Container forming and filling with high viscosity products

Abstract

A method of simultaneously forming and filling a container with a product is provided, the method including a mold cavity, a two-stage injection unit, and a blow nozzle. The mold cavity defines an inner surface and is configured to receive a preform. The two-stage injection unit receives and dispenses the product, in which a first stage includes an extruder and a second stage includes a dispensing reservoir. The extruder applies mechanical energy to the product to reduce a viscosity of the product and deliver the viscosity-reduced product to the dispensing reservoir. The dispensing reservoir receives the viscosity-reduced product from the extruder and dispenses an amount of the viscosity-reduced product. The blow nozzle delivers the amount of the viscosity-reduced product dispensed from the dispensing reservoir into the preform to expand the preform toward the inner surface of the mold cavity and form a final container.

Description

TECHNICAL FIELD

[0001] The present technology relates to simultaneous forming and filling of containers, including using a two-stage injection unit to expand a preform and produce a final container filled with a high viscosity product. BACKGROUND

[0002] This section provides background information relating to the present disclosure and 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 finish to be formed into a container, and a closed distal end, where the finish can include threads thereon. The preform can then be heated above the plastic glass transition temperature, stretched longitudinally with a stretch rod, and blown into a container using high pressure gas (e.g., air) to conform to a mold. As the preform expands, it elongates and stretches, assuming the shape of the mold cavity. The plastic solidifies as it contacts the cooler surfaces of the mold, and the finished hollow container is subsequently ejected from the mold. Injection stretch blow molding processes can form plastic containers for packaging consumer beverages, among other liquids and materials. However, the process has certain limitations, including undesirable gates or discontinuities on the bottom portion of the container and limitations on the possible range of designs that can be achieved using stretch blow molding processes, such as containers with handles or void spaces therein.

[0005] Extrusion blow molding can be used to form certain plastic containers in which a continuously extruded thermoplastic tube or parison is captured within a mold and expanded against the inner surfaces of the mold to form a container parison. The mold can be designed to travel at the speed of movement of the extruded parison when the mold is closed on the parison so that the process can be operated on a continuous basis. 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 rotational or circular motion. While the extrusion blow molding process has addressed the need for improved plastic containers that avoid some of the inherent shortcomings of containers manufactured using stretch blow molding processes, the extrusion blow molding process requires multiple steps to form the container, which is then later filled and capped. Thus, significant costs can be incurred in separately performing the container forming and filling processes, including transportation and time investment.

[0006] Blow molding of the container and subsequent filling of the container thus develops into two separate processes, operating in many cases at different facilities. In order to make container filling more cost effective, some filling facilities have installed blow molding equipment on the facility, 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 efforts to combine the two processes together, blow molding and filling continue to be two separate, distinct processes. Thus, significant costs can be incurred in separately performing the two processes.

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

[0008] However, there are obstacles in using high viscosity products to fill and form containers in which the high viscosity product remains in the final container. These high viscosity products include those having a paste or gel-like consistency that can behave more like a solid than a liquid. Moving and dispensing these high viscosity products can be problematic. Likewise, the time to form and fill a container can depend on the speed at which the high viscosity product can be transferred into the preform, while accounting for the cooling of the heated preform and the time to expand the preform to conform to the mold. Balancing the heat loss of the preform and the fill / expand rate to form a container can be important. Certain high viscosity products (e.g., having a viscosity in the range of thousands to tens of thousands of centipoise) cannot be used to form a preform into a final container and fill the final container using existing systems because these systems cannot transfer the high viscosity product and maintain the preform heat profile within a time window to reproducibly form and fill the final container, or if the final container is formed completely, exhibit satisfactory performance characteristics. SUMMARY

[0009] The present technology includes systems, processes, and articles of manufacture relating to the simultaneous forming and filling of containers using high viscosity products under certain pressure conditions in which the product remains in the container.

[0010] Methods of simultaneously forming and filling a container with a product are provided, including or employing a mold cavity, a two-stage injection unit, and a blow nozzle. The mold cavity defines an inner surface and is configured to receive a preform. The two-stage injection unit is configured to receive and dispense a product, where the two-stage injection unit includes a first stage including an extruder and a second stage including a dispensing reservoir. The extruder is configured to apply mechanical energy to the product to reduce the viscosity of the product and transfer the reduced viscosity product to the dispensing reservoir. The first stage can also include a heater configured to apply heat energy to the product to further reduce the viscosity of the product. The dispensing reservoir is configured to receive the reduced viscosity product from the extruder and dispense the amount of reduced viscosity product. The dispensing reservoir can include a piston configured to drive an amount of reduced viscosity product from the dispensing reservoir through the blow nozzle under a pressure and for a period of time to expand the preform toward the inner surface of the mold cavity and form a final container. The blow nozzle is configured to transfer the amount of reduced viscosity product dispensed from the dispensing reservoir into the preform to expand the preform toward the inner surface of the mold cavity and form a final container, where the reduced viscosity product remains as a final product within the container. A stretch rod can also be included configured to mechanically stretch the preform within the mold cavity prior to the transfer of the amount of reduced viscosity product into the preform through the blow nozzle.

[0011] 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

[0012] The drawings described herein are for illustrative purposes only of selected embodiments and are not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0013] Figure 1 is a schematic depiction of a system for simultaneously forming and filling a container according to the present technology, wherein a heated preform enters into a mold station, a secondary injection fluid is coupled to a blow nozzle, and a stretch rod is configured to pass through the blow nozzle into the preform.

[0014] Figure 2 is Figure 1 is a schematic depiction of the system shown in

[0015] Figure 3 is Figure 2 is a schematic depiction of the system shown in

[0016] Figure 4 is Figure 3 is a schematic depiction of the system shown in

[0017] Figure 5 is Figure 4 is a schematic depiction of the system shown in

[0018] Figure 6 is Figure 5 is a schematic depiction of the system shown in

[0019] Figure 7 is Figure 6schematic depiction of a system wherein the secondary injection unit has completed the delivery of a quantity of product to the newly formed container, the stretch rod is withdrawn, and the mold halves are separated to release the final container filled with product.

[0020] Figures 8A to 8B schematic depiction of an embodiment of a manifold capable of coupling a secondary injection unit to a plurality of blow nozzles and associated molds. DETAILED DESCRIPTION

[0021] The following description of technology is merely exemplary in nature and is not intended to limit the scope, applicability, or utilization of any of the subject matter, methods, processes, or apparatuses described herein. Rather, the description of technology is intended to provide an overview for understanding a manner of practicing one or more of the described subject matter, methods, processes, or apparatuses. The steps of the processes described herein are presented in an exemplary order and thus, the order of the steps can be different in various embodiments. As used in this document, "and" and "or" as used herein, when used in a list of entities (for example, a list of items, entities, etc.) means items in the list are one of either disjunctively (for example, only one of these items can be selected) or conjunctively (for example, one or more of these items can be selected). As used in this document, "one" and "a" indicate "at least one," and there can be a plurality of such items present, as possible. Unless specifically set forth herein, no identification of the direction or magnitude of the force applied to an object is intended to limit the scope of the technology described herein to only forces applied in a particular direction or magnitude. Unless specifically indicated otherwise, all numerical quantities in this description are to be understood as approximated by the term "about" and all geometric and spatial descriptors are to be understood as approximated by the term "substantially." As applied to numerical values, "about" indicates some slight inexactitude in the calculation or measurement of the value (closeness to the exact value; nearness; in close approximation to; nearly). If, for some reason, the inexactitude provided by "about" and / or "substantially" is not understood in the art, as used herein "about" and / or "substantially" indicates variations that can be caused, for example, by measurement of a parameter with normal equipment and methods when used under normal conditions of use.

[0022] Unless specifically indicated otherwise, all documents (including patents, patent applications, and scientific literature) cited in this detailed description are incorporated by reference. In the event of any conflict or ambiguity between the documents incorporated by reference and this detailed description, the present detailed description controls.

[0023] Although the open-ended term“comprise” as a synonym for terms such as contain, include or have, is used herein to describe and claim embodiments of the present technology, embodiments can alternatively be described using the more restrictive term“consist of’ or“consist essentially of.” Thus, for any given embodiment reciting a composition, process, or method, the present technology also specifically includes embodiments where the composition, process, or method consists of or consists essentially of the recited elements, excluding additional elements of only the materials, components or process steps that do not materially affect the operation of the embodiments, even if such additional materials, components or process steps are not expressly listed in the application. For example, recitation of a composition or process comprising elements A, B, and C specifically envisions embodiments consisting of or consisting essentially of A, B, and C, excluding additional elements of element D that can be recited in the art, even if element D is not explicitly described as excluded herein.

[0024] All percentage compositions as cited herein are by weight of the total composition, unless otherwise specified. Unless otherwise specified, the disclosure of a range includes the endpoints and all different values and further partitioned ranges within the entire range. Thus, for example, a range of“from A to B” or“from about A to about B” includes A and B. The disclosure of values and ranges of values for specific parameters, such as amounts, weight percentages, and the like, do not exclude other values and ranges of values useful in the present technology. It is envisioned that two or more specifically exemplified values of a given parameter can define the endpoints of a range of values that can claim the value of the parameter. For example, if a parameter X is exemplified herein as having a value of A and also 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 the disclosure of two or more ranges of values for a parameter, whether these ranges are nested, overlapping or distinct, contains all possible combinations of ranges of values that might be claimed using the endpoints of the disclosed ranges. For example, if a parameter X is exemplified herein as having a value in the range of 1-10 or 2-9 or 3-8, it is also envisioned that parameter X can have a range of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, 3-9, and the like.

[0025] When an element or layer is referred to as being "on" or "connected to" or "coupled to" another element or layer, it can be directly on or connected or coupled to the other element or layer, or intervening elements or layers can be present. In contrast, when an element is referred to as being "directly on," or "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 terms.

[0026] 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 by these terms. These terms are 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 connote 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.

[0027] Spatially relative terms (such as "inner," "outer," "beneath," "below," "lower," "above," "upper," and the like) can be used herein for ease of description to describe one element's 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.

[0028] The present technology allows for the simultaneous forming and filling of a container using a high viscosity product dispensed from a two-stage injection unit to provide a container filled with a product. The various systems, methods, and articles described herein allow for the simultaneous forming and filling of a container with a product by using a mold cavity, a two-stage injection unit, and a blow nozzle. The mold cavity defines an inner surface and is configured to receive a preform. The two-stage injection unit is configured to receive a product and dispense the product. The two-stage injection unit includes a first stage including an extruder and a second stage including a dispensing accumulator. The extruder is configured to apply mechanical energy to the product to reduce the viscosity of the product and deliver the reduced viscosity product to the dispensing accumulator. The first stage can include a heater configured to apply thermal energy to the product to further reduce the viscosity of the product. The dispensing accumulator is configured to receive the reduced viscosity product from the extruder and dispense an amount of the reduced viscosity product. The dispensing accumulator can include a piston configured to drive an amount of the reduced viscosity product from the dispensing accumulator through the blow nozzle at a pressure and for a period of time to cause the preform to expand toward the inner surface of the mold cavity and form a final container. In this way, the present technology can use high viscosity products (e.g., viscosities in the range of thousands of centipoise to tens of thousands of centipoise) to form and fill a container. It can be necessary to reduce the viscosity of these products by the extruder and rapidly dispense these products by the dispensing accumulator to successfully dispense these high viscosity products within a window of time in which the preform can maintain a thermal profile to reproducibly form and fill a final container exhibiting desired performance characteristics.

[0029] Referring to the several drawings, an embodiment of a system according to the present technology is shown and is generally indicated by reference numeral 10. Figures 1 to 7 An embodiment of a sequence for simultaneously forming and filling a container C using the system 10 according to the present technology is shown. As will be appreciated from the following description, the system 10 and associated method utilize a product to apply a required pressure that causes a preform 12 to expand or further expand to assume the shape of a mold cavity 16, thereby simultaneously forming and filling a final container C with a product.

[0030] An embodiment of a two-stage injection unit including an extruder and a dispensing accumulator is shown as being provided by Figures 1 to 7The pointillism frame labeled "A" in FIG. 1 encloses. Examples of secondary injection units include the secondary electric injection unit described by U.S. Patent No. 5,863,567 to M. Barr Klaus, which is incorporated herein by reference. Those skilled in the art will appreciate that certain other embodiments and features described in U.S. Patent No. 5,863,567 to M. Barr Klaus can be employed herein. Likewise, other secondary injection units employing a first stage having an extruder and a second stage having a separate reservoir can be employed in the present technology in accordance with the guidance and principles described herein. Thermal energy can be operated in conjunction with the mechanical energy applied by the extruder to reduce the viscosity of the product to be used to form and fill the container, which is then transferred to the separate reservoir. Certain secondary injection units can include a first stage having a heater configured to apply thermal energy to the product to further reduce the viscosity of the product. It should also be noted that it is understood that other drive means can be employed in place of the electric motors provided in the embodiments depicted herein to drive the extruder and / or the separate reservoir, including one or more hydraulic drives and / or pneumatic drives. Various types of extruders and various types of separate reservoirs can also be used. Suitable secondary injection units for use in the present technology also include the Mold-Masters E-Multi type secondary injection units available from Milacron LLC (Cincinnati, Ohio).

[0031] The components of the injection unit 114 are designed to implement motor drive technology in a secondary injection unit. These primary elements include an electrically driven extruder 118 and an electrically driven separate reservoir 120. By using a non-reciprocating feed screw 130, the extruder 118 can be operated in a manner that continuously applies mechanical energy to the product to reduce the viscosity of the product. However, the secondary injection unit 114 can be configured with a reciprocating feed screw.

[0032] The product can be supplied to the extruder 118 in various ways, such as through a hopper 124. The rotational power of the screw 130 in the extruder 118 can be provided by a motor 126 connected to a reduction gear box 128 to drive the screw 130. Because the motion of the embodiment of the screw 130 shown in the figures is only rotational, the drive system can be simplified on a secondary injection unit having a screw with reciprocating motion.

[0033] With the aid of a cylindrical barrel 132 and a piston 134 that moves linearly within the barrel 132, the dosing reservoir 120 can be configured as a variable volume reservoir. The relative sizes of the barrel 132 and the piston 134 and the stroke of the piston 134 can vary for a particular mold depending on the amount of viscosity-reduced product needed to form and fill a final container. In the configuration of the dosing reservoir 120, the end shapes of the barrel 132 and the piston 134 can be designed to minimize the amount of viscosity-reduced product that remains in the barrel 132 when the piston 134 is fully extended.

[0034] By optimizing the stroke length and the diameter of the piston 134, certain advantages can be realized. The diameter of the piston 134 can dictate the load requirements of a ball screw that converts the rotational motion of a motor into linear motion of the piston 134. However, by providing an increased stroke length at a relatively small diameter, a greater shot capacity can be easily realized with a two-stage design. For example, under a 2.75 inch diameter piston 134, the embodiment of the two-stage design depicted in the drawings can produce an injection capacity of at least 150 ounces, where the piston can be operated at 20,000 psi with a 5.5 inch diameter ball screw.

[0035] In setting the dimensions of the components of the melt dosing reservoir 120, certain advantages can be realized when the ratio of the full stroke of the piston 134 to the diameter of the piston 134 is eight or higher, preferably in the range of ten to fifteen (this criteria is analogous to the L / D of a reciprocating screw). This configuration of the dosing reservoir 120 enables the use of commercially available ball screws while providing a longer stroke at higher dispensing pressures (improving shot size accuracy and repeatability).

[0036] The outlet of the extruder 118 is connected to the dosing reservoir 120 via a suitable conduit 142. At a convenient point between the extruder 118 and the inlet 140 to the dosing reservoir 120, a ball check valve 146 or other suitable check or anti-backflow device can be provided to control the direction of flow through the conduit 142. When the dosing reservoir 120 is activated to dispense an amount of viscosity-reduced product through a blow nozzle and into a preform within a mold cavity, the check valve 146 prevents the product from backflowing into the extruder 118 due to a pressure differential. The outlet of the dosing reservoir 120 can be fluidly coupled to the blow nozzle 22 by way of a nozzle 156 of the two-stage injection unit 114 and the conduit 18 (as shown). Alternatively, the conduit 18 can be configured as a manifold to divide an amount of product into portions that can be directed to multiple blow nozzles having corresponding preforms and molds. In Figure 8A One example of a manifold that can divide an amount of viscosity-reduced product into two portions is shown in FIG. 6, and another example of a manifold that can divide an amount of viscosity-reduced product into four portions is shown in FIG. 7. Figure 8B One example of a manifold that can divide an amount of viscosity-reduced product into two portions is shown in FIG. 6, and another example of a manifold that can divide an amount of viscosity-reduced product into four portions is shown in FIG. 7.

[0037] The piston 134 of the dispensing reservoir 120 is actuatable by the electromechanical drive assembly 160. The drive assembly 160 can include a ball screw 162, a ball nut 164 having a support housing 166, a variable speed motor 168, and a motor support 170 that allows linear movement of the motor 168. The ball nut 164 can be carried within the support housing 166 and can be constrained from rotation by attachment to the housing 166 by suitable means such as a load cell. The driven end of the ball screw 162 is connected to the motor shaft 158; the other end of the screw 162 is connected to the piston 134 of the dispensing reservoir 120 by means of a coupling 172. The coupling 172 can allow the ball screw 162 to rotate freely with respect to the piston 134 to transmit linear force from the ball screw 162 to the piston 134 without adversely affecting the product contained in the dispensing reservoir 120. In particular, the piston 134 can "float freely" in the cylinder of the dispensing reservoir 120 such that the linear motion of the piston is affected only by the ball screw 162.

[0038] Since the shaft 158 of the motor 168 can be directly attached to the ball screw 162, the motor 168 can reciprocate back and forth as the ball screw 162 is used to move the piston 134. Accordingly, the support 170 for the motor 168 can be configured to provide stability to the motor 168 while allowing it to move linearly in a direction parallel to the movement of the piston 134, as indicated by the double-headed arrow B.

[0039] The operating cycle of the secondary injection unit 14A can include the following aspects. The feed screw 30A can be rotated within the barrel 138 by the extruder motor 126 to begin applying mechanical energy to the product, thereby reducing the viscosity of the product, and delivering the reduced viscosity product to the dispensing reservoir 120. Rotation of the screw 130 establishes pressure at the end of the screw 130, moves (opens) the ball check valve 146 and causes the reduced viscosity product to flow through the conduit 142 and into the dispensing reservoir 120. When the pressure of the reduced viscosity product reaches a certain level, it will begin to push the piston 134 back, thereby causing the ball screw 162 and the motor 168 (the support housing 166 remains stable as it moves toward the rear of the injection unit 114). In particular, the rearward movement of the piston 134 applies a force to the ball screw 162 through the coupling 172, causing the ball screw 162 to move rearward as well; the ball screw rotates as it is pushed through the ball nut 164.

[0040] The rate of backward movement of the piston 134 (and the ball screw 162) can be controlled by the motor 168. In particular, the motor 168 can be used as a brake to stop the rotation of the ball screw 162, which slows the backward movement of the piston 134, thereby increasing the back pressure on the product. Alternatively, the motor 168 can be used to speed up the rotation and backward movement of the ball screw 162, which increases the rate of backward movement of the piston 134, thereby decreasing the back pressure on the product.

[0041] When sufficient amount of viscosity-reduced charge is accumulated in the front of the piston 134 in the injection reservoir 120, the extrusion function is completed and the rotation of the feed screw 130 is stopped, the manifold, as part of the conduit 18, fluidly couples the plurality of blow nozzles with the corresponding preforms and the mold when filling one cavity of one mold or a plurality of cavities of a plurality of molds is required. To initiate the dispensing function of the injection reservoir 120, the motor 168 can be rotated in the clockwise direction so that the ball screw 162 advances through the ball nut 164 constrained by the support housing 166. The translational (linear) movement of the screw 162 is imparted to the piston 134 contained in the injection reservoir 120. Since they are parts of the same assembly, the motor 168 can also move translationally with the ball screw 162 as the piston 134 moves linearly in the cylinder 132 of the injection reservoir 120.

[0042] The forward movement of the piston 134 causes an amount of viscosity-reduced product to pass through the nozzle 156, where the product can be dispensed and delivered through the conduit 18 to the blow nozzles 22 and into the preforms 12 within the mold 14. The injection pressure created by the movement of the piston 134 moves the ball check valve 146 to a position that prevents the delivery of product into the extruder 118. After a batch of product is delivered into the mold cavities 116 to form the preforms 12 into containers C and fill the containers, the injection reservoir 120 can be stopped and held for a predetermined time as needed. At this point, the injection reservoir 120 is substantially empty of product. In this way, by applying sufficient force to move the piston 134 rapidly forward in the cylinder 132, the viscosity-reduced product is pushed to flow through the outlet of the injection reservoir 120, continue through the nozzle 56 and the conduit 18, completing the dispensing of the viscosity-reduced product, where the viscosity-reduced product is delivered through the blow nozzles 22 into the preforms 12 within the mold 14.

[0043] Valve 200, such as a check valve or a selectively actuated valve, can be positioned in the fluid path between the two-stage injection unit 114 and the blow nozzle 22. Valve 200 can be used to control the movement of any residual product in the fluid path between the two-stage injection unit 114 and the blow nozzle 22, including where the two-stage injection unit 114 is used to provide product at a lower pressure when the product does not need to be substantially reduced in viscosity by the processing of the extruder 118 and the distribution reservoir 112. Valve 200 can be operated to prevent the dripping or flow of residual lower viscosity product in the fluid path between the two-stage injection unit 114 and the blow nozzle 22. This can improve the performance of the product with lower viscosity and allow the system 10 to be used with high viscosity products as well as low viscosity products.

[0044] The operation of the two-stage injection unit 114 will now be described in relation to other aspects of the overall system 10 in the simultaneous forming and filling of a container. Referring to Figures 1 to 2 , the system 10 can generally include a mold 14 having a mold cavity 16, a two-stage injection unit 114, a blow nozzle 22, and a stretch rod 26. The exemplary mold cavity 16 shown in the drawings includes two mold halves 30, 32 that cooperate to define an inner surface 34 corresponding to the desired outer profile of the final 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 supported by a polyester material such as polyethylene terephthalate (PET), can have a shape similar to a test tube having a generally cylindrical cross-section, and can have a length of approximately fifty percent (50%) of the height of the final container C. The support ring 38 can be used to carry or orient the preform 12 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 assist in positioning 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 after manufacture.

[0045] Blow nozzle 22 can generally define an inlet 50 for receiving product from secondary injection unit 114 and an outlet 56 for delivering the viscosity-reduced product to preform 12. As the viscosity-reduced product passes from nozzle 156 of secondary injection unit 114 through conduit 18 and blow nozzle 22 and ultimately into preform 12, the receipt of the viscosity-reduced product into preform 12 can simultaneously open valves 200, 54, 76 positioned in the fluid transfer path of the viscosity-reduced product into preform 12. As shown, valve 76 can be positioned within blow nozzle 22 to control the delivery of the viscosity-reduced product into preform 12, where, when valve 76 is open, blow nozzle 22 transfers a portion of the viscosity-reduced product into preform 12 to partially inflate preform 12 toward inner surface 34 of mold cavity 16. It should be understood that outlet 56 can define a shape complementary to preform 12 near support ring 38 such that blow nozzle 22 can couple or easily engage or mate with preform 12 during the forming / filling process. In certain embodiments, blow nozzle 22 can define an opening 58 for slidably receiving stretch rod 26, which is used to initiate mechanical stretching of preform 12.

[0046] The viscosity-reduced product can be introduced into preform 12 and ultimately plastic container C from secondary injection unit 114 at an elevated temperature (e.g., above room temperature). For example, the operation of extruder 118 to apply mechanical energy to the product can also cause an increase in the temperature of the product due to the friction and pressure applied to the product by extruder 118. The increase in thermal energy of the product can combine with the mechanical energy operation applied by the extruder to reduce the viscosity of the product, where the heated and viscosity-reduced product is transferred into distribution reservoir 120. Although not shown in the embodiments depicted in the figures, certain secondary injection units can have a first stage that includes a heater configured to apply thermal energy to the product to further reduce the viscosity of the product. For example, the heater can be in contact with barrel 138 of extruder 118. Thus, the increase in temperature of the product provides a heated and viscosity-reduced product to the second stage including distribution reservoir 120.

[0047] The system 10 can also be operated to simultaneously form and fill the plastic container C according to the following. 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 final container C can be produced because the reduced viscosity product can be sterilized by the pressure and temperature experienced within the secondary injection unit 114. Thus, the container C need not be formed by a hot fill process. Other examples of sterilizing the preform 12 include contact with one or more various sterilization media such as liquid peroxide. The preform 12 can also be passed through an oven in excess of 212 °F (100 °C) and subjected to forming and filling almost immediately, and the final filled container C can be capped. In this way, the opportunity to expose the empty container to an environment in which it can be contaminated is minimized, and the cost and complexity of aseptic filling can be reduced.

[0048] As shown, the preform 12 is placed into the mold cavity 16; see Figures 1 to 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 it is enclosed within the mold cavity 16. Upon placement of the preform 12 into the mold cavity 16, the secondary injection unit 114 can begin to operate on the viscous product to form the reduced viscosity product in preparation for dispensing such product. 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 at the mouth of 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 impart increased crystallinity levels within the final container C. In other embodiments, the mold cavity 16 can be provided at an ambient temperature or cryogenic temperature of between about 32 °F to 90 °F (about 0 °C to 32 °C). The product can be processed by the extruder 118 in the first stage of the secondary injection unit 114 such that the reduced viscosity product can begin to be delivered and received by the distribution reservoir 120 in the second stage of the secondary injection unit 114.

[0049] Turning now to Figure 3 The stretch rod 26 can extend into the preform 12 to initiate mechanical stretching of the preform 12. Referring to Figure 4, the stretch rod 26 continues to stretch the preform 12, thereby thinning the sidewall of the preform 12 and forming a stretched preform 12. The aliquot reservoir 120 can continue to receive the viscosity-reduced product from the extruder 118 until a quantity of the viscosity-reduced product is contained therein. The quantity of the viscosity-reduced product can correspond to an appropriate volume suitable for forming and filling a final container C. In the event that a manifold (e.g., Figures 8A to 8B ) is included in the system 10, a plurality of branch points are provided in coupling the secondary injection unit 114 to the plurality of blow nozzles 22, the size of these quantities can be set such that their dispensing through the manifold can provide an appropriate size portion that can be directed to the corresponding blow nozzle 22, preform 12, and mold 14.

[0050] With particular reference to Figure 5 , the aliquot reservoir 120 of the secondary injection unit 114 can then begin dispensing a quantity of the viscosity-reduced product from the nozzle 156, wherein the quantity is transferred through the blow nozzle 22 and into the preform 12. The quantity of the viscosity-reduced product is dispensed into the preform 12 along the path marked by the arrow D shown in Figure 5 . Upon providing the viscosity-reduced product to the blow nozzle 22, the valves 54, 76 (if present) are positioned in an open state. As such, the viscosity-reduced product is transferred through the blow nozzle 22 and 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 viscosity-reduced 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 channel 74 defined in the stretch rod 26. The secondary injection unit 114 can be configured to provide the viscosity-reduced product over a period of time and at a pressure to simultaneously form and fill the container C with a product.

[0051] In Figure 6 , a quantity of the viscosity-reduced product is shown being dispensed along the path marked by the arrow D originating from the secondary injection unit 114. Now, the preform 12 is fully inflated to contact the inner surface 34 of the mold 14 to form a final container C, at which the product remains within the container C as a final product. As the viscosity-reduced product further and completely inflates the partially inflated preform 12 toward the inner surface 34 of the mold cavity 16, any residual air within the preform 12 can be expelled through the channel 74 defined in the stretch rod 26. The stretch rod 26 can be withdrawn from the container C at this time.

[0052] As Figure 7As shown, the secondary injection unit 114 has completed dispensing of the reduced viscosity quantity of product, where the appropriate volume of product has been transferred to the newly formed plastic container C. Simultaneously or thereafter, the stretch rod 26 can be fully withdrawn from the formed and filled container C within the mold cavity 16, while continuing to vent any residual air through the passageway 74. In certain embodiments, the stretch rod 26 can be designed to displace a predetermined volume of product as it is withdrawn from the mold cavity 16, thereby allowing for a desired fill level height of the product within the final plastic container C. Typically, the desired fill level can correspond to a level height at or near the level height of the support ring 38 of the plastic container C.

[0053] At this point, the forming and filling cycle is complete. The mold halves 30, 32 can be separated, the blow nozzle 22 can be withdrawn, and the product-filled container C can be removed from the mold 14. The formed and filled container C can now be subjected to various post-forming steps, including various capping, labeling, and packaging operations, as desired. The secondary injection unit 114 can begin another cycle, where the extruder 118 applies mechanical energy to another portion of product fed from the hopper 124 to reduce the viscosity of the other portion of product in preparation for its transfer to the distribution reservoir 20A. Another preform 12 can be positioned within the mold 14. Although not specifically shown, it should be understood that the system 10 can include a controller for communicating signals to one or more of the various components. In this manner, the secondary injection unit 114, the mold 14, the blow nozzle 22, the stretch rod 26, and the various valves can operate in accordance with one or more signals communicated by the controller. It is also contemplated that the controller can be used to adjust different parameters associated with these components in accordance with a given application.

[0054] Figures 8A to 8B are schematic depictions of embodiments of manifolds 800A, 800B that can be used to fluidly couple the secondary injection unit 114 to a plurality of blow nozzles 22. In particular, the nozzle 156 of the distribution reservoir 120 can be fluidly coupled to the conduit 18, where the conduit 18 incorporates the manifolds 800A, 800B, which include branches 805 fluidly coupled to a plurality of blow nozzles 22 and molds 14. Each branch 805 of the manifolds 800A, 800B can include a valve (not shown) that can allow the reduced viscosity product to be selectively directed to certain branches 805 or all of the branches 805. Figure 8A A two-way manifold 800A is shown that can be used to divide a quantity of reduced viscosity product from the secondary injection unit 112 into two blow nozzles 22, each fluidly coupled to a respective mold 14. Figure 8B A four-way manifold 800B is shown that can be used to divide a quantity of reduced viscosity product from the secondary injection unit 114 into four blow nozzles 22 total, each fluidly coupled to a respective mold 14.

[0055] While the present disclosure contemplates the production of PET containers from PET preforms 12, it should be understood that other polyolefin materials (e.g., polyethylene, polypropylene, polyesters, etc.) as well as a variety of other plastics can be processed using the present technology.

[0056] The following benefits and advantages can be realized by the present technology. The present systems and methods of using these systems can form and fill containers with products that are not suitable for other forming and filling operations, such as highly viscous products, where the highly viscous products remain in the final container. These highly viscous products include those with a paste-like or gel-like consistency that can behave more like a solid than a liquid. The present technology provides the ability to transfer these highly viscous products and maintain the preform thermal profile within a certain window of time to reproducibly form and fill a final container that exhibits satisfactory performance characteristics. In particular, the present systems and methods can balance the thermal energy loss of the preform and the fill / expansion rate of forming the container to optimize the forming / filling step. Certain highly viscous products (e.g., with viscosities in the range of thousands to tens of thousands of centipoise) can now be used to form and fill a final container from a preform. For example, the present technology can use a variety of food products (including reconstituted cheese (6500-30000 cP), syrup (4300-8600 cP), mayonnaise (20000 cP)), a variety of consumer products (including shampoo (3000 cP) and toothpaste (70000-100000 cP)), a variety of industrial products (including acetate glue (1200-1400 cP), printer ink (2200 cP), resin solutions (900-7200 cP), and triacetate gunk (48000-60000 cP)) to form / fill a container.

[0057] The 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. It will be apparent to those skilled in the art that specific details need not be employed, that the exemplary embodiments can be embodied in many different forms and should not be construed as limiting. 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 using a product, comprising: A mold cavity that defines an inner surface and is configured to receive a preform; A two-stage injection unit configured to receive and dispense a product, wherein the product is a flowable material having a gel-like or paste-like consistency when received by the two-stage injection unit, the two-stage injection unit comprising: a first stage including an extruder; and a second stage including a dispensing reservoir, the extruder being configured to apply mechanical energy to the product to reduce the viscosity of the product and to convey the viscosity-reduced product to the dispensing reservoir, the dispensing reservoir being configured to receive the viscosity-reduced product from the extruder and dispense a specified amount of the viscosity-reduced product; and A nozzle is configured to deliver a predetermined amount of the viscosity-reduced product dispensed from the liquid reservoir into the preform, causing the preform to expand toward the inner surface of the mold cavity and form a final container, wherein the viscosity-reduced product is retained within the container as a fluid final product having a gel-like or paste-like consistency.

2. The system according to claim 1, wherein, The first stage includes a heater configured to apply heat energy to the product to further reduce the viscosity of the product.

3. The system according to claim 1, wherein, The liquid reservoir includes a piston configured to drive a predetermined amount of the viscosity-reduced product from the liquid reservoir through the nozzle under a first pressure and over a period of time, causing the preform to expand toward the inner surface of the mold cavity and form the final container.

4. The system of claim 3 further includes a tension bar configured to mechanically stretch the preform within the mold cavity before the amount of the viscosity-reduced product under the first pressure is conveyed into the preform through the nozzle.

5. The system according to claim 4, wherein, The tension rod is ventilated.

6. A method for simultaneously forming and filling a container using the system according to claim 1.

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