METHOD OF HANDLING LIQUID TO PREVENT MACHINE CONTAMINATION
DURING FILLING
CROSS-REFERENCE TO RELATED APPLICATIONS
[OOOI] This application claims priority to U.S. Utility Application No.
131230,164, filed on September 12, 201 1, and the benefit of U.S. Provisional
Application No. 61 1382,138, filed on September 13, 201 0. The entire disclosures
10 of the above applications are incorporated herein by reference.
Fl ELD
[0002] This disclosure generally relates to molds for filling containers
with a commodity, such as a liquid commodity. More specifically, this disclosure
15 relates to molds for filling blown polyethylene terephthalate (PET) containers and
methods of using the same to minimize machine contaminations during filling.
BACKGROUND
[0003] This section provides background information related to the
20 present disclosure which is not necessarily prior art.
[0004] As a result of environmental and other concerns, plastic
containers, more specifically polyester and even more specifically polyethylene
terephthalate (PET) containers are now being used more than ever to package
numerous commodities previously supplied in glass containers. Manufacturers
25 and fillers, as well as consumers, have recognized that PET containers are
lightweight, inexpensive, recyclable and manufacturable in large quantities.
[0005] Blow-molded plastic containers have become commonplace in
packaging numerous commodities. PET is a crystallizable polymer, meaning
that it is available in an amorphous form or a semi-crystalline form. The ability of
30 a PET container to maintain its material integrity relates to the percentage of the
PET container in crystalline form, also known as the "crystallinity" of the PET
container. The following equation defines the percentage of crystallinity as a
volume fraction:
% Crystallinity = ( -Pa )x100
Pc -Pa
where p is the density of the PET material; pa is the density of pure amorphous
5 PET material (1.333 glcc); and p, is the density of pure crystalline material
(1.455 glcc).
[0006] Container manufacturers use mechanical processing and
thermal processing to increase the PET polymer crystallinity of a container.
Mechanical processing involves orienting the amorphous material to achieve
10 strain hardening. This processing commonly involves stretching an injection
molded PET preform along a longitudinal axis and expanding the PET preform
along a transverse or radial axis to form a PET container. The combination
promotes what manufacturers define as biaxial orientation of the molecular
structure in the container. Manufacturers of PET containers currently use
15 mechanical processing to produce PET containers having approximately 20%
crystallinity in the container's sidewall.
[0007] Thermal processing involves heating the material (either
amorphous or semi-crystalline) to promote crystal growth. On amorphous
material, thermal processing of PET material results in a spherulitic morphology
20 that interferes with the transmission of light. In other words, the resulting
crystalline material is opaque, and thus, generally undesirable. Used after
mechanical processing, however, thermal processing results in higher
crystallinity and excellent clarity for those portions of the container having biaxial
molecular orientation. The thermal processing of an oriented PET container,
25 which is known as heat setting, typically includes blow molding a PET preform
against a mold heated to a temperature of approximately 250°F - 350°F
(approximately 121 "C - 177"C), and holding the blown container against the
heated mold for approximately two (2) to five (5) seconds. Manufacturers of PET
juice bottles, which must be hot-filled at approximately 185°F (85"C), currently
use heat setting to produce PET bottles having an overall crystallinity in the
range of approximately 25% -35%.
SUMMARY
5 [0008] This section provides a general summary of the disclosure, and
is not a comprehensive disclosure of its full scope or all of its features.
[0009] According to the principles of the present disclosure, a mold
device for injecting a fluid into a container is provided. The mold device comprises
a first mold portion having a first mating surface and a second mold portion having
10 a second mating surface. The second mating surface is shaped complementary to
the first mating surface to defining a sealing engagement therebetween and a mold
cavity disposed within the first mold portion and the second mold portion. The
mold device further comprises an interlocking mating surface system disposed
between or made a part of the first mold portion and second mold portion to define
15 a fluid seal therebetween and align the first mold portion to the second mold portion
in at least a first direction.
[OOIO] Further areas of applicability will become apparent from the
description provided herein. The description and specific examples in this
summary are intended for purposes of illustration only and are not intended to
20 limit the scope of the present disclosure.
DRAWINGS
[OOII] The drawings described herein are for illustrative purposes only
of selected embodiments and not all possible implementations, and are not
25 intended to limit the scope of the present disclosure.
[0012] FIG. 1 is a top view of a conventional mold device for the
manufacturing and/or filling of a plastic container;
[0013] FIG. 2 is a top view of a mold device for the manufacturing
and/or filling of a plastic container according to the principles of the present
30 teachings;
[0014] FIG. 3A is a partial cross-sectional view illustrating a mating
surface and interlocking mating surface according to some embodiments of the
present teachings;
[0015] FIG. 3B is a partial cross-sectional view illustrating a mating
5 surface and interlocking mating surface according to some embodiments of the
present teachings;
[0016] FIG. 4 is a partial cross-sectional view illustrating a mating
surface and interlocking mating surface, together with additional channels,
according to some embodiments of the present teachings;
10 [0017] FIG. 5 is a side view of a mold device for the manufacturing
and/or filling of a plastic container according to the principles of the present
teachings;
[0018] FIG. 6 is a side view, with portions in phantom, of a filling
nozzle and mold device according to the principles of the present teachings; and
15 [0019] FIG. 7 is a schematic view of a manufacturing system according
to the present teachings.
[0020] Corresponding reference numerals indicate corresponding parts
throughout the several views of the drawings.
DETAILED DESCRIPTION
[0021] Example embodiments will now be described more fully with
reference to the accompanying drawings. Example embodiments are provided
so that this disclosure will be thorough, and will fully convey the scope to those
who are skilled in the art. Numerous specific details are set forth such as
25 examples of specific components, devices, and methods, to provide a thorough
understanding of embodiments of the present disclosure. It will be apparent to
those skilled in the art that specific details need not be employed, that example
embodiments may be embodied in many different forms and that neither should
be construed to limit the scope of the disclosure.
30 [0022] The terminology used herein is for the purpose of describing
particular example embodiments only and is not intended to be limiting. As used
herein, the singular forms "a", "an" and "the" may be intended to include the
plural forms as well, unless the context clearly indicates otherwise. The terms
"comprises," "comprising," "including," and "having," are inclusive and therefore
specify the presence of stated features, integers, steps, operations, elements,
and/or components, but do not preclude the presence or addition of one or more
5 other features, integers, steps, operations, elements, components, and/or groups
thereof. The method steps, processes, and operations described herein are not
to be construed as necessarily requiring their performance in the particular order
discussed or illustrated, unless specifically identified as an order of performance.
It is also to be understood that additional or alternative steps may be employed.
10 [0023] When an element or layer is referred to as being "on", "engaged
to", "connected to" or "coupled to" another element or layer, it may be directly on,
engaged, connected or coupled to the other element or layer, or intervening
elements or layers may be present. In contrast, when an element is referred to
as being "directly on," "directly engaged to", "directly connected to" or "directly
15 coupled to" another element or layer, there may be no intervening elements or
layers present. Other words used to describe the relationship between elements
should be interpreted in a like fashion (e.g., "between" versus "directly between,"
"adjacent" versus "directly adjacent," etc.). As used herein, the term "and/or"
includes any and all combinations of one or more of the associated listed items.
20 [0024] Although the terms first, second, third, etc. may be used herein
to describe various elements, components, regions, layers and/or sections,
these elements, components, regions, layers and/or sections should not be
limited by these terms. These terms may be only used to distinguish one
element, component, region, layer or section from another region, layer or
25 section. Terms such as "first," "second," and other numerical terms when used
herein do not imply a sequence or order unless clearly indicated by the context.
Thus, a first element, component, region, layer or section discussed below could
be termed a second element, component, region, layer or section without
departing from the teachings of the example embodiments.
30 [0025] Spatially relative terms, such as "inner," "outer," "beneath",
"below", "lower", "above", "upper" and the like, may be used herein for ease of
description to describe one element or feature's relationship to another
element(s) or feature(s) as illustrated in the figures. Spatially relative terms may
be intended to encompass different orientations of the device in use or operation
in addition to the orientation depicted in the figures. For example, if the device in
the figures is turned over, elements described as "below" or "beneath" other
5 elements or features would then be oriented "above" the other elements or
features. Thus, the example term "below" can encompass both an orientation of
above and below. The device may be otherwise oriented (rotated 90 degrees or
at other orientations) and the spatially relative descriptors used herein
interpreted accordingly.
10 [0026] The present teachings provide for a mold device and method of
using the same for filling and/or manufacturing containers. The mold design of
the present teachings, unlike conventional molds, provides increased fluid (i.e.
water, liquid commodity, air, etc.) containment in the event of container failure,
rupture, runoff, washdown, and/or spillage.
15 [0027] As will be discussed in greater detail herein, the shape of the
mold of the present teachings can be formed according to any one of a number
of variations. By way of non-limiting example, the mold of the present disclosure
can be configured to hold any one or more of a plurality of containers and be
used in connection with a number of fluids and commodities, such as beverages,
20 food, hot-fill type materials, cold fill materials, aseptic, carbonated, or just air.
[0028] It should be appreciated that the size and the exact shape of
the mold are dependent on the size of the container and the required operational
parameters. Therefore, it should be recognized that variations can exist in the
presently described designs. According to some embodiments, it should also be
25 recognized that the mold can comprise various features for use with containers
having vacuum absorbing features or regions, such as panels, ribs, slots,
depressions, and the like, and various pressure devices.
[0029] As illustrated in the several figures, the present teachings
provide an improved mold design, and method of using the same, that minimizes
30 contamination caused within the mold or other manufacturing/filling machine in
the event water, sterilization fluid, and/or product fill sprays out of or otherwise
leaks during a container filling process.
[0030] As illustrated in FIG. 1, conventional mold designs 100
comprise a pair of mold halves or mold portions 102, 104 that are movably
spaced from one another. Each of the mold halves 102, 104 can comprise an
internal mold contour (not shown) for holding, conforming, or otherwise following
5 a shape of the container to be formed or filled. Mold halves 102, 104 can be
positioned together such that a parting line 106 is formed extending along the
mating face or surface between mold halves 102, 104. Traditionally, this parting
line 106 is a flat, and generally uniform, planar mating surface or seam. The
parting line 106 can include, however, an orifice or aperture for permitting the
10 water or product fill to be introduced or injected into the container (not shown).
[0031] However, it has been found that in operation, conventional mold
designs 100 suffer from the disadvantage of becoming contaminated in the event
of blowout or leaking during the filling process. This can occur due to failure of
the container, the filling connection, or one of a number of other critical factors.
15 When a blowout or leak occurs, water or product can fill at least a portion of the
mold and other surrounding machinery. In many applications, where sanitation
is desired and/or required, this can lead to substantial downtime as the
equipment must be torn down and cleaned. Such downtime can lead to reduced
production and increased delays.
20 [0032] According to the principles of the present teachings, as
illustrated in FIG. 2, a mold design is provided that can comprise an interlocking
mating surface. That is, mold device 10 can comprise a pair of mold halves 12,
14 (or additional mold portions) that are movably spaced from one another.
Each of the mold halves 12, 14 can comprise an internal mold contour (not
25 shown) for holding, conforming, or otherwise following a shape of the container
to be formed or filled. Mold halves 12, 14 can be positioned together such that a
parting line 16 is formed extending along the mating face or surface between
mold halves 12, 14. The parting line 16 can include an orifice or aperture 18 for
permitting the water or product fill to be introduced or injected into the container
30 (not shown).
[0033] As seen in FIG. 2, parting line 16 can comprise an interlocking
mating surface system 20 for aligning mold half 12 with mold half 14 in at least a
first direction. However, in some embodiments, interlocking mating surface
system 20 can align mold halves 12, 14 in at least two dimensions and/or
directions. Interlocking mating surface system 20 can comprises a first feature
22 disposed on first mold half 12 and a second feature 24 disposed on second
5 mold half 14. First feature 22 is configured to matingly engage second feature
24 to at least define a mated connection 26 therebetween. This mated
connection 26 can serve to define a seal engagement between first mold half 12
and second mold half 14 to in turn define a sealed internal volume 28 within
mold device 10. Sealed internal volume 28 can be used to collect and/or contain
10 water or product during a filling operation. In this way, the machinery as a whole
can remain uncontaminated, while the internal volume 28 of mold device 10 can
be evacuated, drained, or otherwise cleansed.
[0034] In some embodiments, as illustrated in FIGS. 3A and 3B,
interlocking mating surface system 20 can comprise a pair of cooperating
15 features wherein a first protrusion 32 formed on one mold half is received within
a complementary sized depression 34 formed on the other mold half. In some
embodiments, as illustrated in FIG. 3A, the first protrusion 30 can be triangularlyshaped
and the depression 34 can be a similarly-sized triangular shape. It
should be appreciated that additional protrusions and complementary sized
20 depressions can be formed along parting line 16. In some embodiments, such
as illustrated, the protrusion and depression combinations can be in mirror
relationship about parting line 16 to ensure a proper mating connection.
[0035] It should be understood that alternative shapes can be used to
form the interlocking mating surface system 20, such as offset, generally
25 rectangular sections, as illustrated in FIG. 3B. However, it should be
appreciated that additional, non-illustrated, shapes can be used, such as arcuate
and any other complementary shape that ensures a proper mating connection. It
should also be appreciated that additional members, such as O-rings, can be
used to facilitate this mating connection. It should be recognized that other
30 sealing members can be used, such as NSF or other governing body approved
material members or food grade sealing material members. Moreover, it should
be recognized that any sealing member need not define a hermetic seal in all
embodiments.
[0036] With reference to FIG. 4, in some embodiments, mold device 10
can comprise a channel or other relief passage 40 extending along the mating
5 surface system 20 to permit water, solution, or product to be collected and, in
some embodiments, drained to a central containment area. In some
embodiments, mold device 10 can comprise a series or plurality of channel or
passages 40 that can be used to collect andlor evacuate air, water, solution,
andlor product either separately or in a multi-stage configuration. That is, in
10 some embodiments, a first channel 40A can be used to permit air to be
evacuated during an initial closing of the mold and filling of the container. This
air can be routed as necessary. In some embodiments, first channel 40A can be
positioned inboard of interlocking mating surface system 20 proximal to the mold
cavity. A second channel 40B can be used as a second stage for collecting any
15 air, water, solution, or product that has flown past first channel 40A, interlocking
mating surface system 20, and into second channel 40B. In this way, in some
embodiments, second channel 40B can be positioned outboard of interlocking
mating surface system 20 distal to the mold cavity. It should be appreciated that
passagelchannel 40, 40A, and 40B can having any one of a number of cross-
20 sectional shapes.
[0037] It should be recognized that passagelchannel 40 (40A and 40B)
can have any one or a number of different profile shapes and contours. For
instance, passagelchannel 40 can generally define a profile that is ready
machined to facilitate automated fabrication thereof. To this end,
25 passagelchannel 40 can define a generally smooth profile, such as a U-shaped
or C-shaped profile. Passagelchannel 40 can be sized to define an area andlor
volume of about 5% to 50% (or greater) of the mold cavity area or volume,
respectively. In some embodiments, it has been found that passagelchannel 40
can define an area or volume of about 20% relative to the area or volume of the
30 mold cavity.
[0038] With reference to FIG. 5, in some embodiments, mold device 10
can comprise a collection system 50 for draining or otherwise fluidly
communicating fluid from in and around passage 40, 40A, 40B to a central
location, such as a drain channel or other conduit 54, via a drainage line 52. It
should be understood that drain channel or conduit 54 can include other
structure or components (i.e. pumps, basin, trough, etc.) for evacuating fluid
5 collected therein. In some embodiments, drain channel or other conduit 54 can
be used to collect fluid or other liquid draining from the mold to prevent
contamination of the machine during operation. In some embodiments, drain
channel or other conduit 54 can be used to collect fluid used to spray down,
wash down, or otherwise sterilize/sanitize the container being formed and/or
10 mold device components. This sterilization/sanitation process can be completed
during the molding process or during part of other processing steps. In some
embodiments, a sensor 56 can be used to detect a leak or presence or absence
of fluid. In this way, sensor 56 can be used to stop a processing step, alert a
professional of a potential problem, and/or provide a useful feedback of a
15 processing condition. It should be understood that any one of a number of
sensors and sensor types can be used, such as optical, electrical, mechanical,
and the like. In some embodiments a sensor could be used in the pressure
profile of the fill cylinder. In this regard, if pressure loss is detected, the mold can
be opened and the preform and/or defective container can be discarded, the
20 mold can be cleaned, sprayed (steam, hot water, air, etc.), or otherwise reset for
further use.
[0039] With particular reference to FIG. 7, in some embodiments,
cleaning, washing, sterilizing or otherwise addressing any detected spill or
collection of fluid can be localized to a region along the manufacturing line that is
25 particularly suited for such cleaning and recovery. That is, in some
embodiments, the container of the present teachings can be manufactured using
a rotary-style system wherein mold cavities sweep along a circular path as they
are both formed and filled, simultaneously, with liquid commodity. If a leak or
spill is experienced, collection system 50 can contain the spill and prevent
30 overall contamination of the manufacturing system. In this way, cleaning,
washing, sterilizing or otherwise addressing the spill can be handled at a location
along the manufacturing line that is equipped to seamlessly and effectively
complete the task. As illustrated in FIG. 7, this clean-up zone 100 can be
positioned, in some embodiments, at a region located between about 25" and
295O, wherein 0° denotes the start and finish of the rotary-style system where,
generally, unformed preforms are inserted into the open mold cavity and
5 completed and filled containers are removed from the mold cavity. By employing
the containment system of the present teachings, cleaning, washing, sterilizing,
and the like can be located in a centralized location and thus benefits from
improved componentry and implementation.
[0040] With reference to FIG. 6, in some embodiments, mold device 10
10 can comprise a blow nozzle mating surface 60 generally surrounding aperture
18. In some embodiments, blow nozzle mating surface 60 can comprise a
depression 62 for receiving a tip 64 of the blow nozzle 66 for a secure and
positively positioned connection. This provides a positive connection to maintain
a reliable fluid seal between nozzle 66 and mold device 10 during filling of the
15 container. It should be appreciated, however, that other selectively interlocking
connections can be used. In some embodiments, a drainage line 68 can be
fluidly coupled to depression 62 or other portion of blow nozzle mating surface
60 (or annular ring or depression) to collect fluid and transfer the fluid via
drainage line 68 to channel or conduit 54. In some embodiments, a channel or
20 conduit that is separate from channel or conduit 54 can be used.
[0041] The foregoing description of the embodiments has been
provided for purposes of illustration and description. It is not intended to be
exhaustive or to limit the invention. Individual elements or features of a
particular embodiment are generally not limited to that particular embodiment,
25 but, where applicable, are interchangeable and can be used in a selected
embodiment, even if not specifically shown or described. The same may also be
varied in many ways. Such variations are not to be regarded as a departure from
the invention, and all such modifications are intended to be included within the
scope of the invention.
CLAIMS
What is claimed is:
1. A mold device for injecting a fluid into a container, said mold device
5 comprising:
a first mold portion having a first mating surface;
a second mold portion being movable relative to said first mold portion and
having a second mating surface, said second mating surface being shaped
complementary to said first mating surface for engagement therewith;
10 a mold cavity disposed within said first mold portion and said second mold
portion; and
an interlocking mating surface system disposed between or made a part of
said first mold portion and second mold portion to align said first mold portion with
said second mold portion in at least a first direction.
15
2. The mold device according to Claim 1 wherein said interlocking
mating surface system is disposed at least a part of said first mating surface and
said second mating surface.
20 3. The mold device according to Claim 1 wherein said interlocking
mating surface system aligns said first mold portion with said second mold portion
in at least said first direction and a second direction, said second direction being
different from said first direction.
4. The mold device according to Claim 1 wherein said interlocking
mating surface comprises a first feature extending from said first mold portion and
a corresponding second feature complementary to said first feature formed in said
second mold portion, said first feature being sized to closely conform to said
second feature to align said first mold portion and said second mold portion in at
30 least said first direction.
5. The mold device according to Claim 4 wherein said first feature is a
protrusion and said second feature is a depression.
6. The mold device according to Claim 4 wherein said first feature is a
5 triangular protrusion and said second feature is a triangular depression.
7. The mold device according to Claim 4 wherein said first feature is a
rectangular protrusion and said second feature is a rectangular depression.
10 8. The mold device according to Claim 4 wherein said first feature
matingly engages said second feature to define a mated connection.
9. The mold device according to Claim 8 wherein said mated
connection defines a fluid seal engagement.
15
10. The mold device according to Claim 9 wherein said fluid seal
engagement extends about at least a portion of said first mold portion and said
second mold portion to define a sealed internal volume for collecting a fluid.
20 11. The mold device according to Claim 1 wherein said interlocking
mating surface comprises a first feature extending from said first mold portion and
a corresponding second feature complementary to said first feature formed in said
second mold portion for mating engagement therewith, said interlocking mating
surface further comprising a third feature extending from at least one of said first
25 mold portion and said second mold portion and a corresponding fourth feature
complementary to said third feature formed in the other of said first mold portion
and said second mold portion for mating engagement therewith.
12. The mold device according to Claim 11 wherein said first feature and
30 said second feature are in mirrored relationship with said third feature and said
fourth feature.
13. The mold device according to Claim 1 wherein said interlocking
mating surface comprises an O-ring member for enhanced sealing engagement.
14. The mold device according to Claim 1 wherein said first mating
5 surface and said second mating surface define a sealing engagement
therebetween.
15. The mold device according to Claim 1, further comprising:
a first channel extending along said first mating surface and said second
10 mating surface, said first channel collecting and fluidly communicating a fluid from
said mold cavity to a predetermined location.
16. The mold device according to Claim 1, further comprising:
a first channel extending adjacent said mold cavity; and
a second channel outboard of said first channel.
17. The mold device according to Claim 16 wherein said second channel
is disposed outboard of said interlocking mating surface system.
18. The mold device according to Claim 1, further comprising:
a collection channel fluidly coupled to at least one of said first mold
portion and said second mold portion to collect fluid.

19. A moid device for injecting a fluid into a container, said mold device comprising:
a first portion having a first mating surface;
a second mold portion being movable relative to said first mold portion and having a second mating surface being shaped complementary to said first mating surface engagement therewith;
a mold cavity disposed within said first mold portion and said second mold portion; and
an interlocking mating surface system disclosed between said first mold portion and said second mold portion.

20. The mold device according to Claim 19 wherein said interlocking mating surface comprise a first feature extending from said first mold portion and a corresponding second featur complementary to said first feature formed in said second mold portion.