US20240351090A1

US20240351090A1 - Roller assembly

Info

Publication number: US20240351090A1
Application number: US18/687,922
Authority: US
Inventors: Joshua OKRAH; Michael RIGHTMYER; Harold James Marshall
Original assignee: Belvac Production Machinery Inc
Current assignee: Belvac Production Machinery Inc
Priority date: 2021-09-02
Filing date: 2022-09-02
Publication date: 2024-10-24
Also published as: JP2024535746A; CN118201725A; CA3230434A1; WO2023034584A1; EP4395946A1; KR20240058880A

Abstract

A turret-head assembly including a turret head-assembly support member defining a turret-head axis and a base plate having an aperture through the center thereof, the turret head-assembly support member extending therethrough. The base plate is rigidly coupled to the turret head-assembly support member. The turret-head assembly further comprises a front housing and a pivot plate positioned between the base plate and the front housing. A first side of the pivot plate is coupled with a first side of the front housing. A second side of the pivot plate is coupled with a first side of the base plate. The pivot plate is axially movable along the turret-head axis. The turret-head assembly further comprises a plurality of rollers coupled to the pivot plate. The plurality of rollers is configured to move radially with respect to the turret-head axis. The radial movement corresponds with the axial movement of the pivot plate.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of, and priority to, U.S. Provisional Patent Application No. 63/240,304 filed on Sep. 2, 2021, which is hereby incorporated by reference herein in its entirety.

FIELD

The embodiments of the present invention relate to apparatus and methods for manufacturing containers. Specifically, the embodiments described herein relate to a turret-head assembly having rollers for forming a neck portion of a container-more specifically, for forming a groove on the neck portion of a container for engaging a pilfer band.

BACKGROUND

In the industry, beverage containers for various soft drinks, alcoholic beverages, and the like are typically produced in large quantities in substantially identical shapes. There is an increasing desire among beverage manufacturers to sell products from economical containers, often having unique configurations, to assist in differentiating their products from their competitors.
Conventional beverage containers are typically formed from a preform article, which is a generally cylindrical metal article/container made from an aluminum or aluminum alloy sheet, surface-treated steel, a combination thereof, or the like. The preform article typically includes a closed end and an opposing open end. The preform article typically undergoes multiple stages of expansion or reduction processes to achieve a desired shape. Because of limitations associated with the metal used to form the containers, these processes are conducted incrementally in “stages” so as to minimize or prevent damage to or splitting of the container wall. Multiple diametrical reductions and/or expansions to the open end of the preform article may be performed, for example, to form a narrowed neck portion adjacent to the open end of the container, such as in a bottle-shaped container configuration, to form threads thereon, or the like.
Most containers are adapted to be closed and/or sealed with a generally cylindrical flat cap or closure having threads in the wall thereof that are configured to mate with corresponding threads in the neck portion of the container. A cap blank is applied to the threaded neck portion of a container to seal the container. Threaded ridges/grooves formed on the walls (i.e., a skirt portion) of the cap mate with corresponding grooves/ridges in the threaded neck portion of the container. It is desirable that multiple seals are formed between the threaded neck portion and the cap to reduce or eliminate the possibility of the contents of the container leaking therefrom, to retain freshness, and the like.
It is also desirable to include a tamper-evident feature to indicate when the container has been previously opened/unsealed. Often, the skirt portion of the cap includes a pilfer band at its lower end. The pilfer band is positioned over and wraps around a groove in the neck portion of the container used to generally axially lock the pilfer band. In some instances, the groove is formed below an annular bead positioned below or at the bottom of the threaded portion. The pilfer band is separated from the remaining portion of the skirt portion via bridges or perforations. When the cap is turned counterclockwise, the cap is removed from the neck portion via the interaction of the cap threads with the threads of the neck portion of the container. As such, the bridges/perforation between the skirt portion of the cap and the pilfer band are broken so that the pilfer band may detach from the skirt portion of the cap. To replace the cap, the cap may be placed over the open end of the container and turned clockwise, re-engaging the cap threads with the threads of the neck portion of the container.
In conventional processes, the groove in the neck portion of the container around which the pilfer band wraps is formed by necking the container down to a desired diameter of the groove. Subsequently, another portion of the neck of the container is expanded out to a desired diameter of the annular bead. Such processes involve numerous stages and machines, and the expanding process presents a higher risk of splitting the container wall.
It is an object of the embodiments disclosed herein to efficiently produce a necked container having a groove configured to engage a pilfer band. The embodiments provide new systems and methods for forming the groove.

SUMMARY

According to aspects disclosed herein, a turret-head assembly for forming an article is disclosed. The turret-head assembly comprises a turret head-assembly support member defining a turret-head axis. The turret-head assembly further comprises a base plate having an aperture through the center thereof, the turret head-assembly support member extending therethrough. The base plate is rigidly coupled to the turret head-assembly support member. The turret-head assembly further comprises a front housing having an opening configured to receive an open end of the article therethrough. The turret-head assembly further comprises a pivot plate positioned between the base plate and the front housing. A first side of the pivot plate is coupled with a first side of the front housing. A second side of the pivot plate is coupled with a first side of the base plate. The pivot plate is axially movable along the turret-head axis. The turret-head assembly further comprises a plurality of rollers coupled to the pivot plate such that the plurality of rollers is configured to move radially with respect to the turret-head axis. The radial movement corresponds with the axial movement of the pivot plate.
According to further aspects disclosed herein, a method of forming an article is disclosed. The method comprises providing a turret-head assembly. The turret-head assembly includes a turret head-assembly support member defining a turret-head axis. The turret-head assembly further includes a base plate having an aperture through the center thereof, the turret head-assembly support member extending therethrough. The base plate is rigidly coupled to the turret head-assembly support member. The turret-head assembly further includes a front housing having an opening configured to receive an open end of the article therethrough. The turret-head assembly further includes a pivot plate positioned between the base plate and the front housing. A first side of the pivot plate is coupled with a first side of the front housing. A second side of the pivot plate is coupled with a first side of the base plate. The pivot plate is axially movable along the turret-head axis. The turret-head assembly further includes a plurality of rollers coupled to the pivot plate such that the plurality of rollers is configured to move radially with respect to the turret head axis. The radial movement corresponds with the axial movement of the pivot plate. The method further comprises moving at least one of the turret-head assembly and the article toward one another such that an open end of the article passes through the opening in the front housing. The method further comprises axially advancing at least one of the turret-head assembly or the article against the other of the turret-head assembly or the article such that the pivot plate moves in a first direction toward the base plate, thereby decreasing the distance between the pivot plate and the base plate, thereby moving the rollers radially inward toward the neck portion. The method further comprises rotating the turret-head assembly about the turret-head axis. The method further comprises engaging the plurality of rollers with a portion of a neck portion of the necked article, thereby forming a groove on the necked article.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below.

FIG. 1 illustrates a machine line for forming articles according to one embodiment.

FIG. 2A illustrates containers resulting from various stages of a process according to one embodiment.

FIG. 2B illustrates a close-up view of a necked article of FIG. 2A.

FIG. 3A illustrates a top perspective view of a turret-head assembly according to aspects of the present disclosure.

FIG. 3B illustrates a bottom perspective view of the turret-head assembly of FIG. 3A.

FIG. 4 illustrates a top perspective view of the turret-head assembly of FIGS. 3A-3B with a top plate removed.

FIG. 5A illustrates a top perspective view of a base plate according to one embodiment.

FIG. 5B illustrates a bottom perspective view of the base plate of FIG. 5A.

FIG. 6 illustrates a top perspective view of the turret-head assembly of FIGS. 3A-3B with the base plate of FIGS. 5A-5B removed.

FIG. 7A illustrates the turret-head assembly of FIG. 6 in a compressed position.

FIG. 7B illustrates the turret-head assembly of FIG. 7A in an expanded position.

FIG. 8A illustrates a close-up view of pivot arms and rollers of the turret-head assembly of FIG. 7A.

FIG. 8B illustrates a close-up view of the pivot arms and rollers of the turret-head assembly of FIG. 7B.

FIG. 9 illustrates a top perspective view of the turret-head assembly of FIGS. 3A-3B with a pivot plate having been removed.

FIG. 10 illustrates a side view of the turret-head assembly of FIGS. 3A-3B with certain components not shown.

FIG. 11A illustrates a perspective top view of the turret-head assembly of FIGS. 3A-3B with certain components not shown.

FIG. 11B illustrates a perspective bottom view of the turret-head assembly of FIG. 11A.

FIG. 12A illustrates a perspective bottom view of a front housing according to one embodiment.

FIG. 12B illustrates a perspective top view of a compression hub and bearing according to one embodiment.

FIG. 12C illustrates a perspective bottom view of the compression hub of FIG. 12B.

FIG. 13A illustrates a perspective bottom view of a roller mounted the pivot arm, according to one embodiment.

FIG. 13B illustrates a perspective bottom view of the pivot arm of FIG. 13A having the roller removed.

FIG. 13C illustrates a perspective bottom view of the pivot arm of FIG. 13B having bearings removed.

FIG. 14A is a top perspective view of a turret-head assembly according to another embodiment.

FIG. 14B is a bottom perspective view of the turret-head assembly of FIG. 14A.

FIG. 14C is a top view of the turret-head assembly of FIGS. 14A-14B.

FIG. 14D is an exploded view of the turret-head assembly of FIGS. 14A-14C.

FIG. 15A is a cross-sectional view of the turret-head assembly of FIGS. 14A-14D along line 15A-15A of FIG. 14C.

FIG. 15B is a cross-sectional view of the turret-head assembly of FIGS. 14A-14D along line 15B-15B of FIG. 14C.

While the invention is susceptible to various modifications and alternative forms, specific forms thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but, on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

DETAILED DESCRIPTION

Existing processes and apparatus for forming an annular bead and groove (e.g., a locking ring over which a pilfer band is positioned) for engaging a pilfer band suffer from a number of significant limitations. In particular, for example, the processes and tools used to form the annular bead and groove require necking down (reducing the diameter of) the container to a desired groove diameter followed by expanding the necked container to a desired diameter of the annular bead. This process has several disadvantages. For example, existing apparatus for performing such processes require numerous machines (e.g., for reducing and for expanding the neck diameter). Moreover, the expansion process makes the container vulnerable to splitting.
According to aspects of the present disclosure, apparatus and methods are described for improving article (e.g., container) necking processes. Although the embodiments described herein are discussed with respect to roll-on pilfer band processes, it is contemplated that the apparatus and the methods of using the same may also be applied in association with other processes that result in forming a groove on or otherwise processing/modifying a neck portion of an article adjacent to an open end of the article.
In the embodiments described herein, a container is necked down to a desired diameter of the annular bead and rolled to form a groove on the neck portion. Subsequently, necking steps may be performed to reduce the diameter of the neck portion for threading. After that, additional necking steps may be performed to further reduce the diameter of the neck portion for curling. Thus, in the embodiments described herein, expansion of the neck portion is not required to form the pilfer band groove, thereby reducing the number of stages required and the risk of splitting the container.
The articles described herein may be a can or container, any suitable food or beverage container, jar, bottle, or any other suitable article. The article has an open end opposite a closed end and a sidewall bridging the open end and the closed end. Alternatively, the article may be open at both ends. A top, lid, or other closure may be added to the article after the necking process. The article may be held to a respective device (e.g., a pusher device) using, e.g., vacuum.
Referring to FIG. 1 , an exemplary machine line 102 for forming articles is shown. The machine line 102 includes a plurality of modules 103. Each module 103 is configured to perform at least one working step to a received article 10 prior to passing the article downstream. The modules 103 generally include one or more forming turrets configured to perform a working operation on the article. The forming turret(s) generally include at least one forming starwheel (e.g., forming turret 21) having a plurality of pockets and tooling configured to perform a working operation on an article within a respective pocket.
Modules 103 generally further include at least one transfer starwheel (e.g., transfer starwheels 20) having a plurality of pockets thereon. The pockets are configured to receive the articles from an upstream starwheel and transport the article to a downstream starwheel. Optionally, a recirculation system can be employed. An example recirculation system is described in PCT/US2015/018119, which is hereby incorporated herein by reference in its entirety.
Referring now to FIG. 2A, a plurality of containers 200 resulting from various stages of a process according to one embodiment is shown. Each of the plurality of containers 200 includes a generally cylindrical body 201 having an open end 202. A preform container or article 200 a is shown having a generally smooth, narrowed neck portion 204 extending from the open end 202 and a shoulder portion 214 bridging the neck portion 204 and the cylindrical body 201. As the preform article 200 a is passed downstream, working operations are performed on the neck portion 204 to form an annular bead and groove to engage and generally axially lock a pilfer band in place, threads, and the like. For example, the neck portion 204 of the preform article 200 a is modified (e.g., rolled) to form a groove 206 for engaging a pilfer band to form a first pass article 200 b. The groove 206 is configured to assist in generally holding the pilfer band positioned over the groove 206 in place and restrain the movement of the pilfer band in an axial direction. Further necking operations can be performed to further modify the neck portion 204 of the article (see articles 200 c, 200 d, 200 c) and/or to form threads 210 thereon.
FIG. 2B illustrates a close-up view of an upper portion of the second pass article 200 c. As shown in the illustrated embodiment, the neck portion 204 c has a groove 206 for engaging a pilfer band. During necking procedures, the open end 202 of the preform article 200 a (see FIG. 2A) is diametrically reduced in stages to form the finished neck portion 204 (see article 200 f of FIG. 2A). The procedure is performed in multiple stages to assist in preventing misforming, breaching, or splitting the article.
In accordance with aspects of the present disclosure, axial movement of a portion of a turret-head assembly in turn causes radial movement of tooling (e.g., rollers) with respect to the turret-head axis. For example, in one embodiment, mechanical actuation of a turret-head assembly into a position to form a processing operation on an article being formed or modified is accomplished using the article itself. This is advantageous because, unlike existing devices, external components or mechanisms are not required, e.g., to actuate rollers to contact the neck portion of the article so that a groove for engaging a pilfer band may be formed thereon. Thus, less equipment may be required, thereby decreasing the cost associated with forming the groove. In other embodiments, radial movement of the tooling may be actuated by a secondary mechanism (e.g., a cam actuator) external to the turret-head assembly causing axial movement of the turret-head assembly.
FIGS. 3A-3B illustrate an example of a turret-head assembly 300 according to aspects of the present disclosure. The turret-head assembly 300 includes a turret-head supporting member (e.g., mounting screw) 386, which defines a turret-head axis. The turret head-supporting member 386 with a washer 388 (e.g., a Belleville washer or other suitable type of washer) is used to mount the whole turret-head assembly 300 to a machine (see FIGS. 11A-11B). The turret-head assembly 300 includes a top plate 302, a base plate 304, and a pivot block 306 (see FIG. 10 ), all of which are generally stationary during operation with respect to the other components of the turret-head assembly 300. The turret-head assembly 300 further includes a generally ring-shaped front housing 308 including a generally ring-shaped guide plate or compression hub 310 positioned in the center thereof. The front housing 308 is rigidly connected to a pivot plate 312. When a force is applied thereto (e.g., when an article is inserted into the turret-head assembly 300, as described in detail below), the front housing 308 and pivot plate 312 slide up along a plurality of alignment pins 314 and along the turret-head axis in the direction of Arrow A. The alignment pins 314 couple the base plate 304 to the pivot plate 312 and have a plurality of resilient devices (e.g., compression springs) 340 coupled thereto. The base plate 304 is rigidly fixed to the alignment pins 314, and the pivot plate 312 is slideably coupled to the alignment pins 314, as discussed further below with respect to FIGS. 7A-7B. The pivot block 306 is rigidly coupled to the turret-head supporting member 386. Stationary inner ends 315 of a plurality of H-links 316 are coupled to the pivot block 306, and opposing free outer ends 317 of the plurality of H-links 316 are coupled to a respective plurality of pivot arms 318. Each of the pivot arms 318 includes an opening 374 positioned through a generally central portion of a body 375 thereof (see FIG. 10 ). Each pivot arm 318 is slidably coupled to the pivot plate 312 via a slot 319 therein. The upward movement of the pivot block 306 in the direction of Arrow A causes the distance between the base plate 304 and the pivot plate 312 to decrease, thereby moving an opposing free end of each of the H-links 316 radially outward, which, in turn brings lower ends 320 of each of the pivot arms 318 radially inward toward the center of the turret-head assembly 300. A plurality of tooling devices (e.g., rollers 322) having a constant radius are coupled to the lower end 320 of each of the pivot arms 318 and are, thus, moved inwardly toward the center of the turret-head assembly 300 to press against the neck portion of the article and form a groove thereon. Although the tooling shown in the illustrated embodiments is a plurality of rollers 322, it is contemplated that the embodiments described herein may also be used with other types of tooling including but not limited to, trimmers, flanging devices, curling devices, threading devices, any combination thereof, or the like.
A lower end of the turret-head assembly 300 is configured to be axially moved along the turret head axis. As best seen in the embodiment of FIG. 3B, the lower end of the turret-head assembly 300 is configured to be pressed on by an article (e.g., article 200 of FIG. 2A) passing through a central opening 342 in the front housing 308 and compression hub 310. Thus, the diameter of the opening 342 is configured to allow a neck portion 204 of the article therethrough and block a shoulder portion 214 of the article from passing therethrough.
Although the exemplary embodiments discussed herein describe the shoulder portion 214 of the article (see FIG. 2B) as contacting and pushing against a bottom/outer side of the front housing 308 and/or compression hub 310, it is contemplated that the components of the turret-head assembly 300 may be pushed by any portion of the article or any other external mechanism causing axial movement of a portion of the turret-head assembly 300. For instance, in one non-limiting example, the open end 202 of the article may push against a pilot 382 coupled to a bottom side of the pivot plate 312 (see FIGS. 11A-11B). In other embodiments, a cam actuator is used to axially move the lower end of the turret-head assembly 300.
Furthermore, the exemplary embodiments detailed herein describe the article axially advancing along the turret-head axis toward a generally stationary turret-head assembly 300 (using, for example, a cam-follower arrangement on a rotating turret) and pushing components coupled to the turret-head assembly upward in the direction of Arrow A into a compressed position (see FIG. 7A). However, in some embodiments, the article is generally stationary and the turret-head assembly 300 is axially advanced along the turret-head axis in the direction of Arrow B to engage the article. In such embodiments, contact with the stationary article causes the turret-head assembly 300 to compress (see FIG. 7A). In other embodiments, both the article and the turret-head assembly 300 are axially advanced along the turret-head axis in opposite directions toward one another to engage a portion of the article with a component of the turret-head assembly 300 to compress the turret-head assembly 300 shown in FIG. 7A.
In still other embodiments, the turret-head assembly 300 is compressed independently of the article. For example, the lower end of the turret-head assembly (e.g., the front housing 308) may be axially moved, e.g., via a cam actuator, thereby compressing the turret-head assembly 300 (see FIG. 7A) and, accordingly, causing radial movement of the rollers 322.
Referring back to FIGS. 3A-3B, compressing the turret-head assembly 300, e.g., moving the article through the central opening 243 in the front housing 308, triggers the pivot arms 318 to move the rollers 322 coupled thereto toward the center of the turret-head assembly 300. The turret-head assembly 300 generally spins about the turret-head axis such that the rollers 322 travel on the neck portion 204 circumferentially while moving inwardly toward the center of the turret-head assembly 300. As such, the rollers 322 roll against the neck portion 204 of the article, thereby forming the groove for holding the pilfer band. During forming, the turret-head assembly 300 spins rapidly relative to the article, and the article remains generally stationary with the compression hub 310 via friction. In some embodiments, the turret-head assembly 300 may spin at a speed of 2000 rpm or more. It is contemplated that, in other embodiments, the article spins rapidly relative to the turret-head assembly 300, which remains generally stationary.
FIGS. 4-6 show the internal structure of the turret-head assembly 300 according to one embodiment. For example, FIG. 4 illustrates the turret-head assembly 300 with the top plate 302 removed. By removing the top plate 302, top ends 324 of the alignment pins 314 are exposed. The top plate 302 is coupled to the base plate 304 by one or more fasteners 326. The fasteners 326 may include, e.g., button head cap screws or any other suitable type of fastener.
FIGS. 5A-5B illustrate a top side 328 and a bottom side 330 of the base plate 304, respectively, according to one embodiment. The base plate 304 includes counterbores 332 configured to mount to the alignment pins 324. The base plate 304 further includes threaded holes 334 for mounting the base plate 304 to the pivot block 306. Although the illustrated embodiment includes three counterbores 332 and three threaded holes 334, it is contemplated that any suitable number of counterbores and/or threaded holes may be used.
FIG. 6 illustrates a plurality of fasteners 336 connecting the pivot block 306 and the base plate 304 after the base plate 304 has been removed so that various components can be more easily viewed. Although three fasteners 336 in the form of cap screws are shown, it is contemplated that any number and/or any suitable type of fastener may be used. Each alignment pin 324 has two washers 338, with the spring 340 positioned therebetween. The springs 340 are used to return all moving parts (e.g., the pivot plate 312, pivot block 306, pivot arms 318, rollers 322, and front housing 308) back to their initial expanded positions (see FIG. 7B) after the groove has been formed on the article and the article has been retracted away from the turret-head assembly 300.
FIGS. 7A-7B illustrates two positions of the turret-head assembly 300 of FIGS. 3A-6 . FIG. 7A illustrates a first, compressed position resulting from an article passing through an opening 342 in the front housing 308 and compression hub 310. The compression hub 310 may include a profile that generally corresponds with that of the shoulder 214 of the article such that the contact area between the article and the compression hub 310 may be minimized. As the article moves through the opening 342 and presses against the compression hub 310, e.g., the pivot plate 312 and the front housing 308 are pushed into the compressed position (FIG. 7A). The pivot block 306 is generally stationary, so the inner ends 315 of the H-links 316 coupled thereto are likewise generally stationary. As the article is pushed further into the turret-head assembly 300, the front housing 308 and pivot plate 312 move upward in the direction of Arrow A, causing outer ends 317 of the H-links 316 to likewise move upward in the direction of Arrow A (FIG. 7A) into an activated position. This movement of the H-links 316 results in a bottom end 358 of the pivot arms 318 and the rollers 322 coupled thereto to move radially inward toward the pivot block 306 and center of the turret-head assembly 300 such that the rollers 322 contact the neck portion 204 of the article and form the groove thereon. Because there is a plurality of rollers 322 (e.g., three) surrounding the article, generally no additional support for the article is needed.
As shown in FIG. 7B, after the groove has been formed on the article and the article is removed from the turret-head assembly 300, the springs 340 push the pivot plate 312 downward in the direction of Arrow B into an expanded position. As a result, the outer ends 317 of the H-links 316 move downward into a deactivated position following the pivot plate 312. Accordingly, the bottom ends 358 of the pivot arms 318 and the rollers 322 coupled thereto flare radially outward, thereby breaking contact with the neck portion 204 of the article and providing a clearance for removing the article.
The bottom end 348 of each alignment pin 324 has a washer 350 thereon, which is held in place by a respective fastener, e.g., a cap screw 352. The washer 350 acts as a stop so that the pivot plate 312 cannot axially move past the washer 350. FIG. 7B shows the pivot plate 312 coming into contact with the washers 350 in the expanded position.
FIGS. 8A-8B illustrate how the pivot arms 318 and the rollers 322 pivot generally radially inward and outward during operation. Referring to FIG. 8A, when an article is inserted through the opening 342 (see FIGS. 7A-7B) in the front housing 308 and compression hub 310, the pivot plate 312 rises in the direction of Arrow A. As a result, the radial distance 354 between the two opposing ends 315, 317 of each H-link 316 increases. Moreover, because the inner end 315 of each H-link 316 generally does not move radially, the outer ends 317 of each H-link 316 push a top portion 356 of the pivot arms 318 radially outward and upward as the article is further inserted into the turret-head assembly 300. Thus, the opposing bottom ends 358 of each pivot arm 318 are moved radially inward toward the center of the turret-head assembly 300 to press the rollers 322 onto the workpiece, i.e., the neck of the article. As such, movement of the components of the turret-head assembly 300 occurs via contact with/by the article and by movement of the article with respect to the turret-head assembly 300.
FIG. 9 shows components of the turret-head assembly 300 described above with the pivot plate 312 being removed. With the pivot plate 312 removed, bushings 360 for sliding the pivot plate 312 along the alignment pins 324 and pivots 362 used to couple the pivot arms 318 to the pivot plate 312 can be viewed. The bushings 360 may be made of plastic or any other suitable material. A plurality of fastening devices (e.g., screws) 364 rigidly couple the pivot plate 312 with the front housing 308 such that they generally move together, as discussed above. Nuts 366, washers 368, and spring washers 370 clamp the pivot plate 312 to the screws 364. The distance between the pivot plate 312 and the front housing 308 may be adjusted by changing the length of the screws 364 to accommodate varying article shapes, lengths, and/or geometries.
FIG. 10 illustrates the turret-head assembly 300 described above with the alignment pins 324, bushings 360, and screws 364 being removed, such that the H-links 316 and pivot arms 318 can be more easily viewed. To illustrate the components more clearly, one pivot arm 318, H-link 316, and roller 322 connected to the pivot arm 318 were also removed.
Although used with all of the pivot arms 318 in operation, a pivot pin or precision fastener (e.g., screw) 372 is shown positioned through the opening 374 in the body 375 of the pivot arm 318 a. In some embodiments, the opening 374 is positioned in a generally central location on the pivot arms 318. The precision screw 372 mounts the pivot arm 318 a to the pivot plate 312 such that the pivot arm 318 can freely rotate about the precision screw 372. A set of pivot pins 376 used to pivotably couple each H-link 316 to the pivot block 306 and pivot arm 318, respectively, is also shown.
As shown with respect to the H-link 316 b of FIG. 10 , each H-link also includes four flanged bushings 378 thereon: two of the flanged bushings 378 a slide against the pivot pin 376 to the pivot block 306, and the remaining two flanged bushings 378 b slide against the pivot pin 376 to the pivot arm 318. A bushing 380 is positioned in the middle opening 374 of the pivot arm 318 to slide against the precision screw 372. The bushings 378, 380 may be made of plastic or any other suitable material.
Turning now to FIGS. 11A-11B, the pivot arms 318, H-links 316, and rollers 322 have been removed to expose the pivot block 306 and the pilot 382. The pilot 382 supports the open end of the article as it is moved into the turret-head assembly 300, thereby assisting with precisely forming the groove. In some embodiments, the pilot 382 may be inserted about 0.50 inches to about 1.25 inches deep into the open end of the article. In other embodiments, the pilot 382 may be inserted about 0.75 inches to about 1 inch deep into the open end of the article. A pilot shaft 384 is secured to (e.g., screwed into) a bottom side of the pivot plate 312 (see, e.g., FIGS. 3A-3B) through a central aperture in the front housing 308. The pilot 382 is coupled to the pilot shaft 384 and is free spinning via a rotatable mount (not shown) such as, but not limited to, ball bearings, taper bearings, bushings, etc. In some embodiments, when the article passes through the central opening 342 in the front housing 308 and compression hub 310, an open end of the neck portion 204 of the article engages the pilot 382, thereby pushing the pivot plate 312 coupled to the pilot 382 in a first direction toward the base plate 304. As such, the rollers 322 are moved radially inward toward the neck portion. In some embodiments, the pilot 382 enters through the open end of the article 200, thereby being positioned adjacent to an inner wall of the neck portion 204 of the article 200. In such embodiments, the open end 202 of the container is used to actuate movement. Thus, it is not necessary that the shoulder 214 of the article 200 contacts (e.g., is blocked from further entrance into the turret-head assembly 300 by) the front housing 308.
FIGS. 12A-12C show a portion of the front housing 308 and related components that may contact the shoulder 214 of the article (see FIG. 2B) when the article is inserted into the turret-head assembly 300. The compression hub 310 is positioned generally concentrically with the generally central opening 342. A compression hub bearing retainer 390 holds a bearing 323 in place between the compression hub 310 and the front housing 308. The bearing 323 may be viewed upon removing the retainer 390 and screws 392 coupling the retainer 390 to the front housing 308 (see FIG. 12B). The bearing 323 allows the compression hub 310 to freely rotate against the front housing 308. When inserted into the turret-head assembly 300, the article pushes against the compression hub 310 and an O-ring 394 during rolling. Friction keeps the compression hub 310 generally stationary relative to the article, and the rollers 322 spin rapidly due to friction with the article, thereby rolling and forming a groove on the neck portion 204 of the article.
The compression hub 310 may be formed of a non-marring material that is generally soft and smooth enough to generally protect against scratching the article or decorations/designs thereon. Non-limiting examples of suitable materials include, but are not limited to, plastic resins (e.g., DELRIN® (DuPont Polymers, Inc., Wilmington, Delaware)) or any other suitable material or combinations thereof.
FIGS. 13A-13C show how the rollers 322 are mounted on respective pivot arms 318. A roller support member (e.g., a low-profile shoulder screw) 396 is used to mount the roller 322 on the pivot arm 318 (see FIG. 13A). Removing the roller 322 exposes a first and second roller bearing 398 a, 398 b having a spacer 400 positioned therebetween (see FIGS. 13B, 13C). A shim 402 (see FIG. 13C) may also be positioned between the bottom end 358 of the pivot arm 318 and the first bearing 398 a. The bearings 398 a, 398 b allow the rollers 322 to spin freely about the roller support members 396.
FIGS. 14-15 illustrate a turret head assembly 300′ according to another embodiment. The turret-head assembly 300′ includes a front retainer plate 308′ (generally corresponding with the front housing 308 of, e.g., FIG. 3B), a rear mounting plate 304′ (generally corresponding with the base plate 304 of, e.g., FIG. 3B), a slide housing 306′ (generally corresponding with the pivot plate 312 of, e.g., FIG. 3A), and a cover 311′. The front retainer plate 308′ includes a hub bearing retainer 390′ (generally corresponding with the compression hub 310 of, e.g., FIG. 12A) and a compression hub 310′ (generally corresponding with the compression hub 323′ of, e.g., FIG. 12B) positioned generally through the center thereof. The slide housing 306′ includes a front housing 307′ and a rear housing 309′ that are coupled to one another via, e.g., screws 313′ to form a movable case. The turret-head assembly 300′ further includes roller cages 312′ configured to radially slide into and out of the slide housing 306′ between the front housing 307′ and the rear housing 309′. As shown in FIG. 14D, a top side 312 a′ of each roller cage 312′ is generally adjacent to an interior surface (not shown) of a top 309 a′ of the rear housing 309′. A bottom of each roller cage 312′ is generally adjacent to a top surface 307 a′ of the front housing 307′. A sidewall 312 b′ of each roller cage 312′ forms a portion of a sidewall of the slide housing 306′.
A plurality of stationary angled rods 410 are positioned between and mounted to the front retainer plate 308′ and the rear mounting plate 304′ and extend through generally aligned apertures 311 a′, 311 b′, and 311 c′ of the rear housing 309′, roller cages 312′, and front housing 307′, respectively. Lower ends 412 a of each of the angled rods 410 are coupled to the front retainer plate 308′, and upper ends 412 b of the angled rods 410 are coupled to the rear mounting plate 304′. The angled rods 410 are generally fixed at an angle relative to the turret-head axis such that the lower ends 412 a of the angled rods 410 are positioned a further distance from the center of the turret head assembly 300′ than the upper ends 412 b of the angled rods 410.
In FIG. 14 , three roller cages 312′ are shown, however, it is contemplated that any suitable number of roller cages may be used (e.g., 2, 4, or more). Although each roller cage 312′ in the embodiment of FIG. 14D includes two apertures 311 b′ for receiving a respective two angled rods 410 therethrough, because the slide housing 306′ includes more than one roller cage 312′, it is contemplated that each roller cage 312′ may only include one aperture for receiving an angled rod 410 therethrough. Alternatively, each roller cage 312′ may include more than two apertures for receiving respective angled rods 410 therethrough. The dimensions of the apertures 311 b′ of the roller cages 312′ may generally correspond with those of the angled rods 410, whereas the apertures 311 a′ of the rear housing 309′ and the apertures 311 c′ of the front housing 307′ are radially elongated to allow the angled rods to move in a radial direction while positioned therethough (as further detailed below). As described in more detail below, each roller cage 312′ can move radially when sliding along the angled rods 410 in response to an article 200′ being inserted through a central opening 325′ in the front retainer plate 308′.
A plurality of rollers 322′ (see FIGS. 14D and 15B) is generally stationary and/or fixed with respect to the roller cages 312′. In the illustrated embodiment, each roller cage 312′ has a respective roller 322′ coupled to an interior surface thereof. It is contemplated, however, that each roller cage 312′ may have more than one roller 322′ coupled thereto. Although the embodiment described herein describes a plurality of rollers (e.g., two, three, or more), it is contemplated that a single roller may also be used.
When an article 200′ is inserted into the turret head assembly 300′ in the direction of Arrow A′ through the central opening 325′ (see FIGS. 15A, 15B), as described above with respect to other embodiments, the edges (e.g., shoulder) of the article 200′ push against a portion of the compression hub 310′, thereby imparting a force that causes the slide housing 306′ to move toward the rear mounting plate 304′ along the angled rods 410 and to compress one or more resilient devices 340′ positioned between the rear housing 309′ and the rear mounting plate 304′. As the slide housing 306′ moves toward the rear mounting plate 304′ in the direction of Arrow A′, the roller cages 312′ and, accordingly, the rollers 322′, move radially inward to press against the neck portion 204′ of the article, thereby forming the grooves on the neck portion 204′ of the article 200′. The distance that the rollers 322′ are moved radially inward relative to the upward/inward movement of the roller cages 312′ can be varied by varying the angle of the angled rods 410 relative to the turret-head axis. When the article 200′ is removed from the assembly in a direction opposite that of Arrow A′, the one or more resilient devices 340′ decompresses, causing the assembly 300′ to return to an uncompressed position. As discussed with respect to the embodiments above, it is also contemplated that axial movement of a portion of the turret-head assembly 300′ may also occur independent of the article 200′, e.g., via a cam actuator axially moving a lower portion of the turret-head assembly 300′.
In some embodiments, the rollers have a complementary shape to a desired shape of the groove to be formed on the neck portion 204 of the article. For example, the rollers 322, 322′ of the illustrated embodiment are radiused such that engagement of the rollers with the neck portion 204, 204′ of the article reduces the diameter of the engaged neck portion 204 to form the desired groove. The depth of the groove may be predetermined by adjusting the setting of the turret-head assembly, e.g., the amount of force applied by the rollers onto the neck portion. In addition, the plurality of rollers assists with preventing or minimizing undesirable deformation by providing a balanced load on the neck portion of the article.
It is contemplated that the turret- head assemblies 300, 300′ of the illustrated embodiments may include any suitable number of rollers, pivot arms, and related components.
As discussed above, the turret- head assembly 300, 300′ is configured to rotate about the turret-head axis defined by the mounting screw 386. In some embodiments, the turret- head assembly 300, 300′ rotates at a speed greater than about 200 RPM. In some embodiments, the turret- head assembly 300, 300′ is rotatably mounted on mounting screw 386 such that the turret- head assembly 300, 300′ rotates about the turret-head axis independent from the rotation of the mounting screw 386. In some embodiments, the turret- head assembly 300, 300′ is non-rotatably mounted on the mounting screw 386 such that the turret- head assembly 300, 300′ rotates about the turret-head axis with rotation of the mounting screw 386.
Beneficially, the turret- head assembly 300, 300′ can include tooling to simultaneously perform operations on the article such as trimming, flanging, curling, threading, etc. In some embodiments, the tooling is attached to the mounting screw 386.
The turret- head assembly 300, 300′ may be incorporated into one of the machines in the machine line 100. An article is received by a pocket of the turret starwheel. While the turret starwheel continuously rotates about a turret starwheel axis, an open, necked end of an article is received in the opening 342 in the front housing 308 (or front retainer plate 308′) and compression hub 310, 310′, and the article pushes the front housing 308 (or front retainer plate 308′) and pivot plate 312 (or roller cage 312′) into a compressed position (see FIG. 7A).
During engagement, the turret- head assembly 300, 300′ rotates about the turret-head axis. This rotational movement of the turret- head assembly 300, 300′ causes the rollers 322, 322′ to freely rotate. During rotation of the turret- head assembly 300, 300′, the rollers 322, 322′ engage the neck portion 204, 204′ to form the groove 206.
In some embodiments, the turret- head assembly 300, 300′ is rotated about the turret-head axis by an independent motor. In some embodiments, the turret- head assembly 300, 300′ is in a planetary gear configuration such that rotation of the forming turret drives rotation of the turret head assemblies 300, 300′ mounted thereon. In some embodiments, the turret- head assembly 300, 300′ continuously rotates during axial movement of the turret- head assembly 300, 300′ and/or the article. In some embodiments, the turret- head assembly 300, 300′ is rotated about the turret-head axis by a servo motor.
Beneficially, the turret- head assemblies 300, 300′ disclosed herein can be added to existing modules in an existing machine line 102. Beneficially, the free-spinning of the rollers contributes to increased longevity of the turret-head assembly and decreased likelihood of creating additional aberrations as compared to tooling or non-rotational members.
It is contemplated that the embodiments detailed herein may also be used with containers not having a narrowed neck portion. For example, a generally straight-walled container may actuate the pivot plate 312 (or roller cage 312′), front housing 308 (or front retainer plate 308′) etc. into the compressed position of FIG. 7A by pushing against the pilot 382.
Each of the above embodiments and obvious variations thereof are contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims. Moreover, the present concepts expressly include any and all combinations and sub-combinations of the preceding elements and aspects.
As utilized herein, the terms “approximately,” “about,” “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.
It should be noted that the terms “exemplary” and “example” as used herein to describe various embodiments are intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).
Any references herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,” etc.) are merely used to describe the orientation of various elements in the Figures. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.
Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may also be made in the design, operating conditions, and arrangement of the various exemplary embodiments without departing from the scope of the present invention.

Claims

1. A turret-head assembly for forming an article, the turret-head assembly comprising:

a turret head-assembly support member defining a turret-head axis;

a base plate having an aperture through the center thereof, the turret head-assembly support member extending therethrough, the base plate being rigidly coupled to the turret head-assembly support member;

a front housing having an opening configured to receive an open end of the article therethrough;

a pivot plate positioned between the base plate and the front housing, a first side of the pivot plate being coupled with a first side of the front housing, a second side of the pivot plate being coupled with a first side of the base plate, the pivot plate being axially movable along the turret-head axis; and

a plurality of rollers coupled to the pivot plate such that the plurality of rollers is configured to move radially with respect to the turret-head axis, the radial movement corresponding with the axial movement of the pivot plate.

2. The turret-head assembly of claim 1, wherein the article includes a narrowed neck portion extending from the open end, a body portion, and a shoulder portion bridging the neck portion and the body portion, the opening in the front housing having a diameter configured to allow the neck portion of the article therethrough and block the shoulder portion of the article.

3. The turret-head assembly of claim 1, further comprising:

a plurality of pivot arms, each of the plurality of pivot arms being pivotably coupled to the pivot plate; and

a plurality of H-links for pivotably coupling a first end of each of the plurality of pivot arms to the base plate,

the plurality of rollers being coupled to a second, generally opposing end of each of the plurality of pivot arms, the front housing being rigidly coupled to the pivot plate.

4. The turret-head assembly of claim 3, further comprising a plurality of resilient devices positioned between the base plate and a second side of the pivot plate.

5. The turret-head assembly of claim 4, further comprising a plurality of alignment pins coupling the base plate to the second side of the pivot plate and having the plurality of resilient devices coupled thereto, the base plate being rigidly fixed to the plurality of alignment pins, the pivot plate being slideably coupled to the plurality of alignment pins.

6. The turret-head assembly of claim 3, wherein each of the plurality of pivot arms includes an opening positioned through a body thereof, the turret-head assembly further comprising a plurality of fasteners positioned through the openings of the pivot arms to pivotably mount each of the plurality of pivot arms to the pivot plate.

7. The turret-head assembly of claim 1, further comprising a pilot coupled to the first side of the pivot plate through a generally central aperture therein.

8. The turret-head assembly of claim 7, further comprising a pilot shaft rigidly mounted to the first side of the pivot plate, the pilot being rotatably coupled to the pilot shaft.

9. The turret-head assembly of claim 1, wherein the front housing includes a compression hub positioned within and generally concentrically with the opening of the front housing, the compression hub being freely rotatable about the turret-head axis.

10. The turret-head assembly of claim 1, further comprising a plurality of angled rods coupled to the front housing, the pivot plate having a plurality of apertures therethrough, the plurality of angled rods extending through the respective plurality of apertures in the pivot plate such that the pivot plate is configured to slide along the lengths of the plurality of angled rods.

11. The turret-head assembly of claim 10, wherein the plurality of rollers is rigidly coupled to the pivot plate.

12. A method of forming an article, the method comprising:

providing a turret-head assembly including

a turret head-assembly support member defining a turret-head axis,

a base plate having an aperture through the center thereof, the turret head-assembly support member extending therethrough, the base plate being rigidly coupled to the turret head-assembly support member,

a front housing having an opening configured to receive an open end of the article therethrough,

a pivot plate positioned between the base plate and the front housing, a first side of the pivot plate being coupled with a first side of the front housing, a second side of the pivot plate being coupled with a first side of the base plate, the pivot plate being axially movable along the turret-head axis, and

a plurality of rollers coupled to the pivot plate such that the plurality of rollers is configured to move radially with respect to the turret head axis, the radial movement corresponding with the axial movement of the pivot plate,

moving at least one of at least a portion of the turret-head assembly and the article toward one another such that an open end of the article passes through the opening in the front housing;

axially advancing at least one of the at least a portion of the turret-head assembly or the article against the other of the turret-head assembly or the article such that the pivot plate moves in a first direction toward the base plate, thereby decreasing the distance between the pivot plate and the base plate, thereby moving the rollers radially inward toward the neck portion;

rotating the turret-head assembly about the turret-head axis; and

engaging the plurality of rollers with a portion of a neck portion of the necked article, thereby forming a groove on the necked article.

13. The method of claim 12, wherein the article includes a narrowed neck portion extending from an open end, a body portion, and a shoulder portion bridging the neck portion and the body portion,

14. The method of claim 13, wherein the axial advancing occurs via the shoulder portion abutting a second opposing side of the front housing.

15. The method of claim 14, wherein the shoulder portion of the article contacts a compression hub positioned within and generally concentrically with the opening of the front housing, the compression hub being freely rotatable about the turret-head axis and formed of a generally non-marring material.

16. The method of claim 12, wherein the turret-head assembly further comprises

a plurality of pivot arms, each of the plurality of pivot arms being pivotably coupled to the pivot plate, and

17. The method of claim 16, wherein the turret-head assembly further comprises a plurality of resilient devices being positioned between the base plate and a second side of the pivot plate.

18. The method of claim 17, wherein the turret-head assembly further includes a plurality of alignment pins coupling the base plate to the pivot plate and having the plurality of resilient devices coupled thereto, the base plate being rigidly fixed to the plurality of alignment pins, the pivot plate being slideably coupled to the plurality of alignment pins.

19. The method of claim 18, wherein moving the pivot plate in the first direction toward the base plate compresses the plurality of resilient devices positioned therebetween.

20. The method of claim 16, wherein the plurality of pivot arms includes an opening positioned through the body thereof, the turret-head assembly further comprising a plurality of precision fasteners positioned through the openings of the pivot arms to pivotably mount each of the plurality of pivot arms to the pivot plate.

21. The method of claim 12, further comprising moving the at least one of the at least a portion of turret-head assembly and the article away from one another such that the article having the groove formed thereon is removed from the opening in the front housing.

22. The method of claim 12, wherein the article is advanced axially toward the turret-head assembly, thereby pushing the pivot plate in a first direction toward the base plate.

23. The method of claim 12, wherein the front housing is rigidly connected to the pivot plate by a plurality of fastening devices.

24. The method of claim 12, wherein the turret-head assembly further comprises a pilot coupled to the first side of the pivot plate, the axial advancing occurring via the open end of the neck portion of the article engaging the pilot.

25. The method of claim 12, wherein the turret-head assembly is incorporated into a machine line.