Container forming and filling system with hydrophobic properties

Abstract

A means for simultaneously forming and filling a container with a liquid product is provided that includes a mold cavity, a dispensing device, a blow nozzle, a conduit, and a hydrophobic surface. The mold cavity defines an interior surface and receives a preform. The dispensing device receives the liquid product and dispenses a charge of the liquid product. The blow nozzle transfers the charge of the liquid product dispensed from the dispensing device into the preform to cause the preform to expand toward the interior surface of the mold cavity and form a resulting container. The liquid product remains within the container as a final product. The conduit fluidly couples the dispensing device to the blow nozzle. The hydrophobic surface contacts the liquid product when the system simultaneously forms and fills the container, wherein the hydrophobic surface forms a portion of the dispensing device, the blow nozzle, and / or the conduit.

Description

TECHNICAL FIELD

[0001] The present technology relates to improved transfer of a liquid for simultaneously forming and filling a container with the liquid, including a container forming and filling system having a hydrophobic liquid transfer surface. BACKGROUND

[0002] This section provides background information relating to the present disclosure which is not necessarily prior art.

[0003] Various products are distributed in plastic containers, such as containers formed from one or more polymers. Common polymers used to form containers include polyesters, such as polyethylene terephthalate (PET), high and low density polyethylene, polycarbonate, and polypropylene, among others. Plastic containers can be manufactured using various blow molding processes, including injection blow molding and extrusion blow molding.

[0004] Injection blow molding can be used to form certain plastic containers in one or more stages and can involve the use of a stretch rod. In a two-stage injection stretch blow molding process, a plastic is first molded into a preform using an injection molding process. The preform includes a neck and mouth of the container to be formed, which can include threads thereon, and a closed distal end. The preform can then be heated above the plastic glass transition temperature, stretched longitudinally by a stretch rod, and blown into a container conforming to a mold using a high pressure gas, e.g., air. As the preform expands, it elongates and stretches, taking on the shape of the mold cavity. The plastic solidifies upon contact with the cooler surface of the mold and the finished hollow container is subsequently ejected from the mold. Injection stretch blow molding processes can be used to form plastic containers for packaging consumer beverages, among other liquids and materials. However, the process has certain limitations, including undesirable gate wells or discontinuities on the bottom portion of the container, and limitations on the possible design range that can be achieved using the stretch blow molding process, such as handles incorporated or containers with void space therein.

[0005] Extrusion blow molding can be used to form certain plastic containers, in which a continuously extruded hot plastic tube or parison is captured within a mold and expanded against the inner surface of the mold to form a container parison. The mold can be designed to travel at the speed of the moving parison as the mold closes on the parison, such that the process can be operated continuously. There are several different types of extrusion blow molding machines, including shuttle molds designed to travel in linear motion and extrusion blow molding wheels that travel in a rotational or circular motion. While the extrusion blow molding process has addressed the need to eliminate some of the drawbacks inherent to containers manufactured using the stretch blow molding process to improve plastic containers, the extrusion blow molding process requires a number of steps to form the container and then fill and cap the container. As a result, a significant amount of cost can be incurred in separately performing the container forming and filling processes, including transportation and time expenditures.

[0006] Blow molded containers and subsequent container filling have thus evolved as two separate processes, which in many cases are operated at different facilities. In order to make container filling more cost effective, some filling facilities have on-site installed blow molding equipment, thereby in many cases integrating the blow molding machine directly into the filling line. Equipment manufacturers have recognized this advantage and are selling "integrated" systems designed to ensure that the blow molding machine and the filling machine are perfectly synchronized. Despite the efforts to combine the two processes, blow molding and filling remain two independent, distinct processes. Thus, performing the two processes separately can result in a significant amount of costs.

[0007] In response to the separate blow molding and filling processes, certain liquid or hydraulic blow molding systems have emerged that mold and fill a container in a single operation. The liquid product used to mold and fill the resulting container from a preform can thereafter remain with the completed container. Thus, the combination of the molding and filling steps can optimize the packaging of the liquid product by eliminating the transportation of empty bottles and the time requirements associated with a subsequent filling operation.

[0008] However, there are certain obstacles in molding and filling containers with certain products. Specifically, certain products can exhibit low surface tension, high viscosity, and / or have an affinity or even reactivity with certain surfaces. Handling and transferring such products to mold and fill a container can result in residual product adhering, sticking to portions of the surface contacted by the product, or reacting with portions of the surface contacted by the product. This can be problematic when attempting to transfer a defined charge or amount of product through a molding and filling system, as any residual product left in the material handling components, such as reservoirs, conduits, pumps, dispensing units, etc., results in an inaccuracy in the transfer of the defined charge of product. For example, residual product left behind can reduce the amount of product charge that passes through the system, while pre-existing residual within the system can increase the volume of product charge that passes through the system. In either case, the reduction in certainty of handling a defined amount of product can be detrimental to simultaneously molding and filling a container with a charge of product, where the preform is designed to expand a defined amount within a defined mold volume. There is thus a need to optimize the transfer of certain products by minimizing product residue when simultaneously molding and filling a container. SUMMARY

[0009] The present technology includes systems, processes, and articles of manufacture that relate to maximizing the accuracy of transferring a liquid product for simultaneously molding and filling a container using one or more hydrophobic liquid transfer surfaces, where the liquid product remains in the container as a final product. Such hydrophobic liquid transfer surfaces can further improve cleaning by facilitating the removal of residual liquid product or cleaning solution.

[0010] A way for simultaneously forming and filling a container with a liquid product is provided that includes a mold cavity, a dispensing device, a blow nozzle, a hydrophobic surface, and a conduit fluidically coupling the dispensing device to the blow nozzle. The mold cavity defines an interior surface and is configured to receive a preform, the dispensing device is configured to receive a charge of the liquid product and dispense the charge of the liquid product. The blow nozzle is configured to deliver the charge of the liquid product dispensed from the dispensing device into the preform so as to inflate the preform toward the interior surface of the mold cavity and form a resulting container with the liquid product remaining as a final product within the container. The hydrophobic surface contacts the liquid product when the system simultaneously forms and fills the container, where the hydrophobic surface forms part of the dispensing device, the blow nozzle, and / or the conduit therebetween. In certain embodiments, a stretch rod is provided that is operable to mechanically stretch the preform within the mold cavity prior to the delivery of the charge of the liquid product through the blow nozzle into the preform. In the presence of the stretch rod, the hydrophobic surface can form part of the dispensing device, the blow nozzle, the conduit, and / or the stretch rod. Various types of hydrophobic surfaces can be used, where the hydrophobic surface includes a hydrophobic coating (such as a polymeric coating (e.g., polyethylene, polystyrene, polyvinyl chloride, polytetrafluoroethylene, polydimethylsiloxane, etc.)), a hydrophobic microstructure, a hydrophobic coating with a hydrophobic microstructure, and a surface treatment (e.g., a plasma treatment, an anodization treatment, etc.).

[0011] A way for cleaning various systems for simultaneously forming and filling a container with a liquid product is provided. Specifically, a gas can be blown through a hydrophobic surface that contacts the liquid product to remove residual liquid from the hydrophobic surface when the system simultaneously forms and fills the container. The residual liquid can include residual liquid product from a previous forming and filling operation and / or a cleaning solution used to flush and clean the system. The gas can also be a dry gas (e.g., dry carbon dioxide or nitrogen) to help evaporate the residual liquid.

[0012] Further areas of application will become apparent from the description provided herein. The description and specific examples in the summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0013] The drawings described herein are for purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0014] Figure 1 is a schematic of a system for simultaneously forming and filling a container according to the present technology, where a heated preform has entered a mold station, a dispensing unit is fluidically coupled to a blow nozzle, and a stretch rod is configured to enter the preform through the blow nozzle.

[0015] Figure 2 is Figure 1Schematic diagram of a system shown, in which the mould halves are closed around the preform and the liquid product can be loaded into the dispensing unit.

[0016] Figure 3 yes Figure 2 Schematic diagram of the system shown, in which a stretch rod is extended into the preform to initiate its mechanical stretching.

[0017] Figure 4 yes Figure 3 Schematic diagram of a system in which the stretch rod has fully stretched the preform and the dispensing unit has received a charge of liquid product.

[0018] Figure 5 yes Figure 4 Schematic diagram of a system in which a charge of liquid product is dispensed from a dispensing unit into a stretched preform to partially expand the stretched preform to form a partially expanded preform.

[0019] Figure 6 yes Figure 5 Schematic diagram of a system in which the remaining portion of the charge of liquid product is dispensed from a dispensing unit and transferred through a blow nozzle into the partially expanded preform to complete the expansion and forming of the container in the mold, wherein the stretch rod is removed.

[0020] Figure 7 yes Figure 6 Schematic diagram of a system in which the dispensing unit has completed transferring the charge of liquid product into the newly formed container, the stretch rod is withdrawn, and the mold halves are separated to release the resulting container filled with product.

[0021] Figures 8A-8B is a schematic diagram of an embodiment of a manifold that can couple a distribution unit to a plurality of blow nozzles and associated molds. DETAILED DESCRIPTION

[0022] The following description of technology is merely exemplary in nature of one or more embodiments, manufacture, and use of the subject matter, and is not intended to limit the scope, applicability or utilization of any particular invention in this application or in the claims, or of any similar application, now known or later developed. With reference to the disclosed methods, the order of the steps presented is exemplary only, and in various embodiments the order of the steps can be different. As used herein, "a" and "an" indicate "at least one" of the items; a plurality of such items can be present. Unless otherwise expressly specified, all numerical quantities in this description are understood to be modified by the word "about" and all geometric and spatial descriptors are understood to be modified by the word "substantially" in describing the subject technology. "About" indicates that the value cited is the approximate value, and thus the value can vary from the cited value by a margin of error. If the value is a range, the margin of error can be at either end of the range. "Substantially" indicates that the value cited is the approximate value, and thus the value can vary from the cited value by a margin of error. If the value is a range, the margin of error can be at either end of the range. If there are any inconsistencies between the specification, examples, and claims, the claim language will control.

[0023] Unless otherwise expressly stated, all documents, including patents, patent applications, and scientific literature, cited in this detailed description are incorporated by reference. In the event of any conflict between the text of this detailed description and the documents incorporated by reference, the text of this detailed description will control.

[0024] Although the open-ended term "comprising," as the synonym of non-limiting terms such as "including," "containing," or "having," is used herein to describe and claim embodiments of the present technology, the more limiting terms such as "consisting of" or "consisting essentially of" can alternatively be used to describe embodiments. Thus, for any given embodiment reciting a combination of materials, components, or process steps, the present technology also specifically includes embodiments consisting of the recited combination of materials, components, or process steps, excluding additional materials, components or process steps (for "consisting of"), and further excluding additional materials, components or process steps that do not materially affect the essential nature of the embodiment, i.e., that do not materially affect the essential characteristics and properties of the embodiment (for "consisting essentially of"), even if such additional materials, components or process steps are not expressly stated in this application. For example, recitation of a composition or process reciting elements A, B, and C specifically contemplates embodiments consisting of A, B, and C, and embodiments consisting essentially of A, B, and C, excluding additional element D, even if element D is not expressly stated in the application, as an additional element that is recited in the art.

[0025] As referred to herein, disclosure of a range includes the endpoints and all different values and subranges within the range. Thus, for example, a range from A to B includes A and B. Disclosure of a value and a range for a particular parameter (such as an amount, weight percent, etc.) does not exclude other values and ranges for the parameter. It is envisioned that two or more specific exemplified values of the parameter can define the endpoints of a range of values that can be claimed for the parameter. For example, if a parameter X is exemplified as having a value of A and is also exemplified as having a value of Z, it is envisioned that parameter X can have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter, whether such ranges are nested, overlapping or distinct, includes all possible combinations of the values within the ranges that can be claimed for the parameter. For example, if a parameter X is exemplified as having a range of 1-10, or 2-9, or 3-8, it is also envisioned that parameter X can have other ranges of values, including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, 3-9, etc.

[0026] 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 one or more intervening elements or layers can 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 are no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between”, “adjacent” versus “directly adjacent”, etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0027] Although the terms first, second, third, etc. can 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 to these terms. These terms are only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first”, “second” and other numerical terms when used herein do not connote a sequential or chronological order, unless specifically stated to do so. 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.

[0028] Spatially relative terms, such as "inner," "outer," "below," "lower," "bottom," "top," "upper," and the like, can be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms can be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0029] The present technology allows for simultaneous molding and filling of a container with a liquid product in contact with a hydrophobic surface to maximize transfer of a charge of liquid product and minimize residual liquid product in a product-filled container. The various systems, processes, and articles described herein allow for simultaneous molding and filling of a container with a liquid product by utilizing a mold cavity, a dispensing device, a blow nozzle, a conduit, and one or more hydrophobic surfaces. The mold cavity defines an inner surface and is configured to accept a preform. The dispensing device is configured to receive a liquid product and dispense a charge of the liquid product. The blow nozzle is configured to transfer the charge of liquid product dispensed from the dispensing device into the preform so as to cause the preform to expand toward the inner surface of the mold cavity and mold a resulting container with the liquid product retained within the container as a final product. The conduit fluidly couples the dispensing device to the blow nozzle. The hydrophobic surface contacts the liquid product when the system simultaneously molds and fills the container, wherein the hydrophobic surface forms a portion of the dispensing device, the blow nozzle, and / or the conduit. As such, the present technology is capable of improving certainty in handling a defined amount of product for simultaneous molding and filling of a container. Thus, transfer of certain products and accuracy of product charge volume can be optimized by minimizing product residual.

[0030] Certain embodiments of the present technology include a stretch rod configured to mechanically stretch a preform within a mold cavity prior to a charge of liquid product being delivered through a blow nozzle into the preform. In such embodiments, the hydrophobic surface forms part of the dispensing device, the blow nozzle, the conduit, and the stretch rod. For example, where the stretch rod remains at least partially within the stretched preform during filling and expansion of the preform within the mold cavity, the stretch rod can come into contact with the liquid product. Subsequent removal of the stretch rod from the partially filled and expanded preform or from the filled and expanded container can remove a portion of the liquid product that adhered or attached to the stretch rod. Removal of such residue can reduce the accuracy of the amount of liquid product within the resulting container. Likewise, the residual liquid product that adhered or attached to the stretch rod can be introduced into a subsequently formed and filled container. Providing a hydrophobic surface on at least a portion of the stretch rod that comes into contact with the liquid product during the forming and filling operation can thereby minimize residue from products having low surface tension, high viscosity, and / or affinity or even reactivity with certain surfaces. The stretch rod can also be vented, and the internal conduit of the stretch rod used for venting can include a hydrophobic surface to minimize residue of any liquid product that comes into contact therewith.

[0031] The dispensing device used in the present technology can take several forms. In certain embodiments, the dispensing device includes a pressure source. The pressure source can have an inlet, a chamber, an outlet, and a mechanically driven piston device that is movable in a first direction within the chamber to draw liquid product into the chamber through the inlet and is movable in a second direction to push the liquid product out of the chamber through the outlet as a dose of liquid product. The piston device can be one of a piston, a pump, and an accumulator. Particular examples include the pressure source 20 described in U.S. Patent No. 8,435,026 to Andison et al. and the pressure source 20 described in U.S. Patent No. 8,858,214 to Andison et al., each of which is incorporated herein by reference. In certain embodiments, the dispensing device can include the pressure source 20 and servo system 60 described in initial publication no. WO / 2019 / 002944 filed by DISCMA AG on June 28, 2018, which is incorporated herein by reference. In certain embodiments, the dispensing device includes a pressure source and a hydraulic intensifier. Particular examples include the pressure source 20 and hydraulic intensifier 60 as described in U.S. Provisional Patent Application No. 62 / 867,546 to Sieradzki filed on June 27, 2019, each of which is incorporated herein by reference. In certain embodiments, the dispensing device includes a two-stage injection unit. The two-stage injection unit can be configured to receive and dispense liquid product, where the two-stage injection unit includes a first stage including an extruder and a second stage including an accumulator. The extruder can be configured to apply mechanical energy to the product to reduce a viscosity of the product and to deliver the reduced viscosity product to the accumulator. The accumulator is configured to receive the reduced viscosity product from the extruder and to dispense a dose of the reduced viscosity product. Particular examples include the two-stage electric injection unit described in U.S. Patent No. 5,863,567 to M. Barr Klaus, which is incorporated herein by reference. Two-stage injection units suitable for use in the present technology also include those available as Mold-Masters E-Multi from Milacron LLC (Cincinnati, OH).

[0032] Hydrophobic surfaces used in the present technology can take several forms. In certain embodiments, a hydrophobic surface comprises a hydrophobic coating. For example, one or more portions of a dispensing device (e.g., a plunger, a cavity, a reservoir, a hydraulic intensifier, an extruder, an accumulator, etc.), a blow nozzle, a conduit fluidly coupling the dispensing device and the blow nozzle, and / or a stretch rod can be coated with a hydrophobic coating to increase the interfacial tension of a liquid product in contact therewith, to decrease the adhesion or affinity of the liquid product to the surface, and / or to decrease the reactivity of the liquid product to the surface. Certain examples include cases where the hydrophobic coating comprises a polymeric coating, with specific examples including polymeric coatings of polyethylene, polystyrene, polyvinyl chloride, polytetrafluoroethylene, and / or polydimethylsiloxane. In certain embodiments, a hydrophobic surface can comprise a hydrophobic microstructure. Examples of hydrophobic microstructures include those associated with the so-called “lotus effect,” which can increase the surface tension of a liquid product relative to a hydrophobic microstructure. In certain embodiments, a hydrophobic surface can comprise a hydrophobic coating having a hydrophobic microstructure. Examples include certain hydrophobic microstructure films applied to one or more surfaces. In certain embodiments, a hydrophobic surface is formed by a surface treatment. Examples of such surface treatments include plasma treatment and anodization treatment. Means for providing a hydrophobic surface can also include examples as described in U.S. Patent No. 10,137,606 to Chauvin et al., which is incorporated herein by reference, or that provide hydrophobic properties.

[0033] The present technology also includes various systems and system components having the features provided herein. The present technology also contemplates use of such systems and components to methods of simultaneously forming and filling a container with a liquid product. Also provided are precisely filled containers formed using the present technology (e.g., method-defined products). Methods of cleaning such systems are provided, including blowing a gas through a hydrophobic surface that contacts a liquid product to remove residual liquid from the hydrophobic surface while the system simultaneously forms and fills a container. Some embodiments include cases where the residual liquid comprises a liquid product. Other embodiments include cases where the residual liquid comprises a cleaning solution.

[0034] Reference is now made to the drawings in several embodiments of systems according to the present technology and their operation are shown and generally referenced by the reference numeral 10. Figures 1-7 An embodiment of a sequence for simultaneously forming and filling a container C using a system 10 according to the present technology is shown. As will be appreciated from the following description, the system 10 and associated methods utilize a liquid product to apply the pressure required to inflate or further inflate a preform 12 to assume the shape of a mold cavity 16, thereby simultaneously forming and filling a resulting container C with the liquid product.

[0035] System 10 includes a dispensing device, represented by reference numeral 100, or in the case where a multi-piece dispensing device is contemplated, the dispensing device can be represented by reference numerals 100 and 200. For example, in the case where the dispensing device includes a pressure source, such as described in U.S. Patent No. 8,435,026 to Andison et al. or U.S. Patent No. 8,858,214 to Andison et al., pressure source 20 can be located at reference numeral 100 in the present disclosure Figures 1-7 . In the case where the dispensing device includes a pressure source and a servo system, such as described by DISCMA AG in initial publication no. WO / 2019 / 002944, filed June 28, 2018, pressure source 20 and servo system 60 can be located at reference numeral 100 in the present disclosure Figures 1-7 . In the case where the dispensing device includes a multi-piece pressure source, such as described by pressure source 20 and hydraulic intensifier 60 in U.S. Provisional Patent Application No. 62 / 867,546 to Sieradzki, filed June 27, 2019, in the present disclosure Figures 1-7 , reference numeral 100 and the hydraulic intensifier can be located at reference numeral 200. In the case where the dispensing device includes a two-stage injection unit, such as described in U.S. Patent No. 5,863,567 to M. Barr Klaus or a two-stage injection unit available from Milacron LLC, Cincinnati, Ohio, known as Mold-Masters E-Multi, the two-stage injection unit can be located at reference numeral 100 in the present disclosure Figures 1-7 .

[0036] The dispensing device, whether one piece 100 or multi-piece 100, 200, is configured to receive a liquid product and dispense a charge of the liquid product. System 10 can include a reservoir 400 that provides a source of the liquid product for molding and filling containers. Valve 52 is openable to allow dispensing device 100, 200 to receive the liquid product from reservoir 400. Multiple reservoirs 400 can be provided for multiple liquid products and can include conduits and valves to selectively couple each of the multiple reservoirs (not shown) to the remainder of system 10. Reservoir 400 can be coupled to the dispensing device (e.g., one piece 100 or multi-piece 100, 200) in various ways and can be selectively coupled to other portions of system 10 via one or more valves; see, for example, valves 52, 54, 76, 68, 80.

[0037] The conduit 300 fluidically couples the dispensing device 100, 200 to the blow nozzle 22. Thus, a charge of liquid product is dispensed through the conduit 300 to the blow nozzle 22, where it is delivered by the blow nozzle 22 into the preform 12 within the mold 14. The conduit 300 can be configured in various ways and include various valves (see, e.g., valves 52, 54, 76, 68, 80). In the case where the system 10 employs a one-piece dispensing device 100, the dispensing device 100 can direct a charge of liquid product through the conduit 100 and through the blow nozzle by, e.g., opening valves 54, 76. In the case where the system 10 employs a two-piece dispensing device 100, 200, the first piece of the dispensing device can include a pressure source at 100, which can deliver a charge of liquid product to the second piece of the dispensing device, which can include a hydraulic intensifier at 200 with valves 54, 78 open. The hydraulic intensifier at 200 can then provide a charge of liquid product to the blow nozzle 22 when valves 78, 76 are open.

[0038] The operation of the system 10 to simultaneously form and fill a container can include the following aspects. Referring to Figures 1-2 , the system 10 can generally include a mold 14 having a mold cavity 16, a dispensing device 100, 200, a blow nozzle 22, a conduit 300, a stretch rod 26, and a hydrophobic surface that contacts the liquid product when the system simultaneously forms and fills a container. The example mold cavity 16 shown in the figures includes two mold halves 30, 32 that cooperate to define an inner surface 34 that corresponds to a desired outer profile of the resulting container C. The mold cavity 16 can be moved from an open position Figure 1 to a closed position Figure 2 such that a support ring 38 of the preform 12 can be captured at an upper end of the mold cavity 16. The preform 12 can be formed of a polyester material, such as polyethylene terephthalate (PET), and can have a shape similar to a test tube having a generally cylindrical cross-section and can have a length that is about fifty percent (50%) of the height of the resulting container C. The support ring 38 can be used to carry and orient the preform 12 through and at various stages of manufacture. For example, the preform 12 can be carried by the support ring 38, the support ring 38 can be used to help position the preform 12 in the mold cavity 16, and the support ring 38 can be used by an end consumer to carry the plastic container C (once manufactured).

[0039] Blow nozzle 22 can generally define an inlet 50 for receiving liquid product from dispensing device 100, 200 and an outlet 56 for delivering a charge of liquid product into preform 12. Receiving liquid product into preform 12 can occur simultaneously with opening valve 54, which is positioned in a delivery path for a charge of liquid product to enter preform 12, in which the charge passes from dispensing device 100, 200 through blow nozzle 22 and into preform 12 via conduit 300. Another valve 76 can be positioned within blow nozzle 22 to control delivery of liquid product into preform 12, with valve 76 opening when blow nozzle 22 delivers a portion of liquid product into preform 12 to partially inflate preform 12 toward inner surface 34 of mold cavity 16. It should be appreciated that outlet 56 can be defined in a shape complementary to preform 12 near support ring 38, such that blow nozzle 22 can couple or readily engage or mate with preform 12 during the molding / filling process. In certain embodiments, blow nozzle 22 can define an opening 58 for slidably receiving stretch rod 26 for initiating mechanical stretching of preform 12.

[0040] As shown, conduit 300 can fluidly couple dispensing device (whether one piece 100 or multiple pieces 100, 200) to blow nozzle 22. Conduit 300 can also be fluidly coupled to other components, for example, as shown by the valve and conduit 300 portions extending to either side of dispensing device 100, 200. Such other components can include one or more product reservoirs (e.g., reservoir 400), recirculation systems or loops, purge or flush systems, etc. Conduit 300 can also be configured as a manifold (e.g., Figures 8A-8B ), which provides multiple branch points to couple dispensing device 100, 200 to multiple blow nozzles 22 and corresponding multiple preforms 12 and molds 14.

[0041] The hydrophobic surfaces that are part of the present technology can include any surface of system 10 that contacts liquid product when system 10 is simultaneously molding and filling a container C. Multiple surfaces of multiple portions of system 10 can include hydrophobic surfaces, where such hydrophobic surfaces can be the same type or form of hydrophobic surface or different types or forms of hydrophobic surfaces. In particular, the hydrophobic surfaces can form part of the product-contacting surfaces in dispensing device 100, 200, blow nozzle 22, conduit 300, stretch rod 26, and / or reservoir 400.

[0042] The liquid product can be introduced from the dispensing apparatus 100, 200 into the preform 12 and resulting plastic container C at an elevated temperature (e.g., above room temperature). For example, the dispensing apparatus 100, 200 can include a heater or heat exchanger to transfer thermal energy to the liquid product. As another example, where the dispensing apparatus 100 includes a two-stage injection unit, the first stage can include a heater configured to apply thermal energy to the liquid product to reduce the viscosity of the liquid product. The increased temperature of the liquid product can thus provide a warmed and reduced viscosity product to the second stage of the two-stage injection unit.

[0043] According to the following aspects, the system 10 can further operate to simultaneously form and fill the plastic container C. In certain embodiments, the preform 12 can be sterilized by steam or other means prior to being introduced into the mold cavity 16. By subjecting the preform 12 to a sterilization technique (e.g., steam and / or heat), a sterile preform and resulting container can be produced, as the dispensing apparatus 100, 200 can be configured to dispense a charge of liquid product in a sterile or aseptic manner. The container C thus need not be formed by a hot-fill process. Other examples of sterilizing the preform 12 include contact with one or more different sterilization media, such as liquid peroxide. The preform 12 can also be subjected to an oven in excess of 212°F (100°C) and immediately formed and filled, and the resulting filled container C can then be capped. In this way, the opportunity for the empty container to be exposed to an environment in which it can become contaminated is minimized and the cost and complexity of aseptic filling can be reduced.

[0044] The preform 12 can be placed into the mold cavity 16; see Figures 1-2 For example, a machine (not shown) can deliver the preform 12, which is heated to a temperature of between about 190°F to 250°F (about 88°C to 121°C), to the mold 14, where the preform 12 is encapsulated in the mold cavity 16. When the preform 12 is placed into the mold cavity 16, the dispensing apparatus 100, 200 can begin operating on the liquid product to prepare a charge of liquid product for dispensing. The mold halves 30, 32 of the mold cavity 16 can close thereby capturing the preform 12; see Figure 2 The blow nozzle 22 can form a seal on the preform 12. The mold cavity 16 can be heated to a temperature of between about 250°F to 350°F (about 93°C to 177°C) in order to apply an increased level of crystallinity within the resulting container C. In other embodiments, the mold cavity 16 can be provided at an ambient temperature or a low temperature of between about 32°F to 90°F (about 0°C to 32°C).

[0045] Turning now to Figure 3 The stretch rod 26 can extend into the preform 12 to initiate mechanical stretching. Referring to Figure 4, the stretch rod 26 continues to stretch the preform 12, thereby thinning the sidewall of the preform 12 and forming the stretched preform 12. The dispensing device 100, 200 can complete the preparation of the charge of liquid product. The charge of liquid product can correspond to an appropriate volume suitable for shaping and filling the resulting container C. In certain embodiments, the conduit 300 can be configured with a manifold (e.g., Figures 8A-8B ), which can provide multiple branch points to fluidly couple the dispensing device 100, 200 to multiple blow nozzles 22 that can be associated with multiple preforms 12 and molds 14. In such cases, the charge of liquid product can be sized such that division of the charge by the manifold in the conduit 300 can provide appropriately sized portions that can be directed to corresponding blow nozzles 22, preforms 12, and molds 14.

[0046] With particular reference to Figure 5 , the dispensing device 100, 200 can then begin dispensing the charge of liquid product, where the charge is conveyed through the conduit 300 and through the blow nozzle 22 into the preform 12. For a one-piece dispensing device 100, dispensing the charge of liquid product into the preform 12 follows the path of the arrows shown in Figure 5 . In cases where a multi-piece dispensing device 100, 200 is employed, the charge of liquid product can travel from reference number 100 through the conduit 300 to reference number 200, where the charge of liquid product then travels back through the conduit 300 and into the blow nozzle for conveyance into the preform 12. The valves 54, 76, 78 can be used to control the movement of the charge of liquid product from the respective one-piece or multi-piece dispensing device 100, 200 and blow nozzle 22 to the preform 12.

[0047] In the example shown by the arrows in Figure 5 , the valves 54, 76 (if present) can be positioned in an open state to provide liquid product from the dispensing device 100 to the blow nozzle 22. From there, the liquid product is conveyed through the conduit 300 to the blow nozzle 22 and through the valve 76 into the stretched preform 12 to partially inflate the stretched preform 12 toward the inner surface 34 of the mold cavity 16, thereby forming a partially inflated preform 12. As the liquid product partially inflates the stretched preform 12 toward the inner surface 34 of the mold cavity 16, any residual air within the preform 12 can be expelled through the passage 74 defined in the stretch rod 26. The dispensing device 100, 200 can be configured to provide the liquid product over a period of time and at a pressure so as to simultaneously shape and fill the container C with the product.

[0048] The charge of liquid product is shown as being conveyed through the conduit 300 and into the blow nozzle 22, where the liquid product is conveyed into the stretched preform 12 to partially inflate the stretched preform 12 toward the inner surface 34 of the mold cavity 16, thereby forming a partially inflated preform 12. As the liquid product partially inflates the stretched preform 12 toward the inner surface 34 of the mold cavity 16, any residual air within the preform 12 can be expelled through the passage 74 defined in the stretch rod 26. The dispensing device 100, 200 can be configured to provide the liquid product over a period of time and at a pressure so as to simultaneously shape and fill the container C with the product. Figure 6The dispensing device 100, 200 in the embodiment of the present invention is dispensed wherein the preform 12 is fully expanded to contact the inner surface 34 of the mold 14 to form the resulting container C, wherein the liquid product remains in the container C as the final product. In the example shown, the complete dispensing of the charge of liquid product follows Figure 6 However, as described herein, a charge of liquid product can be transferred from the first portion 100 of the dispensing device (e.g., a pressure source) to the second portion 200 of the dispensing device (e.g., a hydraulic intensifier) ​​via conduit 300 and then to the blow nozzle 22. As the liquid product causes the partially expanded preform 12 to further expand toward the inner surface 34 of the mold cavity 16, any remaining air within the preform 12 can be further expelled through the passage 74 defined in the stretch rod 26. The stretch rod 26 can now be removed from the container C.

[0049] As described above, hydrophobic surfaces that contact the liquid product when the system 10 simultaneously forms and fills the container C may form part of the dispensing device 100, 200, the blow nozzle 22, the conduit 300, and / or the stretch rod 26. In certain embodiments, the hydrophobic surface may provide continuous contact with the liquid product from the point where the charge of liquid product is formed in the dispensing device 100, 200, through the path of the charge of liquid product through the conduit 300, through the blow nozzle 22, and to the point where the charge of liquid product is transferred to the preform 12. This minimizes any product residue along the entire path of the charge of liquid product from the dispensing device 100, 200 to the preform 12. If the system 10 includes a reservoir 400, the dispensing device (e.g., a one-piece or multi-piece dispensing device 100, 200) is configured to receive the liquid product from the reservoir 400. Thus, as the liquid product moves through the reservoir 400 , the dispensing device (eg, one-piece 100 or multi-piece 100 , 200 ), the mouthpiece 22 , the conduit 300 , and the stretch rod 26 , the hydrophobic surface comes into contact with the liquid product.

[0050] like Figure 7 As shown, the dispensing device 100, 200 has completed dispensing the charge of liquid product, wherein the transfer of the appropriate volume of liquid product to the newly molded plastic container C is complete. Simultaneously with or after this, the stretch rod 26 can be completely withdrawn from the molded and filled container C within the mold cavity 16 while continuing to evacuate any residual air through the passage 74. In certain embodiments, the stretch rod 26 can be designed to displace a predetermined volume of product when it is removed from the mold cavity 16, thereby allowing a desired fill level of product within the resulting plastic container C. Typically, the desired fill level can correspond to being at or near the level of the support ring 38 of the plastic container C. In the event that the surface of the stretch rod 26 includes a hydrophobic surface, the hydrophobic surface can minimize any residual product adhering to or attached to the stretch rod 26 when the stretch rod is removed from the molded and filled container C.

[0051] At this point, the forming and filling cycle is complete. The mold halves 30, 32 can be separated, the blow nozzle 22 can be removed, and the product-filled container C is removed from the mold 14. The formed and filled container C can now be subjected to various post-forming steps as desired, including various capping, labeling, and packaging operations. The dispensing device 100, 200 can begin another cycle to prepare another charge of liquid product. Another preform 12 can be positioned within the mold 14. Although not specifically shown, it will be appreciated that the system 10 can include a controller for communicating signals to one or more of the various components. In this manner, the dispensing device 100, 200, the mold 14, the blow nozzle 22, the stretch rod 26, and the various valves can be operated in accordance with one or more signals communicated by the controller. It is also contemplated that the controller can be used to adjust various parameters associated with these components in accordance with a given application.

[0052] Figures 8A-8B is a schematic view of an embodiment of a manifold 800A, 800B that can be incorporated into the conduit 300 for fluidly coupling the dispensing device 100, 200 to a plurality of blow nozzles 22. Specifically, the conduit 300 can incorporate one of the embodiments of the manifold 800A, 800B, each having a plurality of branches 805 fluidly coupled to a plurality of blow nozzles 22 and molds 14. Each branch 805 of the manifold 800A, 800B can include a valve (not shown) that can allow the liquid product to be selectively directed to certain branches 805 or all of the branches 805. Figure 8A A two-way manifold is shown that can be used to split a charge of liquid product from the dispensing device 100, 200 into two blow nozzles 22, each coupled to a respective preform 12 and mold 14. Figure 8B A four-way manifold is shown that can be used to split a charge of liquid product from the dispensing device 100, 200 into four blow nozzles 22, each coupled to a respective preform 12 and mold 14. As part of the conduit 300, such a manifold can include one or more hydrophobic surfaces that come into contact with the liquid product when the system 10 is simultaneously forming and filling a container C.

[0053] Methods for cleaning systems for simultaneously forming and filling containers with liquid products are provided. Such systems include various systems described herein and illustrated in the figures. In particular, the cleaning methods include blowing a gas through hydrophobic surfaces that contact the liquid product to remove residual liquid from the hydrophobic surfaces while the system is simultaneously forming and filling containers. The residual liquid can include residual product from previous forming and filling operations and / or cleaning solution used to flush and clean the system. The gas can also be a dry gas or low humidity gas (e.g., completely dry carbon dioxide, dry nitrogen) to help remove and evaporate the residual liquid. The gas can be blown through the path of the liquid product travel to form and fill the resulting containers. The gas can also be blown through various directions through the system and sub-portions of the system. For example, where the hydrophobic surfaces are part of the dispensing device, blow nozzle, conduit, stretch rod, and / or reservoir, various valves can be opened and the gas blown through them. Further examples include introducing the gas through the dispensing device 100, dispensing device 200, and / or reservoir 400 when valves 52, 54, 76, 78, 80 are open. Various portions of the system also have the gas continuously blown through them. Examples include blowing the gas through the dispensing device 100 with valves 54 and 76 open, blowing the gas through the dispensing device 200 with valve 80 open or valves 78 and 76 open, blowing the gas through the reservoir 400 with valves 52, 54, 76 open, including various sequences of performing such steps. Contamination is thus reduced, stagnation or drying of residual liquid within the system is reduced, and the need to disassemble portions of the system for effective cleaning is reduced.

[0054] Methods for cleaning systems for simultaneously forming and filling containers with liquid products accordingly minimize contamination between different liquid products, including where the system includes more than one reservoir for more than one type of liquid product. Cleaning can be performed prior to shutdown or storage of the system to minimize residual liquid product in the system. Cleaning can also be performed between successive dispensing operations of different liquid products.

[0055] While the present disclosure contemplates the production of PET containers, it should be understood that other polyolefin materials (e.g., polyethylene, polypropylene, polyesters, etc.) as well as many other plastics can be processed using the present technology.

[0056] The present technology can achieve the following benefits and advantages. The systems of the present invention and the manner of using such systems can shape and fill containers with liquid products that exhibit low surface tension, high viscosity, and / or have affinity or even reactivity with certain surfaces. Reduction to substantially elimination of residual product or cleaning solution is possible. Minimizing any sticking, sticking or reaction of the surface portion of the liquid product in contact with the liquid product can significantly improve the handling and transfer of such products when simultaneously shaping and filling containers. The ability to transfer accurately defined charges or amounts of product through the system aids in optimizing the process. For example, preforms can be designed to expand a defined amount within a defined mold volume, where now more accurately defined charges of liquid product can be applied to form the preform and fill it into the resulting container. Additional benefits and advantages relate to improved cleaning of the system, as the hydrophobic liquid transfer surfaces aid in removal of any residual liquid product or cleaning solution, where residual liquid can bead and have minimal contact with the hydrophobic liquid transfer surfaces, and is more easily blown out of the system by pressurized gas.

[0057] Exemplary embodiments are provided so that the present disclosure will be thorough, and will fully convey the scope to those who are 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. Those skilled in the art will recognize, however, that embodiments of the present disclosure can be practiced without one or more of the specific details. The present embodiment can also be employed in other ways without departing from the scope of the present disclosure. In some exemplary 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 can be made within the scope of the present technology, with essentially similar results.

Claims

1. A system for simultaneously forming and filling a container with a liquid product, the system comprising: a mold cavity defining an interior surface and configured to receive the preform; a liquid reservoir, containing the liquid product; a dispensing device configured to receive the liquid product from the reservoir and dispense a charge of the liquid product; a blow nozzle configured to transfer the charge of the liquid product dispensed from the dispensing device into the preform to force the preform to expand toward the inner surface of the mold cavity and shape the resulting container, wherein the liquid product is retained within the container as a final product; a conduit fluidly coupling the reservoir to the dispensing device and thereby fluidly coupling the dispensing device to the mouthpiece; as well as A hydrophobic surface is formed along an entire flow path extending from the reservoir to an outlet of the mouthpiece, wherein the hydrophobic surface is formed along each of the reservoir, the dispensing device, the conduit, and the mouthpiece on the flow path.

2. The system of claim 1 , further comprising a stretch rod configured to mechanically stretch the preform within the mold cavity before the charge of the liquid product is transferred into the preform through the blow nozzle, wherein The stretching rod further comprises an inner duct for ventilation, wherein the flow path further extends to the inner duct of the stretching rod, and wherein the hydrophobic surface is formed along the inner duct of the stretching rod.

3. The system according to claim 1, wherein: The hydrophobic surface is continuously formed along the flow path between the liquid reservoir and the outlet of the blow nozzle, so that the liquid product is in continuous contact with the hydrophobic surface while flowing along the flow path between the liquid reservoir and the outlet of the blow nozzle.

4. The system according to claim 2, wherein: The stretch rod is ventilated.

5. The system according to claim 1, wherein: The dispensing apparatus comprises a pressure source, and wherein the pressure source has an inlet, a chamber, an outlet, and a mechanically driven piston-type device, the piston-type device being movable in a first direction within the chamber to draw the liquid product into the chamber through the inlet, and the piston-type device being movable in a second direction to push the liquid product out of the chamber through the outlet as the charge of the liquid product, and wherein the piston-type device is one of a piston, a pump, and an accumulator.

6. The system according to claim 1, wherein: The dispensing device includes a servo system.

7. The system according to claim 1, wherein: The dispensing device includes a pressure source and a hydraulic intensifier.

8. The system according to claim 1, wherein: The dispensing device comprises a two-stage injection unit.

9. The system according to claim 1, wherein: The hydrophobic surface includes a hydrophobic coating.

10. The system according to claim 9, wherein: The hydrophobic coating comprises a polymer coating comprising a member selected from the group consisting of polyethylene, polystyrene, polyvinyl chloride, polytetrafluoroethylene, polydimethylsiloxane, and combinations thereof.

11. The system according to claim 1, wherein: The hydrophobic surface includes a hydrophobic microstructure.

12. The system according to claim 1, wherein: The hydrophobic surface includes a hydrophobic coating having a hydrophobic microstructure.

13. The system of claim 1, wherein: The hydrophobic surface is formed by surface treatment.

14. The system according to claim 13, wherein: The surface treatment includes one of plasma treatment and anodizing treatment.

15. The system of claim 1, further comprising means for removing residual liquid from the hydrophobic surface formed along the flow path using pressurized gas blown along the flow path.

16. The system according to claim 15, wherein: The residual liquid includes at least one of the liquid product and a cleaning solution.

17. The system according to claim 15, wherein: The pressurized gas is a dry gas or a low-humidity gas to help evaporate the residual liquid.

18. The system according to claim 15, wherein: The pressurized gas is provided in one or both of the following ways: introduced into the flow path through the reservoir and then exiting the flow path through the mouthpiece; and It is introduced into the flow path via the distribution device and leaves the flow path via the blowing nozzle.

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