same.
This patent application is currently assigned to POLYTOP CORPORATION. Invention is credited to Patrick J. Brannon, Joseph E. Johnson, Clifford W. Skillin.
Application Number | 20060043100 11/164262 |
Document ID | / |
Family ID | 34915288 |
Filed Date | 2006-03-02 |
United States Patent
Application |
20060043100 |
Kind Code |
A1 |
Johnson; Joseph E. ; et
al. |
March 2, 2006 |
VIAL WITH HINGED CAP AND METHOD OF MAKING SAME
Abstract
An integrally molded dispensing vial having a vial body, vial
lid and living hinge structure connecting the vial lid to the vial
body. The vial body having an upper lip with an inner and outer
annular sealing bead. The vial lid having a U-shaped sealing
channel having an inner and outer annular sealing wall, and a snap
rim depending from the outer annular sealing wall. The upper lip
and U-shaped sealing channel cooperably engageable to form complete
peripheral seals.
Inventors: |
Johnson; Joseph E.;
(Woodstock, CT) ; Skillin; Clifford W.;
(Blackstone, MA) ; Brannon; Patrick J.; (Warwick,
RI) |
Correspondence
Address: |
BARLOW, JOSEPHS & HOLMES, LTD.
101 DYER STREET
5TH FLOOR
PROVIDENCE
RI
02903
US
|
Assignee: |
POLYTOP CORPORATION
110 Graham Drive
Slatersville
RI
|
Family ID: |
34915288 |
Appl. No.: |
11/164262 |
Filed: |
November 16, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11160675 |
Jul 5, 2005 |
|
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11164262 |
Nov 16, 2005 |
|
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60587276 |
Jul 12, 2004 |
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Current U.S.
Class: |
220/839 ;
220/375; 220/4.23 |
Current CPC
Class: |
B29C 66/91221 20130101;
B29C 66/91216 20130101; B29L 2031/772 20130101; B29C 45/7207
20130101; B29C 66/8322 20130101; B29C 66/542 20130101; B29C 66/549
20130101; B29C 45/0081 20130101; B65D 43/162 20130101; B29C 45/006
20130101; B29C 66/91411 20130101; B29C 65/58 20130101; B29C 65/7861
20130101; B29L 2031/565 20130101; B29L 2031/712 20130101; B29C
66/8242 20130101 |
Class at
Publication: |
220/839 ;
220/004.23; 220/375 |
International
Class: |
B65D 6/28 20060101
B65D006/28; B65D 43/14 20060101 B65D043/14 |
Claims
1. A dispensing vial comprising: a vial body having an upper body
portion, a lower body portion depending from the upper body
portion, an upper lip extending from the upper body portion forming
a dispensing orifice, a bottom surface depending from and enclosing
the lower body portion; a vial lid having a top portion, a U-shaped
sealing channel having an inner annular sealing wall extending from
the top portion, an upper wall depending from the inner annular
sealing wall, an outer annular sealing wall depending from the
upper wall, a snap rim depending from the outer annular sealing
wall of the U-shaped sealing channel, a living hinge structure
pivotably joining the vial lid to the vial body, the vial lid being
pivotably movable about the living hinge structure between an open
position and a closed position; and cooperable sealing means
providing a complete peripheral seal between the upper lip and the
U-shaped sealing channel.
2. The dispensing vial of claim 1 wherein the vial lid further
comprises stop ribs depending from the upper wall and across the
U-shaped sealing channel to connect to the inner annular sealing
wall and outer annular sealing wall, the stop ribs preventing the
upper lip from contacting the upper wall of the U-shaped sealing
channel of the vial lid when in the closed position.
3. The dispensing vial of claim 2 wherein there are three stop
ribs, the first stop rib located centrally on the upper wall, the
second and third stop robs spaced radially apart on either side of
the first stop rib along the upper wall.
4. The dispensing vial of claim 1 wherein the cooperable sealing
means comprises an outer annular sealing bead formed on the outer
surface of the upper lip, the outer annular sealing bead engaging
the outer annular sealing wall of the U-shaped sealing channel to
form a complete peripheral seal.
5. The dispensing vial of claim 4 wherein the cooperable sealing
means further comprises an inner annular sealing bead formed on the
inner surface of the upper lip, the inner annular sealing bead
engaging the inner annular sealing wall of the U-shaped sealing
channel to form a complete peripheral seal.
6. The dispensing vial of claim 1 wherein the cooperable sealing
means comprises an inner annular sealing bead formed on the inner
surface of the upper lip, the inner annular sealing bead engaging
the inner annular sealing wall of the U-shaped sealing channel to
form a complete peripheral seal.
7. The dispensing vial of claim 6 wherein the cooperable sealing
means further comprises an outer annular sealing bead formed on the
outer surface of the upper lip, the outer annular sealing bead
engaging the outer annular sealing wall of the U-shaped sealing
channel to form a complete peripheral seal.
8. The dispensing vial of claim 1 wherein the vial body is a
semi-elliptical tube.
9. The dispensing vial of claim 1 wherein the snap rim further
comprises a plurality of snap beads to provide the vial lid with an
audible an tactile snap when closed.
10. The dispensing vial of claim 9 wherein the plurality of snap
beads are radially spaced apart.
11. The dispensing vial of claim 9 wherein there are three of the
plurality of snap beads.
12. The dispensing vial of claim 10 wherein the snap beads are
radially spaced apart.
13. A dispensing closure for a container comprising: a closure body
adapted to be mounted on a container and having an upper lip
extending from the closure body forming a dispensing orifice; a
closure lid having a top portion, a U-shaped sealing channel having
an inner annular sealing wall extending from the top portion, an
upper wall depending from the inner annular sealing wall, an outer
annular sealing wall depending from the upper wall, a snap rim
depending from the outer annular sealing wall of the U-shaped
sealing channel, a living hinge structure pivotably joining the
closure lid to the closure body, the closure lid being pivotably
movable about the living hinge structure between an open position
and a closed position; cooperable sealing means providing a
complete peripheral seal between the upper lip and the U-shaped
sealing channel.
14. The dispensing closure of claim 13 wherein the closure lid
further comprises stop ribs depending from the upper wall and
across the U-shaped sealing channel to connect to the inner annular
sealing wall and outer annular sealing wall, the stop ribs
preventing the upper lip from contacting the upper wall of the
U-shaped sealing channel of the closure lid when in the closed
position.
15. The dispensing closure of claim 14 wherein there are three stop
ribs, the first stop rib located centrally on the upper wall, the
second and third stop robs spaced radially apart on either side of
the first stop rib along the upper wall.
16. The dispensing closure of claim 13 wherein the cooperable
sealing means comprises an outer annular sealing bead formed on the
outer surface of the upper lip, the outer annular sealing bead
engaging the outer annular sealing wall of the U-shaped sealing
channel to form a complete peripheral seal.
17. The dispensing closure of claim 16 wherein the cooperable
sealing means further comprises an inner annular sealing bead
formed on the inner surface of the upper lip, the inner annular
sealing bead engaging the inner annular sealing wall of the
U-shaped sealing channel to form a complete peripheral seal.
18. The dispensing closure of claim 13 wherein the cooperable
sealing means comprises an inner annular sealing bead formed on the
inner surface of the upper lip, the inner annular sealing bead
engaging the inner annular sealing wall of the U-shaped sealing
channel to form a complete peripheral seal.
19. The dispensing closure of claim 18 wherein the cooperable
sealing means further comprises an outer annular sealing bead
formed on the outer surface of the upper lip, the outer annular
sealing bead engaging the outer annular sealing wall of the
U-shaped sealing channel to form a complete peripheral seal.
20. The dispensing closure of claim 13 wherein the snap rim further
comprises a plurality of snap beads to provide the closure lid with
an audible an tactile snap when pivoted to the closed position.
21. The dispensing closure of claim 20 wherein the plurality of
snap beads are radially spaced apart.
22. The dispensing closure of claim 20 wherein there are three of
the plurality of snap beads.
23. The dispensing closure of claim 22 wherein the snap beads are
radially spaced apart.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/160,675 filed Jul. 5, 2005, which claims
the benefit of the filing date of earlier filed U.S. Provisional
Application No. 60/587,276, filed Jul. 12, 2004, the entire
contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to containers and vials having
hinged closures that maintain a seal. More specifically, the
present invention relates to a vial having an integrally hinged cap
and a method for manufacturing the vial.
[0004] 2. Background of the Related Art
[0005] Containers and vials having hinged closures are well known
in the art. In this regard, there are dozens of patents that
describe various different configurations of dispensing closures
and vials with hinged caps, as well as different methods for
manufacturing such products. The U.S. patents to Hayberg, U.S. Pat.
No. 4,351,630; Wilson et al, U.S. Pat. No. 4,220,248; Hazzard, U.S.
Pat. No. 4,377,247; Eitzinger, U.S. Pat. No. 4,847,988; and Wilson,
U.S. Pat. No. 5,271,536 are just a few examples of the art in this
area. As can be seen from many of the drawing figures in these
patents, dispensing closures and vials generally include a main
body and hinged lid integrally formed with and connected to the
main body by a living hinge. The main body typically includes an
"orifice" for dispensing of the product, while the lid usually
includes a "spud" which is received in friction fit into the
orifice to form a seal and prevent unwanted dispensing of the
product. The one-piece assembly is obviously molded in the open
position, and then closed in a subsequent processing operation.
Because many of the dispensing closures are used on liquid beauty
products, such as shampoo, and food products, such as ketchup and
syrups, a leak-proof seal must be formed at the "spud" and
"orifice" of the closure.
[0006] In the area of manufacturing there is also a significant
body of prior art for automated molding and closing of dispensing
closures. As early as 1983 many companies began using automation
apparatus for the handling and closure of dispensing closures after
molding. For example, several early closure machines were based
upon a rotary table closure system that included a vibratory feed
(see U.S. Pat. No. 4,847,988). Molded parts were dropped out of the
mold onto a conveyor that in turn dumped into the vibratory feed
bowl. The vibratory feed oriented the loose parts and fed them to a
processing line that in turn fed into a multi-station continuous
motion, rotating table. As each part was fed onto the table and
rotated to the next position, the lid of the closure would be
successively lifted up and over until finally rotated to the fully
closed position. These rotary table processing machines are still
actively in use today in manufacturing facilities. As early as
1984, manufacturers also began experimenting with automated closing
processes using part removal robots.
[0007] In the past, it was also well accepted that the best way to
conform sealing surfaces for the best sealing characteristics was
to mate the sealing surfaces together shortly after molding while
the plastic material was still somewhat warm, i.e. not fully set.
In the context of plastic materials intended for use in everyday
life, "fully set" should be understood to mean that the material
has returned to an ambient "normal use" temperature.
[0008] In the molding of plastic closures, the plastic material is
injected molded at a temperature of about 420.degree.
F.-430.degree. F. After molding, the material must be cooled in the
mold to about 100.degree. F.-120.degree. F., at which temperature
the plastic is cool enough so as not to deform upon removal from
the mold, but yet is still above ambient temperature and warm
enough to still provide some conforming shrinkage or "set" as it
continues to cool down to room temperature. It is thus common
knowledge that the dispensing closures should be closed shortly
after removal from the mold to provide a "better" seal at the
contact of the spud and orifice.
[0009] This teaching is clearly identified in several U.S. patents
from the 1970's through the early 1990's. For example, in the U.S.
patent to Hayberg, U.S. Pat. No. 4,351,630 (1982), the inventors
identified the importance of exercising the living hinge soon after
molding (still in the mold) (See column 1, lines 37-50). Hayberg
also recognized the importance of closing of the lid shortly after
closing to insure a good seal (See column 1 lines 50-64.)
[0010] The U.S. patent to Eitzinger U.S. Pat. No. 4,847,988 (1989)
also recognized the importance of closing the lid shortly after
molding (See column 3, lines 24-32).
[0011] Turning back to the vial configuration of the present
invention, the vials and dispensing closures described hereinabove
were, until recently, predominantly used for storing and dispensing
liquid products. However, there has been a recent trend in the
candy industry to develop unique dispensing packages for small
candy products, such as sugar-coated chocolates, and other
sugar-based candies.
[0012] In this regard, several candy manufacturers have adopted the
use of a vial with a hinged closure for the sale and dispensing of
such sugar-based candy products. Please refer to U.S. Pat. No.
5,133,470 (Abrams), U.S. Pat. No. 4,807,425 (Abrams), and U.S. Pat.
No. 4,783,056 (Abrams) for an example of one such vial (cylindrical
in shape) currently used in the candy industry.
[0013] Dispensing vials with a hinged cap provide a simple
configuration for filling and sealing of the product during
manufacture, and further provide the end consumer with the ability
to open and close the package multiple times. While the existing
vial configurations are effective for their intended purpose, there
is a perceived need in the industry for additional vial
configurations which will allow candy manufactures to distinguish
their product from others with different shaped vials and cap
designs.
[0014] However, there are unique environmental issues that must be
addressed in the packaging of food products, and in particular
sugar-based candy products. Sugar based candies pose a particular
problem in that the container must have an adequate seal to prevent
the infiltration of moisture into the interior of the vial. Sugar
based candy must remain isolated from significant amounts of
moisture or the candies will become soft and will stick
together.
[0015] Accordingly, the vial must have a certain minimum level of
sealing capability to prevent the unwanted infiltration of air and
moisture and for the candy to have an acceptable shelf life.
SUMMARY OF THE INVENTION
[0016] The dispensing vial of the present invention includes a
unique oval body with an open top and a lid integrally connected to
the body by a living hinge structure. The body and cap are
substantially oval in shape having a short linear side and arcuate
front and rear surfaces. The upper lip of the body defines the
"orifice" and includes an inner sealing bead and an outer sealing
bead, the outer sealing bead being slightly larger than the inner
sealing bead. The lid is formed with a complementary U-shaped
sealing channel that is configured and arranged to be received over
the lip in sealed relation when the lid is rotated about the living
hinge to a closed position. The outer wall of the channel is
provided with a sealing shoulder that is snap received over the
outer sealing bead. The inner wall of the channel forms the "spud"
which is received into the inside of the lip of the vial.
[0017] The body and lid are configured to mate and seal along two
(2) separate engagement lines. The upper lip of the vial is not
received entirely into the channel leaving a small gap above the
upper edge of the lip. The first sealing engagement occurs at the
contact of the inner sealing bead against the inner wall of the
channel. The second sealing engagement occurs at the contact of the
outer sealing bead and the outer wall.
[0018] In use, when the lid is closed onto the body, the U-shaped
channel snaps over the sealing bead. The channel walls initially
deflect outwardly to ride over the sealing beads, but then squeeze
inwardly to provide a sealing force of the wall against the sealing
beads and shoulder.
[0019] The manufacturing process for making the vial is also unique
because of its unique oval shape and the configuration of the
elongated U-shaped sealing channel. In the past, it was well
accepted that the best way to conform sealing surfaces for the best
sealing characteristics was to mate the sealing surfaces together
shortly after molding while the plastic material was still somewhat
warm, i.e. not fully set. Despite the well-known advantages of
sealing a cap onto a body while the plastic is still warm, the
present vial configuration did not perform as expected (did not
have a sufficient seal) when closed immediately after molding.
[0020] The Applicants have speculated that the sealing
configuration of the present oval vial behaved differently than a
cylindrical vial and more specifically that the flexible channel
walls in the lid were being flexed outwardly and permanently
deformed during seating of the lid on the body (if the plastic was
too warm). Thus, that the channel walls were thus not providing the
proper compressive force to maintain a good seal. It was thereafter
determined that an extended set-up (cooling) time prior to closing
the cap provided the required sealing characteristics. Ultimately,
this led the Applicants to the inventive manufacturing process
wherein the sealing surfaces of the vials are cooled to a
temperature below ambient temperature (<60.degree. F.) upon
removal from the mold and then closed while the plastic is still
cold (fully set).
BRIEF DESCRIPTION OF THE DRAWINGS FIGURES
[0021] These and other features, aspects, and advantages of the
present invention will become better understood with regard to the
following description, appended claims, and accompanying drawings
where:
[0022] FIG. 1 shows front plan view of the vial of a version of the
present invention;
[0023] FIG. 2 shows a top view thereof;
[0024] FIG. 2a shows a close-up view of the lid thereof;
[0025] FIG. 3 shows a bottom view thereof;
[0026] FIG. 4 shows a cross-sectional view thereof taken along line
4-4 of FIG. 2;
[0027] FIG. 5 shows a cross-sectional view thereof taken along line
5-5 of FIG. 2;
[0028] FIG. 6 shows a cross-sectional view thereof taken along line
6-6 of FIG. 2;
[0029] FIG. 7 shows an enlarged cross-sectional view of the snap
bead detail circled in FIG. 6;
[0030] FIG. 8 shows an enlarged cross-section view of the lid
detail circled in FIG. 6;
[0031] FIG. 8a shows an enlarged cross-section view of the lid
along line 8a-8a of FIG. 2a;
[0032] FIG. 9 shows an enlarged cross-sectional view of the vial
bead detail circled in FIG. 5;
[0033] FIG. 10 shows an enlarged cross-sectional view of the cap
received onto the vial rim in a closed position;
[0034] FIG. 11 shows a top plan view of the robotic end of arm
tooling used to hold and move the vials during manufacturing;
[0035] FIG. 12 shows a side view thereof showing the vials being
ejected off of the molding tool into the nest cavities of the end
of arm tooling;
[0036] FIGS. 13A-D shows plan views of the processing line where
the vial lids are initially flexed and then fully closed while cold
while traversing through a series of processing zones;
[0037] FIG. 14A shows a side view of the vial lid being flexed;
[0038] FIG. 14B shows a side view of the dispensing vial being
cooled by blown refrigerated air;
[0039] FIG. 14C shows the final close of the vial lid against the
vial body; and
[0040] FIG. 15 shows a graph illustrating sealing characteristics
compared to time before closing the lid onto the vial.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] A. The Vial
[0042] Referring to FIGS. 1-10, the dispensing vial of the present
invention, shown generally at 20, includes a vial body 22 with an
dispensing orifice 46 and a vial lid 48 integrally connected to the
vial body 22 by a living hinge structure 62. The vial body 22 and
vial lid 48 are substantially oval or elliptical in shape having a
short linear side 24 and arcuate front surface 26 and an arcuate
rear surface 28 (See FIGS. 2 and 3 for oval shape). Although the
preferred embodiment of the present invention has an oval shape
cross-section, the present invention can be applied to other vial
geometries, such as square, circular or triangular to name a few,
and the present invention should not be limited as such.
[0043] In many ways, the dispensing vial 20 is identical to that of
a dispensing closure (not shown). The main exception being that the
lower body portion 30 of the dispensing vial 20 is closed by a
bottom surface 34, while the skirt (not shown) of the dispensing
closure is open so that it can be threaded onto a container (not
shown). In all other ways, the dispensing vial 20 is similar to the
dispensing closure.
[0044] The upper lip 36 of the vial body 22 defines the dispensing
orifice 46 and includes an inner annular sealing bead 42 and an
outer annular sealing bead 44, the outer annular sealing bead 44
being slightly larger than the inner annular sealing bead 42 (See
FIGS. 1, 4, 5, 9 and 10). The vial lid 48 is formed with a
complementary U-shaped sealing channel 50, depending from a top
portion 49, that is configured and arranged to be received over the
upper lip 36 in sealed relation when the vial lid 48 is rotated
about the living hinge structure 62 to a closed position (See FIGS.
4, 6, 7, 8 and 10).
[0045] The outer annular sealing wall 44 of the U-shaped sealing
channel 50 is provided with a snap rim 60 that is snap received
over the outer annular sealing bead 44 (See FIGS. 2 and 10). An
optional thumb catch 61 to assist the consumer in opening the vial
lid 48 may be located on the snap rim 60. Referring to FIG. 2, the
outer annular sealing wall 44 is actually provided with three
separate snap beads 57 that provide the lid with an audible and
tactile snap when the lid is closed. These snap beads 57 can best
be seen in FIG. 2a.
[0046] The U-shaped sealing channel 50 of the vial lid 48 is
further provided with three separate stop ribs 58 that project
downwardly from the upper wall 56 of the U-shaped sealing channel
50 to maintain the gap at the top of the U-shaped sealing channel
50 and prevent the vial lid 48 from being closed too far. The inner
annular sealing wall 42 of the U-shaped sealing channel 40
effectively forms a "spud" that is received into the inside of the
upper lip 36 of the vial body 22.
[0047] The vial body 22 and vial lid 48 are configured to mate and
seal along two (2) separate engagement lines identified in FIG. 2
as 4-4 and 5-5. The upper lip 36 of the vial body 22 is not
received entirely into the U-shaped sealing channel 50 leaving a
small gap (See FIG. 10) above the upper edge of the upper lip 36.
The first sealing engagement occurs at the contact of the inner
annular sealing bead 52 against the inner annular sealing wall 52
of the U-shaped sealing channel 50. The second sealing engagement
occurs at the contact of the outer annular sealing bead 44 and the
outer annular sealing wall 54. (Please note that FIG. 10 does not
show the actual deflected positions of the annular sealing walls
42, 44 and that the drawings are intended for the purpose of
illustrating the position of the sealing lines.)
[0048] In use, when the vial lid 48 is closed onto the vial body
22, the U-shaped sealing channel 50 snaps over the outer annular
sealing bead 44. The annular sealing walls 52, 54 initially deflect
outwardly (See arrow in FIG. 10) to ride over the outer annular
sealing bead 44 and inner annular sealing bead 42, but then squeeze
inwardly to provide a sealing force of the annular sealing walls
52, 54 against the annular sealing beads 42, 44.
[0049] B. The Manufacturing Process
[0050] I. General Discussion of Methodology
[0051] Despite the well-known advantages of sealing the cap onto
the body while the plastic is still warm, the vials of the present
invention did not perform as expected (did not have a sufficient
seal) when closed immediately after molding. After repeated testing
with the same results, the Applicants speculated that the sealing
configuration of the oval vial behaved differently than a
cylindrical vial. The forces would naturally be uneven around the
peripheral edge. In the process of development, the vials were
molded and then allowed to set up for various periods of time. A
chart of the various testing scenarios is attached as FIG. 15.
[0052] Surprisingly, the longer the vials were allowed to stand
before closure, the better the final seal. Please refer to the
yellow line (triangle symbol 15A-3) in FIG. 15 representing the
best sealing characteristics were obtained if the vials were
allowed to sit for 24 hours. This testing led the Applicants to
further speculate that the sealing walls in the lid were being
flexed outwardly and permanently deformed during seating of the lid
on the vial (if the plastic was too warm) and that the sealing
walls were thus not providing the proper compressive force to
maintain a good seal. The change in manufacturing criteria is thus
believed to be a direct result of the physical design of the vial
and lid.
[0053] While the extended set-up (cooling) time provided the
required sealing characteristics, it was determined that it would
not be feasible from a mass manufacturing perspective to mold the
dispensing vials, let them sit for 24 hours and then close
them.
[0054] Ultimately, this led the Applicants to its proposed
manufacturing process wherein the sealing walls of the lid and vial
are actively cooled to a temperature below ambient temperature
(<60.degree. F.) upon removal from the mold and then closed
while the plastic is still cold (fully set). The specific details
of the proposed manufacturing process are outlined in the preferred
process described below.
[0055] II. Detailed Discussion of Manufacturing Steps
[0056] This invention envisions the use of an injection mold press
(not shown) to produce the dispensing vials. In this embodiment, an
injection mold press with a capacity for twenty-four (24) units was
utilized, but other configurations would be equally as
effective.
[0057] In the first step, the dispensing vials 20 are injection
molded in the injection mold press. The vial body 22 and vial lid
48 are integrally molded together, connected by a living hinge
structure 62. At the time of molding, the vial lid 48 and upper 36
are disposed in the same plane, or in other words are disposed in a
position of 180.degree. open.
[0058] Second, the mold halves are separated (not shown). The vial
body 22 and vial lid 48 are retained on the post half of the mold
163 by retaining the outer annular sealing bead 44 on the upper lip
36 within its molding channel (not shown).
[0059] A robotic arm (not shown) descends into mold apparatus
between mold halves. The robotic arm includes an End of Arm Tool
(EOAT) 164 provided with nest cavities 166 for receiving the
freshly molded dispensing vials 20 (See FIGS. 11 and 12). The
dispensing vials 20 are completely ejected from the mold posts 163
into the nest cavities 166 on the EOAT 164 using compressed air.
More specifically, the vial body 22 is moved forward on the mold
post 163 as air jets feed air into vial body at the end of mold
post. A mechanical stripper (not shown) initiates complete
ejection. Compression builds until the force is sufficient to strip
the outer annular sealing bead 44 from the mold channel. The
dispensing vial 20 then shoots off the end of the most post 163
into a nest cavity 166 on the EOAT 164.
[0060] Thereafter, the robotic arm ascends out of the mold
apparatus and traverses to a hand-off tool 168. (See FIGS. 13A-D).
The hand-off tool 168 includes posts 170 to receive the dispensing
vials 20. The dispensing vials 20 are placed onto posts 170 of the
hand-off tool 168. The dispensing vials 20 are held in place by
vacuum ports 172 on the posts 170. The robotic arm then returns to
the injection mold press for next shot.
[0061] The hand-off tool 168 rotates 90.degree. to place dispensing
vials 20 in a transport shuttle 174 so they are oriented vertically
for further processing. The transport shuttle 174 includes grippers
176 for holding the vial body 22 during processing.
[0062] The vial lid 48 is moved upward by a first closing rod 175
to 90.degree. when placed in transport shuttle to flex the living
hinge structure 62 while the plastic is still warm. (See FIG. 14A).
As identified in the prior art, it is still important to flex the
living hinge structure while the plastic is still warm.
[0063] The transport shuttle 174 is indexed forward to an enclosed
first cooling zone 178 where the vial lids 48 are further rotated
by a second closing rod 179 to a position about 165.degree. from
its original molding position (almost closed or 15.degree. open) so
that the U-shaped sealing channel 50 and upper lip 36 are in close
proximity, but not actually closed. The first cooling zone 178 is
cooled with refrigerated compressed air to maintain a cooling zone
temperature of about 56.degree. F. at a dew point of about
43.degree. F. and 55% relative humidity. The first cooling zone 178
also includes nozzles 180 that blow cold air directly onto the vial
lid 48 and upper lip 36 of the vial body 22. For purposes of
forming the seal, it is of primary importance that the plastic of
the sealing structures at the vial lid and upper lip be cooled. The
transport shuttle 174 remains in first cooling zone 178 for about
20 seconds. During this time the plastic material in the vial lid
48 and upper lip 36 of the vial body 22 are cooled to a temperature
of less than 60.degree. F., and more preferably to a temperature of
about 56.degree. F. (See FIGS. 13A-D, and 14B). The plastic could
be cooled to even lower temperatures. However, for purposes of the
present invention, and to speed manufacturing time, the specified
temperatures are sufficient to achieve the required seal.
[0064] The transport shuttle 174 is then indexed forward to a
second cooling zone 182, which is the same in construction as first
cooling zone 178. The transport shuttle 174 remains in the second
cooling zone 182 for about another 20 seconds. The cooling zones
178, 182 effectively age the dispensing vials 20 (and the sealing
surfaces) equivalent to a set period of about 24 hours. With
cooling to less than 60.degree. F., the plastic is effectively in
its "fully set" state as it would be found during normal use. (See
FIGS. 13A-D, and 14B).
[0065] The transport shuttle 174 is indexed forward out of the
second cooling zone 182 to a closing device 184. The temperature of
the plastic material of the vial lid 48 and upper lip 36 of each
vial 20 are measured (by infrared temperature sensors) outside of
the second cooling zone 182 prior to full closure. As an optional
step, any dispensing vial 20 not at or below 60.degree. F. can be
rejected if desired. The grippers 176 open and drop the vial 20 at
this stage, before the final close. (See FIGS. 13A-D).
[0066] A closing device 184 then closes the vial lid 48 against the
vial body 22 forming a complete peripheral seal. The dispensing
vials 20 are supported on their bottom surfaces 34. Pneumatic
cylinders 186 move the vials 20 upwardly and compress vial lids 48
against a top plate 188 where compression springs 190 exert an
equal pressure downwardly for a full closure. It is important to
note that the vial lids 48 are closed while the annular sealing
walls 52, 54 and upper lip 36 of the vial body 22 are cool. (See
FIGS. 13A-D, and 14C).
[0067] The transport shuttle 174 then moves to an inspection
station 192 where the closure of vial lid 48 is confirmed. Properly
closed dispensing vials 20 are released into bin (not shown).
Defective dispensing vials 20 are sorted for reprocessing. The
cooled dispensing vials 20 then return to room temperature in a
closed state.
[0068] While there is shown and described herein certain specific
structure embodying the invention, it will be manifest to those
skilled in the art that various modifications and rearrangements of
the parts may be made without departing from the spirit and scope
of the underlying inventive concept and that the same is not
limited to the particular forms herein shown and described except
insofar as indicated by the scope of the appended claims.
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