WO1998005585A1

WO1998005585A1 - Flexible nozzle for reducing the mixing of product and air

Info

Publication number: WO1998005585A1
Application number: PCT/US1997/013249
Authority: WO
Inventors: Peter Giacomelli; Robert Muns; Anders Andren; Yutaka Kaneko; Bengt Andersson; Par Svensson
Original assignee: Tetra Laval Holdings & Finance S.A.
Priority date: 1996-08-01
Filing date: 1997-07-29
Publication date: 1998-02-12
Also published as: JPH1059301A; AU3897297A

Abstract

A filling system (10) of a packaging machine for reducing the mixing of product and air during the filling of a container with flowable material. The fill pipe (40) of the system (10) may have an elliptical cross section (306) reducing the velocity of material entering the container while allowing for increased production time. The system (10) includes a fill pump (75) and nozzle (80) having a collar (225), plurality of lugs (120, 230) and flexible flaps (130, 270) conformed to engage with the sidewalls of a container to thereby inhibit the mixing of product and air. The fill pipe (40) has an elongate body, an inlet end (300) and an outlet end (302). The inlet end (300) is in flow communication with the fill pump (750) and may have a circular cross section. The outlet end (302) is in flow communication with the nozzle (80) and may have an elliptical cross section. The cross section of the elongate body gradually transforms from a circular cross section at the inlet end (300) to an elliptical cross section at the outlet end (302).

Description

TITLE

FLEXIBLE NOZZLE FOR REDUCING THE MIXING OF PRODUCT AND AIR

TECHNICAL FIELD

The present invention relates to a method and apparatus for filling cont^ers, .and more particularly, to a filling system including a fill pipe with an elliptical cross-section.

BACKGROUND ART

Packaging machines are known that integrate the various components necessary to fill and seal a container into a single machine unit. This packaging process, generally stated, includes feeding cartons blanks into the m.achine, sealing the bottom of the cartons, filling the .cartons with the desired contents, se ing the tops of the cartons, and then off loading the filled cartons for shipping. Trends within the field of packaging machines point toward increasingly high capacity machines intended for rapid, continuous filling and sealing of a very l.arge number of identical or similar packaging containers, e.g., containers of the type intended for liquid contents such as milk, juice, .and the like. One such machine is disclosed in U.S. Patent No. 5,488,812, issued February 6, 1996, and entitled "Packaging Machine." The machine disclosed in the '812 patent includes a plurality of processing stations, each .station implementing one or more processes to form, fill .and seal the containers. Each of the processing stations is driven by one or more servomotors that drive the various components of each of the processing stations. Other such machines include the TR-6™ and the TR-8™ packaging machines available from Terra Rex Packaging Systems, Incorporated of Buffalo Grove, Illinois. The increased throughput and decreased size requirements of packages on their packaging machines have increased the dem-ands that are placed on the fill systems that are employed. Various apparatus and corresponding methods for filling containers, such as gable-top containers, have therefor been devised for these machines. In accordance with one of the ^"more popular filling methods, the container is lifted from a conveyor to a fill pipe by means of a lifting mechanism. The container lifting mechanism gradu ly lowers the container as product is dispensed through the fill tube. The container then again engages the conveyor where it is tr.ansported to a top sealing station. Alternatively, the filling and top sealing operations may be performed at a single location within the machine. In such instances, the container may be top sealed after it has been lowered from the fill pipe. Such a method and apparatus are shown and described in the foregoing '812 patent, and, further, in U.S.S.N. 08/315,414, filed September 28, 1994, and entitled "Control System For A Packaging Machine."

One problem encountered when attempting to increase the speed with which a container is filled with product relates to the foaming and turbulence that occurs as a result of air and product mixing in the container. Generally stated, foaming increases as the speed with which the container is filled increases. When fosuning is excessive, the product splashes into the Mailing areas of the container resulting in improper seeing in subsequent sealing operation and/or contamination of the sealing area resulting in a reduction in the hygiene of the seal than would otherwise be obtained. The rate at which the container may be filled is thus limited by the foaming that occurs for a given fill rate. This problem is exacerbated with containers having a rectangular cross-section. A reduction in the velocity of the flowable material flowing through a fill pipe with a circular cross-section would lead to a reduction in the number of units produced per hour which is not a viable solution to the problem. DISCLOSURE OF THE INVENTION

One aspect of the present invention is a fill pipe for utilization in conjunction with a packaging machine for filling containers that have sidewalls defining a cross-sectional area. The packaging machine has a fill pump for pumping a flowable material such as milk. The fill pipe includes an elongate body, .an inlet end and an outlet end. The elongate body has an interior passageway with possibly a portion of the interior passageway having an elliptical cross-section. The inlet end provides for flow communication between the fill pump and the interior passageway. The outlet end is in flow communication with interior passageway and provides for dispensing of the flowable material from the fill pipe. The outlet end may have an elliptical cross-section.

The fill pipe may further includes a nozzle connected to the outlet end of the fill pipe. The nozzle includes a collar and a plurality of flaps. The collar connects the nozzle to the outlet end of the filling pipe. The collar may have an elliptical cross-section. The plurality of flaps are formed from a flexible material and extend from the coll.ar. The plurality of flaps are biased to a clo.sed state. The nozzle seals the outlet end of the fill pipe when in the closed state. The collar may be composed of a silicone material of a predetermined durometer capable of ma taiiiing the nozzle on the outlet end of the fill pipe during operation of the packaging machine.

The elongate body may be composed of stainless steel or alternatively a plastic material. The flowable material is a liquid food product. The flowable material may be milk, especially low fat milk. The elliptical cross-section of the outlet end and at least a portion of the elongate body may provide for a fill pipe capable of filling a container at a velocity at least twenty percent lower ώan a fill pipe having a circular cross-section with a circumference subs.tantially equal to the circumference of the inlet end. In this manner, the same quantity of flowable material is delivered to the container in the same amount of time as a fill pipe with a circul∑ir cross-section. Another .aspect of the present invention is a fill system for a packaging machine. The fill system includes a container, a fill pump, a fill pipe, a nozzle and a moving me.ans. The container has a cross-section defined by a plurality of sidewalls, an interior bottom engaging the sidewalls, and an open top. .Another aspect of the invention is a method for filling a container with a flowable material. The method commences with the step of providing a container having sidewalls defining a predetermined cross-section. The next step is positioning the container beneath a fill pipe of a filling machine. The next step is bringing a bottom portion of the container and a nozzle that is disposed at the outlet end of the fill pipe proximate to one another. The next step is pumping a flowable material through the fill pipe, through the no.zzle and into the container. The final step is moving the bottom of the container and the nozzle away from one another as the container is filled with the flowable material. The movement being controlled to maintain a lower end of the nozzle slightly above a surface level of the flowable material in the container.

It is a principal object of the present invention to provide a fill system for a packaging machine to fill containers with rectangular cross-sections at a reduced velocity.

It is another object of the present invention to provide a fill system for a packaging machine to fill containers with rectangul.ar cross-sections with a substantial reduction in turbulence .and foaming.

It is yet another object of the present invention to provide a fill system for a packaging machine to fill containers with rectangul.ar cross-sections at an increased operating speed for the p.ackaging machine. It is yet another object of the present invention to provide a fill pipe with an elliptical cross-section.

It is yet another object of the present invention to provide a nozzle capable of facilitated opening to dispense a product into a container with a particulϊir cross-section. BRIEF DESCRIPTION OF THE DRAWINGS

Several features of the present invention are further described in connection with the accompanying drawings in which: There is illustrated in FIG. 1 a schematic view of a typical filling machine that may incorporate the fill system of the present invention.

There is illustrated in FIG. 2 a side view of a filling nozzle .and a filling pipe of the present invention disposed in an empty container.

There is illustrated in FIG. 3 a side view of a filling nozzle .and a filling pipe of the present invention disposed in a partially-filled container.

There is illustrated in FIG. 4 a side view of a filling nozzle and a filling pipe of the present invention disposed in a filled container.

There is illustrated in FIG. 5 a perspective view of one embodiment of a filling nozzle of the present invention. There is illustrated in FIG. 5A a cut-away top view of the nozzle of FIG.5.

There is illustrated in FIG. 6 a perspective view of another embodiment of a filling nozzle of the present invention.

There is illustrated in FIG. 7 a perspective view of a filling nozzle of the present invention for utilization in conjunction with a fill pipe having an elliptical cross-section at its outlet end in order to fill a container having a rectangular cross-section.

There is illustrated in FIG. 7A a top plan view of the filling nozzle of FIG. 7 showing the position of its various components in both open and clo∞d positions. There is illustrated in FIG. 7B a top perspective view of the filling nozzle of FIG. 7.

There is illustrated in FIG. 7C a cross-sectional view of the filling nozzle of FIG. 7A along the 8-8 line.

There is illustrated in FIG. 7D a side view of the filling nozzle of FIG. 7 There is illustrated in FIG. 7E a cross-sectional view of the filling nozzle of FIG. 7D along the 10-10 line. There is illustrated in FIG. 8 a bottom perspective one embodiment of the nozzle of the present invention.

There is illustrated in FIG. 9 a cross-sectional view along line E-E of the nozzle of FIG. 8. FIG. 10 is a graph of one of many motion profiles that may be used in accordance with the disclosed apparatus and method.

There is illustrated in FIG. 11 a side view of a filling pipe of the present invention.

There is illustrated in FIG. 12 a cross-sectional view of the filling pipe of FIG. 11 along the 12-12 line.

There is illustrated in FIG. 13 a more detailed side view of a filling pipe of the present invention.

There is illustrated in FIG. 14 a cross-sectional view of the filling pipe of FIG. 13 along the 14-14 line. There is illustrated in FIG. 15 a cross-sectional view of the filling pipe of

FIG. 13 along the 15-15 line.

There is illustrated in FIG. 16 a cross-sectional view of the filling pipe of FIG. 13 along the 16-16 line.

There is illustrated in FIG. 17 a top perspective view of a fill pipe of the present invention.

There is illustrated in FIG. 18 a bottom plan view of the fill pipe of FIG. 17.

There is illustrated in FIG. 19 a side view of an alternative embodiment of a fill pipe of the present invention. There is illustrated in FIG. 20 a cross-sectional view of the fill pipe of

FIG. 19.along the 20-20 line.

There is illustrated in FIG. 21 is a top perspective of the fill pipe of FIG. 19.

There is illustrated in FIG. 22 a top plan view of the fill pipe of FIG. 19. MODES FOR CARRYING OUT THE INVENTION

There is illustrated in FIG. 1 a schematic view of a typical filling machine that may incorporate the fill system of the present invention. However those skilled in the pertinent art will readily recognize that other filling machines may be employed in practicing the present invention without departing from the scope and spirit of the present invention. As shown in FIG. 1 , the filling system shown generally at 10 is constructed and operated in the manner described herein. A conveyor 15 having a plur ity of container support members 20 is driven, for example, by a motor 25, such as a servomotor or a belt mechanism. The support members 20 each support a single, open topped container 30 that has its bottom sealed. The conveyor 15 is driven by motor 25 under the control of, for example, a programmable control system 35, or the like, to present the containers 30 successively below a fill pipe 40 of the fill system 10. A storage or balance tank 50 containing a flowable material 55 is connected to provide a flow of the flowable material through a flow control system 60. The flow control system 60, generally stated, comprises an inlet valve 65, an outlet valve 70, pump mechanism 75, the fill pipe 40, and a nozzle 80. The inlet .and outlet valves 65 and 70 are operated to control the flow of the flowable material into .and from a pump chamber 82 of the pump mechanism 75. The pump mechanism 75 may be .any type of pump mechanism, such as one disclosed in U.S. Patent No. 4,877,160, which pertinent parts are hereby incorporated by reference. The pump mechanism 75 may be driven, for example, by a servomotor 85 under the direction of the programmable control system 35. As shown in FIG. 1 , the containers 30.are successively brought below the nozzle 80 for filling with the flowable material, such as low fat milk. To this end, each container 30 is lifted in the direction of arrow 90 so that the nozzle 80 is disposed in the interior of the container. This lifting may be done using a lifting mechanism 100 that executes a motion profile under the direction of, for example, the programmable control system 35. One such lifter mechanism and corresponding carton gripping mechanism are disclosed in U.S.S.N. 08/315,410, filed September 28, 1994. Alternatively, the lifting may be accomplished by a carton gripper which grips each container 30 and through a hydraulic cylinder or the like, lifts the container toward the no.zzle. The flow control system 60 is then operated to fill the container 30 with the flowable material as the container 30 is lowered from the nozzle 80 by the lifting mech-anism 100, preferably mamtaining the nozzle 80 above the surface level of the flowable material throughout this downw.ard motion. Even more preferably, the flaps 130 are maintained approximately 2-3 mm above the surface of the flowable material being dispensed into the container 30.

The nozzle 80 is disposed over the outlet 110 of the fill pipe 40. The nozzle 80 includes a plurality of flaps which are made of a flexible material, such as FDA approved silicone or the like. The flaps are flexible between .an open position in which the flowable material is allowed to flow therefrom and a closed position in which the nozzle seals the outlet end 110 of the fill pipe 40. The flaps are biased to a closed position, for example, by virtue of their inherent resiliency or by a separate mechanical biasing element. Movement of the flaps to their open position may ensue by virtue of the pressure of the flowable material against the inherent resiliency or through a separate mechanical opening element. The separate mechanical opening element may be a tiansformable wire as disclosed in copending U.S. S. N. 08/752,135 filed on November 19, 1996, entitled "Flexible Nozzle Integrated With A Transformable Wire," which pertinent parts thereof .are hereby incorporated by reference. AN alternative means of opening the flaps is discussed below in reference to FIGS. 8 and 9. Some of the advantages of the pre∞nt invention are exemplified in the filling process illustrated in FIGS. 2-4. There is illustrated in FIG. 2 a side view of a filling nozzle and a filling pipe of the pre∞nt invention disposed in .an empty container. There is illustrated in FIG. 3 a side view of a filling nozzle and a filling pipe of the present invention disposed in a partially-filled container. There is illustrated in FIG. 4 a side view of a filling nozzle and a filling pipe of the 9 present invention disposed in a filled container. In an exemplary filling process, the bottom portion 160 of the container 30 and the nozzle 80 are brought proximate to one a . nother while the nozzle 80 is in a closed state. The flaps 130 are then urged to the open state by, for example, the pressure ofthe flowable material against the flaps as produced by the pump mechanism 75 and/or gravity.

Alternatively, an opening mechanism that directly engages the flaps to urge them to an open state may be employed, such as a movable plunger. Still further, the flaps 130 may be provided with electrically sensitive supports disposed therein or thereon that change shape in response to an electrical stimulus to thereby urge the flaps to their open .and/or closed states.

The position ofthe flaps in the open state are shown in phantom in FIG. 2.

As shown, the flaps 130 conform to and engage the sidewalls 145 ofthe container

30 to thereby form a seal with the sidewalls 145 that is sufficient to inhibit mixing between the flowable material and the .ambient gas, such as air, during subsequent filling.

Product begins to be dispensed when the no.zzle 80 a . nd container 30 a . re in the relative position shown in FIG.2. As product is dispensed into the container 30, the nozzle 80 and container 30.are moved relative to one another by, for example, the foregoing carton gripper to thereby begin extracting the nozzle from engagement with the interior ofthe container 30 during filling. During this extraction and filling process, the flaps 130 preferably remain in their open state and the motion profile used to cause the disengagement is preferably controlled to maintain the lower end ofthe nozzle 80 at a level slightly above the flowable material surface (see FIG. 3). Ultimately, as shown in FIG.4, the container 30 is filled with the desired volume of product and the flaps 130 go to their closed state. To reduce the likelihood that a further amount of product will drip into the container 30, the pump mechanism 75 may provide a slight backpressure tliat assists in retaining the flaps 130 in their closed state. The container 30 is shown in an intermediate state in which the bottom has been sealed to form a flat bottom structure. Other bottom .structures, however, may be utilized as well. Without limitation, and with reference to FIGS. 2-4, the container 30 may have sidewalls 145 defining a cross-section of 95 mm x 70 mm. However, those sl illed in the pertinent a . rt will recognize that the fill system ofthe present invention may be practiced with containers having cross-sections of various shapes and dimensions.

FIG. 5 is a perspective view of one embodiment ofthe nozzle 80 while FIG. 5 A is a top view ofthe same. As illustrated, the nozzle 80 has a collar 115 that is sized for connection to the fill pipe 40. The nozzle 80 has a plur ity of flaps that extend from the collar 115. In the embodiment shown, the plurality of flaps comprise four, V-shaped lugs 120 that are disposed for ex∑imple at about 90 degrees from one another. Each V-shaped lug 120 is defined by side edges 125. Inwardly extending flaps 130 extend between opposed edges 125 of adjacent V- shaped lugs. The measurement denoted by LI as the perpendicular line between the vertices ofthe V-shaped lugs 120 and the fold defining the inw.ardly extending flaps 130 is preferably substantially equal to one half of the length of a sidewall of the container for which the nozzle is designed to fill. The inwardly extending flaps 130 join together in the closed position illustrated to form a cross-shaped, sealed slit 140. The inwwdly extending flaps 130 are preferably biased under the influence of their inherent resiliency to the closed position illustrated. An angled .sealing lip 142 may be disposed along the inner edge ofthe inwardly extending flaps 130 to facilitate sealing when in the closed position.

The phantom lines of FIG. 5 A illustrate the positions ofthe V-shaped lugs 120 and inwardly extending flaps 130 in the open state ofthe nozzle 80. As illustrated, the inwardly extending flaps 130 and V-shaped lugs 120 now extend outward so that the lowered edges ofthe opened nozzle conform to a general square cross-section and engage the sidewalls 145 ofthe container 30 . Opening ofthe flaps 1 0 to the illustrated position may take place by generating a slight overpressure in the fill tube 40 that acts against the inherent resiliency that biases the flaps to the closed position. Alternative manners of opening the nozzle are disclosed below in reference to FIGS. 8 and 9. The dimensions ofthe nozzle 80 in the open state are of particular import in connection with the present system. In the embodiment illustrated in FIGS. 2- 4, the lower portion ofthe nozzle 80 flares to define a generally sqitare cross- section. With reference to FIGS. 2-4, the cross-section ofthe lower portion ofthe nozzle 80 is designed to conform with the crosβ-section of the container 30 as defined by the sidewalls 145 of the container 30 when the flaps ofthe nozzle 80 are in the open state.

Without limitation, and with reference again to FIGS. 5 and 5 A, the container 30 may have sidewalls 145 defining a cross- section of 70 mm x 70 mm. In such instance, the dimension LI (see FIG. 5) is preferably about 35 mm.

FIG. 6 illustrates a further embodiment of a nozzle 80' suitable for use in the foregoing fill system. In this embodiment, the nozzle 80' has been designed to fill a container having sidewalls defining a cross - section, such as, without limitation, a 47 mm x 47 mm container. Accordingly , the length LI' of FIG. 6 is about 23.5 mm. It is apparent from FIG. 6 that the nozzle is elongated compared to the embodiment of FIG. 5. This elongation makes the nozzle particularly adapted to fill smaller cross-section containers. The elongated design reduces the stiffness ofthe flaps and lugs when compared to a shorter nozzle ofthe same material and is preferred when the carton lias a small cross-section. There is illustrated in FIG. 7 a perspective view of a filling nozzle of the present invention for utilization in conjunction with a fill pipe having an elliptical cross-section at its outlet end in order to fill a container having a rectangular cross-section. The nozzle 80 of FIG. 7 is particularly designed for use with a filling pipe having an outlet end with an elliptical cross-section. As previously shown in FIGS 2-4, the nozde 80 is positioned near the bottom of a container 30 during filling, .and subsequently moved from the bottom .as the container 30 fills with a flowable material.

As illustrated in FIGS. 7, 7A-7E , the nozzle 80 includes a collar portion 225 and a plurality of flaps and lugs extending from the collar portion 225. The collεir 225 is of a substantially elliptical shape to accommodate an elliptical- shaped fill pipe outlet. A plurality of flaps and lugs extend from the collar 225. In the disclosed embodiment, there .are four V-shaped lugs 230 a-d. V-shaped lugs 230a and 230b are adjacent one another on opposite sides of major axis 240 and are preferably at a 45 degree angle Θ with respect to the major axis 240. V- shaped lugs 230c and 230d are adjacent one another on opposite sides of major axis 240 and are each, likewise, preferably at a 45 degree .angle with respect to the major axis 240. V-shaped lugs 230a and 230b are disposed on a side of minor axis 250 opposite from V-shaped lugs 230c and 230d. Inwardly directed, inverted V-shaped flaps 255 connect adjacent V-shaped lugs 230a and 230b while inwardly directed, inverted V-shaped flaps 255 connect adjacent V-shaped lugs 230c and 230d. Non-adjacent V-shaped lugs 230b and 230c are connected with one another by an inwardly directed tri-panel flap 270 while non-adjacent V- shaped lugs 230a and 230d are connected with one .another by a further inwardly directed tri-panel flap 275. By way of example, if the nozzle 80 is designed to fill a 95 mm x 70 mm rectangular container, the length "a" is preferably about 35 mm in length (or 1/2 ofthe width ofthe container to be filled), .and length "b" may be about 25 mm in length (or the difference between the length ofthe longer container sidewall and 2*a). As illustrated in phantom in FIG. 7, the nozzle 80 opens to a generally rectangul.ar cross-section that csm eng.age the sidewalls of a rectangular container to reduce the mixing of product and air during container filling. A fill system employing the embodiment ofthe nozzle of FIGS. 7, 7A-7E may be operated in accordance with the foregoing description ofthe filling process provided in connection with FIGS. 2-4.

As shown in FIGS. 7A and 7D, when the nozzle 80 is in the open state, the V-.shaped lugs 230a-d, V-shaped flaps 255 and 260, and tri-panel flaps 270 and 275 extend outwarf so that the lower edges ofthe opened nozzle conform to a generally rectangular cross-action and engage the sidewalls 145 ofthe container 30. Opening of the fltφs to the illustrated position may take place by generating a slight overpressure in the fill tube 40 that acts against the inherent resiliency that biases the flaps to the clo.sed position. There is illustrated in FIG. 8 a bottom perspective one embodiment of the nozzle of the present invention. There is illustrated in FIG. 9 a cross-sectional view along line E-E ofthe nozzle of FIG. 8. As shown in FIGS. 8 and 9, the nozzle 80 is similar to the nozzle 80 of FIG. 5. Those sleilled in the art will recognize that the nozzle 80 may be as contemplated in FIG. 7. The plurality of V-shaped lugs 120 are defined by edges 125. The inwardly extending flaps 130 extend between opposed edges 125 ofthe adjacent V-shaped lugs 120. The folding ridges 150A-150D in this embodiment ofthe invention have a reduced material thickness in order to provide for facilitated opening ofthe V shaped lugs 120 during the open state. This hinge function is accomplished by reducing the material thickness of .all or part ofthe folding ridges 150A-150D. In a preferred embodiment, the material reduction may be half that ofthe V-shaped lug 120. Thus, if the mater ial thickness of the nozzle 80 is 1.50 mm, then the folding ridges 150 will have a thickness of approximately 0.75 mm. However, other thickness .are contemplated by the present invention.

The edges 125 ofthe V-shaped lugs 120 may also have a material thickness reduction in order to facilitate opening ofthe V-shaped lugs 120. A nozzle may have material reductions in the edges 125, the folding ridges 150A- 150D, or both. The material reduction should not affect the closing of the lugs 120.

Alternative manners of opening the nozzle 80 are likewise contemplated. For example, a mechanism applying a force against the fold ridges may be utilized such as a downwardly movable cylindrical plunger ( not shown) having an aperture through which the flowable material may flow. Preferably, the vertices ofthe V-shaped lugs 230a-d flare to engage interior corner portions ofthe container. Such flaring may be generated in accordance with .any ofthe foregoing methods for opening the nozzle 80. Where the nozzle 80 is opened solely using an overpressure ofthe flowable material, the nozzle is preferably maintained below the level ofthe flowable material in the container and the overpressure creates an upward force against the flaps ofthe nozzle to thereby cause the flaps to flare outwardly against the sidewalls ofthe container. Further, the material of the nozzle 80 may be changed from a 40 durometer material to a 30 or 35 durometer material to allow for easier opening ofthe lugs 120. The nozzle 80 may be made from any suitable flexible material such as soft plastic or rubber of suitable hardness. In the case of packaging foodstuffs, such as low fat milk, the nozzle 80 may more preferably be made from approved nitrile, silicone rubber, or the like. In a preferred embodiment, the collar 225 is composed of a 80-durometer silicone material to provide strength and rigidity to the nozzle in order to maintain the nozzle 80 on the fill pipe 40 during operation ofthe packaging machine. A 80 durometer silicone material for the collar 225 is available from Dow Corning. The 80 durometer material ofthe collar 225 is in comparison to the 40 durometer material ofthe entirety ofthe nozzle 80. It will be understood that the nozzles of the present invention may take on any number of different forms which may substantially conform to the cross- sectional area ofthe container to be filled when the flaps are in an open position. For example, the container cross-section may be hexagonal, octagorral, round, etc., the illustrated embodiments being merely exemplfuy. FIG. 10 is a graph of one of many motion profiles that may be used in accordance with the disclosed apparatus .and method. More particularly, FIG. 10 shows the timing relationships between the pumping cycle of the pump mechanism 75, the volume of product in the container, .and the position ofthe container with respect to the bottom ofthe nozzle 80, for a 70 cm x 70 cm cross- section, 1000 milliliter volume package, using a filling velocity of 3300 ml./second. the right Y - .axis represents the level ofthe container 30 in millimeters with zero being the lowest level ofthe container .after it has been filled (i.e., in the conveyor). The left Y - axis represents fill volume in millimeters. Line 200 represents the cycle ofthe pumping mechanism 75. As shown (and as applied to the filling process shown in FIG.1 ), the pump mechanism 75 is initially in a suction cycle, at which time it draws product 55 from the tank 50, from time 0 until about .375 seconds. Then the pump mec.banism 75 begins its dispensing cycle at which time it dispenses the product 55 from the chamber 82 into the container 30 through nozzle 80. The pump mechanism 75 completes its dispensing cycle at approximately .855 seconds. Thereafter, the pump mechanism 75 begins a new suction cycle. The line 210 represents the level to which the container 30 is lifted by lifter mechanism 100. As shown by line 210, the container 30 is lowered with respect to the bottom of the nozzle 80 as it is filled with product 55. In this manner, the lower end of nozzle 80 remains below the rising level of product 55 as the container 30 is filled, thereby inhibiting frothing of the product 55 such as that caused tlirough the mixing of air and product.

An important aspect ofthe present invention is the fill pipe 40. As previously mentioned, the filling of a container having a rectangular cross-section with a fill pipe having a circular cross-section may lead to foaming and turbulence. A reduction in the velocity ofthe flowable material into the container 30 may resolve these problems however it also reduces the number of units (containers filled and sealed) produced in an hour. The fill pipe ofthe present invention resolves all of these problems.

There is illustrated in FIG. 11 a side view of a filling pipe of the present invention. There is illustrated in FIG. 12 a cross-sectional view ofthe filling pipe of FIG. 11 along the 12-12 line. As shown in FIGS. 11 .and 12, the fill pipe 40 has an inlet end 300 and an outlet end 302. The inlet end 300 is connected to the pump mechanism 75 and the outlet end 302 is connected to the nozzle 80. The fill pipe 40 is defined by .an elongate body 304 having an internal passageway 306 extending therethrough. The internal passageway 306 provides for flow communication between the pump mechanism 75 and the nozzle 80 thereby .allowing for a flow of flowable material from the pump mechanism 75 into a container 30.

In this embodiment ofthe fill pipe 40, the elongate body 304 is composed of a plurality of portions 308-320. The inlet end 300 has a circular cross-section for facilitated engagement with most pump mechanisms. However, the outlet end 302 has an elliptical, or oval, cross-section. The plurality of portions 308-320 have cross-sections which depend on their proximity to either the inlet end 300 or the outlet end 302. The portions 308, 310 and 312 have cross-sections which are substantially circular with portion 308 having a more circular cross-section than portion 312. The portions 316, 318 and 320 have cross-sections which are substantially elliptical with portion 320 having a more elliptical cross-section than portion 316.

In this manner, the fill pipe 40 is capable of delivering a flowable material to a container 30 at a velocity of at least twenty percent lower than that of fill pipe having only a circuit cross-section throughout, while the fill pipe 40 delivers .an equal .amount of flowable material into the container 30 in ,an equal time period as a fill pipe having only a circular cross-section. The fill pipe 40 ofthe present invention accomplishes this feat with substanti reduction in foaming and turbulence thereby allowing for the packaging machine to operate at a higher capacity, upwards to fifty percent faster. For example, a packaging machine producing a gabled top carton having a cross-section of 95 mm x 70 mm using a fill pipe having a circular cross-section may produce four thousand cartons per hour. While that .same packaging machine using a fill pipe 40 ofthe present invention, along with a corresponding nozzle 80 ofthe present invention, will produce upwards to six thousand cartons per hour.

There is illustrated in FIG. 13 a more detailed side view of a filling pipe of the present invention. The embodiment of the fill pipe 40 of the present invention shown in FIG. 13 has a greater circumference for the lower portions 316-320 than that of the fill pipe 40 of FIG. 11. There is illustrated in FIG. 14 a cross-sectional view ofthe filling pipe of FIG. 13 along the 14-14 line. As is shown in FIG. 14, the interior passageway and the portion 318 have .an elliptical, or oval, cross-section. The elliptical cross-section for the filling pipe 40 has proven to be quite beneficial for filling containers 30 having rectangular cross- sections. There is illustrated in FIG. 15 a cross-sectional view ofthe filling pipe of

FIG. 13 along the 15-15 line. As shown in FIG. 15, the fill pipe 40 may have an indentation 324 for engaging with the collar of a nozzle 80. In this manner, the no-zzle 80 is more securely fastened to the fill pipe 40. There is illustrated in FIG. 16 a cross-sectional view ofthe filling pipe of FIG. 13 along the 16-16 line. As shown in FIG. 16, the transformation of the cross-sections of the various portions 314, 316 and 318 of the elongate body 304 is ver-y cleωly seen. The 17 cross-section of portion 314 is substantially circular while the cross-section of portion 316 is elliptical. The cross-section of portion 318 is still more elliptical than the cross-section of portion 316.

There is illustrated in FIG. 17 a top perspective view of a fill pipe ofthe present invention. There is illustrated in FIG.-l 8 a bottom plan view of the fill pipe of FIG. 17. As previously mentioned, the cross-section of the elongate body 304 becomes more elliptical near the outlet end 302 while the inlet end 300 has a circular cross-section. The inlet end 300 also has a flange 326 to prevent leakage from the pump mech.anism to the fill pipe 40. There is illustrated in FIG. 19 a side view of an alternative embodiment of a fill pipe ofthe present invention. There is illustrated in FIG. 20 a cross- sectional view ofthe fill pipe of FIG. 19 along the 20-20 line. There is illustrated in FIG. 21 is a top perspective ofthe fill pipe of FIG. 19. There is illustrated in FIG. 22 a top plan view ofthe fill pipe of FIG. 19. Instead of a plurality of portions, this embodiment ofthe fill pipe 40 has an elongate body 304 without division into further small components. The cross-section ofthe elongate body gradually transforms from having a circutar cross-section near the inlet end 300, to having an elliptical cross-section towards the outlet end 302.

Claims

CLAIMSWe ctaim as our invention:

1. A fill system for a packaging machine-eomprising: a container having a cross-section defined by a plurality of sidewalls, an interior bottom engjiging the sidewalls, and an open top; a fill pump for pumping a liquid product; a fill pipe having .an inlet receiving the flowable product under pressure from the fill pump .and an outlet overlying the container; a nozzle disposed over the outlet end ofthe fill pipe, the nozzle comprising a collar for connecting the nozzle to the outlet end ofthe fill pipe, and a plurality of flaps formed from a flexible material and extending from the colla. r, the plurality of flaps being biased to a closed state, the nozzle sealing the outlet end ofthe fill pipe when in the closed state; and moving means for relatively moving the container and nozzle toward one another at a first position in which the nozzle is disposed in the interior bottom ofthe container and a second position in which the no.zzle is disposed distal from the interior bottom ofthe container; the fill pump operating to pump the liquid product through the fill pipe under pressure when the container and nozzle are disposed in their relative first position to thereby urge the flaps ofthe nozzle from the closed .state to an open state, the flaps ofthe nozzle being dimensioned to substanti-ally conform .and seal with the sidewalls ofthe container when the flaps are urged to the open state to thereby inhibit mixing of air and product as liquid product is dispensed into the container through the nozzle .and the moving means is operated to relatively move the container and nozzle from the first position to the s .econd position.

2. The fill system according to claim 1 wherein the container sidewalls define a rectangular cross-section.

3. The fill system according to claim 1 wherein the fill pipe comprises an elongate body having an interior passageway, at least a portion ofthe interior passageway having an elliptical cross-section; and an inlet end for flow communication between the fill pump and the interior passageway, the outlet end in flow communication with the interior passageway, the outlet end dispensing the liquid product from the fill pipe into the nozzle, the outlet end having an elliptical cross-section.

4. The fill system according to claim 1 wherein the plurality of flaps are dimensioned to seal substanti ly with the sidewalls ofthe container at the engagement between the sidewalls and bottom ofthe container when the container and nozzle are in the first position and the nozzle is in the open state.

5. The fill system according to claim 1 wherein the container sidewalls define an octagonal cross-section, a hexagonal cross-section or a circular cross- section.

6. The fill system according to claim 1 wherein the plurality of flaps comprise a plurality of V-sliaped lugs formed from a flexible material extending from the collar, the V-shaped lugs each having a side corner portion having vertices spaced at corners that are disposed for alignment with the corner sections ofthe container, adjacent V-shaped lugs being joined to one smother by inwardly turned flaps being dimensioned to substantially seal with the sidewalls ofthe container to be filled when the V-shaped lugs and inwardly turned flaps are in an open .state to thereby inhibit mixing of air and liquid product during filling of the container.

7. A nozzle according to claim 6 further comprising a plurality of fold ridges ofthe nozzle, each ofthe fold ridges having a material thickness less than the material thickness of each of the plurality of V-shaped lugs thereby allowing for facilitated opening of each ofthe plurality of V-shaped lugs when the V-shaped lugs are in the open state.

8. A nozzle according to claim 6 further comprising a plurality of edges of each ofthe plurality of V-shaped lugs, each ofthe edges having a material thickness less th.an the material thickness ofthe entirety of each ofthe plurality of V-shaped lugs thereby allowing for facilitated opening of each ofthe plurality of V-shaped lugs when the V-shaped lugs are in the open state.

9. The fill system according to claim 8 wherein the nozzle comprises four V- shaped lugs for alignment with the corner sections of a rectangular container.

10. The fill system according to claim 1 wherein the coltar is composed of a silicone material of a predetermined durometer capable of maintaining the nozzle on the outlet end ofthe fill pipe during operation ofthe packaging machine.

11. The fill system according to claim 1 wherein the container sidewalls define a 95 mm x 70 mm cross-section.

12. The fill system according to claim 3 wherein the entire interior passageway has an elliptical cross-section.

13. The fill system according to claim 3 wherein the inlet end .has a circular cross-section.

14. The fill system .according to ctaim 3 wherein at least a portion ofthe interior p.assageway nearest the inlet end has a circular cross-section.

15. A fill system according to claim 1 wherein the container sidewalls define a square cross-section.

16. A fill system according to claim 3 wherein the container sidewalls define a 70 mm x 70 mm cross-section

17. A fill system according to claim 1 wherein the plurality of flaps comprise: first, second, third, and fourth, V-shaped lugs , each having a side corner portion, the V-shaped lugs comprising: a first inwardly turned, inverted V-shaped portion extending between the side corner portions ofthe first and second V-shaped lugs; a second inwardly turned, inverted V-shaped portion extending between the side corner portions ofthe first and second V-shaped lugs; a third inwardly turned, inverted V-shaped portion extending between the side comer portions ofthe third and fourth V-shaped lugs; a fourth inwardly turned, inverted V-shaped portion extending between the side comer portions ofthe fourth .and first V-shaped lug.

18. A fill system as cleiimed in Claim 17 wherein the V-shaped lugs are disposed at about 90 degree intervals about a circle having a diameter of about 70 mm measured about a bottom portion ofthe nozzle.

19. The fill system according to claim 1 wherein the fill pipe comprises an elongate body having an interior passageway in flow communication with the fill pump at an inlet end and in flow communication with the nozzle at an outlet end, the elongate body composed of a plurality of portions, the portion adjacent the inlet end having a circuit cross-section and the portion adjacent the outlet end having an elliptical cross-section, each ofthe other portions having cross-sections which are gradually more elliptical the closer the portion is to the outlet end thereby gradually transforming the cross-section ofthe fill pipe from a circular cross-section at the inlet end to an elliptical cross-section at the outlet end.

20. A nozzle for use with packaging machines for filling packages that have sidewalls defining a cross-sectional area, the nozzle comprising: a collar for connecting the nozzle to the packaging machine; and a plurality of flaps formed from a flexible material extending from the collar, the flaps being dimensioned to substantially seal with the sidewalls of the container to be filled when the flaps are in an open state to thereby inhibit mixing of air and liquid product during filling of the container.

21. A nozzle for use with packaging machines for filling packages that have sidewalls, adjacent sidewalls joining together at comer sections and defining a cross-sectional area, the nozzle comprising: a collar for connecting the nozzle to the packaging machine; and a plurality of V-shaped lugs formed from a flexible material extending from the coU.ar, the V-shaped lugs each having a side comer portion having vertices spaced at comers that are disposed for alignment with the comer section of the containers, adjacent V-shaped lugs being joined to one another by inwardly turned flaps, the V-shaped lugs and inwardly turned flaps being dimensioned to substantially seal with the sidewalls ofthe container to be filled when the V-shaped lugs and inwardly turned flaps being dimensioned to substanti ly .seal with the sidewalls ofthe container to be filled when the V- shaped lugs and inwardly turned flaps are in an open state to thereby inhibit mixing of air and liquid products during filling of the container.

22. A nozzle according to claim 21 , wherein the nozzle comprises four V- shaped lugs for alignment with the comer sections of a rectangular container

23. A nozzle according to claim 21 , wherein the nozzle comprises four V- shaped lugs for alignment with the comer sections of a

container.

24. A nozzle according to claim 21 , wherein the no.zzle comprises six V-shaped lugs for alignment with the comer sections of a hexagonal container.

25. A nozzle according to claim 21 , wherein the nozzle comprises eight V- shaped lugs for alignment with the comer sections of an octagonal container.

26. A nozzle according to claim 22, wherein the inwardly turned flaps have a length substantially equal to 1/2 ofthe length of a sidewall ofthe container, the length being measured along a perpendicular from the vertex of e adjacent V- shaped lug to an edge of the inwardly turned flap.

27. A nozzle according to claim 21 further comprising means for facilitating the opening of each ofthe plurality of V-shaped lugs when the V-shaped lugs are in the open state.

28. A nozzle according to claim 27 wherein the facilitating means comprises a plurality of fold ridges ofthe nozzle, each ofthe fold ridges having a material thickness less than the material thickness of each ofthe plurality of V-shaped lugs thereby allowing for facilitated opening of -each ofthe plurality of V-shaped lugs when the V-shaped lugs are in the open state.

29. A nozzle according to claim 27 wherein the facilitating means comprises a plurality of edges of each ofthe plurality of V-shaped lugs, each ofthe edges having a material thickness less than the material thickness ofthe entirety of each ofthe plurality of V-shaped lugs thereby allowing for facilitated opening of each ofthe plurality of V-shaped lugs when the V-shaped lugs are in the open state.

30. A fill pipe for utilization in conjunction with a packaging machine for filling containers that have sidewalls defining a cross-sectional area, the packaging machine having a fill pump for pumping a flowable material, the fill pipe comprising:

.an elongate body having an interior passageway, at least a portion ofthe interior passageway having an elliptical cross-section; an inlet end for flow communication between the fill pump and the interior passageway; and an outlet end in flow communication with interior passageway, the outlet end dispensing the flowable material from the fill pipe, .and the outlet end having an elliptical cross-section.

31. The fill pipe according to claim 30 wherein the entire interior passageway has an elliptical cross-section.

32. The fill pipe according to claim 30 wherein the inlet end has a circul∑ir cross-section.

33. The fill pipe according to ckύm 30 wherein at a portion of the interior passϊigeway nearest the inlet end has a circular cross-section.

34. The fill pipe according to claim 30 wherein the elongate body comprises a plurality of portions, the portion .adjarcnt the inlet end having a circular cross- section and the portion adjacent the outlet end having an elliptical cross-section, each ofthe other portions having cross-sections which are gradually more elliptical the closer the portion is to the outlet end thereby gradufdly trarisforrning the cross-section of the fill pipe from a circular cross-section at the inlet end to an elliptical cross-section at the outlet end.

35. The fill pipe according to claim 30 wherein the sidewalls ofthe container define a rectangular cross-section.

36. The fill pipe according to claim 30 wherein the sidewalls of the container define a cross-section of 95 mm x 70 mm.

37. The fill pipe according to claim 30 further comprising a nozzle connected to the outlet end ofthe fill pipe, the nozzle comprising: a collar for connecting to the nozzle to the outlet end of the filling pipe, the collar having an elliptical cross-section; and a plurality of flaps formed from a flexible material and extending from the collar, the plurality of flaps being bi,ased to a closed state, the nozzle sealing the outlet end ofthe fill pipe when in the closed .state.

38. The fill pipe according to claim 30 wherein the elongate body is composed of a plastic material.

39. The fill pipe according to claim 30 wherein the elongate body is composed of a stainless steel material.

40. The fill pipe according to claim 30 wherein the container sidewalls define an octagonal cross-section, a hexagonal cross-section, or a circuit cross-section.

41. The fill pipe according to claim 32 wherein the elliptical cross-section of the outlet end and at least a portion ofthe elongate body provide for a fill pipe capable of filling a container at a velocity at least twenty percent lower than a fill pipe having a circular cross-section with a circumference substanti-ally equal to the circumference ofthe inlet end.

42. The fill pipe according to claim 37 wherein the collar is composed of a silicone material of a predetermined durometer capable of maintaining the nozzle on the outlet end ofthe fill pipe during operation ofthe pacli-aging machine.

43. A method for filling a container with a .flowable material, the method comprising: providing a container having sidewalls defining a predetermined cross-section; positioning the container beneath a fill pipe of a filling machine, the fill pipe comprising an elongate body having an interior passageway, at least a portion ofthe interior passageway having an elliptical cross-section, an inlet end for flow communication between a fill pump .and the interior passageway; and an outlet end in flow communication with interior pas.sageway, the outlet end having an elliptical cross-section; bringing a bottom portion of the container and a nozzle that is disposed at the outlet end ofthe fill pipe proximate to one another; pumping a flowable material through the fill pipe, tlirough the nozzle a . nd into the container; and moving the bottom ofthe container and the no.zzle away from one another as the container is filled with the flowable materi , the movement being controlled to maintain a lower end ofthe nozzle slightly above a level ofthe flowable material in the container.

44. The method .according to claim 43 wherein the nozzle comprises: a collar for connecting to the nozzle to the outlet end ofthe filling pipe, the collar having an elliptical cross-section; and a plurality of flaps formed from a flexible material and extending from the collar, the plurality of flaps being biased to a clos^ state, the nozzle sealing the outlet end ofthe fill pipe when in the closed state.

45. The method according to claim 43 wherein at least a portion ofthe interior p.assageway nearest the inlet end has a circular cross-section.

46. The method according to claim 43 wherein the elongate body comprises a plurality of portions, the portion adjacent the ^"inlet end having a circul,ar cross- section and the portion adjacent the outlet end having an elliptical cross-section, each ofthe other portions having cross-sections which are gradually more elliptical the closer the portion is to the outlet end thereby gradually transforming the cross-section of the fill pipe from a circular cross-section at the inlet end to an elliptical cross-section at the outlet end.

47. The method according to claim 43 wherein the elliptical cross-section of the outlet end .and at least a portion ofthe elongate body provide for a fill pipe capable of filling a container at a velocity at least twenty percent lower than a fill pipe having a circuit cross-section with a circumference substantially equal to the circumference ofthe inlet end.