U.S. patent application number 10/521362 was filed with the patent office on 2006-06-29 for method of inserting a barrier line into a closure.
Invention is credited to Clive Buswell, Reginald Denny.
Application Number | 20060140745 10/521362 |
Document ID | / |
Family ID | 27809296 |
Filed Date | 2006-06-29 |
United States Patent
Application |
20060140745 |
Kind Code |
A1 |
Buswell; Clive ; et
al. |
June 29, 2006 |
Method of inserting a barrier line into a closure
Abstract
The present invention relates to a method and apparatus for
positioning a disc, such as a barrier disc (20), in a closure (40).
In particular, the invention relates to a method and apparatus for
positioning a barrier disc (20) in a self-sealing moulded plastic
closure (40) having a sealing fin arrangement (22) for providing a
seal when the closure (40) is appropriately applied to a finish of
container (30). The method comprises the steps of providing a
barrier disc (20) in a position ready for insertion within the
closure (40); pressing the barrier disc (20) relatively into the
closure (40) such that at least a portion of the disc (20) is
positioned at least adjacent the top panel thereof; and applying a
fluid pressure to the barrier disc (20) such that the entire disc
is forced into a position at least adjacent the top panel. The
apparatus comprises an insertion station for supporting the closure
(40) through the disc positioning process and a tool (50) that is
movable relative to the insertion station to drive the disc (20)
relatively into the closure (40). The tool (50) comprises a plunger
(55) adapted to press the disc (20) into the closure (40) such that
at least a portion of the disc (20) is adjacent the top panel
thereof, and a fluid flow passage through which fluid travels to
apply fluid pressure to the disc (20) and force the entire disc
(20) past the sealing fin (22) and into a position at least
adjacent the top panel.
Inventors: |
Buswell; Clive; (West
Midlands, GB) ; Denny; Reginald; (Worcestershire,
GB) |
Correspondence
Address: |
MCDERMOTT WILL & EMERY LLP
600 13TH STREET, N.W.
WASHINGTON
DC
20005-3096
US
|
Family ID: |
27809296 |
Appl. No.: |
10/521362 |
Filed: |
July 11, 2003 |
PCT Filed: |
July 11, 2003 |
PCT NO: |
PCT/AU03/00906 |
371 Date: |
August 24, 2005 |
Current U.S.
Class: |
413/8 ; 29/525;
29/773; 29/801; 413/58; 413/9 |
Current CPC
Class: |
Y10T 29/49945 20150115;
B29C 2043/3605 20130101; B65D 41/3428 20130101; Y10T 29/53443
20150115; Y10T 29/53322 20150115; B65D 53/04 20130101; B65D 41/045
20130101; B21D 51/46 20130101; B29C 43/18 20130101 |
Class at
Publication: |
413/008 ;
029/525; 029/801; 029/773; 413/009; 413/058 |
International
Class: |
B21D 51/44 20060101
B21D051/44; B21D 51/46 20060101 B21D051/46 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 15, 2002 |
AU |
2002950194 |
Claims
1. A method of forming a closure for application to a container
comprising the steps of: (a) providing a closure having a top panel
and a skirt depending from the top panel; (b) providing a disc in a
position ready for insertion within the closure; and (c) pressing
said disc relatively into said closure such that at least a portion
of said disc is positioned at least adjacent the top panel.
2. A method of forming a closure according to claim 1 wherein the
closure further has an annular sealing fin extending inwardly and
downwardly from an interior of the closure and being integrally
formed with the top panel, the sealing fin being adapted to engage
a rim of a container and be folded into a sealing arrangement with
the rim and at least a side of the finish of the container when the
closure is secured to the container.
3. A method of forming a closure according to claim 2 wherein the
method further comprises the following step: (d) applying a fluid
pressure to the disc such that the entire disc is forced into a
position at least adjacent the top panel.
4. A method of forming a closure according to claim 1 wherein the
disc is a barrier disc.
5. A method of forming a closure for application to a container
comprising the steps of: (a) providing a closure having a top
panel, a skirt depending from the top panel, and an annular sealing
fin extending inwardly and downwardly from an interior of the
closure and being integrally formed with the top panel, the sealing
fin being adapted to engage a rim of a container and be folded into
a sealing arrangement with the rim and at least a side of the
finish of the container when the closure is secured to the
container; (b) providing a disc in a position ready for insertion
within the closure; (c) pressing said disc relatively into said
closure such that at least a portion of said disc is positioned at
least adjacent the top panel; and (d) applying a fluid pressure to
the disc such that the entire disc is forced into a position at
least adjacent the top panel.
6. A method of forming a closure according to claim 5 wherein step
(b) comprises a step of cutting or punching a disc from a sheet or
feedstock of disc material positioned adjacent a closure.
7. A method of forming a closure according to claim 6 wherein a
cutter is used to form a circular disc for pressing into the
closure.
8. A method of forming a closure according to claim 6 wherein the
step of pressing the disc relatively into said closure is performed
concurrently with the cutting or punching step.
9. A method of forming a closure according to claim 7 wherein at
least steps (b) and (c) are performed with the closure in an
insertion station positioned beneath the sheet or feedstock of disc
material, with the disc being moved relatively downwardly into the
closure.
10. A method of forming a closure according to claim 5 wherein the
step of pressing the disc into the closure in step (c) is performed
using a tool having a plunger.
11. A method of forming a closure according to claim 10 wherein the
plunger comprises a cylindrical tube, the tube having a lumen and a
disc abutment surface.
12. A method of forming a closure according to claim 11 wherein a
pin extends through the tube of the plunger and also has an outer
surface and a disc abutment surface.
13. A method of forming a closure according to claim 12 wherein a
fluid flow passage extends through the tool, the passage being
defined by the outer surface of the pin and the lumen of the
plunger.
14. A method of forming a closure according to claim 13 wherein
during step (c), air is drawn relatively through the fluid flow
passage away from the disc to form a region of relatively low
pressure between the disc and the disc abutment surface of the pin
and/or plunger, the region of lower pressure serving to hold the
disc to the tool as it is pressed into the closure.
15. A method of forming a closure according to claim 14 wherein
step (d) comprises forcing air through the fluid flow passage so
as-to force the disc fully into the closure and into abutment with
the underside of the top panel.
16. A method of forming a closure according to claim 15 wherein the
air flow forces the periphery of the disc past the sealing fin that
is extending inwardly and downwardly into the closure.
17. A method of forming a closure according to claim 5 wherein the
disc is a barrier disc.
18. An apparatus for positioning a disc in a closure, wherein the
closure has a top panel, a skirt depending from the top panel, and
an annular sealing fin extending inwardly and downwardly from an
interior of the closure and being integrally formed with the top
panel, the sealing fin being adapted to engage a rim of a container
and be folded into a sealing arrangement with the rim and at least
a side of the finish of the container when the closure is secured
to the container; the apparatus comprising: (a) an insertion
station for supporting a closure for at least a portion of the disc
positioning process; and (b) a tool movable relative to the
insertion station to relatively drive a disc into the closure, the
tool comprising a plunger for relatively pressing said disc into
said closure such that at least a portion of the disc is adjacent
the top panel, and a fluid flow passage through which fluid travels
to apply fluid pressure to the disc and force the entire disc past
the sealing fin and into a position at least adjacent the top
panel.
19. An apparatus according to claim 17 wherein the insertion
station is positioned beneath the tool when the disc is to be
inserted into the closure, the closure being positioned such that
the annular skirt extends upwardly from the top panel.
20. An apparatus according to claim 19 wherein the tool moves
downwardly when forcing the disc into the closure.
21. An apparatus according to claim 18 wherein the tool comprises a
cutter positioned around the plunger for cutting a circular disc
from a sheet or feedstock of disc material positioned adjacent the
closure when the closure is in said insertion station.
22. An apparatus according to claim 21 wherein the tool is operable
such that the cutter and plunger, at least initially, move
together.
23. An apparatus according to claim 18 wherein the plunger is in
the form of a cylindrical tube having a lumen and a disc abutment
surface.
24. An apparatus according to claim 23 wherein a pin extends
through the lumen of the tube of the plunger and has an outer
cylindrical surface and a disc abutment surface.
25. An apparatus according to claim 24 wherein the pin and the
plunger are adapted to move into the closure concurrently.
26. An apparatus according to claim 24 wherein the fluid flow
passage extends through the tool and is defined by the outer
surface of the pin and the lumen of the plunger.
27. An apparatus according to claim 26 wherein the fluid flow
passage comprises a passage for air flow.
28. An apparatus according to claim 27 wherein the apparatus
further comprises an air suction device and an air blower device,
said fluid flow passage being in fluid communication with said air
suction device and said air blower device.
29. An apparatus according to claim 28 wherein the air suction
device and the air blower device comprise the same device.
30. An apparatus according to claim 28 wherein on initial relative
movement of the plunger, air is drawn through the fluid flow
passage by the air suction device so as to hold the disc to the
disc abutment surface as the plunger is firstly inserting the disc
into the closure so bringing at least a portion of the disc into
said position at least adjacent the underside of the top panel.
31. An apparatus according to claim 30 wherein once the disc is in
said position, the air blower device activates to blow air through
the fluid flow passage and so force the disc, and particularly the
periphery thereof, past the sealing fin and into a position between
the top panel and the sealing fin.
32. An apparatus according to claim 18 wherein the disc is a
barrier disc.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a method and apparatus for
forming a closure having a disc or liner, such as a barrier disc.
The closure formed thereby has particular application for sealing
containers for gas-sensitive product, such as oxygen-sensitive
products.
BACKGROUND OF THE INVENTION
[0002] Many products, such as beer and other malt beverage
products, dairy products and real juices, must be packaged in such
way that oxygen cannot migrate into the package before the package
is opened to permit consumption of its contents; otherwise, over
the normal shelf life of the filled package oxygen will degrade the
flavor of its contents. Heretofore, such products, when packaged in
glass containers, or, more recently in plastic bottles, have been
capped with a closure, such as an aluminium roll-on closure or a
molded plastic closure, that is lined with an internal liner that
functions both as a sealing liner and, to a lesser extent, an
oxygen-barrier liner. U.S. Pat. No. 4,721,221 (Barriac), the
disclosure of which is incorporated by reference herein, discloses
a molded plastic closure with a sealing liner, this reference
teaching a top seal only liner for non-pressurized beverage
products and a top and side seal liner for pressurized beverage
products. In either case, the liner must sealingly engage the rim
of the associated container, either on its top or both on its top
and side, to properly seal the filled and capped container.
[0003] In recent years, there has been a concerted effort to
eliminate the need for inserting a sealing liner in a molded
plastic closure to eliminate the expense relating thereto. To that
end, self-sealing molded plastic closures have been developed, and
U.S. Pat. Nos. 5,638,972 (Druitt) and 5,836,464 (Druitt),
disclosure of each of which is also incorporated by reference
herein, teach unlined, molded plastic closures of a general type
that has proven to be quite successful in the packaging of
carbonated soft drink products, which, though somewhat less
sensitive to the migration of CO.sub.2 out of the product, are not
particularly sensitive to the migration of oxygen into the packaged
product. However, such closures, as heretofore used in the
packaging of carbonated soft drinks, are not sufficiently
oxygen-impermeable to permit their use in the packaging of beer and
other malt beverage products, and other oxygen-sensitive products,
when such products must undergo a normal shelf life between
packaging and opening for consumption.
[0004] One example of a self-sealing closure that also has a
barrier disc that underlies the top panel of the closure is
described in U.S. Application No. 20030057175 (Willingham and
Druitt), the disclosure of which is also incorporated by reference
herein.
[0005] A potential problem with the use of barrier discs in
closures is the necessity of achieving highly reliable positioning
of the disc within the closure, particularly, in a relatively
high-speed closure manufacturing process. This problem is
potentially compounded in situations where the barrier disc is to
be placed in unlined closures having other moulded structures
therein adapted to provide sealing of the container on application
of the closure.
[0006] The present invention is directed to a method and apparatus
for positioning a disc, such as a barrier disc, into a closure
otherwise suitable for sealing a container, in particular, a
container for a pressurised product.
[0007] Any discussion of documents, acts, materials, devices,
articles or the like which has been included in the present
specification is solely for the purpose of providing a context for
the present invention. It is not to be taken as an admission that
any or all of these matters form part of the prior art base or were
common general knowledge in the field relevant to the present
invention as it existed before the priority date of each claim of
this application.
SUMMARY OF THE INVENTION
[0008] Throughout this specification the word "comprise", or
variations such as "comprises" or "comprising", will be understood
to imply the inclusion of a stated element, integer or step, or
group of elements, integers or steps, but not the exclusion of any
other element, integer or step, or group of elements, integers or
steps.
[0009] The present invention relates to a method and apparatus for
positioning a disc, such as a barrier disc, in a closure. In
particular, the invention relates to a method and apparatus for
positioning a disc in a self-sealing moulded plastic closure having
a sealing fin arrangement for providing a seal when the closure is
appropriately applied to a finish of a container.
[0010] According to a first aspect, the present application is
directed to a first invention comprising a method of forming a
closure for application to a container comprising the steps of:
[0011] (a) providing a closure having a top panel and a skirt
depending from the top panel;
[0012] (b) providing a disc in a position ready for insertion
within the closure; and
[0013] (c) pressing said disc relatively into said closure such
that at least a portion of said disc is positioned at least
adjacent the top panel.
[0014] In this aspect, the closure can further have an annular
sealing fin extending inwardly and downwardly from an interior of
the closure and being integrally formed with the top panel, the
sealing fin being adapted to engage a rim of a container and be
folded into a sealing arrangement with the rim and at least a side
of the finish of the container when the closure is secured to the
container. The method can also further comprise the following
step:
[0015] (d) applying a fluid pressure to the disc such that the
entire disc is forced into a position at least adjacent the top
panel.
[0016] According to a second aspect, the present application is
directed to a second invention comprising a method of forming a
closure for application to a container comprising the steps of:
[0017] (a) providing a closure having a top panel, a skirt
depending from the top panel, and an annular sealing fin extending
inwardly and downwardly from an interior of the closure and being
integrally formed with the top panel, the sealing fin being adapted
to engage a rim of a container and be folded into a sealing
arrangement with the rim and at least a side of the finish of the
container when the closure is secured to the container;
[0018] (b) providing a disc in a position ready for insertion
within the closure;
[0019] (c) pressing said disc relatively into said closure such
that at least a portion of said disc is positioned at least
adjacent the top panel; and
[0020] (d) applying a fluid pressure to the disc such that the
entire disc is forced into a position at least adjacent the top
panel.
[0021] In one embodiment of the above aspects, step (b) can
comprise a step of cutting or punching a disc from a sheet or
feedstock of disc material. The step of cutting or punching the
disc can occur while the sheet or feedstock is positioned adjacent
a closure. A cutter, such as an annular or circular cutter, is
preferably used to form a circular disc for pressing into the
closure. The step of pressing the disc relatively into said closure
can be performed at least essentially concurrently with the cutting
or punching step. In another embodiment, pre-cut discs can be
utilised and positioned ready for insertion into the closure in
step (c).
[0022] In a further embodiment of the above aspects, at least steps
(b) and (c) are performed with the closure in an insertion station
positioned beneath the sheet or feedstock of disc material, or the
pre-cut disc, with the disc being moved relatively downwardly into
the closure in the process. In another embodiment, the insertion
station can be positioned above the sheet or feedstock of disc
material, or the pre-cut disc, with the disc being moved relatively
upwardly into the closure in the process. In a still further
embodiment, the insertion station can be positioned beside the
sheet or feedstock of disc material, or the pre-cut disc, with the
disc being moved sidewardly into the closure in the process.
[0023] The step of pressing the disc into the closure in step (c)
is preferably performed using a tool having a plunger. The plunger
is preferably adapted to move, preferably relatively downwardly, in
operation and has a disc abutment surface.
[0024] The plunger can be in the form of a cylindrical tube having
an outer and an inner surface and an annular disc abutment surface,
the inner surface defining a lumen. In one embodiment, a pin can
extend through the lumen of the plunger and also has an outer
surface and a disc abutment surface. The outer surface of the pin
is preferably also cylindrical. In another embodiment, the lumen
can act as a fluid flow passage as defined below.
[0025] Where the pin extends through the lumen, the construction of
the tool is preferably such that fluid flow can occur through the
tool between the outer surface of the pin and the inner surface of
the plunger. In one embodiment, air flow can occur between these
two surfaces. Where no pin is present, fluid flow can occur through
the lumen of the plunger.
[0026] During step (c), fluid, preferably air, can preferably be
drawn through the tool. Where the pin is present, fluid can be
drawn between the pin and plunger so as to form a region of
relatively low pressure between the disc and the disc abutment
surface of the pin and/or plunger. Where no pin is present, fluid
can be drawn through the lumen to form a region of relatively low
pressure between the disc and the disc abutment surface. In one
embodiment, air is drawn relatively upwardly through the tool. This
region of lower pressure serves to hold the disc to the tool as it
is pressed into the closure by the plunger.
[0027] Once at least a portion of the disc, for example a central
portion, is positioned close to or adjacent the top panel within
the closure, the fluid flow through the tool can stop. This can
then be followed by a flow of air or other fluid being forced
through the tool in an opposite direction to that hitherto. Where
the air flow direction had been relatively upwardly, the air flow
can now move through the tool relatively downwardly. This fluid
flow is directed against the disc and preferably serves to force
the disc fully into the closure and into abutment with the
underside of the top panel. In particular, the fluid flow
preferably serves to force the periphery of the disc past the
sealing fin that is extending inwardly and downwardly into the
closure. Where the pin is present in the plunger, the fluid flow
can be between the pin and the plunger. Where no pin is present,
the fluid flow can be through the lumen of the plunger.
[0028] Either after, during or prior to the provision of fluid flow
to force the disc into the closure, the plunger, and the pin where
present, can be withdrawn, the direction of withdrawal being again
preferably relatively upwardly.
[0029] According to a third aspect, the present application is
directed to a third invention comprising an apparatus for
positioning a disc in a closure, wherein the closure has a top
panel and a skirt depending from the top panel, the apparatus
comprising:
[0030] (a) an insertion station for supporting a closure for at
least a portion of the disc positioning process; and
[0031] (b) a tool movable relative to the insertion station to
drive a disc into the closure, the tool comprising a plunger
adapted to press said disc into said closure such that at least a
portion of the disc is adjacent the top panel.
[0032] In this aspect, the closure can have an annular sealing fin
extending inwardly and downwardly from an interior of the closure
and being integrally formed with the top panel, the sealing fin
being adapted to engage a rim of a container and be folded into a
sealing arrangement with the rim and at least a side of the finish
of the container when the closure is secured to the container. When
used with such a closure, the apparatus can further have a fluid
flow passage through which fluid travels to apply fluid pressure to
the disc and force the entire disc past the sealing fin and into a
position at least adjacent the top panel.
[0033] According to a fourth aspect, the present application is
directed to a fourth invention comprising an apparatus for
positioning a disc in a closure, wherein the closure has a top
panel, a skirt depending from the top panel, and an annular sealing
fin extending inwardly and downwardly from an interior of the
closure and being integrally formed with the top panel, the sealing
fin being adapted to engage a rim of a container and be folded into
a sealing -arrangement with the rim and at least a side of the
finish of the container when the closure is secured to the
container, the apparatus comprising:
[0034] (a) an insertion station for supporting a closure for at
least a portion of the disc positioning process; and
[0035] (b) a tool movable relative to the insertion station to
relatively drive a disc into the closure, the tool comprising a
plunger for relatively pressing said disc into said closure such
that at least a portion of the disc is adjacent the top panel, and
a fluid flow passage through which fluid travels to apply fluid
pressure to the disc and force the entire disc past the sealing fin
and into a position at least adjacent the top panel.
[0036] In a preferred embodiment of the third and fourth aspects,
the closure is preferably positioned within the insertion station
beneath the tool. In this embodiment, the tool preferably moves
relatively downwardly in operation, with the tool forcing the disc
into the closure. In this case, it will be understood that the
closure is positioned such that the annular skirt extends upwardly
from its top panel.
[0037] In an embodiment of the third and fourth aspects, the tool
can further comprise a cutter for cutting a disc from a sheet or
feedstock of disc material positioned adjacent the closure when the
closure is in its insertion station. The cutter is preferably able
to cut a circular disc from the sheet or feedstock of disc
material. The cutter can be annular in form.
[0038] The cutter is preferably positioned so as to cut the sheet
or feedstock material immediately outwardly of a disc abutment
surface of the plunger. In a preferred embodiment, the tool is
operable such that the cutter and plunger at least initially move,
preferably downwardly, together. As such, the disc is preferably
immediately moved downwardly by the plunger on the cutter passing
through the sheet or feedstock.
[0039] The tool is further adapted such that a stop is provided to
prevent further travel of the cutter once it has passed through the
sheet or feedstock material. In one embodiment, the cutter
preferably moves upwardly at the end of its down stroke ready for
the next cycle.
[0040] In one embodiment of the third and fourth aspects, the
plunger is in the form of a cylindrical tube having an inner and
outer surface and the disc abutment surface, the inner surface
defining a lumen. In one embodiment, a pin can extend through the
lumen of the tube of the plunger and also preferably has an outer
cylindrical surface and a disc abutment surface. The pin and the
plunger are preferably adapted to move into the closure in concert.
Once the disc has been inserted into the closure, the pin and
plunger also preferably move together relatively out of the
closure. Despite this, it will be appreciated that the pin and
plunger could move separately within the tool if required.
[0041] In another embodiment, the tool can be provided without a
pin in the lumen of the plunger, the lumen providing a fluid flow
passage as described below.
[0042] Where the pin extends through the lumen, the construction of
the tool in the third and fourth aspects is preferably such, that
the fluid flow passage is provided between the outer surface of the
pin and the surface of the lumen of the tubular plunger. In this
embodiment, the fluid flow passage is preferably annular in form.
Where no pin is present, fluid flow can occur through the lumen of
the plunger.
[0043] The fluid flow passage preferably comprises a passage for
air flow. The apparatus further preferably comprises an air suction
device and/or an air blower device. The fluid flow passage is
preferably in fluid communication with the air suction device and
the air blower device. In one embodiment, the air suction device
and air blower devices can be separate items. In another
embodiment, the air suction device and the air blower device can
comprise the same device. Where the air suction device and air
blower device are different devices, the apparatus can further
comprise a valve for switching the passage from being in fluid
communication with the suction device to being in fluid
communication with the air blower device and vice versa In one
embodiment, a compressor can be used to provide air flow through
the tool.
[0044] On initial relative movement of the plunger, the fluid flow
passage is preferably in fluid communication with the suction
device. This serves to hold the disc to the disc abutment surface
as the plunger is firstly inserting the disc into the closure so
bringing at least a portion, such as a central portion, of the disc
into a position at least adjacent the underside of the top
panel.
[0045] Once in this position, the suction device can be
de-activated and the air blower device can be activated to blow air
through the fluid flow passage. Alternatively, the valve can be
activated and so disconnect the passage from the suction device and
bring the passage into fluid engagement with the blower device.
This air flow preferably serves to force the disc, and particularly
the periphery thereof past the sealing fin and into a position
between the top panel and the sealing fin.
[0046] The apparatus can be adapted to be manually operated as
required. For example, the plunger and cutter, and pin if present,
can be mounted to a handle to allow manual control of the operation
of these components of the tool. In another embodiment, the
apparatus can be adapted to operate semi-automatically or
automatically while ever suitable closures are fed to the insertion
station. In one embodiment, the apparatus can have a control system
that senses when no closure is present in the insertion station and
so prevents operation of the apparatus. The control system can also
preferably sense when no sheet or feedstock material for the disc
is present for feeding into the apparatus and so prevents operation
of the apparatus.
[0047] In one embodiment of the above aspects, the sealing fin of
the closure can comprise an inner or root portion that extends
downwardly from an underside of the top panel of the closure. In
one embodiment, the inner or root portion can, for at least a
portion of its length, be also integral with the skirt of the
closure. In another embodiment, the inner or root portion can be
positioned radially inwardly from the skirt portion. In this
embodiment, the inner or root portion preferably has an inner
surface substantially parallel to the skirt of the closure.
[0048] Still further, the sealing fin preferably has a second
portion that tapers inwardly and downwardly from the inner or root
portion and defines an opening smaller than the diameter of the
disc. Due to the flexibility of the sealing fin and the fluid
pressure exerted on the disc, the disc is able to move past the
sealing fin and remain in place between the underside of the top
panel and the sealing fin until the closure is applied to the
container. On securing of the closure to the container, the second
portion is preferably engaged by the rim of the container and
folded back towards the inner surface of the inner or root portion
to form a seal between with the rim and at least a side of the
finish of the container. When the closure is applied to the
container, an effective top and side seal is provided between the
closure and the finish of the container. The step of securing the
closure to the container also preferably serves to trap the disc
between the upwardly facing surface of the second portion of the
sealing fin and the underside of the top panel. In this
arrangement, the disc is preferably out of contact with all
portions of the container and does not participate in forming a
seal between the closure and the container.
[0049] In a still further embodiment of the above aspects, the disc
is moulded or fabricated from a polymeric material. In one
embodiment, the disc can be a barrier disc with the disc formed
from a polymeric material that preferably has gas barrier
properties. In one embodiment, the polymeric material can be
selected from the group comprising ethylene vinyl alcohol (EVOH)
and a liquid crystal polymer polyester material (LCP). In a further
embodiment, the polymeric material can include an oxygen-scavenging
material embedded therein.
[0050] In yet another embodiment, the closure is moulded in a
single piece. The closure can be moulded from a polymeric material.
The polymeric material can be selected from a group comprising high
density polyethylene, low density polyethylene, polypropylene, and
co-polymers of polyethylene and polypropylene.
[0051] In a still further embodiment, the inner surface of the
skirt of the closure can have an inwardly projecting and helically
extending continuous or interrupted thread complementary to a
thread on the finish of the container.
[0052] In yet another embodiment, the lower, free end of the skirt
can be provided with a tamper-indicating band for engagement with a
bead or other projection on the finish of a container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] By way of example only, a preferred embodiment of the
invention is now described with reference to the accompanying
drawings, in which:
[0054] FIGS. 1a-1f depict the steps of one embodiment of the
process for inserting a disc or liner in one embodiment of a
closure according to the present invention;
[0055] FIG. 2 is a plan view of another embodiment of a closure
having a liner or disc inserted using the process depicted in FIGS.
1a-1f;
[0056] FIG. 3 is a sectional view taken along line 3-3 of FIG.
2;
[0057] FIG. 4 is a fragmentary view, showing in cross-section, the
closure of FIGS. 2 and 3 applied to a finish of a container;
and
[0058] FIG. 5 is a cross-sectional view of a portion of another
embodiment of an apparatus according to the present invention.
PREFERRED MODE OF CARRYING OUT THE INVENTION
[0059] The steps of a method and portions of a tool for inserting a
disc or liner, such as a barrier disc, within a closure are
depicted in FIGS. 1a-1e. One embodiment of a closure having a disc
inserted therein is depicted generally as 40 in the drawings.
[0060] Closure 40 has been moulded prior to the liner insertion
process depicted in FIGS. 1a-1e and delivered to a position
adjacent and relatively below the insertion tool 50. While not
depicted in FIGS. 1a-1e, it will be appreciated that the closure
would be supported in an insertion station in the position depicted
in these Figures to ensure appropriate alignment of the closure 40
with the tool 50. In this regard, FIG. 5 depicts an alternative
apparatus, generally depicted as 70, having an insertion station 71
having a chamber 73 for receiving a closure. The insertion station
71 could equally be used in conjunction with the insertion tool 51
depicted in FIGS. 1a-1e.
[0061] As depicted by FIG. 1a, on delivery of the closure 40 to the
insertion location below the tool 50, a sheet of disc material 51,
in this case barrier disc material, has been loaded so as to be
passed through the tool 50. During the process steps depicted by
FIGS. 1a-1e, the sheet 51 is stationary. However, it will be
appreciated that when the tool reverts to the position depicted in
FIG. 1a, the sheet 51 can be advanced through the tool 50 using a
drive so that a fresh disc can be cut therefrom. While not
depicted, the film could be advanced by drive wheels or belts as
known in the art.
[0062] While the tool 50 is depicted as being adapted to cut discs
from the sheet 51 of barrier material as part of the insertion
process, it will be appreciated that the tool 50 could be modified
such that pre-cut discs were delivered to the tool 50 ready for
insertion using the process steps as described herein.
[0063] The depicted tool 50 has a disc cutter 52 for cutting a disc
from the sheet 51 of disc material during the insertion process.
The cutter 52 is shaped to cut a circular disc 20 from the sheet 51
having a diameter suitable to allow the disc 20 to be positioned
within the closure 40 as is described in more detail below.
[0064] The cutter 52 is positioned so as to cut the sheet 51
immediately radially outwardly of a lower disc abutment surface 54
of a plunger 55. As depicted in FIG. 1b, the tool 50 is operable
such that the cutter 52 and plunger 55 at least initially move
downwardly together. As such, the disc 20 is immediately moved
downwardly by the plunger 55 on the cutter 52 passing through the
barrier sheet 51. When the cutter 52 and plunger 55 reach the
position depicted in FIG. 1b, a stop (not visible) prevents further
downward travel of the cutter 52. While the cutter remains depicted
at the lower end of its range of travel in FIGS. 1b-1e, it will be
appreciated that the cutter 52 will eventually revert to its start
position depicted in FIG. 1a. This could happen prior to the return
of the plunger 55 to its start position or concurrently
therewith.
[0065] The plunger 55 is in the form of a cylindrical tube having
an inner surface 56 and an outer surface 57. In FIGS. 1a-1e, the
tool 50 further comprises a central pin 58 that extends through the
lumen of the tube of the plunger 55 and also has an outer
cylindrical surface 59 and a lower disc abutment surface 61. The
pin 58 and the plunger 55, as depicted in FIGS. 1b-1e, are adapted
to move downwardly into the closure 40 in concern. Once the disc 20
has been inserted into the closure, the pin 58 and plunger 55 also
move relatively upwardly out of the closure 40. Despite this, it
will be appreciated that the pin 58 and plunger 55 could move
separately within the tool 50 if required.
[0066] As depicted in FIGS. 1c and 1d, the plunger 52 firstly
presses the disc 20 into the closure 40 such that at least a
central portion of the disc 20 is adjacent the underside of the top
panel of the closure 40.
[0067] To prevent the disc 20 falling off the end of the plunger 55
during the insertion steps depicted in FIGS. 1c and 1d, suction is
provided to form a region of relatively low pressure at the disc
abutment surface 54 that is sufficient to hold the disc 20
thereto.
[0068] To provide the suction, the tool 50 has an annular air flow
passage passing at least partially therethrough between the outer
surface 59 of the pin 58 and the surface 56 of the lumen of the
tubular plunger 55. As depicted in the drawings, the air flow
passage is provided by providing the pin 58 within an outer
diameter that is just relatively smaller than the diameter of the
plunger 55. It has been determined by the present inventors that a
relatively small passage width is sufficient to provide the
necessary degree of suction to the disc 20 as it is inserted into
the closure during the steps depicted in FIGS. 1c and 1d. This
small passage width can be provided by simply ensuring that the pin
58 is able to slide relatively freely within the lumen of the
plunger 55.
[0069] Before completing the description of tool 50, it is
appropriate to review an alternative construction for the plunger
depicted in FIG. 5. In this case, the tool 70 also has a cutter 72
and a plunger 75. In this embodiment, no pin is provided in the
lumen 76 of the plunger and instead, the lumen 76 itself acts as a
fluid flow passage through the tool. Here, the sheet or feedstock
51 of disc material is fed through a slot 74 in the receiving
station 71 and is thus appropriately positioned relative to the
closure when the closure is present in the chamber 73.
[0070] Returning to the embodiment depicted in FIG. 1d, because of
the presence of the sealing fin 22 and the diameter of the disc 20,
the periphery 20a of the disc 20 is unable to be fully pressed into
the closure 40 by plunger 55. To force the periphery 20a of the
disc 20 past the sealing fin 22, the air flow through the passage
is changed when the plunger 55 has reached the position depicted in
FIG. 1d. In this regard, the direction of air flow is changed from
travelling in direction A depicted in FIG. 1e to direction B
depicted in FIG. 1e. The application of air pressure to the disc 20
results in the periphery 20a of the disc moving past the sealing
fin 22 with the result that the entire disc 20 is held in the
closure 40 between the sealing fin 22 and the underside of the top
panel.
[0071] While not depicted, it will be appreciated that an air
suction/air blower device could be used in fluid communication with
the passage to provide the airflow as described above. A compressor
could also be utilised in combination with the apparatus.
[0072] Either after, during or just prior to the provision of air
flow to force at least the periphery 20a of the disc 20 past the
sealing fin 22 into the closure 40, the plunger 55 and the pin 58
can be withdrawn relatively upwardly.
[0073] Another depiction of a closure that can have a liner or disc
inserted using the apparatus and method defined herein is provided
by FIGS. 2-4. These drawings serve to highlight the features of the
closure formed using the apparatus and method of the present
invention.
[0074] The closure assembly 40 is made up of a generally cup-shaped
closure element 12, which is made up of an imperforate top panel 14
with an annular skirt 16 depending downwardly from an edge of the
top panel 14. The closure assembly 40 also includes, as a separate
element, a disc-shaped liner 20 that underlies the underside or
inwardly facing side of the top panel 14. In this case, the liner
20 of closure 40 is placed in the closure using the method and
apparatus described in association with FIGS. 1a-1e.
[0075] The closure element 12, which also has an inwardly
projecting helical thread 18 for application to a glass or plastic
bottle with an externally projecting helical thread on its neck or
finish, is produced by injection or compression moulding from a
suitable thermoplastic material, for example, high density
polyethylene, polypropylene, low density polyethylene, or
copolymers of polyethylene and polypropylene. Unfortunately, such
materials have relatively low resistance to the permeation of gases
therethrough, either oxygen from the atmosphere into the package or
CO.sub.2 or N.sub.2 from the interior of the package to which the
closure assembly is applied to its exterior. This problem is
overcome by inserting a disc-shaped barrier liner 20 having barrier
properties into the closure element 12.
[0076] The depicted liner 20 is molded or fabricated from a
material that has excellent resistance to the passage of gases
therethrough, for example, EVOH (ethylene vinyl alcohol) or LCP
(liquid crystal polymer), and these materials are especially
resistant to the migration of oxygen therethrough. Resistance to
the migration of oxygen into a container filled with an
oxygen-sensitive product, such as beer or anther malt beverage
product, is especially important because of the propensity of
oxygen to degrade the flavor of such a packaged product, and this
factor may be enhanced by embedding oxygen-scavenging materials
into the material from which the liner 20 is molded or fabricated.
In any case, such liner materials, with or without an oxygen
scavenger, also inhibit the outflow of CO.sub.2 from a container
filled with carbonated soft drinks, and the outflow of N.sub.2 from
plastic containers filled with still drinks, such as sports drinks,
which are often pressurized with N.sub.2 to rigidify an otherwise
flexible container during shipment and handling. Further, a thin
layer of a moisture barrier material, may, desirably, be provided
over an inwardly-facing surface of the liner 20 when it is formed
of a moisture-sensitive material, such as EVOH, and such covering
layer may also have an oxygen-scavenging material embedded
therein.
[0077] In the case of a closure assembly 40 intended for the
packaging of a pressurized beverage, it is contemplated that the
helical thread 18, which is shown as being continuous between its
ends, may also be interrupted at various locations along its
length, for example, in accordance with the teachings of U.S. Pat.
No. 5,782,369 (Tansey), the disclosure of which is also
incorporated by reference herein. In this case, it may also be
preferred to provide a complementary formed helical rib on a
container with an interrupted thread.
[0078] The closure element 12 has an integrally-molded sealing rib
22 that is molded concentrically with the annular skirt 16. The
sealing rib 22 has an inner or root portion 24 that extends
downwardly from the underside of the top panel 14 of the closure
element 12 approximately parallel to the annular skirt 16, and a
second portion 26 that extends downwardly from a distal end of the
inner portion 24. The second portion 26 tapers inwardly and
downwardly from the inner portion 24 and has a distal end that
defines an opening that is smaller than the diameter of the liner
20. Thus, due to the flexibility of the sealing rib 22, it is
possible to insert the liner 20 into the closure element 12 to the
position depicted in FIG. 3, and the liner 20 will then remain in
place until the closure assembly 40 is applied to a finish of a
container 30, a fragment of which is depicted in FIG. 4.
[0079] In the application of the closure assembly 40 to the finish
of the container 30, a rim or an annular surface 32 of the
container 30 engages a free or distal end of the second portion 26
of the sealing rib 22 and forces it back towards the inner portion
24 of the sealing rib 22. Thus, an outer portion of the second
portion 26 of the sealing rib 22 will form a pressure seal against
the rim 32 of the container 30, and an inner portion of the second
portion 26 of the sealing rib 22 will form a pressure seal against
a terminal side portion 34 of the finish of the container 30. As a
result, when the closure assembly 40 is applied to a container 30,
there will be an effective top and side seal between the liner 20
of the closure assembly 40 and the container 30, and such a top and
side seal is considered to be required for proper sealing of a
pressurized container. The step of applying the closure assembly 40
to the container 30 will also trap the liner 20 between an upwardly
facing surface of the outer portion 26, of the sealing rib 22 and
an inwardly facing surface of the top panel 14 of the closure
element 12. In this position, the liner 20 will be out of contact
with all portions of the container 30, and will not participate in
forming a seal between the closure assembly 40 and the container
30.
[0080] While not specifically shown in FIGS. 2-4, the lower, free
end of the skirt 16 of the closure element 12 in this embodiment
may also be provided with a tamper-indicating band for engagement
with a bead or other projection on the finish of a container, as
taught, for example, by the aforesaid U.S. Pat. Nos. 5,782,369 and
4,721,221. FIG. 1f does depict closure 40 having one type of
tamper-evident band 41 that can be moulded with the closure.
[0081] The present invention provides an apparatus and method for
inserting a liner within a moulded closure.
[0082] It will be appreciated by persons skilled in the art that
numerous variations and/or modifications may be made to the
invention as shown in the specific embodiments without departing
from the spirit or scope of the invention as broadly described. The
present embodiments are, therefore, to be considered in all
respects as illustrative and not restrictive.
* * * * *