Note: Descriptions are shown in the official language in which they were submitted.
CA 02248278 1998-10-23
PRECONDITIONED PAPERBOARD CONTAINERS AND
METHOD AND APPARATUS FOR MAKING THE SAME
This is a divisional application of application Serial
No. 2,144,360 having a filing date of March lO, 1995.
Techni~l Field
The present invention relates to the formation of paperboard containers
5 and more particularly to a preconditioned paperboard container and method
and apparatus for preconditioning the container side wall before brim forming
in order to increase forming strain limits and increase the rigidity and
acceptability of the resultant container.
Background of th~ Invention
An ever present concern in the manufacture of paperboard containers
is to provide a rigid container which is capable of holding a substantial amountof fluid without collapsing wh~n grasped by the consumer. It is also a major
concern that such rigid containers be manufactured in an economical manner
to produce a container which will be pleasing to the consumer.
1~ Paper container rigidity is d~fined by the load which when applied tothe side walls of the container deflects the side wall of the container inwardlyone quarter of an inch. Further, this test is carried out at a point on the sidewall of the container which is two-thirds the height of the overall container.
This rigidit~ test deRrmines the ability of the container to be picked up by the~O consumer without collapsing inu ardly and spilling the contents when the
CA 02248278 1998-10-23
container is grasped by the side wall. The rigidity of a particular container
is affected by th~ tensile and bending stiffness in both the vertical and
circumferential directions of the container. One expedient for increasing the
rigidit-y of a paperboard container is to form a brim about the top of the
5 container.
As is disclosed in U.S. Patent No. 2,473,836 issued to Vixen et al.,
conventional brim curling mechanism utilizes complimentary curve dies in
which the lower die is first moved upwardly around an upper end of the
paperboard container to an upper periphery thereof where it firmly holds the
10 cup against the die. The upper die is then moved downwardly to engage the
upper periphery of the paperboard container between the dies with both of the
dies then moving downwardly together to curl the upper periphery of the
container thereby forming a brim. This brim adds significantly to the rigidity
of the overall container structure.
Similarly, U.S. Patent No. 3,065,677 issued to Loeser discloses a brim
curling mechanism for paperboard containers. A lower die having a curve
forming upper surface is m~int~ined stationary while an upper die having a
curve forming lower surface descends downwardly toward the stationary lower
die. deflecting the upper edge portion of the cup secured by the lower die and
20 again forming a brim about an upper periphery of the container. This brim
as stated previously~ adds significantly to the overall rigidity of the container.
As is illustrated in Figure lA, each of the above-mentioned containers
are formed ~ith the machine direction of the paperboard material aligned in
an alcial direction of the container and the cross machine direction of the
CA 02248278 1998-10-23
paperboard mat~riaI aligned in the circumferential direction of the container
as shown by the arrows ~IDI and CDI, respectively. Paperboard material,
when formed using conventional paper manufacturing processes, has what is
known in the art as a "machine direction and a cross machine direction." The
S machine direction of the paper is generally that a~is of the paper aIong whichthe paper is moved as it was being formed. The cross machine direction is
perpendicular to the m~chine direction of the paper and has approximately
twice the ma~imum stretch as that of the machine direction, while the tensile
and bending stiffness of the board in the machine direction is greater than that10 in the cross machine direction. Therefore, in order to easily forrn brims about
the upper periphery of the container, the paperboard blank used in forming the
cup is generally positioned as illustrated in Figure lA.
In an effort to increase the overall rigidity of the paperboard container
and to increase the paperboard container's acceptance by the consumer by
eliminating cracks in the brim curl, U.S. Patent No. 5,029,749 issued to
Aloisi and assigned to the assignee of the subject invention proposes
reorienting the paperboard material when forming the blanks in accordance
with conventional practices. That is. the machine direction of the paperboard
material is ori~nted so as to e~tend in the circumferential direction of the
20 paperboard container with the cross machine direction of the paperboard
container being aligned with the axial direction of the container as illustratedin Figure lB. While this orientation of the paperboard material does in fact
result in an increased rigidity of the container, the size of the brim curl
formed about an upper periphery of the container is limited by the orientation
CA 02248278 1998-10-23
and properties of the paperboard mat~rials. That is, because board stretch in
the machine direction is less than that in the cross machine direction the size
of brim curls about the upper periphery of the container will be smaller than
brim curl of the container illustrated in Figure lA.
S The use of moisture in aiding in the formation of brim curls has been
known as illustrated in European Patent Application No. 0,129,064 wherein
a brim forming press for forming brim curls includes a spray and nozzle for
producing an annular spray pattern of atomized water and directing such spray
on the inside top margin of the annular wall of the cup during engagement of
the deflector with an upper periphery of the cup. However, the atomized
water is used to lubricate the top margin of the ~nnul~r cup when forming the
brim curls in a convention manner. In doing so, the frictional engagement
between the cup and the forming press is lessened.
Sirnilarly, U.S. Patent No. 2,541.905 issued to Amberg discloses the
moistening of the upper portion of a cup in order to form satisfactory brims
on the cup. Again, the moistening of the upper portion of the cup is done so
as to aid in the formation of a brim curl about the upper periphery of the cup
in a conventional manner. This being done at the brim curling station.
In addition to the foregoing. U.S. Patent No. 1,743,215 issued to Hill
2() discloses a process for the production of paper containers and particularly cup-
shaped paperboard containers having rolled rims where the edge rolling step
of the prccess can be executed more advantageously if the edge to be rolled
is moistened before being subjected to a rolling process. Herein. as with the
above-noted references. the formation of brim curls about an upper periphery
CA 02248278 1998-10-23
.
of a paperboard container utilizing conventional forming devices can be aided
with the use of moisture. Particularly, in U.S. Patent No. 1,743,21~, a stack
of disks to be formed into paper cups is forrned with the edges of the disks
being moistened for edge forming purposes while m~int~ining the central
5 portion of the disk dry. These disks are then subsequently formed into paper
cups using conventional forming devices. That is, the disclosure of Hill has
recognized that by subjecting the blanks to moisture, brim curls of a
conventional size and shape can be more readily carried out. However, the
use of moisture in the Hill disclosure does not increase the overall rigidity of10 the resultant container.
Clearly, there is a need for a container and more specifically a
paperboard container which exhibits an increased degree of rigidity than that
previously achieved by producing a paperboard container having an erllarged
brim curl about an upper periphery thereof adds to the rigidity of the
15 paperboard container and provides a paperboard container which is more
acceptable to the consumer without increasing the basis weight of the
paperboard material.
Summary of the Invention
It is a primary object of the present invention to overcome the
20 shortcomings associated with previously-known paperboard containers.
Yet another object of the present invention is to increase the forming
strain limits in order to improve rigidity of the resultant container by allowing
.
CA 02248278 1998-10-23
larger brims than previously-known to be formed about an upper periphery of
the container.
Another object of the present invention is to provide a device for
systematically subjecting a brim portion of a container blank or shell to a
S humid atmosphere in order to extend the forming strain limits encountered
during forrnation of brim curls about an upper periphery of the container.
A further object of the present invention is to insure -proper exposure
of the upper periphery of the paperboard blank or shell to the humid
atmosphere in order to significantly reduce and elimin~te defects in the brim
10 curl of the resultant container.
A further object of the present invention is to provide a process for
extending the forming strain limits encountered when forrning paperboard
containers from paperboard blanks having the machine direction of the
paperboard material extending in a circumferential direction of the resultant
15 container in order to permit larger brim curls to be formed about an upper
periphery of the container.
A further object of the present invention is to provide a method and
apparatus for increasing the paperboard moisture content in order to readily
form brim curls about an upper p~riphery of a container formed from such
20 paperboard material without brim-cracking defects.
These as well as additional objects of the present invention are achieved
by providing a plurality of container blanks for forming containers, forming
a plurality of container shells from the plurality of blanks. accumulating the
plurality of container shells at an accumulation station, subjecting at least an
CA 02248278 1998-10-23
upper periphery of the shells to a humid atmosphere to precondition the shells with the atmosphere
preferably including steam, successively removing the shells from the accumulator and
subsequently forming a brim curl about an upper periphery ofthe shell with the shells being subject
to the humid atmosphere for a predetermined time period sufficient to form defect-free brim curls
by extending the forming strain limits of the paperboard material. This method being carried out
by using an accurnulator for accumulating the container shells for further processing with the
accumulator comprising an elongated housing for accommodating the plurality of shells, a
mechanism for retaining the shells in the housing and means for creating a humid atmosphere
within said housing for subjecting at least an upper periphery of the shells to said humid
atmosphere.
Alternatively, the container blanks can be retained in a retaining device comprising
positioning means for positioning a plurality of blanks and m~int:~ining the blanks in a retrievable
position, restraining means for restraining the blanks within said positioning means such that the
blanks can be sequentially removed from said positioning means, and means for creating a humid
atmosphere about the blanks for subjecting at least a portion of the blanks intended to form an
upper periphery of a container to said humid atmosphere. Preferably the retaining device is a
hopper and the portion of the container blank to be formed into the brim of the container is left
exposed, with the retaining device including a positioning frame for positioning the plurality of
blanks and maintaining the blanks in a substantially upright position, a restraining mechanism for
restraining the plurality of blanks in the retaining device and permitting the blanks to be
.
CA 02248278 1998-10-23
sequentially removed from the positioning frame and an injection manifold extending parallel to
the blanks for directing steam toward an upper portion of the blank. Again, the blanks are
subjected to a humid atmosphere for a time sufficient to form substantially defect-free brim curls
by extending the forming strain limits of the paperboard material.
CA 02248278 1998-10-23
These as well as additional objects of the present invention will become
apparent from the following detailed description of the invention when read
in light of the several figures.
Rrief Descnption of ~he Drawin~s
S Figures lA and lB are elevational views of a container illustrating the
paperboard orientation of containers forrned in accordance with the present
inventlon.
Figure 2A is a cross-sectional view of a brim curl formed about an
upper periphery of the container illustrated in Figure lB when using
conventional forming methods.
Figure 2B is a schematic representation of the cooperating tool dies for
forming the brim curl of Figure 2A.
Figure 3A is a cross-sectional view of a brim curl formed about an
upper periphery of the container illustrated in each of Figures lA and lB
1~ when formed in accordance with the present invention.
Figure 3B is a schematic representation of the cooperating tool dies for
forming the brim curl of Figure 3A.
Figure 4 is a cross-sectional view of an upper tool die for forming brim
curls in accordance with the present invention.
Figure S is a cross-sectional view of a lower tool die for forming the
brim curl in accordance with the present invention.
CA 02248278 1998-10-23
Figures 6A, 6B and 6C are top views of containers forrned in
accordance with the present invention.
Figure 7 is a schematic illustration of a brim conditioning system in
accordance with the present invention.
S Figure 8 is a schematic illustration of a container blank hopper
incorporating the brim conditioning system in accordance with the present
nventlon.
Figure 9 is an end view of the container blank hopper illustrated in
Figure 8.
Figure 10 is an elevational view of an accumulator for accumulating
paperboard container shells for further processing in accordance with the
present invention.
Figure l l is a bottom view of the accumulator of Figure 10 illustrating
the retaining mechanism for permitting sequential removal of containers from
the accumulator.
Figure 12 is a cross-sectional view taken along line A-A of Figure 10.
Figure 13 is a schematic illustration of the brim conditioner provided
in the accumulator in accordance with the present invention.
Figure 14 is a schematic illustration of a portion of the brim conditioner
~0 illustrated in Figure 13.
Figure 15 is a schematic illustration of an injection manifold provided
in the brim conditioner illustrated in Figure 13.
.
CA 02248278 1998-10-23
- 10 -
n~t~iled Description of t~le Present Invention
As discussed hereinabove, paperboard containers having brim curls
formed about an upper periphery thereof may be forrned having the machine
direction of the paperboard material extending in either the axial direction of
5 the container or the circumferential direction of the container. That is, as can
be seen from Figure lA, paperboard containers 2 are manufactured with the
machine direction of the paperboard blank being aligned in the vertical or
axial direction of the container as designated by arrow MDI and the cross
machine direction of the paperboard material is aligned in the circumferential
10 direction of the container as illustrated by arrow CDI. Because the cross
machine direction of the paperboard material exhibits a maximum stretch of
approximately twice that of the machine direction, a brim curl 4 can be readily
formed about an upper periphery of the cup 2 while avoiding the forrnation of
vertical cracks about the brim. It should be noted, however, that even with
15 the machine direction of the paperboard material extending in the axial
direction of the cup, the size of the brim curl 4 formed about an upper
periphery of the container is subj~t to forming strain limits which dictate the
formation of the brim curl. As discussed hereinabove. it is an object of the
present invention to provide a method and apparatus for forming larger brim
20 curls than those previously achie~,-ed on paperboard containers ha~ing the
machine direction of the paperboard material extending in an axial direction
of the container.
CA 02248278 1998-10-23
Further, as discussed hereinabove and with reference to Figure lB, it
has been found that in order to enhance the overall rigidity of the paperboard
container, the paperboard material is reoriented in a manner such that the
machine direction of the paperboard material is aligned in the circumferential
5 direction of the cup 2' as illustrated by arrow MD2 and the cross m~r~ine
direction of the paperboard material is aligned in the vertical or axial direction
of the container 2' as illustrated by arrow CD~. By reorienting the pap~rboard
material in the manner illustrated in Figure lB, a greater rigidity against
deformation of the container when grasped by the consumer as compared to
10 previously-known paperboard containers is achieved in that as discussed in
U.S. Patent No. 5,029,749 it has been determined that the container rigidity
is strongly dependent on the stiffness of the side wall about its circumference
Referring now to Figures 2A and 2B, when reorienting the paperboard
material in the manner illustrated in Figure lB, brim curls formed in
15 accordance with conventional methods exhibit a width W2 and a thickness T2
and are formed by the cooperating dies illustrated in Figure 2B. Because the
paperboard material is reoriented in a manner such that the machine direction
of the paperboard material is aligned in the circumferential direction of the
container, her~tofore. only brim curls of a smaller size due to the lower
~0 stretch in the machine direction were permitted in order to minimize brim curl
defects of the r~sultant containers. In accordance with the present invention,
brim curls having a wider dimension Wl, as illustrated in Figure 3A, can be
provided when a paperboard container is manufactured having the paperboard
material orient~d in the manner illustrated in either Figure lA or Figure lB.
CA 02248278 1998-10-23
Sirnilarly, forming dies 6 and 8 illustrated in Figure 3B having a wider
dimension may b~ used in forming brim curls in accordance with the present
invention. It should be noted that while larger brim curls are achieved using
both paperboard orientations when compared to conventional brim curls the
5 brim curls achieved for the container having the paperboard oriented as
illustrated in Figure lA will be larger than those of the container illustrated
in Figure lB.
Turning now to Figures 4 and 5, the particular die arrangement for
forming the brim curls about an upper periphery of the paperboard containers
10 are formed in a conventional manner using the male and female die
arrangement illustrated. Specifically, Figure 4 illustrates an upper or male die10 which may be manipulated by conventional brim-forming devices such as
those illustrated in U.S. Patent Nos. 2,473,836 and 3,065,677 discussed
hereinabove. The upper die 10 includes a lower surface having a flange 12
15 extending axially therefrom thereby providing a slanted outer surface 14 and
an under cut 16, the significance of which will be described in greater detail
hereinbelow. The lower or female die 18 illustrated in Figure 5 includes an
axial bore 20 for receiving a container shell formed from paperboard material
which may have the machine direction oriented in either the axially direction
~0 of the container or the circumferentia] direction of the container with the bore
20 having an upper diameter corresponding to the diameter of the container
shell at the point where the brim is to be formed, and a lower diameter which
corresponds to an adjacent portion of the container shell in order to secure theshell in position during formation of the brim curl. As illustrated in Figure
,
CA 02248278 1998-10-23
- 13 -
5, the lower diam~ter is less than the upper diameter in that containers having
a tap~red side wall as illustrated in Figures lA and lB are being formed.
However, containers having vertically extending side walls may also be readily
formed in accordance with the present invention. Further, as with
S conventional forming dies, the upp~r periphery of the bore 20 includes a
ch~nnel 22 which receives the paperboard material during formation of the
brim curl. Again, while the overall construction of the die arrangement is
essentially as conventionally known, the size of the undercut 16 and channel
22 are larger than those used previously for forming containers of the same
10 size and paperboard properties.
Paperboard containers may be formed in a variety of configurations in
accordance with the present invention. As can be seen from Figure 6A, 6B
and 6C, the paperboard container may be either circular as illustrated in
Figure 6A, rectangular or square as illustrated in Figure 6B, or oblong as
1~ illustrated in Figure 6C. Each of these containers benefit from forming the
brim curls B in a manner consistent with the present invention.
As discussed previously, by forming containers in accordance with the
present invention, the forming strain limits may be extended to permit larger
brim curls to be formed than with conventional methods. The maximum
~0 forming strain is a function of the basis weight of the paperboard material.
moisture content and stretch of the paperboard material with the forming strain
limiting the size of the brim curl which may be formed without defects.
In accordance ~ ith the present invention a paperboard container
formed from a paperboard material having a basis weight in the range of 60
CA 02248278 1998-10-23
- 14 -
to 300 pounds per 3,000 square feet (60 to 300 lbs/RM) and preferrably 120
to 220 Ibs/RM is formed having a brim curl formed about an upper periphery
of the container with the forming strain of the container satisfying the forrnula:
BWC~ ) 100 ( 2BWCf ~100
R+BW(l-C~ D-2BWC~
where BW is a brim width of the container, D is a diameter of the
5 container at an outer periphery of the brim, R is an inner radius of the
curvature of the container at the brim and Cf is a correction factor to account
for the tapered side wall of the container. These dimensions being illustrated
in each of Figures 6A, 6B and 6C. The correction factor Cf for a tapered
container satisfies the formula:
11- sin~
where 0 is the side wall tap~r in degrees.
With respect to the container configurations illustrated in Figures 6B
and 6C, the greatest point of strain on the paperboard material is at the regionwhere the brim curl is curved. Accordingly, the forming strain is thus
determined in this region. A container formed in accordance with the present
. . . ~
CA 02248278 1998-10-23
invention being void of brim curl defects in the curved region will be void of
brim curl defects along the elongated portions of the brim curl B as well.
Referring now to Figure 7, a first embodiment of forming containers
in accordance with the present invention will be discussed in detail. In this
embodiment, container blanks 100 are forrned from a known stamping process
and positioned within a hopper 110 in a conventional manner for subsequent
removal and manipulation into the resultant container. In accordance with the
present invention, the hopper 110 includes a hood 112 which will be discussed
in greater detail hereinbelow. Provided in the hood 112 at an outlet end 114
thereof, is an injection manifold for generating a humid atmosphere within the
hood 112 of the hopper 110. Steam is provided and directed to an air steam
rnixing manifold 118. The steam passes through a regulator 120 in order to
regulate the amount of steam being supplied to the air/steam mixing manifold.
Similarly, low pressure air is provided through the passage 122 and regulated
by regulator 124 before being passed to the air/steam mi~ing manifold 118
where a predetermined air/steam mixture is formed and passed to the hood
112. While the surface of the hood 112 is heated using strip heaters to
minimize condensation, the hopper 110 includes a drip pan 126 for draining
any condensation which may be created from the hopper 1 lO.
The container blanks 100 are retained within the hood 112 of the
hopper I lO for a time period sufficient to moisten the portion of the blank 100which is to form the brim curl of a resultant container. This time p~riod
bein~ in the ran~e of 80 to l~0 seconds and preferably 100 to 120 seconds.
The hood l 1~ ~-ould thus be dimensioned so as to retain the container blanks
CA 02248278 1998-10-23
- 16 -
within the hood for a predetermined time period dependent upon the number
of containers per minute b~ing manufactured by the container manufacturing
device 128. As with conventional container manufacturing devices, the
container blanks are sequentially removed from the hopper and formed in a
5 continuous manner.
Referring now to Figures 8 and 9, the construction of the hopper 110
will be explained in detail. As discussed previously, the container bla~ks 100
are positioned within the hopper 110 and are supported on support rails 130
and 132. Lateral support rails 134 are also provided in order to m~int~in the
10 paperboard blanks in a substantially upright position. It should be noted that
the position Gf the support rails 134 are variable by adjusting the vertical
position along columns 136 and 138 such that the hopper 110 can
accommodate a variety of container blank configurations. The rails 134 being
adjusted in a conventional manner through the adjustment means 140.
Similarly, upper support rails 142 and 144 are provided and readily adjustable
by adjustment means 146 along columns 136 and 138, respectively. The rails
142 and 144 again may be adjusted in order to accommodate a variety of
container blank configurations. While the blanks are illustrated as being
substantially upright. it may in some instances be advantageous to permit the
~0 blanks lean either for~ard or bacl~-ward in order to expose a greater portion of the brim region of the blank to the humid atmosphere.
The hopper 110 also includes the hood 112 ~hich extends along a
substantial length of the carton blank stack. Also positioned above the carton
blank stack is an injection manifold 148 ~hich is positioned at an outlet end
CA 02248278 1998-10-23
of the hopper 110 for forrning a humid atmosphere within the hood 112. As
discussed hereinabove, the injection manifold is connected to the air/steam
mixing manifold for injecting a predetermined amount of steam into the hood
1 12 of the hopper I 10. Stearn is mix~d with air at a ratio in the range of 0.1S CFM (cubic feet per minute) s~am per 1.0 CFM air to 1.0 CFM stearn per
1.0 CFM air. The requisite ratio is dependent upon a number of variables
including the initial moisture content of the paperboard material, the
paperboard characteristics and thickness as well as the relative humidity of thesurrounding environment. Also positioned at a forward end of the hopper 110
are restraining mechanisms 150 which restrain the container blanks 100
within the hopper in a manner such that a removal turret, illustrated
schematically as turret 152, can sequentially remove the furthestmost blank
from the hopper 110 for further processing.
Referring now to Figures 10 through lS and in particular, Figure 10,
15 a preferred embodiment of the present invention will be discussed in greater
detail. Figure 10 illustrat~s an accumulator 200 for accumulating container
shells 202 which have been previously formed in accordance with conventional
container manufacturing processes. The shells 202 are retained within the
accumulator 200 and sequentially removed from a lowermost end 204 of the
~1) accumulator 200 and dispensed into a receiving pocket at a conventional
forming station for forming brim curls about an upper periphery of the
container sh~ll 202. The accumulator 200 includes a housing 206 having an
inlet and outlet for receiving and disp~nsing container sh~lls 202. r~spectively.
The output ~nd of the accumulator 200 includes a retaining and dispensing
CA 02248278 1998-10-23
- 18 -
mech~nism 208 which is illustrated in detail in Figure 11. As illustrated
therein, the retaining device 208 includes a drive wheel 210 for interrnittentlydispensing a container shell 202 from the accumulator 200. The retaining
device 208 also includes a plurality of biased support wheels 212 which are
S urged against the container shells by springs 214 in order to aid in the proper
alignment and dispensing of the container shell. The drive wheel 210 is
intermittently driven by motor 216 by way of belt 218 with the motor being
controlled by control unit 220 which senses the position of the lowermost
container shell by way of sensor 222. While only one of the wheels is
10 illustrated as being a drive wheel, more than one and possibly all four of the
wheels may be driven by motor 216 or similar drive mechanism. The wheels
210 and 212 position the lowermost shell 202 in a manner such that air jets
224 can sequentially remove one shell at a time while the subsequent sh~lls are
restrained by the wheels. The air jets are operated in timed sequence with the
15 cup forming machine so that the shell is properly dispensed into the bore in
die 18 when the die is positioned below the dispensing mechanism 208.
Provided within the housing 206 of the accumulator 200 and in
sulToundino relationship about the container shells 202 is the system for
creating a humid atmosphere within the accumulator 200. As is illustrated in
~0 Fi,ure 12, a low pressure air passage 226 is provided about an interior of the
housing 206 and surrounds a plurality of steam passages 228 which extend
along a length of the housing 200. Also provided within the housing 206 are
injection manifolds 230 for injectin~ the humid atmosphere into contact with
the container shells 202. ~'hile Figure 12 illustrates three injection manifolds,
. .
CA 02248278 1998-10-23
- 19 -
any number of injection manifolds may be utilized so long as an appro~liate
atmosphere is provided about the container shells 202.
Referring to Figure 13, a lower pressure air inlet 232 is provided for
introducing the low pressure air into the low pressure air passage 226 and a
5 steam inlet 234 is provided for allowing steam to pass into the steam passages228. Condensation drain passages 236 are provided at a lowermost end of the
housir.g 200 in order to permit any condensation to be drained from the
housing. Steam is mixed with air at a ratio in the range of 0.1 CFM (cubic
feet per minute) steam per 1.0 CFM air to 1.0 CFM steam per 1.0 CFM air.
10 As discussed previously, the requisite ratio is depend~nt upon a number of
variables including the initial moisture content of the paperboard material, thepaperboard characteristics and thickness as well as the relative humidity of thesurrounding environment.
With reference now being made to Figure 14, air and steam are
15 provided to their respective inlets in a manner similar to that illustrated in
Figure 7, and discussed hereinabove. The flow of both the air and steam
being regulated by regulators such that a proper air/steam mixture can be
formed in the mixing manifold 238. Once the proper air/steam mixture is
formed within the mixing manifold 238. the mixture is forced under lower
~0 pressure into the injection manifold 230 and through the plurality of injection
orifices 240 provided in the injection manifold 230. Again, the number of
injection manifolds and injection orifices is dependent upon the amount of
steam desired on the shells 202. It should be noted that the humid atmosphere
in both the hopper and accumulator discussed hereinabove is achieved by the
.. . . ~
CA 02248278 1998-10-23
- 20 -
use of steam. While steam has been determined to provide superior results,
moisture in the form of atomized water may also effectively be used in each
of the above-noted devices.
As with the previous embodiment, it is desired that the container shells
S be maintained in the humid atmosphere for a time period in the range of 80
to 150 seconds and preferably 100 to 120 seconds. In doing so, an example
of the dimensions of an accumulator for forming sixteen ounce cups at 153
cups per minute would be approximately 75 inches long in order to provide
sufficient conditioning time. Further, the accumulator and its selective
10 components are preferably formed of stainless steel.
The particular board properties of the paperboard material from which
either the container blanks or container shells are formed has an impact on
brim curl defects as is illustrated in Table 1.
CA 02248278 1998-10-23
TABLF 1: Accumulator Stearn Trial
! ~r~e Rrim Cups
Strain > 4.41 + 0.0156 x B
DEFECTS
BASIS CD
S TRIAL WT STRETCH CONTROL STEAM
120 5.0 2.8 0.2
130 5.2 2.4 0.0
140 5.3 1.5 0.0
II 120 5.5 2.9 0.0
130 5.7 2.1 0.0
III 220 5.4 3.0 0.0
Reoriented Blank Cups
Strain > 4.0%
DEFECTS
BASIS MD
TRIAL WT STRETCH CONTROL STEAM
120 2.9 2.8 0.2
I 130 2.7 2.5 0.0
140 2.5 2.3 0.0
II 120 2.4 3.0 1.8
130 3.6 2.8 0.0
lII 220 2.8 NO DATA 0.0
Defect Key:
0 = None
20 1 = Slight- dimples. no visible cracks
2 = Moderate - visible cracks on outside of brim
3 = Severe - large cracks which propagate to inside of cup
CA 02248278 1998-10-23
- 22 -
Cup shells were made from paperboard material having three various
basis weights of approximately 120 pounds per ream, 130 pounds p~r ream
and 140 pounds per ream. As can be seen from Table I, the severity of the
defects decreases as board stretch increases and board basis weight increases.
S Less severe defects occur with large brim cups forrned using 140 pounds per
ream board which has a 5.3% stretch than with the 120 pounds per ream
board having a 5.û% stretch. Further, cups formed from paperboard material
having a basis weight of 220 pounds per ream exhibit a reduction in brim
defects when preconditioned with steam. Accordingly, as can be seen from
10 Table I, preconditioning the blanks and shells with steam prior to formation
of the brim curls significantly reduces and often eliminates undesirable brim
curl defects.
In addition to the basis weight of the paperboard material used in
forming the paperboard containers, the conditioning settings, that is the time,
15 temperature and amount of moisture, also affect the formation of brim curls
about an upper periphery of the container. Table II illustrates results of trials
conducted using various conditioning settings in the accumulator embodiment
of the present invention for forming large brim cups.
CA 02248278 1998-10-23
TAB!.F. 11: Accumulator Steam Trial
T.~r~,~e Brim Cups
Strain > 4.41 + 0.0156 x B
TIME 120 130
CONDITIONING SETUP (see.) Lbs/RM Lbs/RM
Cl. Control - Dry Board --- 3.0 2.8
C2. Hot Air (200 F) 100 3.0 2.4
C3. Steam - Low Flow Rate 100 1.6 1.8
C4. Steam - High Flow Rate 30 1.4 1.0
C5. Steam - High Flow Rate 60 1.4 0.2
C6. Steam - High Flow Rate 100 0.6 0.0
C7. Steam - High Flow Rate 120 0.0 0.0
Defect Key:
0 = None
1 = Slight - dimples, no visible cracks
1~ 2 = Moderate - visible cracks on outside of brim
3 = Severe - large cracks which propagate to inside of cup
Accordingly~ by subjecting the container shells to a humid atmosphere
as discussed hereinabove results in the formation of paperboard containers
e chibiting no visible defects which results in a container having an increased
~0 rigidity ar.d ~hich is pleasing to the consumer.
Further tests ~ ere conducted in order to compare the brim forming
characteristics achieved in accordance with both the preferred embodiment and
alternative embodiment set forth hereinabove. As can be seen from Table III
CA 02248278 1998-10-23
- 24 -
hereinbelow, trials were conducted for both large bnm cups and reorient~d
blank cups using both the hopper and accumulator embodiments.
TABLE lII: Comparison of Conditionin~ Methods
T.~r~e E3rim Cups
SStrain > 4.41 + 0.0156 x B
LOCATION METHOD 120 LBS/RM 130 LBS/RM
HOPPER CONTROL 2. 8 0. 8
100 seconds of SPRAY 2.4 0.0
conditioning STEAM 1.5 0.0
ACCUMULATOR CONTROL 2.9 2.1
100 seconds of SPRAY 2.7 2.1
conditioning STEAM 0.0 0.0
Reoriented Blank Cups
Strain > 4.0%
LOCATION METHOD 120 LBS/RM 130 LBS/RM
HOPPER CONTROL 3.0 2.4
100 seconds of SPRAY 2.9 2.0
conditioning STEAM 2.8 0.5
ACCUMULATOR CONTROL 3.0 2.8
~0 100 seconds of SPRAY 3.0 2.5
conditioning STE.~M 1.8 0.0
Defect Key:
0 = None
1 = Slight - dimples, no ~isible cracks
'5 2 = Moderate - ~isible cracks on outside of brim
3 = Severe - large cracks which propagate to insid~ of cup
CA 02248278 1998-10-23
Each was subjected to brim conditioning for lOO seconds using both
moisture spray and steam. Therein, when forming large brim cups using the
accumulator set forth hereinabove, and subjecting the paperboard shells to a
humid atmosphere including steam, no brim defects were detected. Again, as
5 can be seen from Table III, the number of brim curl defects detected is
dependent upon the basis weight of the paperboard material as well as the type
of humid atmosphere to which the paperboard shells or blanks are subjected.
Further, the forming defects are greater when utilizing reoriented paperboard
shells and blanks. That is, when forming paperboard containers having the
10 machine direction of the paperboard material extending in a circumferential
direction of the paperboard container.
While the present invention has been described with reference to a
preferred and alternative embodiment, it will be appreciated by those skilled
in the art that the invention may be practiced otherwise than as specifically
15 described herein without departing from the spirit and scope of the invention.
It is, therefore. to be understood that the spirit and scope of the invention belimited only by the appended claims.
.
