APPARATUS AND METHOD FOR DELIVERING A PRODUCT INTO A RECEPTACLE

FIELD AND BACKGROUND OF THE INVENTION

The present invention, in some embodiment thereof, relates to packaging of component materials, and more particularly, but not exclusively, to the mixing and storage of component materials before and during the packaging.

Various materials are formed by mixing two or more chemical components. For example foam, which is a mixture of isocyanate and polyol, expands and hardens within about 10-30 seconds. In many cases, a foam dispensing gun is used to generate the foam at the packaging site.

U.S. Pat. No. 3,178,157 by Cole, U.S. Pat. No. 6,691,898 by Hurray et al., and U.S. Pat. No. 5,462,204 by Finn, the disclosures of which are incorporated herein by reference, describe dispensing guns used in the making of foams, such as urethane foams.

As foam materials harden within a short time, remnants of the foam may harden within the dispensing apparatus and clog flow passageways. One solution to the clogging of passages is to include a solvent flushing path in the gun, which provides a solvent that cleans out portions of the gun that require cleaning, after every use. U.S. Pat. No. 4,262,847 by Stitzer et al. describes one such gun.

Other dispensing guns include a mechanical cleaning device that passes through the mixing chamber between uses. U.S. Pat. No. 5,405,083 by Moses, the disclosure of which is incorporated herein by reference, describes another dispensing gun in which, a disposable mixing tube is replaced, each time the gun is used.

U.S. Pat. No. 5,429,308 to Brown describes a mixing gun having a replaceable nozzle including a mixing chamber. Those parts of the gun that come in contact with the mixed chemicals are included in the replaceable nozzle. In the non-disposable part of the gun, respective valves are used to control the flow of each of the chemical components into the mixing chamber.

U.S. Pat. No. 6,375,096 by Rashidi describes a foam gun with a disposable nozzle attachment including a mixing chamber in which the chemicals mix. The disposable nozzle includes one way valves for each of the chemicals entering the nozzle attachment, so as to prevent backflow of the chemicals into the non-disposable part of the gun. The cost of the disposable nozzle attachments is not negligible and their replacement is time consuming. It is therefore desired to reduce and even eliminate the need for replacement of the disposable nozzle attachments, without incurring the costs and inconvenience involved in a solvent flushing system or a mechanical cleaning system.

U.S. Pat. No. 4,262,848 to Chabria describes a dispensing gun, which does not have a mixing chamber at all. The chemicals are mixed a short distance distal from the dispensing gun. Such mixing in the air, may result in a reduced quality of the foam. A flexible extension is suggested to be used to separately lead the chemicals before they are mixed to a location forward of the gun.

SUMMARY OF THE INVENTION

The present invention, in some embodiments thereof, relates to the delivery of fluids comprising a plurality of fluidic components into one or more receptacles, by directing the fluidic components into a mixing chamber located at a proximity of the receptacle. In the mixing chamber, the fluidic components are mixed and/or react together to form the fluid that is delivered into the receptacle.

According to an aspect of some embodiments of the present invention there is provided an apparatus for delivering a product into a receptacle having a feeding aperture. The apparatus comprises a mixing chamber having a plurality of inlets each configured for separately receiving at least one of a plurality of component materials and at least one outlet, the mixing chamber being configured for forming the product by mixing the plurality of component materials and injecting the product to the feeding aperture via the at least one outlet and a feeding element configured for being secured in a feeding channel for allowing the injecting.

Optionally, the distance between the mixing chamber and the aperture during the injecting is less than 5 centimeters.

Optionally, each the inlet being separately connected to a hydraulic tube configured for conducting respective the component material from a pump, wherein the distance between the mixing chamber and the pump is more than 10 centimeters.

Optionally, each the inlet being separately connected to a hydraulic tube configured for conducting respective the component material from a container, wherein the distance between the mixing chamber and the container is more than 10 centimeters.

Optionally, at least one of the feeding element and the mixing chamber is detachable.

Optionally, the distance between the mixing chamber and the aperture during the injecting is less than 1 centimeter.

Optionally, the feeding element is configured for containing the mixing chamber.

Optionally, the product is formed as an outcome of a chemical reaction between at least two of the plurality of component materials.

Optionally, the mixing chamber having a volume of less than 5 cubic millimeter for performing the mixing.

More optionally, the apparatus further comprises a motor unit configured for motivating at least one of the mixing chamber and the receptacle to the distance before the injecting.

More optionally, the apparatus further comprises a control unit configured for synchronizing between the motivating and the injecting.

Optionally, the apparatus further comprises a pumping unit configured for directing the plurality of component materials into the mixing chamber, the directing being controlled by at least one user instruction.

Optionally, the apparatus further comprises a feeding element configured for supporting the positioning of the aperture in front of the at least one outlet before the injecting.

More optionally, the receptacle is a member of a roll of a plurality of receptacles connected to a feeding channel, further comprising a motor unit configured for conducting the feeding element in the feeding channel for supporting the positioning of respective the aperture of each member of the roll.

More optionally, the feeding element comprises a wedge configured for cutting the feeding channel during the conducting.

According to an aspect of some embodiments of the present invention there is provided a roll of a plurality of receptacles for storing a product. The roll comprises a plurality of receptacles each comprises a container configured for storing the product of a mixture of a plurality of components and a feeding aperture configured for receiving the product. The apparatus further comprises a feeding channel configured for covering each the feeding aperture and supporting the positioning of each the feeding aperture in front of an injection unit having a mixing chamber during a filling of respective the container.

Optionally, the feeding channel is configured for being cut to allow the filling of respective the container with the product.

According to an aspect of some embodiments of the present invention there is provided a method for creating a packaging element. The method comprises using a feeding element for feeding a receptacle having a feeding aperture to a distance of less than 5 centimeter from an injection unit having a mixing chamber, separately conveying a plurality of component materials into the mixing chamber, mixing the plurality of component at the mixing chamber to form a mixing product, injecting the mixing product via the feeding aperture into the receptacle, and allowing the mixing product to solidified in the receptacle according to a shape of a packaged item.

Optionally, the method further comprises using the receptacle with the solidified mixing product for packaging the packaged item without closing the aperture.

More optionally, the feeding comprising actuating a roll of a plurality of receptacles to allow the positioning of the receptacle in front an injection unit performing the injecting.

Optionally, the method further comprises getting at least one user instruction, before the separately conveying and separately conveying the plurality of component materials according to the at least one user instruction.

Optionally, the plurality of component materials comprises isocyanate and polyol, the mixing product comprises polyurethane.

Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.

Implementation of the method and/or system of embodiments of the invention can involve performing or completing selected tasks manually, automatically, or a combination thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.

In the drawings:

FIG. 1 is a schematic illustration of an exemplary apparatus having a mixture chamber designed for mixing a plurality of component materials to form a fluid, and for delivering the fluid into one or more receptacles placed at a proximity of the mixture chamber, according to some embodiments of the invention; the apparatus is shown to receive the component materials from two reservoirs.

FIG. 2 is a schematic illustration of an apparatus through which component materials flow for forming a product, and through which the product is delivered into a receptacle, according to some embodiments of the invention;

FIG. 3 is a schematic illustration of an exemplary apparatus for forming a product from the component materials and delivering the product into a receptacle, where the apparatus is characterized by external gear pumps, according to some embodiments of the invention;

FIG. 4 is a schematic illustration of two receptacles, according to some embodiments of the present invention;

FIGS. 5A and 5B are schematic illustrations of an apparatus for forming a product from the component materials and delivering the product into a plurality of receptacles, according to some embodiments of the invention;

FIGS. 5C and 5D are schematic illustrations of a feeding element in a rail of a receptacle and an exemplary apparatus for forming a product from the component materials, according to some embodiments of the invention;

FIG. 5E is a schematic illustration of an exemplary apparatus that comprises the mixing chamber and the feeding channel of FIGS. 5C and 5D, according to some embodiments of the invention;

FIG. 5F is a schematic illustration of a feeding element in a rail of a receptacle and an exemplary apparatus for forming a product from the component materials, according to some embodiments of the invention; and

FIG. 6 is a flowchart of a method for delivering a product into receptacles, according to some embodiments of the invention.

DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION

As used herein, to mix two or more materials means to induce a chemical reaction, to blend, and/or to bring the materials into contact with each other. As used herein, the term “delivery time” refers to the time between the formation of a product, from mixing two or more component materials, and the delivery of the product to a receptacle.

According to an aspect of some embodiments of the present invention, an apparatus for forming a fluidic product by mixing fluidic component materials together and for delivering the newly formed product to a receptacle is provided. The mixing of the component materials occurs in a mixing chamber that is positioned at proximity of the receptacle—for example, less than 5 centimeters from the receptacle, for example between 0.01 and 2 millimeters. In such a manner, the product is delivered into the receptacle substantially immediately after the mixing. For example, the product may be delivered to the receptacle approximately between 1 and 50 milliseconds after being formed. The apparatus comprises a feeding element that allows the feeding of one or more receptacles toward a position about the mixing chamber. Optionally, in use, the feeding element is placed in a feeding channel that is attached to the one or more receptacles. The feeding channel supports the feeding of the one or more receptacles in front of the mixing chamber that delivers the product thereto.

The short time between the mixing of the component materials within the mixing chamber and the delivery of the product to the receptacle makes the apparatus useful for mixing isocyanate and polyol, for forming and delivering polyurethane. Polymers, such as polyurethane, are known to solidify relatively short time after being formed.

The short time between the formation and the delivery of the product allows the delivery of the product to take place when the product is still in fluid form. This may reduce or eliminate any clogging which may be formed as a result of the hardening of packaging material inside the apparatus.

Optionally, the above apparatus is designed for being conveyed by a motor unit to a position at which a delivering element of the apparatus is aligned with an inlet, such as a receiving aperture, of the receptacle.

Optionally, the above apparatus is designed for moving the receptacle, for example by using rollers, to a point in which the inlet of the receptacle is aligned with the delivering element, such as a nozzle, of the apparatus. For example the apparatus and/or receptacle may be moved so that the delivering element is aligned with the inlet. Optionally, the apparatus and/or receptacles may be moved relative to each other, in order to deliver the product to a plurality of receptacles, one by one.

According to an aspect of some embodiments of the present invention, a receptacle is provided. The receptacle includes a container, designed for storing a product, an inlet, designed for receiving a product in a fluidic state, and a feeding channel, for supporting the motivation of the receptacle toward an element that delivers the product into the receptacles. Optionally, the inlet is covered by the feeding channel. In use, the feeding channel may be torn, for example by a wedge, to allow a delivering element to directly access the inlet. The inlet may be sealed after being opened, for example by heating the open sides thereof and joining them together.

Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details of construction and the arrangement of the components and/or methods set forth in the following description and/or illustrated in the drawings and/or the Examples. The invention is capable of other embodiments or of being practiced or carried out in various ways.

FIG. 1 is a schematic illustration of an apparatus 110 for mixing a plurality of component materials at a proximity of a receptacle 112 that is designed for storing the product of the mixing, according to some embodiments of the invention. The apparatus 110 is designed to be attached and/or contained in a feeding element that allows the feeding of one or more receptacles toward a position about the mixing chamber, for example to a position at a distance of less than 5 millimeter.

In FIG. 1, apparatus 110 separately receives a plurality of component materials 104, 108 from respective reservoirs 102, 106. Component materials 104 and 108 are conveyed to a mixing chamber 114 in which component materials 104 and 108 are mixed. The conveying is done by conveyers, for example pipes, tubes, and capillaries. The product of the mixing is delivered to a receptacle 112, which is positioned at proximity of the mixing chamber 114, optionally in a distance of less than 5 centimeters therefrom.

Optionally, the mixing chamber 114 comprises a plurality of inlets each configured for receiving another component material and one or more outlets configured for injecting the product via an aperture in the receptacle. Optionally, the diameter of the aperture is less than 5 centimeters. Optionally, the diameter of the aperture is less than 2 centimeters. Optionally, the diameter of the aperture is less than 1 centimeter. As the component materials which are conducted via the plurality of inlets may accumulate in a manner that blocks the mixing chamber 114 the inlets and/or the outlets of the mixing chamber 114, the mixing chamber 114 may be detachable. In such a manner, the mixing chamber 114 may be replaced in order to ensure a continuous functioning of the apparatus 110. Optionally, the apparatus 110 and/or the mixing chamber 114 comprises one or more coupling fitments that allows the replacement, cleaning, and/or repositioning of the mixing chamber 114. Optionally, the apparatus 110 may be detachable and/or replaceable, allowing the user to maintain a system that uses the apparatus 110 for filling receptacles, such as a packaging system.

Optionally, apparatus 110 is connected to a motor unit that is designed to move apparatus 110 to face receptacle 112 or vice versa. Such an actuation allows apparatus 110 to deliver the product into receptacle 112, which is optionally a member of a roll of a plurality of receptacles, without a conduit or any other piping device. For example, apparatus 110 may be placed on a rail and moved along the rail by a motor. Optionally, apparatus 110 includes actuators for the moving one or more receptacles 112 into a delivery position, in which the product is delivered into receptacle 112. As further described below, apparatus 110 may include rollers for actuating the roll's receptacles, for example the receptacle shown at 112.

As mixing chamber 114 is brought to proximity of receptacle 112, the delivery time of the mixed product is reduced. Apparatus 110 may therefore be used to mix fluids which harden and/or solidify shortly after being mixed. Reducing the product's delivery time allows the delivery of the product to take place when the product is still fluidic. In such a manner, the clogging of the product conveyers is reduced or eliminated.

The presence of apparatus 110 allows first and second component materials 104 and 108 to be stored separately. In such a state, each one of the component materials 104 and may be contained in their respective reservoirs for an extended period of time, such as half a year, a year and/or any other shelf life at inert state and/or before crystallizing. Therefore, reservoirs 102 and 106 may hold large amount of component materials.

According to exemplary embodiments of the present invention, apparatus 110 is designed for forming polyurethane. In such embodiments, the first component material 104 is isocyanate, and the second component material 108 is polyol. According to exemplary embodiments of the present invention, apparatus 110 may be used for forming polyurethane bags for packaging. In use, the apparatus 110 may be used for mixing components in a liquid state of aggregation to form polyurethane foam which is spread around the shape of a packaged item. The mixture solidified to form a hardened wraparound that is adjusted to the dimensions of the packaged item.

It must be noted that apparatus 110 is not limited to be used with any specific component materials. Apparatus 110 (and consequently apparatus 200 of FIG. 2, apparatus 300 of FIG. 3, and apparatus 500 of FIG. 5) may be used with many component materials, to form a large range of desired products.

Optionally, more than two component materials are needed for forming the desired product. Apparatus 110 is optionally designed for receiving more than two component materials and housing a mixing of the component materials, for obtaining the desired product. Optionally, the component materials may form the desired product through a series of sequential mixing processes. For example, a first component material combines with a second component material, forming an intermediate product, and the intermediate product combines with a third component material, to form the desired product.

FIG. 2 is a schematic illustration of an apparatus through which component materials flow for forming a product and, and through which the product is delivered into a receptacle, according to some embodiments of the invention.

Apparatus 200 includes conveyers 202 and 204, for receiving component materials from reservoirs and conveying the component materials to mixing chamber 206, a mixing chamber 206, for mixing the component materials, and a delivering element 208, such as a nozzle, for directing the product formed in mixing chamber 206 to the receptacle. Optionally, conveyers 202 are pipes, tubes, capillaries, or a combination thereof.

Optionally, apparatus 200 further includes a pumping unit, which for example includes pumps 210 and 212. Pumps 210 and 212 are placed along conveyers 202 and 204, respectively, for regulating the flow of the component materials out of the reservoirs and into mixing chamber 206. Optionally, pump drivers 214 and 216 are provided, for driving pumps 210 and 212, respectively. Optionally, pump drivers 214 and 216 are motors. Optionally, a control unit (not pictured) is provided to control the operation of pump drivers 214 and 216, and consequently, of pumps 214 and 216. Optionally, the control unit is controlled by a user, and the pumping unit is controlled by at least one user instruction.

Conveyer 202 is connected to a reservoir, for example reservoir 102 of FIG. 1, at an entry point 202a, for receiving a component material, for example component material 104 of FIG. 1. The component material flows through conveyer 202 and into mixing chamber 206. Similarly, a second component material, for example component material 108 of FIG. 1, flows to mixing chamber 206 through conveyer 204. Optionally, at least one flow parameter of the component materials is regulated by pumps 210 and 212. In mixing chamber 206, a mixing between the component materials takes place, and a product is formed. The product exits apparatus 200 through delivering element 208, and enters the receptacle where the product is to be stored. Since the flow of the product out of mixing chamber 206 through delivering element 208 is related to the flow of the component materials into mixing chamber 206, the flow properties of the product through delivering element 208 depends on the settings of pumps 210 and 212. The flow of the product out of delivering element 208 is therefore regulated by pumps 210 and 212.

Optionally, pumps 210 and 212 control the pressure at which the component materials are directed into mixing chamber 206. Optionally, pumps 210 and 212 control the quantities of the component materials directed into mixing chamber 206.

Optionally, pumps 210 and 212 are external gear pumps. Optionally pumps 210 and 212 are internal gear pumps. Optionally pumps 210 and 212 are gerotor pump. Optionally pumps 210 and 212 are peristatic pump. Optionally pumps 210 and 212 are positing displacement pumps. Pumps 210 and 212 may be placed at any location that allows them to control the flow of the component materials, for example, anywhere along pipes 202 and 204, respectively.

Optionally, mixing chamber 206 is constructed according to the mixing chamber described in PCT Applications WO2005IL00355 and WO2005IL00356 by Malik et al., which are herein incorporated by reference. According to some embodiments of the present invention, mixing chamber 206 is characterized by a small volume, for example 20 mm³. A small-sized mixing chamber may reduce the time between the formation of the desired product and the delivery of the product into the receptacle.

Optionally, delivering element 208 is an integral part of mixing chamber 206. Optionally, delivering element 208 is an aperture on the surface of mixing chamber 206, through which the product formed in mixing chamber 206 leaves apparatus 200. Optionally, delivering element 208 comprises a hollow tubular element, such as a needle, for injecting the product via the inlet of the receptacle. Optionally, delivering element 208 is a narrow element having a cross sectional area of between 0.5 and 1 mm². Optionally, delivering element 208 partially or fully protrudes from apparatus 200. Protruding delivering element 208 may enter the receptacle, for example through an inlet of the receptacle. In such a manner, protruding delivering element 208 delivers the product to the receptacle from the inside of the receptacle, and therefore reduces or eliminates a spillage of the product during delivery. A narrow delivering element 208 may produce a precise delivery of the product into the receptacle, by causing the product to exit apparatus 200 at a narrow stream.

According to some embodiments of the present invention, a conveyer is provided for each component material. Optionally, a pump is also provided for each component material. For example, if three, four, or six component materials are needed to be mixed in order to form a desired product, then three, four, or six conveyers are provided, such that each conveyer is connected to a different reservoir. Optionally, three, four, or six pumps are provided, each pump regulating the flow of a different component material.

FIG. 3 is a schematic illustration of an apparatus 300 for forming a product from the component materials and delivering the product into a receptacle, where the apparatus is characterized by external gear pumps, according to some embodiments of the invention. Apparatus 300 is an embodiment of apparatus 110 of FIG. 1, and of apparatus 200 of FIG. 2.

Apparatus 300 includes the same elements and units as apparatus 200 depicted in FIG. 2. Apparatus 300 is an exemplary embodiment of apparatus 200, as apparatus 300 is characterized by a first and a second external gear pumps.

An external gear pump is characterized by two gears connected to each other. One of the gears is rotated by a user, either manually or automatically, for example through a motor. The connection between the gears causes the second gear to rotate as well. The rotation of the gears forces the fluid to flow from the entrance area of the pump to an outlet area of the pump. The rate of rotation of the gears affects the pressure at which the fluid enters and exits the pump.

An exemplary external gear pump measures about 2 cm by 3 cm by 4 cm. This pump pumps a fluid of a viscosity of about 200 mPa×s out of a conveyer, for example conveyer 202, and into mixing chamber 206, at a pressure which may be varied between about 5 BAR and 15 BAR, leading the newly formed product out of delivering element 208 at a pressure between 5 and 15 BAR. The fluid of viscosity 200 mPa×s is, for example isocyanate, which is a typical component material of packaging material.

A first external gear pump is associated with conveyer 202. The entrance area of first external pump is connection point 202b between conveyer 202 and pump cover 302, and the outlet area of the first external pump is the continuation of conveyer 202. The first external gear pump includes a pump cover 302 to house the two interconnected gears, a gear casing 304, to connect the pump cover to the continuation of conveyer 202, and a drive shaft 306, which is connected to one gear and is designed for rotating the one gear. Optionally, the first external gear pump also includes a motor-gear coupling element 308, designed for coupling drive shaft 306 to a motor, and allowing the motor to apply a torque upon drive shaft 306, which in turn applies a torque upon one of the gears. For example, motor-gear coupling element may be used to couple drive shaft 306 to pump driver 214 shown in FIG. 2.

Similarly to the first external gear pump, a second external gear pump, associated with conveyer 204, is characterized by a second pump cover 310, a second gear casing 312, a second drive shaft 314, and optionally a second motor-gear coupling 316.

As the gears of the first external gear pump are rotated, first component material 104 contained in reservoir 102 of FIG. 1 is directed through conveyer 202 into pump cover 302. The gears within pump cover 302 direct the component material via gear casing 304 to the continuation of pipe 202 and to mixing chamber 206. In a similar manner, second component material 108, contained in reservoir 106 of FIG. 1, reaches mixing chamber 206, and a mixing between the first and second component materials occur, to form the desired product. The product exits mixing chamber 206, flows through delivering element 208, and enters the receptacle.

It should be noted that such an external gear pump builds up a relatively high pressure in a relatively small mixing chamber 206.

FIG. 4 is a schematic illustration of two receptacles, according to some embodiments of the present invention.

Receptacle 400 is characterized by an feeding aperture 402, designed for receiving a product, a container 403, for storing the product, and a feeding channel 404 for covering feeding aperture 402 and supporting the motivation of receptacle 400 toward a filling apparatus, such as apparatus 110 of FIG. 1, apparatus 200 of FIG. 2, and/or apparatus 300 of FIG. 3.

Optionally, feeding aperture 402 is positioned on the perimeter of the container and allows the delivering of the product after receptacle 400 has been moved to align feeding aperture 402 with a filling apparatus. According to some embodiments of the present invention, feeding channel 404 is interposed between feeding aperture 402 and the filling apparatus, and therefore prevents access to feeding aperture 402 by the filling apparatus. Optionally, feeding channel 404 is designed to be torn, for example by a wedge, such as a blade, that is connected to the filling apparatus, during the delivery process, as described below, in FIGS. 5A and 5B. Such a tear allows access by a delivering element of the filling apparatus to feeding aperture 402. Optionally, the inlet is closed and the product is delivered to receptacle 400 after the feeding aperture 402 is punctured, for example using the delivering element. Optionally, feeding aperture 402 may be sealed after the product's delivery, for example by heating the sides of feeding aperture 402 to a temperature of about 120°, causing a partial melting of the heated areas, and joining the sides together. Optionally, the melted material is a high-density polyethylene (PEHD).

Feeding channel 404 is tubular and is designed for being traversed, for example by feeding element, such as a rod or a rail. Optionally, feeding channel 404 is replaced by a series of loops designed to be traversed by the feeding element. The feeding element may enter feeding channel 404 through opening 406, thereby actuating receptacle 400 to face the filling apparatus, which delivers a product to receptacle 400. The actuating may be achieved, for example, by supporting the motivation of, or constraining the movement of receptacle 400 along the feeding element.

Optionally, receptacle 400 is collapsible. Optionally, receptacle 400 is made out of PEHD. Optionally, receptacle 400 is rigid. Optionally, receptacle 400 is shaped to determine the shape of a product, like packaging material, which solidifies shortly after being formed by the component materials thereof. It should be noted that as the product is injected into a receptacle having a relatively limited feeding aperture, optionally with a diameter of less than 2 centimeters, the receptacle 400 may not be seamed, welded, and/or otherwise closed. The product, which is injected in a fluid state of aggregation and solidified in the receptacle to a solid state of aggregation does not, or substantially does, not extend beyond the sides of the walls of the receptacle 400. The product solidifies before or substantially before it extends beyond the sides of the walls of the receptacle 400 and therefore the closing of the receptacle 400 may not be required in order to create a packaging element therefrom.

Optionally, receptacle 400 is used as a packaging element, to be filled with packaging material—for example polyurethane. Optionally, receptacle 400 is used as a polyurethane packaging element.

According to some embodiments of the present invention, a roll 401 is provided, in which receptacle 400 is joined on a side thereof to a second receptacle 408, having an inlet 412, and feeding channel 414. On the side that is common to receptacles 400 and 408, a line of perforations 410 is optionally provided, in order to allow an easy separation between the receptacles, following the product delivery to the receptacles. Optionally, channels 404 and 414 are joined together to assemble a central feeding channel. Optionally, the roll includes a plurality of receptacles joined at the sides and assembling the central feeding channel. The roll is optionally fed to a filling apparatus, which delivers a product to the receptacles, by inserting a feeding element into opening 406 of feeding channel 404. Optionally, the apparatus moves along the feeding element and delivers the product to each receptacle in turn. Optionally, the apparatus is fixed, and the receptacles are moved along the feeding element toward the apparatus, so that the apparatus delivers the product to each receptacle in turn, as illustrated below (FIGS. 5A and 5B).

FIGS. 5A and 5B are schematic illustrations of an apparatus 500 with a feeding element 502 for forming a product from component materials and delivering the product into a plurality of receptacles, according to some embodiments of the present invention. FIG. 5A is a front view of apparatus 500, and FIG. 5B is an isometric view of apparatus 500.

Apparatus 500 includes all the elements of apparatus 300, for forming a desired product and delivering to a receptacle, the feeding element 502, designed for being inserted into a feeding channel 404 described in FIG. 4, and rollers 504, for moving the receptacles along feeding element 502. Optionally feeding element 502 is a rod or a rail. Optionally, feeding element 502 includes a wedge, such as a blade wedge, for example as shown at 506 of FIG. 5A. The wedge cuts feeding channel 404, thereby allowing continued movement of the receptacles along rod 502. Optionally, the blade also cuts open the inlets of the receptacles, thereby allowing feeding of the receptacles and the delivery of the product to the receptacles.

Optionally, apparatus 500 further comprises a sealing device (not shown), for sealing the receptacles once the product delivery is complete. Optionally, sealing device seals the receptacles, by heating the open sides of the inlet and joining them together, as explained above. Optionally, the sealing device includes a resistor based heater.

In FIGS. 5A and 5B, feeding element 502 is inserted into a central feeding channel of a roll which includes receptacles 400 and 408. Rollers 504 move the receptacles in direction 508, along feeding element 502. The wedge 506 on feeding element 502 cuts the central feeding channel, to allow access to feeding aperture 402 by apparatus 500, and to prevent the kit from getting stuck on feeding element 502, thus ensuring that the receptacles can continue to be moved. Optionally, the wedge 506 on feeding element 502 also cuts open feeding aperture 402, if feeding aperture 402 is closed. When a delivering element of apparatus 500 is aligned with open feeding aperture 402, the rollers stop moving, therefore stopping the movement of the receptacles and the delivery of the product takes place, as previously described. After the delivery to receptacle 400 is complete, the rollers resume their movement, and the receptacles resume moving in direction 508. Feeding aperture 402 passes by sealing device, and receptacle 400 is sealed, in the manner described above. As the movement continues, inlet 412 of receptacle 408 is cut open, and the process is repeated.

Optionally, the receptacles are fixed, and apparatus 500 moves along a feeding channel, such as a rail, inserted into the central feeding channel of the roll of receptacles, to deliver the product to the receptacles. Optionally, rollers 504 are substituted by different means for moving the receptacles, such as pneumatic manipulators.

Optionally, the product delivery is synchronized with the movement of the receptacle. This may be done, for example, by connecting flow control units to rollers 504. Exemplary flow control units are the pumps of apparatus 500 and/or pump drivers 214 and 216, as described above. According to some embodiments of the present invention, product delivery is not executed when rollers 504 move. Optionally, a control unit 512 is provided, to control the operation of rollers 504 and of pump drivers 214 and 216.

Optionally, control unit 512 is programmable by a user, in order the set the parameters of the synchronization between rollers 504 and pump drivers 214 and 216. For example, the user may change, via control unit 512, the speed of rotation of the rollers and/or the torque provided by pump drivers 214 and 216 to the pumps of apparatus 500. Optionally, if apparatus 500 moves and the receptacles are fixed, the motor unit for moving apparatus 500 is synchronized with pump drivers 214 and 216. Optionally, control unit 512 controls the operation of the motor unit for moving apparatus 500 and of pump drivers 214 and 216. Optionally, control unit 512 is programmable by a user, in order the set the parameters of the synchronization between the motor unit and pump drivers 214 and 216. For example, the user may change, via control unit 512, the speed at which apparatus 500 moves and/or the torque provided by pump drivers 214 and 216 to the pumps of apparatus 500.

Optionally, control unit 512 is designed to receive at least one instruction from a user, for example through a computer program. Optionally, the instruction is given in order to set quantities and/or pressures of the component materials directed into the mixing chamber and the quantity and/or the pressure of the product formed by the component materials as the product is directed into the receptacles. Optionally, control unit 512 includes a computer.

Optionally, apparatus 500 includes a sensor placed next to delivering element 208, shown in FIGS. 2 and 3. The sensor detects the position of feeding aperture 402 in relation to the outlet of the mixing chamber, which may be referred to herein as a delivering element 208. Optionally, the sensor is designed to send a signal to control unit 512, when feeding aperture 402 is in a position suitable for product delivery by apparatus 500, and cause the moving means to stop the movement of the receptacles, and/or the movement of apparatus 500.

Optionally, the sensor is part of an image capturing device, such as a charge coupled device (CCD) sensor, or a complementary metal oxide semiconductor (CMOS) sensor. The position of the feeding aperture 402 is determined according to an analysis of the image captured by the sensor. The analysis is optionally performed by control unit 512.

Optionally, the sensor is part of a photo detector, which includes a light source, and a sensor. Light emitted by the light source illuminates the receptacle, and is reflected back to the sensor. When the emitted light illuminates feeding aperture 402, light is reflected in a different manner toward the sensor. For example, a higher percentage, or a lower percentage may be reflected. The position of the inlet is determined according to the change in the properties of light detected by the sensor.

Reference is now made to FIGS. 5C and 5D which are schematic illustrations of a feeding element 601 in a feeding channel 602 of a receptacle 613 and an exemplary mixing chamber 607 for forming a product from the component materials which is connected to hydraulic tubes 604 and designed to be contained in the feeding element, according to some embodiments of the invention. Reference is also made to FIG. 5E, which is a schematic illustration of an exemplary apparatus 650 that comprises the mixing chamber 607 and the feeding channel 602, according to some embodiments of the invention. In the exemplary apparatus 650, the mixing chamber 607 is contained in the feeding channel 602. Optionally, the hydraulic tubes 604 have valves for adjusting the streaming of the material components therein. The hydraulic tubes may be flexible, rigid, and/or having flexible and rigid segments. The hydraulic tubes may be covered by one or more heating sleeves to maintain the temperature of the streamed component materials. Optionally, different tubes are coated with different heating sleeves to maintain different temperatures of different streamed component materials.

The feeding element 601 is optionally defined as described above in relation to feeding element 502. In addition, the feeding element 601 is designed to contain apparatus 603 that is depicted in FIG. 5D, for example as depicted in FIG. 5F. As depicted in FIG. 5D, apparatus 603 comprises two inlets 606 configured for separately receiving different component materials for injecting the product via an aperture in the receptacle, such as the inlet shown at 412 of FIG. 4. The apparatus 603 comprises a mixing chamber 607 for mixing the received component materials, for example as described above in relation to FIG. 1. Each one or the inlets 606 is connected to a conducting element 608, such as a conveyer, for example a tube, which is designed to conduct the respective component material thereto. The conducting element 608 is stretched along the feeding element 601. The feeding element 601 has an injecting aperture (not shown) for allowing the apparatus 603 to inject the product via the receptacle's aperture. In such a manner, the product is injected directly to the receptacle 613. The direct injection reduces the waste of component materials as it assures that the product is injected directly into the receptacle 613. In addition, the cleaning frequency may be reduced.

Optionally, the apparatus 603 comprises a blade 651 for cutting the feed channel 404 to allow the aforementioned injection. As described above, the feeding channel 404 is designed to be torn by the blade 651 during the delivery process. Such a tear allows the delivering of the product via the delivering element of the mixing chamber 607 to the receptacle 613.

It should be noted that the hydraulic tubes 604 allows the positioning of the mixing chamber in a distance from the pumps and/or the containers. For example, the distance may be 1, 2, 3, 4, 5, 10, 20, 30, 40, 50, 100, 200, and 500 centimeter(s). In such a manner, the mixing chamber 607 can easily replaced when plugged. Furthermore, the hydraulic tubes 604 allows the positioning of the mixing chamber 607 in feeding elements having different structures which are adapted for feeding different receptacles. In such a manner, different feeding elements may be attached to the apparatus 603 to allow the feeding of receptacles from different materials and/or of various forms.

FIG. 6 is a flowchart of a method 700 for delivering a product into receptacles, according to some embodiments of the invention.

At 702, component materials of the product are provided, for examples inside reservoirs. Optionally, the component materials are the component materials needed for forming packaging material, as described above. Optionally, two component materials are needed for forming the desired product. Optionally, more than two component materials are needed for forming the desired product.

At 704, an access is opened to the receptacle. For example, a closed inlet of the receptacle may be opened. Optionally the feeding aperture 402 is punctured by a needle, as described above. Optionally, the feeding aperture 402 is cut open by a blade, as described above. Optionally, a channel covering the feeding aperture 402 is cut, for example as shown at numeral 651 in FIG. 5E and described above.

At 706, at least one user instruction is received. Optionally, the instruction is sent via a control unit to a pumping unit, as described above. Optionally, the instruction is used to set one or more flow parameters of one or more component materials. For example, a pressure and/or a quantity of a component material is chosen.

At 708, the component materials flow out of the reservoirs and are received conveyers described above. Optionally, the component materials are pumped out of the reservoirs and into the conveyers. At this stage, the component materials do not come in contact with each other.

At 610, the flow of the component materials is adjusted, if needed, according to the user instruction of 706. The adjustment may be performed, for example by monitoring the flow properties of the component materials and/or the product, and changing the flow properties, according to the user instruction. This may be accomplished, for example, by changing a torque provided by a pump driver to a gear of an external gear pump, as described above.

At 712, the component materials reach a mixing chamber. In the mixing chamber, the component materials are mixed, and a product is formed, as described above.

At 714, the product formed in the mixing chamber is directed by a delivering element to the receptacle, for example through the inlet opened at 604.

At 718, another receptacle is moved into position, and the process is repeated, starting from step 704.

Method 700 may be used with the apparatuses shown in FIGS. 1, 2, 3, 5A, and 5B. Method 700 is useful for quickly forming and delivering products which harden and/or solidify within a short period of time after being formed, and need to be delivered to a receptacle while still in fluid form. Such a product is packaging material, which solidifies about 10-30 seconds after being formed. Method 700 is also useful for forming and delivering products that are affected by contact with air, while the component materials of the products are not affected by being exposed to air.

It is expected that during the life of a patent maturing from this application many relevant products and component materials will be developed and the scope of the term “product” and “component material” is intended to include all such new technologies a priori.

As used herein the term “about” refers to ±10%.

The terms “comprises”, “comprising”, “includes”, “including”, “having” and their conjugates mean “including but not limited to”.

The term “consisting of” means “including and limited to”.

The term “consisting essentially of” means that the composition, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.

As used herein, the singular form “a”, an and the include plural references unless the context clearly dictates otherwise. For example, the term “a compound” or “at least one compound” may include a plurality of compounds, including mixtures thereof.

Throughout this application, various embodiments of this invention may be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

Whenever a numerical range is indicated herein, it is meant to include any cited numeral (fractional or integral) within the indicated range. The phrases “ranging/ranges between” a first indicate number and a second indicate number and “ranging/ranges from” a first indicate number “to” a second indicate number are used herein interchangeably and are meant to include the first and second indicated numbers and all the fractional and integral numerals therebetween.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements.

Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention. To the extent that section headings are used, they should not be construed as necessarily limiting.

APPARATUS AND METHOD FOR DELIVERING A PRODUCT INTO A RECEPTACLE

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