Note: Descriptions are shown in the official language in which they were submitted.
85362-91
APPARATUS AND METHOD FOR ORIENTING A BEVERAGE CONTAINER END
CLOSURE AND APPLYING INDICIA IN A PREDETERMINED LOCATION
[0001]
FIELD OF THE INVENTION
[0002] The present invention relates generally to the manufacture of container
end closures. More
specifically, the present invention relates to methods and apparatus for
orienting and registering a
plurality of container end closures at high speed and providing printed
indicia on predetermined
portions of each end closure.
BACKGROUND
[0003] The global beverage industry, including soft drinks, beers, ciders,
spirits and wines, was
valued at $1.4 trillion in 2008. The industry includes roughly 1,500 soft
drink brands and about 20,000
beer brands. Many of these brands package their beverages in metallic beverage
containers. As a
result, approximately 80 billion metallic beverage containers are used every
year globally.
[0004] Metallic beverage containers offer bottlers, distributors, and
retailers an ability to stand out at
the point of sale because metal beverage containers provide ideal surfaces to
decorate with brand
names, logos, designs, product information, and/or other preferred indicia for
identifying, marketing,
and distinguishing the beverage container and its contents from other products
and competitors.
Currently the container body is the primary surface of a beverage container
that is decorated. However,
container bodies and the decorations thereon are frequently obstructed during
consumption of a
beverage by the consumer's hand. Further, the alignment between decorations on
the container body
and the pour opening of the container end closure is random and therefore the
decoration may be
positioned away from the consumer during consumption.
[0005] Metal end closures provide a unique and effective surface for
decorating with advertising and
marketing indicia in new and creative ways. Unlike the container body,
consumers naturally align the
end closure to open and drink from the container. Thus, the end closure is
positioned to be viewed by
the consumer. Further, the end closure is
1
CA 2996493 2019-07-18
85362-91
typically not obstructed or blocked during consumption of the beverage.
However, end closures are
frequently left undecorated because there are several disadvantages with the
known methods of
decorating them. Therefore, container end closures provide an underutilized
opportunity for
differentiating products at the point of sale and for attracting consumers.
[0006] Container end closures, or shells, are formed separately from the
container body. The
manufacture of end closures requires a number of processing steps collectively
referred to as a
conversion process and is generally illustrated and described in "How Ball
Makes Beverage Ends,"
available at
http://www.ball.com/images/ball_com/product_options_files/How_Ball_Makes_Bevera
ge_Ends.pdf
(last visited June 13, 2014) and U.S. Patent No. 6,533,518. During the
conversion process, the end
closures are transported to a number of processing stations. Typically, a
shell press punches out
circular blanks from a roll or coil of a metal material and forms the blanks
into shells. A curler forms a
peripheral curl around a circumference of the shells and forms a countersink
in the shells. Liners apply
sealing compounds to the shells. A conversion press then converts the shells
into end closures. The
orientation of the shells entering the conversion press is random because
there is no need, or reliable
method, for orienting the shells in the current conversion process. The
conversion press contains
multiple progressive die sets which raise a rivet in the center of the shell,
forms severable scores to
define a tear panel and a pour opening, and connects a pull tab to the rivet.
The end closures are then
bagged, palletized, and stored until needed to seal a filled container body.
[0007] Current manufacturing methods limit the types and locations of
decorations that can be
applied to the end closures. One known method of decorating end closures
applies the decoration to the
metal stock material before forming the shells. Examples of this method are
described in WIPO
Publication Number WO 2007/007102, IJK Patent No. 2,428,659, and UK Patent No.
2,428,668.
Although both coils and cut sheets of metal stock material can be decorated
before the shells are formed
in the conversion process, indexing and printing decorations on coils and cut
sheets is complicated and
cost prohibitive. In addition, there is a high probability of damaging the
decoration when the stock
material is used to form the end closures in the conversion process. For
example, if the decoration is
not properly registered with the shell press a portion of the decoration may
be cut off. The decoration
2
CA 2996493 2019-07-18
85362-91
may also be intersected and damaged by scores or positioned in an area
obstructed from view by the
pull tab. Additionally, the decoration can be damaged by tools used in the
conversion process.
[0008] Another known method of decorating end closures involves decorating the
shells before the
shells enter the conversion press. However, because shells are not oriented
when they enter the
conversion press, the decoration can be intersected by scores, positioned
beneath the pull tab, or located
partially on the tear panel. As a result, the decoration may be hidden from
view by the tab or damaged
when the tear panel is opened.
[0009] Methods of decorating converted end closures after the tear panel is
formed and the pull tab is
attached to the central panel are also known. One such method uses an optical
means of orienting
converted end closures prior to decorating the end closures. However, the
known methods of
decorating converted end closures are generally slow and/or do not apply
decorations in predetermined
areas of the end closure because the end closures are not oriented before the
decoration is applied.
[0010] Another method or orienting an end closure is described in U.S. Patent
No. 6,524,048 to
Tsukada et al. ("Tsukada"). Tsukada generally describes an apparatus that
detects a mark or pattern on
an end shell and then orients an end shell. A tab is subsequently fixed to the
oriented end shell. Yet
another method of orienting an end closure is described in U.S. Patent No.
4,016,968 to Stelter
("Steller"). Stelter generally describes a method and apparatus that uses a
temporary orientation tab
positioned on a lower side of an end closure to rotate the end closure to a
predetermined position.
However, the methods described by Tsukada and Stelter are generally slow and
not suited for the
commercial container industry which requires an apparatus and method capable
of orienting and
decorating end closures at significant production speeds of at least several
thousand end closures per
minute.
[0011] Due to the numerous limitations associated with the existing process of
manufacturing and
decorating end closures, there exists an unmet need for an economical, fast,
and reliable method and
apparatus for orienting post-conversion end closures to enable the application
of decorations and other
preferred indicia to specific areas of the end closures.
SUMMARY OF THE INVENTION
[0012] The present invention provides methods and apparatus for orienting end
closures relative to a
reference axis in a cost-effective, fast, and reliable manner. After the end
3
CA 2996493 2019-07-18
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
closures are oriented, the end closures may be decorated at specific areas
that are not
obstructed or interrupted by the pull tab or scored portions of the end
closure. One aspect
of the present invention is to provide methods and devices for maintaining the
desired
orientation of the oriented end closures to ensure that decorations are
applied to specific
areas of the end closures. Another aspect of the present invention is to
provide an
improved, economical and reliable method for applying decorations to the
oriented, post-
conversion end closures. Still another aspect of the present invention is to
provide an
orienting apparatus that can quickly and efficiently orient converted end
closures in a high
speed production process. In one embodiment of the present invention, the
orienting
apparatus is operable to orient the end closures by mechanical contact with an
exterior
surface portion of the end closure. In another embodiment, the orienting
apparatus does
not require optical or other sensors to orient the end closures.
[001.3] In accordance with one aspect of the present invention, a novel method
of
orienting and decorating an exterior surface of an end closure for a beverage
container is
provided. This includes, but is not limited to, a method generally comprising:
(1)
providing an end closure; (2) placing an orientation head in rotational
contact with an
exterior surface of the end closure; (3) rotating the end closure to a
predetermined
orientation; (4) securing the end closure in the predetermined orientation;
(5) disengaging
the orientation head from the end closure; and (6) decorating a predetermined
portion of
the exterior surface of the end closure with an image. The end closure may
comprise one
or more of, but is not limited to: a peripheral curl, a chuck wall extending
downwardly
from the peripheral curl, a countersink interconnected to a lower end of the
chuck wall, a
central panel interconnected to the countersink, a tear panel in the central
panel, and a tab
operably interconnected to an exterior surface of the central panel. In one
embodiment of
the present invention, the end closure comprises a peripheral curl and a
central panel. In
another embodiment, the end closure includes a tab.
[001.4] Additionally, the method may further comprise: (7) placing the end
closure on a
die cap, the die cap operable to selectively prevent rotation and movement of
the end
closure; (8) forming a recess in one or more printing blankets, wherein the
recess is
adapted to receive the tab; (9) removably affixing the printing blankets onto
a drum of a
coater; (10) applying a base coat material to a predetermined portion of the
printing
blankets; (11) transferring the base coat material from the printing blankets
to the
predetermined portion of the exterior surface of the end closure.
[001.5] The method may further include: (12) forming a recess in one or more
printing
4
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
blankets, wherein the recess is adapted to receive the tab; (13) removably
affixing the
printing blankets onto a drum of a printer; (14) forming the image on a print
head; (15)
applying ink to the image; (16) transferring the ink from the print head to a
predetermined
portion of the printing blankets; (17) transferring the ink from the printing
blankets to the
predetermined portion of the exterior surface of the end closure; and (18)
curing the image
with ultra violet light. In one embodiment, the print head comprises six print
heads, and
each print head receives a different color or type of ink. In another
embodiment, the
printing blankets are removably affixed in from 1 to 10 rows to a
circumference of the
drum of the printer, and from 1 to 10 end closures are decorated
simultaneously. In still
another embodiment, decorating the predetermined portion of the exterior
surface of the
end closure comprises decorating a predetermined portion of at least one the
central panel,
the tear panel, and the pull tab.
[001.6] In one embodiment, rotating the end closure to the predetermined
orientation
further comprises rotating the end closure until a Y-axis of the end closure
is substantially
parallel to a reference axis. In another embodiment, an angle between the Y-
axis and the
reference axis is less than about 50. In one embodiment, the orientation head
is operable
to rotate the end closure to the predetermined orientation. In another
embodiment, rotating
the end closure to the predetermined orientation comprises rotating the end
closure while
the orientation head remains aligned with the predetermined orientation. The
end closure
rotates until a predetermined surface feature of the exterior surface of the
end closure is
engaged by the orientation head. After the orientation head engages the
surface feature of
the end closure, the end closure stops rotating and is aligned in the
predetermined
orientation.
100171 In still another embodiment, the orientation head comprises a body
portion, a
face portion, a pocket formed in the face portion to receive the pull tab of
the end closure,
a tapered portion extending from the face portion to a bottom of the pocket,
and a wall
extending from the bottom of the pocket substantially vertically to the face
portion,
wherein when the orientation head is rotated the pull tab slides into the
pocket and is
retained in the pocket by the wall.
100181 In accordance with another aspect of the present invention, an
apparatus for
orienting and decorating an exterior surface of an end closure which is
adapted for
interconnection to a neck of a beverage container is disclosed, the apparatus
operable to
simultaneously orient and decorate multiple end closures. The apparatus
generally
comprises, but is not limited to: (1) a balancer operable to receive the end
closure and
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
place the end closure in a holder, the holder operable to move the end closure
through the
apparatus and selectively prevent rotation of the end closure; (2) an
orientor, the orientor
operable to receive the holder with an end closure and rotate the end closure
to a
predetermined orientation, wherein the holder prevents rotation of the end
closure from the
predetermined orientation; (3) a coater operable to apply a base coat material
to a
predetermined portion of the exterior surface of the end closure; (4) a
printer operable to
transfer an image to a predetermined portion of the end closure; and (5) at
least one curer
operable to cure the base coat material and the image. In one embodiment, the
end closure
comprises a peripheral curl, a central panel, and a tab interconnected to an
exterior surface
portion of the central panel. In another embodiment, the end closure is
comprised of a
peripheral curl, a chuck wall extending downwardly therefrom, a countersink
interconnected to the chuck wall, and a central panel interconnected to the
countersink.
[001.9] In one embodiment, the orientor includes an orientation head having a
geometry
adapted to locate and engage an exterior surface feature on the end closure.
In one
embodiment, the exterior surface feature is a pull tab interconnected to an
exterior surface
of the central panel. In another embodiment, the exterior surface feature is a
tear panel of
the central panel. In still another embodiment, the exterior surface feature
is the central
panel. In another embodiment, the orientation head comprises a body portion, a
face
portion, a pocket formed in the face portion to receive the pull tab of the
end closure, a
tapered portion extending from the face portion to a bottom of the pocket, and
a wall
extending from the bottom of the pocket substantially vertically to the face
portion, and
wherein the orientation head is operable to rotate around a longitudinal axis
of the body
portion.
100201 In one embodiment, the orientation head is fixed in alignment with the
predetermined orientation. The face portion of the orientation head is adapted
to contact
the exterior surface portion of the end closure and allow the end closure to
rotate. The
orientation head is further adapted to stop the rotation of the end closure
when the end
closure is aligned with the predetermined orientation. In another embodiment,
the
orientation head is adapted to rotate around a longitudinal axis substantially
perpendicular
to the face portion of the orientation head. The orientation head is adapted
to engage a
predetermined exterior surface feature of the end closure and rotate the end
closure to the
predetermined orientation. The orientation head rotates the end closure until
the end
closure is in the predetermined orientation.
100211 In one embodiment, the holder includes a clamp that applies pressure to
the end
6
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
closure to hold the end closure in the predetermined orientation. In yet
another
embodiment, the apparatus is operable to orient and decorate from 1 to 5 end
closures
simultaneously.
[0022] In one embodiment, the printer generally comprises, but is not limited
to, (1) at
least one print head with the image formed thereon; (2) an inker operable to
transfer ink to
the image on the print head; and (3) a drum, the drum having a circumference
with one or
more printing blankets affixed thereto, the printing blankets each having a
recess adapted
to receive a pull tab interconnected to the exterior surface of the end
closure, the drum
operable to move the printing blankets into rotational contact with the print
head and the
exterior surface of the end closure, wherein the image is transferred from the
print head to
the printing blankets and then to the predetermined portion of the end
closure.
100231 It is another aspect of the present invention to provide an orientation
head for an
orientor used to position an end closure in a decorating process. The
orientation head
generally comprises: (1) a body portion; (2) a face portion, the face portion
oriented in a
plane generally perpendicular with respect to a longitudinal axis of the body
portion; and
(3) a pocket formed in a portion of the face portion, the pocket having a size
adapted to
receive a pull tab of the end closure, the pocket having a bottom end
substantially parallel
to the face portion, a first side sloping upward from the bottom end to the
face portion, and
a second side forming a substantially vertical wall from the bottom end to the
face portion.
In one embodiment, the body portion is adapted to be interconnected to an
orientor used in
an end closure decorating process.
[0024] In one embodiment, the orientation head is adapted to rotate around the
longitudinal axis. In another embodiment, the face portion of the orientation
head is
adapted to slide across an exterior surface of a pull tab interconnected to
the end closure as
the orientation head rotates. In still another embodiment, the orientation
head does not
rotate around the longitudinal axis as the end closure is rotated around the
longitudinal
axis. In yet another embodiment, the face portion is adapted to enable the
exterior surface
of the pull tab interconnected to the end closure to slide across face portion
as the end
closure rotates while the orientation head does not rotate. In another
embodiment, the
orientation head is fixed in a predetermined orientation and is adapted to
engage a
predetermined surface feature of an end closure when the end closure rotates
to the
predetermined orientation.
[0025] In another embodiment, the first side is adapted to direct a pull tab
interconnected to the end closure from the face portion into the pocket. In
yet another
7
85362-91
embodiment, the wall is adapted to retain a pull tab interconnected to the end
closure in the pocket and
the wall applies a force to a side surface of the pull tab to rotate the end
closure to a predetermined
orientation. In one embodiment, the face portion comprises a substantially
planar surface. In one
embodiment, the pocket has a depth greater than a distance between the
exterior surface of the pull tab
and the end closure to which the pull tab is interconnected. Thus, the
exterior surface of the pull tab
does not contact the bottom portion of the pocket when the pull tab is engaged
by the orientation head.
In another embodiment, the pocket has a depth that is less than or about equal
to the distance between
the exterior surface of the pull tab and the end closure to which the pull tab
is interconnected.
Accordingly, the exterior surface of the pull tab may contact the bottom
portion of the pocket when the
pull tab is engaged by the orientation head.
[0026] In one embodiment, at least a portion of the pocket is adapted to
engage the pull tab of the
end closure and apply a rotational force to the end closure. In another
embodiment, at least a portion of
the pocket is adapted to engage the pull tab of the end closure to stop the
rotation of the end closure
when the end closure is in the predetermined orientation. In one embodiment,
the pocket includes an
opening that forms a void in a portion of the body portion of the orientation
head. In another
embodiment, the pocket has a asymmetric shape.
[0027] Still another aspect of the present invention is a novel method of
orienting and decorating an
end closure for a container. The method includes, but is not limited to: (1)
providing a plurality of end
closures which are adapted for interconnection to a neck of a container; (2)
feeding at least one end
closure with a pull tab interconnected to an exterior surface into a first end
of a guide assembly of an
orientor; (3) engaging an orientation head of the orientor with the exterior
surface of the end closure,
wherein the orientation head is interconnected to a distal end of a spoke of
the orientor; (4) rotating the
at least one end closure while in the guide assembly to align the pull tab of
the at least one end closure
in a predetermined orientation; (5) placing the at least one end closure on a
holder proximate to the
second end of the guide assembly of the orientor; (6) disengaging the
orientation head from the at least
one end closure; and (7) decorating a predetermined portion of the exterior
surface of the at least one
end closure. The decoration may be in any orientation and any location of the
exterior surface of the
end closure. As will be appreciated, after the end closure is oriented in the
predetermined orientation,
the end closure may be decorated by any method known to those of skill in the
art. For example, in one
embodiment, the end closure is decorated using one or more printing processes
including, but not
limited to, offset printing, dry offset printing, gravure printing, intaglio
printing, screen printing, tampo
printing, and inkjet printing. In another embodiment of the present invention,
the end closure is
8
CA 2996493 2020-03-13
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
decorated by a laser marking system. Accordingly, in one embodiment of the
present
invention, decorating the predetermined portion of the exterior surface of the
end closure
comprises one or more of an image, a laser marking, a code, and a text message
formed on
the end closure by any means. In one embodiment, the end closure is comprised
of a
peripheral curl, a chuck wall extending downwardly therefrom, a countersink
interconnected to the chuck wall, and a central panel interconnected to the
countersink.
100281 In one embodiment of the present invention, the guide assembly further
comprises an inner rail interconnected to an outer rail. The inner and outer
rails are
separated by a distance approximately equal to a height of the end closure.
The inner and
outer rails are operable to retain the exterior surface of the end closure in
contact with the
orientation head as the orientation head moves the end closure from the first
end to the
second end of the guide assembly. In another embodiment, the guide assembly of
the
orientor has a substantially arcuate shape.
190291 In one embodiment of the present invention, the orientation head of the
orientor
is interconnected to a distal end of a spoke. In another embodiment, the spoke
is operable
to rotate the orientation head around a longitudinal axis of the spoke. In
still another
embodiment, a first end of the spoke is interconnected to a hub of the
orientor. The hub is
operable to rotate axially at a predetermined rate. In still another
embodiment, the spoke
is adapted to move the orientation head along an arcuate path from the first
end to the
second end of the guide assembly.
100301 In one embodiment, the spoke is further adapted to rotate the
orientation head
around the longitudinal spoke axis as the spoke moves the orientation head
from the first
end to the second end of the guide assembly. In another embodiment, the spoke
is adapted
to begin rotating the orientation head at a first point and stop rotating the
orientation head
at a second point as the hub of the orientor rotates axially. In one
embodiment. the first
point is proximate to the first end of the guide assembly and the second point
is between
the first end and the second end of the guide assembly. In still another
embodiment, the
spoke further comprises a first gear adapted to engage a bevel gear of the
hub. The first
gear and the bevel gear are adapted to initiate rotation of the orientation
head at the first
point and stop rotation of the orientation head at the second point.
100311 In one embodiment, the spoke is adapted to rotate the orientation head
a
predetermined number of times around the longitudinal spoke axis. In another
embodiment, the spoke is adapted to rotate the orientation head one time
around the
longitudinal spoke axis. In yet another embodiment, the spoke is adapted to
rotate the
9
85362-91
orientation head between approximately one time and approximately four times
around the longitudinal
spoke axis.
[0032] In another embodiment of the present invention, the orientor is
operable to rotate the end closure
around a longitudinal axis of the spoke while the orientation head remains
aligned with the
predetermined orientation. The orientation head is operable to stop the
rotation of the end closure when
the end closure is aligned in the predetermined orientation. In one embodiment
of the present invention,
a predetermined portion of the end closure contacts a stationary structure of
the orientor. The contact
between the end closure and the stationary structure causes the end closure to
rotate around the
longitudinal spoke axis. In one embodiment, the stationary structure is a
friction rail. In another
embodiment, one or more of the inner and the outer rails are adapted to apply
a frictional force
sufficient to rotate the end closure. In still another embodiment, a drive
roller or a motion belt of the
orientor are adapted to rotate the end closure.
[0033] In one embodiment of the present invention, the spoke comprises a
plurality of spokes
interconnected to the hub of the orientor. In another embodiment, the spoke
comprises six spokes. In
still another embodiment, the spoke comprises from two to nine spokes
interconnected to the hub of the
orientor.
[0034] In one embodiment, rotating the end closure to align the end closure in
a predetermined
orientation further comprises rotating the end closure until a Y-axis of the
end closure is substantially
parallel to a reference axis. In another embodiment, an angle between the Y-
axis and the reference axis
is less than about 5 .
[0035] In yet another embodiment, decorating a predetermined portion of the
exterior surface of the end
closure further comprises providing one or more printing blankets. Each
printing blanket comprising a
recess adapted to receive a pull tab which is interconnected to the exterior
surface of the end closure.
The printing blankets are removably affixed onto a drum of a printer. A image
is formed on a print
head. Ink is applied to the image. The ink is then transferred from the print
head to a predetermined
portion of the printing blankets. The ink is transferred from the printing
blankets to the predetermined
portion of the exterior surface of the end closure.
[0036] In accordance with another aspect of the present invention, a novel
apparatus for receiving and
orienting an end closure which is adapted for interconnection to a neck of a
container is disclosed. The
apparatus generally comprises: (1) an arcuate guide assembly comprising a
first end and a second end,
the first end adapted to receive an end closure with a pull tab and the second
end adapted to release the
end closure; (2) a hub operable to rotate proximate to
CA 2996493 2020-03-13
85362-91
the arcuate guide assembly at a predetermined rate; (3) a plurality of spokes
radially interconnected to
the hub; and (4) an orientation head interconnected to a distal end of each
spoke, the orientation head
adapted to engage an exterior surface portion of the end closure at the first
end of the arcuate guide
assembly and rotate the exterior surface portion of the end closure to align
the pull tab interconnected to
the exterior surface portion to a predetermined orientation as the orientation
head and the end closure
move axially from the first end to the second end of the arcuate guide
assembly.
[0037] In one embodiment, at least a portion of each of the plurality of
spokes is operable to rotate
around a longitudinal axis of each spoke. In another embodiment, the apparatus
further comprises a
bevel gear operably engaged to the hub and a pinion gear interconnected to the
spoke. The bevel gear
comprises a face portion oriented substantially perpendicular to an axis of
rotation of the hub. Teeth are
formed on a portion of an annulus of the face portion of the bevel gear.
Accordingly, teeth of the pinion
gear engage the teeth formed on the bevel gear to rotate the rotatable portion
of the spoke and an
orientation head interconnected thereto during a predetermined portion of each
rotation of the hub.
[0038] In another embodiment of the present invention, the arcuate guide
assembly further comprises
an inner portion spaced from an outer portion. At least a portion of the
exterior surface portion of the
end closure contacts the inner portion of the arcuate guide assembly. In
addition, at least a portion of an
interior surface portion of the end closure contacts the outer portion of the
arcuate guide assembly.
100391 In one embodiment, the orientation head further comprises a body
portion interconnected to the
spoke. A face portion of the orientation head comprises a substantially planar
surface orientated in a
plane generally perpendicular to the body portion. A pocket is formed in a
portion of the face portion,
the pocket comprising a geometric profile adapted to receive a pull tab
interconnected to the exterior
surface portion of the end closure. In another embodiment, the orientation
head is adapted to engage the
exterior surface of the end closure. The orientation head rotates the end
closure around the longitudinal
spoke axis as the orientation head and the end closure travel between the
first end and second end of the
arcuate guide assembly.
[0040] In still another embodiment of the present invention, the apparatus is
operable to rotate the end
closure around a longitudinal spoke axis as the orientation head and the end
closure move between the
first end and second end of the arcuate guide assembly. During the movement
between the first end and
the second end, the orientation head does not rotate around the longitudinal
spoke axis. The orientation
head is operable to stop the
11
CA 2996493 2020-03-13
85362-91
rotation of the end closure when the end closure is aligned to the
predetermined orientation. In one
embodiment, a portion of the arcuate guide assembly applies a friction force
to the end closure which
causes the end closure to rotate around the longitudinal spoke axis. In one
embodiment, the portion of
the arcuate guide assembly is a friction rail. In another embodiment, one or
more of the inner and the
outer rails are adapted to apply the frictional force to the end closure. In
still another embodiment, a
drive roller or a motion belt associated with the arcuate guide assembly are
adapted to rotate the end
closure.
[0041] In one embodiment of the present invention, the apparatus comprises two
arcuate guide
assemblies and a hub associated with each arcuate guide assembly. In yet
another embodiment, the
apparatus comprises four arcuate guide assemblies with a hub associated with
each arcuate guide
assembly. In still another embodiment, the apparatus comprises from one to
eight arcuate guide
assemblies and hubs. Each hub has a plurality of spokes. In one embodiment of
the present invention,
the plurality of spokes comprises six spokes interconnected to each hub. In
another embodiment, the
plurality of spoke comprises from two to ten spokes interconnected to each
hub. Each distal end of the
plurality of spokes comprises an orientation head.
In accordance with another aspect of the present invention, a novel method of
orienting a metallic end
closure is provided. This includes, but is not limited to, a method generally
comprising: (1) providing
an orientor, comprising: an arcuate guide assembly including a first end, a
second end, and a means for
engaging and supporting the metallic end closure; a hub operable to rotate at
a predetermined rate; a
plurality of spokes extending radially from the hub; and an orientation head
interconnected to the distal
end of each spoke, the orientation head having a face portion adapted to
engage an exterior surface
portion of the metallic end closure, wherein each of the plurality of spokes
are adapted to move the face
portion of the orientation head interconnected thereto from the first end to
the second end of the arcuate
guide assembly; (2) receiving the metallic end closure at the first end of the
arcuate guide assembly,
and wherein a pull tab interconnected to the exterior surface portion of the
metallic end closure is
positioned in the arcuate guide assembly proximate to the hub and a face
portion of one of the
orientation heads; (3) rotating the hub, wherein the face portion of the
orientation head engages the
metallic end closure and moves the metallic end closure from the first end to
the second end of the
arcuate guide assembly; and (4) rotating the metallic end closure around a
longitudinal axis of the
spoke associated with the orientation head such that the metallic end closure
and the pull tab are aligned
in a predetermined orientation when the metallic end closure exits the second
end of the
12
CA 2996493 2020-03-13
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
arcuate guide assembly. In one embodiment, the method further comprises
disengaging
the orientation head from the end closure after the end closure is aligned in
a
predetermined orientation. In one embodiment, the end closure is adapted for
interconnection to a beverage container. The end closure may comprise a
peripheral curl,
a chuck wall extending downwardly from the peripheral curl, a countersink
interconnected
to a lower end of the chuckwall, and a central panel interconnected to the
countersink.
190431 In one embodiment of the present invention, at least a portion of each
of the
plurality of spokes is operable to rotate around a longitudinal spoke axis. In
another
embodiment, the orientor further comprises a bevel gear interconnected to the
hub and a
pinion gear interconnected to each of the plurality of spokes. The bevel gear
comprises a
predetermined number of teeth formed on a portion of the bevel gear. In this
manner,
when the hub rotates, the teeth of the pinion gears engage the teeth of the
bevel gear and at
least the rotatable portion of each spoke and the orientation head
interconnected thereo
rotates.
100441 In another embodiment of the present invention, the orientation heads
of the
orientor do not rotate around the longitudinal spoke axis. The orientation
heads are
aligned in a fixed position with respect to the predetermined orientation. The
arcuate
guide assembly is operable to rotate the end closure around the longitudinal
spoke axis.
As the end closure rotates in contact with the face portion of the orientation
head, the pull
tab interconnected to the end closure rotates and is engaged by the
orientation head. The
engagement of the pull tab by the orientation head prevents further rotation
of the end
closure. In one embodiment, contact between a portion of the arcuate guide
assembly and
the end closure causes the end closure to rotate around the longitudinal spoke
axis. In
another embodiment, the arcuate guide assembly includes a friction rail
adapted to rotate
the end closure. In another embodiment, the means for engaging and supporting
of the
arcuate guide assembly is operable to rotate the end closure. In still another
embodiment,
the orientor further comprises one or more of a drive roller and a motion belt
operable to
rotate the end closure.
100451 In another embodiment, the spoke is biased in a radially extended
position.
Thus, the face portion of the orientation head applies a force to the exterior
surface portion
of the end closure when the end closure is engaged to the face portion of the
orientation
head.
100461 The arcuate guide assembly may engage and support the end closure
through a
variety of devices and means. In one embodiment, the means for engaging and
supporting
13
85362-91
includes at least two rails. In another embodiment, the means for engaging and
supporting includes an
inner rail interconnected to an outer rail. The inner and outer rails are
separated by a distance
approximately equal to a height of the end closure. In still another
embodiment, the means for
engaging and supporting includes a first end and a second end, the first end
adapted to receive an end
closure and the second end adapted to release the end closure. In yet another
embodiment, the means
for engaging and supporting includes an inner portion spaced from an outer
portion. The inner and
outer portions are adapted to contact predetermined portions of the end
closure. In still another
embodiment, the means for engaging and supporting is operable to rotate the
end closure.
[0046a] In accordance with another aspect of the present invention, a novel
method of orienting an
end closure prior to applying a decoration in a predetermined location of the
end closure is provided,
the method comprising: (1) providing the end closure which is adapted for
interconnection to a neck of
a container; (2) feeding the end closure into a first portion of an orientor;
(3) rotating the end closure in
a predetermined direction; (4) engaging a predetermined surface feature of an
exterior surface of the
end closure with a portion of the orientor that is aligned in a predetermined
orientation, wherein the end
closure stops rotating and is aligned in the predetermined orientation; and
(5) placing the end closure on
a holder proximate to a second portion of the orientor in the predetermined
orientation prior to applying
a decoration.
1004613] In accordance with another aspect of the present invention, a novel
apparatus is provided for
receiving and orienting an end closure which is adapted for interconnection to
a neck of a container
prior to applying a decoration in a predetermined location of the end closure
is provided, the apparatus
comprising: (I) an orientation assembly comprising a receiving portion and a
discharge portion, the
receiving portion adapted to receive an end closure and the discharge portion
adapted to release the end
closure, wherein the orientation assembly is operable to rotate the end
closure around a longitudinal
axis which is substantially perpendicular to a central panel of the end
closure; and (2) a stop feature
adapted to engage an exterior surface portion of the end closure downstream
from the receiving portion
of the orientation assembly and stop the rotation of the end closure when the
end closure is aligned with
a predetermined orientation, the stop feature being aligned with the
predetermined orientation, wherein
the apparatus is operable to position the end closure on a holder proximate to
the discharge portion of
the orientation assembly.
[0046c] In accordance with another aspect of the present invention, a novel
method of orienting a
metallic end closure is provided, the method comprising:
14
CA 2996493 2019-07-18
85362-91
(1) providing an orientation assembly with: a receiving portion; a discharge
portion; means to rotate the
end closure; and an orientation head having a face portion adapted to engage a
pull tab interconnected
to an exterior surface portion of the end closure, wherein the orientation
head is adapted to move the
end closure from the receiving portion to the discharge portion of the
orientation assembly; (2)
receiving the end closure at the receiving portion of the orientation
assembly, wherein the pull tab of
the end closure is positioned proximate to the face portion of the orientation
head; (3) rotating the end
closure around a longitudinal axis which is substantially perpendicular to a
central panel of the end
closure; and (4) receiving the pull tab of the end closure in a pocket of the
orientation head, wherein the
pocket stops the rotation of the end closure, and wherein the end closure and
the pull tab are aligned in
a predetermined orientation when the end closure exits the discharge portion
of the orientation
assembly.
[0047] The above-described embodiments, objectives, and configurations are
neither complete nor
exhaustive. As will be appreciated, other embodiments of the invention are
possible using, alone or in
combination, one or more of the features set forth above or described in
detail below.
[0048] References made herein to "end closures," or "container end closures"
should not necessarily
be construed as limiting the present invention to a particular size, shape, or
type of end closure. It will
be recognized by one skilled in the art that the present invention may be used
to orient and decoration
end closures of any variety, size, or type, including end closures with one or
more pour or vent
openings or other areas or features. An end closure may comprise one or more
of, but is not limited to:
a peripheral curl, a chuck wall extending downwardly from the peripheral curl,
a countersink
interconnected to a lower end of the chuck wall, a central panel
interconnected to the countersink, a tear
panel in the central panel, and a tab operably interconnected to an exterior
surface of the central panel.
In one embodiment of the present invention, the end closure comprises a
peripheral curl and a central
panel. In another embodiment, the end closure includes a tab interconnected to
an exterior surface
portion of the central panel.
[0049] The phrases "at least one," "one or more," and "and/or," as used
herein, are open-ended
expressions that are both conjunctive and disjunctive in operation. For
example, each of the expressions
"at least one of A, B and C," "at least one of A, B, or C," "one or more of A,
B, and C," "one or more
of A, B, or C," and "A, B, and/or C" means A alone, B alone, C alone, A and B
together, A and C
together, B and C together, or A, B and C together.
[0050] References made herein to "decoration" should not necessarily be
construed as limiting the
present invention to a particular type or method of printing, enhancing, or
decorating end closures.
Those of skill in the art will recognize that the present invention
14a
CA 2996493 2019-07-18
85362-91
may be used with any variety of decorating processes, including lithography,
offset printing, dry offset
printing, gravure printing, intaglio printing, screen printing, tampo
printing, inkjet printing,
flexographic printing, laser printing, and combinations thereof. Further, the
term "decoration" as used
herein refers to any indicia placed on the end closure for any purpose,
including identifying the
contents, location and date of manufacture, recommended use date, manufacturer
of the container or
container component, providing trade names, advertising, promotion, or the
like. In addition, it will be
understood that the term decoration may include the application of primers,
coatings, and decorative
inks of all types to the end closures.
[0051] References made herein to "lithographic printing" or aspects thereof
should not necessarily
be construed as limiting the present invention to a particular method or type
of printing. It will be
recognized by one skilled in the art that the present invention may be used in
other printing processes
such as offset printing, dry offset printing, gravure printing, intaglio
printing, screen printing, laser
printing, and inkjet printing.
[0052] As will be appreciated by one of skill in the art, the method and
apparatus of the current
invention may be used to orient and decorate end closures any material.
Further, the method and
apparatus of the current invention may be used orient and decorate end
closures of any size, shape, and
type for any type of container, including, but not limited to, metallic
beverage containers and metallic
food containers.
[0053] Unless otherwise indicated, all numbers expressing quantities,
dimensions, conditions, and
so forth used in the specification and claims are to be understood as being
modified in all instances by
the term "about."
[0054] The term "a" or "an" entity, as used herein, refers to one or more
of that entity. As such,
the terms "a" (or "an"), "one or more" and "at least one" can be used
interchangeably herein.
[0055] The use of "including," "comprising," or "having" and variations
thereof herein is meant to
encompass the items listed thereafter and equivalents thereof as well as
additional items. Accordingly,
the terms "including," "comprising," or "having" and variations thereof can be
used interchangeably
herein.
[0056] It shall be understood that the term "means" as used herein shall be
given its broadest
possible interpretation. Accordingly, a claim incorporating the term "means"
shall cover all structures,
materials, or acts set forth herein, and all of the equivalents thereof.
Further, the structures, materials,
or acts and the equivalents thereof shall include all those described in the
CA 2996493 2019-07-18
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
Summary of the Invention, Brief Description of the Drawings, Detailed
Description,
Abstract, and Claims themselves.
100571 The Summary of the Invention is neither intended nor should it be
construed as
being representative of the full extent and scope of the present invention.
Moreover,
references made herein to "the present invention" or aspects thereof should be
understood
to mean certain embodiments of the present invention and should not
necessarily be
construed as limiting all embodiments to a particular description. The present
invention is
set forth in various levels of detail in the Summary of the Invention as well
as in the
attached drawings and the Detailed Description and no limitation as to the
scope of the
present invention is intended by either the inclusion or non-inclusion of
elements or
components. Additional aspects of the present invention will become more
readily
apparent from the Detailed Description, particularly when taken together with
the
drawings.
BRIEF DESCRIPTION OF DRAWINGS
100581 The accompanying drawings, which are incorporated herein and constitute
a part
of the specification, illustrate embodiments of the invention and together
with the
Summary of the Invention given above and the Detailed Description of the
drawings given
below serve to explain the principles of these embodiments. In certain
instances, details
that are not necessary for an understanding of the disclosure or that render
other details
difficult to perceive may have been omitted. It should be understood, of
course, that the
invention is not necessarily limited to the particular embodiments illustrated
herein.
Additionally, it should be understood that the drawings are not necessarily to
scale.
100591 Fig. 1 is a schematic flow diagram of one embodiment of the present
invention
which depicts a system for orienting and decorating end closures;
[00601 Fig. 2 is a perspective view of one embodiment of a die cap of the
present
invention which is adapted for holding an end closure;
100611 Fig. 3 is a side elevation view of the system of Fig. I illustrating an
end closure
orientation assembly in one embodiment of the present invention;
100621 Fig. 4 is a perspective view of an orientation head of one embodiment
of the
present invention;
100631 Figs. 5A - 5C depict a method of orienting an end closure with an
orientation
head according to one embodiment of the present invention;
(0064j Fig. 6 is a process diagram of a method of orienting and decorating end
closures
according to one embodiment of the present invention;
16
CA 02996493 2018-02-23
WO 2017/039765
PCT/US2016/032736
100651 Fig. 7 is a schematic flow diagram of another embodiment of a system of
the
present invention operable to orient and decorate end closures;
[0066] Fig. 8 is an exploded perspective view of an orientor of an embodiment
of the
present invention;
[0067] Fig. 9A is a front elevation view a wheel and guide assembly of the
orientor of
Fig. 8 with a cover portion of the wheel removed to show bevel gears
associated with
spokes of the orientor;
100681 Fig. 9B is a side elevation view of the wheel and guide assembly of
Fig. 9A;
[0069] Fig. 10A is another front elevation view of a wheel and guide assembly
of the
orientor of Fig. 8 interconnected to a mount and further illustrating a sensor
associated
with the orientor;
[0070] Fig. 10B is a side elevation view of the wheel and guide assembly of
Fig. 10A
and further illustrating two wheels of the orientor interconnected axially to
the mount and
further illustrating a motor of the orientor;
100711 Fig. 11 is a perspective view of an orientor of the present invention
comprising
four wheels arranged in two staggered rows and further illustrating a holder
receiving
oriented end closures from the or
[0072] Figs. 12A and 12B are two perspective views of an orientation head of
an
embodiment of the present invention; and
[0073] Fig. 13 is a process diagram of a method of orienting and decorating
end closures
according to an embodiment of the present invention.
100741 Similar components and/or features may have the same reference number.
Components of the same type may be distinguished by a letter following the
reference
number. If only the reference number is used, the description is applicable to
any one of
the similar components having the same reference number.
[0075] To assist in the understanding of one embodiment of the present
invention the
following list of components and associated numbering found in the drawings is
provided
herein:
Number Component
2 Orienting and decorating system
4 Balancer
6 Orientor
8 Coater
Printer
17
CA 02996493 2018-02-23
WO 2017/039765
PCT/US2016/032736
12 Curer
14 Collector
15 Interior surface of end closure
16 End closure
17 Exterior surface of end closure
18 Conversion press
19 Peripheral curl
20 Central panel
22 Tear panel
23 Secondary vent panel
24 Pull tab
25 Pull tab side surface
26 Holder
27 Chain
28 Y-axis
30 Reference axis
32 Clamping mechanism
34 Drum
35 Gear
36 Printing blankets
37 Rows of blankets
38 Recess
40 Application roller
42 Print head
44 hiker
45 Inspection station
46 Image
48 Die cap
50 Body
52 Bore
54 Face
56 Aperture
58 Clamp
60 Clamp end
18
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
62 Orientation head
64 Chain
66 Wheels
68 Chain
70 Orientation head body
72 Longitudinal axis
74 Head
76 Face
78 Tapered portion
80 Pocket
82 Wall
83 Endwall
84 Method of decorating and orienting end closures
86 Start
88 Load end closures
90 Rotate end closures
92 Lock end closures in predetermined orientation
94 Inspect for proper orientation
96 Pre-treat end closures
98 Apply and cure base coating
100 Decoration applied and cured
102 Optional over-coat applied and cured
104 Inspect end closures
106 Collect rejected end closures
108 Collect decorated end closures
110 End
120 Orienting and decorating system
124 Feeder
126 Orientor
128 Wheel
129 Motor
130 Guide assembly
132 Mount
133 Axle
19
CA 02996493 2018-02-23
WO 2017/039765
PCT/US2016/032736
134 Mounting plate
136 Bearing
138 Bevel gear
139 Anti-rotation guide
140 Hub
142 Hub apertures
144 Spoke
145 Spoke bearing
146 Pinion
148 First axle
149 Pinion bearing
150 Second axle
152 Tension spring
154 Linear spline assembly
156 First End
158 Second End
160 Inner rails
162 First extensions of inner rails
164 Second extensions of inner rails
166 Pinion teeth
168 Bevel gear teeth
170 Outer rails
172 Rail
174 Rail end
176 Sensor
178 Protrusion of holder
180 Method
182 Start
184 Feeder separates end closures
186 Orientor receives end closures
188 Orientation head rotates end closures
190 Inspection
192 Collect rejected end closures
194 Load end closures in holder
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
196 Optional pre-treatment
198 Pre-coat applied and cured
200 Decoration applied and cured
202 Over coated applied
204 Decoration inspected
206 Passing end closures collected
208 End
DETAILED DESCRIPTION
[0076] The present invention has significant benefits across a broad spectrum
of
endeavors. It is the Applicant's intent that this specification and the claims
appended
hereto be accorded a breadth in keeping with the scope and spirit of the
invention being
disclosed despite what might appear to be limiting language imposed by the
requirements
of referring to the specific examples disclosed. To acquaint persons skilled
in the
pertinent arts most closely related to the present invention, a preferred
embodiment that
illustrates the best mode now contemplated for putting the invention into
practice is
described herein by, and with reference to, the annexed drawings that form a
part of the
specification. The exemplary embodiment is described in detail without
attempting to
describe all of the various forms and modifications in which the invention
might be
embodied. As such, the embodiments described herein are illustrative, and as
will become
apparent to those skilled in the arts, may be modified in numerous ways within
the scope
and spirit of the invention.
[0077] Although the following text sets forth a detailed description of
numerous
different embodiments, it should be understood that the detailed description
is to be
construed as exemplary only and does not describe every possible embodiment
since
describing every possible embodiment would be impractical, if not impossible.
Numerous
alternative embodiments could be implemented, using either current technology
or
technology developed after the filing date of this patent, which would still
fall within the
scope of the claims. To the extent that any term recited in the claims at the
end of this
patent is referred to in this patent in a manner consistent with a single
meaning, that is
done for sake of clarity only so as to not confuse the reader, and it is not
intended that such
claim term by limited, by implication or otherwise, to that single meaning.
100781 Referring now to Fig. 1, a system 2 for orienting and decorating end
closures at a
predetermined location is illustrated. The system generally includes a
balancer 4, an
21
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
orientor 6, a cower 8, a printer 10, a curer 12, and a collector 14.
100791 The balancer 4. in one embodiment, receives converted end closures 16
from a
conversion press 18. In one embodiment, the end closures 16 are transported
from the
conversion press 18 to the balancer 4 in a cylindrical stack (not
illustrated). The
cylindrical stack includes a rod with the end closures stacked along the axis
of the rod.
The end closures 16 generally include a peripheral curl 19, a central panel
20, a tear panel
22, and a pull tab 24 operably interconnected to an exterior surface 17 of the
end closure
16. Optionally, other features may be formed on the end closure, such as a
secondary vent
panel 23. Each end closure 16 has a Y-axis 28 aligned with a diameter of the
end closure
and that generally divides each end closure and tab 24 into substantially
symmetric halves.
100801 The balancer 4, in one embodiment, is a mechanical sponge that controls
the
flow of the end closures 16 between the conversion press 18 and the system 2.
The
balancer 4 maintains the proper speed and flow of the end closures 16 to
ensure a
consistent, non-interrupted flow of end closures into the orientor 6. The
balancer 4
accumulates end closures 16 from the conversion press 18 to ensure the system
2 is
supplied with end closures 16 if the conversion press 18 or other upstream
equipment goes
offline, for example, for maintenance, during unscheduled stops, or when new
coils of
sheet metal are loaded in the uncoiler (not illustrated).
100811 In one embodiment, the balancer 4 loads the end closures 16 into a
flight or
holder 26 with the pull tab 24 facing upward. The holders 26 stabilize and
transport the
end closures 16 through the system and provide support to the end closures 16
when the
end closures are decorated and cured. When loaded into the holders 26 at point
A, the end
closures are unoriented with the tabs 24 and tear panels 22 of each end
closure 16
randomly oriented with respect to the reference axis 30 of the system 2.
Further, the Y-
axis 28 of an end closure 16 may not be parallel to the Y-axis of another end
closure.
100821 The holders 26 are adapted to rotate through the system from point A to
point C.
In one embodiment, the holders 26 are interconnected to a belt or a chain 27
that forms a
continuous loop that rotates through the system 2 from point A to point C. In
another
embodiment, two chains 27 form the continuous loop. Although only three
holders 26 are
illustrated, it should be understood by one skilled in the art that any number
of holders 26
can be used with the system 2 of the present invention. The holders 26 are
generally
spaced at regular intervals along the chain 27 in the system 2. In one
embodiment, the
holders are comprised of two longitudinal rails connected by shorter lateral
rungs. The
rails and rungs form pockets in the holders 26 that are adapted to receive the
end closures.
22
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
The size of each holder 26 can be increased or decreased to hold end closures
16 of any
size. The holders 26 are operable to allow the end closures 16 to rotate about
a vertical
axis when the holders 26 transport the end closures through the orientor 6.
The vertical
axis is substantially centered on the central panel 20 of the end closures and
perpendicular
to the Y-axis 28. In one embodiment, the holders 26 control the position of
the end
closures by contact with an inside surface of the central panel or by contact
with an
outside surface of a peripheral curl of the end closure.
100831 Although the holders 26 illustrated in Fig. 1 are shown with four end
closures 16,
it will be appreciated by one of skill in the art that the holders 26 may be
configured to
transport fewer or more end closures. For example, in one embodiment, the
system 2 is
designed to orient and decorate one end closure 16 at a time and the holders
26 transport
one end closure. In another embodiment, the system 2 is designed to orient and
decorate
two end closures simultaneously and the holders 26 transport two end closures.
In still
another embodiment, the holders 20 can transport live end closures 16 through
the system
2. In yet another embodiment up to 12 end closures 16 are transported by each
holder 26.
The holders 26 transport the end closures 16 through the system 2 with a line
drawn
through a center of each end closure generally perpendicular to the reference
axis 30 of the
system 2.
100841 Referring now to Fig. 2, the holders may include a die cap 48 adapted
to receive
each end closure 16. The die cap 48 has a generally cylindrical body 50 with a
diameter
approximately equal to an inside diameter of the end closures 16. One or more
ridges,
bumps, or protrusions may be formed on body 50 to frictionally engage the
inside surface
of the end closures. Optionally, the bumps are biased and can be extended
from, or
retracted into, the body 50 to increase or decrease friction between the die
cap 48 and the
end closure 16.
100851 In one embodiment of the present invention, the die cap 48 is
interconnected to a
holder 26 by an axle (not illustrated) retained in a bore 52. During
orientation of an end
closure 16, the die cap 48 can rotate around the bore 52. After the end
closure 16 is
oriented, the die cap 48 can lock the axle to prevent unintended or
inadvertent rotation of
the die cap 48 to keep the end closure 16 oriented. The die cap 48 has a
generally flat or
substantially linear face portion 54 that is generally perpendicular to a
longitudinal axis of
the body 50. In one embodiment of the present invention, one or more apertures
56 are
formed in the face portion 54. The apertures 56 are interconnected to a vacuum
pump and
are operable to apply a suction force to an interior surface of the end
closure to prevent
23
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
movement of the end closure 16. Optionally, another aperture 56A is
interconnected to a
tank of a compressed gas, such as air. To release the end closure 16 from the
die cap 48, a
flow of the compressed gas is released from the tank through the aperture 56A
to blow the
end closure 16 off of the die cap 48. Additionally, a pivoting clamp 58 may be
positioned
on the body 50. The clamp 58 is illustrated in an engaged position in which
clamp end 60
applies a force to a circumferential surface of an end closure (not
illustrated) to prevent
unintended rotation of the end closure 16 on the die cap 48. The clamp 58 can
pivot to a
disengaged position such that the end 60 does not contact the end closure 16.
In one
embodiment, the clamp 58 comprises three clamps 58 spaced around the
circumference of
the body 50. In this embodiment, each clamp 58 can be moved to an engaged or
disengaged position independently.
100861 Referring now to Fig. 3, one embodiment of the orientor 6 is
illustrated. The
orientor 6 includes orientation heads 62 that are brought into rotational
contact with an
exterior surface of the unoriented end closures 16. In one embodiment, the
orientation
heads 62 are interconnected to a belt or chain 64 that is flexible. In one
embodiment, the
chain 64 is positioned above the path of the holders 26 through the system 2.
The
orientation heads 62 are spaced on the chain 64 to match the spacing of the
holders 26.
The orientor 6 includes a sufficient number or orientation heads 62 to contact
each end
closure 16 positioned in each holder 26. The chain 64 forms a continuous loop
around
wheels 66. The movement of the orientation heads 62 on the chain 64 is
synchronized by
a belt or chain 68 operably interconnected to the chain 27 to which the
holders are
attached such that the orientation heads 62 move at the same rate through the
system 2 as
the holders 26. As the chain 64 rotates, the orientation heads 62 are lowered
into contact
with the end closures 16 that are randomly oriented at point A.
[00871 As the holders 26 move the end closures 16 through the orientor 6, the
end
closures 16 are rotated to a preferred orientation with respect to the
reference axis 30. In
one embodiment of the present invention, as discussed in conjunction with
Figs. 5A-5C,
below, the orientation heads 62 rotate the end closures to the preferred
orientation. In
another embodiment of the present invention, the holders 26 are adapted to
rotate the end
closures while the orientation heads do not rotate and remain aligned with the
preferred
orientation. The orientation heads 62 have a geometry adapted to locate and
engage an
exterior surface feature of the end closures 16. In one embodiment, the
exterior surface
feature is a pull tab 24 interconnected to the exterior surface 17 of the
central panel 20. In
another embodiment, the exterior surface feature is a tear panel 22 of the
central panel 20.
24
CA 02996493 2018-02-23
WO 2017/039765
PCT/US2016/032736
In still another embodiment, the exterior surface feature is the central panel
20. In yet
another embodiment, the exterior surface feature is a rivet that interconnects
the pull tab
24 to the central panel 20. In still another embodiment, the exterior surface
feature is a
debossed area formed in the central panel 20. In another embodiment, the
exterior surface
feature is a score formed on the end closure 16. When the holders 26 exit the
orientor near
point B, the end closures 16 are aligned at the preferred orientation.
100881 Although Fig. 3 illustrates an embodiment of the present invention in
which the
orientation heads are lowered into contact with the unoriented end closures
16, it will be
appreciated by one of skill in the art that other methods of bringing the
orientation heads
62 into contact with the end closures may be used with the present invention.
In one
embodiment, the orientation heads 62 are positioned on a lever that moves the
orientation
heads 62 into contact with the unoriented end closures 16. After the end
closures are
oriented, the lever moves the orientation heads 62 off of the oriented end
closures 16.
100891 It should be understood that although only one orientor 6 is
illustrated in Fig. 3,
any number of orientors 6 may be used in parallel in the system 2 of the
present invention.
For example, in one embodiment illustrated in Fig. I, the system 2 has four
orientors 6. In
another embodiment, the system 2 has six orientors 6.
100901 Referring now to Fig. 4, an embodiment of an orientation head 62
adapted to
orient an end closure 16 is illustrated. The orientation head 62 has a body 70
that is
interconnected to the chain 64 of the orientor 6. In one embodiment, the body
70 has a
generally cylindrical shape. The body 70 has a head 74 at an end distal from
the chain 64.
In one embodiment, the head 74 has a diameter greater than the diameter of the
body 70.
In another embodiment. the head 74 has the same diameter as the body 70. In
yet another
embodiment, the head 74 has a diameter that is less than the diameter of the
body 70. The
head 74 has a face portion 76 that is generally perpendicular to a
longitudinal axis 72 of
the body 70. The face portion 76 is adapted to allow an exterior surface of a
pull tab 24 of
an end closure 1610 slide along the face portion 76 as one of the orientation
head 62 and
the end closure 16 rotates without applying a rotational force to the pull tab
24. A feature
is formed on the face portion 76 that engages a predetermined portion of the
end closure.
In one embodiment, the feature is a pocket 80 formed in a portion of the face
portion 76.
In one embodiment, the pocket 80 captures and rotates a tab 24 and applies a
force to a
portion of the tab 24 to rotate the end closure 16 to a predetermined
orientation. In
another embodiment, the pocket 80 engages the tab 24 and applies a force to a
portion of
the tab 24 to stop rotation of the end closure when the end closure has been
rotated to the
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
predetermined orientation. In one embodiment, the pocket 80 includes a tapered
portion
78 that slopes into the face portion 76 toward the body 70 and forms a first
side of the
pocket 80. The tapered portion 78 is adapted to enable the tab 24 to slide
into the pocket
80. The pocket 80 is adapted to receive the pull tab 24 as one of the
orientation head 62
and the end closure are rotated about the longitudinal axis 72. A wall 82
extends
substantially vertically upward from the pocket 80 to the face portion 76 and
forms a
second side of the pocket 80. The wall 82 is adapted to engage and apply a
force to a side
surface of the pull tab 24. In one embodiment, illustrated in Figs. 5A and 5B,
the face
portion 76 has a diameter substantially equal to a diameter of the central
panel 20 of the
end closure 16. In another embodiment, not illustrated, the face portion 76
has a diameter
substantially equal to a diameter of the end closure 16.
100911 Referring now to Figs. 5A - 5C, an end closure 16 is rotated into a
preferred
orientation by an orientation head 62 in a number of successive operations. As
shown in
Fig. 5A, the end closure 16 is positioned on a die cap 48 with a pull tab 24
facing away
from the die cap. A Y-axis 28 of the end closure 16 is positioned at a random
angle with
respect to a reference axis 30. "l be end closure 16 is moved to a position
where a vertical
axis of the end closure is substantially co-linear with a longitudinal axis 72
of an
orientation head 62.
100921 A face portion 76 of the orientation head 62 is moved into contact with
an
exterior surface of the pull tab 24, as illustrated in Fig. 5B. A small top
force is applied to
the end closure 16 by the orientation head 62. Contact between the orientation
head 62
and the pull tab 24 is utilized to rotate the Y-axis 28 of end closure 16 into
a preferred
orientation with respect to the reference axis 30. More specifically, after
contacting the
end closure 16, the orientation head 62 rotates about the longitudinal axis
72. The
orientation head 62 rotates in a direction that allows the pull tab 24 to move
from
contacting the face portion 76 up into the pocket 80. The face portion 76 of
the orientation
head 62 slides along the pull tab 24 until the pull tab 24 reaches the tapered
portion 78
formed in the face portion 76. The orientation head 62 continues rotating and
moves
closer to the exterior surface of the central panel 20 as the pull tab 24
slides along the
tapered portion 78 and into the pocket 80. As the orientation head 62
continues to rotate, a
side surface 25 of the pull tab 24 contacts the wall 82, retaining the pull
tab 24 in the
pocket 80. The orientation head 62 continues to rotate and the wall 82 applies
a force to
the side surface 25 of the pull tab 24, rotating the end closure 16 and the
die cap 48
simultaneously. The force applied by the orientation head 62 is sufficient to
rotate the end
26
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
closure 16 and the die cap 48 without the pull tab 24 spinning freely on the
end closure 16.
Although Fig. 5B illustrates the orientation head 62 and the end closure 16
rotating
counter-clockwise, the orientation head 62 may rotate clockwise if the
position of the
tapered portion 78 and the wall 82 are reversed on the face portion 76 of the
orientation
head 62.
[0093] Referring now to Fig. 5C, the orientation head 62 stops rotating after
about one
rotation around the longitudinal axis 72. Regardless of the starting
orientation of the Y-
axis 28, one rotation of the orientation head 62 is generally sufficient to
rotate the Y-axis
28 of the end closure 16 into a predetermined alignment with the reference
axis 30.
However, in one embodiment, the orientation head 62 may rotate up to two times
around
the longitudinal axis 72. In another embodiment, the orientation head 62 may
make up to
three rotations around the longitudinal axis 72.
[0094] When the predetermined number of rotations of the orientation head 62
is
complete, the orientation head 62 is moved away from the end closure 16. The Y-
axis 28
of the end closure 16 is substantially parallel with the reference axis 30. In
one
embodiment, an angle between the Y-axis 28 and the reference axis 30 is less
than about
. In a more preferred embodiment, the angle between the Y-axis 28 and the
reference
axis 30 is less than about 2 . In a still more preferred embodiment, the angle
between the
Y-axis 28 and the reference axis 30 is less than about 10
[0095] In one embodiment, as the orientation head 62 rotates, the end closure
16 spins
freely on the die cap 48 while the die cap remains stationary. In another
embodiment, the
die cap 48 rotates the end closure 16 while the orientation head 62 remains
substantially
stationary. In this embodiment, the wall 82 of the orientation head 62 is
aligned
substantially parallel to the reference axis 30. When the side surface 25 of
the pull tab 24
contacts the wall 82, the end closure 16 stops rotating and spins freely on
the die cap. Said
another way, the orientation head does not rotate around the longitudinal axis
as the end
closure is rotated into the predetermined alignment. In one embodiment, the
holder 26 or
the die cap 48 are adapted to rotate the end closure around the longitudinal
axis. The face
portion 76 of the orientation head 62 is moved into contact with an exterior
surface of the
pull tab 24, as illustrated in Fig. 5B. A small top force is applied to the
end closure 16 by
the orientation head 62. The holder or the die cap 48 rotate the end closure
in a direction
that allows the pull tab 24 to move from contacting the face portion 76 of the
orientation
head 62 up into the pocket 80. The pull tab 24 of the end closure slides along
the face
portion 76 of the orientation head 62 until the pull tab 24 reaches the
tapered portion 78
27
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
formed in the face portion 76. The end closure continues rotating and the face
portion 76
moves closer to the exterior surface of the central panel 20 as the pull tab
24 slides along
the tapered portion 78 and into the pocket 80. As the end closure continues to
rotate, a
side surface 25 of the pull tab 24 contacts the wall 82, retaining the pull
tab 24 in the
pocket 80. The orientation head 62 continues to rotate and the wall 82 of the
pocket 80
applies a force to the side surface 25 of the pull tab 24, preventing further
rotation of the
end closure 16. The force applied by the orientation head 62 is sufficient to
prevent
further rotation of the end closure without the pull tab 24 spinning freely on
the end
closure 16. In one embodiment, the end closure may spin freely on the holder
26 or the
die cap 48 when the pull tab 24 is engaged in the pocket 80. In another
embodiment, the
holder or the die cap 48 are adapted to stop rotating when the wall 82 of the
pocket 80
applies the force to the pull tab 24.
[00961 After the end closure 16 is rotated to a predetermined orientation, the
holders 26
are operable to prevent further rotation of the end closures 16 by any means
known to
those of skill in the art. In one embodiment, a clamping mechanism 32
interconnected to
the holder 26, illustrated in Fig. 1, applies a force to the end closure 16 to
prevent
unintended rotation of the end closure 16. In one embodiment, the clamping
mechanism
32 comprises a single bar that is moved into contact with all of the end
closures 16 in the
holder 26. In another embodiment, the holders 26 include a matching contour
friction
clamp 32 or a multipoint circumferential contact clamp 32 to prevent
unintended
movement of the end closures 14. In another embodiment, the holders 26 apply a
suction
force to a surface of the end closure to prevent unintended rotation of the
end closures 14.
Optionally, a clamp 58 with a pressure applying end 60 may be interconnected
to the die
cap 48 to prevent rotation of the end closure 16 after the Y-axis 28 is
positioned
substantially parallel to the reference axis 30. The end 60 is adapted to
contact and apply
enough force to the end closure 16 to prevent rotation of the end closure 16.
In one
embodiment, the end 60 moves to apply force to the end closure 16 before the
orientation
head 62 is moved from contact with the end closure. In another embodiment, a
suction
force is applied to an interior surface of the end closure 16 through an
aperture 56 in the
die cap 48 to prevent further rotation of the end closure 16 after the Y-axis
28 is aligned
with the reference axis 30.
[00971 Referring again to Fig. 1, the Y-axis 28 of all the end closures 16 are
substantially parallel to each other when the holder 26 exits the orientor 6
at point B. In
one embodiment, the orientor 6 rotates each end closure 16 until the Y-axis 28
is
28
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
substantially parallel to the reference axis 30 of the system 2 and the tear
panel 22 is
positioned to the right of the pull tab 24, as viewed in Fig. 1. Although the
reference axis
30 is generally horizontal as seen in Fig. 1, it will be appreciated that the
reference axis
can be aligned at any desired angle. For example, in one embodiment of the
present
invention, the reference axis is rotated 180 and all of the end closures 16
are oriented with
their pull tabs 24 exiting the orientor 6 before the tear panels 22. in
another embodiment,
the reference axis is rotated 90 clockwise and all of the end closures 16
exit the orientor 6
with the pull-tab 24 oriented towards the top of Fig. 1. In yet another
embodiment, the
reference axis is rotated 90 counter-clockwise and all of the end closures 16
exit the
orientor 6 with the pull-tab 24 oriented towards the bottom of Fig. 1. The
orientation of
the reference axis 30 may be selected by an operator and may be adjusted to
any desired
angle.
[00981 After the end closures 16 are aligned into an oriented position by the
orientor 6, a
clamping mechanism 32 prevents inadvertent and unintended movement of the end
closures 16 as they are transported through the system 2 by the holders 26.
Maintaining
the orientation of the end closures is necessary to add decorations to the
desired locations
on the end closures 16. If the end closures are allowed to rotate out of the
desired oriented
position, any decorations may be applied to undesired areas, such as on the
pull tab or on
scored areas. The clamping mechanism 32 may be actuated by a cam mechanism
positioned in the path of the holders 26 through the system 2.
100991 In one embodiment, the clamping mechanism 32 is interconnected to the
holder
26 and contacts and applies a force to a side surface of the oriented end
closure 16. The
clamping mechanism 32 can include a pivoting arm, a fastener, a gripping
device, a rod, a
bar, a hold, a pneumatic device that creates suction, and/or combinations
thereof or any
other means known by those of skill in the art to prevent inadvertent and
unintended
movement or rotation of the end closures 16. In one embodiment; the clamping
mechanism 32 prevents movement of the oriented end closures 16 by applying a
force to
an inside panel wall or an outside curl diameter. In another embodiment, the
clamping
mechanism 32 physically engages a portion of the oriented end closures to
maintain the
preferred orientation.
101001 In one embodiment, the clamping mechanism 32 is similar to the clamp 58
illustrated in Fig. 2. The clamping mechanism can include an end similar to
the end 60
that rotates to contact and apply pressure to a surface of the end closures
16. In one
embodiment, the clamping mechanism 32 applies pressure to a side surface of
the end
29
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
closures 16. In another embodiment, the clamping mechanism 32 applies pressure
to a top
surface of the end closures. in yet another embodiment, the clamping mechanism
32
applies pressure to an outer circumference of the end closures 16. The pivot
point of the
clamping mechanism 32 can be moved to increase the force applied by the end.
In one
embodiment, the end has an arcuate shape with a radius of curvature
approximately equal
to a radius of curvature of an exterior surface of' an end closure 16.
101011 The holders 26 with the oriented end closures 16 next enter the coater
8.
Optionally, the coater 8 can pre-treat the exterior surface of the end
closures 16. In one
embodiment, the pretreatment is a corona surface treatment, or air plasma
treatment, that
uses a low temperature corona discharge plasma to change the surface
properties of the
end closures 16. In another embodiment, one or more of a corona surface
treatment, flame
plasma treatment, chemical plasma treatment, electroplating, electrostatic
plating,
chemical coating, anodic oxidation, hot dipping, and thermal spraying may be
performed
to pre-treat the exterior surface of the end closures 16. The pretreatment
generally
improves adhesion and bonding between a base coating applied by the coater 8
and the
exterior surface of the end closure 16.
101021 The coater 8 applies a base coating material to the exterior surface of
the end
closures 16. The base coating material generally improves the appearance of
colored inks
that are applied by the printer 10. The base coating material may be an ink,
adhesive, or
lacquer of any desired color. In one embodiment, the base coating material is
a
photosensitive compound that can be cured with ultra violet light. In one
embodiment, a
white base case coating material is applied to the end closures 16. In another
embodiment.
a clear base coating material is applied to the end closures 16. However, as
will be
understood by one of skill in the art, base coatings of any desired color may
be applied by
the coater 8. Additionally, more than one coating can be applied to the end
closures. For
example, in one embodiment, the system 2 includes two or more coaters 8 that
each apply
a different base coating or a base coating of a different color.
101031 The coater 8 includes a drum 34 that is positioned above the path of
the holders
26 through the system 2. The drum 34 can rotate about an axis that is
substantially
perpendicular to the reference axis 30 of the system 2. The drum 34 has radial
section that
matches the pitch or frequency of the holders 26 moving through the system 2.
[01041 Offset printing blankets 36 are attached in rows 37 that run around an
exterior
circumference of the drum 34. The number of rows 37 of blankets is equal to
the number
of end closures 16 in each holder 26. Printing blankets of any size,
thickness, or material
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
may be used. If necessary, the printing blankets 36 may be cut to fit the end
closures. The
number and positions of the printing blankets 36 can be altered depending on
the size of
the end closures 16 and the number of aid closures in each holder 26. In one
embodiment.
the printing blankets 36 have an adhesive backing that is used to interconnect
the blankets
36 to the drum 34. However, it will be understood that any suitable means may
be used to
interconnect the blankets 36 to the drum.
101051 The diameter of the drum 34 can be increased or decreased to match the
pitch of
the holders 26 and to adjust the quality and amount of coating applied by the
coater 8. For
example, if the distance between each holder 26 is increased, the diameter of
the drum 34
can be increased to ensure proper alignment between the printing blankets and
the end
closures 16. The drum 34 rotates at a rate determined to match the frequency
or pitch of
the holders 26 moving through the system. In one embodiment, the drum 34 has a
gear 35
to engage the chain 27 to control the drum's rate of rotation. The drum 34 is
synchronized
so that the gear 35 engages the chain 27 to initiate contact with the end
closures 16 at a
fixed location. The gear 35 sets the application of the coating in a
controlled location on
the end closures 16 and ensure runtime phenomena such as stretching of the
chain 27 do
not degrade the quality of the coating or improper placement of the coating.
The
synchronization of the coater 8 and the holders 26 is monitored and may be
corrected by a
computer. In one embodiment, when the computer detects an end closure is not
properly
seated in the holder 26 or that a holder 26 is not synchronized with the
coater 8, the
computer can raise the drum 34 of the coater 8 to prevent contact between the
blankets 36
and end closures 16. The end closures will then pass through the system 2
without
receiving coatings and decorations and will be rejected when they reach the
inspection
station 45 and separated from properly decorated end closures.
[01061 Because the central panel 20 is generally recessed and is lower than
the
peripheral curl 19, as illustrated in Fig. 3, the printing blankets 36
generally protrude from
a circumference of the drum 34. The printing blankets 36 generally only
contact portions
of the end closures 16 that require coatings. To prevent contact between the
printing
blankets 36 and portions of the end closures 16 that will not be decorated,
recesses 38 may
be formed in the printing blankets 36. In one embodiment, the recesses 38 are
sized to
align with the pull tabs 24 and prevent contact between the pull tabs 24 and
the blankets
36 during the application of coatings. The size and shape of the recesses 38
can be
adjusted for various features such as larger pull tabs, vents, or other
features on the
exterior surface of the end closures. In one embodiment of the present
invention, the
31
CA 02996493 2018-02-23
WO 2017/039765
PCT/US2016/032736
recesses 38 have a shape that corresponds to the shape of the pull tabs 24 of
the end
closures 16. In another embodiment, the recesses 38 have a depth at least
equal to the
height of the exterior surface of the tab 24 above the exterior surface 17 of
the end closure.
Optionally, the recesses 38 can include a shape corresponding to the shape of
the tear
panels 22 as illustrated in Fig. 1. However, it should be understood that the
printing
blankets can include areas that contact and apply coatings to the tear panels
22 and to the
pull tabs 24. Although only one recess 38 is illustrated in each printing
blanket 36, it will
be understood that more than one recess may be formed in each printing blanket
36.
Further, one of skill in the art will recognize that the size and shape of the
printing
blankets 36 and recess 38 can be tuned or adjusted to apply coatings only in
one or more
predetermined areas of each end closure.
101071 As the holders 26 with the oriented end closures 16 move through the
coater 8,
the drum 34 rotates about an axis substantially perpendicular to the reference
axis 30. The
base coating material is applied to each printing blanket 36 by an application
roller 40.
The application roller 40 is operable to transfer the base coating to
predetermined portions
of each printing blanket 36. the location, size, shape, and amount of base
coating
transferred to each printing blanket 36 can be adjusted to conserve the base
coating
material and to match the decoration that will be applied to the end closure
by the printer
10.
101081 After receiving the base coating material from the application roller
40, the drum
34 continues to rotate and brings each printing blanket 36 into contact with
an end closure.
The printing blankets 36 protrude at least partially into the end closures 16
and make
contact with a predetermined portion of the exterior surface of the end
closures 16. The
height of the drum 34 above the holders 26 can be adjusted higher or lower to
increase or
decrease the amount of pressure the printing blankets 36 apply to the end
closures 16.
101091 The holder 26 continues to a curer 12 that cures the base coating with
an ultra
violet light source. However, the curer 12 may also cure the base coating
using any
method known to those skilled in the art, including thermal curing and infra-
red curing. In
one embodiment, the ultra violet light of the curer 12 is produced by light
emitting diodes
(LEDs). In another embodiment, the ultra violet light is produced by mercury-
vapor
lamps.
101101 Next, the holders 26 transport the end closures 16 to the printer 10.
The printer
includes a drum 34A that is the same as or similar to the drum 34 of the
coater 8. The
drum 34A is positioned above the path of the holders 26 and rotates above an
axis
32
CA 02996493 2019-02-23
WO 2017/039765
PCT1US2016/032736
substantially perpendicular to the reference axis 30 of the system 2. The
diameter of the
drum can be increased or decreased to match the pitch of holders 26 moving
through the
system 2.
[0111] Printing blankets 36A are attached in rows 37 to an exterior
circumference of the
drum 34A and protrude from the surface of the drum 34A. The printing blankets
36A can
he el any size, shape, or thickness and can include one or more recesses 38A
as discussed
above. The recesses 38A can have the same size and shape of the recesses 38
attached to
the drum 34 of the coater 8. Optionally, the printing blankets 36A can have a
different
shape than the printing blankets 36. The distance between the holders 26 and
the drum
34A can be adjusted to increase or decrease the pressure the blankets 36A
apply to each
end closure 16.
[0112] As the drum 34A rotates, each printing blanket 36A contacts up to six
different
print heads 42. Images are formed on predetermined portions of each print head
42. Each
print head 42 may have a different image, or portion of an image, formed
thereon.
Additionally, each print head 42 may have images formed in rows that
correspond to the
rows 37 of the drum 34A. In this manner, the print heads 42 may transfer
different images
to each row 37 of printing blankets 36A attached to the drum 34A.
[0113] lnkers 44 transfer ink to the print heads 42. Each inker 44 applies a
single color
of ink to the image of each print head 42. As the dnim 34A rotates, each of
the print heads
42 contacts a printing blanket 36A and transfers its image and particular
color of ink to the
printing blanket. The recesses 38A do not receive ink. When all of the print
heads 42
have transferred their ink colors and images to the printing blankets 36A, a
final
lithographic image is formed on the printing blankets 36A. The printing
blankets 36A
then continue to rotate until they contact and transfer the lithographic image
to the
predetermined portion of the exterior surface of the end closures 16. The
recess 38A
formed in the printing blanket 36A prevent contact between printing blanket
36A and
portions of the end closures 16 that will not be decorated. In one embodiment,
the recess
38A has a shape that prevents contact between the printing blanket 36A and the
pull tab 24
and other features and structures of the end closure 16 that will not be
decorated. In
another embodiment, the recess 38A has a shape that prevents contract between
the
printing blanket 36A and a first portion of the pull tab 24 and the printing
blanket 36A
transfers the lithographic image to a second portion of the pull tab 24.
[0114] The method of offset printing can be varied to use any number of
colors. As will
be appreciated by one of skill in the art, any type of ink may used with the
present
33
85362-91
invention. In one embodiment, the inks are UV curable. In another embodiment,
the inks are powders
or pastes. In another embodiment, specialty inks of any type may be used to
decorate the end closures.
Various type of specialty inks are described in U.S. Patent Application No.
14/686,517.
[0115] Any method may be used to form the images on the print heads 42 and the
printing blankets
36A to form a high resolution lithographic image for transfer to the end
closures. Optionally, one or
more printing blankets 36A interconnected to the drum 34A of the printer 10
may have a different
image formed thereon to transfer a different image to the end closures. For
example, in one
embodiment, the image formed on the printing blankets of row 37A may be
different than the image
formed on the printing blankets of row 37D. Further, the printing blankets 36A
in row 37A may have a
different recess 38A than the printing blankets in row 37D. In addition, the
printing blankets 36A may
be comprised of soft photopolymer plates or soft secondary plates with images
formed thereon, as
described in U.S. Patent Application No. 14/301,018 and U.S. Patent
Application No. 14/686,517.
Optionally, an image may also be formed on each printing blanket 36A. For
example, the printing
blankets 36A may include etched or engraved portions that do not receive ink
to form multiple images
from a single set of printing blankets, as described in International Patent
Publication No. WO
2014/008544.
[0116] The holder 26 next enters a second curer 12A that is operable to cure
the decoration applied
to the end closures 16. The second curer 12A uses an ultra violet light source
to cure the inks of the
decoration. Optionally, the second curer 12A may use a heat source to cure the
decoration as will be
appreciated by one of skill in the art.
[0117] Optionally, an overcoat material may be applied by a second coater 8A.
The second coater
8A is the same as or similar to the coater 8 described above. The overcoat
material is used to enhance
the appearance of the decoration applied to the end closure 16 and to protect
the decoration from the
environment and from contact with other objects. The overcoat material is
applied by the second coater
8A in the same manner as the base coat material. In one embodiment, the
overcoat material is a clear
coating. Optionally, the second coater 8A may be a second printer 10A. The
second printer 10A can
apply a second decoration to the end closures 16 or apply different coatings
and colors to the decoration
applied by the first printer 10. If the optional overcoat material or a second
34
CA 2996493 2019-07-18
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
decoration are applied, the coating or decoration is cured in a third curer
12B using an
ultra violet light source or a heat source.
101181 The holders 26 may optionally transport the decorated end closures 16
to an
inspection station 45 to ensure the decoration has been applied to the
intended location of
the end closures 16. The inspection station 45 can also determine if the
decoration meets a
predetermined quality. In one embodiment, the inspection station 45 includes a
camera for
each end closure 16 positioned in the holder 26. However, it will be
understood by those
of skill in the art that the inspection station may include any means known by
those of skill
in the art to ensure the location and the quality of the decoration meet or
exceed
predetermined quality criteria. End closures that pass the inspection are
separated from
the end closures that do not pass the inspection and are collected separately.
101191 After the holders 26 exit the curer 12A or 12B at point C, the end
closures 16 are
transferred to the collector 14 where each decorated end closure is bagged and
prepared
for shipment to a bottler or for storage. A blast of air may be directed
through an aperture
56 of the die cap 48 to move the end closures 16 to the collector 14. In one
embodiment,
as the chain 27 reaches point C, the chain 27 rotates around a roller. The
holders 26 rotate
out of a generally horizontal position and the end closures fall out of the
holders 26.
[0120] When the end closures 16 are removed from the holders 26 at point C,
the
holders 26 cycle back to receive another group of unoriented end closures 16
from the
balancer 4 at point A. The end closures 16 remain in the holders 26 as the
holders move
from the balancer 4 until the end closures are removed at the collector 14.
101211 Optionally, the system may include a mandrel and tools for embossing,
debossing, andlor engraving the exterior surface of the end closures 16. In
one
embodiment, the tools comprise rollers with contact surfaces with a shape
predetermined
to form a raised or embossed profile or indicia onto one or more portions of
the end
closures 16. The system 2 may further comprise tools, such as an abrasive
tool, polisher,
or grinder, to selectively remove coatings and/or ink from a predetermined
exterior surface
portion of the embossed profile formed on the end closure 16 to produce an end
closure 16
with a bare metal embossed decoration. Optionally, the bare metal embossed
decoration
can be decorated with coatings by the coater 8, printer 10, and/or the second
coater 8A. In
one embodiment, the embossing tools of the system 2 form an embossed profile
or indicia
on the end closures 16 before coatings or decorations are applied to the end
closures 16.
(0122j An example of a decorated end closure 16B is also illustrated in Fig.
1. The end
closure 16B includes a first image 46A positioned in a predetermined portion
of the
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
central panel 20. A second image 46B of an arrow points toward the secondary
vent 23
formed on the central panel 20. A third image 46C of a recycle indicator is
formed on the
tear panel 22. Because the end closure 16B was oriented by the orientor 6
before being
decorated, the images 46 are located in predetermined areas of the end closure
16B that
are not obstructed by the pull tab 24, the secondary vent 23, or other
structures of the end
closure. it will be appreciated that images 46 may be formed at any location
on the end
closure, including the tear panel 22 and the pull tab 24. Further, the images
46 may
include text, customer identification information, branding information,
directions of use
(for example, the arrow 46B) or any other desired decoration or indicia.
101231 The system 2 can orient and decorate approximately 2,000 end closures
at 16 per
minute. In one embodiment, the system can orient and decorate approximately
1,000,000
end closures in 8 hours. The printer 10 can form images 46 using up to six
different colors
or types of ink with a resolution of 133 lines per inch.
191241 Referring now to Fig. 6, an embodiment of a method 84 for orienting and
decorating end closures 16 is illustrated. While a general order of the method
84 is shown
in Fig. 6, the method 84 can include more or fewer steps, or can arrange the
order of the
steps differently than those shown in Fig. 6. Generally, the method 84 starts
with a start
operation 86 and ends with an end operation 110. Hereinafter, the method 84
shall be
explained with reference to the apparatus 2 described in conjunction with
Figs. 1-5.
101251 A balancer 4 loads 88 converted end closures 16 into a holder 26.
Optionally,
the end closures 16 can be positioned on a die cap 48. The holder 26
transports the end
closures 16 into an orientor 6. The orientor 6 rotates 90 the end closures 16
to a
predetermined orientation. The end closures 16 are locked 92 in the
predetermined
orientation by a clamping mechanism 32. Optionally, a clamp 58 interconnected
to the die
cap 48 may lock the end closures 16 in the predetermined orientation.
Additionally, the
end closures 16 may be locked in the predetermined orientation by a suction
force applied
through an aperture 56 of the die cap 48.
101261 The end closures 16 are inspected 94 to determine if the end closures
16 are in
the predetermined orientation. If the end closures 16 are not in the
predetermined
orientation, method 84 proceeds NO and the rejected end closures 16 are
collected 106. If
the end closures 16 are in the predetermined orientation, method 84 proceeds
YES and the
end closures 16 are optionally pre-treated 96.
101271 The holder 26 transports the end closures 16 to a coater 8 and a curer
12 that are
operable to apply and cure 98 base coatings to predetermined areas of the end
closures 16.
36
CA 02996493 2019-02-23
WO 2017/039765
PCT1US2016/032736
The holder 26 then transports 100 the end closures 16 to a printer 10 and a
second curer
12A. The printer 10 is operable to apply a decoration to one or more
predetermined areas
of the end closures 16. Optionally, the decorator can apply different
decorations to each of
the end closures positioned in the holder 26. The second curer 12A is operable
to cure the
decoration applied to the end closures 16 by the printer 10. Optionally, an
over coating
may be applied 102 to the end closures 16 by a second comer 8A and cured by a
third
curer 12B.
101281 The end closures 16 are then inspected 104 to ensure the decoration is
in a proper
location and quality. If the end closures 16 do not pass the inspection 104,
the method 84
proceeds NO and the rejected end closures 16 are collected 106. If the end
closures 16
pass the inspection 104, the method 84 proceeds YES and the end closures are
collected
108 by the collector 14. The method 84 then ends 110.
[0129] Referring now to Fig. 7, another embodiment of a system 120 of the
present
invention for orienting and decorating a predetermined location of an end
closure is
illustrated. The system 120 is similar to system 2 and generally includes a
balancer 4, a
feeder 124, an orientor 126, a coater 8, a printer 10, a curer 12, and a
collector 14. In one
embodiment of the present invention, the balancer 4, coater 8, printer 10,
curer 12, and
collector 14 are the same as, or similar to, the balancer, coater, printer,
curer, and collector
described above in conjunction with Fig. 1.
101301 Orienting the end closures is beneficial to ensure the decoration is
located at a
predetermined location of the end closure. In one embodiment, in order for the
blankets
36, 36A of the coater 8 and printer 10 of systems 2, 120 to decorate the
exterior surface 17
of the end closures without the raised tab 24 of the end closure interfering
with the
decorating process of the system 120, the end closures are rotated to a
predetermined
orientation. The blankets 36, 36A of systems 2, 120 include recesses 38, 38A
to receive
the tab 24 and to prevent the tab from contacting the print surface of the
blankets 36, 36A.
Accordingly, the raised portions of the end closures, such as the tab 24,
projecting from
the exterior surface 17 of the end closure 16, must be oriented to fit within
the recesses 38,
38A. In addition to avoiding interference of the tab 24 with the blankets 36,
36A, the tab
24 of the end closure 16 must be in a predictable location to create
substantially uniform
print locations based on the design of the decoration. The accuracy of the tab
location is
known as registration. Registration of end closures is directly related to
having a
predetermination location of the end closure selected for decoration in a
known or
predictable location. The orientors 6, 126 of the present invention facilitate
accurate
37
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
registration of end closures. In another embodiment of the present invention,
the end
closure is oriented in order for a laser of the printer 10 to form indicia on
one or more
predetermined location of the exterior surface of the end closure. Orienting
the end
closures is also beneficial when decorating end closures without tabs. For
example. an
end closure without a tab may be oriented to ensure decorations are located in
predetermined portions of the end closure to avoid other portions of the end
closure. The
other portions of the end closure may include scores, embossing, rivets, tear
panels, vents,
and other structures that would interfere with, or degrade, the decoration.
[0131] In one embodiment of the present invention, the balancer 4 receives the
converted end closures 16 from the conversion press 18. The end closures 16
are then
transported to the feeder 124. In one embodiment of the present invention, a
plurality of
end closures 16 are transported to the feeder 124 in a cylindrical stack or
"stick" format to
the feeder 124.
101321 The feeder 124 is operable to separate the plurality of end closures
from the stick
into individual end closures 16. The feeder 124 generally includes two counter
rotating
discs and a guide track. Each disc includes a groove with a helical shape
formed around a
circumferential edge. The groove of the discs wrap around the circumferential
edge in
opposite directions similar to a first screw with a right-hand thread and a
second screw
with a left-hand thread. The grooves have the same number of wraps around the
discs.
The pitch of the groove of each of the two discs is substantially identical.
101331 In one embodiment, the rotating discs of the feeder 124 are spaced
apart a
distance approximately equal to a diameter of the end closure. In this manner,
two points
approximately 180 apart on the exterior edge or peripheral curl 19 of an end
closure are
contacted by the rotating discs. As the discs rotate, one end closure at a
time is captured
by a start of each groove and lifted from the stick. The rate of rotation of
the discs is
synchronized so that the groove of each disc lifts each end closure in a
substantially planar
orientation between the discs.
101341 After a predetermined number of rotations of the discs, the end closure
reaches
an end of each groove at substantially the same time. The end closure then
enters the
guide track. The end closures remain in single file in the guide track. In one
embodiment,
the guide track includes a twist to feed the end closures into the orientor
126 with the
exterior surface 17 including the tab 24 proximate to the orientation heads 62
of the
orientor 126.
38
CA 02996493 2019-02-23
WO 2017/039765
PCT1US2016/032736
101351 The feeder 124 then provides the individual end closures 16 to the
orientor 126.
The Y-axis 28 of the end closures 16 is generally randomly oriented with
respect to the
reference axis 30 of the system 120 when the end closures are received by the
orientor
126. Further, the Y-axis 28 of an end closure 16 may not be parallel to the Y-
axis of
another end closure. The orientor 126 is operable to receive the unoriented
end closures
16 and rotate them to a predetermined orientation with respect to the
reference axis 30 of
the system 120.
101361 Referring now to Figs. 8 - 10, an embodiment of the orientor 126 of the
present
invention is illustrated. The orientor 126 generally comprises a wheel 128,
end closure
effectors or orientation heads 62 interconnected to the wheel, a motor 129
operable to
rotate the wheel 128, a guide assembly 130, and a mount 132. The mount 132 is
adapted
to keep the other components of the orientor 126 in a predetermined alignment.
The
orientation heads 62 are the same as, or similar to, the orientation heads 62
described
above in conjunction with Figs. 4-5. Optionally, in one embodiment of the
present
invention, the orientor 126 may include orientation heads 62A, described below
in
conjunction with Fig. 13. In one embodiment of the present invention, the
orientation
heads 62 are rotatably interconnected to the wheel 128. In another embodiment
of the
present invention, the orientation heads 62 are aligned in a predetermined
orientation and
do not rotate as the wheel rotates.
101371 The motor 129, illustrated in Fig. 10B, is operably associated with one
or more
wheels 128. The motor 129 is capable of providing a force to rotate the wheels
at a
predetermined rate. In one embodiment, the motor 129 may receive a signal from
a
controller (not illustrated) of the system 120 to change the rate of rotation
of the wheels.
For example, the controller may send a signal to the motor 129 to start, stop,
or change the
rate of rotation of the wheels 128. In one embodiment of the present
invention, the motor
129 is interconnected to the wheels 128 by an axle 133.
[0138] The wheels 128 generally comprise a mounting plate 134, a bearing 136,
a bevel
gear 138, an anti-rotation guide 139, a hub 140, and spokes 144. The spokes
144 are
interconnected to the hub 140. In one embodiment of the present invention,
each wheel
128 includes six spokes 144. However, it will be appreciated by one of skill
in the art that
the number of spokes on each wheel 128 may be changed to adjust the rate of
operation of
the orientor 126. In one embodiment of the present invention, each wheel has
from three
to twelve spokes. In another embodiment, each wheel has five spokes. In one
embodiment of the present invention, the hub 140 includes apertures 142
adapted to
39
CA 02996493 2019-02-23
WO 2017/039765
PCT1US2016/032736
receive a portion of the spokes 144. However, one of skill in the art will
appreciate that
the spokes may be interconnected to the hub 140 in a variety of different
ways.
101391 In one embodiment of the present invention, the spokes 144 comprise a
bearing
145. a pinion 146, a first axle 148, a pinion bearing 149, a second axle 150,
a tension
spring 152, and a linear spline assembly 154. An orientation head 62 is
interconnected to
each linear spline assembly 154. In one embodiment of the present invention,
each spoke
has a fixed length extending from the hub 140. In another embodiment of the
present
invention, the length of each spoke 144 is variable. The linear spline
assembly 154 and
the orientation head 62 interconnected thereto are biased to a radially
extended position
distally from the hub 140 by the tension spring 152. Accordingly, the
orientation head 62
interconnected to each spoke 144 may rotate around the wheel 128 at a variable
radius. In
one embodiment, the orientation heads 62 rotate in a cam like profile around
the wheel
128. Thus, at least a portion of the rotational path of the orientation heads
62 may be
substantially linear instead of having a continuous arcuate path throughout
its 360
rotation around the wheel 128.
101401 In one embodiment of the present invention, an aperture is formed
axially in at
least a portion of the second axle 150. The first axle 148 is substantially
concentric with
the aperture and the first axle 148 has an exterior diameter less than the
internal diameter
of the aperture of the second shaft. Accordingly, the first axle 148 may at
least partially
slide into the aperture of the second axle 150. The tension spring 152 applies
a
predetermined biasing force to the spline assembly 154 to move the second axle
150 to a
predetermined position in relation to the first axle 148. The linear spline
assembly 154
and the orientation head 62 interconnected thereto are thus biased by the
tension spring
152 to a position radially extended from the hub 140.
[01411 In one embodiment of the present invention, at least a portion of each
spoke 144
is operable to rotate around a longitudinal spoke axis 72. In one embodiment
of the
present invention, the entire spoke 144 rotates around the longitudinal axis
72. In another
embodiment, only a portion of the spoke 144 rotates around the longitudinal
axis. For
example, in one embodiment of the present, at least the linear spline assembly
154 and the
orientation head 62 interconnected thereto rotate around the spoke's
longitudinal axis 72.
The orientation heads 62 may rotate in either direction around the
longitudinal axis 72.
[0142i The guide assembly 130 is adapted to bring the exterior surface portion
17 of the
end closures 16 into contact with an orientation head 62 of the orientor 126.
The guide
assembly may have a variety of shapes. In one embodiment, the guide assembly
has a
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
generally arcuate shape that substantially matches a portion of the rotational
arc of the
orientation heads 62 interconnected to the spokes 144. The guide assembly may
include a
variety of devices and means for engaging and supporting an end closure. The
guide
assembly generally comprises a first end 156 and a second end 158. End
closures 16 are
received at the first end 156 from the guide track of the feeder 124. In one
embodiment,
the single file of end closures in the guide track are aligned substantially
with the direction
of rotation of the orientation heads 62 at the first end.
101431 The guide assembly is adapted to allow the end closures to rotate
around the
longitudinal axis 72 of the spokes 144. In one embodiment, the end closures
are rotated
about the longitudinal spoke axis 72 as the orientation heads 62 rotate. In
another
embodiment of the present invention, the end closures rotate around the
longitudinal spoke
axis 72 and the orientation heads do not rotate around the longitudinal spoke
axis. The
end closures 16 are positioned in the guide assembly by the feeder 124 with an
interior
surface portion 15 facing radially outward away from the orientation heads.
Accordingly,
when the end closures 16 are positioned in the guide assembly 130, the
exterior surface
portion 17 and the tab 24 of each end closure faces radially inward proximate
to the
orientation heads 62 of the orientor 126. When the end closures 16 enter the
first end 156
of the guide assembly 130, the Y-axis 28 (illustrated in Fig. 7) of each end
closure 16 is
randomly oriented with respect to the reference axis 30 of the system 120
101441 In one embodiment, the guide assembly 130 has a generally uniform
radius of
curvature. In another embodiment of the present invention, the radius of
curvature of the
guide assembly 130 varies along the arcuate length of the guide assembly 130.
In another
embodiment of the present invention, a portion of the guide assembly 130
contacts a
portion of the orientation head 62 interconnected to each spoke 144. The
contact
compresses the spring 152 and moves the orientation head 62 and linear spline
assembly
154 radially inwardly.
10145] The guide assembly 130 includes means for engaging and supporting the
end
closure. The means for engaging and supporting may comprise any structure or
structures
for receiving and end closure and supporting the end closure as the end
closure is rotated
to align the end closure in a predetermined orientation. In one embodiment of
the present
invention, the means for engaging and supporting comprises a least one inner
rail 160 and
at least one outer rail 170. The inner and outer rails 160, 170 are separated
by a
predetermined distance selected to retain the exterior surface of the end
closure in contact
with the orientation head as the orientation head rotates the end closure
around the
41
CA 02996493 2019-02-23
WO 2017/039765
PCT1US2016/032736
longitudinal axis 72 and moves the end closure from the first end 156 to the
second end
158 of the guide assembly. In one embodiment, the inner and outer rails 16,
170 are
separated by a distance approximately equal to the height of an end closure.
In another
embodiment, the means for engaging and supporting comprises two inner rails
and two
outer rails; however, one of skill in the art will appreciate that any number
of inner and
outer rails may be used with the guide assembly of the present invention. In
still another
embodiment of the present invention, the inner rails 160 include extensions
162 that
project circumferentially beyond the outer rails 170 at the first end 156 of
the guide
assembly. The extensions 162 are adapted to receive individual end closures 16
from the
feeder 124 and hold the end closure until engaged by an orientation head 62.
The
extensions 162 are also adapted to contact a portion of the orientation head
62 and move
the orientation head 62 radially inward. In still another embodiment, the
inner rails 160
include extensions 164 at the second end of the guide assembly 130.
101461 The means for engaging and supporting may also include a means for
reducing
friction between the means for engaging and supporting and the end closure.
The means
for reducing friction may include, but are not limited to, bearings, ball
bearings, rollers,
wheels, non-stick surfaces, lubricant, and any other suitable structure,
device, or
composition for reducing friction.
101471 As each spoke 144 rotates with the huh 140, the orientation head 62
interconnected to the spoke moves to a position proximate to the first end 156
of the guide
assembly. The orientation head 62 engages an unoriented end closure 16 at the
first end.
The spoke continues to rotate the orientation head 62 toward the second end
158 of the
guide assembly, capturing the end closure in the guide assembly. In one
embodiment of
the present invention, the radius of curvature of the guide assembly 130
decreases between
the first end 156 and the second end 158. Accordingly, because each
orientation head 62
is biased to a radially extended position, each orientation head 62 applies a
predetermined
radial force to the exterior face portion 17 of the engaged end closure 16 as
the orientation
head and the end closure rotate from the first end 156 to the second end 158.
101481 In one embodiment of the present invention, as the orientation head 62
moves
from the first end 156 to the second end 158, the orientation head 62 rotates
the engaged
end closure 16 to a predetermined orientation, in a manner similar the
operation of the
orientation heads described above in conjunction with Figs. 5A-5C. More
specifically,
each orientation head 62 has a geometry adapted to locate and engage a feature
on the
exterior surface portion 17 of the end closures 16. In one embodiment, the
exterior surface
42
CA 02996493 2019-02-23
WO 2017/039765
PCT1US2016/032736
feature is a pull tab 24 interconnected to the exterior surface 17 of the end
closure 16. In
another embodiment, the exterior surface feature is a tear panel 22 of the end
closure 16.
In still another embodiment, the exterior surface feature is a central panel
20 of the end
closure. In yet another embodiment, the exterior surface feature is a rivet
that
interconnects the pull tab 24 to the central panel 20. In still another
embodiment, the
exterior surface feature is a debossed area formed in the central panel 20. In
another
embodiment, the exterior surface feature is a score formed on the end closure
16.
101491 After contacting an end closure 16, an orientation head 62 rotates
until the
exterior surface feature is engaged. In one embodiment of the present
invention, a face
portion 54 of the orientation head 16 slides across the pull tab 24 of the end
closure 16.
When a pocket 80 formed in the face portion 76 of the orientation head 62
aligns with the
pull tab 24, the orientation head moves radially outward closer to the
exterior surface 17 of
the end closure, and the tab 24 is received in the pocket 80. The orientation
head 62
continues to rotate and an edge 82 of the pocket 80 applies a force to the
side surface 25
(illustrated in Fig. 5A) of the pull tab 24, rotating the end closure 16 and
the pull tab 24
simultaneously. 'Ibe force applied by the orientation head 62 is sufficient to
rotate the end
closure 16 without the pull tab 24 spinning freely on the end closure 16.
101501 To orient the end closures 16, the orientation heads 62 rotate a
predetermined
number of revolutions around the longitudinal axis 72 of each spoke. The
orientation
heads 62 may rotate one or more times around the longitudinal axis of the
spoke.
Regardless of the starting orientation of the Y-axis 28 of an end closure 16,
one rotation of
the orientation head 62 around the longitudinal axis 72 as the spoke 144 moves
between
the first end 156 and the second end 158 of the guide assembly 130 is
generally sufficient
to rotate the Y-axis 28 of the end closure 16 into a predetermined alignment
with the
reference axis 30 of the system 120. However, in one embodiment, the
orientation head
62 may rotate up to two times around the longitudinal axis 72. In another
embodiment,
the orientation head 62 may make up to three rotations around the longitudinal
axis 72.
101511 In one embodiment of the present invention, the orientation heads 62
rotate
around the longitudinal axis 72 substantially continuously as the wheel 128
rotates. In
another embodiment, the orientation heads 62 are adapted to rotate during a
predetermined
portion of each rotation of the wheel 128. In one embodiment, each orientation
head 62
begins rotating proximate to the first end 156 of the guide assembly 130. Each
orientation
head 62 stops rotating proximate to the second end 158 of the guide assembly.
In another
embodiment, each orientation head stops rotating before the orientation head
62 is
43
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
proximate to the second end 158. For example, in one embodiment of the present
invention, each orientation head 62 is adapted to begin rotating when the
orientation head
62 is proximate to the first end 156. After the orientation head 62 rotates a
predetermined
number of revolutions around the spoke longitudinal axis 72, the orientation
head 62 stops
rotating before the orientation head is proximate to the second end 158. In
one
embodiment, each orientation head 62 is adapted to stop rotating after the
spoke has
rotated between approximately 120' to approximately 1800 from the first end
156 toward
the second end 158 of the guide assembly. In another embodiment, each
orientation head
62 stops rotating after the spoke has rotated between approximately 1350 and
approximately 165 . In a more preferred embodiment, each orientation head 62
stops
rotating after the spoke has rotated between approximately 145 to
approximately 155
from the first end 156 of the guide assembly. In a still more preferred
embodiment of the
present invention, each orientation head 62 stops rotating when the spoke has
rotated
approximately 1500 from the first end 156.
101521 In one embodiment of the present invention (illustrated in Fig. 8),
teeth 166 of
the pinion 146 of each spoke engage with teeth 168 formed on the bevel gear
138 during at
least a portion of the rotation of the hub 140. The engagement between the
teeth 166 of
the pinion 146 and the teeth 168 of the bevel gear 138 transmits a force to
the spoke
causing at least the linear spline assembly 154 and the orientation head 62 to
rotate around
the longitudinal axis 72. In one embodiment of the present invention, the
bevel gear teeth
168 are formed on only a porfion of an axial surface of bevel gear 138. In
another
embodiment, the teeth are formed on 360 of the axial surface of the bevel
gear 138.
101531 In one embodiment of the present invention, contact between the
orientation head
62 and the guide assembly 130 proximate to the first end 156 moves at least a
portion of
the pinion 146 radially inwardly. As the pinion 146 moves radially inward, the
pinion
teeth 166 engage with the bevel gear teeth 168 and the orientation head 62
begins to rotate
around the longitudinal axis 72. Al a predetermined point before the second
end 158 of
the guide assembly, the radius of curvature of the guide assembly increases.
When the
orientation head 62 rotates along the guide assembly to the predetermined
point, the
orientation head 62 and the pinion 146 move radially outwardly. As the pinion
146 moves
outwardly, the pinion teeth 166 lose engagement with the bevel gear teeth 168
and the
orientation head 62 stops rotating around the longitudinal axis 72.
101541 In one embodiment of the present invention, the guide assembly 130
includes
means to rotate the orientation head. In one embodiment, a portion of at least
one of the
44
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
linear spline assembly and the orientation head contacts a stationary rail 172
(illustrated in
Fig. 9A) associated with the guide assembly 130. The contact between the rail
172 and
the linear spline assembly and/or the orientation head causes the orientation
head 62 to
rotate around the spoke's longitudinal axis a predetermined number of
revolutions. When
the spoke 144 rotates past the end 174 of the rail 172 the orientation head 62
stops
rotating. In one embodiment of the present invention, the rail 172 is
interconnected to one
of the two inner rails 160. In another embodiment, the rail 172 is
interconnected to one of
the two outer rails 170. In still another embodiment, the rail 172 is
interconnected to the
mount 132.
101551 In still another embodiment of the present invention, the orientation
head 62 is
adapted to remain in a predetermined orientation with respect to the reference
axis 30 of
the system 120. The end closure 16 rotates around the longitudinal spoke axis
72 until the
orientation head 62 stops the rotation of the end closure when the end closure
is in
substantial alignment with the reference axis 30 of the system 120. In one
embodiment,
for at least a portion of the movement of the end closure from the first end
156 to the
second end 158, a predetermined portion of the end closure contacts a
stationary structure
of the orientor 126. The contact between the end closure and the stationary
structure is
adapted to rotate the end closure around the longitudinal spoke axis 72 as the
orientation
head contacts the exterior face portion 17 of the end closure 16. In one
embodiment, the
predetermined structure is a friction rail similar to rail 172. In another
embodiment, one or
more of inner and outer rails 160, 170 are adapted to apply a frictional force
sufficient to
rotate the end closure. In still another embodiment, a drive roller or a
motion belt of the
orientor 126 are adapted to rotate the end closure.
101561 The face portion 76 of the orientation head is adapted to allow the end
closure to
rotate until a predetermined feature on the exterior surface portion 17 of the
end closure is
engaged by the orientation head. When the orientation head engages the
predetermined
feature of the end closure, the orientation head applies a force to the end
closure sufficient
to prevent further rotation of the end closure. In this manner, because the
orientation head
is in a predetermined orientation with respect to the reference axis 30 of the
system 120,
when the orientation head stops the rotation of the end closure, the end
closure is in the
predetermined orientation. In one embodiment of the present invention, the end
closure
rotates until the pull tab 24 is aligned with, and engaged in, the pocket 80
formed in the
orientation head 16.
CA 02996493 2019-02-23
WO 2017/039765
PCT/US2016/032736
101571 Referring now to Fig. 10A, the orientor 126 may include one or more
sensors
176. The sensors are adapted to provide data to a controller that is operable
to determine
the orientation of the end closures 16. If the controller determines the Y-
axis 28 of an end
closure is not in a predetermined orientation, the controller is operable to
send a signal to
orientor 126 and the improperly oriented end closure is rejected and prevented
from
proceeding through the system 120. In one embodiment of the present invention,
the
sensors 176 are positioned to sense the interior surface portion 15 of the end
closures. In
another embodiment of the present invention, the sensors 176 are positioned to
sense the
orientation of the end closures while the end closures are engaged by the
orientation heads
62 and retained by the guide assembly 130. In one embodiment of the present
invention,
the sensors 176 comprise high speed cameras.
101581 Referring now to Fig. 11, holders 26 are synchronized with the spoke
spacing of
the wheels 128 of the orientor 126. When the orientation head 62 and the
oriented end
closure 16 reach the second end 158 of the guide assembly 130, the end closure
16 is
received by the holder 26. In one embodiment, as the orientation head 62 moves
past the
guide assembly, the orientation head 62 extends radially to apply a
predetermined force to
the end closure to seat the end closure on a holder 26. The orientation head
62 continues
to rotate with the hub 140, releasing the oriented end closure 16 and
returning to an axially
extended position.
101591 The holders 26 are adapted to prevent inadvertent or unintended
rotation of the
oriented end closures. In one embodiment, protrusions 178 are formed on the
holders 26.
Friction between each protrusion 178 and the interior surface of an end
closure prevents
inadvertent rotation of the end closure. In another embodiment, a clamping
mechanism 32
interconnected to the holder 26, illustrated in Fig. 7, applies a force to the
end closure 16
to prevent unintended rotation of the end closure 16. In one embodiment, the
clamping
mechanism 32 comprises at least one bar that is moved into contact with all of
the end
closures 16 in the holder 26. in another embodiment, the holders 26 include a
matching
contour friction clamp 32 or a multipoint circumferential contact clamp 32 to
prevent
unintended movement of the end closures 14. In another embodiment, the holders
26
apply a suction force to a surface of the end closure to prevent unintended
rotation of the
end closures 14.
101601 The orientor may have any number of wheels and guide assemblies in any
combination. For example, as illustrated in Fig. 11, the orientor 126 may
comprise four
wheels and guide assemblies positioned in two staggered rows. Alternatively,
as
46
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
illustrated in Fig. 7, the orientor 126 may have two wheels and guide
assemblies in one
row.
(0161] Referring again to Fig. 7, the Y-axis 28 of all the end closures are
substantially
parallel to each other when the holder exits the orientor 126 at point B. The
Y-axis 28
may have any predetermined orientation with respect to the reference axis 30
of the
system 120. In one embodiment; the Y-axis 28 of each end closures 16 is
substantially
parallel with the reference axis 30 of the system 120 when each end closure is
placed on
the holder by the orientation head 62. In another embodiment, an angle between
the Y-
axis 28 and the reference axis 30 is less than about 50. In a more preferred
embodiment,
the angle between the Y-axis 28 and the reference axis 30 is less than about 2
. In a still
more preferred embodiment, the angle between the Y-axis 28 and the reference
axis 30 is
less than about 1 . In one embodiment, the orientor 126 rotates each end
closure 16 until
the Y-axis 28 is substantially parallel to the reference axis 30 of the system
120 and the
tear panel 22 is positioned to the right of the pull tab 24, as viewed in Fig.
7. Although the
reference axis 30 is generally horizontal as seen in Fig. 7, it will be
appreciated that the
reference axis can be aligned at any desired angle. For example, in one
embodiment of the
present invention, the reference axis is rotated 180 and all of the end
closures 16 are
oriented with their pull tabs 24 exiting the orientor 126 proximate to Point B
before the
tear panels 22. In another embodiment, the reference axis is rotated 90'
clockwise and all
of the end closures 16 exit the orientor 126 with the pull-tab 24 oriented
towards the top of
Fig. 7. In yet another embodiment, the reference axis is rotated 90 counter-
clockwise and
all of the end closures 16 exit the orientor 126 with the pull-tab 24 oriented
towards the
bottom of Fig. 7. The orientation of the reference axis 30 may be selected by
an operator
and may be adjusted to any desired angle.
[01621 The holders 26 with the oriented end closures next enter the coater 8
of the
system 120. The coater 8 is operable to pre-treat the exterior surface 17 of
the end
closures 16 as described above in conjunction with Fig. I. The comer 8 may
also apply a
base coating material of any predetermined type to the exterior surface 17 of
the end
closures 16.
101631 The holders 26 continue to the curer 12 of the system 120. The curer 12
is
substantially the same as the curer of system 2, described above. The curer 12
cures the
base coating, if any, that is applied to the end closures by the coater 8.
(0164j The end closures are next transported to the printer 10 of system 120
by the
holders 26. The printer 10 is operable to decorate the exterior surface 17 of
the end
47
CA 02996493 2018-02-23
WO 2017/039765
PCT/US2016/032736
closure with a preferred indicia. In one embodiment of the present invention,
the printer
comprises a laser marking unit operable to form an image of a predetermined
size, shape,
and orientation on the exterior surface of the end closure.
[0165] In another embodiment of the present invention, the printer includes a
drum 34A
that is the same as or similar to the drum 34A of the printer 10 of system 2.
The drum
34A includes printing blankets 36A with recesses 38A as described above in
conjunction
with Fig. 1. In one embodiment of the present invention, the printer 10 can
form images
46 using up to six different colors or types of ink with a resolution of 133
lines per inch.
[0166] After being decorated by the printer 10, the end closure may optionally
enter a
second curer 12A to cure the decoration applied to the end closure. An
overcoat material
may be applied to the end closures by a second coater 8A. The end closures may
receive
another curing by a third curer 12B. Optionally, the holders 26 may transport
the end
closures to an inspection station 45. The inspection station 45 includes
sensors that are
operable to ensure the decoration has been applied to the intended location of
the end
closures. The inspection station 45 is also operable to determine if the
decoration meets a
predetermined quality. 'lite inspection station 45 may send and receive
signals from the
controller of the system 120. The inspection station may include any means
know-n to one
of skill in the art to ensure the location and the quality of the decoration
meet or exceed
predetermined quality criteria End closures that do not pass the inspection by
the
inspection station 45 are rejected and separated from the end closures that
pass the
inspection. In one embodiment of the present invention, the printer 10 can
form images 46
using up to six different colors or types of ink with a resolution of 133
lines per inch. In
one embodiment of the present invention, the system 120 can orient and
decorate
approximately 2,000 end closures per minute. In another embodiment, the system
can
orient and decorate approximately 1,000,000 end closures in an 8 hour period.
[0167] After the holders 26 exit the curer 12A or 12B proximate to Point C.
the end
closures 16 are transferred to the collector 14. The end closures are
separated from the
holders 26 as described above with respect to Fig. 1. The empty holders 26
then cycle
back to Point A proximate to the orientor 126 to receive more oriented end
closures from
the orientor 126.
101681 Fig. 7 also includes an example of an end closure 16B of one embodiment
decorated by system 120. The end closure 16B is substantially the same as the
end closure
16B described above with respect to Fig. 1. One or more images 46 may be
positioned in
48
CA 02996493 2018-02-23
WO 2017/039765
PCT/US2016/032736
a variety of predetermined portions of the exterior surface 17 of the end
closure, including
on the central panels, the tear panel, and the tab 24.
101691 Referring now to Fig. 12, another embodiment of an orientation head 62A
of the
present invention is illustrated. The orientation head 62A is adapted for use
with both
orientor 6 and orientor 126. The orientation head 62A has a body 70A that is
adapted to
be interconnected to the orientor 6 or a linear spline assembly 154 of a spoke
144 of
orientor 126. In one embodiment, the body 70A has a generally cylindrical
shape. The
body 70A has a head 74A. In one embodiment, the head 74A has a diameter
greater than
the diameter of the body 70A. In another embodiment, the head 74A has the same
or
similar diameter as the body 70A. In yet another embodiment, the head 74A has
a
diameter that is less than the diameter of the body 70A. The head 74A has a
face portion
76A that is generally perpendicular to a longitudinal axis 72 of the body 70A.
The face
portion 76A is adapted to allow an exterior surface of a pull tab 24 of an end
closure 16 to
slide along the face portion 76A as one of the orientation head 62A and the
end closure 16
rotates without applying a rotational force to the pull tab 24. A pocket 80A
formed on the
face portion 76A is adapted to capture a tab 24 of the end closure. When the
tab is aligned
with the pocket, the tab is received in the pocket. In one embodiment in which
the
orientation head is adapted to rotate the end closure, when the tab is
received in the
pocket, a portion of the pocket ROA applies a force to the tab 24 to rotate
the tab and the
end closure 16 simultaneously to a predetermined orientation. For example, in
one
embodiment, a wall 82A of the pocket 80A applies the force to the tab 24 to
rotate the end
closure. In another embodiment of the present invention in which the
orientation head
does not rotate around the longitudinal spoke axis, when the tab is received
in the pocket,
a portion of the pocket 80A, such as, for example, the wall 82A, applies a
force to the tab
24 to prevent further rotation of the end closure.
101701 In one embodiment, the pocket 80A is recessed into the face portion 76A
toward
the body 70A. The pocket 80A is adapted to receive the pull tab 24 when the
pull tab 24 is
aligned with the pocket 80A. A wall 82A extends substantially vertically
upward from the
pocket 80A to the face portion 76A. In one embodiment of the present
invention, the wall
is continuous around the perimeter of the pocket 80A. The wall 82A is adapted
to engage
and apply a force to a side surface of the pull tab 24. The pocket 80A may
have any
predetermined shape and size adapted to receive a pull tab 24. In one
embodiment of the
present invention, the pocket 80A has a shape substantially corresponding to
the shape of a
particular size and style of tab 24 of an end closure. In another embodiment
of the present
49
CA 02996493 2019-02-23
WO 2017/039765
PCT1US2016/032736
invention, the pocket 80A is adapted to receive a variety of tabs 24 of
different sizes and
shapes. in one embodiment of the present invention, illustrated in Fig. 12,
the pocket has
generally linear sidewalls 82A with generally arcuate endwalls 83A. In one
embodiment
of the present invention, the pocket 80A is formed in a portion of the face
portion 76 and
the pocket does not intersect the exterior circumference of the head 74A. In
another
embodiment, the pocket 80A at least partially intersects the exterior
circumference of the
head 74A similar to the pocket 80 illustrated in Fig. 4. In still another
embodiment of the
present invention, the pocket 80A has a substantially symmetric shape. In
another
embodiment of the present invention, the pocket 80A has an asymmetric shape.
101711 In one embodiment of the present invention, the pocket 80A has a depth
at least
equal to a height from the exterior surface 17 of the end closure to the
exterior surface of
the tab 24. When the tab 24 is received in the pocket 80A of this embodiment
of the
orientation head, the face portion 76A may contact and apply a force to the
exterior
surface 17 of the end closure. In another embodiment, the pocket 80A has a
depth less
than the height of the exterior surface of the tab 24 above the exterior
surface 17 of the end
closure. Accordingly, in this embodiment, when the tab 24 is received in the
pocket of the
orientation head, the face portion 76A of the orientation bead does not
contact the exterior
surface 17 of the end closure.
101721 In one embodiment, the face portion 76A of the orientation head 62A has
a
diameter substantially equal to a diameter of the central panel 20 of the end
closure 16. In
another embodiment, the face portion 76A has a diameter substantially equal to
a diameter
of the end closure 16. In still another embodiment of the present invention,
the face
portion 76A has a diameter greater than a diameter of the end closure 16.
101731 Referring now to Fig. 13, an embodiment of a method 180 for orienting
and
decorating end closures 16 is illustrated. While a general order of the method
180 is
shown in Fig. 13, the method 180 can include more or fewer steps, or can
arrange the
order of the steps differently than those shown in Fig. 13. Generally, the
method 180
starts with a start operation 182 and ends with an end operation 208.
Hereinafter, the
method 180 shall be explained with reference to apparatus 2, 120 and with
Figs. 1-12.
101741 A balancer 4 combines converted end closures 16 into a stick format
comprising
a plurality of individual end closures. In one embodiment, the end closures
include a
peripheral curl and a tab interconnected to an exterior surface portion of the
end closure.
A feeder 124 receives the sticks of end closures and separates 184 individual
end closures
16 from the sticks. The orientor 126 receives 186 the individual end closures
from the
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
feeder 124. Orientation heads 62 of the orientor 126 contact an exterior
surface portion of
the end closures. The end closures are rotated 188 by the orientor 126 to a
predetermined
orientation. In one embodiment, the orientation heads rotate the end closures
to the
predetermined orientation. In another embodiment, the orientor 126 rotates the
end
closures and the orientation heads stop the rotation of the end closures when
the end
closures are in the predetermined orientation.
101751 The end closures 16 are inspected 190 to determine if the end closures
16 are in
the predetermined orientation. In one embodiment of the present invention, a
sensor 176
associated with each wheel of the orientor senses the end closures. If the end
closures 16
are not in the predetermined orientation, method 180 proceeds NO and the
rejected end
closures 16 are collected 192. If the end closures 16 are in the predetermined
orientation,
method 180 proceeds YES and the end closures are loaded 194 into a holder 26
by the
orientor 126.
101761 The holder 26 is operable to move the oriented end closures through the
system
120. Optionally, the end closures are pre-treated 196. The holder 26 may also
transport
the end closures 16 to one or more of a coater 8 and a curer 12 that are
operable to
optionally apply and cure 198 base coatings applied to predetermined areas of
the exterior
surface 17 of the end closures 16. The holder 26 then transports 200 the end
closures 16 to
a printer 10 and a second curer 12A. The printer 10 is operable to apply a
decoration to
one or more predetermined areas of the exterior surface 17 of the end closures
16. The
decorations may be in any desired location or orientation and can be of any
size or shape.
Optionally, the decorator can apply different decorations to each of the end
closures
positioned in the holder 26. The second curer 12A is operable to cure the
decoration
applied to the end closures 16 by the printer 10. Optionally, an over coating
may be
applied 202 to the end closures 16 by a second coater 8A and cured by a third
curer 12B.
101771 The end closures 16 are then inspected 20410 determine if the
decoration is in a
proper location and quality. If the end closures 16 do not pass the inspection
204, the
method 180 proceeds NO and the rejected end closures 16 are collected 192. If
the end
closures 16 pass the inspection 204, the method 180 proceeds YES and the end
closures
are collected 206 by the collector 14. The method 180 then ends 208.
101781 The description of the present invention has been presented for
purposes of
illustration and description, but is not intended to be exhaustive or limiting
of the
invention to the form disclosed. Many modifications and variations will be
apparent to
those of ordinary skill in the art. The embodiments described and shown in the
figures
51
CA 02996493 2018-02-23
WO 2017/039765
PCT1US2016/032736
were chosen and described in order to best explain the principles of the
invention, the
practical application, and to enable those of ordinary skill in the art to
understand the
invention.
101791 While various embodiments of the present invention have been described
in
detail, it is apparent that modifications and alterations of those embodiments
will occur to
those skilled in the art. Moreover, references made herein to "the present
invention" or
aspects thereof should be understood to mean certain embodiments of the
present
invention and should not necessarily be construed as limiting all embodiments
to a
particular description. It is to be expressly understood that such
modifications and
alterations are within the scope and spirit of the present invention, as set
forth in the
following claims.
52
