阅读说明：本技术 用液体吹塑成型的方法 (Blow molding method using liquid ) 是由 理查德·谢拉兹基 小戴维·利舍·G 格雷戈里·卡彭特 于 2018-06-29 设计创作，主要内容包括：本申请提供了用于同时形成和填充容器的系统和方法,其中,压力源从初始状态加速达到预定的处理速度,同时向一定体积的流体施加压力。当达到预定的处理速度时,一定体积的流体被流体地耦接到预制件,压力源将一定体积的流体的至少一部分引导到预制件中并且拉伸预制件以形成容器,其中,容器包括一定体积的流体的至少一部分。一定体积的流体从容器流体地分离并且然后压力源从预定的处理速度朝向初始状态减速。(Systems and methods for simultaneously forming and filling a container are provided in which a pressure source is accelerated from an initial state to a predetermined processing rate while applying pressure to a volume of fluid. When a predetermined processing speed is reached, a volume of fluid is fluidly coupled to the preform, a pressure source directs at least a portion of the volume of fluid into the preform and stretches the preform to form a container, wherein the container includes at least a portion of the volume of fluid. A volume of fluid is fluidly separated from the container and then the pressure source is decelerated from a predetermined processing speed toward an initial state.)

1. A method of simultaneously forming and filling a container comprising:

accelerating the pressure source from an initial state to a predetermined processing speed while applying pressure to the volume of fluid;

upon reaching the predetermined processing speed, fluidically coupling the volume of fluid to a preform, the pressure source directing at least a portion of the volume of fluid into the preform and stretching the preform to form the container, the container comprising at least a portion of the volume of fluid;

fluidly separating the volume of fluid from the container;

after fluidly separating the volume of fluid from the container, decelerating the pressure source from the predetermined processing speed toward the initial state.

2. The method of claim 1, wherein the pressure source has a velocity of about zero in the initial state.

3. The method of claim 1, wherein the pressure source directs at least a portion of the volume of fluid into the preform at a substantially constant process speed until the volume of fluid is fluidly separated from the container.

4. The method of claim 1, wherein the pressure source directs at least a portion of the volume of fluid into the preform and stretches the preform to form the container in less than about 0.5 seconds.

5. The method of claim 1, wherein the pressure source directs at least a portion of the volume of fluid into the preform and stretches the preform to form the container in about 0.03 seconds to about 0.15 seconds.

6. The method of claim 1, wherein the pressure source directs at least a portion of the volume of fluid into the preform and stretches the preform to form the container in less than about 0.1 seconds.

7. The method of claim 1, wherein at least a portion of the preform is disposed in a mold, the pressure source directing at least a portion of the volume of fluid into the preform and stretching the preform to form the container in accordance with the mold.

8. The method of claim 1, wherein the preform is at or above a phase transition/solidification temperature of a material from which the preform is made.

9. The method of claim 1, wherein the preform comprises polyethylene terephthalate.

10. The method of claim 1, wherein the preform is at a temperature between about 190 ° F and about 250 ° F.

11. The method of claim 1, wherein the volume of fluid comprises a liquid.

12. The method of claim 1, wherein the pressure source comprises a member selected from the group consisting of: a servo pressure system; a piston arrangement actuated by one of pneumatic, mechanical and hydraulic pressure; and a hydraulic pump.

13. The method of claim 1, further comprising mechanically stretching the preform with a stretch rod.

14. The method of claim 1, wherein the volume of fluid being fluidly coupled to the preform comprises: opening a valve that isolates a blow nozzle to which the preform is coupled from the volume of fluid.

15. The method of claim 14, wherein fluidly separating the volume of fluid from the container comprises closing the valve.

16. The method of claim 1, wherein stretching the preform to form the container comprises a hydraulic pressure within the preform of about 100psi to about 600 psi.

17. The method of claim 1, wherein the time required to form the container is less than the time required to form a container by a method comprising:

accelerating the pressure source from the initial state to a predetermined processing speed while applying pressure to the volume of fluid that is fluidly coupled to the preform, the pressure source directing at least a portion of the volume of fluid into the preform and stretching the preform; and

decelerating the pressure source from the predetermined processing speed toward the initial state, thereby completing the drawing of the preform and forming the container comprising at least a portion of the volume of fluid.

18. A method of simultaneously forming and filling a container comprising:

accelerating a pressure source from an initial state to a predetermined processing speed while applying pressure to a volume of fluid, the volume of fluid comprising a liquid;

upon reaching the predetermined processing speed, fluidically coupling the volume of fluid to a preform, the preform being at or above a phase change/solidification temperature of a material from which the preform is made, the preform being disposed in a mold, the pressure source directing at least a portion of the volume of fluid into the preform and drawing the preform against the mold to form the container, the container comprising at least a portion of the volume of fluid;

fluidly separating the volume of fluid from the container;

after the volume of fluid is fluidly separated from the container, decelerating the pressure source from the predetermined processing rate toward the initial state.

19. The method of claim 19, further comprising mechanically stretching the preform with a stretch rod prior to fluidly coupling the volume of fluid to the preform when the predetermined processing speed is reached.

20. The method of claim 19, wherein the pressure source comprises a servo pressure system.

Technical Field

The present disclosure relates to methods of forming and filling containers, and in particular, to systems and processes that allow for the simultaneous formation and filling of plastic containers.

Background

This section provides background information related to the present disclosure that is not necessarily prior art.

Due to environmental and other concerns, various plastic containers, including polyolefin and polyester containers, are used to package many goods that were previously supplied in glass and other types of containers. Manufacturers and fillers, as well as consumers, have recognized that plastic containers are lightweight, inexpensive, recyclable, and capable of being manufactured in large quantities. Blow molded plastic containers are therefore becoming popular in packaging many commercial products. Examples of plastic materials used to form blow molded containers include various polyolefins and polyesters such as polypropylene (PP), Polyethylene (PE), High Density Polyethylene (HDPE), and polyethylene terephthalate (PET).

Traditionally, blow molding of containers and subsequent filling of containers has evolved into two separate processes that are typically performed by different entities. In order to make filling of bottles more cost effective, some fillers move the blow molding mechanism and, in some cases, integrate the blow molding equipment directly into the container filling line. Equipment manufacturers have recognized the advantages associated therewith and have provided "integrated" systems designed to ensure complete synchronization of the blow molding equipment and the filling equipment. Despite efforts to link these two processes more closely together, blow molding and filling continue to be two separate, distinct processes. Therefore, significant costs may be incurred in terms of time and equipment expense when constructing and performing the two processes separately.

One process for simultaneously forming and filling containers is described in U.S. patent No. 8,573,964, the entirety of which is incorporated herein by reference. In the process disclosed in the' 8,573,964 patent, a preform (e.g., a PET preform) is heated prior to entering a blow molding system. The preforms exit the oven at about 140 ℃. During the forming process, the temperature of the preform is desirably maintained between about 140 ℃ and about 63 ℃ (the phase transition/cure temperature of PET), which ensures that the resulting container has the desired aesthetic and functional properties. Thus, the container must be formed at or above the phase change/solidification temperature of the material used to form the container. The preforms heated at their highest temperature have a known (or knowable) amount of thermal energy that is available for distribution during the blow molding operation during the formation of the container.

During the blow molding operation, this thermal energy is lost to the mold surrounding the preform, to the fluid used to expand the heated preform into a container, and is also distributed along a larger surface area of the container formed by stretching and blowing the preform. Because a portion of the thermal energy of the preform is provided in the neck-finish and therefore cannot be used for dissipation or distribution during the blow-molding process, a smaller portion of the total thermal energy is available for distribution to the fill fluid, mold, etc., since the neck-finish is neither in contact with the fluid used for the blow-molding operation nor detracts from the appearance or otherwise through the effects of the blow-molding operation. Thus, unwanted heat losses may cause the continuous formation and filling of the container. There is a need to develop methods of forming containers that maintain the thermal properties of the heated preform during expansion and filling of the container.

Disclosure of Invention

The present technology includes systems and processes involving blow molding using simultaneous forming and filling operations, wherein the container formation rate is maximized and the heat loss from the container preform is minimized.

A container may be formed and filled by accelerating a pressure source from an initial state to a predetermined processing rate while applying pressure to a volume of fluid. When a predetermined processing speed is reached, a volume of fluid is fluidly coupled to the preform, wherein the pressure source injects at least a portion of the volume of fluid into the preform and stretches the preform to form the container. The resulting container thus comprises at least a portion of the volume of fluid. The volume of fluid is then fluidly separated from the container. Once the volume of fluid is separated from the container, the pressure source is decelerated from the predetermined process rate toward an initial state. At least a portion of the preform may be disposed in a mold, and the pressure source may direct at least a portion of the volume of fluid into the preform and draw the preform in accordance with the mold to form the container. The stretching rod may also be used to mechanically stretch the preform. The volume of fluid may comprise a liquid.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this specification are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Drawings

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible embodiments, and are not intended to limit the scope of the present disclosure.

FIG. 1 is a schematic depiction of a heated preform entering a mold station.

Fig. 2 is a schematic depiction of the system shown in fig. 1, wherein the two mold portions are closed around the preform.

Fig. 3 is a schematic depiction of the system shown in fig. 2, wherein the stretch rod extends into the preform.

Fig. 4 is a schematic depiction of the system of fig. 3, wherein the stretch rod mechanically stretches the preform.

Fig. 5 is a schematic depiction of the system of fig. 4, wherein a pressure source injects a volume of fluid comprising a liquid into the preform thereby expanding the preform toward the walls of the mold cavity.

Fig. 6 is a schematic depiction of the system of fig. 5, wherein the pressure source has injected an appropriate volume of liquid into the preform, the preform is expanded in accordance with the mold and forms a container holding the liquid, and the stretch rod is retracted.

Fig. 7 is a schematic depiction of the system of fig. 6, wherein the two mold sections are separated from the formed and filled container.

FIG. 8 is a graph showing velocity of a pressure source injecting at least a portion of a volume of liquid into a preform to form and fill a resulting container versus time.

Detailed Description

The following technical description is merely exemplary in nature in the subject matter, manufacture, and use of one or more inventions, and is not intended to limit the scope, application, or use of any particular invention claimed in this application, or in other applications that may be filed as priority for this application, or in patents issued therefrom. The order of steps presented is exemplary in nature with respect to the disclosed methods, and thus, the order of steps may differ in various embodiments. "an" and "an" as used herein mean the presence of "at least one" item; there may be a plurality of such items, if possible. Unless expressly stated otherwise, all numbers in this description are to be understood as modified by the word "about", and all geometric and spatial descriptors are to be understood as modified by the word "substantially", for the purpose of describing the broadest scope of the present technology. "about" when applied to a numerical value means that the calculation or measurement allows some slight imprecision in the value (with some degree of accuracy in the value; approximately or reasonably close to the value; approximately). If, for some reason, the imprecision provided by "about" and/or "substantially" is not otherwise understood in the art with this ordinary meaning, then "about" and/or "substantially" as used herein at least denotes variations that may result from ordinary methods of measuring or using such parameters.

All documents cited in this detailed description (including patents, patent applications, and scientific documents) are incorporated by reference herein, unless expressly stated otherwise. This detailed description controls conflicts and ambiguities that may exist between documents incorporated by reference herein and the detailed description.

Although the open-ended term "comprising" is used herein to describe and claim embodiments of the present technology as a synonym for non-limiting terms such as comprising, containing, or having, embodiments may alternatively be described using more limiting terms (such as "consisting of … …" or "consisting essentially of … …"). Thus, recitation of a material, component, or process step for any given embodiment also specifically includes embodiments that are comprised of or consist essentially of such material, component, or process step, that excludes additional materials, components, or processes (for which it is intended to be encompassed) and excludes significant impact of additional materials, components, or processes on the performance of the embodiment (consisting essentially of it), even if such additional materials, components, or processes are not explicitly recited herein. For example, the recitation of a composition or process that recites elements A, B and C specifically contemplates embodiments consisting of and consisting essentially of A, B and C, excluding elements D that may be recited in the art, even if element D is not explicitly described herein as being excluded.

Unless otherwise stated, the ranges of the disclosure as referred to herein include the endpoints and include all the different values and further divided ranges within the full range. Thus, for example, a range of "from a to B" or "from about a to about B" includes a and B. The disclosed values and ranges of values do not exclude other values and ranges of values from being useful herein for the particular parameter (such as amount, weight percent, etc.). It is contemplated that for a given parameter, two or more particular exemplary values may define the endpoints of a range of required values for the parameter. For example, if parameter X illustratively has a value a herein, and also illustratively has a value Z, it is contemplated that parameter X may have a range of values from about a to about Z. Similarly, it is contemplated that two or more ranges of values disclosed for a parameter (whether such ranges are nested, overlapping, or different) include all possible combinations of ranges of values that may be claimed using the endpoints of the disclosed ranges. For example, if parameter X is illustratively herein to have a value in the range of 1-10, or 2-9, or 3-8, it is also contemplated that parameter X may have other ranges of values, including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, 3-9, and the like.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having" are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It should also be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it can be directly on, engaged, connected or coupled to the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to" or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" and "directly between," "adjacent" and "directly adjacent," etc.). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as "inner," "outer," "below," "over," "above," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated. Spatially relative terms may be intended to encompass different orientations of the object in use or operation in addition to the orientation depicted in the figures. For example, if the objects in the figures are turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the exemplary term "below" can encompass both an orientation of above and below. The object may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The present technology is directed to methods and systems that allow for the formation and filling of preforms at speeds previously unattainable by conventional methods and systems. In particular, methods of simultaneously forming and filling a container and systems configured for performing such methods include accelerating a pressure source from an initial state to a predetermined processing rate while applying pressure to a volume of fluid. A volume of fluid is fluidly coupled to the preform when a predetermined processing speed is reached, wherein the pressure source injects at least a portion of the volume of fluid into the preform and stretches the preform to form the container. The resulting container includes at least a portion of the volume of fluid. A volume of fluid is fluidly coupled from the container, and then the pressure source is decelerated from a predetermined processing speed toward an initial state.

Based on the method and system, the pressure source is allowed to accelerate to a predetermined processing speed before fluidly coupling the preform to the volume of fluid, and then the volume of fluid is decoupled from the container before the pressure source decelerates. This provides an improvement in fill time, wherein certain embodiments may reduce the fill time by about 40%. In certain embodiments, the fill channel to the preform may be vented at the point where the pressure source stops moving (e.g., forward motion of the servo pressure system is at a maximum), and then the fill line may vent the gas. Improving the sequence of fluid coupling and decoupling improves the fill and form time for blow molding the preform, provides an increase in the speed at which the preform can be handled without introducing any process instabilities, and may not require power to be added to the pressure source for increased fill and form speeds.

The pressure source may include a variety of structural and functional aspects. The pressure source may have a velocity of about zero in the initial state. That is, the pressure source is turned on from a rest state, where substantially no pressure is applied to a volume of fluid. The pressure source can inject at least a portion of the volume of fluid into the preform at a substantially constant process velocity until the volume of fluid is decoupled from the vessel. The constant processing speed may take into account a predetermined draw speed and a predetermined fill volume for a given container. In some instances, a substantially constant processing speed may be established for a particular container having a particular volume, and even for a particular mold type and shape. The pressure source, and its predetermined processing speed, may cause the preform to form and fill into a container for some predetermined period of time. This includes injecting at least a portion of the volume of fluid into the preform and stretching the preform to form the container by a pressure source in less than about 0.5 seconds, in about 0.03 seconds to about 0.15 seconds, and in less than about 0.1 seconds. The present technique may be used with a variety of types of pressure sources, including servo pressure systems, piston-type devices (actuated by one of pneumatic, mechanical, and hydraulic pressures), and hydraulic pumps. Another pressure source may also be used, however, the acceleration time of the pressure source is important for a given container formation and filling time, and thus, a rapid acceleration pressure source such as a servo pressure system is particularly useful in certain embodiments.

The preform may include the following aspects. At least a portion of the preform may be disposed in a mold, and the pressure source may inject at least a portion of the volume of fluid into the preform and stretch the preform in accordance with the mold. In this way, a container comprising at least a portion of a volume of fluid is formed and filled. The preform may be at or above the phase change/solidification temperature of the material from which the preform is made. For example, the preform may be heated or preheated to about the melting point of the material from which it is made. It is known in the art that a variety of plastics and polymer types (including blends thereof) can be used for blow molding. However, one preferred plastic that may be used in conjunction with the present techniques may be polyethylene terephthalate. The plastic may be heated or preheated to a temperature between about 190 ° F and about 290 ° F. The preform may also be mechanically stretched with a stretch rod, for example, a heated or preheated preform may be mechanically stretched in the direction of the axis using a stretch rod, wherein a pressure source injecting at least a portion of the volume of fluid into the preform causes stretching of the preform in the radial direction. The pressure source may also assist in axial stretching of the preform in some embodiments.

The volume of fluid used to form and fill the container can include various fluids, amounts of fluids, and fluids from various process streams. Examples of a volume of fluid include a liquid, wherein the volume of fluid includes a gaseous fluid portion and a liquid fluid portion, or wherein the volume of fluid is substantially all liquid. The fluid may be subjected to temperature control and may be output from various sterilization operations, including various filtration, mixing and/or aeration or degassing operations. Types of fluids include solutions, suspensions, and emulsions of various liquids including various food and beverage products, detergents, soaps, detergents, pharmaceuticals, chemicals, and solvents, to name a few non-limiting examples.

Fluidly coupling and decoupling a volume of fluid to a preform may include the following: in certain embodiments, fluidly coupling the volume of fluid to the preform includes opening a valve positioned between the preform and the volume of fluid. For example, a valve may separate a blow nozzle from a volume of fluid, wherein a preform is coupled to the blow nozzle. Fluidly decoupling the volume of fluid from the container may include closing a valve.

With at least a portion of the volume of fluid injected into the preform by the pressure source, the following aspects may exist: stretching the preform to form the container may include providing a hydraulic pressure in the preform of about 100psi to about 600 psi. The pressure within the preform may be selected based on several factors including the size of the container and/or the speed at which the forming and filling operations are completed. It should be understood that contact between the preform and a portion of the volume of fluid injected into the preform may, in certain embodiments, result in heat transfer from the preform to the fluid. Thus, the formation and filling of the container involves the selection of parameters that balance the cooling rate of the preform with the rate of formation and filling to maximize the formation of the container before any heat loss presents problems with stretching of the preform and the integrity of the resulting container.

It should be appreciated that the present techniques may provide improvements in forming and filling times for a given blow molding operation. Specifically, there is no time to facilitate formation and filling when the pressure source accelerates from an initial state to a predetermined process rate. Likewise, there is no time to facilitate formation and filling when the pressure source is decelerating from the predetermined process rate toward the initial state. The fluid is fluidly coupled in a window defined by the attainment of a predetermined processing speed and contact time between the preform and a portion of the fluid injected into the preform is minimized prior to deceleration, thereby minimizing heat loss from the preform to the fluid. In particular, certain embodiments of the present techniques may reduce formation and fill times by 40%. In other words, the present techniques may include a time required to fill and form the container that is less than a time required to form the container by a method comprising: accelerating a pressure source from an initial state to a predetermined processing speed while applying pressure to a volume of fluid, the volume of fluid being fluidly coupled to the preform, the pressure source injecting at least a portion of the volume of fluid into the preform and stretching the preform, thereby completing the stretching of the preform and forming a container, the container comprising at least a portion of the volume of fluid.

Certain embodiments of the present technology include simultaneously forming and filling a container in the following manner: the pressure source accelerates from an initial state to a predetermined processing speed while applying pressure to a volume of fluid, wherein the volume of fluid comprises a liquid. Upon reaching a predetermined processing speed, a volume of fluid is fluidly coupled to the preform, wherein the preform is located at or above a phase change/solidification temperature of a material from which the preform is made. The preform is positioned in a mold, and a pressure source injects at least a portion of a volume of fluid into the preform and draws the preform against the mold to form a container. The resulting container includes at least a portion of the volume of fluid. The volume of fluid is then fluidly decoupled from the container. The pressure source is then decelerated from the predetermined process speed toward the initial state. Upon reaching the predetermined processing speed, the preform may be mechanically stretched with a stretch rod prior to fluidly coupling a volume of fluid to the preform. The pressure source may be configured as a servo pressure system.

Embodiments of a system implementing a method in accordance with the present technology are now described with reference to fig. 1 through 7. A mold station 10 is provided that is adapted to utilize a liquid commodity L (e.g., an end product for forming and filling containers) wherein the pressure required to impart the liquid to expand a heated preform 12 to obtain the shape of the mold and thereby simultaneously form and fill the resulting container C. The systems and methods shown have a number of specific means to carry out certain structural and functional aspects of the present technology. However, it should be understood that other similar means may be employed and not all structural and functional aspects illustrated in fig. 1 through 7 need be present in various embodiments of the present technology. Likewise, the present techniques may include other aspects including those described herein that are not shown in fig. 1-7.

Referring first to fig. 1, the mold station 10 may include the following details: the mold station 10 generally includes a mold cavity 16, a pressure source 20, such as a high speed servo drive unit, a blow nozzle 22, and an optional stretch rod 26. The mold cavity 16 shown in fig. 1-7 includes two mold sections 30, 32 (e.g., mold halves) that cooperate to define an interior surface 34 that corresponds to the desired exterior profile of the blown container. The mold cavity 16 is movable between an open position (fig. 1) and a closed position (fig. 2) such that the support ring 38 of the preform 12 is coupled, supported, or secured at an upper end of the mold cavity 16.

In one example, the pressure source 20 may be, but is not limited to, a servo drive unit or servo pressure system, a charge cylinder, a manifold, a chamber, a piston-type device (e.g., a piston-type device actuated by a suitable device such as pneumatic, mechanical, and/or hydraulic pressure), a pump (e.g., a hydraulic pump, etc.), or a combination thereof. It should be appreciated that in some embodiments, the movable charging cylinders, manifolds, or chambers may not provide sufficient space optimization or facility efficiency. Further, in some embodiments, it may be difficult to obtain and/or route pressurized fluid from the first location to the preform forming location.

As shown in fig. 1-7, the pressure source 20 is a servo system 60 that generally includes one or more servo motors 62 actuated via lines 66 by one or more controllers 64. As will be discussed in greater detail herein, the servo system 60 may be positioned adjacent to the preform forming position to achieve additional benefits. The servo system 60 comprises an inlet 46 for receiving the liquid commodity L and an outlet 48 for delivering the liquid commodity L to the blow nozzle 22. It will be appreciated that the inlet 46 and outlet 48 each include at least one valve 47, 49, respectively, that assists the flow of fluid (including the liquid commodity L) through the die station 10. The servo motor 62 may be operable in a first direction to draw the liquid commodity L from a fluid source (not shown) via the inlet 46 and output the liquid commodity L from the outlet 48 to the blow nozzle 22 (e.g., forward flow). The servo system 62 may also be operable in a second direction to draw (e.g., reverse flow) the liquid commodity L from the outlet 48, the blow nozzle 22, and/or the preform 12, as will be described in greater detail below. The inlet 46 of the pressure source 20 may be fluidly connected to a fluid source (e.g., a reservoir or container) comprising the liquid commodity L, such as by a tube or tubing. It should be appreciated that the pressure source 20 may be configured differently in different embodiments.

In some embodiments, the servo system 60 and any associated fill cylinders may be located substantially adjacent to the blow nozzle 22. For the reasons listed herein, the flow rate and pressure can be maximized by minimizing the flow distance. In some embodiments, as shown, corners and other limitations including corners, bends, and/or compression fittings may be minimized or eliminated. Indeed, in some embodiments, the servo system 60 and/or any associated filling cylinders may be mounted directly to the blow nozzle 22. However, such a direct-mount configuration is not required, as benefits can be realized by minimizing the flow path length and mandrel curvature, and keeping the inner diameter of the flow path as large as possible, for the total distance from the servo 60 and any associated filling cylinders to the blow nozzle 22.

In addition to these mechanical modifications, the servo system 60 and any associated filling cylinders may be sized to output a volume of liquid commodity L required to fully form and fill the container C, which may occur very quickly (e.g., in less than about 0.02 seconds) via the stroke of the servo. It should be appreciated that servo system 60 may provide a variable or selectable flow rate and/or operate at a variable or selectable pressure for a predetermined amount of time.

In some embodiments, the form and fill operation may use a high speed servo drive unit in cooperation with a fill cylinder. Ideally, this would be a matched system that could generate pressures up to about 600psi while accelerating fast enough to fill a 2L container in less than 0.4s seconds (more desirably about 0.2s fill time). The servo system 60 can be selected to have the required mechanical properties, can be coupled to a ball screw of the appropriate pitch, and can be attached to a selected and appropriately sized stuffing piston cylinder. By way of non-limiting example, the following configurations are shown that are acceptable in some instances: a 400Volt, 6kW servomotor coupled to a 12mm pitch ball screw and a 6inch post. Alternatively, the following configuration may be used in some embodiments: a servo of 7.5kW coupled to a 14mm ball drive and a 5.5inch column. Thus, it has been found that the present technique can be used to form and fill a 16oz container and a 64oz container in approximately the same relative time (i.e., in about 0.03 seconds to about 0.04 seconds), depending on the neck finish size and final container geometry.

In some embodiments, the servo motor 62 may be used to overcome some difficulties in metering accuracy and/or minute quantities of liquid commodity L. That is, the servo motor 62 can be precisely and variably controlled to allow precise metering of the liquid commodity L circulation at variable speeds. This precise and variable control may be coupled with a feedback loop to provide active and real-time monitoring and control of the filling process, including stopping the filling process when a problem is detected, such as a resulting container bursting. In this manner, a feedback loop may be formed as part of the controller 64, with appropriate sensors (e.g., pressure sensors, flow sensors, shape sensors, etc.) being provided at any one of a number of locations to provide sufficient data to detect the relevant parameter. Since active control of the pressure and flow rate of the liquid commodity L is generally important for the final formed product, the use of the servo system 60 is particularly well suited to provide this benefit. It should also be appreciated that the servo system 60 may require less power to operate relative to other systems configured as pressure sources, thereby providing additional benefits in terms of reduced electrical consumption and cost.

The blow nozzle 22 generally defines an inlet 50 for receiving the liquid commodity L from the outlet 48 of the pressure source 20 and provides an outlet 56 (see fig. 1) for delivering the liquid commodity L into the preform 12. It should be appreciated that the outlet 56 may define a shape that is complementary to the preform 12 adjacent the support ring 38 such that the blow nozzle 22 may be easily engaged or mated with the preform 12 during the forming/filling process. In embodiments employing a gasket disposed between the blow nozzle 22 and the preform 12, it should be noted that the gasket may have minimal overlap with the flow path, and thus the gasket does not impede the flow of the liquid commodity L into the preform 12.

In some embodiments, the blow nozzle 22 and/or the pressure source 20 may define an opening 58 for slidably receiving an optional stretch rod 26 for initiating mechanical stretching of the preform 12. However, it should be appreciated that stretch rod 26 is not required in all embodiments. In embodiments employing stretch rod 26, stretch in the preform may be created by only initially mechanically stretching the preform 12 using a stretch rod retraction system (SRWS). Once the drawing is mechanically initiated, the fluid flow of the liquid commodity L may begin to fill and form the preform 12. At this point, the stretch rod 26 may be retracted while the fill sequence is activated, thus increasing the available area for fluid to flow into the preform 12. In some embodiments, the stretch rod 26 may be used to first enter the preform to expel air within the preform to assist in the subsequent introduction of the liquid commodity L. To this end, stretch rod 26 may be simultaneously retracted during introduction of the fluid stream to provide enhanced vacuum suction on the fluid introduction. In addition to increasing the fluid path to the maximum design allowed value, the system may also be used to return to filling in the container to accurately set the fill level via a process of volume displacement. In addition, vent holes may be formed in the stretch rod 26 to assist in venting air contained within the preform prior to filling.

As described herein, it has been found that increasing the filling speed provides an increase in container mass and an increase in manufacturing efficiency by increasing the speed at which the container is allowed to form and fill in less than about 0.4 seconds. Furthermore, in some embodiments, it has been found that combining a forming and filling period of about 0.3 seconds to about 0.2 seconds provides even more improved container quality and manufacturing efficiency. Structurally, it has been found that this rapid formation and filling process of the present teachings results in improved container structures on a crystalline scale. Ideally, it has been found that all container sizes appear to benefit from a forming and filling process in the range of about 0.03 seconds to about 0.15 seconds. In certain embodiments, rapid forming and filling may minimize heat loss from the preform 12 to the liquid commodity L.

In the method of forming and filling the container C described below, the liquid commodity L may be in continuous flow communication within the pressure source 20 and/or the filling chamber via the inlet 46. The temperature of the liquid L can be controlled and the liquid L can be heated or cooled, if desired. Furthermore, the resulting container C may be suitable for other high temperature heat sterilization, or retort filling processes, or other thermal processes. In another example, the liquid commodity L may be introduced into the resulting container at ambient or chilled temperature. Thus, by way of example, the resulting container C may be filled at ambient or chilled temperatures, such as those located between approximately 32 ° F to 90 ° F (approximately 0 ℃ to 32 ℃), and more preferably approximately 40 ° F (approximately 4.4 ℃).

A method of simultaneously forming and filling the resulting container C is described with reference to fig. 1 to 7. Initially, preform 12 may be placed into mold cavity 16. In one example, a machine (not shown) places the preform 12 heated to a temperature above the transformation/solidification temperature of the preform (for PET, at a temperature of about approximately 190F. to about 250F., approximately 88℃. to 121℃.) into the mold cavity 16. The mold portions 30, 32 of the mold cavity 16 may then be closed thereby retaining the preform 12 (fig. 2). The blow nozzle 22 may form a seal at the terminal end (finish) of the preform 12. Mold cavity 16 may be heated to a temperature between approximately 250 ° F and 350 ° F (approximately 93 ℃ to 177 ℃). In another example, mold cavity 16 may be set at an ambient or cooling temperature between approximately 32 ° F and 90 ° F (approximately 0 ℃ to 32 ℃).

While the preform 12 is in the mold cavity 16, the pressure source 20 may begin to draw the liquid commodity L into the filling cylinder, manifold, or chamber via the inlet 46. The liquid commodity L may continue to be drawn into the system by the pressure source 20 while the preform 12 is sealed to the blow nozzle and/or while the mold sections 30, 32 are closed.

Turning now to fig. 3, stretch rod 26 may be extended into preform 12 to initiate mechanical stretching of the preform. Referring to fig. 4, in some embodiments, stretch rod 26 may continue to stretch preform 12 thereby thinning the sidewalls of preform 12. However, as noted above, stretch rod 26 may be retracted immediately after initiating stretching, with pressurized fluid flowing into preform 12. The volume of liquid commodity L in the filling cylinder, manifold, or chamber may be increased to an appropriate volume suitable for forming and filling the resulting container C. It should be noted that this may be done at any point in time. Furthermore, in some embodiments, liquid commodity L may be applied into the preform 12 during this stretching stage to prevent the preform from contacting the stretch rod and/or filling the resulting space with liquid rather than air that is subsequently vented during filling.

The liquid commodity L flowing into the mould station 10 flows through a closed filling channel line comprising a fluid source (not shown) for supplying the liquid commodity L, via an inlet 46 to an outlet 48, and into the preform 12. Excess fluid L not used to form the preforms 12 or fluid removed during the blow and fill process may be recycled back to the fluid source.

For certain blow molding and filling processes, the fill channel line defined by the portion of the mold station 10 located between the valves 47, 48 and including the pressure source 20 is filled with the desired volume of liquid L from the fluid source. The fill channel line is then isolated by closing valve 49 and valve 47. Once the fill channel line is isolated, the pressure source 20 is allowed to accelerate to a predetermined process speed, whereupon the pressure source is allowed to decelerate after the time the fill channel line reopens to assist the flow of fluid to the preforms 12. The valve 51 is either open or not in the mold station 10 during acceleration and deceleration of the pressure source. This process is illustrated in fig. 8, which depicts a graph of the velocity of the pressure source versus time, where line a represents an accelerating pressure source, line B represents a decelerating pressure source, line D represents closing valves 47, 49, and line E represents opening valves 47, 49.

However, in accordance with the present technique, the flow of the liquid commodity L in the mold station 10 may be modified to optimize the time required for the forming and filling process to result in a faster production of the container C, thereby minimizing the loss of thermal energy from the preform 12. Here, the pressure source 20 is allowed to accelerate to a predetermined process speed (line a of fig. 8) before the fill channel line is fluidly coupled to the preform through the open valve 51 (the opening of the valve 51 is represented by line F in fig. 8). It should be noted that a needle valve or other valve may be substituted for the valve 51 within the blow nozzle 22 for controlling the fluid coupling between the volume of liquid commodity L and the preform 12. For example, the valve 51, the needle valve, and/or the valve located within the blow nozzle 22 may be opened at line F of fig. 8, thereby fluidly coupling a volume of fluid (liquid commodity L) to the preform 12 when the pressure source 20 (servo 60) reaches a predetermined processing speed. This allows the pressure source 20 to inject at least a portion of the volume of fluid (liquid commodity L) into the preform 12 and stretch the preform 12 to form the container C. The valve 51 (or needle valve, and/or valve located within the blow nozzle) is then closed before the pressure source 20 decelerates (represented by line G in FIG. 8). This results in an increase in fill time of about 38% compared to the known process described herein. For example, the formation and filling time between line F and line G is compared to the formation and filling time between line D and line E in fig. 8. The improved sequence involving filling the channel lines improves the fill time between sequence changes without introducing process instability and without increasing the power used by the pressure source 20. Thus, the fill time of the preform 12 can be reduced by up to about 40%, and thus, to about 0.05-0.4 seconds or less, depending on the neck finish size and container geometry.

In certain embodiments, the fill passage line may vent when movement of the pressure source 20 ceases (e.g., when the accelerated movement of the pressure source 20 is at a maximum). Referring to fig. 5, the servo system 60 can be actuated to initiate a rapid transfer of the liquid commodity L from the filling cylinder, manifold, or chamber to the preform 12. In one example, the hydraulic pressure within the preform 12 may reach between approximately 100PSI to 600 PSI. The liquid commodity L causes the preform 12 to expand towards the inner surface 34 of the mould cavity 16. The residual air may be vented via a passage (not shown) defined in the stretch rod 26 (fig. 5). As shown in fig. 6, servo system 60 has now fully delivered the appropriate volume of liquid commodity L to the newly formed resultant container C. Next, stretch rod 26 may be withdrawn from mold cavity 16 (if it has not already been withdrawn). Stretch rod 26 may be designed to expel a predetermined volume of liquid commodity L when it is withdrawn from mold cavity 16, thereby allowing for a desired fill level and/or a desired headspace of liquid commodity L within the resulting container C.

Referring to fig. 7, the fill cycle is shown complete. The molds 30, 32 may be separated and the blow nozzle 22 may be retracted. The resulting filled container C is now ready for post-forming steps such as capping, labeling and packaging. At this point, the servo system 60 may begin the next cycle by drawing liquid commodity L through the inlet 46 of the pressure source 20 in preparation for the next fill/form cycle. Although shown specifically, it should be appreciated that the mold station 10 may include a controller 64 for communicating signals to the various components. In this manner, the components including, but not limited to, the mold cavity 16, the blow nozzle 22, the stretch rod 26, the pressure source 20, and the various valves (if employed) may be operated in response to signals communicated through the controller. It is also contemplated that for a given application, the controller may be utilized to adjust parameters associated with these components.

In the exemplary process described herein, the preform may be passed through an oven at over 212 ° F (100 ℃) and immediately filled and capped. In this way, the chance of an empty container being exposed to an environment in which it may become contaminated is significantly reduced. Thus, the cost and complexity of aseptic forming and filling can be significantly reduced.

In some instances of hot filling of a product, the package must be designed to accommodate the high temperatures to which it is exposed during filling and the internal vacuum to which it is exposed due to cooling of the product. Designs that accommodate such conditions may require an increase in container weight. Liquid/hydraulic blow molding can reduce or eliminate the additional material required for the hot fill process and thus reduce package weight.

The methods described herein are useful for filling applications such as isotonic fruit juices, tea and other commodities that are susceptible to biological contamination. As such, these commodities are typically filled in a controlled, sterile environment. Commercially, various methods can be used to achieve the desired sterile environment. One of the primary methods for filling beverages is through the use of a sterile filling environment. The filling operation is performed in a clean room. All components of the product (including the packaging) must be sterilized prior to filling. Once filled, the product may be sealed until it is consumed to prevent any possibility of bacteria being introduced.

Various types of bottled products can be produced by using the technology. Products such as dairy products, alcoholic beverages, household cleaners, salad dressings, sauces, spreads, syrups, edible oils, personal care products and others can be bottled using this method. Many of these products are currently in blow molded PET containers, but also in extruded plastic containers, glass bottles and/or cans. The present techniques may improve the economics of packaging manufacturing and filling such products.

While much of the description focuses on producing PET containers, it is contemplated that other polyolefin materials (e.g., polyethylene, polypropylene, etc.), as well as many other plastics, can be processed using the systems and methods provided herein.

The present techniques achieve certain benefits and advantages. In particular, it has been found that in the development of a dual purpose forming and filling method and system, the best container quality is obtained by keeping the forming and filling times to a minimum. It has been found that increasing the filling speed to a speed that allows the formation and filling of containers in less than about 0.4 seconds provides an increase in container mass and an increase in manufacturing efficiency. Furthermore, in some embodiments, it has been found that combining a forming and filling period of about 0.3 seconds to about 0.2 seconds provides even more improved container quality and manufacturing efficiency. Structurally, it has been found that this rapid formation and filling process of the present teachings results in improved container structures on a crystalline scale. Ideally, it has been found that all container sizes appear to benefit from a forming and filling process in the range of about 0.03 seconds to about 0.15 seconds. By reducing the forming and filling process time, the amount of time available for heat energy loss from the heated preform used to form the container may also be reduced. By minimizing the loss of thermal energy from the heated preform, the preform can be maintained at a temperature at or above its transformation/solidification temperature, thereby improving the appearance and performance of the resulting container formed from the preform. The principles of the present teachings combine the benefits of high speed two-step blow molding (with consistent cycle times) with the efficiency of simultaneously filling containers, resulting in a single-step, rapid-to-use manufacturing system.

The exemplary embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that should not be construed as limiting the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Equivalent changes, modifications and variations of some embodiments, materials, compositions and methods may be made within the scope of the present technology with substantially similar results.