Method for blow molding with liquid

Abstract

Systems and methods for simultaneously forming and filling containers are provided in which a pressure source accelerates from an initial state to a predetermined processing speed while applying pressure to a volume of fluid. When a predetermined processing speed is reached, a volume of fluid is fluidly coupled to the preform, a pressure source directs at least a portion of the volume of fluid into the preform and stretches the preform to form a container, where the container includes at least a portion of the volume of fluid. A volume of fluid is fluidly separated from the container and then the pressure source decelerates from a predetermined processing speed toward an initial state.

Description

[0001] This application is a divisional application of Chinese Patent Invention Application No. 201880043808.4, filed on June 29, 2018, entitled "Method for blow molding with liquid". Technical Field

[0002] This disclosure relates to methods for forming and filling containers, and more particularly, to systems and processes that allow for the simultaneous formation and filling of plastic containers. Background Technology

[0003] This section provides background information in connection with this disclosure, which is not necessarily prior art.

[0004] Due to environmental and other concerns, a variety of plastic containers, including polyolefin and polyester containers, are used to package many goods previously supplied in glass and other types of containers. Manufacturers, fillers, and consumers have recognized that plastic containers are lightweight, inexpensive, recyclable, and can be mass-produced. Blow-molded plastic containers have therefore become common in packaging many goods. Examples of plastic materials used to form blow-molded containers include various polyolefins and polyesters, such as polypropylene (PP), polyethylene (PE), high-density polyethylene (HDPE), and polyethylene terephthalate (PET).

[0005] Traditionally, container blow molding and subsequent container filling have evolved into two separate processes typically performed by different entities. To make bottle filling more cost-effective, some fillers have moved their blow molding facilities, and in some cases, integrated blow molding equipment directly into the container filling line. Equipment manufacturers have recognized the associated advantages and offer “integrated” systems designed to ensure complete synchronization between blow molding and filling equipment. Despite efforts to bring these two processes closer together, blow molding and filling remain two separate and distinct processes. Therefore, constructing and performing these two processes separately can incur significant costs in terms of time and equipment expenditure.

[0006] A process for simultaneously forming and filling a container is described in U.S. Patent No. 8,573,964, the entirety of which is incorporated herein by reference. In the process disclosed in Patent No. 8,573,964, a preform (e.g., a PET preform) is heated before entering the blow molding system. The preform exits the oven at approximately 140°C. During the molding process, the temperature of the preform is ideally maintained between approximately 140°C and approximately 63°C (the phase change / curing temperature of PET), a temperature that ensures the resulting container has the desired aesthetic and functional properties. Therefore, the container must be formed at or above the phase change / curing temperature of the material used to form the container. The preform, heated at its highest temperature, has a known (or known) amount of thermal energy that can be distributed during the blow molding operation to form the container.

[0007] During blow molding operations, heat energy is lost to the mold surrounding the preform, to the fluid used to expand the heated preform into the container, and also distributed along the larger surface area of ​​the container formed by stretching and blow molding the preform. Because a portion of the heat energy of the preform is provided in the neck and therefore cannot be used for loss or distribution during the blow molding process—since the neck neither comes into contact with the fluid used in the blow molding operation nor is it affected by the blow molding operation in terms of appearance or other factors—a smaller portion of the total heat energy can be distributed to the filling fluid, the mold, etc. Therefore, unwanted heat loss can cause continuous container formation and filling. There is a need to develop methods for forming containers that maintain the thermal properties of the heated preform during the expansion and filling of the container. Summary of the Invention

[0008] This technology includes systems and processes involving blow molding that utilizes simultaneous forming and filling operations, wherein the container forming rate is maximized and the heat loss of the container preform is minimized.

[0009] A container can be formed and filled by accelerating a pressure source from an initial state to a predetermined processing speed while applying pressure to a volume of fluid. Upon reaching the predetermined processing speed, the volume of fluid is fluidly coupled to a preform, wherein the pressure source injects at least a portion of the volume of fluid into the preform and stretches the preform to form the container. The resulting container thus includes at least a portion of the volume of fluid. The volume of fluid is then fluidly separated from the container. Once the volume of fluid has separated from the container, the pressure source decelerates from the predetermined processing speed toward the initial state. At least a portion of the preform can be disposed in a mold, into which the pressure source can guide at least a portion of the volume of fluid and stretch the preform according to the mold to form the container. A stretching rod can also be used to mechanically stretch the preform. The volume of fluid may include a liquid.

[0010] Further areas of applicability will become more apparent from the description provided herein. The descriptions and specific examples in this specification are for illustrative purposes only and are not intended to limit the scope of the invention. Attached Figure Description

[0011] The accompanying drawings are provided to further illustrate the invention and constitute a part of this invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: The accompanying drawings described herein are for illustrative purposes only for selected embodiments and are not all possible embodiments, and are not intended to limit the scope of this disclosure.

[0012] Figure 1 It is a schematic description of a preform that has been heated and is being placed in a mold station.

[0013] Figure 2 yes Figure 1 The diagram shows a schematic description of the system, in which two mold sections are closed around the preform.

[0014] Figure 3 yes Figure 2 The diagram shows a schematic description of the system, in which tension rods extend into the preform.

[0015] Figure 4 yes Figure 3 A schematic description of the system, in which a tension rod mechanically stretches a preform.

[0016] Figure 5 yes Figure 4 A schematic description of the system in which a pressure source injects a certain volume of fluid, including liquid, into a preform, thereby causing the preform to expand toward the wall of the mold cavity.

[0017] Figure 6 yes Figure 5 A schematic description of the system, wherein a pressure source has injected an appropriate volume of liquid into a preform, the preform expands according to a mold to form a container holding the liquid, and a tension rod retracts.

[0018] Figure 7 yes Figure 6 A schematic description of the system, in which two mold sections separate from the formed and filled container.

[0019] Figure 8 It is a graph showing the velocity of a pressure source relative to time, which injects at least a portion of a certain volume of liquid into a preform to form and fill the resulting container. Detailed Implementation

[0020] The following technical description is exemplary in nature in terms of the subject matter, manufacture, and use of one or more inventions and is not intended to limit the scope, application, and use of any particular invention claimed in this application, or as a result of other applications that may be filed claiming priority to this application, or from any patents published therefrom. The presented sequence of steps, with respect to the disclosed methods, is exemplary in nature, and therefore the sequence of steps may differ in various embodiments. As used herein, “a” and “an” mean the presence of “at least one” item; multiple such items may be present, if possible. Unless otherwise expressly stated, all quantities in this specification are to be understood as being modified by the word “about,” and all geometric and spatial descriptors are to be understood as being modified by the word “substantially,” to describe the widest range of the art. When applied to numerical values, “about” means that the calculation or measurement allows for some slight imprecision in the value (having some degree of accuracy in the value; approximating or reasonably close to the value; approximately). If, for some reason, the imprecision provided by “about” and / or “generally” is not understood in the art in its ordinary sense, then “about” and / or “generally” as used herein at least indicate variations that may arise from ordinary methods of measuring or using such parameters.

[0021] Unless otherwise expressly stated, all references (including patents, patent applications, and scientific literature) cited in this detailed specification are incorporated herein by reference. This detailed specification controls for any conflicts and ambiguities that may arise between the references cited herein and this detailed specification.

[0022] While the open-ended term "comprising" is used herein as a synonym for non-limiting terms such as "comprising," "containing," or "having," to describe and claim embodiments of the present technology, embodiments may alternatively be described using more restrictive terms such as "consisting of" or "substantially consisting of." Therefore, for any given embodiment, listing materials, components, or process steps specifically includes embodiments that consist of or substantially consist of such materials, components, or process steps, excluding additional materials, components, or processes and excluding any significant effect of such additional materials, components, or processes on the performance of the embodiment (substantially consisting of), even if such additional materials, components, or processes are not expressly listed in this application. For example, listing components or processes including elements A, B, and C specifically contemplates embodiments that consist of and substantially consist of A, B, and C, excluding element D, which may be listed in the art, even if element D is not expressly described herein as excluded.

[0023] Unless otherwise stated, the scope of disclosure mentioned herein includes endpoints and encompasses all distinct values ​​and further subdivisions within the entire scope. Thus, for example, a scope “from A to B” or “from about A to about B” includes both A and B. The disclosed values ​​and ranges of values, for a particular parameter (such as quantity, weight percentage, etc.), do not exclude other values ​​and ranges of values ​​useful herein. It is conceivable that, for a given parameter, two or more specific exemplary values ​​may define the endpoints of the range of values ​​required for the parameter. For example, if parameter X exemplarily has value A herein and also exemplarily has value Z, then parameter X may have a range of values ​​from about A to about Z. Similarly, it is conceivable that two or more ranges of values ​​disclosed for a parameter (whether nested, overlapping, or distinct) encompass all possible combinations of the range of values ​​required using the endpoints of the disclosed range. For example, if parameter X in this document exemplarily has a value in the range of 1-10, or 2-9, or 3-8, it is also conceivable that parameter X may have other ranges of values, including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, 3-9, etc.

[0024] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. The singular forms “a,” “an,” and “the,” as used herein, may also include the plural forms unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having” are inclusive and therefore indicate the presence of the stated features, integrals, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily achieving their performance in the particular order discussed or shown, unless specifically identified as a performance order. It should also be understood that additional or alternative steps may be employed.

[0025] When an element or layer is referred to as “on another element or layer,” “joined to,” “connected to,” or “coupled to” another element or layer, the element or layer may be directly on, joined to, connected to, or coupled to another element or layer, or there may be intermediate elements or layers. Conversely, when an element is referred to as “directly on another element or layer,” “directly joined to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intermediate elements or layers. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0026] Although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may only be used to separate one element, component, region, layer, or segment from another. Terms such as “first,” “second,” and other numbers, when used herein, do not imply sequence or order unless the context clearly indicates otherwise. Therefore, the first element, component, region, layer, or segment discussed below may be referred to as the second element, component, region, layer, or segment without departing from the teachings of the exemplary embodiments.

[0027] Spatial relative terms, such as “inside,” “outside,” “below,” “below,” “above,” and “above,” are used herein for ease of description to depict the relationship between one element or feature and another element (or feature) or feature (or feature), as shown in the figure. Spatial relative terms may be intended to cover different orientations of an object in use or operation other than those shown in the figure. For example, if the object in the figure is flipped, the element described as being “below” or “below” other elements or features is oriented to be “above” other elements or features. Thus, the exemplary term “below” can cover both above and below orientations. An object may be otherwise oriented (rotated 90 degrees or in other orientations) and thus the spatial relative descriptors used herein shall be interpreted.

[0028] This technology relates to several methods and systems that allow the formation and filling of preforms at speeds previously unattainable by conventional methods and systems. Specifically, methods for simultaneously forming and filling containers and systems configured to perform such methods include accelerating a pressure source from an initial state to a predetermined processing speed while simultaneously applying pressure to a volume of fluid. Upon reaching the predetermined processing speed, the volume of fluid is fluidly coupled to the preform, wherein the pressure source injects at least a portion of the volume of fluid into the preform and stretches the preform to form a container. The resulting container comprises at least a portion of the volume of fluid. The volume of fluid is fluidly coupled from the container, and subsequently, the pressure source decelerates from the predetermined processing speed toward the initial state.

[0029] Based on this method and system, a pressure source is allowed to accelerate to a predetermined processing speed before fluidly coupling the preform to a volume of fluid, which is then decoupled from the container before the pressure source decelerates. This provides improvements in fill time, where, in some embodiments, fill time can be reduced by approximately 40%. In some embodiments, the fill channel to the preform can be vented at the point where the pressure source stops moving (e.g., when the forward movement of the servo pressure system is at its maximum), and then the fill line can vent the gas. Improving the sequence of fluid coupling and decoupling improves the fill and forming time for blow-molded preforms, provides the ability to handle increased preform speeds without introducing any process instabilities, and eliminates the need to increase the power to the pressure source for the increased fill and forming speeds.

[0030] The pressure source can include various structural and functional aspects. The pressure source can initially have a velocity of approximately zero. That is, the pressure source is turned on from a stationary state, at which point essentially no pressure is applied to a given volume of fluid. The pressure source can inject at least a portion of a given volume of fluid into the preform at a substantially constant processing rate until the given volume of fluid is decoupled from the container. This constant processing rate can take into account a predetermined stretching rate and a predetermined filling volume for a given container. In some examples, the substantially constant processing rate can be tailored for a specific container with a specific volume, or even for a specific mold type and shape. The pressure source, and its predetermined processing rate, can cause the preform to form and fill into the container within certain predetermined time periods. This includes injecting at least a portion of a given volume of fluid into the preform and stretching the preform to form the container in times less than about 0.5 seconds, between about 0.03 seconds and about 0.15 seconds, and less than about 0.1 seconds. This technology can use various types of pressure sources, including servo pressure systems, piston devices (actuated by pneumatic, mechanical, and hydraulic pressure), and hydraulic pumps. Another pressure source may also be used; however, the acceleration time of the pressure source is important for the formation and filling time of a given container, and therefore, a fast-accelerating pressure source such as a servo pressure system is particularly useful in some embodiments.

[0031] The preform can include several aspects. At least a portion of the preform can be disposed in a mold, and a pressure source can inject at least a portion of a certain volume of fluid into the preform and stretch the preform according to the mold. In this way, a container comprising at least a portion of a certain volume of fluid is formed and filled. The preform can be at or above the phase change / curing temperature of the material from which the preform is made. For example, the preform can be heated or preheated to about the melting point of the material from which it is made. Various types of plastics and polymers (including mixtures thereof) are known in the prior art for use in blow molding. However, a preferred plastic that can be used in conjunction with this technology is polyethylene terephthalate. This plastic can be heated or preheated to a temperature between about 190°F and about 290°F. The preform can also be mechanically stretched using a stretching bar, for example, a heated or preheated preform can be mechanically stretched in the axial direction using a stretching bar, wherein a pressure source injecting at least a portion of a certain volume of fluid into the preform causes stretching of the preform in the radial direction. In some embodiments, the pressure source also contributes to the axial tension of the preform.

[0032] The fluid used to form and fill the container at a given volume can include a variety of fluids, fluid volumes, and fluids from various industrial production fluid streams. Examples of fluids including a given volume include liquids, wherein the given volume of fluid comprises a gaseous fluid portion and a liquid fluid portion, or wherein the given volume of fluid is substantially entirely liquid. The fluid can be temperature-controlled and can be discharged from a variety of sterilization operations, including various filtration, mixing, and / or aeration or degassing operations. Types of fluids include solutions, suspensions, and emulsions of various liquids from various food and beverage products, cleaning agents, soaps, detergents, pharmaceuticals, chemicals, and solvents (only a few non-limiting examples are listed).

[0033] Fluidly coupling and decoupling a volume of fluid to a preform may include, in some embodiments, opening a valve positioned between the preform and the volume of fluid. For example, the valve may separate a blow molding nozzle from the volume of fluid, wherein the preform is coupled to the blow molding nozzle. Fluidly decoupling a volume of fluid from a container may include closing the valve.

[0034] As at least a portion of a volume of fluid is injected into a preform via a pressure source, the following aspects can exist: stretching the preform to form a container may include providing hydraulic pressure of approximately 100 psi to approximately 600 psi within the preform. The pressure within the preform can be selected based on several factors, including the size of the container and / or the speed at which the forming and filling operations are completed. It should be understood that contact between the preform and a portion of the volume of fluid injected into the preform can, in some embodiments, result in heat transfer from the preform to the fluid. Therefore, the forming and filling of the container involves the selection of parameters that balance the cooling rate of the preform with the forming and filling rate to maximize container formation before any heat loss occurs due to stretching of the preform and issues with the overall integrity of the resulting container.

[0035] It should be understood that this technology can provide improvements in formation and filling time for a given blow molding operation. Specifically, there is no time for formation and filling when the pressure source accelerates from an initial state to a predetermined processing speed. Similarly, there is no time for formation and filling when the pressure source decelerates from the predetermined processing speed toward the initial state. Fluid coupling within a window defined by reaching the predetermined processing speed and minimizing the contact time between the preform and a portion of the fluid injected into the preform before deceleration, thereby minimizing heat loss from the preform to the fluid. Specifically, certain embodiments of this technology can reduce formation and filling time by 40%. In other words, the time required for filling and forming a container as included in this technology can be less than the time required to form a container by a method including the following steps: accelerating the pressure source from an initial state to a predetermined processing speed while applying pressure to a volume of fluid, the volume of fluid being fluidly coupled to the preform, the pressure source injecting at least a portion of the volume of fluid into the preform and stretching the preform, thereby completing the stretching of the preform and forming a container comprising at least a portion of the volume of fluid.

[0036] Some embodiments of this technology involve simultaneously forming and filling a container as follows: a pressure source accelerates from an initial state to a predetermined processing speed while applying pressure to a volume of fluid, wherein the volume of fluid comprises a liquid. Upon reaching the predetermined processing speed, the volume of fluid is fluidly coupled to a preform, wherein the preform is located at or above the phase change / curing temperature of the material from which the preform is made. The preform is placed in a mold, and the pressure source injects at least a portion of the volume of fluid into the preform and stretches the preform according to the mold to form a container. The resulting container includes at least a portion of the volume of fluid. The volume of fluid is then fluidly decoupled from the container. The pressure source then decelerates from the predetermined processing speed toward the initial state. Upon reaching the predetermined processing speed, the preform can be mechanically stretched using a tension rod before fluid coupling the volume of fluid to the preform. The pressure source can be configured as a servo pressure system.

[0037] Now for reference Figures 1 to 7 Embodiments of a system for implementing the method according to the present technology are described. A mold station 10 is provided suitable for utilizing a liquid commodity L (e.g., an end product for forming and filling containers), wherein the liquid is subjected to the required pressure to expand a heated preform 12 to obtain the shape of a mold and thereby simultaneously form and fill the resulting container C. The illustrated system and method have several specific means to perform certain structural and functional aspects of the present technology. However, it should be understood that other similar means may be employed, and not all of them are suitable. Figures 1 to 7All structural and functional aspects illustrated need to be presented in the various embodiments of this technology. Similarly, this technology may include other aspects, including those described herein but not otherwise specified. Figures 1 to 7 Other aspects shown in the document.

[0038] First refer to Figure 1 The mold station 10 may include the following details: the mold station 10 generally includes a mold cavity 16, a pressure source 20 such as a high-speed servo drive unit, a blow molding nozzle 22, and an optional tension bar 26. Figures 1 to 7 The mold cavity 16 shown includes two mold portions 30, 32 (e.g., half molds) that cooperate to define the inner surface 34 of the required outer contour of the corresponding blown container. The mold cavity 16 can be in an open position ( Figure 1 ) and closing position ( Figure 2 The movement between the preform 12 and the support ring 38 of the preform 12 is coupled, supported or fixed at the upper end of the mold cavity 16.

[0039] In one example, pressure source 20 may be, but is not limited to, a servo drive unit or servo pressure system, a filling cylinder, manifold, chamber, piston device (e.g., a piston device actuated by a suitable means such as pneumatic, mechanical, and / or hydraulic pressure), pump (e.g., a hydraulic pump), or a combination thereof. It should be understood that in some embodiments, a movable filling cylinder, manifold, or chamber may not provide sufficient space optimization or facility efficiency. Furthermore, in some embodiments, it may be difficult to obtain and / or define a path for the pressurized fluid from the first position to the preform forming position.

[0040] like Figures 1 to 7As shown, pressure source 20 is servo system 60, which generally includes one or more servo motors 62 actuated via line 66 by one or more controllers 64. As will be discussed in more detail herein, servo system 60 can be positioned adjacent to the preform forming location for additional benefits. Servo system 60 includes an inlet 46 for receiving liquid commodity L and an outlet 48 for delivering liquid commodity L to blow molding nozzle 22. It should be understood that inlet 46 and outlet 48 each respectively include at least one valve 47, 49, which facilitates the flow of fluid (including liquid commodity L) through mold station 10. Servo motor 62 can be operable in a first direction to draw liquid commodity L from a fluid source (not shown) via inlet 46 and output liquid commodity L from outlet 48 to blow molding nozzle 22 (e.g., forward flow). Servo system 62 can also be operable in a second direction to draw liquid commodity L from outlet 48, blow molding nozzle 22, and / or preform 12 (e.g., reverse flow), which will be described in more detail below. The inlet 46 of the pressure source 20 may be fluidly connected, for example, via a pipe or fitting, to a fluid source (e.g., a reservoir or container) that includes the liquid commodity L. It should be understood that the pressure source 20 may be configured differently in different embodiments.

[0041] In some embodiments, the servo system 60 and any associated filling cylinders may be located substantially adjacent to the blow molding nozzle 22. For the reasons listed herein, flow rate and pressure can be maximized by minimizing the flow distance. In some embodiments, as shown, corners, bends, and / or corners of compression fittings and other limitations can be minimized or eliminated. In fact, in some embodiments, the servo system 60 and / or any associated filling cylinders may be directly mounted to the blow molding nozzle 22. However, such a direct mounting configuration is not required because several benefits can be achieved by minimizing the flow path length and mandrel bend, and keeping the inner diameter of the flow path as large as possible, for the total distance from the servo system 60 and any associated filling cylinders to the blow molding nozzle 22.

[0042] In addition to these mechanical modifications, the servo system 60 and any associated filling cylinders can be sized to output the required volume of liquid commodity L fully formed and filled into container C, via the servo stroke, which can occur very quickly (e.g., in less than about 0.02 seconds). It should be understood that within a predetermined time period, the servo system 60 can provide variable or selectable flow rates and / or operate at variable or selectable pressures.

[0043] In some embodiments, the forming and filling operations can utilize a high-speed servo drive unit coupled with a filling cylinder. Ideally, this could be a matched system capable of generating pressures up to approximately 600 psi while accelerating quickly enough to fill a 2L container in less than 0.4 s (preferably a filling time of approximately 0.2 s). The servo system 60 can be selected to have the desired mechanical characteristics, can be coupled to a ball screw of appropriate pitch, and can be attached to a selected and appropriately sized filling piston cylinder. By way of non-limiting example, the following configuration, acceptable in some embodiments, is shown: a 400 Volt, 6 kW servo motor coupled to a 12 mm pitch ball screw and a 6-inch post. Alternatively, the following configuration can be used in some embodiments: a 7.5 kW servo coupled to a 14 mm ball drive and a 5.5-inch post. Therefore, this technique has been found to be usable for forming and filling 16oz and 64oz containers in approximately the same relative time (i.e., in about 0.03 to about 0.04 seconds), depending on the neck size and the final container geometry.

[0044] In some embodiments, the servo motor 62 can be used to overcome difficulties in metering accuracy and / or handling very small quantities of liquid commodity L. That is, the servo motor 62 can be precisely and variably controlled to allow accurate metering of the liquid commodity L at variable speeds. This precise and variable control can be coupled to a feedback loop to provide active and real-time monitoring and control of the filling process, including stopping the filling process when a problem is detected (such as a burst container). In this way, the feedback loop can be formed as part of a controller 64, placing appropriate sensors (e.g., pressure sensors, flow sensors, shape sensors, etc.) at any of a plurality of locations to provide sufficient data to detect relevant parameters. Since actively controlling the pressure and flow rate of the liquid commodity L is often important for the final product, the use of the servo system 60 is particularly well-suited to provide this benefit. It should also be appreciated that the servo system 60 may require less power to operate compared to other systems constructed as pressure sources, thus providing additional benefits in terms of reduced power consumption and cost.

[0045] The blow molding nozzle 22 is typically defined as an inlet 50 for receiving liquid commodity L from outlet 48 of pressure source 20, and provides an outlet 56 for conveying liquid commodity L into preform 12 (see...). Figure 1It should be understood that during the forming / filling process, outlet 56 may be defined near support ring 38 in a shape complementary to preform 12 so that blow molding nozzle 22 can easily engage or mate with preform 12. In the embodiment, a sealing gasket is used between blow molding nozzle 22 and preform 12. It should be noted that the sealing gasket can have minimal overlap with the flow path, so that the sealing gasket does not impede the flow of liquid commodity L into preform 12.

[0046] In some embodiments, the blow molding nozzle 22 and / or pressure source 20 may define an opening 58 for slidably receiving an optional stretching rod 26 for initiating mechanical stretching of the preform 12. However, it should be understood that the stretching rod 26 is not required in all embodiments. In embodiments employing the stretching rod 26, a stretching rod retraction system (SRWS) can be used to generate stretching in the preform by initially mechanically stretching the preform 12 only. Once stretching is mechanically initiated, a fluid flow of the liquid commodity L can begin to fill and form the preform 12. At this point, the stretching rod 26 can retract as the filling sequence is activated, thus increasing the usable area for fluid flow into the preform 12. In some embodiments, the stretching rod 26 can be used to initially enter the preform to expel air within it to facilitate the subsequent introduction of the liquid commodity L. For this purpose, the stretching rod 26 can retract simultaneously during fluid flow introduction to provide enhanced vacuum suction on fluid introduction. In addition to increasing the fluid path to the maximum design allowable value, the system can also be used to return to the container for filling to accurately set the fill level via a process of volume displacement. In addition, vent holes can be formed in the tension bar 26 to help expel air contained in the preform before filling.

[0047] As described herein, it has been found that increasing the fill rate to allow for container formation and filling in less than about 0.4 seconds provides an increase in container quality and improved manufacturing efficiency. Furthermore, in some embodiments, it has been found that combining formation and fill periods of about 0.3 seconds to about 0.2 seconds provides even more improved container quality and manufacturing efficiency. Structurally, it has been found that this rapid formation and fill process of the present teachings results in improved container structure at the crystal level. Ideally, it has been found that all container sizes appear to benefit from a formation and fill process in the range of about 0.03 seconds to about 0.15 seconds. In some embodiments, rapid prototyping and filling can minimize heat loss from the preform 12 to the liquid commodity L.

[0048] In the method of forming and filling container C described below, the liquid commodity L can flow continuously through the pressure source 20 and / or the filling chamber via inlet 46. If desired, the temperature of the liquid L can be controlled, and the liquid L can be heated or cooled. Furthermore, the resulting container C can be adapted to other high-temperature sterilization, distillation filling processes, or other thermal processes. In another example, the liquid commodity L can be introduced into the resulting container at an ambient or cooling temperature. Thus, by way of example, the resulting container C can be filled at an ambient or cooling temperature, such as between approximately 32°F and 90°F (approximately 0°C and 32°C), more preferably at approximately 40°F (approximately 4.4°C).

[0049] refer to Figures 1 to 7 A method is described for simultaneously forming and filling the resulting container C. Initially, a preform 12 can be placed into a mold cavity 16. In one example, a machine (not shown) places the preform 12, heated to a temperature higher than the phase change / curing temperature of the preform (approximately 190°F to approximately 250°F, or approximately 88°C to 121°C for PET), into the mold cavity 16. The mold portions 30, 32 of the mold cavity 16 can then be closed, thereby retaining the preform 12 ( Figure 2 The blow molding nozzle 22 can form a seal at the finish of the preform 12. The mold cavity 16 can be heated to a temperature between approximately 250°F and 350°F (approximately 93°C to 177°C). In another example, the mold cavity 16 can be set at an ambient or cooling temperature between approximately 32°F and 90°F (approximately 0°C to 32°C).

[0050] When the preform 12 is in the mold cavity 16, the pressure source 20 can begin to draw liquid product L through the inlet 46 into the filling cylinder, manifold, or chamber. When the preform 12 is sealed to the blow molding nozzle and / or when the mold sections 30, 32 are closed, the pressure source 20 can continue to draw liquid product L into the system.

[0051] Turn now Figure 3 The tension rod 26 can extend into the preform 12 to initiate mechanical tensioning of the preform. (Reference) Figure 4In some embodiments, the tension rod 26 can continue to stretch the preform 12, thereby thinning the sidewalls of the preform 12. However, as noted above, the tension rod 26 can retract immediately after the stretching is initiated, while pressurized fluid flows into the preform 12. The volume of the liquid commodity L in the filling cylinder, manifold, or chamber can be increased to a suitable volume for forming and filling the resulting container C. It should be noted that this can be done at any point in time. Furthermore, in some embodiments, the liquid commodity L can be applied to the preform 12 during this stretching phase to prevent the preform from contacting the tension rod and / or to fill the resulting space with liquid instead of air subsequently expelled during filling.

[0052] Liquid product L flowing into mold station 10 flows through a closed filling channel line, which includes a fluid source (not shown) for supplying liquid product L, via inlet 46 to outlet 48, and into preform 12. Excess fluid L not used to form preform 12, or fluid removed during blow molding and filling processes, can be recycled back to the fluid source.

[0053] For certain blow molding and filling processes, a filling channel line defined by a portion of the mold station 10 located between valves 47 and 48, including a pressure source 20, is filled with the required volume of liquid L from a fluid source. The filling channel line is then isolated by closing valves 49 and 47. Once the filling channel line is isolated, the pressure source 20 is allowed to accelerate to a predetermined processing speed, followed by deceleration after a period of time when the filling channel line reopens to facilitate fluid flow to the preform 12. During the acceleration and deceleration of the pressure source, valve 51 is either open or not in the mold station 10. This process is illustrated in a graph depicting the speed of the pressure source relative to time. Figure 8 The diagram shows that line A represents the accelerating pressure source, line B represents the decelerating pressure source, line D represents the closing valves 47 and 49, and line E represents the opening valves 47 and 49.

[0054] However, according to this technology, the flow of the liquid commodity L in the mold station 10 can be modified to optimize the time required for the forming and filling processes, resulting in faster production of the container C, thereby minimizing heat loss from the preform 12. Here, the filling channel line passes through the open valve 51 (the opening of valve 51 is in...). Figure 8 (Represented by line F) Before the fluid is coupled to the preform, the pressure source 20 is allowed to accelerate to a predetermined processing speed. Figure 8 (Line A). It should be noted that a needle valve or other valve can be used within the blow molding nozzle 22 to replace valve 51 for controlling the fluid coupling between a certain volume of liquid product L and the preform 12. For example, valve 51, needle valve, and / or valves located within the blow molding nozzle 22 can be used. Figure 8The pressure source 20 (servo system 60) opens at line F, thereby fluidly coupling a certain volume of fluid (liquid commodity L) to the preform 12 when the pressure source 20 reaches a predetermined processing speed. This allows the pressure source 20 to inject at least a portion of the certain volume of fluid (liquid commodity L) into the preform 12 and stretch the preform 12 to form the container C. Then, valve 51 (or needle valve, and / or valve located within the blow molding nozzle) decelerates the pressure source 20 (by... Figure 8 Line G in the diagram represents the line that is closed before the process. This results in a fill time improvement of approximately 38% compared to the known processes described herein. For example, comparing the formation and fill time between line F and line G with... Figure 8 Compared to the formation and filling time between lines D and E, the improved sequence of filling channel lines improves the filling time between sequence changes without introducing process instability and without increasing the power used by pressure source 20. Therefore, the filling time of preform 12 can be reduced by up to about 40%, thus reducing the filling time to about 0.05-0.4 seconds or less, depending on the orifice size and container geometry.

[0055] In some embodiments, the filling channel line can vent when the movement of pressure source 20 stops (e.g., when the accelerated movement of pressure source 20 is at its maximum). Reference Figure 5 This can actuate the servo system 60 to initiate a rapid transfer of liquid commodity L from the filling cylinder, manifold, or chamber to the preform 12. In one example, the hydraulic pressure within the preform 12 can reach approximately 100 PSI to 600 PSI. The liquid commodity L causes the preform 12 to expand toward the inner surface 34 of the mold cavity 16. Residual air can be contained via the tension rod 26 ( Figure 5 The pathway (not shown) in the passage is discharged. For example... Figure 6 As shown, the servo system 60 has now fully transferred the appropriate volume of liquid commodity L to the newly formed container C. Next, the tension rod 26 can be retracted from the mold cavity 16 (if it has not already been retracted). The tension rod 26 can be designed to discharge a predetermined volume of liquid commodity L when it retracts from the mold cavity 16, thereby allowing the required fill level and / or required headspace for the liquid commodity L within the resulting container C.

[0056] refer to Figure 7The filling cycle shown is now complete. Molds 30 and 32 can be separated and blow nozzle 22 can be retracted. The resulting filled container C is now ready for post-forming steps such as capping, labeling, and packaging. At this point, servo system 60 can begin the next cycle by drawing liquid merchandise L through inlet 46 of pressure source 20 to prepare for the next filling / forming cycle. Although not specifically shown, it should be understood that mold station 10 may include a controller 64 for communicating signals to the various components. In this way, components including, but not limited to, mold cavity 16, blow nozzle 22, tension rod 26, pressure source 20, and various valves (if used) can be operated according to signals communicated via the controller. It is also conceivable to use the controller to adjust parameters associated with these components for a given application.

[0057] In the exemplary method described herein, preforms can be passed through an oven at temperatures exceeding 212°F (100°C) and immediately filled and capped. In this way, the chances of empty containers being exposed to an environment where they could become contaminated are significantly reduced. Consequently, the cost and complexity of aseptic formation and filling can be significantly reduced.

[0058] In some cases of hot-fill products, the packaging must be designed to withstand the high temperatures it is exposed to during filling and the internal vacuum caused by product cooling. Designs that accommodate these conditions may increase container weight. Liquid / hydraulic blow molding can reduce or eliminate the additives required for the hot-fill process, thus reducing packaging weight.

[0059] The methods described herein are useful for filling applications such as isobaric juices, teas, and other commodities susceptible to biological contamination. These commodities are typically filled in a controlled, sterile environment. Commercially, various methods can be used to achieve the desired sterile environment. One primary method for filling beverages is through the use of a sterile filling environment. The filling operation is performed in a clean room. All components of the product, including the packaging, must be sterilized prior to filling. Once filled, the product can be sealed until it is consumed to prevent any possibility of introducing bacteria.

[0060] This technology can be used to produce a wide variety of bottled products. Products such as dairy products, alcoholic beverages, household cleaners, salad dressings, sauces, spreads, syrups, cooking oils, personal care products, and others can be bottled using this method. Many of these products are currently packaged in blow-molded PET containers, but also in extruded plastic containers, glass bottles, and / or jars. This technology can improve the economics of packaging manufacturing and filling such products.

[0061] While most of the description focuses on the production of PET containers, it is anticipated that other polyolefin materials (e.g., polyethylene, polypropylene, etc.) and many other plastics can be processed using the systems and methods provided herein.

[0062] This technology achieves certain benefits and advantages. Specifically, it has been found that in the development of dual-purpose forming and filling methods and systems, the best container quality is obtained by keeping the forming and filling time to a minimum. It has been found that increasing the filling speed to a level that allows the container to be formed and filled in less than about 0.4 seconds provides an increase in container quality and improved manufacturing efficiency. Furthermore, in some embodiments, it has been found that combining forming and filling periods of about 0.3 seconds to about 0.2 seconds provides even more improved container quality and manufacturing efficiency. Structurally, it has been found that this rapid forming and filling process of the present teachings results in improved container structure at the crystal level. Ideally, it has been found that all container sizes appear to benefit from forming and filling processes in the range of about 0.03 seconds to about 0.15 seconds. By reducing the forming and filling process time, the amount of available time for heat loss from the preform used to form the container can also be reduced. By minimizing heat loss from the heated preform, the preform can be maintained at or above its phase transition / curing temperature, thereby improving the appearance and performance of the resulting container formed from the preform. The principles of this teaching combine the benefits of high-speed two-step blow molding (with consistent cycle time) with the efficiency of simultaneous container filling, resulting in a single-step, fast-use manufacturing system.

[0063] The provision of exemplary embodiments makes this disclosure exhaustive and fully conveys the scope to those skilled in the art. Numerous specific details, such as examples of specific components, apparatuses, and methods, are set forth to provide a thorough understanding of embodiments of this disclosure. It will be apparent to those skilled in the art that specific details are not required, exemplary embodiments may be implemented in many different forms, and should not be construed as limiting the scope of this disclosure. In some exemplary embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail. Equivalent variations, modifications, and alterations to embodiments, materials, compositions, and methods may be made within the scope of this art, resulting in substantially similar outcomes.

Claims

1. A method of simultaneously forming and filling a container, comprising: providing a fill channel line containing a volume of liquid and including a pressure source, the pressure source including a piston device configured to apply pressure to the volume of liquid, a first valve disposed at an inlet of the fill channel line, and a second valve disposed at an outlet end of the fill channel line; isolating the fill channel line by closing each of the first valve and the second valve such that the volume of liquid is confined within the fill channel line; accelerating the piston device of the pressure source from an initial velocity to a predetermined processing velocity while the fill channel line is isolated and while the piston device increases the pressure of the confined volume of liquid, thereby compressing the volume of liquid without flowing out of the fill channel line; when the piston device reaches the predetermined processing velocity, fluidically coupling the volume of liquid contained within the fill channel line to a preform by opening the second valve, the piston device being driven at substantially the predetermined processing velocity such that the pressure source directs at least a portion of the compressed volume of liquid into the preform and stretches the preform to form the container, the container including at least a portion of the volume of liquid retained therein; fluidically decoupling the volume of liquid contained within the fill channel line from the container by closing the second valve while the piston device is still driven at substantially the predetermined processing velocity; decelerating the piston device from the predetermined processing velocity toward the initial velocity after the volume of liquid is fluidically decoupled from the container.

2. The method of claim 1, wherein, the piston device has a velocity of zero in an initial state.

3. The method of claim 1, wherein, the piston device directs at least a portion of the volume of liquid into the preform at a substantially constant processing velocity until the volume of liquid is fluidically decoupled from the container.

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

5. The method of claim 1, wherein, the piston device directs at least a portion of the volume of liquid into the preform and stretches the preform to form the container in 0.03 to 0.15 seconds.

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

7. The method of claim 1, wherein, at least a portion of the preform is disposed in a mold, and the piston device directs at least a portion of the volume of liquid into the preform and stretches the preform to form the container in accordance with the mold.

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

9. The method of claim 1, wherein, The preform is coupled to a blow molding nozzle, and wherein the second valve is disposed between the pressure source and the blow molding nozzle relative to a direction of liquid flow to the preform.

10. The method of claim 1, wherein, Stretching the preform to form the container includes a hydraulic pressure of about 100 psi to about 600 psi within the preform.

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