WO2004043684A1

WO2004043684A1 - Apparatus for manufacturing and filling plastic bags

Info

Publication number: WO2004043684A1
Application number: PCT/US2002/035795
Authority: WO
Inventors: Elmer B. Woods; Bruce A. Bliefnick
Original assignee: Pdc Facilities, Inc.
Priority date: 2002-11-08
Filing date: 2002-11-08
Publication date: 2004-05-27
Also published as: AU2002368352A1; CN1498745A

Abstract

The invention recites a sealing apparatus for sealing at least a first web and a second web, the first web (85) and the second (85) web eachincluding sides. The sealing apparatus includes a first press having a first tool (220A, 220B) adapted to receive the first web. The first press is operable to move the first tool between an open position and a closed position to seal the sides of the first web. The apparatus further includes a second press (220A, 220B) having a second tool adapted to receive the second web. The second press is operable to move the second tool between an open position and a closed position sealing the sides of the second web independent of the first tool.

Description

APPARATUS FOR MANUFACTURING AND FILLING PLASTIC BAGS

Backfiround of the Invention

The present invention relates to an apparatus for manufacturing bags, and particularly to an apparatus for manufacturing plastic bags. More particularly, the present invention relates to an apparatus for making and filling bags made from a double- wound web.

To manufacture a bag, a double-wound web is unrolled and fed into an apparatus that forms seals on the sides and end. A press supports tooling that compresses and heats the plastic to form the side and end seals. A die separates the individual bags from the web such that each bag contains one of the end seals. A port is inserted and sealed into the open end to complete the bag.

The completed bag is then directed to a filling apparatus that fills the bag using one of two common methods. The first method inserts a nozzle into a port and completely fills the bag as the bag moves along a linear path toward a capping station. The second method employs a plurality of nozzles, each responsible for partially filling the bag. In this method, a bag proceeds to the first nozzle where it stops and is partially filled. The bag then proceeds to the next nozzle where additional liquid is added. The bag proceeds to the next station where the process continues until the bag is completely filled.

To speed manufacture, the apparatus commonly includes two or more manufacturing lines operating parallel to one another. A single actuator operates the side seal press and the end seal press to form two bags simultaneously.

Plastic bags manufactured as just described are commonly used to contain liquids such as intravenous ("IV") solutions. Generally, the plastic bags are manufactured from a PNC or non-PNC material arranged flat or in a double- wound web. The double-wound web comprises two layers of plastic sandwiched together. Often times the layers are held together by static electricity and the vacuum between the sheets.

Summary of the Preferred Embodiments

The present invention provides a sealing apparatus for sealing at least a first web and a second web, the first web and the second web each including sides. The sealing apparatus includes a first press having a first tool adapted to receive the first web. The first press is operable to move the first tool between an open position and a closed position to seal the sides of the first web. The apparatus further includes a second press having a second tool adapted to receive the second web. The second press is operable to move the second tool between an open position and a closed position sealing the sides of the second web independent of the first tool. In another embodiment, the invention provides an apparatus for cutting a web of material used to make a fluid container, the web having a leading portion and a width. The apparatus includes a drive system operable to advance the web in an advancement direction. The apparatus also includes a cutting member movable in a direction substantially normal to the advancement direction across the width of the web and operable to separate the leading portion from the web to define a partially complete fluid container.

In yet another¹ embodiment, the invention provides an apparatus for filling bags with an intravenous solution. The apparatus includes an accumulating station operable to receive and support a plurality of empty bags, and a filling station operable to receive the plurality of empty bags from the accumulating station and to temporarily maintain the bags stationary. The filling station includes a corresponding plurality of nozzles. Each of the corresponding plurality of nozzles fills one of the plurality of empty bags with an intravenous solution when the plurality of empty bags are held stationary, to produce a plurality of full bags. Additional features and advantages will become apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments exemplifying the best mode of carrying out the invention as presently perceived.

Brief Description of the Drawings The detailed description particularly refers to the accompanying figures in which:

Fig. 1 is a perspective view of an intravenous IN bag; Fig. 2 is a schematic of an apparatus for manufacturing bags embodying the present invention;

Fig. 3 is a front view of the web unwind module of Fig. 2; Fig. 4 is a top view of the web unwind module of Fig. 2;

Fig. 5 is a front view of the side seal module of Fig. 2; Fig. 6 is a perspective view of the lower side seal tooling of Fig. 5; Fig. 7 is a front view of the top seal module of Fig. 2;

Fig. 8 is a front view of the cutting module of Fig. 2;

Fig. 9 is a perspective view of the cutting module of Fig. 2 shown in the process of separating a partially completed bag from the web; Fig. 10 is a perspective view of the fill conveyor of Fig. 2;

Fig. 11 is a side view of the bag transfer station of Fig. 10;

Fig. 12 is a side view of the filling station of the fill conveyor of Fig. 10;

Fig. 13 is a front view of the filling station of Fig. 12 illustrating the motion of the nozzles; Fig. 14 is a top view of the filling station of Fig. 12;

Fig. 15 is a perspective view of a portion of the capping station of Fig. 10;

Fig. 16 is a perspective view of a portion of the capping station of Fig. 10;

Fig. 17 is a perspective view of the supporting beam and indexing beam of the fill conveyor of Fig. 10 at the beginning of a transfer cycle; Fig. 18 is a perspective view of the supporting beam and indexing beam of the fill conveyor of Fig. 10 in the middle of a transfer cycle;

Fig. 19 is a perspective view of the supporting beam and indexing beam of the fill conveyor of Fig. 10 at the end of a transfer cycle;

Fig. 20 is a perspective view of a bag support.

Detailed Description of the Drawings

The present invention relates to an apparatus 5 that is arranged as illustrated in Fig. 2 to manufacture and fill plastic bags such as IN bags 10. The apparatus is particularly useful for filling plastic bags with an intravenous ("IV") solution (e.g., saline, glucose, glucose and sodium chloride, etc.).

Fig. 1 illustrates a typical IV bag 10 manufactured using the apparatus of Fig. 2. The bag 10 is manufactured from a suitable plastic such as non-PVC (polyvinyl chloride) plastics, with polyolefins being the preferred material. The bag 10 includes two side seals 15, a top seal 20, a bottom seal 25, a port 30, and a cap 35. Each of the side seals 15 extends along a substantial portion of the length of the bag 10 and intersects the top seal 20 and bottom seal 25. The top seal 20 includes a punched hole 40 or partial hole that leaves a flap (D-flap). The hole 40 or partial hole is suitable for hanging the IV bag 10. The bottom seal 25 defines a sloped intersection on the inside of the bag 10 that serves to guide all of the fluid within the bag to the port 30 when the bag 10 hangs from the hole 40.

The port 30 is a plastic member that is sealed to the bag 10 as part of the bottom seal 25. The port 30 allows for the insertion of a fill device to fill the bag 10 and receives the cap 35 to seal the bag 10 for storage. The port 30 includes several cylindrical surfaces 45 that are suitable for use in supporting and moving the bag 10 during the manufacturing and filling process.

It should be noted that the present invention is suited to manufacture bags of many sizes and shapes. The bag 10 illustrated in Fig. 1 is illustrative of one such bag and should not limit the invention to devices that manufacture only that bag.

Turning to Fig. 2, a schematic of the apparatus 5 is illustrated. The apparatus 5 includes a web unwind module 50, a side seal module 55, a print module 60, a top seal module 65, a rotary station 70, and a fill conveyor 75. The apparatus 5 illustrated in Fig. 2 shows two manufacturing lines parallel and adjacent one another. Thus, the apparatus 5 manufactures two bags 10 simultaneously on two separate lines. Because the lines are identical, only one will be described in detail with references made to the second line as appropriate.

During the manufacturing process, a double-wound web 80 is unrolled from a drum 85 and delivered to the apparatus 5. The double- wound web 80 includes two layers of polyolefin plastic that are stuck to one another at what will become the IV bag's inner surfaces. The double-wound web 80 defines a width that is substantially equal to the final width of the finished IV bag 10. The web 80 is stored on the drum 85 as a continuous band of material, thus enabling the mass production of the bags 10. It should be noted that other arrangements of material may also be used with the present invention. For example, tube material may be used rather than a double-wound web 80. Furthermore, cast material produced in a single layer and slit to size and rewound together or folded and rewound such that one side is sealed and the other is open may also be used in the present invention. It should be clear to a person having ordinary skill in the art that any arrangement of material in which two layers are disposed next to one another is suitable for use in manufacturing bags using the present invention. Therefore, the terms "double-wound web" or "web" as used herein are meant to encompass any arrangement of material in which two plies, separate or attached to one another, are arranged adjacent one another.

The web unwind module 50 allows the web 80 to unwind from the drum 85, and orients the web 80 to the apparatus 5. The web 80 first enters the side seal module 55. The side seal module 55 forms the side seals 15 in the double- wound web 80 as it passes through the module 55. From the side seal module 55, the double- wound web 80 enters the printing module 60. Within the printing module 60, information such as instructions, warnings, and bag contents are printed on the web 80. After printing, the double- wound web 80 proceeds to the top seal module 65. The top seal module 65 operates to form top seals 20 in the double- wound web 80 as it passes. After the top seal 20 is formed the double-wound web 80 double-wound web 80 proceeds to the rotary station 70.

The rotary station 70 rotates in a clockwise fashion as illustrated in Fig. 2 to allow for more modules to fit into a smaller space. The rotary station 70 includes a cutting module 90, a bag opening module 95, a port insert and first bottom seal module 100, a second bottom seal module 110, and a transfer module 115 that transfers completed empty bags 10 to the fill conveyor 75.

The cutting module 90 cuts the double-wound web 80 to separate a partially completed IV bag from the web 80. Once cut, the rotary station 70 rotates the partially completed bag to the bag opening module 95. The bag opening module 95 opens the bag and prepares it for receipt of a port 30. Again, the rotary station 70 indexes to the next station. The port insert and first bottom seal module 100 inserts the port 30 into the bag, connects the port 30 to the bag, but does not seal the entire bottom of the bag. Instead, the bags rotate to the second bottom seal module 110 where the bottom seal 25 is completed. The bag 10 is then rotated to the transfer module 115 where it is transferred to the fill conveyor 75.

The fill conveyor 75 extends substantially normal to the direction of travel of the double-wound web 80 and includes an accumulating station 120, a filling station 125, a capping station 130, and a dispensing station 135. The completed empty bags 10 are transferred to the accumulating station 120 by the transfer module 115. The bags 10 are stored in the accumulating station 120 until the desired number of bags 10 are present. The bags 10 are then transferred to the filling station 125. In the filling station 125, a plurality of nozzles 140 simultaneously fill each of the empty bags 10 to produce a plurality of full bags 145. The full bags 145 are transferred to the capping station 130, where a plurality of caps 35 are simultaneously installed on the now full bags 145. After capping, the capped bags 150 are transferred to the dispensing station 135 where they are dispensed to a conveyor or other device. Figs. 3 through 20 illustrate the various modules in greater detail and will now be discussed. WEB UNWIND MODULE

Turning first to Figs. 3 and 4, the web unwind module 50 is illustrated as including the drum 85 supporting the double- wound web 80, a plurality of tension control rollers 155, an angled turning roller 160, and a feed roller 165. A spindle 170 supports the drum 85 for rotation, thereby allowing the drum 85 to rotate freely and dispense the double- wound web 80. A drive mechanism located downstream of the web unwind module 50 pulls the web 80 from the drum 85 and through the various modules. The web 85 travels through the plurality of tension control rollers 155 in a serpentine fashion before going to the angled turning roller 160. Two of the tension control rollers 155 are supported for rotation on a movable arm 175. The arm 175 is able to move to accommodate changes in tension in the web 80, thus maintaining the desired tension during the intermittent motion of the web 80.

The angled turning roller 160, best illustrated in Fig. 4, turns the web 80 such that it travels on an exit path that is substantially normal to the entry path of the web 80. The web 80 then travels around the feed roller 165 toward the side seal module 55. In another construction, the web 80 is fed parallel to the desired direction of travel, thereby eliminating the need for the angled turning roller 160. SIDE SEAL MODULE The side seal module 55, best illustrated in Fig. 5, includes a lower actuator 180 supporting a lower press 185, and an upper actuator 190 supporting an upper press 195. A support table 200 supports the lower actuator 180 and the lower press 185 in the desired position. A plurality of spacer rods 205 attach to the support table 200 and support an upper platform 210 a distance above the support table 200. The upper platform 210 supports the upper actuator 190 and the upper press 195 in the desired position. The actuators 180, 190 are pneumatic cylinders movable between an open position and a closed position. In the open position, the web 80 is free to advance between the upper and lower press 195, 185. hi the closed position, the upper press 195 and lower press 185 move together to define a gap sized to form the side seals 15. The upper actuator 190 has a fixed stroke length, while the lower actuator 180 has an adjustable stroke length. An adjusting member such as an adjusting screw 215 on the lower actuator 180 allows for precise control of the gap. In another construction, the upper actuator 190 is adjustable, while the lower actuator 180 has a fixed stroke length, hi still other constructions, both actuators 180, 190 are adjustable. While a pneumatic actuator has been described, it should be understood that many other actuators could be used to form the side seals 15. For example, in one construction a stepper motor drives a screw that precisely positions the upper press a desired distance from the lower press to form the side seal. The use of a stepper motor allows for the precise positioning of the presses and adjustment of the gap. hi still other constructions, adjustable hydraulic cylinders are used.

The upper press 195 and the lower press 185 each support side seal tools 220 positioned and shaped to form the desired side seal 15. The upper side seal tools 220A are generally flat, while the lower side seal tools 220B are contoured to form the side seal 15. The bottom side seal tools 220B, illustrated in Fig. 6, include seal blocks 225, bearing blocks 230, a lead screw 235, a heating element 240, and a thermocouple 245. Each of the seal blocks 225 includes a thermocouple bore, a heating element bore and a raised seal-forming surface 250. The heating element bore receives the heating element 240 and is positioned adjacent the seal-forming surface 250. The thermocouple 245 is disposed in the thermocouple bore and is operable to measure the temperature of the seal block 225. A controller cycles each of the heating elements 240 on and off to maintain the seal block 225 at the desired temperature for seal formation.

The bearing blocks 230 support the lead screw 235 for rotation and are attached to the lower press 185. One half of the lead screw 235 is threaded with a right-hand thread, while the other half is threaded with a left-hand thread. Two nuts (not shown) engage the seal blocks 225 and are threaded onto the lead screw 235. One nut includes right-hand threads and is threaded on the right hand portion. The other nut includes left-hand threads and is threaded on the left-hand portion. Both nuts are positioned such that they cannot rotate in response to rotation of the lead screw 235. Thus, rotation of the lead screw 235 in one direction moves the two nuts towards one another and rotation in the opposite direction moves the nuts away from one another. The seal blocks 225 engage the nuts and move along with them. Thus, with a simple rotation of the lead screw 235, the width between side seals 15 can be adjusted, thereby allowing one set of side seal tools 220 to be useful for the manufacture of any width bag 10 to accommodate double- wound web 80 material of varying widths.

The adjustable side seal tools 220 allow for a quick transition from one bag size to another. In previous devices, several hours were required to replace the side seal tooling. With the apparatus described herein, the side seal tools can be adjusted in a matter of minutes.

As previously mentioned, the upper side seal tools 220A are generally flat. However, like the lower side seal tools 220B, the upper side seal tools 220A include heating elements 240 and temperature sensors such as thermocouples 245 adjacent the portion of the tool where the seal is formed. The heating elements 240 are cycled by the controller in response to the temperature of the upper side seal tools 220A as measured by the thermocouples 245. Thus, the controller maintains both the upper and lower side seal tools 220A and 220B at a desired temperature.

To form a side seal 15, the web 80 is positioned between the open upper press 195 and lower press 185. The web travel stops and the upper press 195 and lower press 185 move to their closed position. The heated side seal tools 220A and 220B contact and heat the web 80 at the desired side seal locations. In addition, the actuators 180, 190 provide a predetermined amount of compression to allow the heated plies of the double- wound film 80 to weld to one another and form the side seals 15. After a predetermined length of time (e.g., two seconds) the upper press 195 and lower press 185 return to their open position and the web 80 advances to the printing module 60.

It is important to note that the side seal module 55 illustrated in Fig. 5 includes two upper presses 195 and two lower presses 185 capable of forming side seals 15 in two separate webs 80 simultaneously. As can be seen in Fig. 5, the two upper presses 195 each include their own actuator 190 and are separately actuatable as are the bottom presses 185. Furthermore, each of the bottom actuators 180 includes it's own adjusting screw 215. As such, the lower presses 185 are independently adjustable as well as independently actuatable.

PRINTING MODULE

The printing module 60 receives the web 80 after the side seals 15 have been formed. The printing module 60 prints any necessary information onto the bags 10 (e.g., instructions, warnings, manufacturer, contents, etc.). From the printing module 60, the double- wound web 80 proceeds to the top seal module 65.

TOP SEAL MODULE

With reference to Fig. 7, a top seal module 65 is illustrated as including an upper actuator 250, a lower actuator 255, an upper press 260, and a lower press 265. The upper and lower actuators 250, 255 are supported in much the same manner as was described with regard to the side seal actuators 180, 190. The upper actuator 250 supports the upper press 260 and is operable between an open position and a closed position. The lower actuator 255 supports the lower press 265 and is operable between an open position and a closed position. Like the side seal module 55, one or both of the actuators 250, 255 may be adjustable to allow for the precise control of the seal formation process.

The upper press 260 and the lower press 265 support top seal tools 270 shaped and positioned to form a top seal 20 in the web 80 when the upper press 260 and the lower press 265 are in the closed position, hi most constructions, the upper top seal tool 270A is generally flat and the lower top seal tool 270B is contoured to form the top seal

20. However, other arrangements are possible. For example, the upper top seal tools

270A could be contoured rather than the lower top seal tools 270B.

The contour of the top seal tool 270 in preferred constructions is such that the same contour can be used for several different bag widths. This allows for a quick change in the size of bag being produced, without the long duration downtime of previous machines. The same top seal tool 270 is capable of forming top seals 25 in multiple width bags.

Like the side seal tools 220, both the upper and lower top seal tools 270A and

270B include a heating element and a thermocouple adjacent the heating elements. The thermocouples measure the temperature of the top seal tools 270 A and 270B. The controller cycles the heating elements on and off based on the temperature readings of the thermocouples to maintain the top seal tools 270A and 270B at the ideal temperature. To form a top seal 20, the web 80 is positioned between the open upper press 260 and lower press 265. The web travel stops and the upper press 260 and lower press 265 move to their closed positions. The heated top seal tools 270 contact and heat the web 80 at the desired top seal location. In addition, the actuators 250, 255 provide a predetermined amount of compression to allow the heated plies of the double- wound film 80 to weld to one another and form the top seals 20. After a predetermined length of time (e.g., two seconds) the upper press 260 and lower press 265 return to their open position and the web 80 advances to the cutting module 90.

Again, it is important to note that the second manufacturing line shown in Fig. 7 is substantially identical and independent of the first manufacturing line. CUTTING MODULE

The cutting module 90 is the first module in the rotary station 70 and is operable to separate a partially completed bag from the double-wound web 80. As shown in Figs. 8 and 9 the cutting module 90 includes an actuator such as a pneumatic cylinder 280, a cutter 285, a cutting surface 290, a first clamp 295 (shown in Fig. 9), and a second clamp 300. The cutting surface 290 extends immediately below the web 80 and supports the web 80 when clamped into the cutting position to facilitate an accurate and straight cut through the double-wound web 80. A slot 305 in the cutting surface 290 extends in a direction perpendicular to the direction of travel of the double-wound web 80 and defines a cut line.

The first clamp 295, illustrated in Fig. 9 is movable between an open position and a closed position. In the open position, the web 80 is free to enter and exit the clamp 295. In the closed position, the clamp 295 firmly retains the web 80. The first clamp 295 is located on the rotary station 70 such that it rotates with the station 70 when the station 70 { is indexed to the next module. The second clamp 300 moves from an open position to a closed position and is operable to retain the web 80 between a clamp foot 310 and the cutting surface 290. The first clamp 295 and the second clamp 300 are pneumatically actuated with other actuators (e.g., hydraulic, motor-driven, etc.) being usable.

In some constructions, the clamp foot includes a slot that when in the closed position aligns with the slot 305 in the cutting surface 290. The clamp foot 310 includes a contoured bottom shaped to engage the web 80 adjacent both sides of the slot 305. In another construction illustrated in Fig. 9, the foot 310 does not include a slot. Instead, the cutter 285 passes along a cut line adjacent the foot 310, as illustrated in Fig. 9.

The cutter 285 is disposed at least partially within the slot 305 and is movable between a first position and a second position. The cutter 285 is a sharp knife-edge blade such as a razor blade. In another construction, another cutter is used (e.g., laser, hot-wire, etc.). The cutter 285 is supported and moved by the pneumatic cylinder 280 between the first position wherein the cutter 285 is adjacent one side of the web 80 and the second position wherein the cutter 285 is adjacent the opposite side of the web 80. In some constructions, the cutter 285 is hook or crescent shaped with the sharpened portion located on the interior of the hook-shape.

The cutting module 90 is operable to separate a partially completed bag from the double-wound web 80. The free end of the web 80 including the top seal 20 is fed through the open second clamp 300 and into the open first clamp 295. The first clamp 295 closes to retain the free end of the web 80. The second clamp 300 closes to retain the web 80 adjacent the cut line. The pneumatic cylinder 280 moves the cutter 285 from one side of the web 80 to the opposite side to cut the web 80 and produce a separated partially complete bag and a new free end on the web 80. The second clamp 300 opens to release the end of the partially complete bag and the web 80. However, the first clamp 295 remains closed as the rotary station 70 indexes to the next station along with the newly separated partially complete bag.

The use of a cutter 285 rather than a die to separate the partially completed bags from the web 80 provides several advantages. For example, the cutter reduces waste and the need to handle waste by separating the partially completed bag without detaching other portions of the web 80. Thus, the entire web 80 is used for bags and there is no need to collect the small pieces of scrap material that previous devices discarded. In addition, dies sometimes produce dust (particulate matter, (pm)) as they cut the web 80. The dust (pm) can get into the bags or other modules and cause damage or excessive wear of moving components. Furthermore, die-type cutters and clicker press cutters produce particulate matter (pm) that can get into bags. In many constructions, one or more alignment devices are positioned between the web unwind module 50 and the drive mechanism located adjacent the cutting module 90. The drive mechanism pulls the web 80 through all of the modules and pushes the web 80 through the cutting module 90. However, the drive mechanism cannot correct for misalignment of the web 80 as it moves between the various modules. Thus, alignment devices are employed to maintain the web 80 in the desired track. Sensors detect the web's position and operate skew rollers to adjust the track of the web 80. The skew rollers comprise one or more rollers on which the web travels. The skew rollers are positioned at an angle to the direction of web travel that is adjustable. By changing the angle of the skew roller, the web 80 is forced to move to the left or to the right of its travel path. Skew rollers of this type are well known in the art of bag manufacture. In other constructions, mechanical tracking devices such as guides are employed to assure proper alignment of the web 80 in the various modules.

The drive mechanism is capable of precise positioning of the web 80 to allow for accurate cutting and a further reduction in waste. Each partially completed bag is cut where desired, thereby reducing the amount of extra web material left on the bags following the cutting operation. ROTARY STATIONS

From the cutting module 90, the rotary station 70 illustrated in Fig. 2 moves the partially completed bag to the bag opening station module 95. In the bag-opening module 95, the two sheets of the double-wound bag are partially separated to facilitate insertion of the port 30. Once opened, the rotary station 70 again indexes. The next station is the port insertion and first seal module 100. A port 30 is inserted into the partially open bag and a partial seal is made between the bag and the newly inserted port 30. The first bottom seal assures the proper positioning of the port 30 within the bag prior to making the final seal at the second bottom seal module 110. At the second bottom seal module 110 in the next indexed position, tooling similar to that described with regard to the side seal module 55 and the top seal module 65 forms the bottom seal 25 and sealably attaches the port 30 to the bag. Following the second bottom seal module 110, the bag 10 is complete and all that remains are the filling and capping operations. The rotary station 70 indexes the bag 10 to the transfer module 115 where the first clamp 295 releases the bag 10 and the bag 10 is transferred to the fill conveyor 75. Once transferred by the transfer module 115, the rotary station 70 indexes again to begin a new cycle. TRANSFER MODULE

The transfer module 115 delivers completed bags 10 to the fill conveyor 75. The transfer module 115, illustrated in Fig. 11 includes a carriage 315, an arm member 320, a gripper 325, and a track 330. The gripper 325 is shaped to selectively engage the port 30 of a completed bag 10 at the rotary station 70. The arm member 320 supports the gripper 325 and the bag 10. The arm member 320 pivotally attaches to the carriage 315 such that the arm 320 is pivotable through a 90° arc. The carriage 315 moves along the track 330 to deliver the bags 10 from the rotary station 70 to the accumulating station 120.

To move a completed bag 10, the carriage 315 moves to a first position such that the arm 320 and gripper 325 are located adjacent the completed bag 10. The gripper 325 clutches the port 30 extending from the bag 10 as the first clamp 295 disengages the bag 10. The carriage 315 moves towards the accumulating station 120 as the arm 320 pivots 90° to reorient the bag 10 in a port up position. The bag 10 is positioned and released within the accumulating station 120 and the arm 320 returns for the next bag 10. In addition to the gripper 325, the transfer module 115 includes a suction member

(not shown) that engages the bag 10 as it is transferred, hi certain situations, it is possible for the gripper 325 to fail in transferring the bag 10. For example, a defective bag, or a defective port may prevent engagement. Under these conditions, the suction member extracts the bag 10 from the rotary station 70 and deposits it in a waste container. The suction member prevents the defective bag from remaining in the first clamp 295 as the clamp 295 attempts to receive a new bag at the cutting module 90. FILL CONVEYOR

The fill conveyor 75, illustrated in Fig. 10, includes the accumulating station 120, the filling station 125, the capping station 130, and the dispensing station 135. The accumulating station 120 receives the empty bags 10 and establishes a queue. While any number of bags 10 can define the queue, Figs. 10-17 illustrate a queue of four bags 10. The use of the accumulating station 120 allows for additional time in the filling station 125 and the capping station 130, thereby allowing both operations to be performed while the bags are stationary. It should be noted that the fill conveyor 75 is separately operable from the modules that manufacture the bags 10. In some applications, completed empty bags 10 are shipped to a different site or different location within a plant for filling. Therefore, while the illustrations included herein show the fill conveyor 75 receiving empty bags 10 directly from the manufacturing device, the invention should not be limited to that application alone.

The accumulating station 120 includes a bag support such as a receiving channel 335 and a transfer device such as an indexing beam 340. The receiving channel 335, best illustrated in Figs. 17-19, is an open channel in which the transfer module 115 deposits the empty bags 10 in a port up position. The receiving channel 335 includes a slot that is wide enough to receive the ports 30 and narrow enough to support the ports 30. Once placed, the transfer arm 320 returns to retrieve the next bag 10. A positioning bar (not shown) that includes four extensions moves down from above the receiving channel 335 and engages the port 30 or ports of the bags 10 disposed in the receiving channel 335. One of the extensions engages the port 30 of each of the bags 10 and advances the bags 10 in the channel 335 to properly space the bags 10 apart from one another. The extension nearest the transfer module 115 engages the port 30 of the first bag 10 and slides it down the receiving channel 335 one bag position. After the second bag 10 is placed in the receiving channel 335, the positioning bar again drops and the first two extensions engage the two bags 10 disposed in the channel 335. The positioning bar again moves one bag position advancing the two bags 10. A third bag 10 is placed in the receiving channel 335 and the positioning bar moves into engagement with the three bags 10 to index them one bag position. A fourth bag 10 is placed into the receiving channel 335 and the positioning bar moves into engagement with all four bags 10. The positioning bar indexes the bags 10 one more position, thus placing them in a position that allows for their movement into the filling station 125. FILLING STATION Referring to Figs. 12-14 and 17-19, the filling station 125 of the invention is shown. The filling station 125 includes a supporting beam 345 positioned above the indexing beam 340 that is movable between an open position and a closed position. The supporting beam 345 extends between the filling station 125 and the capping station 130 to support bags therein. The empty bags 10 are transferred from the accumulating station 120 to the filling station 125 by the indexing beam 340. The supporting beam 345 remains open until the indexing beam 340 positions the bags 10 at the desired location within the filling station 125. The supporting beam 345 then moves to its closed position to engage and support the bags 10 in the filling station and the indexing beam 340 opens to release the bags 10. As the filling process begins, the indexing beam 340 moves back to the accumulating station 120 to transfer the next set of bags 10.

The filling station 125 includes a plurality of nozzles 140, each adapted to engage the port 30 of one of the empty bags 10. The bags 10 are filled with a fluid through the nozzles 140. In many cases it is necessary to fill the bags 10 slowly so as not to disturb the fluid, h addition to nozzles 140, flow regulators, filters and other fluid handling equipment may be needed and used within the filling station 125. By filling the plurality of bags 10 simultaneously, sufficient time is available to completely fill the bags 10 in one stationary position using a single nozzle 140 for each bag 10, while simultaneously reducing the likelihood of excessive foaming.

The nozzles 140 are positioned over the ports 30 of the four bags 10 and are movable vertically to engage and fill the bags 10. In addition, as shown in Fig. 13 the nozzles 140 are pivotable between an idle position and a cleaning position to facilitate cleaning.

As illustrated in Figs. 12-14, the filling station includes a main solution pipe 350 disposed above the filling station 125. The pipe 350 delivers solution to each of the nozzles 140. The flow path of the solution to each nozzle 140 is similar for all of the nozzles 140, thus only one flow will be described. The flow may pass through a series of pipes, valves, and filters before reaching the nozzle 140 and ultimately the bag 10. Each flow path includes a plurality of sanitary diaphragm valves. A first valve 355 controls the flow of solution into the bag 10. The valve 355 opens to deliver solution and closes to prevent the flow of solution. A second sanitary diaphragm valve 360 controls the application of vacuum to the nozzle 140. Vacuum is applied following a fill operation to prevent solution from dripping. In addition, each fill position includes a sanitary CIP diaphragm valve 365 that is operable to initiate and terminate a clean-in- place (CIP) operation.

Additional, valves and fittings are also positioned to facilitate a steam-in-place (SIP) process. The apparatus, as illustrated in Figs. 12-14, is capable of performing either a CIP or SIP operation to clean the apparatus to suitable standards, hi addition, each nozzle includes a dispensing port 370 and an isolation valve 375. The dispensing port 370 allows for the individual testing of each of the flow paths. The isolation valves 375 allow one or more of the flow paths to be cut-off to allow for further cleaning of only the flow paths that require cleaning. For example, following a CIP operation, each flow path can be individually tested. The isolation valves 375 of flow paths that pass the test can be closed, while the isolation valves 375 of the paths that do not pass remain open to facilitate additional cleaning.

A flow meter 380 and filter 385 are positioned in each flow path. The flow meter 380 measures the volume of solution delivered to the bag 10 and controls the diaphragm valve 355 to assure an accurate fill. The filter 385 is positioned in the flow path to filter out any debris that may become introduced into the flow stream. Once the filling operation is completed, the indexing beam 340 closes and the supporting beam 345 opens to allow the now full bags 145 to be transferred to the capping station 130. CAPPING STATION

Turning now to Fig. 15-16, the capping station 130 of the invention is shown. The capping station 130 receives caps 35 from a cap feeder bowl 390 and attaches them onto the filled bags 145 to complete the assembly and filling process. The capping station 130 includes a cap-receiving bar 395, a plurality of cap actuators 400, a plurality of heaters 405, and the supporting beam 345.

A cap hopper 410 discharges caps 35 into the cap feeder bowl 390 as illustrated in Fig. 10. The cap feeder bowl 390 vibrates to reposition the caps 35 such that they are in the desired orientation for installation into the ports 30. The vibration also works to deliver the caps 35 single-file to a cap gate 415 that selectively allows one cap 35 at a time to enter the cap-receiving bar 395.

Returning to Fig. 15, the cap-receiving bar 395 indexes to receive additional caps 35 until the bar 395 is full. Again, the construction described herein caps four bags simultaneously. Other constructions may cap more or fewer bags as desired. The actuators 400 move into an engagement position such that each actuator is positioned above one of the caps 35. The actuators 400 move engaging members into contact with the caps 35 to pick them up out of the cap-receiving bar 395. hi some constructions, vacuum or suction is used to grab the caps 35. Other constructions use grippers. Once the caps 35 are removed, the cap-receiving bar 395 moves to receive four new caps 35 for the next set of bags 145. Turning to Fig. 16, the plurality of heating elements 405 are shown in a heating position between the ports 30 and the caps 35. The heaters 405 are supported on a pivotable and slidable support 420. The support 420 slides into heating alignment and then pivots the heaters 405 into heating position above the ports 30. In some constructions, the heating elements 405 pivot into position, while in other constructions the heaters 405 move in a linear motion. The actual path the heaters 405 take to get into and out of the heating position are not important to the function of the invention.

Once the heater 405 is positioned, the actuator 400 moves the caps 35 into position immediately above the heater 405 such that each heater 405 may simultaneously heat the port 30 and cap 35 for one of the bags 145. Like the side seal and end seal heaters 240, the cap/port heaters 405 include thermocouples that measure the heater temperature and allow a controller to cycle the heating element 405 to maintain the desired temperature.

Once the ports 30 and caps 35 are heated sufficiently, the heaters 405 are moved out of the heating position and the actuators 400 move the caps 35 into engagement with the ports 30. The actuators 400 maintain the engagement position for a predetermined length of time (e.g., 4 seconds) to weld the caps 35 to the ports 30 and form a permanent airtight seal.

In some applications, it is desirable to reduce the oxygen content within the filled and capped bags 150. To facilitate this process, the heaters 405 each include a tube that allows for the introduction of a gas into the filled bag 145 as the port 30 and cap 35 are being heated. In most cases, medical grade nitrogen is introduced to displace the air and reduce the oxygen content by as much as 95% before capping the bag.

Once capped, the filled bags 150 are ready to be dispensed from the apparatus. The indexing beam 340 closes to engage the filled and capped bags 150 and the supporting beam 345 opens to release the filled and capped bags 150. The four filled and capped bags 150 are advanced to the dispensing station 135 by the indexing beam

340.

DISPENSING STATION With reference to Figs. 18-19, the dispensing station 135 includes three separately actuatable pickers 425. Each of the pickers 425 closes to engage one of the filled and capped bags 150 as the indexing beam 340 opens. Because the fourth bag 150 is not engaged by a picker 425 it drops to a conveyor positioned below and is transported away from the apparatus 5. The remaining three pickers 425 open in a predetermined timed interval to position the bags 150 on the conveyor as desired. For example, one construction opens the first of the pickers 425 two seconds after the indexing beam 340 opens. The second picker 425 opens two seconds after the first picker 425 and the third and final picker 425 opens two second after the second picker 425. In this construction, it takes six seconds to dispense the four bags 150 to the conveyor. Other constructions may use longer or shorter intervals as desired. For example, another construction eliminates the individual pickers 425 and dispenses all four bags simultaneously. ADJUSTABLE HEIGHT BAG DRAG

Disposed beneath the filling and capping stations 125, 130 is an adjustable height bag support 430. The bag support 430, illustrated in Fig. 20, includes a trough 435 and a support member such as two parallel bars 440. The bags 10 enter the filling station 125 and are supported by the parallel bars 440 so that they cannot hang freely. By supporting the bags 10 in this manner, the internal volume to which they expand when filled is reduced. This has the desirable effect of reducing the amount of air in the bag 10 after the desired shot of fluid has been injected into the bag 10. The filled bags 145 remain in this position until they are capped, thus reducing the volume of air in the capped bag 150. The trough 435 includes a drain 445 that redirects any spilled fluid to a desired collection point. The entire trough 435 is supported for movement up or down to allow the bag support 430 to function with any size bag 10 (e.g., 250 ml, 500 ml, 1000 ml, etc.). INDEXING AND SUPPORTING BEAMS

Before describing the function of the indexing beam 340 and supporting beam 345 in detail, it should be noted that the description of the fill conveyor 75 contained herein describes a system in which the accumulating station 120 is immediately adjacent the filling station 125 which is immediately adjacent the capping station 130 which is immediately adjacent the dispensing station 135. It should be understood that many constructions may require idle stations between one or more of the above described stations. The idle stations allow for the efficient spacing of components in the fill conveyor 75. If idle stations are present, the indexing beam 340 and supporting beam 345 would extend into these idle stations and advance or support bags in much the same manner as they do in the aforementioned stations. Therefore, the invention should not be limited to fill conveyors 75 in which the above-described stations are immediately adjacent one another.

As described herein and illustrated in Fig. 17, the indexing beam 340 moves empty bags 10 from the accumulating station 120 to the filling station 125, full bags 145 from the filling station 125 to the capping station 130, and capped bags 150 from the capping station 130 to the dispensing station 135 simultaneously. In addition, the single supporting beam 345 supports the bags 10 being filled in the filling station 125 and the bags 145 being capped in the capping station 130.

Fig. 17 illustrates the fill conveyor 75 at the beginning of a transfer cycle. The indexing beam 340 is closed to support four empty bags 10 in the accumulating station

120, four full bags 145 in the filling station 125, and four capped bags 150 in the capping station 130.

Fig. 18 illustrates the fill conveyor 75 after the bags have been transferred. The indexing beam 340 has moved the empty bags 10 into the filling station 125, the full bags 145 into the capping station 130, and the capped bags 150 into the dispensing station 135.

Once in this position, the supporting beam 345 closes to engage the bags 10, 145 in the filling station 125 and the capping station 130 and the three actuatable pickers 425 in the dispensing station 135 each engage one of the bags 150. As illustrated in Fig. 18, the pickers 425 engage only the three bags 150 nearest the capping station 130, thus allowing the endmost bag 150 to drop.

Fig. 19 illustrates the fill conveyor 75 a short time after the transfer of the bags illustrated in Fig. 18. The indexing beam 340 has opened and is in the process of returning to the position illustrated in Fig. 17 with the exception that the indexing beam

340 remains open. The outer most bag 150 has dropped to the conveyor below and the first picker 425 has released its bag 150 leaving the final two capped bags 150 supported by the final two pickers 425. The supporting beam 345 is closed and supports the bags

145, 10 being capped and filled.

The construction illustrated herein positions the indexing beam 340 beneath the supporting beam 345. Other constructions reverse this position, hi still other constructions, separate indexing beams and/or separate supporting beams are employed to allow more control over the opening and closing timing within the accumulating station 120, the filling station 125, the capping station 130, and the dispensing station 135.

While the dispensing station 135 has been described as dispensing the bags 150 to a conveyor, it should be understood that the conveyor is not important to the invention. Other constructions may dispense the completed bags 150 into stationary receptacles that are moved away by workers, thus eliminating the conveyor.

Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of the invention as described and defined in the following claims.

Claims

ClaimsWhat is claimed is:

1. A sealing apparatus for sealing at least a first web and a second web, the first web and the second web each including sides, the sealing apparatus comprising: a first press having a first tool adapted to receive the first web, the first press operable to move the first tool between an open position and a closed position sealing the sides of the first web; and a second press having a second tool adapted to receive the second web, the second press operable to move the second tool between an open position and a closed position to seal the sides of the second web independent of the first tool.

2. The sealing apparatus of claim 1, wherein the first sealing tool includes an upper tool portion and a lower tool portion such that in the open position the upper and lower tool portions are separated and out of contact with the web, and such that in the closed position the upper and lower tool portions define a sealing gap and the first web is positioned within the sealing gap in contact with the upper and lower tool portions.

3. The sealing apparatus of claim 2, wherein the first press includes an upper actuator operable to move the upper tool portion, and a lower actuator operable to move the lower tool portion, and wherein at least one of the upper actuator and the lower actuator is adjustable to vary the sealing gap.

4. The sealing apparatus of claim 3, wherein the upper and lower actuators are pneumatic cylinders.

5. The sealing apparatus of claim 4, wherein at least one of the upper and lower actuators includes an adjustment screw that varies the sealing gap.

6. The sealing apparatus of claim 2, wherein the first web defines a longitudinal direction and an axial direction perpendicular to the longitudinal direction, wherein at least one of the upper and lower tool portions includes first and second side portions separated by a distance, and wherein at least one of the first and second side portions is movable in the axial direction to vary the distance between the first and second side portions.

7. The sealing apparatus of claim 6, wherein the first tool includes a lead screw operable to move at least one of the side portions in the axial direction.

8. The sealing apparatus of claim 2, wherein at least one of the upper and lower tools includes a heating element.

9. The sealing apparatus of claim 8, wherein at least one of the upper and lower tools includes a thermocouple.

10. The sealing apparatus of claim 1, wherein the first and second webs are double-wound film.

11. The sealing apparatus of claim 10, wherein the apparatus is used to seal intravenous fluid containers.

12. The sealing apparatus of claim 1, wherein the apparatus is used to seal intravenous fluid containers.

13. The sealing apparatus of claim 1, wherein the double- wound film is made of a non-PVC material.

14. The sealing apparatus of claim 13, wherein the non-PVC material is a polyolefϊn material.

15. An apparatus for cutting a web of material used to make a fluid container, the web having a leading portion and a width, the apparatus comprising: a drive system operable to advance the web in an advancement direction; and a cutting member movable in a direction substantially normal to the advancement direction across the width of the web and operable to separate the leading portion from the web to define a partially complete fluid container.

16. The apparatus of claim 15, further comprising a die operable to punch the web and at least partially remove a portion to define a hole.

17. The apparatus of claim 15, further comprising a pneumatic cylinder operable to move the cutting member across the width of the web.

18. The apparatus of claim 15, wherein the cutting member is a blade.

19. The apparatus of claim 15, wherein the web includes a plurality of end seals, the cutting member cutting the web adjacent to one of the plurality of end seals such that after the leading portion is separated by the cutting member the leading portion includes only one of the plurality of end seals.

20. The apparatus of claim 15, further comprising a clamp movable between an open position and a clamped position that resists movement of the web, the clamp being in the clamped position when the cutting member separates the leading portion

21. The apparatus of claim 20, wherein the clamp includes a first clamp adjacent to the leading portion and a second clamp adjacent to the cutting member.

22. The apparatus of claim 21, wherein the cutting member is at least partially received within the second clamp.

23. The apparatus of claim 20, further comprising a pneumatic cylinder operable to move the clamp between the open position and the clamped position.

24. The apparatus of claim 15, wherein the web of material passes through the drive system before it passes through the cutting member.

25. The apparatus of claim 15, wherein the fluid container is an intravenous fluid container.

26. The apparatus of claim 15, wherein the web is a double- wound film.

27. The apparatus of claim 26, wherein the double- wound film is made of a non-PVC material.

28. The sealing apparatus of claim 27, wherein the non-PVC material is a polyolefin material.

29. An apparatus for filling bags with an intravenous solution comprising: an accumulating station operable to receive and support a plurality of empty bags; and a filling station operable to receive the plurality of empty bags from the accumulating station and to temporarily maintain the bags stationary, the filling station including a corresponding plurality of nozzles, wherein each of the corresponding plurality of nozzles fills one of the plurality of empty bags with the intravenous solution when the plurality of empty bags are held stationary, to produce a plurality of full bags.

30. The apparatus of claim 29, wherein each of the plurality of bags includes a respective port, and wherein the accumulating station and the filling station support each of the plurality of empty bags by the port.

31. The apparatus of claim 29, further comprising an indexing mechanism operable to move the plurality of empty bags from the accumulating station to the filling station.

32. The apparatus of claim 31 , wherein the indexing mechanism is operable to move the plurality of full bags from the filling station to the capping station.

33. The apparatus of claim 29, further comprising a capping station operable to receive and support the plurality of full bags from the filling station, and to cap the plurality of full bags to produce a plurality of capped bags.

34. The apparatus of claim 33, wherein each of the plurality of bags includes a respective port, and wherein the capping station includes a plurality of heating elements, each heating element operable to heat one of a plurality of caps and a port.

35. The apparatus of claim 34, wherein the capping station connects one of the plurality of caps to a port after the one of the plurality of caps and the port is heated by the heating element.

36. The apparatus of claim 33, further comprising a bag support positionable beneath the bag to support the bag in the filling and capping stations and operable to reduce the volume within the filled bag.

37. The apparatus of claim 33, further comprising a discharge station operable to receive and support the plurality of capped bags to controUably discharge each of the plurality of capped bags from the discharge station.

38. The apparatus of claim 37, wherein the indexing mechanism is operable to move the plurality of capped bags from the capping station to the discharge station.

39. The apparatus of claim 38, wherein the indexing mechanism includes a supporting beam movable between an open position and a clamped position capable of supporting a plurality of empty bags in the filling station, and an indexing beam movable between an open position and a clamped position capable of supporting a plurality of empty bags, the indexing beam being movable relative to the supporting beam to move the plurality of empty bags between the accumulating station and the filing station when the indexing beam is in the clamped position and the supporting beam is in the open position.

40. The apparatus of claim 37, wherein the discharge station includes a plurality of independently operable supports, each of the plurality of independently operable supports receiving and supporting one of the plurality of capped bags.

41. The apparatus of claim 40, wherein the plurality of independently operable supports release the plurality of capped bags at timed intervals.

42. The apparatus of claim 29, wherein the bags are made from a double- wound film.

43. The apparatus of claim 29, wherein the bag is made from a non-PVC material.

44. The apparatus of claim 29, wherein the non-PVC material is a polyolefm material.

45. The apparatus of claim 29, wherein the plurality of nozzles are movable between an idle position and a cleaning position.