U.S. patent application number 17/370127 was filed with the patent office on 2021-10-28 for methods and systems for forming vacuum insulated containers.
The applicant listed for this patent is THERMOS (CHINA) HOUSEWARES CO., LTD., THERMOS L.L.C.. Invention is credited to Tinghong Chen, Marvin Lane, Ronald K.Y. Mak, Jun Zhou.
Application Number | 20210330126 17/370127 |
Document ID | / |
Family ID | 1000005705435 |
Filed Date | 2021-10-28 |
United States Patent
Application |
20210330126 |
Kind Code |
A1 |
Mak; Ronald K.Y. ; et
al. |
October 28, 2021 |
METHODS AND SYSTEMS FOR FORMING VACUUM INSULATED CONTAINERS
Abstract
Methods and systems for forming vacuum insulated containers,
such as beverage and food containers, are described. The methods
and systems include using a laser to close openings in walls of the
container while the container is held at vacuum conditions. The
closing of the opening forms the vacuum space within the walls of
the container.
Inventors: |
Mak; Ronald K.Y.; (Shanghai,
CN) ; Chen; Tinghong; (HuaiAn, CN) ; Zhou;
Jun; (HuaiAn, CN) ; Lane; Marvin; (Brandon,
MS) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
THERMOS L.L.C.
THERMOS (CHINA) HOUSEWARES CO., LTD. |
Schaumburg |
IL |
US |
|
|
Family ID: |
1000005705435 |
Appl. No.: |
17/370127 |
Filed: |
July 8, 2021 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15881992 |
Jan 29, 2018 |
11071411 |
|
|
17370127 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B23K 2101/12 20180801;
B23K 26/10 20130101; B23K 26/282 20151001; A47J 41/02 20130101;
B23Q 3/00 20130101 |
International
Class: |
A47J 41/02 20060101
A47J041/02; B23K 26/10 20060101 B23K026/10; B23Q 3/00 20060101
B23Q003/00; B23K 26/282 20060101 B23K026/282 |
Claims
1. A vacuum insulated container, comprising: an inner shell; an
outer shell; an intershell space between the inner shell and the
outer shell; a portion of the outer shell forms a side of the
container; a bottom portion generally opposite of an upper portion;
one or more openings in the portion of the outer shell forming the
side of the container; and, one or more welds sealing the one or
more openings to form a vacuum in the intershell space.
2. The vacuum insulated container according to claim 1, wherein a
bottom shell covers the one or more welds and forms the bottom
portion of the container.
3. The vacuum insulated container according to claim 1, wherein the
container has a two-piece construction of only the inner shell and
the outer shell.
4. The vacuum insulated container according to claim 1, wherein the
inner shell forms an interior of the container configured to hold a
beverage or a food item.
5. The vacuum insulated container according to claim 1, wherein the
container has a four-piece construction, and the container further
comprises an inner bottom shell and an outer bottom shell.
6. The vacuum insulated container according to claim 1, wherein the
one or more openings correspond with a design element of the
container.
7. The vacuum insulated container according to claim 1, wherein the
side of the container is curved, and the one or more openings are
in the curved side of the container.
8. A vacuum insulated container, comprising: an inner shell; an
outer shell; an intershell space between the inner shell and the
outer shell; the inner shell forms an interior of the container
configured to hold a beverage or a food item; the outer shell forms
an exterior of the container; one or more openings along an edge of
the container; and, one or more welds sealing the one or more
openings to form a vacuum in the intershell space.
9. The vacuum insulated container according to claim 8, wherein the
edge of the container is between a side and a bottom portion of the
container.
10. The vacuum insulated container according to claim 9, wherein a
bottom shell covers the one or more welds.
11. The vacuum insulated container according to claim 8, wherein
the edge of the container is an inside edge of the container.
12. The vacuum insulated container according to claim 8, wherein
the edge of the container is an outside edge of the container.
13. The vacuum insulated container according to claim 8, wherein
the edge of the container is curved.
14. The vacuum insulated container according to claim 8, wherein
the edge is part of the outer shell.
15. A method for forming a vacuum insulated container, comprising:
joining an inner shell and an outer shell together to form a
container, wherein a portion of the outer shell forms an outer side
wall of the container; forming an intershell space between the
inner shell and the outer shell; cutting one or more openings in
the portion of the outer shell forming the outer side wall of the
container; applying a vacuum to the container; directing a laser
beam at the one or more openings; sealing the one or more openings;
and, sealing the vacuum in the intershell space.
16. The method for forming a vacuum insulated container according
to claim 15, further comprising cutting the one or more openings in
the portion of the outer shell forming the outer side wall of the
container wall after the joining of the inner shell and the outer
shell together to form the container.
17. The method for forming a vacuum insulated container according
to claim 15, further comprising cutting the one or more openings in
the portion of the outer shell forming the outer side wall of the
container wall along an edge of the container.
18. The method for forming a vacuum insulated container according
to claim 15, further comprising joining a bottom shell to the
container and covering the one or more openings that were
sealed.
19. The method for forming a vacuum insulated container according
to claim 15, further comprising sealing the one or more openings by
welding the one or more openings.
20. The method for forming a vacuum insulated container according
to claim 15, further comprising sealing the one or more openings
without using solder.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/881,992 filed Jan. 29, 2018, which is
hereby incorporated by reference.
FIELD OF INVENTION
[0002] The present invention relates to methods and systems for
forming vacuum insulated containers, such as beverage and food
containers.
BACKGROUND
[0003] Vacuum insulated beverage and food containers generally have
a vacuum space defined by inner and outer shells of the container.
The vacuum space provides thermal insulation to the container.
Existing methods of forming such containers typically use a solder
material to seal the vacuum space between the inner shell and the
outer shell. The solder material may include a glass material that
will melt and adhere to the outer shell.
[0004] During production of vacuum insulated beverage and food
containers using such existing methods, a dimple or other
depression is usually formed in a bottom surface of the outer shell
or a bottom shell of the container. An opening through the outer
shell is then formed in the dimple. The solder material is placed
over the opening. The container (with the solder material over the
opening) is then placed in a vacuum oven, where ambient pressure
around the container is lowered and a temperature in the vacuum
oven is raised. The vacuum oven creates a vacuum state in and
around the unfinished container. When the temperature in the oven
rises to or above a melting point of the solder material, the
solder material melts and flows about the opening in the dimple to
close the opening. The melted solder seals the opening and the
vacuum within the space between the inner shell and the outer
shell--namely, the intershell space. The temperature in the oven is
reduced, and the melted solder cools and hardens over the opening.
As the intershell space is now sealed within the container by the
solder material, the container may now be removed from the vacuum
oven for further finishing.
[0005] The existing methods use much energy to provide the heat
needed to melt the solder material. Further, the existing method is
slow--as much time is needed for the oven to heat and for the oven
to cool. Further, the existing methods generally require a flat
surface on the container that is held parallel to a horizontal
plane during the vacuum forming process in order for the melted
solder material to fill the opening in the dimple. It is difficult
to seal an opening in a vertically oriented surface of the
container, since the solder material is likely to fall or drip off
of the container. In addition, in existing methods, it is difficult
to seal a curved or otherwise non-linear surface. Further, in the
existing methods, additional cap structures are often used for
aesthetic purposes to cover or hide the dimple and the hardened
solder material. Further, in the existing methods, the physical
structure of the dimple passing inward from the outer shell toward
the inner shell requires extra space between the outer shell and
the inner shell in order to maintain integrity of the vacuum
space--this extra space for the vacuum space may limit or decrease
an overall size of the container.
SUMMARY
[0006] Certain embodiments of methods and systems for forming
vacuum insulated containers are shown and described. The methods
and systems use a laser to seal or weld closed an opening to an
intershell space of the container while the container is maintained
in a vacuum environment. The vacuum environment may be formed in a
container holding element, which is sized and shaped to enclose
part of the container or all of the container. The container
holding element may be made from a material sufficient to maintain
a vacuum within its interior. Examples of a container holding
element include a vacuum chamber, vacuum fixture, or any other unit
configured for this purpose.
[0007] In one aspect, the method includes joining an inner shell
and an outer shell together to form an unfinished container. The
method includes creating one or more openings in the outer shell of
the unfinished container. The method includes placing the
unfinished container in a container holding element and drawing a
vacuum throughout the inside of the container holding element and
around or about the unfinished container. The method includes
lowering pressure around the unfinished container. The method
includes passing a laser through a window of the container holding
element and welding closed the one or more openings to seal the
vacuum in a vacuum space between the inner shell and the outer
shell of the container. In any step, welding may be replaced by any
other method known in the art configured to close an opening of the
container, depending on the material from which the container is
made.
[0008] The vacuum space has a low pressure and is formed in between
the inner and outer shells. The vacuum space provides insulation
for the container. During the process, the whole unfinished
container may be placed inside of the container holding element.
The unfinished container may be completely enclosed or partially
enclosed by the container holding element.
[0009] In another aspect, the method includes welding inner shells
and outer shells together to form unfinished containers with a
vacuum space between the inner shell and the outer shell. The
method includes creating one or more openings in the outer shell
with a laser, with the openings connecting to the vacuum space. The
method includes placing the unfinished containers in a container
holding element, without adding additional heat, and drawing a
vacuum around the unfinished containers. The method includes
lowering pressure around the unfinished containers to a desired
level. The method includes pulling a vacuum through the one or more
openings. The method includes passing a laser through a window of
the container holding element and welding closed the one or more
openings to seal the vacuum in the chamber between the inner shell
and the outer shell to form a vacuum space between the inner and
the outer shells. As the methods form the vacuum space at ambient
or room temperatures, energy savings may be achieved.
[0010] In another aspect, a stainless steel shell bottom is first
welded up without any hole in a bottom. Then, a beam of laser is
applied to cut one or more slits in the bottom. Next, the stainless
steel shell bottom is placed inside of a container holding element
with a transparent window. Next, a vacuum is pulled through the
slit in the shell bottom in the container holding element generally
at room temperature. After attaining the desired vacuum level, a
laser from outside the container holding element shoots through the
transparent window and welds up the slit. After the shell is
removed from the container holding element, the shell may
optionally be put in an oven (at atmospheric pressure) to activate
a getter inside of the shell. The transparent window in the
container holding element may be made from glass or any other
material having properties sufficient to permit the laser to pass
therethrough to reach the container that also permit the desired
vacuum level to be maintained in the container holding element.
[0011] The methods and systems may be used to form a variety of
insulated containers. For example, the containers may be a
two-piece design, four-piece design, or other designs. A two piece
design generally includes an inner shell and an outer shell. The
four piece design general includes an inner shell, an inner bottom
shell, an outer shell, and an outer bottom shell. The containers
may be used to store hot or cold beverages, food products, or other
consumer products. The containers may be beverage containers,
beverage tumblers, jugs, food jars, carafes, pump pots, sippy cups,
can insulators, etc.
[0012] Optionally, the methods include removing the containers from
the vacuum space and heating the container in an oven, at
atmospheric pressure, to activate a getter container within the
vacuum space. The getter may remove any oxygen or other residual
molecules from any air left in the vacuum space.
[0013] The methods and systems may form and close the one or more
openings on any location of the container that is accessible by the
laser beam. For the example, the one more opening may be on the
sides, bottom surfaces, interior or exterior edges, or interior
surfaces of the container. The methods and system utilize laser
welding techniques or other laser implemented methods that do not
require a solder material that is placed over the region of the
container that is to be sealed.
[0014] The methods and systems of the present disclosure form
vacuum insulated containers faster and more efficiently than prior
methods. As no heating is required, the methods and systems of the
present disclosure utilize much less energy than prior methods.
Further, the one or more openings may be formed anywhere on or in
the container that the laser can reach, which permits strategic
placement of the opening. There may be some strategies to hide the
opening, for example, along an edge of the container. Other
strategies include placing the opening to correspond with a design
of the container. Further, the one or more openings that have been
sealed by the present method may be painted over. In addition, the
one or more openings that have been sealed using the present method
are often stronger and less likely to sustain breakage than a
traditional solder-type closing. This reduces the need for a
further cap or structure to cover the soldered opening formed in
the prior methods. Also, since the current method does not require
solder, this reduces materials needed as well.
[0015] In another aspect, a method for forming a vacuum insulated
container is described. The method includes joining an inner shell
and an outer shell together to form an unfinished container,
wherein the unfinished container has a vacuum space between the
inner shell and the outer shell. The method includes creating one
or more openings in the outer shell of the unfinished container.
The method includes placing the entire unfinished container inside
of a container holding element. The method includes drawing a
vacuum around the unfinished container. The method includes
lowering a pressure around the unfinished container to a desired
level. The method includes pulling a vacuum through the one or more
openings. The method includes directing a laser beam through the
container holding element and welding closed the one or more
openings to seal the vacuum in the space between the inner shell
and the outer shell to form a vacuum space between the inner shell
and the outer shell.
[0016] In another aspect, a method for forming vacuum insulated
containers is described. The method includes joining inner shells
and outer shells together to form a plurality of unfinished
containers, wherein each unfinished container has a space between
the inner shell and the outer shell. The method includes creating
one or more openings in the outer shell of each of the unfinished
containers. The method includes placing the plurality of the
unfinished containers in an interior of a container holding
element. The method includes closing the container holding element
with a cover. The method includes drawing a vacuum in the interior
of the container holding element and around the unfinished
containers. The method includes lowering a pressure around the
unfinished containers to a desired level. The method includes
pulling a vacuum through the one or more openings. The method
includes directing a laser beam through the cover of the container
holding element and welding closed the one or more openings of a
first container of the plurality of containers to seal the vacuum
in the space between the inner shell and the outer shell of the
first container to form a vacuum space between the inner shell and
the outer shell of the first container. The method includes moving
a source of the laser beam to a second container of the plurality
of containers to seal the vacuum in a space between the inner shell
and the outer shell of the second container to form a vacuum space
between the inner shell and the outer shell of the second
container.
[0017] In another aspect, a system for forming vacuum insulated
containers is described. The system includes a container holding
element defining an interior. The interior is configured to hold a
plurality of containers. The container holding element includes a
base and a cover. The cover is configured to sealingly engage to
the base. A vacuum source is in connection with the container
holding element. The vacuum source is configured to draw a vacuum
in an interior of the container holding element to simultaneously
reduce pressure around all of the plurality of containers. A laser
source is configured to direct a laser beam through the cover. The
cover allows the laser beam to pass into an interior of the
container holding element and reach the container.
[0018] In another aspect, a system for forming vacuum insulated
containers is described. The system includes a housing to position
a plurality of container holding elements. The system includes a
mounting element proximate the plurality of container holding
elements. The mounting element includes a horizontal track and a
vertical track. The container holding elements are configured to
each hold a container. The container holding elements include a
cover. A vacuum source is in connection with the container holding
elements. The vacuum source is configured to draw a vacuum in the
interiors of the container holding elements. A visual detection and
laser welding assembly is mounted to the mounting element to move
the visual detection and laser welding assembly horizontally and
vertically. The visual detection and laser welding assembly
includes a laser configured to direct a laser beam through the
covers. The covers allow the laser beam to pass into interiors of
the container holding elements.
[0019] In another aspect, a container holding element for forming
vacuum insulated containers is described. The container holding
element includes a base. The base includes a generally square shape
or generally rectangular shape with four side walls. The four side
walls extend generally upwardly from a bottom of the base to define
an interior of the container holding element. A cover sealingly
engages to a top of the base to close the interior. A rack is
configured to hold a plurality of the containers. The rack is
shaped to fit into the interior of the base. The bottom of the base
includes a vacuum port configured to engage with a vacuum
source.
BRIEF DESCRIPTION OF DRAWINGS
[0020] FIG. 1 is perspective view of an embodiment of the system
for forming vacuum insulated containers.
[0021] FIG. 2 is a sectional view of a first embodiment of the
container holding element of the system for forming vacuum
insulated containers.
[0022] FIG. 3 is a sectional view of a second embodiment of the
container holding element of the system for forming vacuum
insulated containers.
[0023] FIG. 4 is a view of the slit of a first embodiment of the
container.
[0024] FIG. 5 is a view of the slits of a second embodiment of the
container.
[0025] FIG. 6A is a view of the slit of a third embodiment of the
container.
[0026] FIG. 6B is a view of the slit of the third embodiment of the
container.
[0027] FIG. 7 is a top perspective view of the container holding
element for holding a plurality of containers.
[0028] FIG. 8 is a sectional view of the container holding element
for holding a plurality of containers.
[0029] FIG. 9 is an exploded view of the container holding element
for holding a plurality of containers.
[0030] FIG. 10 is a top down view of the container holding element
for holding a plurality of containers.
[0031] FIG. 11 is perspective view of a second embodiment of the
system for forming vacuum insulated containers.
[0032] FIG. 12 is sectional view of a second embodiment of the
system for forming vacuum insulated containers.
[0033] FIG. 13 is an exploded view of a second embodiment of the
system for forming vacuum insulated containers.
[0034] FIG. 14 is a layout of the controller of the system of FIG.
1.
[0035] FIG. 15 is a layout of the controller of the system of FIGS.
11-13.
DETAILED DESCRIPTION
[0036] For purposes of this application, any terms that describe
relative position (e.g., "upper", "middle", "lower", "outer",
"inner", "above", "below", "bottom", "top", etc.) refer to an
embodiment of the invention as illustrated, but those terms do not
limit the orientation in which the embodiments can be used.
[0037] A system 10 will now be described with reference to FIGS.
1-6B. The system 10 directs a laser beam from a laser source 205
through a container holding element 300 to weld up an opening 52 in
a container 50 that is within the container holding element
300.
[0038] The system 10 includes a housing 100. The housing 100
comprises a visual detection and laser welding assembly 200 that
positions the laser source 205 proximate to the container holding
element 300. The visual detection and laser welding assembly 200
may be mounted to the housing 100 as shown in FIG. 1. In others
aspects, the visual detection and laser welding assembly 200 may be
positioned over or supported proximate to the housing 100.
[0039] The housing 100 may define a space in which a vacuum source
110 is positioned. The vacuum source 110 is connected to the
container holding element 300 by bellows or other conduit, and is
configured to draw the vacuum inside of the container holding
element 300. An example of a vacuum source 110 is a vacuum pump.
The vacuum source 110 creates the vacuum for the container holding
element 300 that lowers the pressure in the container holding
element 300. In other aspects, the vacuum source 110 may be
positioned proximate the housing 100 and connected to the container
holding element 300 by additional bellows or other conduits.
[0040] The visual detection and laser welding assembly 200 includes
the laser source 205 to emit laser pulses to weld the one or more
openings 52. The visual detection and laser welding assembly 200
further includes a detector 210 to register the pulses from the
laser source 205 with the openings 52 of the containers 50. The
system 10 includes a controller 15 to operate at least certain
elements of the system 10. The controller 15 may include a
programmable logic controller. For example, the controller 15 may
cause turning on, turning off, moving, calibrating or otherwise
directing any or all of the laser source 205, the detector 210, or
the vacuum source 110.
[0041] The container holding element 300 receives the container 50
into an open interior 310 of the container holding element 300. A
lower portion 320 of the container holding element 300 includes a
positioner 325 to hold the container 50. In other embodiments not
illustrated, a positioner 325 could be present in any orientation
configured to properly position the container 50 for access by the
laser source 205. For example, in another embodiment, the
positioner 325 may include a hook from which the container 50 may
hang for a laser source 205 positioned below the container holding
element 300.
[0042] The container holding element 300 includes a window 350 made
from, for example, an optical glass. The window 350 may be made
from any optical glass that allows sufficient light energy from the
laser source 205 to pass into the interior 310. The window 350 may
be made from other materials that allow for transmission or passage
of the light energy and permit the vacuum to be drawn within the
container holding element 300. The window 350 separates the
interior 310 from the ambient environment of the system 10. In the
aspect shown, the laser source 205 is external to the container
holding element 300. The laser beam from the laser source 205
passes through the window 350 and to the container 50 in the
interior 310 of the container holding element 300. In aspects in
which the laser source 205 is positioned inside the container
holding element 300, a window 350 would not be necessary. In the
illustrated aspect, the window 350 forms the cover of the container
holding element 300, but such window could be positioned anywhere
on the container holding element 300.
[0043] During production, the vacuum is formed within the interior
310 of the container holding element 300 by the vacuum source 110.
In the aspect shown, the container holding element 300 includes an
upper portion 330 and the lower portion 320 that are removably
connected. For example, the upper portion 330 may be removed from
the lower portion 320 for inserting the container 50 into the
container holding element 300. For example, the upper portion 330
may seal to the lower portion 320 via a threaded, frictional,
press-fit, or other mechanical connection that holds the upper
portion 330 and the lower portion 320 together and to provide for
the vacuum to form in the interior 310 of the container holding
element 300. Gaskets or other pliable seals may be used between the
upper portion 330 and the lower portion 320 to seal the interior
310 such that the vacuum may be formed in the interior 310. In
other aspects, the cover 300 provides access to the interior 310 of
the fixture 300. For example, the cover 300 may be temporarily
removed from the container holding element 300 in order to place
the container 50 in the interior 310 of the container holding
element 300.
[0044] The lower portions 320 of the container holding elements 300
may be securely fastened to the frame 150 and/or the housing 100.
The lower portions 320 generally remain fastened to the frame 150
and/or the housing 100 during operation of the system 10 and/or
during the loading and unloading of the containers 50 into the
lower portions 320. The lower portions 320 may pass through
openings 106 in an upper surface 102 of the housing 100 and into an
interior 104 of the housing 100.
[0045] In the aspect shown in FIG. 2, the window 350 is positioned
at an upper end 335 of the container holding element 300. In the
aspects shown, the container 50 is held by the positioner 325 in an
inverted position. This provides for the system 10 to form the
openings 52 in a bottom 54 of the container 50. The openings 52 are
shown in FIG. 5. In the aspect shown in FIG. 3, the window 350 is
positioned in a side wall 328 of the container holding element 300.
As shown in FIG. 4, this provides for the system 10 to form the
openings 52 in a side 56 of the container 50, i.e., the laser
source 205 is welding the openings 52 that are in a non-horizontal
portion of the container 50. The laser source 205 may weld the
opening 52 that are in nearly any orientation--since no solder is
needed to be used on the opening 52. For example, FIGS. 6A and 6B
illustrate the opening 52 along an edge between the bottom 54 and
the side 56 of the container 50. Of course, the opening 52 may
formed along any other edge of the container 50.
[0046] The positioner 325 may include an extension 327 that fits
into an interior of the container 50. In other aspects, the
positioner 325 may include threads to threadably engage with
complementary threads of a mouth of a container 50. The positioner
325 holds the container 50 steady during the laser welding
process.
[0047] During the forming process, the unfinished containers 50 are
placed completely inside of the container holding element 300. The
unfinished containers 50 are completely enclosed by the container
holding element 300. For example, a container 50 may have a two
piece design with an inner shell and an outer shell. During the
forming process, both the inner shell and the outer shell may be
completely contained inside of the container holding element 300.
For example, a four piece design may have an inner shell, an inner
bottom shell, an outer shell, and an outer bottom shell. During the
forming process, all of the inner shell, the inner bottom shell,
the outer shell, and the outer bottom shell may be completely
contained inside of the container holding element 300.
[0048] The container holding element 300 includes a conduit 380
leading to a bellows 390, which are in communication with the
vacuum source 110. The container holding element 300 may include
pressure sensors to monitor the pressure of the interior 310 of the
container holding element 300. In the aspect shown, the conduit 380
joins the bellows 390 with a conduit opening 322 in the lower
portion 320 of the container holding element 300. The conduit
opening 322 provides passage into the interior 310 of the container
holding element 300. Opposite of the conduit 380, the bellows 390
lead to the vacuum source 110. The vacuum source 110 creates the
vacuum for the container holding element 300 that lowers the
pressure in the container holding element 300 and around or about
the openings 52 of the containers 50.
[0049] The housing 100 supports a mounting element 120 configured
to position the visual detection and laser welding assembly 200.
The mounting element 120 may move the visual detection and laser
welding assembly 200 in the X (generally horizontal) and the Y
(generally vertical) directions to weld the openings 52 of the
containers 50. The illustrated aspect of the mounting element 120
includes a horizontal track 130 and a vertical track 140. The
visual detection and laser welding assembly 200 moves up and down
on the vertical track 140. The vertical track 140 moves left and
right on the horizontal track 130. The mounting element 120 may be
mounted to the upper surface 102 of the housing 100. After initial
set up, the visual detection and laser welding assembly 200 may
only need to move in the horizontal plane in order to laser weld
the containers 50. Non-illustrated aspects of a mounting element
120 may include a pivotable section, a mechanical arm, or any other
configuration sufficient to properly support and position the
visual detection and laser welding assembly 200. Other aspects may
include a separate mounting element 120 for each of the laser
source 205 and the detector 210.
[0050] The controller 15 operates the function and movement of the
mounting element 120. The controller 15 may further include a
display and user input controls. The illustrated housing 100
further includes a door 103 leading to the interior 104 of the
housing 100. The vacuum source 110 may be positioned in the
interior 104 underneath the container holding elements 300.
[0051] In the aspect shown, the system 10 includes two visual
detection and laser welding assemblies 200 on separate vertical
tracks 140. The separate vertical tracks 140 move independently on
the horizontal track 130. In other aspects, the system 10 may
include a single visual detection and laser welding assembly 200 or
any number of additional visual detection and laser welding
assemblies 200.
[0052] The housing 100 further includes the frame 150 to hold
and/or position the container holding elements 300. The frame 150
may be mounted to the upper surface 102 of the housing 100 adjacent
to or supporting the mounting element 120.
[0053] The vacuum source 110, such as a pump, is positioned in or
proximate the housing 100. The vacuum source 110 draws the vacuum
used to form the vacuum spaces within the containers 50. One or
more containers 50 are placed in the container holding elements
300. The vacuum source 110 begins drawing a vacuum. The detector
210 determines the position of the openings 52 in order to direct
the pulses from the laser source 205 to the openings 52. When a
sufficient or desired pressure is reached in the container holding
element 300, the laser source 205 welds the one or more openings 52
closed. The visual detection and laser welding assembly 200 moves
to the next container 50 in a container holding element 300.
[0054] The vacuum source 110 draws the vacuum in the container
holding element 300 and in the vacuum space of the container 50.
The air pressure may be reduced from ambient pressure conditions to
approximately 10-3 tor to approximately 10-4 tor depending on the
materials used for the container 50 or other variables as needed.
During the forming process, the whole unfinished container 50 is
placed inside of the container holding element 300. The unfinished
container 300 is completely enclosed by the container holding
element 300.
[0055] The controller 15 may direct the movement of the visual
detection and laser welding assembly 200 to the respective
container holding elements 300. The detector 210 is in
communication with the controller 15 to determine the positioning
of the openings 52. The controller 15 may modulate the positioning
of the laser welding assembly 200 based on input from the detector
210. The controller 15 also monitors pressure of the container
holding elements 300 via sensors internal to the container holding
elements 300 or by readings obtained from the vacuum source 110.
The controller 15 may modulate the operation of the vacuum source
110 to obtain the desired vacuum pressures in the container holding
elements 300. When the desired position of the laser source 205
relative to the container 50 and the desired vacuum pressure in the
container holding element 300 are achieved, the controller 15 will
activate the laser source 205 to weld the opening 52.
[0056] The controller 15 may move or change the orientation of the
laser source 205 to direct the laser energy at a full length of the
opening 52. For example, the mounting element 120 may move the
laser source 205, while the laser source 205 is emitting laser
energy, over the full length of the opening 52. In some aspects,
after one opening 52 is sealed, the mounting element 120 may move
the laser source 205 to seal another opening 52 on the same
container 50. After one container 50 is sealed, the mounting
element 120 may move the laser source 205 to successive containers
50 for sealing their openings 52. As such, the system 15 may
serially seal the openings 52 of a batch of the containers 50.
[0057] The methods and systems 10 may include an optional
pre-heating step or stage that vaporizes any surface moisture on or
in the container 50. Such surface moisture may lead to discoloring
or interfere with further processing. In dry conditions, the
pre-heating may not needed. If the pre-heating is employed, the
unfinished container 50 is placed in oven and the temperature is
raised to approximately 150.degree. C. to approximately 200.degree.
C. for a suitable time period to remove the moisture.
[0058] The laser source 205 may form one or more openings 52
anywhere on the container 50, for example: on the edges, outer
shell, inner shell, and/or the bottom outer shell of the container
50. The one or more openings 52 may include slits, geometrically
shaped openings, and/or amorphously shaped openings. The one or
more openings 52 may vary in length, width, size, etc. depending on
the container 50, the laser source 205 used to close the one or
more openings 52, the material of the container 50, the size of the
container 50, etc. In one aspect, the openings 52 include two slits
of that are approximately 20 mm in length and having a width of
approximately 0.1 mm to approximately 0.15 mm on the bottom outer
shell of the container 50. Although the two slits 52 are shown in a
parallel configuration, the two slits 52 may be in other angular or
spaced relationships with respect to each other.
[0059] Any type of laser with a proper wavelength may be used for
the laser source 205. The laser source 205 may be pulse or
continuous. The laser source 205 may also simultaneously emit two
laser beams to simultaneously seal two openings 52 on the container
50. The laser source 205 may also emit an array of laser beams to
seal a matching pattern of openings 52 on the container 50.
[0060] The controller 15 operates the function of the system 10.
The controller 15 may be programmed via computer numerical control
program in order to move the laser source 205 to successive
container holding elements 300 A position of each container holding
elements 300 is programmed into the controller 15. The laser source
205 moves from position to position in order to weld the openings
52. The detector 210 may include a photo-eye, orientation sensor,
or other sensor to ensure that the laser source 205 is in proper
position to weld the openings 52. The controller 15 may modulate
the positioning of the laser welding assembly 200 based on input
from the detector 210. The controller 15 also may monitor pressure
of the container holding elements 300. The controller 15 may be
programmed to confirm that the pressure levels within the container
holding elements 300 are acceptable before activating the laser
source 205.
[0061] The methods and system 10 may be used with, for example,
containers made from stainless steels, PE, TX2001, or other metals
and metal alloys.
[0062] The system 10 may include one or more container holding
elements 300. For example, the system 10 illustrated includes 36
individual container holding elements 300. During operation, the
vacuum source 110 may form a vacuum in all of the container holding
elements 300 at the same time. Thus, the laser source 205 may
immediately move on to the next container holding element 300 as
soon as the openings 52 of a container 50 in a prior container
holding element 300 are welded closed. In other aspects, the vacuum
source 110 may form a vacuum in some of the container holding
elements 300 simultaneously.
[0063] In other aspects, the system 10 may employ fewer or
additional container holding elements 300. For example, the system
10 may include a single container holding element 300, 24 container
holding elements 300, or any other number of container holding
elements 300.
[0064] In other aspects, the system 10 may include a laser that is
fixed in position. The containers 300 may be serially sealed by the
laser.
[0065] In other aspects, a single container holding element 300 may
have a larger volume capable of holding several containers 50. The
laser source 205 may move around or proximate to the single
container holding element 300 to weld the containers 50
therein.
[0066] In others aspects, the welding gun or the laser may be
incorporated inside of the vacuum space of the container holding
element.
[0067] FIGS. 7-10 show a container holding element 400 for holding
a plurality of containers 50 for processing. The container holding
element 400 may be incorporated onto the system 10 of FIGS. 1-6B or
other suitable systems. The plurality of containers 50 may be
completely placed inside of the container holding element 400.
[0068] The container holding element 400 allows the user to
simultaneously apply a vacuum to the plurality of the containers
50. A batch of the containers 50 may be loaded into the container
holding element 400, and the pressure inside of the container
holding element 400 may be lowered--thus lowering the ambient
pressure around each of the containers 50 in the batch of the
containers 50. This provides for the ambient pressure around
multiple containers 50 to be lowered in a single step or process.
This increases efficiency by reducing wait time between laser
welding steps of the containers 50, as the laser source 205 may
move to successive containers 50 without waiting for a further
vacuum to be formed.
[0069] The laser source 205 or other laser may be used to weld the
one or more openings in the containers 50. The container holding
element 400 allows for the user to lower the pressure around the
batch of the containers 50, maintain the lowered pressure around
the batch of the containers 50, and then serially weld each of the
containers 50 in the batch of the containers 50. The laser source
205 or other laser may move on to the next container 50 in the
container holding element 400 after the one or more openings in a
first container 50 are welded. The laser source 205 or other laser
may move on to successive containers 50 after the one or more
openings in a prior container 50 are welded. There is generally no
need to reduce pressure and/or open the container holding element
400 between the welding of the individual containers 50 in the
plurality of the containers 50.
[0070] The container holding element 400 includes a base 410 and a
cover 420. The cover 420 seals the base 410 to a closed and
generally air-tight position. In certain aspects, the cover 420
also is the window, while in other aspects, the cover 420 may be
opaque and a window is formed in another portion of the container
holding element 400. The base 410 defines a generally open interior
412 that receives the containers 50. A rack 430 or other suitable
transport device may be loaded with a plurality of the containers
50 and then lowered into the interior 412 of the base 410 of the
container holding element 400.
[0071] The rack 430 may include one or more openings 438 that
receive one or more positioners 470 to align the rack 430 in the
interior 412 of the base 410. The positioners 470 may pass through
the one or more openings 438 in the rack 430. The positioners 470
may extend upwardly from a bottom 460 of the base 410 of the
container holding element 400. In the aspect shown, the base 410
includes four positioners 470, although fewer or additional
positioners 470 may be employed. The rack 430 may also include two
oppositely disposed handles 435 to assist in the placement and
withdrawal of the rack 430 from the base 410 of the container
holding element 400.
[0072] The base 410 may include a generally square or rectangular
shape with four side walls 440A, 440B, 440C, and 440D. The side
walls 440A-440D extend upwardly from the bottom 460 to define the
interior 412. The base 410 may be made from rigid or durable
material, such as solid aluminum or other metal alloy, which
withstands the vacuum forces applied during the vacuum and sealing
steps. The side walls 440A-440D of the base 410 may form a
cross-section just larger than a cross-section of the rack 430,
such that the rack 430 nests within the side walls 440A-440D. In
the aspect shown, the side wall 440A forms a front side, the side
wall 440B forms a right side, the side wall 440C forms a rear side,
and the side wall 440D forms a left side. In the aspect shown, the
side walls 440A and 440C form longer sides than the side walls 440B
and 440D.
[0073] An upper surface 432 of the rack 430 may include one or more
positioning devices or other engaging members that hold the
containers 50 in position on the rack 430. For example, the
container 50 may frictionally fit over a pliable support or
positioner to hold the position of the containers 50 on the rack
430. In other aspects, the containers 50 may threadably engage or
removably fit to the upper surface 432 of the rack 430. The rack
430 is lowered into the interior 412 of the base 410 and rests on
an upper surface 468 of the bottom 460 of the base 410.
[0074] The rack 430 may hold the containers 50 in a matrix or grid
fashion. In the aspect shown, the containers 50 are arranged in six
columns and four rows for a total of twenty-four containers 50. Of
course, in other aspects, fewer or additional columns and/or rows
may be employed in the container holding element 400, and/or fewer
or additional containers 50 may be processed in the container
holding element 400. The container holding element 400 may also be
scaled upwards or downwards in size to change the processing
capacity of the container holding element 400. The container
holding element 400 may be adapted or adaptable for various
container sizes or shapes.
[0075] A sectional view of an aspect of the container holding
element 400 is shown in FIG. 8 In the illustrated aspect, the
bottom 460 of the base 410 includes a vacuum passage 462 passing
from a bottom surface 464 of the bottom 460 upwards into the
interior 412 of the container holding element 400. The rack 430
includes a vacuum opening 434 to allow air and/or gas to pass from
the interior 412 through the vacuum opening 434 and through the
vacuum passage 462. As such, a vacuum is drawn through the vacuum
passage 462 to lower the air pressure in the interior 412 of the
base 410. The bottom surface 464 of the base 410 may include a
vacuum port 480 or other fluidic connections or fittings to
sealingly engage with a vacuum source, such as the vacuum source
110.
[0076] The positioners 470 assist in aligning the rack 430 in a
proper position in the base 410. The positioners 470 also assist in
aligning the vacuum opening 434 of the rack 430 with the vacuum
passage 462. The coordinates or position of the containers 50 on
the rack 430 are programmed into the controller 15. The rack 430
fits into the same position in the base 410, due to the positioners
470 and/or an interior shape of the base 410, which assists the
controller 15 in locating and/or determining the position of the
containers 50 on the rack 430.
[0077] The controller 15 operates the system 10. The controller 15
may be programmed via computer numerical control program in order
to move the laser source 205 to successive containers 50. A
position of each container 50 of the plurality of containers 50 is
programmed into the controller 15. The laser source 205 moves from
position to position in order to weld the openings. The detector
210 may include a photo-eye, orientation sensor, or other scanner
or sensor to ensure that the laser source 205 is in proper position
to weld the openings 52. The controller 15 may modulate the
positioning of the laser welding assembly 200 based on input from
the detector 210. Once the position of the container 50 is
verified/confirmed by the detector 210, the controller may activate
the laser source 205. The controller 15 also may monitor pressure
of the container holding element 400. The controller 15 may be
programmed to confirm that the pressure level within the container
holding element 400 is acceptable before activating the laser
source 205.
[0078] The controller 15 includes at least one processor 16 to
process data and a memory 17 to store the data. The processor 16
processes communications, builds communications, retrieves data
from the memory 17, and stores data to the memory 17. The processor
16 and the memory 17 are hardware. The memory 17 may include
volatile and/or non-volatile memory, e.g., a computer-readable
storage medium such as a cache, random access memory (RAM), read
only memory (ROM), flash memory, or other memory to store data
and/or computer-readable executable instructions such as the
computer numerical control instructions or program. With respect to
FIG. 14, an exemplary layout of the controller 15 is illustrated
with respect to the system 10. As an example, the computer
numerical control instructions include position data and may be
stored in the memory 17. In addition, the controller 15 further
includes at least one communications interface 18 to transmit and
receive communications, messages, and/or signals to the laser
source 205, laser welding assembly 200, vacuum source 110, and/or
container holding element 300, as well as other components,
subsystems, and hardware of the system 10, such as, for example,
the detector 210, vacuum sensors, position sensors, displays, input
controls, drive motors, etc.
[0079] The cover 420 fits down over the base 410 to close the
container holding element 400. The weight of the cover 420 helps to
compress a seal 450 that is positioned at an upper surface 444 of
the side walls 440A-440D. The seal 450 may extend all the way
around the entirety of the upper surface 444. The cover 420 also
includes a flange portion 422 to further help in sealing the
interior 412. The flange portion 422 extends downward from the
cover 420. An inner flange surface 424 of the flange portion 422
fits against an inner side surface 442 of the side walls 440A-440D.
The flange portion 422 helps to properly position and/or align the
cover 420 over the base 410. As the vacuum is drawn in the interior
412, the combination of the cover 420, the seal 450, and the flange
portion 422 provides for the vacuum to form within the interior 412
of the container holding element 400.
[0080] The cover 420 may be formed from a polycarbonate material or
other material that allows for passage of laser light from the
laser source 205 through the cover 420 and to the containers 50.
The cover 420 may be made from any optical glass that allows
sufficient light energy from the laser to pass into the interior
412. In the illustrated aspect, the visual detection and laser
welding assembly 200 further is positioned over the cover 420, but
the visual detection and laser welding assembly 200 may be
positioned in any configuration that permits the laser source 205
to send laser light into the container holding element 400. The
laser source 205 may move over a top of the cover 420, under
direction from the controller 15.
[0081] During the forming process, in one aspect, the plurality of
unfinished containers 50 are placed completely inside of the
container holding element 400. In other aspects, the unfinished
containers 50 are positioned only partially in the container
holding element 400. With respect to FIG. 8, the unfinished
containers 50 are completely enclosed by the container holding
element 400. The entirety of the unfinished containers 50 are
placed completely inside of the container holding element 400. For
example, a container 50 may have a two piece design with an inner
shell and an outer shell. During the forming process, both the
inner shell and the outer shell may be completely contained inside
of the container holding element 400. For example, a four piece
design may have an inner shell, an inner bottom shell, an outer
shell, and an outer bottom shell. During the forming process, all
of the inner shell, the inner bottom shell, the outer shell, and
the outer bottom shell may be completely contained inside of the
container holding element 400.
[0082] In certain aspects, the container holding element 400 may
mount over the housing 100 such that the vacuum source 110 of the
housing 100 draws vacuum through the vacuum passage 462. Similarly,
the visual detection and laser welding assembly 200 may be
positioned over a top of the container holding element 400.
[0083] A system 11 will now be described with reference to FIGS.
11-13. The system 11 directs a laser beam from a laser source 505
through the container holding element 400 of FIGS. 7-10 to weld up
the openings 52 in the containers 50 that are within the container
holding element 400. The system 11 operates similarly to the system
10, and provide provides many of the same advantages and
benefits.
[0084] The system 11 includes vertical supports 510 and 512 that
support a positioner 515 that operates under computer numerical
control program to move the laser source 505 in the X and/or Y
directions. In this aspect, the laser source 505 is positioned at
an underneath surface of the positioner 515. The laser source 505
may be integrated to the positioner 515. The positioner 515 is
movably engaged to a central support 520 that maintains the
positioner 515 above the container holding element 400. In this
aspect, the central support 520 is positioned generally parallel to
the sidewalls 440A and 440C, and the positioner 515 moves along a
length of the central support 520 in the X direction.
[0085] Ends 522 and 524 of the central support 520 are movably
engaged to horizontal supports 530 and 540. The vertical supports
510 and 512 support the horizontal supports 530 and 540. In this
aspect, the horizontal supports 530 and 540 are positioned
generally parallel to sidewalls 440B and 440D, and the central
support 520 moves along a length of the horizontal supports 530 and
540 in the Y direction.
[0086] In the embodiment shown, the positioner 515 travels along
the X axis via the central support 520, while the central support
520 moves along the Y axis via the movable engagement between the
central support 520 and the horizontal supports 530 and 540. The
positioner 515 moves relative to the central support 520, and the
central support 520 moves relative to the horizontal supports 530
and 540. Of course, in other embodiments, the arrangement of travel
may be reversed or altered. Also, in this embodiment, the height of
the positioner 515 is generally fixed. Of course, in other
embodiments, the height of the positioner 515 is adjustable or may
be under computer numerical control program. For example, the
vertical supports 510 and 512 may extend or retract to adjust the
height of the positioner 515.
[0087] The vertical supports 510 and 512 may attach or engage to
outer surfaces of the side walls 440B and 440D of the container
holding element 400 to provide support and stability to the system
11. In other aspects, the container holding element 400 may be
removably placed between the vertical supports 510 and 512. In
other aspects, the vertical supports 510 and 512 are positioned
proximate the container holding element 400.
[0088] A vacuum source 570, such as a pump, draws the vacuum in the
system 11. The vacuum source 570 is engaged to the vacuum port 480
of the vacuum fixture 400 via a vacuum line 575. As such, a vacuum
is drawn by the vacuum source 570, through the vacuum line 575,
through the vacuum passage 462 to lower the air pressure in the
interior 412 of the base 410.
[0089] The system 11 may include the controller 15 of FIGS. 1-6B or
other suitable programmable logic controller to operate at least
certain elements of the system 11. For example, the controller 15
may cause turning on, turning off, moving the positioner 515
relative to the central support 520, moving the central support 520
relative to the horizontal supports 530 and 540, calibrating or
otherwise directing any or all of the laser source 505, the vacuum
source 570, or other components of the system 11.
[0090] With respect to FIG. 15, an exemplary layout of the
controller 15 is illustrated with respect to the system 11. The
controller 15 includes the least one processor 16 to process the
data and the memory 17 to store the data. The processor 16
processes communications, builds communications, retrieves data
from the memory 17, and stores data to the memory 17. The
controller 15 further includes the at least one communications
interface 18 to transmit and receive communications, messages,
and/or signals to the laser source 505, central support 520,
positioner 505, vacuum source 570, and container holding element
400, as well as other components, subsystems, and hardware of the
system 11, such as, for example, detectors, vacuum sensors,
position sensors, displays, input controls, drive motors, etc.
[0091] In the aspects illustrated in FIGS. 1-13, the unfinished
containers 50 are placed completely inside of the container holding
element 300 or are placed completely inside of the container
holding element 400. The systems 10 and 11 and methods described
herein may also be used with container holding elements that only
partially enclose the unfinished containers 50. For example,
certain container holding elements will seal to or engage with
portions of unfinished containers 50. For example, certain
container holding elements will seal over or enclose portions of
the unfinished containers having the openings 52, and then draw the
vacuum to form the vacuum within the space between the inner shell
and the outer shell, while other portions of same unfinished
containers are not enclosed by the container holding element.
[0092] As such, it should be understood that the disclosure is not
limited to the particular aspects described herein, but that
various changes and modifications may be made without departing
from the spirit and scope of this novel concept as defined by the
following claims. Further, many other advantages of applicant's
disclosure will be apparent to those skilled in the art from the
above descriptions and the claims below.
* * * * *