COUPLING UNIT AND COUPLING METHOD FOR COUPLING A COMPONENT TO A CONTAINER AND APPARATUS FOR PRODUCING ARTICLES CORRELATED THERETO

Abstract

A coupling unit for coupling a component for a container includes a coupling equipment. The coupling equipment includes: a frame, a housing constrained to the frame, a gripping device rotatably constrained with respect to the frame and including a retaining element to selectively retain the component, and a coupling device constrained to the gripping device with respect to the frame, the coupling device including a coupling element to constrain a portion of the component to a coupling surface of the container at a coupling position. The gripping device and the coupling device can move along an arc with a curved trajectory to a removal position where the retaining element is oriented to receive at least one component to be retained, and to a coupling position where the retaining element and the coupling element bring an abutment surface of the container and a couplable portion of the component into contact.

Claims

1-26. (canceled)

27. A coupling unit with a coupling equipment for coupling a component for a container, the coupling equipment comprising: a frame, a housing constrained to said frame, the housing comprising at least one seat to receive said container in a stable manner, a gripping device constrained to said frame, the gripping device i) being configured to perform a rotation with respect to said frame through a rotary kinematic mechanism having a horizontal rotation axis and ii) comprising a retaining element configured to selectively retain said component, and a coupling device constrained to said gripping device with respect to said frame, the coupling device comprising a coupling element configured to constrain a couplable portion of said component to a coupling surface of said container at a predetermined coupling position of said component with respect to said container, wherein said gripping device and said coupling device are configured to move, by said rotary kinematic mechanism in accordance with said rotation, along an arc with a curved trajectory, to: a removal position, wherein said retaining element is oriented to be able to receive at least one component to be retained, and a coupling position, wherein said retaining element and said coupling element are placed to bring an abutment surface of said container and a couplable portion of said component into contact.

28. The coupling unit according to claim 27, wherein said coupling device is constrained with ability to move, with respect to said gripping device, from an extended configuration with a predefined spacing different from zero from said couplable portion of said component, to a coupling configuration where the coupling device is in contact with said couplable portion.

29. The coupling unit according to claim 28, wherein: said coupling device is constrained with ability to perform a vertical translation with respect to said gripping device when said coupling device is in said coupling position, and said vertical translation is configured to reversibly move said coupling device between said extended configuration and said coupling configuration.

30. The coupling unit according to claim 27, wherein said retaining element is configured to act at reduced pressure.

31. The coupling unit according to claim 27, wherein said component is a lid.

32. The coupling unit according to claim 27, wherein said container is a capsule.

33. The coupling unit according to claim 27, wherein said coupling element is a thermal or ultrasonic welder.

34. The coupling unit according to claim 27, wherein said removal position is substantially vertical.

35. The coupling unit according to claim 27, wherein said coupling position is substantially horizontal.

36. The coupling unit according to claim 27, wherein said abutment surface is an upper edge of said container defining an upper opening.

37. The coupling unit according to claim 27, wherein said coupling element is translatably constrained to said retaining element.

38. The coupling unit according to claim 27, wherein said housing comprises a plurality of seats configured to be superimposed by a corresponding coupling element when in said coupling position.

39. The coupling unit according to claim 27, further comprising a transporter accommodating said moving coupling member.

40. The coupling unit according to claim 39, wherein said transporter is a rotary carousel.

41. The coupling unit according to claim 39, wherein said seat and said container, when received in said seat, move with a continuous movement.

42. A method for coupling a component of a container to said container, the method comprising: providing a coupling unit with a coupling element, the coupling element comprising: a frame, a housing constrained to said frame, the housing comprising at least one seat to receive said container in a stable manner, a gripping device constrained to said frame with an ability to move, a coupling device constrained to said gripping device with an ability to move, the coupling device being configured to constrain said component to said container at a predetermined coupling position, wherein said retaining element and said coupling element are positioned to bring an abutment surface of said container and a couplable portion of said component into contact with each other, providing said container in said seat, rotating said gripping device to said removal position of said component, selectively removing and retaining said component by said retaining element, rotating said gripping device and said coupling device at said coupling position, activating said coupling element for a predetermined coupling time to produce a stable coupling between said couplable portion of said component and said abutment surface of said container, deactivating said retaining element and said coupling element, thereby deactivating a constraining action between said retaining element and said component, and moving said retaining element and said coupling element away from said component in order to reach said removal position.

43. The method according to claim 42, further comprising: moving said coupling device from an extended configuration where the coupling is at a predefined spacing different from zero from said couplable portion of said component, to a coupling configuration where the coupling device is in contact with said couplable portion.

44. The method according to claim 43, wherein said movement of said coupling device is performed by a vertical translation with respect to said gripping device when said coupling device is in said coupling position.

45. The method according to claim 44, wherein said retaining element operates at reduced pressure.

46. The method according to claim 42, wherein said coupling element is a thermal or ultrasonic welder.

47. The method according to claim 46, wherein: said coupling element is an ultrasonic welder and, before said retaining element and said coupling element moving to return towards the removal position, said coupling element produces an ultrasonic pulse to further detach said component from said coupling element.

48. The method according to claim 42, wherein said coupling unit comprises a transporter receiving said coupling equipment.

49. The method according to claim 48, wherein said transporter is a rotary carousel.

50. The method according to claim 48, wherein said coupling unit moves with a continuous movement.

51. The method according to claim 49, wherein said coupling is performed during a 50° rotation of said rotary carousel.

52. An apparatus for producing articles, comprising at least one coupling unit according to claim 27.

Description

[0179] The characteristics and advantages of the invention will become clearer from the detailed description of an embodiment illustrated, by way of non-limiting example, with reference to the appended drawings in which:

[0180] FIG. 1 is a schematic side sectional view of a coupling unit made in accordance with the present invention in a removal position;

[0181] FIG. 2 is another schematic side sectional view of the coupling unit made in accordance with the present invention in a removal position with containers;

[0182] FIG. 3 is a schematic frontal view in section along line III of FIG. 2;

[0183] FIG. 4 is a schematic perspective view of a coupling unit housing from FIG. 1;

[0184] FIG. 5 is a schematic perspective view of a gripping and coupling device from FIG. 1;

[0185] FIGS. 6a and 6b respectively represent a schematic perspective view of a container used by the coupling unit of the present invention and a schematic side elevation view of a container at the end of the coupling process;

[0186] FIG. 7 represents a schematic perspective view of the coupling unit of FIG. 1 including a rotary carousel;

[0187] FIG. 8 represents a schematic view from above of an article production apparatus according to the present invention.

[0188] With initial reference to FIG. 8, 800 indicated an apparatus for producing articles which is arranged to produce a finished container 10, ready for packaging or use.

[0189] The apparatus 800 preferably comprises a feeding station 801, a shaping station 802 of a filter, a sealing station 803 for sealing the filter to the container 10, a filling station 804 for filling the container 10.

[0190] The example embodiment described below relates to containers 10 in the form of capsules filled with a desired product to which a component 20 is applied.

[0191] In the specific case described herein, the containers 10 are capsule elements for the preparation of beverages for infusion, in particular coffee capsules. More specifically, the filler placed inside the capsule is coffee powder.

[0192] Preferably, said capsule 10 may be made of multilayer material, for example materials that are composed of layers of PP (Polypropylene) and/or EVOH (Ethylene Vinyl Alcohol) in PET (Polyethylene Terephthalate) or PS (Polystyrene). Otherwise capsule is made of multilayer material with at least one metal alloy layer, e.g. aluminium-based.

[0193] In addition, the applied component 20 is a lid of polyamide material. In particular, the lid may be a multilayer polymer laminate in which there is at least one aluminium layer.

[0194] Preferably, on the side of the lid facing towards the inside of the container there may be a layer of adhesive material intended to melt and be joined to the container at the time of welding.

[0195] Preferably, there may be a layer of a higher-melting material on the outer side rather than on the inner side, which must not melt when heat is supplied to melt the layer arranged on the inner side.

[0196] Such a polymeric lid comprises a laminable portion 25 which is effectively heat-weldable to the capsule 10 also made, for example, of polymeric material.

[0197] In the present example and as depicted in FIG. 6, the capsule 10 has a substantially upturned truncated conical shape presenting a base 11 of substantially flat and circular shape from which a lateral wall 12 is transversely projected.

[0198] This lateral wall 12 is inclined with respect to the vertical line having the smaller diameter thereof at the base 11 and the larger diameter thereof at an upper opening 13.

[0199] Again with reference to FIGS. 6 and 7, it can be seen that the lateral wall 12 of the container 10 ends at the top with an edge 14a projecting radially outward the container 10 itself.

[0200] An abutment surface 14B is identified on this edge 14A and which is configured to realise a coupling area with the couplable portion 25 of the lid 20.

[0201] Preferably, the lid 20 is circular in shape and can be superimposed to the upper opening 13 of the capsule 10 and the couplable portion 25 of the lid 20 is an annular portion that can be superimposed to the abutment surface 14b.

[0202] In FIGS. 1 to 3 with 100 is identified a coupling unit of the capsule 10 with the lid 20 comprising a coupling equipment1 in turn comprising: [0203] a frame 2, [0204] a housing 50 constrained to the frame 2 and comprising a pair of seats 51 formed to receive the capsule 10 in a stable manner, [0205] a gripping device 30, comprising a pair of retaining elements 31, each arranged to retain a respective lid 20 for each capsule housed in the housings 51, and [0206] a coupling device 40 comprising a pair of coupling elements 41 each arranged to couple a lid 20 to a respective capsule 10 housed in the seats 51.

[0207] Each seat 51 may be a cylindrical recess in which the capsule 10 is housed, and the two seats 51 are preferably aligned according to a sagittal straight line of the coupling unit 100.

[0208] The housing 50 includes in each seat 51 a retaining device 55 configured to retain the container 10 when housed in the housing 51.

[0209] In one embodiment, each retaining device 55 may selectively retain the container 10 for example by means of a suction cup or similar systems in reduced pressure.

[0210] The housing 50 further comprises a movement device 58 configured to move the retaining device 55, and in particular to vertically translate the retaining device 55 by moving between a lowered configuration, in which it is received within the housing 51, and a raised configuration, in which it protrudes from the housing 51, in a raised position with respect to an upper surface 59 of the housing 50.

[0211] Preferably and as shown in FIG. 1, the movement device 58 comprises a vertically translatable piston 58a configured to move between said lowered and raised configuration.

[0212] Each retaining element 31 is configured to selectively retain the lid 20 to itself and preferably operates at reduced pressure (e.g., suction cup). This engagement condition is depicted in FIG. 1.

[0213] In more detail, FIG. 1 represents a configuration of the gripping device 30 and the coupling device 40 in which they are in a removal position Pp, i.e. in which the retaining element 31 is oriented such that it can receive at least one lid 20 to be retained.

[0214] Preferably, the removal position Pp is identified by a substantially vertical orientation of the retaining element 31.

[0215] From this removal position Pp, the coupling equipment 1 may move towards a coupling position Pa by means of a rotary kinematic mechanism 33 in which the gripping device 30 and the coupling device 40 are rotated towards the housing 50 in such a way as to close the seats 51 and bring the lid 20 into contact with the edge 14 of the respective capsule 10.

[0216] This rotary kinematic mechanism 33 is represented in FIG. 2 as a pivot having a horizontal axis of rotation Z1 and interconnected to the frame 2 and to a box-shaped body 60 comprising within it both the gripping device 30 and the coupling device 40.

[0217] The box-shaped body 60 is substantially parallelepipedal in shape and has the gripping device 30 and the coupling device 40 at a first end 61 opposite to a second end 62 and the pin 33 is constrained to said box-shaped body 60 at an area identified at an intermediate position between the first and second ends 61, 62.

[0218] This configuration allows the gripping device 30 and the coupling device 40 to rotate about said pin 33 according to a same rotation R1 and to perform the curved trajectory C1 to move reversibly from said removal position Pp to said coupling position Pa.

[0219] In the cases shown in the Figure, this curved trajectory C1 is preferably an arc substantially equal to 90°.

[0220] Alternatively, such a curved trajectory C1 can be an arc of an ellipse or parabola or further curved paths that can be achieved by means of linkages or cam mechanisms.

[0221] The coupling device 40 is constrained to the gripping device 30 with possibility to move.

[0222] More specifically, the coupling device 40 is constrained to the gripping device 30 with possibility to translate.

[0223] As shown in FIGS. 1 to 3, the coupling device 40 translates from an extended configuration, in which it is at a predefined non-zero distance from the couplable portion 25 of said component 20, to a coupling configuration, in which it is in contact with said couplable portion 25. This translation preferably takes place in a vertical direction when the coupling device 40 is in the Pa coupling position.

[0224] As shown in FIGS. 1 and 2, the coupling device 40 comprises a coupling element 41 which is a thermal welder.

[0225] Such welder 41 is preferably always active and when in the extended configuration is at sufficient distance from the couplable portion 25 so as to avoid the possibility that the lid 20, when constrained to the retaining element 31, may be overheated before being brought into contact with the capsule 10.

[0226] Preferably, this predefined distance is between 1 mm and 10 mm.

[0227] When the coupling device 30 and the gripping device 40 are brought into the coupling position Pa, the coupling element 41 translates vertically while simultaneously coming into proximity to, or in contact with, the retaining element 31 and in contact with the couplable portion 25 of the lid 20.

[0228] In more detail, the coupling element 41 is housed and shaped in such a way as to present a welding surface 45 that ends substantially in planar continuity with a retaining surface 35 of the suction cup 31 when the coupling position Pa is reached.

[0229] Alternatively, the welding surface 45 may, in its translational stroke, project outwardly from the retaining surface 35 so as to exert additional pressure on the couplable portion 25 during the welding step.

[0230] The retaining surface 35 is substantially circular in shape and preferably has a maximum diameter smaller than the diameter of the upper opening 13 of the capsule 10.

[0231] Preferably, this retaining surface 35 is the bottom surface of a suction cup or similar technical solution.

[0232] The welding surface 45 is substantially in the form of a circular crown arranged radially external to the retaining surface 35.

[0233] The welding surface 45 is shaped in such a way that it can be at least partially overlapped with the abutment surface 14b of the capsule 10 when the coupling element 41 is brought into the coupling position Pa.

[0234] The coupling equipment 1 further comprises an atmosphere modification device 90 arranged to modify the atmosphere within the seats 51 when the gripping device 30 and the coupling device 40 are moved to the coupling position Pa to close the seats 51.

[0235] The atmosphere modification device 90 comprises a suction conduit 91 and an inert gas delivery conduit 92, which are extended into the housing 50 from opposing parts with respect to the seats 51 in a manner substantially parallel to their direction of alignment along the sagittal line.

[0236] In particular, both conduits 91 and 92 are connected to a flange 93, superiorly delimiting the seats 51 to form part of the upper surface 59 of the housing 50. In particular, the edge 14a of the capsule 10 rests on the flange 93 when it is housed within the respective seat 51.

[0237] The flange 93 is also suitably provided with through-holes 94 which place the conduits 91 and 92 in communication with the upper part of the seats 51, so that they are open at the respective upper openings 13 of the capsules 10.

[0238] On the gripping device 30, respective recesses 95 open towards the gripping elements 31 are also provided at the through-holes 94 to allow the flow of gas between the inert gas delivery conduit 92 and the suction conduit 91 at the upper opening 13 of the respective capsule 10.

[0239] The inert gas supplied from the supply line 92 is preferably nitrogen.

[0240] Thus, with reference to FIGS. 1 to 5, the method of coupling the lid 20 to the capsule 10 comprises: [0241] a. Providing the coupling unit 100 with the characteristics described above, [0242] b. Rotating the gripping device 30 to the removal position Pp of the lid 20, [0243] c. Selectively removing and retaining the lid 20 using the suction cup 31, [0244] d. Providing two capsules 10 in the two seats 50, [0245] e. Rotating the gripping device 30 and the coupling device 40 to the coupling position Pa, [0246] f. Translating the welder 41 vertically to the coupling configuration, bringing it into contact with the couplable portion 25, [0247] g. Activating the welder 41 for a predetermined coupling time Ta so as to produce a stable coupling between the couplable portion 25 and the abutment surface 14b, i.e., closing the capsule 10, [0248] h. Deactivating the suction cup 31 and the welder 41, [0249] i. Translating the welder 41 vertically to the extended configuration, [0250] l. Rotating the gripping device 30 and the coupling device 40 to the removal position Pp, [0251] m. Starting again from point c.

[0252] Preferably, the welder 41 is of the thermal type and applies a temperature between 150° C. and 300° C. for the predetermined coupling time Ta which is between 0.2 seconds and 0.8 seconds, preferably being 0.4 seconds. Advantageously, when the welder is thermal, it can always be left on at the desired temperature and approached or not approached to the lid 20 depending on the desired welding operation. Alternatively, the welder can be an ultrasonic welder and it can advantageously be switched on and off during a welding cycle.

[0253] Still preferably, the welder 41 exerts an even pressure on the couplable portion 25 between 45 and 85 Psi.

[0254] Preferably, when the gripping device 30 and the coupling device 40 are rotated into the coupling position Pa, and before activating the welder 41, the suction conduit 91 and the inert gas delivery conduit 92 are opened instead. In this way, the air present inside the seat 51 and in particular the air contained in the capsules 10 is substantially replaced by nitrogen, so that once the lid 20 is closed on the respective capsule 10, the product contained therein remains in an inert atmosphere, substantially devoid of oxygen.

[0255] In addition, the air intake and nitrogen supply are regulated in such a way as to obtain a final pressure inside the housing 50 which is lower than the atmospheric pressure by between 50 and 200 mbar, maintained at this value by the hermetic closure of the gripping device 30 and the coupling device 40 in the coupling position Pa. In this way, the subsequent coupling process takes place at a pressure below atmospheric pressure and this pressure also remains inside the capsule once it has been hermetically sealed by the lid 20.

[0256] Consequently, when the housing 50 is opened again to extract the finished capsules 10, the lid 20 tends to curve slightly inwards towards the capsule, as depicted in FIG. 6b. In this way, the possibility that the lid 20 of the capsule 10 may take on a convex shape, i.e. with a convex outer surface, which could cause some inconvenience during packing, is reduced.

[0257] Once the capsules 10 are completed they are lifted vertically for transfer to subsequent workstations.

[0258] With reference to FIG. 8, it can be seen that the coupling unit 100 comprises a transporter 200 on which a plurality of coupling equipments 1 are housed.

[0259] Such a transporter 200 is a rotary carousel.

[0260] Preferably, the plurality of coupling equipments 1 mounted on the rotary carousel is 48.

[0261] Again with reference to FIG. 8, the plurality of equipments 1 is mounted by aligning each sagittal line on which the centres of the seat pairs of each coupling equipment 1 pass with respective radial lines of said rotary carousel.

[0262] With reference to FIG. 1, it can be seen that the box-shaped body 60 is moved in such a way as to be able to bring the retaining element 31 reversibly from the removal position Pp to the coupling position Pa by means of a first cam system 70.

[0263] Similarly, the retaining device 55 is reversibly moved between the lowered configuration and the raised configuration by the drive device 58 comprising a second cam system 80.

[0264] Preferably, the step of welding the lid 20 onto the capsule 10 is completed in a rotation of the rotary carousel of between 30° and 180°.

[0265] Preferably, the plurality of coupling equipements 1 is constrained on said rotary carousel 200 at its maximum circumference in such a way that the exchange of finished containers with further external devices can be facilitated.

[0266] Thanks to this technical solution, the Applicant has demonstrated that it is able to couple at least 1500 components to containers per minute.