METHOD AND DEVICE FOR PRODUCEING FILLED CONTAINERS FROM PREFORMS

Description

[0001] The invention relates to a method for producing filled containers from preforms, wherein the preforms are each transferred to a rotating forming and filling element of a forming and filling station and are formed into the respective container in a subsequent forming and filling process in a mold of the rotating forming and filling station by the pressure effect of a supplied filling material, wherein the mold with base mold and mold halves is designed in several parts, and the respective container is clamped at least at the end of the forming and filling process between the base mold below and the forming and filling element above, and wherein the container is separated from the respective forming and filling element and the respective mold after forming and filling.

[0002] US2016059469A1 discloses a method and a device for producing filled containers from preforms, with carousel-like rotating forming and filling stations, which are arranged on a working wheel and have forming and filling elements belonging to the stations and molds for receiving the preforms, which thus rotate with the forming and filling stations, wherein the forming and filling element is designed for filling the preform with a liquid filling material and includes at least one filling nozzle, and wherein the forming and filling element is designed to seal an upwardly directed opening of the preform during the filling process so that no filling material can escape uncontrollably, and wherein, for removing the filled container, the forming and filling element can be lifted off the opening and the mold can be opened,wherein the preforms can each be transferred to the forming and filling elements and can be formed into the respective container in the mold by the pressure of a supplied filling material, wherein the mold is designed in several parts with a base mold and mold halves, and the respective container can be clamped between the base mold at the bottom and the forming and filling element at the top, at least at the end of the forming and filling process, and wherein the container can be separated from the respective forming and filling element and the respective mold after forming and filling.

[0003] For an explanation of the background of the invention and the task, reference is made to WO 2012 / 156013 A1. This document discloses forming and filling stations rotating on a working wheel, referred to herein as forming and filling stations. Each forming and filling station comprises a forming and filling element and a mold for receiving a preform and for forming a container.

[0004] The same document also discloses a so-called form-fill process, in which containers, particularly bottles made of thermoplastic material, are manufactured from thermally conditioned preforms and simultaneously filled with a liquid filling material from the forming and filling element. This liquid is supplied as a hydraulic pressure medium to expand the preform or to form the container with a forming and filling pressure. Simultaneously with filling, the respective preform is formed into the container in the mold.

[0005] The preform is filled with the liquid filling material by the forming and filling element, which includes at least one filling nozzle. During the filling process, the forming and filling element seals an upward-facing opening in the preform, preventing any uncontrolled escape of the filling material. To remove the filled container, however, the forming and filling element must be lifted from the opening and the mold opened. This may result in a small amount of filling material getting onto the interior surfaces of the mold. Wetting of the interior surfaces with filling material leads to defects during the filling and forming of a subsequent container, with corresponding quality defects. It also compromises hygiene conditions.

[0006] The mold typically consists of several components: two so-called mold halves and a base mold. The mold halves usually define the side and shoulder contours of the container, while the base mold is designed to form a container base, usually equipped with feet.

[0007] At the end of the forming and filling process, the filled container is held in the mold and clamped between the forming and filling element and the base mold. At the same time, the container is held in place by a station-side holder in the area of ​​the container neck. Removing the forming and filling element from the container directly after opening the mold can, as described above, result in filling material from the area of ​​the forming and filling element being transferred to the inner surfaces of the mold halves and the base mold. Therefore, WO 2012 / 156013 A1 proposes cleaning the interior of the mold.

[0008] It is also known in the prior art that a preform is first provided with an adapter element or an extension element, which then runs through further processing stations together with the preform. For example, US 10,350,815 B2 shows an extension element that is placed on the mouth area of ​​a preform and which is then transferred, together with the preform, to a forming and filling station arranged on a rotating work wheel. After the preform has been formed and filled, the filled container, together with the attached extension piece, is finally transported to another work wheel, where the container and extension piece are separated in order to subsequently close the container. This extension piece is intended to prevent the contents from escaping as a slosh guard.

[0009] The object of the present invention is to provide a method and / or a device such that as little filling material as possible can reach the inner surfaces of the mold.

[0010] To achieve this object, the method according to the invention has the features of claim 1. In particular, it is provided that the mold halves are removed from the respective container before the mold and fill element and the base mold are separated from the container. The mold halves are first detached from the respective container so that splashes or drops of the filling material running down the container cannot, as far as possible, reach the inner surfaces of the mold halves when the mold and fill element is later lifted off. The respective container remains clamped between the mold and fill element and the base mold. Only later are the mold and fill element and the base mold separated from the container. A key feature of the method according to the invention is the illustrated sequence of the individual steps. In the prior art, however, the base mold and side mold halves are removed from the container simultaneously, often even with their movements coupled.

[0011] According to a further concept of the invention, the mold halves can be removed from the respective container laterally and / or diagonally downwards. This allows the mold halves to be moved into a safe position, i.e., protected from contamination by the contents.

[0012] According to a further concept of the invention, the mold halves can be moved downwards after a lateral and / or obliquely downward movement. A combined movement is therefore also possible, initially with a lateral component and then in a downward direction relative to the container.

[0013] According to a further concept of the invention, the respective container can be held in the region of a container neck or support ring while the container and the forming and filling element are separated from each other. The support ring is preferably provided on the container neck. The container neck and support ring are already thicker-walled and more stable than the rest of the container and can absorb the forces otherwise absorbed by the forming and filling element. Before the container and the forming and filling element are separated from each other, the container is gripped in the region of the container neck, preferably on the container neck, on the support ring, or under the support ring.

[0014] According to a further concept of the invention, the respective container can be held in the region of a container neck and on the base mold while the container and the forming and filling element are separated from each other. During this phase, the container can be clamped between the container neck and the base mold.

[0015] According to a further concept of the invention, the bottom mold can be removed downwards from the respective container while the container is held in the region of the container neck. Accordingly, the bottom mold is preferably removed last, after the mold halves and the mold and filler element have been removed from the container.

[0016] According to a further concept of the invention, the respective container can be held on or under a support ring while the base mold is removed downwards from the container. The container is preferably provided with a support ring in the region of the container neck and can be held there.

[0017] According to a further concept of the invention, the base mold can be separated from the respective container after the forming and filling element. The time delay can be in the range of seconds. This ensures that residues of the filling material cannot reach the inner surface of the base mold, but drip off first.

[0018] According to a further concept of the invention, it can be provided that the respective container is gripped by a removal holder in the area of ​​a container neck or support ring after the mold halves have been removed and before the base mold is separated. Accordingly, the container is gripped in this area and during this phase by a special holder. Preferably, the removal holder holds the container at or below the support ring. The removal holder can grip the container in an area that was previously covered by the mold halves.

[0019] According to a further concept of the invention, it can be provided that the respective container in the forming and filling station is held by a station-side holder, that the station-side holder holds the container together with the removal holder while the base mold and the forming and filling element are separated from the container, and that the station-side holder is subsequently released from the container. This sequence ensures that the container is always gripped by at least one of the holders.

[0020] The device provided to achieve the object has the features of claim 11. Preferably, a device for producing filled containers from preforms is provided, in particular with carousel-like rotating forming and filling stations, which have a forming and filling element and a mold for receiving the preforms, wherein the preforms can each be transferred to the forming and filling elements and can be formed into the respective container in the mold by the pressure action of a supplied filling material, wherein the mold is designed in several parts with a base mold and mold halves, and the respective preform can be clamped between the base mold at the bottom and the forming and filling element at the top during the forming and filling process, and wherein the container can be separated from the respective forming and filling element and the respective mold after forming and filling.According to the invention, the mold halves can be removed from the respective container before the mold and filler element and the base mold are separated from the container. For this purpose, the device comprises a suitable control system and devices for moving the mold halves, the base molds, and the mold and filler elements.

[0021] According to a further idea of ​​the invention, it can be provided that the mold halves can be moved laterally and / or obliquely downwards from a molding and filling position into a removal position.

[0022] According to a further idea of ​​the invention, it can be provided that the mold halves can be moved laterally and downwards into the removal position.

[0023] In a conventional manner, station-side holders can be provided at each forming and filling station for gripping the preforms and containers in the area of ​​a container neck or support ring. Likewise, known removal holders can be provided in the area of ​​a removal station for gripping the containers in the area of ​​the container neck or support ring. In particular, the filled container should be temporarily held simultaneously by the station-side holder and the removal holder before the station-side holder is released.

[0024] Further features of the invention will become apparent from the description and the claims. They show: Fig. 1 a schematic plan view of a device for producing filled containers from preforms, Fig. 2 a part of the device according to Fig. 1 in an upright section, in particular a mold with filled container and in a first phase, Fig. 3 the representation according to Fig. 2, in a second phase, and Fig. 4 the representation according to Fig. 3 , in a third phase and with a slightly modified form.

[0025] Reference is first made to Fig. 1 As in WO 2012 / 156014 A1, several forming and filling stations 11.1-11.8 are arranged successively in the circumferential direction around a working wheel 10. The numbering and quantity are arbitrarily chosen. More or fewer forming and filling stations can also be provided. Working wheel 10 and forming and filling stations 11.1-11.8 form a carousel with an upright axis of rotation, to which preforms 13 made of thermoplastic material are fed essentially tangentially by means of a transfer conveyor 12.

[0026] Each forming and filling station 11.1-11.8 has a forming and filling element 14 containing a filling nozzle 15. During their rotation on the working wheel 10, the preforms 13 are filled from the forming and filling element 14 and simultaneously formed into containers 16. The fully formed containers 16 are transferred essentially tangentially to a removal conveyor 18 in the area of ​​a transfer point 17. Accordingly, no container 16 is present in the forming and filling station 11.8, which is located directly between the removal conveyor 18 and the transfer conveyor 12. In the illustrated plan view from above, the working wheel 10 rotates clockwise, while the transfer conveyor 12 and the removal conveyor 18 rotate counterclockwise.

[0027] In each forming and filling station 11.1-11.8, in addition to the forming and filling element 14, a Fig. 1A mold (not shown) is provided for receiving the preforms 13 and for forming them into the containers 16. The mold is shown in the Fig. 2 to 4 and consists in a known manner of two mold halves 19, 20 and a bottom mold 21. The Fig. 2 to 4 refer to the finished container 16 and to a process approximately between the position of the forming and filling station 11.6 and the removal conveyor 18. In this area, the filling and demolding of the containers 16 is completed. The containers cool there to the point where they achieve sufficient dimensional stability. Furthermore, the parts of the mold (mold halves 19, 20 and base mold 21) on the one hand and the forming and filling element 14 on the other, as well as other illustrated device parts, are moved in a special manner.

[0028] As in Fig. 2As shown, the container 16 is held between the mold halves 19, 20, the base mold 21, and the nozzle 15 of the molding and filling element 14. To ensure a tight seal between a container opening 22 at the upper end of a container neck 23 and the nozzle 15, the container 16 is clamped between the base mold 21 and the nozzle 15.

[0029] The container 16 is also held in the area of ​​the container neck 23 by a station-side holder 24 with retaining cheeks 25, 26. The holder 24 is therefore a component of each forming and filling station 11.1-11.8.

[0030] The container 16 has a support ring 27 at the lower end of the container neck 23 and is also provided on the outside with a thread (not shown in detail) for screwing on a closure cap. In terms of its external shape, the container 16 corresponds, for example, to a commercially available PET bottle for mineral water or other so-called soft drinks.

[0031] The nozzle 15 rests against the container neck 23 with a circumferential seal 28.

[0032] After filling and demolding the container 16, the two mold halves 19, 20 are first detached from the container 16 and moved sideways, see arrows 29a. For this purpose, holding and movement means not shown in the figures are provided, such as rotationally or translationally movable and driven support arms or levers. The new position of the mold halves resulting from the sideways movement is shown in the Fig. 2 and 3 with the dotted mold halves 19' and 20' shown. During this phase, the base mold 21 continues to rest against the container 16, so that the container 16 remains clamped between the forming and filling element 14 and the base mold 21, while the mold halves 19, 20 are moved sideways away from the container.

[0033] As in Fig. 2As can be seen, the mold halves 19, 20 extend directly below the support ring 27. After the described lateral movement of the mold halves 19, 20, the container is gripped in the area of ​​the now freely accessible support ring 27 by holding cheeks 30, 31 of a removal holder 32, so that temporarily both the station-side holder 24 and the removal holder 32 hold the container 16.

[0034] In a next step, the mold halves 19, 20 are moved downwards or diagonally downwards, see arrows 29b and dashed-bordered mold halves 19" and 20" in the Fig. 2 and 3 The distance between the mold halves 19" and 20" and the container 16 preferably corresponds to one to four container diameters. Relative to the container height, the mold halves 19" and 20" are lowered by preferably 20-100%, in particular about 30%, as shown in Fig. 3 This prevents any splashing of the filling material from hitting the mold halves in the next phase.

[0035] According to Fig. 4In the next phase, the forming and filling element 14 is lifted from the container opening 22. The container 16 is still held by the station-side holder 24 and the removal holder 32. The bottom mold 21 also still rests against the bottom of the container 16.

[0036] Due to the pressure inside the container 16, in particular after filling with carbonated filling material, filling material residues 33 now escape from the forming and filling element 14 or from the container opening 22 to the outside, for example sideways as splashes or as drops running down the container 16, as in Fig. 4The mold halves 19" and 20" are spaced far enough apart that their inner surfaces cannot be wetted by splashes or drops. The drops run down the outside of the container 16 and the outside of the base mold 21. Splashes fly over the mold halves. The inner surfaces of the base mold 21 are also not wetted. Optimal hygienic conditions are maintained. Defects when producing another container after a new preform is picked up are avoided.

[0037] The Fig. 4 The configuration shown is maintained for a while to ensure complete draining. Only then is the base mold 21 lowered and thus separated from the container 16, see arrow 34. The time period provided for draining corresponds to a partial rotation of the working wheel 4 or a swept angle α, see Fig. 1 . The angle α is preferably 5°-30°.

[0038] The bottom mold 21 is lowered only after the filling material residues 33 have drained out. Due to the rotation of the working wheel 10, some of the filling material residues are also thrown off.

[0039] The containers 16 are then transferred to the removal conveyor 18. For this purpose, the station-side holder 24 releases its retaining cheeks 25, 26 from the container neck 23.

[0040] After the container 16 has been transferred to the removal conveyor 18, the mold halves and base mold are moved back to a position in which the next preform 13 can be picked up and the mold as a whole can be closed quickly.

[0041] Fig. 2 and 3 on the one hand and Fig. 4 on the other hand, show different bottom shapes 21. These can be smaller in diameter than the container 16 or protrude slightly laterally beyond the container 16, see Fig. 4In both cases, the contents 33 can drip off. In the somewhat narrower design of the base mold 21 according to the Fig. 2 and 3 the draining process is somewhat safer. When using the additional base form 21 according to Fig. 4 the mold halves in the lower area must be adjusted.

[0042] The mold halves 19, 20 are not true "halves," since at least the base mold 21 is additionally present. Instead of two mold halves, more parts can also be provided, which together perform the function of the mold halves shown here. Mold halves are typically understood to be the parts of a mold that define the side and shoulder contours of the containers 16, in the present example up to the container neck 23 below the support ring 27. The preforms 13 used are typically already provided with the container neck 23 and support ring 27. List of reference symbols 10 Work wheel 30 retaining cheek 11.1 Forming and filling station 31 retaining cheek 11.2 Forming and filling stations 32 Removal holder 11.3 Forming and filling stations 33 Filling residues 11.4 Forming and filling stations 34 Arrow 11.5 Forming and filling stations 11.6 Forming and filling stations α Angular range 11.7 Forming and filling stations 11.8 Forming and filling stations 12 Transfer conveyor 13 Preforms 14 Form and fill element 15 Filling nozzle 16 container 17 handover point 18 removal conveyor 19 mold half 19' Mold half 19 in a different position 19" Mold half 19 in a different position 20 mold half 20' Mold half 20 in a different position 20" Mold half 20 in a different position 21 Bottom shape 22 Container opening 23 Container neck 24 Station-side holder 25 retaining cheek 26 retaining cheek 27 Support ring 28 seal 29a arrows 29b arrows

Claims

1. A method for producing filled containers (16) from preforms (13) in a circumferentially running forming and filling station, which is arranged on a working wheel and which comprises a mould belonging to the station and thus running circumferentially along with the station and a forming and filling element belonging to the station, thereby running circumferentially along with the station, wherein the filling of the preform with a liquid filling material is carried out by the forming and filling element, which contains at least one filling nozzle and which seals an upward-facing opening of the preform during the filling process so that no filling material can escape uncontrollably, and wherein the forming and filling element can be lifted from the opening and the mould can be opened for the removal of the filled container, wherein the preforms (13) are each transferred to the circumferentially running forming and filling element (14) of the forming and filling station (11.1-11.8) and are formed into the respective container (16) due to the pressure effect of the fed filling material during a subsequent forming and filling process, wherein the mould with mould base (21) and mould halves (19, 20) is designed as a plurality of parts, and the respective container (16) is clamped in at least at the end of the forming and filling process between the mould base (21) below and the moulding and filling element (14) at the top, and wherein the container (16) is separated from the respective forming and filling element (14) after forming and filling, characterized in that the mould halves (19, 20) are removed from the respective container (16) before the forming and filling element (14) and the mould base (21) are separated from the container (16).

2. The method according to Claim 1, characterized in that the mould halves (19, 20) are removed from the respective container (16) in the lateral direction and / or obliquely downwards.

3. The method according to Claim 2, characterized in that the mould halves (19, 20) are moved downwards after a lateral and / or oblique downward movement.

4. The method according to any one of the Claims 1-3, characterized in that the respective container (16) is held in the area of a container neck (23) or support ring (27) while container (16) and forming and filling element (14) are separated from each other.

5. The method according to any one of the Claims 1-4, characterized in that the respective container (16) is held in the area of a container neck (23) and on the mould base (21) while container (16) and forming and filling element (14) are separated from each other.

6. The method according to Claim 5, characterized in that the mould base (21) is removed downwards from the respective container (16) while the container (16) is held in the area of the container neck (23).

7. The method according to any one of the Claims 4-6, characterized in that the respective container (16) is held on or under a support ring (27) while the mould base (21) is removed downwards from the container (16).

8. The method according to any one of the Claims 1-7, characterized in that the mould base (21) is separated from the respective container (16) after the forming and filling element (14) in terms of time.

9. The method according to Claim 8, characterized in that the respective container (16) is grasped by a removal holder (32) in the area of a container neck (23) or support ring (27) after removal of the mould halves (19, 20) and before separation of the mould base (21).

10. The method according to Claim 9, characterized in that the respective container (16) is held in the forming and filling station (11.1-11.8) by a station-side holder (24), that the station-side holder (24) holds the container (16) together with the removal holder (32), while the mould base (21) and the forming and filling element (14) are separated from the container (16), and that the station-side holder (24) is subsequently detached from the container (16).

11. A device for producing filled containers (16) from preforms (13), with carousel-like circumferentially running forming and filling stations (11.1-11.8), which are arranged on a working wheel and comprise forming and filling elements (14) and moulds for receiving the preforms (13) belonging to the stations, which thus circumferentially run with the forming and filling stations, wherein the forming and filling element is designed for filling the preform with a liquid filling material and comprises at least one filling nozzle and wherein the forming and filling element is designed to seal an upward-facing opening of the preform during the filling process so that no filling material can escape uncontrollably, and wherein the forming and filling element can be lifted off from the opening for the removal of the filled container and the mould can be opened, wherein the preforms (13) can each be transferred to the forming and filling elements (14) and can be formed within the mould by means of the pressure of a fed filling material into the respective container (16), wherein the mould with mould base (21) and mould halves (19, 20) is designed as a plurality of parts, and the respective container (16) can be clamped in at least at the end of the forming and filling process between the mould base (21) below and the forming and filling element (14) at the top, and wherein the container (16) can be separated from the respective forming and filling element (14) and the respective mould after forming and filling, characterized in that the mould halves (19, 20) are removable from the respective container (16) before the forming and filling element (14) and the mould base (21) are separated from the container (16).

12. The device according to Claim 11, characterized in that the mould halves (19, 20) can be moved laterally and / or obliquely downwards from a forming and filling position to a removal position.

13. The device according to Claim 12, characterized in that the mould halves (19, 20) can be moved laterally and downwards to the removal position.