packaging forming apparatus

专利摘要:
APPLIANCE FOR PACKAGING FORMATION AND FILLING SYSTEM. A method and apparatus for forming, filling and sealing unit dose packaging for consumer products is described here. A filling system with a filling control system is also presented '. Although the filling system is described in conjunction with a method for forming, filling and sealing unit dose packaging, the filling system and filling control system can be used in other dispensing processes.
公开号:BR112014021374B1
申请号:R112014021374-7
申请日:2013-02-26
公开日:2021-02-09
发明作者:Adal Amine Tecleab；Cullen Joseph Breithaupt；Shawn Christopher Pallotta；Jason Matthew Orndorff；Gavin John Broad；Jon Kevin Mclaughlin
申请人:The Procter & Gamble Company；
IPC主号:

专利说明:

FIELD OF THE INVENTION
[0001] A method and apparatus for forming, filling and sealing unit dose packaging for products intended for the consumer are described here. A filling system with a filling control system is also presented. ] BACKGROUND OF THE INVENTION
[0002] Unit doses of liquid products such as shampoo and hair conditioner are often placed in relatively thin, flat packages known as sachets. Such sachets are typically endowed with water vapor barrier properties to prevent water loss from the product in the packaging over time. Sachets of this type are generally made using vertical forming, filling and sealing (VFFS) processes.
[0003] The present processes exist for formation, filling and vertical sealing, both intermittently and continuously. Vertical forming, filling and sealing (VFFS) processes typically employ a set of filling nozzles that are inserted between two layers of the material used to form the packaging. The nozzles must open and close after filling each package. For intermittent motion processes, filling occurs while the film or packaging material is in motion, and the film stops during the sealing process. Even for continuous processes, where all operations are carried out on moving blankets, fees are limited by the filling process. The ability to dispense precisely the desired amount of liquid in extremely short dispensing cycle times is required.
[0004] Processes also exist for horizontal forming, filling and sealing. Examples of horizontal forming, filling and sealing processes are described in PCT publication WO 2004/033301 A1, Smith, et al .; in US patent application publication 2005/0183394 A1; and EP 1 375 351 B1, Lauretis, et al. Some of these processes may involve thermoforming a portion of the packaging material.
[0005] The search for improved packaging formation processes and filling systems has, however, persisted. In particular, there is a need for faster processes for sachet production, specifically sachets that comprise films produced with vapor barriers that cannot be thermoformed without breaking the vapor barrier. SUMMARY OF THE INVENTION
[0006] A method and apparatus for forming, filling and sealing unit dose packaging for products intended for the consumer are described here.
[0007] In one embodiment, the method comprises a process for producing a package that comprises the steps of: a) positioning a first layer of material that has an original undeflected configuration adjacent to an element that has a cavity in it; b) temporary deflection of a portion of the first blanket of descending material into the cavity to form a deflected portion of said first blanket of material, wherein said deflected portion of said first blanket of material is substantially free of plastic deformation; c) depositing a product on the first layer of material; d) positioning a second layer of material on the first layer of material and the product; and e) closing and sealing at least partial of the first material mat, the first material mat having the portion deflected therein to said second material mat along one or more sealing lines.
[0008] In one embodiment, the apparatus comprises a first feeding zone for receiving a supply of a first layer of material and an element that has a cavity in it. The element that has the cavity in it is located downstream of the first feeding zone. A portion of a first layer of material can be temporarily deflected into the cavity. The cavity comprises a base and a pair of side walls. In this embodiment, the element that has the cavity in it comprises a movable belt that has a surface, and the belt moves in one direction of the machine, the surface of the belt forming a base of the cavity, and the element additionally comprises portions of longitudinal side edges that form the side walls of the cavity. The apparatus may additionally comprise a dispensing device for applying a product to the portion of the first layer of material covering the cavity. The dispensing device is located in a dispensing zone above the element that has a cavity in it. The apparatus may additionally comprise a second feeding zone for receiving a supply of a second layer of material. The second feeding zone can be located downstream of the dispensing device, a second layer of material being arranged to cover the first layer of material with the product in it. The apparatus may additionally comprise a sealing device located downstream of the second feeding zone for sealing the first and second blankets of material together with a product between them.
[0009] A filling system with a filling control system is presented, too. The filling system and the filling control system can be used in the method described here, as well as in other dispensing processes, and can comprise independent inventions. [013] BRIEF DESCRIPTION OF THE DRAWINGS
[00010] Figure 1 is a schematic front view of a sachet modality.
[00011] Figure 2 is a schematic view in perspective of a vertical forming, filling and sealing process.
[00012] Figure 3 is a schematic perspective view of an embodiment of a method and apparatus for forming a package.
[00013] Figure 4 is a schematic cross-sectional view of a portion of an apparatus that has two lanes side by side for packaging, with a filling nozzle for each lane.
[00014] Figure 5 is a schematic cross-sectional view of a portion of the apparatus for mechanically deflecting the blanket of lower material into the interior of cavities.
[00015] Figure 6 is a schematic top view of the portion of the apparatus shown in Figure 5.
[00016] Figure 7 is a schematic cross-sectional view of a portion of the apparatus for deflection of the lower material mat into a cavity.
[00017] Figure 8 is a schematic perspective view of an alternative embodiment of a portion of the apparatus for pulling the blanket of lower material into a cavity in which the bottom of the cavity is formed by a moving mat.
[00018] Figure 9 is a schematic view in perspective of the deformation of the lower material mat with product doses deposited thereon.
[00019] Figure 10 is a schematic perspective view of an alternative embodiment of a portion of the apparatus for pulling the blanket of lower material into a cavity shown in Figure 8 in which the cavity is formed in different pockets.
[00020] Figure 11 is a schematic cross section of another modality of a forming apparatus comprising both a bottom plate and a top plate, each including moving belts, for use in an apparatus that is two lanes wide.
[00021] Figure 12 is a schematic cross section of a variation of the forming apparatus shown in Figure 11, in which only the top plate is shown.
[00022] Figure 13 is a cross-sectional view of a nozzle for use in the filling system.
[00023] Figure 14 is a schematic perspective view of the end of a nozzle that has a circular orifice and a closing mechanism.
[00024] Figure 15 is a schematic perspective view of the end of a nozzle that has a slit-shaped orifice and a closing mechanism.
[00025] Figure 16 is a schematic perspective view of a filling system for filling receptacles.
[00026] Figure 16A is a schematic diagram of a fill control system.
[00027] Figure 16B is a schematic diagram of an alternative fill control system.
[00028] Figure 17 is a schematic cross section showing non-deformed upper and lower blankets.
[00029] Figure 18 is a schematic cross section of a modality in which the blankets of upper and lower material are deformed in the direction transverse to the machine.
[00030] Figure 19 is a schematic side view of a complete embodiment of a HFFS method and apparatus in which the top and bottom blanket forming sections are combined with sealing mechanisms.
[00031] Figure 20 is a schematic side view of an embodiment of a portion of the apparatus that is used to form seals in the direction transverse to the machine.
[00032] Figure 21 is a schematic side view of another embodiment of a filling nozzle.
[00033] Figure 22 is a partially cropped view of the filling nozzle shown in Figure 21.
[00034] Figure 23 is a perspective view of an embodiment of a nozzle component for the nozzle shown in Figures 21 and 22.
[00035] Figure 24 is a perspective view of an embodiment of a plug for the filling nozzle shown in Figures 21 and 22. [040] DETAILED DESCRIPTION OF THE INVENTION
[00036] A method and apparatus for forming, filling, and sealing unit dose packaging for products intended for the consumer are described here. A filling system with a filling control system is also presented. Although the filling system is described in conjunction with a method for forming, filling and sealing unit dose packaging, the filling system and filling control system can be used in other dispensing processes.
[00037] The unit dose package can have any suitable configuration. The contents of the package may be in any suitable form including, but not limited to, solids, liquids, pastes and powders. The term "fluid" can be used here to include both liquids and pastes.
[00038] In certain embodiments, unit dose packages comprise sachets that are filled with products that may include personal care products or household care products including, but not limited to: shampoo, hair conditioners, hair dyes ( dyes and / or developers), laundry detergents, fabric softeners, dish washing detergents, and toothpaste. Sachets may contain other types of products, including, but not limited to, food products such as ketchup, mustard, mayonnaise and orange juice. Such sachets are typically relatively thin and flat, and in some cases, have water vapor barrier properties to prevent loss of water from the product in the packaging over time, or water entering the product from outside the container. packaging.
[00039] Figure 1 shows a non-limiting example of a sachet 10 which is in the form of a sachet of the prior art. The sachet 10 has a front part 12, a rear part 14, a periphery 16, two sides 18, a top 20, and a bottom 22. Sachet 10 additionally has a seal 24 around the periphery. The sachet can be in any suitable configuration including, but not limited to, the rectangular shape shown. The sachet can have any suitable dimensions. In one embodiment, the sachet is 48 mm x 70 mm, and has a 5 mm wide sealed area around all four sides. The dimensions of the pocket 26 inside the sachet (width W and length L) are 38 mm x 60 mm.
[00040] The packaging, like sachet 10, can be produced from any suitable materials. Suitable packaging materials include films, and woven or non-woven materials (where the sachet contains a solid product), or laminates from any of the above. If desired, the packaging material can comprise a liquid and / or vapor barrier in the form of a layer or a coating. The packaging materials may comprise non-aqueous soluble materials, or for some uses, water-soluble materials. The various portions of the sachet (or other type of packaging) can all be produced from the same materials. In other embodiments, different portions of the packaging can be produced from different materials. In one embodiment, sachet 10 is produced from two pieces of the same film that form the front 12 and the rear 14 of the sachet. The film can be any type of suitable film, including single-layer and laminated films.
[00041] The elastic modulus of the packaging material for a sachet can be in the range greater than or equal to about 1,000 N / m (as for a non-woven low density polyethylene) up to about 90,000 N / m for films and laminates comprising films. The elastic module of the packaging material can fit in any narrower band that fits in the above band. For example, in some types of films and laminates that comprise films, the elastic module can be in the range of about 45,000 to about 85,000 N / m.
[00042] In one embodiment, the packaging material is a laminate that comprises the following three layers: a 9 micron thick polyethylene terephthalate (PET) film; a biaxially oriented vacuum metallized polypropylene vapor barrier film (VM BOPP) 18 microns thick; and a polyethylene (PE) film 30 to 50 microns thick. The PET and PE layers are adhered to the VM BOPP film by the adhesives. In this film, the PET layer will comprise the outer surface of the sachet, and the polyethylene layer will comprise a sealing layer inside the sachet. The water vapor barrier properties for this film are important to prevent water loss of the product inside the sachet over time before it is used by the consumer. The film has a target water vapor transmission rate less than or equal to about 0.4 grams / m2 / day. The average machine direction module of this laminated film is about 63,000 N / m, and the average machine directional module is about 75,000 N / m.
[00043] Figure 2 shows a process and an apparatus for forming, filling and vertical sealing (VFFS) 30 for the production of sachets. As shown in Figure 2, two blankets of material 32 and 34 for forming sachets are placed in the apparatus, and are fed to the process in a vertically downward direction. A fill nozzle 36 is inserted between blankets 32 and 34. The tip 38 of the fill nozzle 36 (the view of which is obstructed by the second blanket 34) is located by the tip of the arrow 38. Vertical seals are formed along the sides of blankets 32 and 34 using vertical sealing mechanisms 40. A transverse sealing mechanism 42 is located below the tip 38 of the filling nozzle 36. The transverse sealing mechanism 42 forms the seal that is located at the top of a sachet and in the bottom of the next sachet. A perforation or cutting mechanism 44 is located below the transverse sealing mechanism 42, and forms perforations 46 through the seal formed by the transverse sealing mechanism 42. A finished package or sachet 10 is shown at the bottom of Figure 2.
[00044] The simplified version of the apparatus 30 shown in Figure 2 has only one wide streak (one wide pack). It is known to provide such devices with multiple vertical lanes side by side. However, even with such devices with multiple lanes, due to the configuration of the vertical forming, filling and sealing processes, each lane will have only a single filling nozzle. The product flow, either liquid or powder, must be closed cleanly so as not to contaminate the packaging seal. The ability of a set of filling nozzles, which are inserted between the two layers of material 32 and 34, to open and close cleanly is a speed limiter.
[00045] Figure 3 shows a simplified single lane version L1 of a new forming, filling and sealing process and apparatus 50. The process can be described as a horizontal forming, filling and sealing (HFFS) process. In the embodiment shown, the process and apparatus 50 are used to form sachets containing liquid products. The process, however, is not limited to the formation of sachets (or sachets containing liquid products). In essence, in one embodiment of this process, a blanket of primary or lower material (such as a film) 52 is fed into an apparatus 50, and can then be transported in a generally horizontal orientation. The first mat of material 52 is carried along a primary or lower element that has at least one cavity 56 therein into which a portion of the first mat 52 is temporarily deflected. A product 48 is deposited on the first mat of material 52, as by nozzles 60. The first mat of material is then covered with a mat of secondary or higher material 62, and the two blankets are sealed together to form the sachets. The components of the apparatus 50, and variations thereof, are as follows.
[00046] The first mat of material 52 is carried by a conveyor belt (which in this case is the first element, and which can be called "lower conveyor belt", or "filling conveyor belt") 54. The lower conveyor belt 54 can be any type of suitable conveyor, including, but not limited to, a vacuum conveyor. The lower conveyor belt 54 has a profiled surface that forms at least one pocket or cavity 56 on the surface of the lower conveyor belt 54 into which portions of the first material web 52 are deflected. In this embodiment, the lower conveyor belt has a plurality of cavities 56 formed therein.
[00047] [The first layer of material 52 has an original, deflected configuration. The first blanket of material 52 is kept under tension in the process of transporting it through the apparatus. The first mat of material 52 can be transported by the lower conveyor belt 54 in a continuous movement. In other embodiments, the first mat of material 52 can be transported in an intermittent motion. The first mat of material 52 can, in various embodiments, be moved at substantially the same speed as the lower conveyor belt 54, at a lower speed than that of the lower conveyor belt, or at a speed greater than that of the lower conveyor belt 54.
[00048] The cavity 56 can have any suitable configuration. The modality of the apparatus shown in Figure 3 forms distinct pockets for each dose of product 48 that will be contained within the sachets. It should be understood, however, that in some cases, it is not necessary to form separate pockets for each dose of the product 48 that will be contained within the sachets. In other embodiments, for example, the cavity 56 may be in the form of a continuous recess. The configuration of the cavity 56 formed by the lower conveyor belt 54 determines the shape or configuration of the lower material mat 52. (Although the following description may describe the first material mat 52 as a film, it is understood that the first mat of material material 52 is not limited to a film.) The lower material mat 52 can be shaped in the direction transverse to the machine (or "DT"), and optionally also in the machine direction (or "DM"). The configuration in which the lower material mat 52 can be formed depends on the material module comprising the lower material mat 52 and the properties of the product 48 to be filled.
[00049] [Figure 4 shows a simplified cross section of the formation of a lower material web 52 in a mode in which the process shown in Figure 3 is expanded to provide multiple lanes L1 and L2 in the transverse direction of the machine. This allows rows of sachets side by side to be produced from a single film mat (i.e., a single lower material mat 52 and a single upper material mat described below). The apparatus 50 described herein can comprise any suitable number of multiple lanes, from two to twelve, or more.
[00050] As shown in Figure 4, a portion of the film 52 is made to fit substantially in the cavity 56. This portion of the film 52 can be made to substantially fit or be formed in the cavity 56 by any suitable mechanism. Suitable mechanisms include, but are not limited to: (1) mechanical manipulation (or pre-forming) of the film 52 before it enters the cavity, so that it comprises a portion that more readily fits into the cavity 56; (2) by deflection of the film portion into the cavity 56, with vacuum and / or air pressure exerted on the film; or, (3) both. In still other embodiments, the film 52 can be made to be formed into the cavity by the force of deposition of the product 48 on the film 52. Such mechanisms may, but need not be in the format of the film 52, so that they conform exactly to the shape of cavity 56.
[00051] If a mechanical preform step is used, it will typically be located in the process before (or upstream) from the place where the first blanket of material 52 comes into contact with the forming conveyor belt 54. For example, if such a preforming process is used on the apparatus 50 shown in Figure 3, the mechanical preforming apparatus would be located at the location P1 which is between the location where the first mat of material 52 is fed to the apparatus and the upstream end of the training conveyor belt 54.
[00052] Suitable mechanisms for mechanically manipulating the film include, but are not limited to, rails, skis, spheres, bellows, or semicircles. Figures 5 and 6 show a modality that comprises three lanes side by side, L1, L2 and L3, in which the film 52 is mechanically preformed to assist the film 52 in shaping the shape of the cavities 56 by a combination of components of mechanical formatting. In Figures 5 and 6, the mechanical formatting components are provided by a top forming plate 132 and a bottom forming plate 134. The bottom forming plate 134 comprises spaced channels 138 with rails oriented in the direction of the machine 140 between themselves that are spaced in the transverse direction of the machine and arranged below the film 52. The top forming plate 132 comprises spaced upper elements 136 which are arranged above the film 52. In this embodiment, the upper elements 136 comprise rounded elements such as rounds or semicircles . The upper elements are aligned with the grooves 138 on the bottom formation plate 134. In other embodiments, the positions of the mechanical formatting components can be reversed, so that the grooves 138 and rails 140 are on the top formation plate, and the Dome 136 are on the bottom formation plate.
[00053] As shown in Figure 6, in certain modalities in which there are multiple lanes in the DT of products being formed, it may also be desirable that at least one of the elements in at least one of the lower or upper group of components of mechanical formatting be arranged so that the elements in or adjacent to the lanes in the middle of the forming conveyor belt are further upstream than the elements in, or in a position adjacent to, the external lanes. For example, the upper elements, semicircles 136, could be arranged in a V configuration when viewed from above. This can make the formation of the blanket more gradual. In still other embodiments, it may be desirable for mechanical formatting components in one of the lower or upper group of mechanical formatting components to have an anterior edge that is upstream of the other mechanical formatting components in the opposite group.
[00054] Such mechanical forming mechanisms can be used alone, or in combination with vacuum mechanisms. For example, in some embodiments, the mechanical forming mechanism can preform film 52, so that it is formed to fit substantially in cavity 56, and vacuum can be used to more precisely fit the portion of film 52 to the interior of cavity 56. In other embodiments, the mechanism may preform film 52, so that it is formed to fit precisely into cavity 56, and vacuum is merely used to hold the portion of film 52 in cavity 56 during filling and sealing. In still other embodiments, such mechanical forming mechanisms could be omitted entirely, and the portion of the film 52 can be pulled into the cavity 56 with the use of vacuum alone.
[00055] The depth of film formation 52 depends on the volume of filling and the desired material properties of the product being filled. The lower material web 52 can be deflected, formed, or pulled into cavity 56 at room temperature. The term room temperature, as used here, refers to temperatures below about 38 ° C (100 ° F). Typically, the forming process can be carried out at temperatures of about 4 ° C (40 ° F) to about 35 ° C (95 ° F), or from about 15 ° C (60 ° F) to about 27 ° C (80 ° F). However, depending on the film, it is also possible to form or pull the blanket of lower material 52 into the cavity at an elevated temperature. The temperature of the film can be raised in any suitable manner, such as by heating the lower material mat 52 or by heating the cavity 56. In these, or other embodiments, the lower material mat 52 may also have heat applied indirectly to it, such as due to the heat emitted from the heated sealing bars described here.
[00056] There are several different types of mechanisms that can be used to form the cavities 56. These mechanisms can be used for several purposes, including: deforming the lower material web 52 into the cavities 56; attach a blanket of pre-formed lower material to the cavities; or both. Figure 7 shows a simple execution of the step of deformation of the lower material mat 52 (or retention of a preformed lower material mat in the cavities). In this embodiment, the lower material web 52 is slid over a stationary component that has a profiled shape, such as a plate with a profiled surface that has a cavity 56 therein. In this case, the cavity 56 is in the form of a continuous recess oriented towards the machine. The cavity 56 is defined by the side walls 66 and a bottom 68. As shown in Figure 7, the plate that forms the cavity 56 has a plurality of vacuum channels 70 therein that are connected to a vacuum pipe 72. The vacuum 70 may be located along any suitable portion of cavity 56 including, but not limited to, sides 66 and bottom 68 of cavity 56. In the embodiment shown, a first set of vacuum channels 74 is located where the sides 66 and the bottom 68 of the cavity meet. A second set of vacuum channels 76 can be located laterally outside the cavity 56, and can be used to secure the edge portions 52A of the lower material web 52.
[00057] As shown in Figure 8, in other embodiments, instead of a plate with a profiled surface, the apparatus may comprise a mobile conveyor belt (or simply a "movable belt") 80 that forms the bottom 68 of the cavity 56. The moving belt 80 can be in the form of a closed or endless loop. The conveyor 80 can be part of a conveyor conveyor system comprising at least two cylinders 78 around which the conveyor 80 passes. Cylinders 78 can have a plurality of ridges and ridges crossing in the direction of the rotational geometric axis A of the cylinders. The belt 80 may have a plurality of ridges and grooves oriented in the direction transverse to the machine on its underside which are attached by the ridges and grooves in the cylinders 78 to move the belt 80. In this embodiment, the base surface 68 of the cavity 56 is formed by the top surface of the moving mat 80, and the side walls 66 are formed by the stationary side rails 82. The stationary side rails 82 form a small gap 84 with the moving mat 80 to accommodate the movement of the mat 80. In this embodiment, it is more It is desirable that the lower material mat 52 moves with the moving mat 80, instead of sliding along it, as in the case of the component shown in Figure 7.
[00058] The embodiment shown in Figure 8 also has a first set of vacuum channels 74 and a second set of vacuum channels 76. In the embodiment shown in Figure 8, the openings of the first set of vacuum channels 74 are located at the location of the gap 84 between the side rails 82 and the moving belt 80. This deflects (or retains) the lower material mat 52 into the cavity 56 configuration. The second set of vacuum channels 76 is formed on the side rails 82 as shown to hold the edges of the lower material web 52. In this embodiment, the vacuum tubing 72 can be located within the conveyor belt 80.
[00059] Figure 9 shows that the lower material mat 52 can be formed in a recess, as by the forming apparatus shown or in Figure 7 or Figure 8. The formation of the lower material mat 52 in a simple recess is suitable when the product comprises liquids of medium viscosity (like a shampoo) or high viscosity, like a conditioner for hair. As shown in Figure 9, liquid 48 can be deposited in distinct amounts and will remain separated in the lower material web 52 for extended periods of time.
[00060] As shown in Figure 10, in the case of less viscous liquids, such as liquid home care detergents, rails in the direction transverse to the machine (or "cross members" or "cross rails") 86 can be added to the moving mat 80 to outline distinct pockets 56. The cross rails 86 can be lower in height compared to the side rails 82 to minimize deformation of the lower material mat 52. The components of the mobile conveyor belt 54 shown in Figure 10 can have any suitable dimensions.
[00061] Figure 11 shows another modality of a forming apparatus. The forming apparatus in Figure 11 comprises a combination of fixed plates and moving mats. The forming apparatus comprises a bottom plate 88 and a top plate 90 for use in an HFFS 50 apparatus that is two lanes wide. The bottom forming plate 88 is used to deflect the lower mat 52 (or retain a preformed lower mat in a deflected condition). The top forming plate 90 is used to deflect the upper mat 62 (or retain a preformed upper mat in a deflected condition). Although the top forming plate 90 is shown to be arranged directly on the bottom forming plate 88, it should be understood that the top forming plate 90 is typically located downstream of the bottom forming plate 88 after the zone dispensing 58. The top forming plate 90 will be further described after the dispensing step has been described.
[00062] The bottom forming plate 88 is contoured to provide cavities 56 therein. As shown in Figure 11, the bottom plate 88 comprises raised surfaces 98 between, as well as laterally outside, cavities 56. In a non-limiting embodiment, cavities 56 are 30 mm wide and raised surfaces 98 have a width of 14 mm. The raised surfaces 98 have longitudinal side edges 100 which are curved to avoid breaking the lower material web 52. The bottom forming plate 88 has vacuum channels spaced thereon. There is a first set of vacuum channels 74 at the base of the cavities 56 adjacent to each side of the cavities. There is also a second set of vacuum channels 76 on the raised surfaces 98 that are laterally out of the cavities 56. The vacuum channels 74 and 76 are spaced in the direction of the machine (such as about 10 mm). A moving mat 80 similar to that shown in Figure 8 or Figure 10 is located inside each of the cavities 56, or in a recess 56A adjacent to, or within, each of the cavities 56. In Figure 11, the recesses 56A are formed on the bottom surfaces of the cavities 56. At least a portion of the bottom of the forming cavities 56 can be formed by the top surface 81 of the belts 80. Vacuum is used to form the mat (or retain a preformed lower mat in one deflected condition) and mats 80 are used to transport the mat 52 along static and rigid forming plates.
[00063] A difference between the belts shown in Figure 11 and those shown in the previous figures is that in Figure 11 there may be vacuum channels 77 leading to the top surfaces 81 of the belts 80. The belts 80 can have vacuum holes 79 in the same to keep the mat 52 in contact with the top surfaces 81 of the mats 80. In the embodiment shown in Figure 11, the vacuum holes 79 are located along each longitudinal side portion of the mats 80, although in other embodiments, the mating holes vacuum can be located elsewhere on the tracks, such as along the sides of the track, as shown in Figure 8. In still other versions of this mode, track 80 can have adequate traction to move film 52 without a vacuum being applied to track 80 if the top surface 81 of the mat 80 is raised above (for example, 0.125 mm above) the base of the forming cavity.
[00064] In modalities in which the films are primarily preformed or shaped by a mechanical device to deflect it, the lower material mat 52 can be adequately retained in the cavities 56 with about 76.2 cm (30 inches) of water vacuum. In other modalities, films are primarily shaped by a vacuum. In the later modalities, if the device is twelve lanes wide, the portions of the lower material blanket in the six central lanes can be formed with about 65 cm to 90 cm (25 to 35 inches) of vacuum. The portions of the lower material web 52 on the three outer lanes on each side of the central lanes can be formed with between about 38 to 65 cm (about 15 to 25 inches) of vacuum.
[00065] At least a portion of the lower material web 52 that is deflected or formed in the cavity 56 will undergo elastic deformation. The amount of elastic deformation is desirably less than or equal to the maximum elongation of any vapor barrier associated with the first layer of material 52. The amount of elastic deformation can, for example, be less than or equal to about 4%, 5%, or 6%.
[00066] In at least some embodiments, it is desirable that the film mat 52 is substantially free of plastic deformation, so that the film 52 tends to return towards its original configuration after the mechanisms have finished acting on the film 52. The phrase "substantially free of plastic deformation", as used here, refers to plastic deformation less than or equal to about 1%. In some cases, it may be desirable to have a plastic deformation of less than or equal to about 0.5%, or less than or equal to about 0.2%. The lower material mat 52 can be completely free of plastic deformation. In embodiments in which film 52 is substantially free of plastic deformation, the formed portion of film 52 will typically be free of any macroscopically visible fold lines, grooves, permanently extended regions, or thinned regions. Of course, in other modalities, it is possible that the film contains some amount of plastic deformation. However, if the first blanket of material 52 contains a vapor barrier that would be undesirably broken by such plastic deformation, then such plastic deformation must be avoided. As described in more detail below, in addition to preserving the vapor barrier properties of film 52, ensuring that the film is substantially free of plastic deformation will minimize any stretching of the film that can cause the film width to increase excessively. If the width of the film increases excessively, the edges of the lower material mat 52 may extend beyond the edges of the upper material mat 62 (or vice versa). This may require that the edges of one of the films be trimmed, so that they match.
[00067] When the lower material mat 52 is deflected into the cavities 56, the side edges 52A of the lower material mat 52 are pulled inward, so that the film 52 becomes narrower as a result of the deflection. In the case of the conveyor belt 54 shown in Figure 10 (for example), a reduction in film width of about 2 mm can occur. The total reduction in the width of the lower material mat 52 will be greater if there are two or more pocket strips 56 side by side for forming sachets from a single film mat. For example, in the case of a blanket of lower material 52 which has an initial width of 96 mm, for a two-lane run, film 52 may have a width reduction of about 4 mm, so that the width of the film deflected is about 92 mm. In the case of an example of a twelve-lane run, the lower material web 52 may have an initial width of 585 mm, or more.
[00068] A variety of different methods and mechanisms can be used, so that the lower material mat 52 can be deflected and undergo a reduction in width, while the edge portions 52A of the lower material mat 52 remain trapped by the vacuum. . In one embodiment, the vacuum can be successfully applied initially to the central portion (along the width) of the film 52, and then to the external portions along the edges of the material web. In such an embodiment or in other embodiments, a higher vacuum can be applied to the central portion of the film 52 than to the outer portions along the edges of the film. In still other embodiments, the lower material web 52 may be mechanically shaped or preformed, as described above, before the film enters cavities 56, so that the edges of the web are pulled in in the desired amount before the vacuum be applied.
[00069] As shown in Figures 3 and 4, product 48 can be deposited on the lower material mat 52 by any suitable dispensing device or device including, but not limited to nozzles 60, positive displacement pumps, and devices for dispensing solids or powders, depending on the product to be dispensed. Although the following description describes nozzles, other dispensing devices can be used instead. The nozzles 60 are positioned above the lower film mat 52 in a dispensing zone 58. The nozzles 60 can dispense a product as a liquid (or paste) product 48 on the lower film mat 52, and specifically inside the deflected portions in the lower film web 52 corresponding to the cavities 56. The nozzle 60 and the orifice thereof can be of any suitable type and configuration. Figure 13 shows a suitable nozzle configuration. The nozzle 60 comprises a nozzle structure 150, a chamber 152 that has a piston 154 in it, a nozzle orifice 156 and a mechanism or valve with mushroom closing command 158. The structure of the nozzle 150 has several openings therein, including: an inlet 160 for liquid product 48; an air inlet 162 to open the piston chamber 152 and an air inlet 164 to close the piston chamber 152. The nozzle 60 can have a circular orifice as shown in Figure 14. A suitable nozzle is a circular orifice nozzle with 3.5 cm (1.375 inch) Hibar positive closure, part number 147742, which has an internal diameter of 6.4 mm (% inch), available from Hibar Systems Limited, of Boone, North Carolina, USA.
[00070] Figure 15 shows that in another embodiment, the nozzle may have a slit-shaped orifice. This can be used to deposit a dose of liquid of lower profile (or height) on the lower material web 52 than nozzles having a round hole, which deposit microspheres of embossed liquid. In some embodiments in which a slit-shaped nozzle 60 is used, the nozzle will deposit a relatively flat liquid tape on the lower material web 52. The liquid tape can have any suitable plan view configuration, including, but not limited to, not limited to, a generally rectangular configuration. The slit-shaped nozzle 60 is arranged above the lower material mat 52 with its longest dimension oriented in the direction transverse to the machine and its shortest dimension oriented in the direction of the machine. The hole can be of any suitable size. In one embodiment, the slot can be 25 mm long and 1.1 mm wide. As shown in Figure 15, the nozzle 60 can comprise a closing mechanism 158 that has the same shape as the shape of the slot 156, in order to interrupt the flow of the nozzle.
[00071] In other embodiments, the nozzle may have multiple holes. That is, the nozzle can be a multi-hole or "multi-hole" nozzle. Examples of multi-nozzle nozzles are described in US provisional patent application No. 61 / 713,696, filed on October 15, 2012. Such a multi-nozzle nozzle is shown in Figures 21 and 22. Figure 21 shows that the multi-nozzle assembly 200 can comprise , in general, an air cylinder 222, an optional connecting structure 224 and a nozzle structure 226. The air cylinder 222 moves the plug 228 within the nozzle structure 226 to open and close the nozzle. The optional connecting structure 224 connects the air cylinder 222 to the nozzle structure 226. Figure 22 shows that the air cylinder 222 can comprise a housing 230 that has an interior hollow space 232 therein. The air cylinder 222 additionally comprises a stem 234, a piston 236 and a spring 238. In its normal orientation, during operation, the air cylinder 222 will move the stem 234 upwards to open the nozzle and downwards to close it. the mouthpiece. The spring 238 secures the plug 228 against the openings in the nozzle frame 226 and prevents the liquid from leaving the nozzle in the event of air pressure in the filling machine being turned off (due to an emergency, maintenance, air tubing failure, etc.) . Air cylinder 222 can comprise any suitable commercially available air cylinder. The optional connecting structure 224 can comprise an element of any configuration that is suitable for connecting the air cylinder 222 to the nozzle structure 226.
[00072] The multi-nozzle assembly 200 may comprise a nozzle component 252. The nozzle component 252 comprises or the portion of the nozzle structure 226 that has passages therein; or a separate nozzle piece that has passages formed therein. One embodiment of a nozzle component 252 in the form of a separate nozzle piece is shown in Figure 23. Nozzle component 252 has a periphery 254, an inlet side 256 that has a surface and an outlet side 258 that has a surface. The nozzle component 252 has a plurality of separate passages 250 that extend through the nozzle component from the adjacent position of its inlet side 256 to its outlet side 258, so that the passages 250 form a plurality of openings 250A on the surface of the outlet side 258 of the nozzle component 252. In one embodiment, the surface of the outlet side 258 of the nozzle component 252 has a plurality of grooves 262 therein which are arranged to pass between the openings 250A on the surface of the side outlet 258 of the nozzle component. The nozzle may additionally comprise a plug 228 which can be of any suitable configuration and can be produced from any suitable material (s). In the embodiment shown in Figures 21 and 24, plug 228 is configured to have a substantially flat distal end that is large enough to simultaneously cover all of the opening (s) 250A formed by the passages on the side of nozzle frame inlet. The plug can be produced from any suitable material, such as stainless steel.
[00073] Although the discharge end of the "multi-hole" nozzle assembly and nozzle component is shown to have a circular cross section in the drawings, the discharge end of the nozzle assembly and nozzle component can have any configuration (s) ) appropriate (s). For example, when the multi-hole nozzle is used in a vertical forming, filling and sealing process, it may be desirable that the discharge end of the multi-hole nozzle has a flat shape, such as a flat diamond shape, so that it is better configured to fit in the space between the two blankets of material used to form the packages.
[00074] There can be any suitable number of nozzles 60, from a single nozzle to multiple nozzles. It is typically desirable to have two or more nozzles 60 arranged in the machine direction (DM) on each lane of sachets, as shown in Figure 3, to fill multiple packages on a single lane at the same time. This can substantially increase the filling speed in relation to a VFFS device, such as the one shown in Figure 2. As shown in Figure 4, multiple nozzles can also be supplied in the transverse direction of the machine (DT) in a device that comprises multiple lanes at DT for packaging formation. The multiple nozzles 60 can be substantially aligned, as in rows in both the DM and the DT.
[00075] Nozzles 60 can be stationary or mobile. In certain embodiments, nozzles 60 can move in relation to the receptacle. The "receptacle" comprises the article on, or in which the fluid will be dispensed. The term "no", as used herein with reference to dispensing, includes dispensing both on and in the receptacles, whichever is suitable for proper dispensing of the fluid. The receptacle may comprise any type of article including, but not limited to, cavities in the lower material mat 52, or any type of container that is filled with a fluid, including tubes and other types of containers that contain more than a single dose of product. Although the movement of the nozzles 60 is described here in relation to the dispensing of fluid in the cavities of the lower material web 52, the features of the nozzles and the filling system are applicable to any other type of receptacle.
[00076] Nozzles 60 can be moved reciprocally, for example, so that they move in the same DM direction with cavities 56 and then return to their starting position for the next dispensing cycle. In embodiments where nozzles 60 are mobile, nozzles can, but need not, be fully synchronized to move at the same speed as the lower material mat 52. For example, nozzles 60 can move at the same speed as the mat. lower material 52, or they can move more slowly than the lower material mat 52. Nozzles 60 can move at a constant speed or at a variable speed during dosing. If the speed of the nozzles is variable, the movement of the nozzles may accelerate or decelerate during dosing. For example, it may be desirable for the movement of the nozzles to slow down, so that the dose of product has a height (or profile) as low and uniform as possible. This will help to prevent the product from being dispensed or flowing into portions of the blankets that will be sealed together. If nozzles 60 are movable, nozzles 60 can dispense product 48 at any of the following times: when nozzles 60 are stationary; when the nozzles 60 are moving in the same direction and at the same speed as the lower material mat 52; when the nozzles 60 are moving in the same direction, but at a different speed from the lower material mat 52; or, when the nozzles 60 are moving in the opposite direction to that of the lower material mat 52. Using the motion and filling control system described here, the nozzles 60 can be moved in a custom motion profile during the sequence of filling to control the shape of the deposit in the receptacle.
[00077] The movable nozzle mechanism and filling system described herein can be used in the method described here, as well as in other dispensing processes. Such other dispensing processes include, but are not limited to: vertical forming, filling and sealing processes (VFFS); and filling processes for any type of container that is filled with a fluid, including those that are used to fill tubes and other types of containers that contain more than a single dose of the product. Thus, the filling system described here is not limited to filling unit dose packages of the types described here. As shown in Figure 2, if the movable nozzle mechanism is used in a vertical forming, filling and sealing (VFFS) process, the nozzles would move vertically up and down in the direction of the arrow.
[00078] It is desirable for each dose of liquid to be dispensed cleanly on or in the receptacle, such as the lower material blanket 52 and to stop the flow of liquid between doses substantially immediately. If the dispensing nozzle 60 drips or produces strips of product between doses, the seal area between doses can be contaminated, potentially causing a seal failure and a poorly sealed sachet. Dosage control is achieved through the use of a filling system or filling control system. The filling system (or dosing) with a filling control system (together with / or without the mobile nozzle mechanism) described here can also be used in other dispensing processes.
[00079] Figure 16 is a schematic illustration of a modality of a filling system. As shown in Figure 16, the filling system comprises a storage supply 168 for the liquid 48 to be deposited on or in the receptacle, such as the lower material mat 52. The liquid storage supply 168 is connected by a pipe to a tank 170 of liquid 48. Tank 170 can be pressurized, or for products with low viscosity, it does not need to be pressurized and can depend on the level of liquid to control the load pressure. In the modality shown in the drawings, it is pressurized. A regulated air pressure line 172 connects tank 170 to a main air supply 171, and also has the ability to expel excess pressure in the tank based on pressure control by air capsule 179. A line 174 for transporting liquid 48 to nozzle 60 connects tank 170 to nozzle 60. The liquid supply of tank 170 is equipped with a level 175 and pressure test equipment 176 to allow fast and accurate control and monitoring of the load pressure. A combination of a liquid level control 178 using the tank level sensor 175 and control of the inlet flow through various means (such as pumps 177, valves, or an air-powered brush), together with pressure control by air cap of tank 179 allows the charge pressure of the nozzle net to be modulated. Both the tank level control 178 and the tank air capsule pressure control can either be isolated controllers or resident in the PLC 183 as a total integrated process control system. If there are multiple nozzles, the nozzles can be connected to a pipe 180 and an individual nozzle pipe 184, which can have an identical configuration for all nozzles. If desired, an additional pressure sensor 188 can be added next to pipeline 180 to provide an additional full charge pressure monitoring point (liquid charge plus air capsule charge), which can be used to provide an air pressure adjustment. cancellation pressure to air capsule pressure control 179 or liquid level control 178 to maintain a constant full charge pressure.
[00080] The nozzle 60 can have an actuator system 181 connected to it to provide a positive, quick-response, open / close control of the liquid. The actuator system 181 can comprise any suitable device, including, but not limited to, a positive displacement pump, one or more valves, such as air-powered (pneumatic) solenoid valves 186, or electrically driven solenoid valves. The nozzle actuator system 181 can be connected to a flow measurement device (or flow feedback device) such as a flow meter 182. The flow feedback device can be a mass flow meter or a flow meter volumetric to provide an accurate and rapid capture of each sample mass or fluid volume, respectively. A programmable logic controller (PLC) 183 and associated high speed input 185 and output 187 devices (such as the input and output cards in Figures 16A and 16B) may be in communication with the pump, valve (s) and the flow meter, and can be used to allow adequate mass or volume totalizations and nozzle control of each mass or volume filling, as well as the level and pressure control by tank air capsule described above.
[00081] Input device 185 can be any device that is capable of obtaining data from flow meter 182. Input device 185 must be of a type that is capable of obtaining data more quickly from that specific type of flow meter 182. Input device 185 can therefore be selected from the group that includes, but is not limited to: a network card, an Ethernet connection, a digital counter card and an analog card. The actual flow quantity can be calculated at the PLC, or at the input device 185, or it can be calculated at the flow meter 182 itself, depending on the type of flow meter, how the input is received and any necessary pre-processing. The PLC, in this way, receives a quantity of flow feedback to compare it to the desired setpoint to generate an error and then uses this to calculate the corrective action as a new control actuation time. The high-speed output device 187 is described in more detail below.
[00082] An algorithm is associated with the PLC (as being programmed in the PLC). The algorithm receives the feedback of the measured fill quantity as an input and makes corrective adjustments. The PLC data can be used to compute adjustments at the time of filling and the precision time of the solenoid output command for valve control or a control adjustment to the total flow and flow profile of a positive displacement pump for each fill cycle. If suitable high-performance components are coupled to the structure and algorithms of a suitable control system, a filling system providing fast and highly accurate fills with a controlled deposit profile (if desired) can be achieved. Such a filling system can, if desired, be used to dispense relatively small doses of products quickly and precisely (for example, less than or equal to about 5 grams of product). In some cases, doses of product can be dispensed in less than or equal to about 100 milliseconds. In some cases, the cycle time in which doses can be dispensed, measured, calculated for control correction and any reciprocating nozzle car returned to its position, so that it is ready for the next dispensation, can be performed in less that or equal to about 300 milliseconds, alternatively less than or equal to about 200 milliseconds; or in a range of about 50 or about 100 milliseconds to about 300 milliseconds, alternatively from about 50 milliseconds to about 200 milliseconds. The dispensing can also be coupled with precision movement control of the nozzle relative to the receptacle to provide a controlled deposit profile.
[00083] Achieving accurate, high-speed filling that can be coordinated with the movement of the nozzle / receptacle requires a control system, actuators, sensors and a control system architecture and algorithm design to precisely synchronize these capabilities. It also requires a well-designed fluid resupply system for the main fluid supply tank 170, which minimizes load pressure disturbances along with a well-designed load pressure control system that can reject pressure disturbances to the system. This is done by selecting the appropriate control system components and then combining them in a way that allows the most excellent control of the interaction systems. For high-speed filling, it is desirable that all the components necessary for the control of the nozzle as well as the mass flow feedback measurement system meet certain dynamic performance requirements.
[00084] A modality of such a filling control system is shown in Figure 16A. The actuating components of the nozzle can be selected, so that the initialization time inside the PLC 183 until the nozzle itself 60 which is fully open is not more than 30 milliseconds. This is done using an output device such as a planned output device (for example, a programmatically planned digital output card) 187, which electrically controls a valve such as a pneumatic valve 186, which is located in close proximity to the nozzle 60. The planned digital output card 187 has its own processor. This provides the advantage of being able to operate without delay for waiting for a PLC signal and being able to interpolate required open / close events between PLC updates to the card. The planned output may have the ability to control digital outputs in time increments of less than 100 microseconds and, optionally, can be programmatically controlled to trigger the opening using a specific electronic motion position and remain open for the amount of time generated by the control algorithm. The control system has the ability to connect the filling of the flow meter to the profile of the customized flow format using the planned output card, together with the development and execution of the CLP 183 of the movement profiles for the nozzle in relation to to the receptacle. The flow meter component 182 and the associated digital input card 185 can have internal parameter settings to provide no more than 30 milliseconds of delay time from the actual flow start to the flow measurement detected in the CLP 183 and provide the ability to repeatable measurement within the total granted time cycle of 10% or less from heavy samples. The 10% accuracy mentioned here is the actual heavy mass as a function of the target fill mass. This must be distinguished from the variability shown in electronic measurement readings. In other words, the electronic mass measurement may show low variability, but be distant by a slope, and in the present method, this can be corrected to bring the final deposited mass within 10% of the target mass value.
[00085] In general, the version of the control system described here that uses both the high-speed flow measurement counter card 185 as well as the planned output card 187, when designed with the appropriate algorithm, is unique in the sense that it allows very tight synchronization of the fluid filling control system (ie, start or end of filling) with the movement control system (during operation of the blanket or unit in a specific position), while also allowing a control of very precise filling time (controlling the opening / closing time in fractions of a millisecond) due to the architecture, algorithm and component selection of the designed control system.
[00086] An alternative version of a filler control system is shown in Figure 16B. This alternate fill control system, which may not offer such a tight synchronization with the movement position or such precise fill control precision, uses a high speed counter entry card, which may have a high speed output capability. The control algorithm in this case typically needs to provide a trigger point for when the high speed input counter increases beyond a mass totalization limit during filling; the outlet is activated to close the fill valve. This mass totalization limit, or shutdown trigger, will be a mass value less than or equal to the final desired totalized mass due to system delays.
[00087] In short, the filling control system uses the following: input of the flow measurement system feedback; output control of when and for how long the nozzle is opened; and the algorithm provides the corrected fill time and either the start or end related to the trigger to a process variable (such as the position of the nozzle in relation to the receptacle). In the case of modalities like the one shown in Figure 16A, the planned exit card provides the ability to start or stop precisely the filling cycle at times that can occur between updates of the PLC. (The planned exit card can interpolate where the dispensing system is of the position / process type, and can trigger an open or close signal between PLC communications). The control algorithm uses flow volume or mass feedback (that is, the measurement of filling quantity feedback) to make corrective adjustments to the filling time, and generates at least one of a control signal and an actuation time. control for when the actuating system of the dispensing device should supply the fluid. The control signal can comprise an "open" or "closed" signal control, or it can comprise a signal to the planned output card, so that the planned output card can interpolate and trigger an open or close signal ( as described above). The output is determined either when the start or when the end (but typically, not both) of filling will occur. The opposite (end or start) is then adjusted by adding / subtracting the corrective fill time provided by the algorithm).
[00088] In the case of the modality shown in Figure 16B, the algorithm provides a target limit for the total corrective fill amount (meaning that it can be changed dynamically with the use of feedback / error) and sends it to a card digital input / output combined with each filling cycle. The use of an exit card planned in the modality shown in Figure 16A, however, can more accurately adjust the absolute start or end of filling, as well as a more precise adjustment of the total amount of time the nozzle is open (time filling).
[00089] As shown in the general representation of Figure 3, downstream of the dispensing zone 58, a second layer of material, such as an upper layer film 62, is placed in the process above the lower material layer 52. Although the following may describing the secondary (or higher) layer of material as a film, it is understood that the second layer of material is not limited to a film. The upper material mat may be of any specific material types of the present invention, which are suitable for use as the lower material mat. The upper material mat 62 is maintained on the bottom side of a horizontal upper forming conveyor belt (or "upper conveyor belt") 64. The upper conveyor belt 64 can be a vacuum conveyor belt.
[00090] The upper material mat 62 can be laid flat on the formed lower material mat 52 without deflection of the upper material mat 62. However, the upper conveyor belt 64 can also have a profiled surface to create grooves or recesses in the upper material mat 62. The grooves or recesses in the upper material mat 62 can be substantially the same width and depth as the recesses or cavities 56 into which the lower material mat 52 is deflected.
[00091] There are several reasons why it is desirable to deflect the upper material mat 62. Deflecting the upper material mat 62 similarly to the lower material mat 52 provides distance above the accumulated product 48 that has just been placed over the mat. lower material 52, and prevents spreading of liquid products along the blanket of lower material 52. The spreading of liquid products can lead to a variety of problems with the sachet such as wrinkles and / or leaks. Deflecting the upper material blanket 62 also creates a more symmetrical sachet. In addition, in typical sachets, the film on both sides of the sachet will have prints on it (for example, the product name and product information) that are generally surrounded by an unprinted portion that will be arranged in the area of the seal of the finished sachet. Deflecting the upper material mat 62 similarly to the lower material mat 52 allows a film of equal or substantially equal width to be used for both lower and upper material blankets, and creates the same width reduction in both films during the manufacturing process, so that the printed and unprinted portions of the film are aligned with each other. Of course, in other modalities, the film may be free of impressions. In still other embodiments, the impression can be added to the film after the package is formed.
[00092] A forming process similar to that used to form the lower material mat 52 (ie, a similar system with a static plate, moving mats, or combinations thereof) can be used to deflect the upper material mat 62. Figure 11 shows an embodiment of an upper forming element 90 for use in an apparatus that is two lanes wide, comprising lanes L1 and L2. In other words, the upper forming member 90 has (at least) two sets of cavities 96 in it. In such an embodiment the upper film 62 will be wide enough to be pulled into the upper cavities 96 in the adjacent lanes L1 and L2. The deflection step of the upper material mat 62 and the properties of the upper material mat 62 during deflection can be substantially the same, as in the case of the lower material mat 52. (For example, the upper material mat 62 can pass through elastic deformation, but be substantially free of plastic deformation).
[00093] As shown in Figure 11, the upper forming element 90 comprises a plate that has raised surfaces 108 that are situated between, as well as laterally outside, the upper recesses or cavities 96. In a non-limiting embodiment, the cavities 96 they are 30 mm wide and the raised surfaces 108 are 14 mm wide. Raised surfaces 108 have longitudinal side edges 109 that are curved to prevent breaking of the upper material mat 62. Raised surfaces 108 have vacuum channels 110 therein to hold the upper material mat 62 against raised surfaces 108. The upper plate it also has vacuum channels 112 in recesses 96. Vacuum channels 110 and 112 are connected to a vacuum pipe that is connected to a vacuum source. A moving mat 80 similar to that shown in Figure 8 or Figure 10 is located within each of the upper cavities 96, or in a recess 96A adjacent to, or within, each of the upper cavities 96. In Figure 11, the recesses 96A are formed at the base of the cavities 96. As in the case of the lower cavities, at least a portion of the bottom of the forming cavities 96 can be formed by the top surface 81 of the mats 80. (It should be understood that the portion of the upper cavities 96 in which an upper mat 62 is deflected further away will be called the "bottom" of the cavities, although the upper cavities 96 are inverted in relation to the bottom cavities 56. The same convention will be applied with respect to the mat 80 in the upper cavities 96 Thus, the "top surfaces" of the tracks in the upper cavities will correspond to the same surfaces as the top surfaces of the tracks in the lower cavities 56.) Vacuum is used to form the mat (or retain a preformed top mat in a deflected condition) and mats 80 are used to transport mat 62 along static and rigid forming plates.
[00094] As in the case of the lower forming element, there may be vacuum channels 114 leading to the top surfaces 81 of the belts 80. The belts 80 may have vacuum holes 79 in them to keep the mat 62 in contact with the surfaces of the belts. top 81 of the belts 80. In the embodiment shown in Figure 11, the vacuum holes 79 are located along each longitudinal side portion of the belts 80, although in other embodiments, the vacuum holes may be located elsewhere in the belts, as along the sides of the mat, as shown in Figure 8.
[00095] Figure 12 shows an alternative embodiment of the upper plate 90 in which the cavities 96 do not have a separate recess in the floor thereof. In a variation of this alternative embodiment, the mats (if present) are arranged outwardly from the floor of the cavities 96, but are still located inside the cavities. (Such belts would be in the space occupied by the elements designated 102.) In this embodiment, there is a gap between the sides of the cavities 96 and the lateral edges of the belts. In this embodiment, the distance between the top of the raised surfaces 108 and the top of the tracks is the depth of the top cavity. In another variation of this modality, there are no treadmills. In such a variation, the location that would otherwise be occupied by the belts may comprise a stationary plate or piece 102 that is spaced from the innermost portion of the recess to allow air to pass around the stationary plate 102.
[00096] It should be understood that the depth of the top wells 96 and the depth of the bottom wells 56 can be the same, or the depth of the top wells 96 can be less than, or greater than the depth of the bottom wells 56 For example, in modalities in which there are transverse tracks 86 forming the bottom cavities, the depth of the bottom cavities 56 can be 4 mm and the depth of the top cavity or cavities 96 can be about 3 mm, in order to the same phase placement in the transverse direction of the upper material mat 62 is due to the contour of the lower material mat 52 by the transverse rails that form the bottom cavities 56.
[00097] In modalities in which the films are primarily formed by a mechanical device, the upper material mat 62 can be retained with about 130 cm (50 inches) of water vacuum. In other modalities, films are primarily shaped by a vacuum. In later embodiments, if the apparatus is twelve lanes wide, the portions of the upper material blanket on the six central lanes can be formed with about 100 to 130 cm (40 to 50 inches) of vacuum. The portions of the upper material blanket 62 on the three outer lanes on either side of the central lanes can be formed with between about 38 to 65 cm (about 15 to 25 inches) of vacuum.
[00098] The lower material mat 52 and the upper material mat 62 are deflected into the lower cavities 48 and upper cavities 96, respectively, so that the lower material mat 52 and the upper material mat 62 have, each, a profile in the direction transverse to the machine. The blankets of lower and upper material 52 and 62 will, therefore, have a width of direction transverse to the deflected machine that is less than its undeflected width. Figure 17 shows the deflected widths Wu of the lower material mat 52 and the upper material mat 62. Figure 18 shows the deflected widths Wd of the lower material mat 52 and the upper material mat 62 in relation to their non-deflected widths. deflected WU. The width in the transverse direction to the deflected machine Wd of the lower material mat 52 can be substantially equal to that of the upper material mat 62. The term "substantially equal", as used herein in reference to the relative deflected widths Wd of the materials refers to the deflected widths that differ less than or equal to about 0.2% from each other. In some embodiments, it may be desirable that the deflected widths Wd differ by less than or equal to about 0.1% from each other. If the apparatus 50 has at least two lanes in the direction transverse to the machine, it may be desirable that the widths in the machine transverse direction deflected Wd of the lower material mat 52 and of the upper material mat 62 in each ray are substantially equal (different by less than or equal to about 0.2%). The deflected portion of the top material mat 62 and the bottom material mat 52 can be symmetrical. Alternatively, as shown in Figure 18, the deflected portions of the top material mat 62 and the bottom material mat 52 may have different configurations, provided that the deflected portions in each lane are reduced in width by substantially the same amount.
[00099] Figure 19 shows a non-limiting modality of a complete sachet formation process, with additional details in the sealing steps. As shown in Figure 19, the two blankets of material (for example, films) 52 and 62 are rolled up, so that the sealing sides of the materials are facing inward. The formation of the lower film 52 begins first. The lower film 52 can be (optionally) mechanically preformed using an apparatus as shown in Figures 5 and 6 at location P1. Vacuum is applied to the lower film 52 by the lower conveyor belt 54 to either form the lower film in the wells or to hold the preformed film in the wells. A product 48 is dispensed in the recesses, or cavities formed in the lower film 52, as from one or more nozzles 60. The upper film 62 can be (optionally) mechanically preformed with the use of an apparatus as shown in the Figures 5 and 6 at location P2. Vacuum is applied to the upper film 62 by the upper forming conveyor belt 64 to either form the upper film in the configuration of a recess or cavities, or to secure the preformed film in such a configuration. The upper film 62, in this embodiment, is formed with the same profile in the direction transversal to the machine as the lower film 52.
[000100] In this embodiment, a sealing forming device in the machine direction 120 which is used to form seals in the longitudinal or machine direction is shown adjacent to the forming conveyor belts 54 and 64. The seals in the machine direction will form the seals sides in sachets. The sealing forming device in the machine direction can be in the form of heated elements (bars) oriented in the machine direction (DM) 120 which are located between adjacent lanes and also laterally outside the first and last lanes. The heated bars 120 can be spring loaded vertically against each other to seal the two films 52 and 62 together. The sealing-forming device 120 ideally provides adequate pressure to minimize any air between the sealing layers of films 52 and 62, so that the sealing layers are in close contact. The sealing layers are heated to their melting point to heat seal them together.
[000101] After the longitudinally filled and sealed mat leaves the forming area, there may be a sealing contact line in the direction of the machine 122. The sealing contact line in the direction of the machine can be motive or non-motive. The sealing contact line in the direction of the machine 122 applies light pressure to ensure adhesion of the films in the areas of the longitudinal seals (but preferably does not apply pressure to the portions of the film in which the product 48 has been deposited). In one embodiment, the contact line 122 can be formed by a relatively soft cylinder and a support cylinder. The relatively soft cylinder can comprise a cylinder that has a surface that comprises a material with a Shore A 20 durometer. Such a cylinder can be used to press the sealed portions in the direction of the machine (or longitudinal) together better for a more uniform contact. At least one of the cylinders that form the contact line can also be cooled to cool the seals in the DM.
[000102] After the sealing contact line in the direction of the machine 122, a pair of optional opposing vacuum plates 124 can be used to keep the two film materials 52 and 62 separate in the unsealed areas, so that the doses of material 48 deposited in positions other than the lower material mat 52 remain separate.
[000103] Downstream of the filling and forming conveyor belts 54 and 64 is a device 65 for forming seals oriented in the direction transverse to the machine. This will be called the sealing device on DT 65. The sealing device on DT 65 can be any suitable device that is capable of forming seals oriented in the direction transverse to the machine between blankets 52 and 62 in the space between doses of product. A version of such a device is shown in Figure 3, which comprises a pair of upper and lower components 65A and 65B, as bars oriented in the direction transverse to the machine 65A and 65B that come together to form a seal on the single DT. The sealing device in the DT can be stationary in relation to the machine direction of the films 52 and 62, so that the bars oriented in the direction transverse to the upper and lower machine 65A and 65B only move towards each other and to away from each other. In other modalities, the bars oriented in the direction transverse to the upper and lower machine 65A and 65B move with the films 52 and 62. In the mode shown in Figure 3, the bars oriented in the transverse direction to the upper and lower machine 65A and 65B move parallel to films 52 and 62 in a reciprocal manner (in the direction of the arrows), while simultaneously placing the bars oriented in the direction transverse to the upper and lower machine 65A and 65B against the films as they move with the films.
[000104] In other embodiments, as shown in Figure 20, the sealing device on DT 65 can comprise sealing components that have other configurations. Figure 20 shows an embodiment in which the upper and lower components 65A and 65B comprise generally U-shaped elements that each comprise a pair of spaced sealing bars 65A1 and 65A2, and 65B1 and 65B2, respectively. The two sealing bars allow sealing with longer residence time versus only one sealing bar. The sealing rod unit 65 traverses back and forth (upstream and downstream) in relation to the product flow while sealing rods 65A and 65B open and close to seal films 52 and 62. Each of the sealing rods seals can be provided with a spring 67 which is located between the sealing bar and a frame 69, so that they are spring-loaded to move vertically up and down. The upper and lower components 65A and 65B of the sealing device on DT 65 shown in Figure 20 can be used to simultaneously form the seals at the top and bottom of a sachet. The sealing components 65A and 65B comprise an upstream sealing bar, such as 65A1 and 65B1, and a downstream sealing bar, such as 65A2 and 65B2.
[000105] When each sealing component 65A and 65B comprises more than one sealing bar, the sealing bars can be fixed in relation to each other, or adjustable in relation to each other. It may be desirable for at least one of the sealing bars on each sealing component to be fixed. The fixed sealing bar can comprise either the upstream sealing bar or the downstream sealing bar. In the modality shown in Figure 20, the downstream sealing bars 65A2 and 65B2 are adjustable with different configurations 1, 2, 3 and 4. Making at least one of the sealing bars adjustable allows the spacing between the seals to be adjusted to accommodate changes in packaging length. Of course, other variations of such components are possible, including those that have additional sealing bars that are capable of forming three or more seals simultaneously in the DT, such as between multiple sachets.
[000106] The vacuum applied to films 52 and 62 during packaging formation can be released at any suitable stage in the process. The vacuum can be released at any of the following times: (1) before any of the seals are formed (in which case the residual vacuum that remains in the lower material mat 52 after the initial vacuum application to deflect the mat lower material can continue to hold the lower material mat 52 in place); (2) after the formation of the seals in the direction of the machine; (3) after the formation of one of the seals on the DT in a given package; or, (4) after the formation of all seals in a given package. Typically, the vacuum will be released after the formation of the seals in the machine direction in order to facilitate the formation of the seals in the DT. When the vacuum is released, the deflected portions of the first material mat (and the second material mat, if deflected) return towards their original undeflected configurations. Deflected portions can either return completely to their undeflected configuration, or just part of the way to their undeflected configuration (the term "towards" is intended to include both). Typically, the deflected portions have returned only part of the way to their non-deflected configuration due to the presence of the product 48 between the blankets of material comprising the packaging.
[000107] Downstream of the transverse sealing device 65 is an apparatus 126 for forming cracks in the machine direction, and an apparatus 128 for drilling / cutting in the direction transverse to the machine. Slitting in the machine direction can be done by any suitable mechanism 126, including, but not limited to, a compression cutter against an anvil or a shear slitting device. The blanket of unit dose packs can be split between each lane or otherwise, as desired. The cracks can be continuous or they can be intermittent perforations. The drilling process in the direction transverse to the machine can be designed and operated to cut between specific rows to create mats (product matrices). In the modality shown in Figure 19, mechanical tools are used for both the slit cutter in the machine direction 126 and the slit cutter in the machine transverse direction 128. However, laser cut slits in the machine direction or in the transversal direction to the machine it can be used.
[000108] Numerous alternative modalities of the apparatus 50 are possible. For example, in other embodiments, the entire system could comprise moving belts such as those shown in Figures 8 or 10 and side rails 82 can be eliminated and replaced with corresponding raised surfaces on a wider movable mat. In these or other alternative modalities, instead of having vacuum doors in the gaps between the conveyor 80 and the side rails 82, the conveyor 80 can have vacuum doors in the center of the pockets 56. In still other modalities, the conveyor system it can be replaced by a chain system that connects different molds that have cavities formed in them. However, the manufacture of individual molds for such a system is more expensive than the mobile conveyor system described here. In addition, if it is desirable to change the system in order to create sachets of different sizes, the mobile belt system is more easily changed. More specifically, a printing roll system combines the forming and steering functionality in one component, where the belt / plate system described here decouples the formation of the means of transporting the mat. This provides flexibility to change the properties of the mat that moves the mat separately from the shape of the pocket forming tool. The range of possible operating conditions is wider when the formation and transport of the mat is decoupled as described here. It is also a more economical way to achieve the same purpose, in addition to being easier for maintenance. Tolerances can be easily adjusted on the training tool and maintained precisely with little maintenance, as these are not moving parts. The only part that wears out is the mats, which are stock items.
[000109] As discussed above, the filling system and the filling control system can be applied to alternative types of filling processes. This can be used to provide accurate dispensing and short cycle times, as well as to coordinate filling with the movement of the receptacles to be filled. The movable nozzles and sealing mechanisms described here can also be applied to alternative types of filling processes. For example, the filling system and the filling control system can be used in a VFFS modality like the one shown in Figure 2.
[000110] A vertical forming, filling and sealing device (VFFS) 30 like the one shown in Figure 2 can have stationary nozzles 36 and stationary sealing bars 40 and 42 while the machine is working. However, nozzles 36 may need to be able to move up and down in case it is desirable to change the length of the sachet. This is a configuration change that can be made when the machine is not working. In one embodiment, the sealing bars on the DM 40 can be fixed on one side of the blankets, with the surface of the sealing bars on the DM fixed in a plane that is aligned with the center line of the nozzle 36. The opposite sealing bars on the DM 40 can be spring loaded against the sealing bars fixed with films 32 and 34 between them. The nozzles 36 can, for example, remain fixed at a nominal of 20 to 90 mm above the initial contact point of the sealing bar on DT 42, depending on the length of the sachet and the filling volumes.
[000111] When more process adjustment is needed, the sealing bars on the DM 40, the nozzles 36, or both could move up and down together with the downward movement of the blankets 32 and 34. The sealing bars on the DM 40 they could move up and down in a straight way. Alternatively, the sealing bars on the DM 40 could move in a semi-elliptical motion, separating about 1 mm, just enough to lose contact with the films 32 and 34. The bars 40 could then come into contact with the film , move downward to a distance, such as about 5 to about 50 percent of the length of the sachet, with their movement equal to the speed of the film and then retracted and returned to the initial contact position. It is desirable that the movement and length of the sealing bars are designed to ensure that there is a seal in the contiguous DM between what will be successive sachets before cutting the blankets into individual sachets.
[000112] Additionally, the nozzles 36 can be moved, so that the tip of the nozzle 38 always remains at a fixed distance from the filling target. For example, if the bottom of the sachet is located 25 mm below the tip 38 of the nozzle 36 when filling begins, the nozzle 36 could be retracted upwards with the filling processes such as to maintain spacing of at least 25 mm from the tip 38 from the nozzle 36 to the top of the fluid section. The nozzle 36 could then be retracted faster at the end of the fill to allow the sealer on the DT 42 to close. Another alternative for the movement of the nozzle would be to have nozzles 36 spaced as far away from the sealing bar as possible in the DT 42 when the sealing is first made to reduce deformation in the sachet. The tip 38 of the nozzle 36 could then lower down to the sachet once the sealing process in the DT was initiated to progress through the bottom to top filling sequence described above.
[000113] The dimensions and values presented in the present invention should not be understood as being strictly limited to the exact numerical values mentioned. Instead, unless otherwise specified, each of these dimensions is intended to mean both the mentioned value and a range of functionally equivalent values around that value. For example, a dimension displayed as "40 mm" is intended to mean "about 40 mm".
[000114] It should be understood that each maximum numerical limit mentioned in this specification includes each of the lower numerical limits, as if such lower numerical limits were expressly registered in this document. Each minimum numerical limit mentioned in this specification includes each of the upper numerical limits, as if such upper numerical limits were expressly registered in this document. Each numerical range mentioned in this specification includes each more restricted number range that falls within that broader number range, as if such more restricted number ranges were expressly recorded in this document.
[000115] Each of the documents cited in the present invention, including any cross-reference, related patent or patent application, is hereby incorporated in its entirety, by way of reference, unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art in relation to any invention presented or claimed in this document, or that it, alone or in any combination with any other reference or references, teaches, suggest or present any invention like that. In addition, if there is a conflict between any meaning or definition of a term mentioned in this document and any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document will take precedence.
[000116] Although specific embodiments of the present invention have been illustrated and described, it should be obvious to those skilled in the art that various other changes and modifications can be made without departing from the character and scope of the invention. Therefore, it is intended to cover in the appended claims all such changes and modifications that fall within the scope of the present invention.

权利要求:
Claims (3)
[0001]
1. Apparatus (50) for forming a package, said apparatus being characterized by the fact that it comprises: a first feeding zone for receiving a supply of a first layer of material (52); and an element having a cavity (56) therein, said element being located downstream of said first feeding zone, a portion of a first mat of material (52) being temporarily deflected into said cavity (56), said cavity being in the configuration of a continuous recess oriented towards the machine comprising a base (68) and a pair of side walls (66), said element comprising a movable mat (80) having a surface ( 81), said belt (80) moving in one direction of the machine, the surface (81) of the belt (80) forming a base (68) of said cavity (56), said element additionally comprising edge portions longitudinal side (82) forming the side walls (66) of said cavity (56); a dispensing device (60) for applying a product (48) on said portion of said first material mat (52) which is temporarily deflected into said cavity (56), said dispensing device (60) located in a dispensing zone (58) above the element having a cavity (56) therein; a second feeding zone for receiving a supply of a second layer of material (62), said second feeding zone being located downstream of said dispensing device (60), a second layer of material (62) being able to be arranged to cover said first material mat (52) with said product (48) therein; and a sealing device for sealing a first and second blankets of material together with a product between them, said sealing device (65) being located downstream of said second feeding zone; wherein the portion of said first layer of material that is deflected into said cavity has a plastic deformation of less than 0.2%.
[0002]
2. Apparatus (50) according to claim 1, characterized by the fact that the conveyor (80) is in the form of a closed circuit.
[0003]
Apparatus (50) according to claim 1, characterized by the fact that it comprises a mechanism that deflects said first mat (52) to said cavity (56), exerting vacuum or air pressure on said first mat.

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EP2819923B1|2018-04-18|

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JP6411219B2|2018-10-24|

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WO2013130453A4|2013-11-14|

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ES2674970T3|2018-07-05|

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MX2014010072A|2014-10-13|

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EP2819923A1|2015-01-07|

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法律状态:
2018-12-04| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-10-15| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-07-28| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|

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2020-12-01| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-02-09| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 26/02/2013, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US201261604072P| true| 2012-02-28|2012-02-28|

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US61/604,072|2012-02-28|

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PCT/US2013/027774|WO2013130453A1|2012-02-28|2013-02-26|Apparatus for forming packages and filling system|

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