Methods of capping metallic bottles

Abstract

Methods of sealing a metallic container are provided. More specifically, the present invention relates to methods that reduce the amount of force applied to a metallic bottle to seal the metallic bottle with a ROPP closure. The methods include use of a capping apparatus that may include more thread rollers than known capping apparatus. Optionally, the thread rollers may use more forming passes to form threads on the ROPP closure. The capping apparatus may also rotate one or more of the ROPP closure and the metallic container in a closing direction before the metallic container is discharged. In one embodiment, the thread rollers form the closure threads before or after a pilfer roller applies a sideload to the ROPP closure.

Claims

1. A method of sealing a metallic bottle having a threaded neck with a ROPP closure, comprising: providing a capping apparatus having a pressure block ejector, a pressure block, a thread roller, and a pilfer roller; positioning the ROPP closure on the threaded neck of the metallic bottle; applying a predetermined first topload to a top portion of the ROPP closure by the pressure block ejector to at least partially press a liner within the ROPP closure against a curl positioned on an upper portion of the threaded neck of the metallic bottle; applying a predetermined second topload to the top portion of the ROPP closure by the pressure block of the capping apparatus to form a channel with a predetermined depth in an outer radial edge of the ROPP closure; applying a predetermined first sideload with the thread roller of the capping apparatus to an exterior surface of a body portion of the ROPP closure to form closure threads on the body portion; rotating the metallic bottle in a closing direction around a longitudinal axis of the metallic bottle to drive the curl further into the liner after the closure threads are at least partially formed; and applying a predetermined second sideload with the pilfer roller of the capping apparatus to a pilfer band of the ROPP closure, wherein the metallic bottle is sealed by the ROPP closure, and wherein the pilfer roller applies the second sideload after the metallic bottle is rotated in the closing direction.

2. The method of claim 1, wherein the pressure block applies and releases the second topload to the top portion of the ROPP closure before the thread roller applies the first sideload.

3. The method of claim 1, wherein the thread roller applies the first sideload while the pressure block ejector applies the first topload to seal the metallic bottle with the ROPP closure.

4. The method of claim 1, wherein the pilfer roller applies the second sideload to the ROPP closure when the thread roller is not applying the first sideload to the ROPP closure.

5. The method of claim 1, wherein one or more of the pressure block ejector and the pressure block rotate the ROPP closure axially in the closing direction after the closure threads are at least partially formed.

6. The method of claim 1, wherein a tool of the capping apparatus is configured to rotate the metallic bottle in the closing direction at least a portion of one revolution.

7. The method of claim 6, wherein the tool comprises at least one of a chuck positioned proximate to a closed end portion of the metallic bottle and a holder that engages a body portion of the metallic bottle.

8. The method of claim 1, wherein the thread roller is configured to form the closure threads in three or more passes.

9. The method of claim 1, wherein the metallic bottle is comprised of at least one of an aluminum, a plastic, and a glass material.

10. The method of claim 1, wherein the pressure block ejector is adapted to apply a first topload to the ROPP closure which is not greater than about 200 pounds.

11. The method of claim 1, wherein the first sideload applied to the ROPP closure by the thread roller is not greater than about 30 pounds and the second sideload applied to the ROPP closure by the pilfer roller is not greater than about 35 pounds.

12. The method of claim 1, wherein a cumulative load including the first topload and one of the first sideload and the second sideload is not greater than about 320 pounds.

13. The method of claim 1, wherein the pressure block is configured to form the channel such that the channel has a depth of less than about 0.1 inches.

14. A method of interconnecting and sealing a ROPP closure to a threaded neck of a bottle, comprising: providing a capping apparatus having a pressure block ejector, at least one thread roller, and at least one pilfer roller; positioning the ROPP closure on the threaded neck of the bottle; applying a first topload to an upper portion of the ROPP closure with the pressure block ejector of the capping apparatus, the first topload at least partially compressing a liner within the ROPP closure against a curl positioned on an upper portion of the threaded neck of the bottle to seal an opening of the bottle; applying a first sideload with the at least one thread roller of the capping apparatus to an exterior surface of a body portion of the ROPP closure, the first sideload forming closure threads on the body portion while the pressure block ejector continues to apply the first topload to maintain the seal; after forming the closure threads, rotating at least one of the bottle and the ROPP closure such that a distance between an exterior surface of the upper portion of the ROPP closure and the curl is decreased; and applying a second sideload with the at least one pilfer roller of the capping apparatus to a pilfer band of the ROPP closure while the pressure block ejector continues to apply the first topload, wherein the bottle is sealed by the ROPP closure.

15. The method of claim 14, wherein the first sideload and the second sideload are applied sequentially.

16. The method of claim 14, wherein the first sideload is applied by the at least one thread roller during three or more contacts with the body portion of the ROPP closure and the second sideload is applied by the at least one pilfer roller during three or more different contacts with the pilfer band.

17. The method of claim 14, further comprising: applying a second topload by a pressure block of the capping apparatus to form a channel in an outer radial edge of the ROPP closure, the second topload being greater than the first topload.

18. The method of claim 17, wherein the pressure block applies and releases the second topload to the upper portion of the ROPP closure before the at least one thread roller applies the first sideload.

19. The method of claim 17, wherein the pressure block is configured to form the channel such that the channel has a depth of less than about 0.1 inches.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) 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 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 present invention is not necessarily limited to the particular embodiments illustrated herein. Additionally, it should be understood that the drawings are not necessarily to scale.

(2) FIGS. 1A-1D illustrate a method of sealing a metallic bottle with a ROPP closure using a prior art capping apparatus;

(3) FIG. 2 is a graph of the forces applied to a metallic bottle during sealing with a ROPP closure using a prior art capping apparatus;

(4) FIG. 3 is another graph of the forces applied by another prior art capping apparatus to a metallic bottle during sealing of the metallic bottle with a ROPP closure;

(5) FIG. 4 is a graph of the cumulative forces applied by a prior art capping apparatus to a metallic bottle during a capping process and illustrating a failure region in which the cumulative forces may be expected to cause failure of the metallic bottle or loss of seal between a ROPP closure and the metallic bottle;

(6) FIG. 5 is a partial front elevation view of a capping apparatus of one embodiment of the present invention and depicting the neck of a metallic bottle sealed with a ROPP closure by the capping apparatus;

(7) FIG. 6 is a photograph of a cross section of a portion of a metallic bottle curl in contact with a liner within a ROPP closure;

(8) FIG. 7 is a cross-sectional top plan view of the metallic bottle and the ROPP closure taken along line 7-7 of FIG. 5 and further illustrating rotation of one or more of the metallic bottle and the ROPP closure in a closing direction during the sealing of the metallic bottle;

(9) FIG. 8 is a graph of sideload and topload forces applied to a metallic bottle during sealing with a ROPP closure by a capping apparatus of an embodiment of the present invention;

(10) FIG. 9 is a graph of the cumulative forces applied by a capping apparatus of the present invention to a light-weight metallic bottle during a capping process and illustrating a failure region in which the cumulative forces may be expected to cause failure of the light-weight metallic bottle; and

(11) FIG. 10 is a flow chart of one embodiment of a method of sealing a metallic bottle with a ROPP closure.

(12) 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:

(13) TABLE-US-00001 Number Component 2 Metallic bottle 4 Neck portion 6 Curl 8 Bottle threads 9 ROPP shell 10 ROPP closure 12 Body portion of ROPP closure 14 ROPP liner 16 Closure threads 18 Pilfer band 20 Top portion of ROPP closure 22 Prior art capping apparatus 24 Pressure block ejector 25 Pressure block 26 Thread roller 28 Pilfer roller 30 Skirt of metallic bottle 32 Channel of closure 34 Sideload force 35 Roller re-set point 36 Topload force 38 Sideload force 39 Roller re-set point 40 Topload force 41 Initial spike 42 Failure region 44 Failure threshold 46 Nominal load 47 Margin between nominal load and failure threshold 64 Chuck 66 Holder 68 Capping apparatus 70 Pressure block ejector 72 Pressure block 74 Contact surface of pressure block 76 Thread roller 78 Pilfer roller 80 Metallic bottle 81 Longitudinal axis of the metallic bottle 82 Skirt 83 Closing direction of metallic bottle 84 Neck 85 Body portion 86 Curl 87 Closed end portion 88 Bottle threads 90 Opening 92 ROPP closure 93 Closing direction of ROPP closure 94 Pilfer band 96 Body portion of ROPP closure 98 Closure threads 100 ROPP liner 102 Channel of closure 104 Top portion of ROPP closure 106 Beginning contact point 108 Extend of vertical contact 110 Final contact point 112 Region of vertical contact 114 Depth of closure Channel 116 Graph 118 Sideload 120 Topload 122 Maximum topload 124 Topload to maintain seal 126 First sideload 128 Beginning of roller reset 130 No roller contact 132 Roller reset and contact 134 Graph of cumulative failure load 136 Failure region 138 Failure threshold 140 Maintain seal 142 Create closure Channel 144 Sideload force 146 Cumulative force produced by prior art capping apparatus 150 Method of sealing a metallic bottle with a capping apparatus 151 Start operation 153 Generate seal 156 Maintain seal 158 Thread roller applies sideload 160 Pilfer roller applies sideload 162 Rotate ROPP closure in closing direction 164 Determine if sideload operations and/or closure rotation repeat 166 Discharge 168 End operation

DETAILED DESCRIPTION

(14) 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.

(15) Referring now to FIG. 5, a capping apparatus 68 of an embodiment of the present invention is illustrated. The capping apparatus 68 generally includes a pressure block ejector 70, a pressure block 72 with a contact surface 74, at least one thread roller 76, and at least one pilfer roller 78. In one embodiment, at least one of the pressure block ejector 70 and the pressure block 72 are configured to rotate axially around a longitudinal axis 81 of a metallic bottle 80. Optionally, the capping apparatus 68 may include from one to five thread rollers 76. In one embodiment, at least one of the thread rollers 76 has a different thread forming profile than the other thread rollers 76. Optionally, each of the thread rollers 76 may apply different sideload forces during the formation of the closure threads 98. Additionally, from one to five pilfer rollers 78 may be included with the capping apparatus 68.

(16) The capping apparatus 68 may be used to seal a metallic bottle 80 with a ROPP closure 92 that starts as a ROPP shell 9. In one embodiment, the metallic bottle 80 is the same as, or similar to, the prior art metallic bottle 2. In another embodiment, the metallic bottle 80 is a light-weight metallic bottle formed of at least one of less, lighter, and different metallic material than the prior art metallic bottle 2. In one embodiment, at least a portion of the light-weight metallic bottle 80 is at least about 5% thinner than a similar portion of a prior art metallic bottle 2. In another embodiment, the column strength of the light-weight metallic bottle 80 is at least about 8% less than the column strength of the prior art metallic bottle 2. In yet another embodiment, the alloy used to form the light-weight metallic bottle 80 has a column strength that is at least about 15% less than the column strength of the alloy used to form the prior art metallic bottle 2. In one embodiment, the light-weight metallic bottle 80 has a mass of less than about 0.820 oz. In another embodiment, the mass of the light-weight metallic bottle 80 is less than about 0.728 oz.

(17) The metallic bottle 80 generally includes a closed end portion 87, a body portion 85 extending from the closed end portion 87, a neck portion 84 with a reduced diameter, a skirt 82 on the neck portion 84, a curl 86 at an uppermost portion of the neck portion 84, threads 88 generally positioned between the skirt 82 and the curl 86, and an opening 90 positioned at an uppermost portion of the neck portion 84. The metallic bottle 80 may include any number of threads 88 that each have a predetermined size, shape, and pitch. In one embodiment of the present invention, the bottle threads 88 have a pitch of between about 0.10 inches and about 0.15 inches. In another embodiment, the bottle threads 88 have an exterior diameter of between approximately 1.0 inches and approximately 1.6 inches.

(18) The threads 88 may be integrally formed on the neck portion 84. Alternatively, the threads 88 may be formed on an outsert that is interconnected to the neck portion 84 as described in U.S. Patent Application Publication No. 2014/0263150 which is incorporated herein in its entirety. Other methods and apparatus used to form threads on metallic containers are described in U.S. Patent Application Publication No. 2012/0269602, U.S. Patent Application Publication No. 2010/0065528, U.S. Patent Application Publication No. 2010/0326946, U.S. Pat. Nos. 8,132,439, 8,091,402, 8,037,734, 8,037,728, 7,798,357, 7,555,927, 7,824,750, 7,171,840, 7,147,123, 6,959,830, and International Application No. PCT/JP2010/072688 (publication number WO/2011/078057), which are all incorporated herein in their entirety by reference

(19) The body portion 85 of the metallic bottle 80 may have any desired size or shape. For example, in one embodiment, the body portion 85 has a generally cylindrical shape. The bottom portion 87 may include an inward dome. The body portion 85 may include a waist portion with a reduced diameter. In one embodiment, the waist portion includes an inwardly tapered cross-sectional profile. In another embodiment, the body portion 85 of the metallic bottle 80 has a diameter of between about 2.5 inches and about 2.85 inches. In yet another embodiment, the metallic bottle 80 has a height of between about 6.0 inches and about 7.4 inches.

(20) The metallic bottle 80 is illustrated in FIG. 5 after being sealed by the capping apparatus 68 with a ROPP closure 92. The thread roller 76 and the pilfer roller 78 are illustrated in an optional disengaged position for clarity. The ROPP closure 92 may be formed from a prior art ROPP shell 9. The ROPP closure 92 generally includes a pilfer band 94 at a lowermost portion of a body portion 96, threads 98 formed on a portion of the body portion 96, a liner 100 positioned proximate to an interior surface of a top portion 104, and a channel 102 at a radial edge of the top portion 104.

(21) In operation, the capping apparatus 68, ROPP closure 92, and metallic bottle 80 are brought into a predetermined alignment. In one embodiment, at least one of the pressure block ejector 70 and the pressure block 72 apply a predetermined topload force to at least a portion of an exterior surface of the closure top portion 104. The topload force at least partially compresses the ROPP liner 100 against the curl 86 to form and maintain a seal between the ROPP closure 92 and the metallic bottle 80. Said another way, the bottle curl 86 is at least partially embedded in the ROPP liner 100 by the topload force applied by the capping apparatus 68.

(22) In one embodiment, the contact surface 74 of the pressure block 72 applies a predetermined topload force to a portion of the closure top portion 104 to form the closure channel 102. Generally, a depth 114 (illustrated in FIG. 7) of the closure channel 102 is directly related to the amount of the topload applied by the pressure block 72. Stated otherwise, a channel 102 with a greater depth requires more topload to form than a channel 102 with a decreased depth. In one embodiment, the topload force applied by the contact surface 74 of the pressure block 72 is less than the topload force applied to form the closure channel 32 by the prior art capping apparatus 22. Accordingly, in one embodiment, the channel 102 has less depth 114 than the channel 32 produced by the prior art capping apparatus 22.

(23) The capping apparatus 68 forms the closure threads 98 by pressing the thread rollers 76 against predetermined portions of the closure body portion 96. The thread rollers 76 then wind axially around the bottle longitudinal axis 81 and down the body portion 96 along the bottle threads 88. The thread rollers 76 use the bottle threads 88 as a form for the closure threads 98. The closure threads 98 may be formed during one or more passes of the thread rollers 76. During each pass, the thread rollers 76 may make between about 1.75 to about 2 revolutions axially around the closure body portion 96.

(24) In one embodiment, the capping apparatus 68 includes two thread rollers 76. Optionally, each of the two thread rollers 76 may be configured to apply less of a sideload force than the prior art thread rollers 26. For example, in one embodiment, the two thread rollers 76 each apply less than about 30 lbs of force to the metallic bottle 80 and the ROPP closure 92. In another embodiment the thread rollers 76 each apply between about 15 pounds and about 35 pounds of force. To form the closure threads 98, the two thread rollers 76 may make at least two passes in contact with the body portion 96. In one embodiment, the two thread rollers 76 each make three passes to form the closure threads 98. In another embodiment, four passes by each of the two thread rollers 76 are used to form the closure threads 98. Optionally, the sideload force applied by the two thread rollers 76 may be different for one or more of the at least two passes. For example, in one embodiment, the two thread rollers 76 each apply a first predetermined sideload force on one of the passes and a second predetermined sideload force on a different pass. In one embodiment, a first one of the two thread rollers 76 may optionally apply a different sideload force than a second one of the two thread rollers 76.

(25) Optionally, the capping apparatus 68 includes three or more thread rollers 76. In an embodiment, each of the three or more thread rollers 76 may be configured to apply less sideload force than prior art thread rollers 26. The three or more thread rollers 76 may make one or more passes to form the closure threads 98. In one embodiment in which the capping apparatus 68 includes four thread rollers 76, only one pass by each of the four thread rollers 76 is required to form the closure threads 98.

(26) The pilfer rollers 78 apply a sideload force to the metallic bottle 80 to tuck the pilfer band 94 against the bottle skirt 82. In one embodiment, the pilfer rollers 78 tuck the pilfer band 94 against the bottle skirt 82 either before or after the thread rollers 76 form the closure threads 98. In this manner, the cumulative load applied to the metallic bottle 80 by the capping apparatus 68 is reduced compared to the cumulative load applied by the prior art capping apparatus 22 in which the thread rollers 26 and pilfer rollers 28 apply sideloads simultaneously.

(27) In one embodiment, the thread rollers 76 and the pilfer rollers 78 independently and consecutively form the closure threads 98 and tuck the pilfer band 94. In this embodiment the cumulative load applied to the metallic bottle 80 and the ROPP closure 92 is reduced without decreasing the individual sideloads applied by the thread and pilfer rollers 76, 78 from the current sideloads applied by prior art thread and pilfer rollers 26, 28. Accordingly, in one embodiment, the capping apparatus 68 may seal a light-weight metallic bottle 80 of the present invention with each thread roller 76 applying a sideload of less than about 30 lbs either before or after each pilfer roller 78 applies a sideload of less than about 35 lbs.

(28) Similar to the thread rollers 76, the capping apparatus 68 may have two or more pilfer rollers 78. Each of the pilfer rollers 78 may be configured to apply less sideload force than prior art pilfer rollers 28. For example, in one embodiment, each pilfer roller 78 applies less than about 35 lbs of force to the metallic bottle 80 and the ROPP closure 92. The pilfer rollers 78 may tuck the pilfer band 94 against the bottle skirt 82 in any number of passes. In one embodiment in which the capping apparatus 68 includes three or more pilfer rollers 78, each pilfer roller 78 may make only one pass. In another embodiment, each pilfer roller 78 makes more passes but applies less sideload force than the prior art pilfer rollers 28 of capping apparatus 22. Optionally, at least one pilfer roller 78 of the two or more pilfer rollers applies a different sideload force than the other pilfer rollers 78. Additionally, the pilfer rollers 78 may optionally apply a different sideload force during different passes.

(29) As one who is skilled in the art will appreciate, all metal forming operations involve some amount of spring back after a forming load is removed from a metallic workpiece. In metallic bottle sealing operations, after the topload applied by the pressure block ejector 70 and the pressure block 72 are removed, spring back of the metal of the metallic bottle 80 and or the ROPP closure 92 generally result in movement of the ROPP liner 100 axially along the longitudinal axis 81 and away from the bottle curl 86. In order to maintain the seal between the metallic bottle 80 and the ROPP closure 92, a predetermined amount of contact between the curl 86 and ROPP liner 100 must be maintained despite this spring back.

(30) Referring now to FIG. 6, an annotated photograph of portions of the liner 100 between the closure channel 102 of the ROPP closure 92 and the bottle curl 86 are shown. The liner 100 has been outlined for clarity. The liner 100 contacts the curl 86 from approximately point 106 to approximately point 110. A region 112 of vertical contact extends from approximately point 106 to approximately point 108. To maintain the seal between the bottle curl 86 and the ROPP liner 100, the length of the vertical contact region 112 must be greater than a distance of axial travel of the ROPP closure 92 during spring back. The length of the vertical contact region 112 may be increased by increasing the depth 114 of the closure channel 102. However, as described above, to increase the channel depth 114, the topload applied by the pressure block 72 to form the channel 102 must be increased.

(31) Alternatively, and referring now to FIG. 7, to decrease the axial travel of the ROPP closure 92 during spring back, one or more of the metallic bottle 80 and the ROPP closure 92 may be rotated in a closing direction 83, 93, respectively, to drive the bottle curl 86 into the ROPP liner 100. Rotating either the metallic bottle 80 or the ROPP closure in the closing direction 83, 93 during the sealing of the metallic bottle 80 generally improves the seal between the closure liner 100 and the bottle curl 86.

(32) Accordingly, in one embodiment of the present invention, the capping apparatus 68 is operable to rotate the ROPP closure 92 axially in the closing direction 93. In one embodiment at least one of the pressure block ejector 70 and the pressure block 72 rotate axially in the closing direction 93 before the topload is released. The axial rotation of the pressure block ejector 70 and/or the pressure block 72 cause the ROPP closure 92 to rotate axially in the closing direction 93. It will be appreciated by one of skill in the art that the closing direction 93 of the ROPP closure 92 is the opposite of the opening direction which is used to rotate the ROPP closure 92 off of the metallic bottle 80. The closing rotation of the ROPP closure 92 drives the closure threads 98 further onto the bottle threads 88. Rotating the ROPP closure 92 in the closing direction 93 also decreases a distance between a closed bottom portion of the metallic bottle 80 and the top portion 104 of the ROPP closure 92. In this manner, the ROPP liner 100 is compressed further onto the curl 86 without increasing the topload applied by one or more of the pressure block ejector 70 and the pressure block 72. Thus, the length of region of vertical contact 112 of the ROPP liner 100 and the bottle curl 86 can be increased without increasing the topload applied to the metallic bottle 80 and the ROPP closure 92. Additionally, the axial travel of the ROPP closure 92 due to spring back when the topload is released is limited to less than the length of the vertical contact region 112. Accordingly, the metallic bottle 80 may be sealed with a ROPP closure 92 having a channel 102 that has a decreased depth 114 (and is formed with a decreased topload) compared to the channel 32 formed by the prior art capping apparatus 22. Rotating the ROPP closure 92 in the closing direction 93 during sealing of a metallic bottle 80 may also control the amount of torque required to remove the ROPP closure 92 by a consumer. Accordingly, the amount of torque required to remove the ROPP closure 92 may be reduced by rotating the ROPP closure 92 in the closing direction 93 during the sealing of the metallic bottle 80. More specifically, by rotating the ROPP closure 92 in direction 93 during the sealing, the amount of torque subsequently required to remove the ROPP closure 92 is reduced compared to the amount of torque required to remove a similar ROPP closure that was not rotated during the sealing of a similar metallic bottle.

(33) In one embodiment, the ROPP closure 92 is rotated in the closing direction 93 by the capping apparatus 68 before the pilfer roller 78 tucks the pilfer band 94. In another embodiment, the capping apparatus 68 rotates the ROPP closure 92 in the closing direction 93 when the closure threads 98 have been at least partially formed by the thread roller 76. For example, the ROPP closure 92 may be rotated in direction 93 after at least one pass of the thread rollers 76 when multiple passes are used to form the closure threads 98. Optionally, the capping apparatus 68 may rotate the ROPP closure 92 in the closing direction 93 after each pass of the thread rollers 76. In a more preferred embodiment, the ROPP closure 92 may be rotated in direction 93 only after the closure threads 98 have been completely formed. Additionally, in embodiments, the topload applied to the ROPP closure 92 by the pressure block ejector 70 and/or the pressure block 72 may be decreased after the capping apparatus 68 rotates the ROPP closure 92 in the closing direction 93. Optionally, the topload applied by one or more of the pressure block ejector 70 and the pressure block 72 may be completely eliminated (reduced to zero pounds) after the ROPP closure 92 is rotated at least one time in the closing direction 93 by the capping apparatus 68.

(34) It will be appreciated by one of skill in the art that the curl 86 may be driven further into the liner 100 by rotating either the ROPP closure 92 or the metallic bottle 80. Accordingly, in one embodiment, the metallic bottle 80 is rotated axially in the closing direction 83 instead of, or in addition to, each rotation of the ROPP closure 92 in the closing direction 93 described herein. For example, in one embodiment the capping apparatus 68 further comprises a tool to hold the metallic bottle 80 during sealing by the capping apparatus 68. The tool may be one or more of a chuck 64 and a holder 66. The chuck 64 may engage the closed end portion 87 of the metallic bottle 80. The holder 66 may include an aperture which receives the body portion 85 of the metallic bottle 80. In one embodiment, one or more of the chuck 64 and the holder 66 are configured to rotate the metallic bottle 80 axially in the closing direction 83 further into the ROPP closure 92 at one or more predetermined times during the sealing of the metallic bottle 80.

(35) Each rotation of the ROPP closure 92 and/or the metallic bottle 80 may be less than a complete revolution around the longitudinal axis 81. Accordingly, in one embodiment, one or more of the metallic bottle 80 and the ROPP closure 92 are rotated at least a portion of one revolution around the longitudinal axis 81 in the closing direction 83, 93, respectively.

(36) Referring now to FIG. 8, a graph 116 of sideload 118 and topload 120 forces applied to a metallic bottle 80 by a capping apparatus 68 of an embodiment of the present invention to seal the metallic bottle 80 with a ROPP closure 92 are illustrated. In one embodiment, the topload 120 initially increases from zero pounds to a maximum amount at point 122 during formation of the closure channel 102 by the pressure block 72. After the closure channel 102 has been formed, the topload 120 applied by at least one of the pressure block ejector 70 and the pressure block 72 is reduced to point 124. The topload 120 applied at point 124 is sufficient to maintain the seal between the bottle curl 86 and the ROPP liner 100. Optionally, when at least one of the ROPP closure 92 and the metallic bottle 80 are rotated during the sealing to drive the bottle curl 86 further into the ROPP liner 100, the maximum topload 120 may be reduced and is less than the topload of point 122, for example, when the pressure block 72 forms a closure channel 102 with a reduced depth 114. Accordingly, in one embodiment of the present invention, by forming a channel 102 with a reduced depth compared to the channel 32 formed by the prior art capping apparatus 22 and subsequently rotating one of the metallic bottle 80 and the ROPP closure 92 during the sealing of the metallic bottle 80, the capping apparatus 68 of the present invention applies less topload 120 at point 122 than the prior art capping apparatus 22. In this manner, the capping apparatus 68 of one embodiment of the present invention may be used to cap and seal a light-weight metallic bottle 80 of one embodiment of the present invention. Said another way, a light-weight metallic bottle 80 of the present invention would be expected to fail when sealed by a prior art capping apparatus 22 that forms a channel 32 in the ROPP closure 10.

(37) Once the seal between the bottle curl 86 and the ROPP liner 100 has been created, at least one thread roller 76 and at least one pilfer roller 78 apply a sideload 118 at point 126. Thus, in one embodiment, the beginning of the formation of the closure threads 98 and tuck of the pilfer band 94 are purposely delayed until the topload 120 is reduced at point 124 to maintain the seal. The cumulative load comprising the topload 120 and sideload 118 at point 126 is less than the cumulative load applied by the prior art capping apparatus 22.

(38) As previously described, in one embodiment of the present invention, the at least one thread roller 76 and the at least one pilfer roller 78 apply sideloads separately to form the closure threads 98 and tuck the pilfer band 94. Accordingly, in one embodiment, only one of the at least one thread roller 76 and the at least one pilfer roller 78 contact the ROPP closure 92 and apply a sideload to the metallic bottle 80 at any given time. The order of contact with the ROPP closure 92 by the thread roller 76 and the pilfer roller 78 may vary. For example, in one embodiment, the pilfer roller 78 contacts the ROPP closure 92 before the thread roller 76. Alternatively, the pilfer roller 78 contacts the ROPP closure 92 after the thread roller 76.

(39) The at least one thread roller 76 and the at least one pilfer roller 78 may perform their operations in multiple alternating or sequential passes. An example of a change in the sideload 118 between passes of the thread roller 76 and the pilfer roller 78 is illustrated by points 128, 130, 132. At point 128, at least one of the thread roller 76 and pilfer roller 78 begin to reset. A reset of the thread roller 76 comprises movement of the thread roller 76 to an initial position proximate to the closure channel 102. For example, the at least one thread roller 76 may move from a position proximate to the pilfer band 94 back to a point proximate to the closure channel 102. During the movement, the sideload applied by the at least one thread roller 76 and/or the at least one pilfer roller 78 decreases from point 128 to zero pounds at point 130 as the thread roller 76 and pilfer roller 78 move out of contact with the ROPP closure 92. When the thread roller 76 is positioned proximate to the closure channel 102, the thread roller 76 moves into contact with the ROPP closure 92 and begins applying force until the sideload 118 reaches the maximum at point 132. During the reset of the at least one thread roller 76 and the at least one pilfer roller 78, the topload 120 is maintained at a substantially constant amount required to maintain the seal achieved at point 124. Although only one reset of the thread roller 76 and the pilfer roller 78 is illustrated in graph 116, it will be appreciated by one of skill in the art that any number of roller resets associated with passes of the thread roller 76 and the pilfer roller 78 may be used with the capping apparatus 68. For example, in one embodiment, the at least one thread roller 76 performs from one to five passes to form the closure threads 98. Similarly, in another embodiment, the at least one pilfer roller 78 performs from one to five passes to tuck the pilfer band 94 against the bottle skirt 82.

(40) Table 3 illustrates topload and sideload forces generated by a capping apparatus 68 of an embodiment of the present invention to seal a metallic bottle 80 with a ROPP closure 92.

(41) TABLE-US-00002 TABLE 3 INDEPENDENT SIDELOAD/TOPLOAD/METHOD Topload Cumulative Cumulative Operation (lbs) Sideload (lbs) Load (lbs) Reform (Optional) <300 0 <300 Maintain Seal <200 0 <200 Thread/Pilfer Form <200 <120 <320 Thread/Pilfer Roller Reset <200 0 <200 Thread/Pilfer Form <200 <120 <320 Package Discharge 0 0

(42) In one embodiment, the metallic bottle 80 is a light-weight metallic bottle of an embodiment of the present invention. Although only one “thread/pilfer roller reset” is shown in Table 3, row 5, as previously described the capping apparatus 68 may reset one or more of the thread roller 76 and the pilfer roller 78 any number of times.

(43) All values listed in Table 3 are approximate values. Accordingly, in one embodiment, the topload in column 2 may vary by about +/−5%. Alternatively, in another embodiment, the topload may vary by about +/−10 pounds. In one embodiment, the topload required to form the channel 102 in the ROPP closure 92 is no more than about 300 pounds. In another embodiment, the topload required to maintain seal between the ROPP liner 100 and the bottle curl 86 is no greater than about 200 pounds. In one embodiment, the sideload may vary by about +/−5%. In another embodiment, the sideload may vary by about +/−1 pound on each individual roller 76, 78. In another embodiment, the cumulative sideload is less than about 120 pounds. In still another embodiment, the cumulative sideload is less than about 110 pounds.

(44) Referring now to FIG. 9, a graph 134 of production capping loads generated by the methods and capping apparatus 68 of embodiments of the present invention are plotted. Sideload forces generated by at least one thread roller 76 and/or at least one pilfer roller 78 of the capping apparatus 68 are plotted on the X-axis in pounds. Topload forces generated by at least one of the pressure block ejector 70 and the pressure block 72 are plotted on the Y-axis in pounds. The graph 134 includes a cumulative load failure region 136 above a failure threshold line 138 based on an expected failure limit for a light-weight metallic bottle 80 of the present invention. Note that the failure threshold line 138 has been moved closer to the X-axis compared to the failure threshold line 44 illustrated in FIG. 4 for prior art capping apparatus 22.

(45) Notably, all operations performed by capping apparatus 68 fall below the failure threshold line 138 and outside failure region 136. More specifically, at point 140, the pressure block ejector 70 applies a topload to the ROPP closure 92 to generate and maintain a seal between the bottle curl 86 and the ROPP liner 100. In one embodiment, the topload at point 140 is less than about 200 pounds. Optionally, the pressure block 72 applies a topload to a portion of the top portion 104 to create the channel 102 of a predetermined depth 114 at point 142. In one embodiment, the topload at point 142 is no more than about 300 pounds.

(46) Optionally, the depth 114 of the closure channel 102 is less than the depth of the channel 32 of ROPP closure 10 formed by the prior art capping apparatus 22. In one embodiment of the present invention, the closure channel 102 formed by the capping apparatus 68 has a depth 114 of less than approximately 0.1 inches. The depth 114 of the channel is optionally less than about 0.075 inches. In a more preferred embodiment, the depth 114 is less than approximately 0.05 inches. In another embodiment, the depth 114 is no more than about 80% of the distance from an exterior surface of the closure top portion 104 to a bottom portion of the bottle curl 86. In a more preferred embodiment, the depth 114 is less than about 75% of the distance from the exterior surface to the bottom of the bottle curl 86. In still another embodiment, the depth 114 is less than about two times the length of the region 112 of vertical contact between the ROPP liner 100 and the curl 86. Accordingly, as a channel 102 with less depth 114 can be formed with less topload force, the topload force applied at point 142 by the capping apparatus 68 of the present invention is less than the topload force applied by the prior art capping apparatus 22 to form the channel 32. After the optional force associated with formation of the channel 102 is complete, the topload force applied to the ROPP closure 92 is reduced and returns to point 140.

(47) The thread rollers 76 and pilfer rollers 78 next apply sideloads illustrated at point 144. In one embodiment, the cumulative sideload force at point 144 is less than about 120 pounds. In one embodiment, the sideload force at point 144 is a maximum sideload generated by substantially simultaneous contact of at least one thread roller 76 and at least one pilfer roller 78. In another embodiment, the sideload force at point 144 represents the substantially simultaneous contact of two thread rollers 76 and two pilfer rollers 78 with the ROPP closure 92. Accordingly, by independently applying the topload generated by the pressure block 72 and subsequently applying the sideload by the thread and pilfer rollers 76, 78, a light-weight metallic bottle 80 of the present invention may be sealed without reducing any of the individual loads generated the capping apparatus 68 compared to the prior art capping apparatus 22.

(48) In another embodiment in which the number of passes of the thread rollers 76 and the pilfer rollers 78 is increased, the maximum sideload force is less than the sideload force at point 144. Additionally, in an optional embodiment, the thread rollers 76 and the pilfer rollers 78 contact and apply sideloads to the ROPP closure 92 at different times. Accordingly, the sideload force is less than the sideload force of point 144 when the thread rollers 76 and the pilfer rollers 78 perform their actions consecutively (or independently) as described above.

(49) Point 146 represents the cumulative load produced by the prior art capping apparatus 22. As point 146 is within the failure region 136, a light-weight metallic bottle 80 of the present invention sealed by capping apparatus 22 would be expected to fail.

(50) Referring now to FIG. 10, an embodiment of a method 150 of sealing a metallic bottle 80 with a ROPP closure 92 using a capping apparatus 68 of the present invention is generally illustrated. The method 150 generally starts with a start operation 151 and ends with an end operation 168. While a general order of operations of the method 150 is shown in FIG. 10, the method 150 can include more or fewer operations or can arrange the order of the operations differently than those shown in FIG. 10. Additionally, although the operations of method 150 may be described sequentially, many of the operations may in fact be performed in parallel or concurrently. In one embodiment, the method 150 is executed mechanically by the capping apparatus 68. The method 150 can optionally be executed as a set of computer-executable instructions executed by a computer system and encoded or stored on a computer readable medium. The computer system may be operable to control the capping apparatus 68. Hereinafter, the method 150 shall be explained with reference to the apparatus, components, metallic containers, and ROPP closures described in conjunction with FIGS. 1-9.

(51) In operation 153, the capping apparatus 68 receives a metallic bottle 80 and a ROPP shell 9. One or more of the pressure block ejector 70 and the pressure block 72 apply a predetermined sealing topload to at least a portion of the top portion 104 of the ROPP closure 92 to seal the ROPP liner 100 against the curl 86 of the metallic bottle 80. In one embodiment, the metallic bottle 80 is the same as, or similar to, the prior art metallic bottle 2. In another embodiment, the metallic bottle 80 is a light-weight metallic bottle of the present invention.

(52) In operation 154, the capping apparatus 68 creates a channel 102 in the ROPP closure 92. More specifically, the pressure block 72 applies a predetermined reform topload to a radially outer portion of the closure top portion 104. The channel 102 may have a predetermined depth 114 and any desired cross-sectional profile. Accordingly, in one embodiment, the pressure block 72 may apply a decreased predetermined topload to form a channel 102 with a decreased depth 114 compared to channel 32 formed by prior art capping apparatus 22. For example, in one embodiment in which one or more of the ROPP closure 92 and the metallic bottle 80 are rotated in respective closing directions 93, 83 during the sealing to force the curl 86 further into the ROPP liner 100 as described herein, a channel 102 with a decreased depth 114 may be formed by the capping apparatus 68. In this manner, less topload is applied to the ROPP closure 92 by capping apparatus 68 compared to the topload applied to ROPP closure 10 by capping apparatus 22.

(53) In operation 156, at least one of the pressure block ejector 70 and the pressure block 72 continue to apply the predetermined sealing topload to maintain the seal of the ROPP liner 100 against the curl 86 of the metallic bottle 80. The predetermined sealing topload applied in operation 156 is less than the reform topload applied in all embodiments of operation 154.

(54) At least one thread roller 76 may contact and apply a sideload to the ROPP closure 92 in operation 158. Optionally, the at least one thread roller 76 comprises from one to five thread rollers 76. In one embodiment, the thread roller 76 applies a sideload approximately equal to the sideload applied by the thread rollers 26 of the prior art capping apparatus 22. Alternatively, in an embodiment, at least one of the thread rollers 76 applies less of a sideload than the thread rollers 26 of capping apparatus 22. In still another embodiment, the at least one thread roller 76 forms the closure threads 98 in from one to five passes. In one embodiment, the at least one thread roller 76 may apply a sideload force that is different in at least one of the one to five passes compared to sideload forces applied by the at least one thread roller 76 in other passes. In one embodiment, the closure threads 98 are completely formed by the at least one thread roller 76 before method 150 proceeds to operation 160. Accordingly, in one embodiment of the present invention, operations 158 and 160 are performed at different times. Alternatively, the closure threads 98 are only partially formed when method 150 proceeds to operation 160. In another embodiment, operations 158 and 160 are performed substantially simultaneously.

(55) In operation 160, at least one pilfer roller 78 may contact and apply a sideload to the pilfer band 94 to tuck the pilfer band 94 against the bottle skirt 82. Optionally, the at least one pilfer roller 78 comprises from one to five pilfer rollers 78. In one embodiment, the pilfer roller 78 applies a sideload approximately equal to the sideload applied by the pilfer rollers 28 of the prior art capping apparatus 22. Alternatively, in an embodiment, at least one of the pilfer rollers 78 applies a decreased sideload compared to the pilfer rollers 28 of capping apparatus 22. In still another embodiment, the at least one pilfer roller 78 performs its operation in from one to five passes. In one embodiment, the at least one pilfer roller 78 may apply a sideload force that is different in at least one of the one to five passes.

(56) Optionally, in operation 162, the capping apparatus 68 rotates the ROPP closure 92 in the closing direction 93 further down onto the bottle threads 88. More specifically, at least one of the pressure block ejector 70 and the pressure block 72 rotate axially in a closing direction. The axial rotation of the pressure block ejector 70 and/or the pressure block 72 cause the ROPP closure 92 to rotate in the closing direction 93. In another embodiment, a rotating tool of the capping apparatus 68 is used to rotate the ROPP closure 92 in the closing direction 93. Alternatively, the metallic bottle 80 may be rotated axially in the closing direction 83 instead of, or in addition to, the axial rotation of the ROPP closure 92 in operation 162.

(57) Operation 162 may optionally be performed before the closure threads 98 are completely formed. Alternatively, operation 162 may be performed after the formation of the closure threads 98 is completed. Additionally, in one embodiment, one or more of the ROPP closure 92 and the metallic bottle 80 are rotated in the closing direction 93, 83 at least partially in operation 162 before the pilfer roller 78 completes the tucking of the pilfer band 94 against the bottle skirt 82.

(58) In operation 164, method 150 determines whether one or more of operations 158, 160, and 162 should be repeated. Accordingly, method 150 may return YES to any of operations 158, 160, and 162 any number of times until formation of the ROPP closure 92 and sealing of the metallic bottle 80 are complete. When operations 158, 160, and 162 have been performed a predetermined number of times, method 150 proceeds NO to operation 166.

(59) The metallic bottle 80 is discharged from the capping apparatus 68 in operation 166. Capping apparatus 68 may then reset to an initial state to receive another metallic bottle 80 for sealing. The method 150 then ends 168.

(60) 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 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.

(61) 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.