CENTRIPETAL CONTAINER PROCESSING APPARATUS

Abstract

A container processing apparatus comprises a rotor, and a rotor support that is mechanically coupled to the rotor. The rotor comprises at least one container processing station. The rotor support is configured to facilitate rotation of the rotor around the rotor support. The container processing station is configured to releasably capture a container, to exert, via the rotation, centripetal force on the container, and to move material (liquid, granular, shredded, particulate or paste-like material) within the container via the centripetal force.

Description

FIELD

This disclosure relates to an apparatus that uses centripetal forces to clean and/or fill containers.

BACKGROUND

U.S. Pat. No. 3,994,117 describes a method and apparatus for filling containers.

U.S. Pat. No. 4,109,336 describes an apparatus for filling and crowning bottles.

U.S. Pat. No. 4,296,882 describes a centrifugal fluid processing device.

U.S. Pat. No. 4,731,979 describes a capsule filling apparatus.

U.S. Pat. No. 5,050,369 describes a method and apparatus for filling and capping containers.

U.S. Pat. No. 7,010,900 describes a beverage bottling plant.

SUMMARY

The invention described herein makes use of centripetal force to move fluid within a container for the purpose of cleaning and/or filling containers, and/or maintaining fluid within the container during filling and/or sealing.

In one aspect, this disclosure provides a centripetal container processing apparatus that comprises a rotor, and a rotor support which is mechanically coupled to the rotor. The rotor support configured to facilitate rotation of the rotor around the rotor support.

The rotor comprises at least one container processing station. The container processing station is configured to releasably capture a container, to exert, via the rotation, centripetal force on the container, and to move fluid within the container via the centripetal force.

In a second aspect, this disclosure provides a rotor for mounting to a rotor support of a centripetal container processing apparatus. The rotor comprises a plurality of arms that extend radially outwards from a central hub, and a container filling head that is mounted to at least one of the arms. The container filling head is configured to introduce material into a container, and to maintain the introduced material in the container via a centripetal force that is exerted against the material during a rotation of the rotor about the rotor support.

In a third aspect, this disclosure provides a rotor for mounting to a rotor support of a centripetal container processing apparatus. The rotor comprises a plurality of arms that extend radially outwards from a central hub, and a container sealing head that is mounted to at least one of the arms. The container sealing head is configured to maintain material in the container via a centripetal force that is exerted against the material during a rotation of the rotor about the rotor support. The container sealing head is also configured to seal the container as the material is maintained in the container via the centripetal force.

In a fourth aspect, this disclosure provides a rotor for mounting to a rotor support of a centripetal container processing apparatus. The rotor comprises a plurality of arms that extend radially outwards from a central hub, and a container filling head that is mounted to at least one of the arms. The container filling head is configured to maintain material in the container via a centripetal force that is exerted against the fluid during a rotation of the rotor about the rotor support. The container filling head is pivotable between a substantially horizontal orientation and a substantially vertical orientation.

Typically the material introduced into the container is a liquid (foodstuff or non-foodstuff), such as water, juice or soda. However, the material may also be granular, shredded, particulate or paste-like material.

In one implementation, each container processing station comprises a container cleansing head, the container filling head, and a container capping head. The container cleansing head is configured to clean the container by injecting fluid into the container, and to remove the injected fluid from the container via the centripetal force. The container filling head is configured to introduce the fluid into the container, and to maintain the introduced fluid in the container via the centripetal force. The container capping head is configured to maintain the fluid in the container, via the centripetal force, while capping the container.

In another implementation, centripetal force is used to open pouches while filling the pouches with fluid.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of a centripetal processing apparatus will be described, with reference to the accompanying drawings, in which:

FIG. 1 is an isometric view of one embodiment of a centripetal container processing apparatus for filling rigid containers;

FIG. 2 is a perspective view of the centripetal container processing apparatus of FIG. 1, depicting only a portion of the container processing stations;

FIG. 3 is a schematic view of the base of the centripetal container processing apparatus;

FIG. 4 is an isometric view of a pair of head assemblies of the container processing rotor of the centripetal container processing apparatus;

FIG. 5 is a magnified view of the cleansing station, the filling station, and the capping station of one of the head assemblies;

FIG. 6 is a schematic view of the base, configured to receive multiple independent fluid feeds;

FIG. 7 is a side view of the centripetal container processing apparatus, depicting the cap bin and container intake station;

FIG. 8 is a magnified view of the cap magazines of the capping stations;

FIG. 9 is an isometric view of the cleansing station, the filling station, and the capping station of one of the head assemblies;

FIG. 10 is a magnified view of the cleansing station;

FIG. 11 is a top plan view of the container intake station;

FIG. 12 is a perspective view of the container intake station;

FIG. 13 is a perspective view of the star wheel of the container intake station;

FIG. 14 is a perspective view of the rinsing module of a cleansing station;

FIG. 15 is an opposite perspective view of the rinsing module;

FIG. 16 is a perspective view of the rinsing module in a declined position;

FIG. 17 is a magnified view of the cleansing station and the filling station;

FIG. 18 is an isometric view of a head assembly having a pivoting container processing station;

FIG. 19 is a magnified view of the filling nozzle of the filling station;

FIG. 20 is a magnified view of the filling nozzle partially inside a container;

FIG. 21 is an isometric view of nozzle tube of the filling nozzle;

FIG. 22 is a perspective view of a head assembly, with a cleaned container being rotated from the cleansing station to the filling station, and a filled container being rotated from the filling station to the capping station;

FIG. 23 is a perspective view of a head assembly, after the cleaned container is rotated to the filling station;

FIG. 24 is a magnified view of the filling nozzle fully inside a container;

FIG. 25 is a perspective view of a head assembly, with a filled cleaned container being rotated to the capping station;

FIG. 26 is a perspective view of the capping station at the end of the container sealing step;

FIG. 27 is a top isometric view of a capped container being released to the container removal station;

FIG. 28 is a perspective view of a capped container being released to the container removal station;

FIG. 29 is a perspective view of one embodiment of a centripetal container processing apparatus for filling rigid-necked pouches, depicting only a portion of the container processing stations;

FIG. 30 is a front side elevation of a pair of the head assemblies of one of the container processing stations of FIG. 29;

FIG. 31 is a rear side elevation of the pair of head assemblies;

FIG. 32 is a perspective view of the filling station and capping station of the head assemblies;

FIG. 33 is a perspective view of a rigid-necked pouch captured by the filling station;

FIG. 34 is an end elevation of the filling station at the end of the filling step;

FIG. 35 is an end elevation of the filling station, as the filled container is being rotated to the capping station;

FIG. 36 is a perspective view of head assemblies after the filled container is transferred to the capping station;

FIG. 37 is a perspective view of a capped container being released to the container removal station;

FIG. 38 is a perspective view of the base, configured to receive multiple independent fluid feeds;

FIG. 39 is a perspective view of one embodiment of a centripetal container processing apparatus for filling neckless pouches;

FIG. 40 is a perspective view of the centripetal container processing apparatus of FIG. 39, depicting only a portion of the container processing stations;

FIG. 41 is a front elevation of one of the container processing stations of FIG. 39;

FIG. 42 is a rear elevation of the container processing station;

FIG. 43 is an end elevation of a pair of the head assemblies of one of the container processing stations;

FIG. 44 is a rear elevation of the head assemblies;

FIG. 45 is a perspective view of a pouch captured in the sealing/welding anvil jaws of the head assembly;

FIG. 46 is a perspective view of the pouch as the sealing/welding anvil jaws begin to open;

FIG. 47 is a perspective view of the pouch as the pouch is filled by the nozzle sleeve of the head assembly; and

FIG. 48 is an end elevation of a sealed pouch being released to the container removal station.

DETAILS

1. Centripetal Container Processing Apparatus—Overview

Turning to FIG. 1, the centripetal container processing apparatus, denoted generally by reference numeral 100, is shown comprising a container processing rotor 102, a container intake station 104, and a container removal station 106. The container intake station 104 feeds empty containers 108 to the rotor 102, and the container removal station 106 accepts filled containers 108 from the rotor 102. As shown, the container intake and removal stations 104, 106 are disposed proximate the outer radius of the container processing rotor 102.

Typically, the containers 108 are rigid polymeric, metal or glass containers or bottles. However, the containers 108 may comprise other forms of rigid fluid retaining vessels, including water cooler bottles. Further, typically the fill material is a liquid (foodstuff or non-foodstuff), such as water, juice or soda. However, the centripetal container processing apparatus 100 is not so limited, and may be used to fill the containers 108 with granular, shredded, particulate or paste-like material.

As best shown in FIG. 2, the container processing rotor 102 comprises a base 112, a turret 114 that is rotatably mounted to the base 112, a hub 116 that is secured to the turret 114, and at least one container processing station 200 that is connected to the hub 116 and extends radially outwards from the base 112. As shown in FIG. 3, the rotor 102 also includes a base controller 118 (e.g. computer) that is mounted within the base 112 and is configured to control and monitor the operation of the container processing stations 200.

As shown in FIG. 4, each container processing station 200 comprises a substantially straight arm 202 that is secured at its inner end to the rotating hub 116, and one or more head assemblies 212, which are secured to the outer end of the arm 202 and serve to clean, fill and cap the containers 108. Preferably, each arm 202 carries a pair of the head assemblies 212, which are disposed radially adjacent to each other around a common radius of the container processing rotor 102. However, each arm 202 need not support only two head assemblies 212 but may comprise any number of the head assemblies 212.

As shown in FIG. 5, typically each head assembly 212 comprises a container cleansing station 300, a container filling station 400, and a container capping station 500. Further, in each head assembly 212 preferably the container cleansing station 300, container filling station 400, and container capping station 500 are disposed vertically above one another. However, each head assembly 212 need not comprise all three of these stations 300, 400, 500, but might instead comprise only one or two of these stations. For instance, the containers 108 might be pre-cleaned, in which case each head assembly 212 might include only a container filling station 400 and a container capping station 500. Alternately, each head assembly 212 might include only a container filling station 400 to allow the containers 108 to be capped by conventional means.

The arm 202 of each container processing station 200 carries a fluid delivery pipe 204, a cleanser delivery pipe 206, a vacuum pipe 208 and a pressurized air pipe 210 which are all connected to the head assembly/assemblies 212 of the associated container processing station 200. Further, each arm 202 also carries associated electrical wiring, sensors and control valves that are coupled to the base controller 118 for controlling the operation of the head assemblies 212.

As shown in FIG. 2, typically the arms 202 extend substantially horizontally outwards from the hub 116, and the hub 116 rotates the arms 202 about a substantially vertical X-axis that is perpendicular to the plane occupied by the arms 202. However, the arms 202 may also extend vertically outwards from the hub 116, with the hub 116 and arms 202 rotating about a substantially horizontal X-axis that is again perpendicular to the plane occupied by the arms 202. Further, the hub 116 and arms 202 may be configured to rotate about an axis between these two extremes.

As shown in FIG. 3, the base 112 includes a fluid delivery line 120, one or more cleanser delivery lines 122, a vacuum line 124, a fluid delivery manifold (not shown), a cleanser delivery manifold (not shown), and a fluid return manifold (not shown). The fluid delivery manifold, the cleanser delivery manifold and the fluid return manifold are all disposed within the base 112. The fluid delivery line 120 extends through the turret 114 into the base 112, and is connected to the fluid delivery manifold within the base 112. The cleanser delivery line/lines 122 extend through the turret 114 into the base 112, and are connected to the cleanser delivery manifold within the base 112. The vacuum line 124 enters the base 112 through the bottom thereof, and is connected to the fluid return manifold within the base 112.

The fluid delivery pipes 204 of all of the container processing stations 200 are connected to the fluid delivery manifold. The cleanser delivery pipes 206 of all of the container processing stations 200 are connected to the cleanser delivery manifold. The vacuum pipes 208 of all of the container processing station 200 are connected to the fluid return manifold. As a result, as the hub 116 rotates, the fluid delivery line 120 is able to supply fluid (liquid or granular material) to the head assemblies 212, the cleanser delivery line/lines 122 is/are able to supply cleaning agents (e.g. water, steam, dry air) to the head assemblies 212, and the vacuum line 124 is able to receive return fluid (resulting from the supply of the cleaning agents to the containers 108) from the head assemblies 212, via the respective manifolds.

Typically the centripetal container processing apparatus 100 will fill all of the containers 108 with the same fluid. However, as shown in FIG. 6, the base 112 may be fed with a plurality of fluid delivery lines 120, each connected to a respective fluid supply and a respective fluid delivery manifold. Each fluid delivery manifold may be coupled to a respective portion of the head assemblies 212. In this variation, the centripetal container processing apparatus 100 would fill each container 108 with one of a number of different fluids, depending upon the contents of the respective fluid supplies. Further, although the fluid delivery lines 120 are shown in the drawings supplying fluid from the top of the base 112, the fluid delivery lines 120 may instead supply fluid from the bottom of the base 112, or both the top and bottom of the base 112.

As shown in FIG. 7, the centripetal container processing apparatus 100 also comprises a stationary cap bin 132 which is disposed above the rotor 102. The cap bin 132 carries unused container caps 110, and supplies the unused container caps 110 to the container capping stations 500. Each container capping station 500 includes a cap magazine 502 (see FIG. 8) that captures the unused caps 110 from the cap bin 132. As will be explained in further detail below, preferably the cap bin 132 includes a centrifugal or vibrating cap sorter (not shown) that loads the cap magazines 502 with the unused caps 110 as the rotor 102 rotates about its axis (X-axis).

2. Container Cleansing Station

As shown in FIGS. 5 and 9, each container cleansing station 300 includes a Y-axis indexer 302, and an associated rinsing module 304. The Y-axis indexer 302 comprises a substantially flat plate 306, and a pair of U-shaped grippers 308 which are disposed at the opposite ends of the flat plate 306. The U-shaped grippers 308 have substantially parallel sides which are parallel to the longitudinal axis of the flat plate 306.

Preferably, the Y-axis indexer 302 also includes an indexer motor 310 (e.g. servo motor) that is mounted on the arm 202, and an actuator 312 (e.g. servo motor) that is mounted to the indexer motor 310 and the flat plate 306. As will be explained below, the actuator 312 moves the flat plate 306 in a vertical direction, and the indexer motor 310 rotates the flat plate 306 about the Y-axis (tangential to the circumference of the rotor) of the centripetal container processing apparatus 100, both under control of the base controller 118.

Further, as will be explained, in operation the rotor 102 continuously rotates about its axis (X-axis) of rotation. As shown in FIGS. 7, 10 and 11, as the rotor 102 rotates, the Y-axis indexer 302 of each container cleansing station 300 picks up an empty container 108 from the container intake station 104 via the neck of the container 108. Preferably, the width of the U-shaped grippers 308 is slightly less than the diameter of the neck of the container 108, to thereby allow the Y-axis indexer 302 to hold the empty container 108 without a separate mechanical actuator. Alternately, the Y-axis indexer 302 may include alternate gripping means to grip the container 108. For example, the U-shaped grippers 308 may include mechanical jaws (not shown) that grip the container 108 under control of the base controller 118. Further, the container 108 need not be gripped only from the container neck, but may instead be gripped from the body portion and/or the bottom thereof, either by mechanical or vacuum gripping means.

Preferably, the empty containers 108 are delivered substantially horizontally from the container intake station 104 to the cleansing stations 300. The empty containers 108 may be delivered at a different angle (e.g. vertically) to the cleansing stations 300. However, in this variation, preferably the cleansing stations 300 re-orient the containers 108 to the plane of the arms 202 of the rotor 102 upon receipt from the container intake station 104.

As shown in FIGS. 7, 12 and 13, the container intake station 104 may include a conveyor belt 134 that carries the empty containers 108, and a star-wheel 136 that includes a plurality of outwardly-extending gripping channels 138 for lifting the empty containers 108 from the conveyor belt 134 to the cleansing stations 300 via the neck of each container 108. The pitch of the star-wheel 136 may be selected to deliver an empty container 108 to each radially-adjacent cleansing station 300. However, the centripetal container processing apparatus 100 is not so limited but may include an odd number of head assemblies 212, with the pitch of the star-wheel 136 being selected to deliver an empty container 108 to each alternate head assembly 212. This latter variation is advantageous where the speed of the intake conveyor 134 is limited, or where additional time is required to complete the cleansing or filling operations, since it doubles the number of rotor cycles that are required to load and unload the head assemblies 212.

As shown in FIGS. 14 and 15, the rinsing module 304 of each cleansing station 300 includes a vacuum cup 314, a telescoping vacuum pipe 316, a fixed vacuum pipe 318, a rodless cylinder 320, a rinsing nozzle 322, a valve bank 324, a servo motor (not shown), and an indexing motor 328. The vacuum cup 314 includes a conical collar 330, a centrally-positioned inlet that extends from the narrow end through to the wide end of the conical collar 330, and an outlet 332 that opens into the side of the collar 330 and is in fluid communication with the wide end of the collar 330. The vacuum cup 314 is secured to the free end 334 of the rodless cylinder 320. The vacuum cup outlet 332 extends through the free end 334 of the rodless cylinder 320, and is in fluid communication with one end of the telescoping vacuum pipe 316. The opposite end of the telescoping vacuum pipe 316 is slidably disposed within the fixed vacuum pipe 318 which, in turn, is coupled to the vacuum pipe 316 of the associated container processing station 200.

The rodless cylinder 320 includes an internal piston that is coupled to the base of the valve bank 324. The free end 334 of the rodless cylinder 320 is fitted with a pressure regulator (not shown), while the opposite end of the rodless cylinder 320 is connected to the pressurized air pipe 210 of the container processing station 200. The pressure regulator allows the pressurized air escape from the rodless cylinder 320 at a rate that is determined by the pressure regulator.

The valve bank 324 typically comprises a plurality of valves, each of which is connected at its inlet to a respective cleanser delivery pipe 206 of the associated container processing station 200. Each valve of the valve bank 324 is also connected at its outlet to the telescoping rinsing nozzle 322 which, in turn, is slidably received within the central inlet of the vacuum cup 314. The base of the valve bank 324 is carried by a carriage 336 that is slidably mounted on the arm 202 of the associated container processing station 200. The servo motor is coupled to the carriage 336 and to the arm 202, and moves the carriage 336 and the valve bank 324 along a line that is parallel to the arm 202, under control of the base controller 118.

As shown in FIG. 16, the indexing motor 328 is connected to the carriage 336 and the base of the valve bank 324, and serves to rotate the vacuum pipes 316, 318, the rodless cylinder 320, the rinsing nozzle 322 (together with the valve bank 324) between a substantially horizontal position to a declined position, under control of the base controller 118.

3. Container Filling Station

As shown in FIGS. 5 and 16, each container filling station 400 is disposed above the associated container rinsing station 300, and includes a Z-axis indexer 402 and an associated filling nozzle 404. The Z-axis indexer 402 comprises a substantially flat plate 406, and a pair of C-shaped grippers 408 which are disposed at the opposite ends of the flat plate 406. Preferably, the Z-axis indexer 402 also includes an indexer motor 410 (e.g. servo motor) which is mounted on the arm. As will be explained, the indexer motor 410 rotates the flat plate 406 of the Z-axis indexer 402 about the Z-axis (parallel to the axis of the arm 202 of the associated container processing station 200) of the centripetal container processing apparatus 100, under control of the base controller 118.

As shown, the C-shaped grippers 408 have substantially parallel sides which are perpendicular to the longitudinal axis of the flat plate 406 of the Z-axis indexer 402. Further, to allow the C-shaped grippers 408 to easily grab an empty (cleaned) container 108 from the container cleansing station 300, and to release the container 108 after the filled container 108 is capped, the C-shaped grippers 408 may include mechanical jaws (not shown) that grip the empty container 108 under control of the base controller 118.

As shown in FIGS. 16 and 17, the filling nozzle 404 of each container filling station 400 is connected to a telescoping filling nozzle holder 412, and includes a valve spool 414, a nozzle tube 416, a servo motor 418, and a valve spool stop 420. The telescoping filling nozzle holder 412 is connected at one end to the fluid delivery pipe 204 of the associated container processing station 200, and supplies fluid to the nozzle tube 416. Alternately, as shown in FIG. 18, the telescoping filling nozzle holder 412 may be replaced with a flexible fluid supply tube that supplies the fluid to the nozzle tube 416.

The valve spool 414 is tubular in configuration, and the inner surface thereof seals against the outer surface of the nozzle tube 416 near the radially inner end of the valve spool 414. The valve spool 414 is open at the radially outer end 422 thereof, and includes a laterally-extending valve spool flange 424 intermediate the two ends.

The nozzle tube 416 is tubular in configuration, and is slidably received within the valve spool 414. The nozzle tube 416 is connected at the radially inner end thereof to the telescoping filling nozzle holder 412 (or flexible fluid supply tube). The nozzle tube 416 includes a stopper 426 at the opposite end thereof that engages the open end 422 of the valve spool 414 when the nozzle tube 416 is fully withdrawn into the valve spool 414. The nozzle tube 416 includes a nozzle diffuser 428 that is proximate to the stopper 426, and includes a plurality of radially-extending apertures for delivering fluid from the fluid delivery pipe 204 when the nozzle diffuser 428 extends from the open end 422 of the valve spool 414. Preferably, the nozzle diffuser 428 includes a cone deflector, disposed inside the nozzle tube 416, which maintains the pressure of the fluid exiting the apertures substantially uniform along the length of the nozzle diffuser 428.

As shown in FIGS. 16 and 21, the servo motor 418 is connected between the telescoping filling nozzle holder 412, and the arm 202 of the associated container processing station 200, and moves the valve spool 414 and the nozzle diffuser 428 parallel to the arm 202 of the container processing station 200, under control of the base controller 118.

As shown in FIG. 19, the valve spool stop 420 is coupled to the arm 202 of the associated container processing station 200, and includes a spring-loaded stopper 430 and a valve spool travel limiter 432. The valve spool stop 420 also includes a magnet that allows the spring-loaded stopper 430 to be displaced from its home position (FIG. 20) as the valve spool flange 424 engages the spring-loaded stopper 430, and urges the stopper 430 back to the home position as the valve spool flange 424 moves past the stopper 430 (FIG. 21).

4. Container Capping Station

As shown in FIG. 5, each container capping station 500 is disposed vertically above the associated container filling station 400, and comprises the aforementioned container cap magazine 502, a capping head 504, and a capping motor 506. As discussed above, the container cap magazine 502 receives unused container caps 110 from the container cap bin 132, and supplies the unused container caps 110 to the capping heads 504 as the rotor 102 rotates about its axis.

The capping motor 506 is coupled to the capping head 504. The capping motor 506 rotates the capping head 504, and advances the capping head 504 towards and away from the filled containers 108, under control of the base controller 118. The capping head 504 is configured to receive the unused container caps 110 from the container cap magazine 502, and to screw the container caps 110 onto the mouths of the filled containers 108 that are received from the container filling station 400.

As shown, preferably the cleaning, filling and capping stations 300, 400, 500 maintain the container 108 substantially horizontal during the cleaning, filling and capping steps, respectively. However, to ensure that the fluid in the container 108 remains substantially perpendicular to the longitudinal axis of the container 108 during these steps, preferably the stations 300, 400, 500 are pivotable, relative to the arms 202, about the Y-axis, to thereby change the angle of incline of container 108. As shown in FIG. 18, the angle of the stations 300, 400, 500 relative to the arms 202 may be adjusted by a servo motor, to thereby adjust the incline angle of the containers 108 under control of the base controller 118. Alternately, the angle of the stations 300, 400, 500 may be self-adjusting, to thereby allow the incline angle of the containers 108 to self-adjust as the volume of fluid in the containers 108 changes.

5. Method of Operation

(i) Container Cleaning Step

The base controller 118 causes the container processing rotor 102 to continuously rotate around its axis (X-axis) of rotation. Further, the star-wheel 136 of the container intake station 104 rotates in synchronism with the conveyor belt 134 and the container processing rotor 102. Since the conveyor belt 134 is populated with empty containers 108, the star-wheel 136 continuously transfers the empty containers 108 from the conveyor belt 134 to the container processing stations 200 (via the gripping channels 138) as each container processing station 200 moves past the container intake station 104. Similarly, as will be explained, after the empty containers 108 are cleaned, filled and capped, the filled containers 108 are transferred from the container processing stations 200 to the container removal station 106 as each container processing station 200 moves past the container removal station 106.

Prior to receipt of an empty container 108 at the cleansing station 300 of one of the container processing stations 200, the base controller 118 causes the actuator 312 of the container cleansing station 300 to orient the Y-axis indexer 302 substantially parallel to the X-axis (vertical orientation if the rotor 102 is substantially horizontal), and causes the indexing motor 328 to orient the vacuum pipes 316, 318, the rodless cylinder 320, and the rinsing nozzle 322 of the rinsing module 304 substantially parallel to the Z-axis (horizontal orientation if the rotor 102 is substantially horizontal). The base controller 118 also causes the rodless cylinder 320 to position the vacuum cup 314 a sufficient distance away from the flat plate 306 of the Y-axis indexer 302 to allow the U-shaped grippers 308 thereof to receive the neck of an empty container 108.

Preferably, the mouth of each container 108 is directed radially outwards from the centre of the base 112 of the rotor 102. Therefore, upon receipt of an empty container 108 at a cleansing station 300, the flat plate 306 of the Y-axis indexer 302 grips the neck of the container 108 via the U-shaped grippers 308, as shown in FIGS. 9 and 10. As discussed above, the U-shaped grippers 308 may include mechanical jaws, in which case the base controller 118 may cause the mechanical jaws to close around the neck of the container 108 and thereby grip the container 108.

The base controller 118 causes vacuum to be applied to the vacuum cup 314 via the vacuum pipes 316, 318, and also causes the servo motor of the rinsing module 304 to move the carriage 336 towards the mouth of the empty container 108 until the vacuum cup 314 engages the flat plate 306 of the Y-axis indexer 302, as shown in FIG. 14. Preferably, the vacuum cup 314 does not actually touch the mouth of the empty container 108.

The base controller 118 also causes pressurized air to be applied to the rodless cylinder 320 via the pressurized air pipe 210. The pressure that is maintained inside the rodless cylinder 320 by the pressure regulator allows the rodless cylinder 320 to act as a spring that seals the vacuum cup 314 against the flat plate 306 of the Y-axis indexer 302. Preferably, the base controller 118 also causes the rinsing nozzle 322 to extend through the central inlet of the vacuum cup 314 and into the container 108, and to stop proximate the base of the container 108, as shown in FIG. 5. Alternately, the rinsing nozzle 322 may stop proximate the neck of the container 108.

The base controller 118 then opens one of the valves of the valve bank 324, causing the rinsing nozzle 322 to inject one of the cleaning agents (e.g. water, steam or peroxide) into the empty container 108 from the associated cleanser delivery pipe 206. Preferably, the cleaning agents are injected into the container 108 under pressure. Since the rotor 102 is continuously rotating, the resulting centripetal force tends to eject the cleaning agents from the container 108 into the vacuum cup 314. Alternately, the mouth of the container 108 may be oriented towards the centre of the base 112 of the rotor 102, in which case the resulting centripetal force would tend to maintain the cleaning agents in the container 108.

The cleaning agent is injected into the container 108 with sufficient force and/or kept in the container 108 for a sufficient period of time to clean the interior of the container 108. At the end of the cleaning cycle, the base controller 118 closes the open valve of the valve bank 324. The base controller 118 then opens another valve of the valve bank 324 which causes the rinsing nozzle 322 to inject dry air into the empty container 108 from the associated cleanser delivery pipe 206 to thereby dry the interior of the container 108. Since the resulting moist air is removed from the container 108 under vacuum via the vacuum cup 314, misting around the container 108 is less than conventional filling machines.

The dry air is injected into the container 108 for a predetermined period of time that is sufficient to dry the interior of the container 108. At the end of this time period, the base controller 118 closes the open valve of the valve bank 324, and then causes the servo motor to move the carriage 336 (and therefore the vacuum cup 314) away from the mouth of the empty container 108, as shown in FIGS. 15 and 17. As shown in FIG. 16, preferably the base controller 118 then causes the indexing motor 328 to rotate the rinsing module 304 to a declined position in which the vacuum pipes 316, 318, the rodless cylinder 320, and the rinsing nozzle 322 are oriented at an angle below the Y-Z plane, and the vacuum cup 314 is displaced from the empty container 108. This position constitutes the end of the container cleaning step.

During the container cleaning step, to reduce cycle time preferably the linear actuator 312 maintains the centre of the flat plate 306 of the Y-axis indexer 302 below the axis of rotation of the indexer motor 310, thereby aligning the container 108 with the rinsing nozzle 322, as shown in FIG. 17. After the end of the container cleaning step, but prior to the start of the container filling step, the base controller 118 causes the linear actuator 312 to move the flat plate 306 upwards, in a direction parallel to the X-axis, until the centre of the flat plate 306 coincides with the axis of rotation of the indexer motor 310, and then causes the indexer motor 310 to rotate the empty container 108 about the Y-axis, up to the filling station 400, as shown in FIG. 21. Alternately, the indexing motor 328 of the rinsing module 304 may be eliminated, with the servo motor being configured to move the carriage 336 and the vacuum cup 314 a sufficient distance away from the mouth of the empty container 108 to allow the empty container 108 to be rotated up to the filling station 400.

(ii) Container Filling Step

Before the container filling and capping stations 400, 500 are populated with containers 108, the base controller 118 causes the indexer motor 410 of the Z-axis indexer 402 to incline the longitudinal axis of the flat plate 406 relative to the X-axis, as shown in FIGS. 9 and 16. Preferably, the indexer motor 410 orients the longitudinal axis of the flat plate 406 at approximately a 30° angle relative to the X-axis.

Upon receipt of the next cleaned empty container 108 at the container filling station 400, the base controller 118 causes the indexer motor 410 to rotate the flat plate 406 about the Z-axis such that the longitudinal axis of the flat plate 406 is parallel to the X-axis. As a result, one of the C-shaped grippers 408 grips the neck of the empty cleaned container 108, behind the U-shaped gripper 308 of the Y-axis indexer 302, as shown in FIG. 19. As discussed above, the C-shaped grippers 408 may include mechanical jaws, in which case the base controller 118 may cause the mechanical jaws to close around the neck of the container 108 and thereby grip the container 108.

In subsequent iterations, after the container filling and capping stations 400, 500 are populated with containers 108, the base controller 118 causes the indexer motor 410 to rotate the flat plate 406 of the Z-axis indexer 402 180° about the Z-axis, and also causes the servo motor to rotate the flat plate 306 of the Y-axis indexer 302 180° degrees about the Y-axis, as shown in FIG. 22. Preferably, the base controller 118 causes the flat plate 406 to rotate in synchronism with the flat plate 306, so that the next empty cleaned container 108 is transferred from the container cleansing station 300 to the container filling station 400 as the filled container 108 is transferred from the container filling station 400 to the container capping station 500.

After one of the C-shaped grippers 408 has captured the neck of the empty container 108, the base controller 118 causes the linear actuator 312 of the Y-axis indexer 302 to move the flat plate 306 downwards, in a direction parallel to the X-axis, to the cleaning position, in which the centre of the flat plate 306 is below the axis of rotation of the indexer motor 310, as shown in FIG. 23. The downwards movement of the flat plate 306 causes the container 108 that was previously rotated from the cleaning station 300 to the filling station 400 to be released from the U-shaped grippers 308 of the Y-axis indexer 302. The Y-axis indexer 302 then awaits for receipt of the next empty container 108 from the container intake station 104.

The base controller 118 then causes the servo motor of the filling nozzle 404 to move the telescoping filling nozzle holder 412 thereof towards the mouth of the empty container 108, as shown in FIG. 19. Since the rotor 102 is continuously rotating, the resulting centripetal force on the filling nozzle 404 causes the valve spool 414 to move in unison with the nozzle tube 416. Further, the centripetal force urges the open end 422 of the valve spool 414 against the stopper 426 of the nozzle tube 416, thereby preventing fluid leaking from the nozzle tube 416. Additional sealing force is provided by friction between the stopper 426 and the inner surface of the valve spool 414.

After the valve spool 414 enters the empty container 108, the valve spool flange 424 engages the spring-loaded stopper 430, as shown in FIG. 20, thereby forcing the spring-loaded stopper 430 to move away from the valve spool flange 424. As the valve spool 414 moves past the spring-loaded stopper 430, the spring-loaded stopper 430 returns to its original position, and the valve spool flange 424 engages the valve spool travel limiter 432, thereby preventing further movement of the valve spool 414.

As the base controller 118 continues to cause the telescoping filling nozzle holder 412 to move towards the base of the empty container 108, the stopper 426 of the nozzle tube 416 leaves the open end 422 of the valve spool 414 (FIGS. 17 and 24). As a result, fluid from the fluid delivery pipe 204 enters the container 108 through the nozzle diffuser 428. The fluid may be injected into the container 108 under pressure, or may be introduced into the container 108 via the centripetal force acting on the fluid in the nozzle tube 416. The radially-extending apertures of the nozzle diffuser 428 reduce the amount of foaming and turbulence introduced into the container 108 as the container 108 is filled from the filling nozzle 404. Further, since the rotor 102 is continuously rotating, the resulting centripetal force on the fluid urges the fluid to remain in the container 108. As a result, the time required to fill the container 108 is less than state of the art gravity-fed container filling machines.

The base controller 118 then causes the servo motor 418 to withdraw the nozzle tube 416 from the container 108, thereby withdrawing the nozzle diffuser 428 from the container 108. As the nozzle diffuser 428 is withdrawn from the container 108, the valve spool flange 424 engages the spring-loaded stopper 430, thereby preventing the valve spool 414 from moving with the nozzle diffuser 428. The base controller 118 continues to withdraw the nozzle tube 416 from the container 108 until the stopper 426 seals against the open end of the valve spool 414, thereby terminating fluid delivery into the container 108 (FIG. 20).

At this point, the force applied by the servo motor 418 to the telescoping filling nozzle holder 412 exceeds the magnetic force of the valve spool stop 420. As a result, the spring-loaded stopper 430 is forced to move away from the valve spool flange 424, thereby allowing the valve spool 414 to move past the spring-loaded stopper 430 (FIG. 19). The spring-loaded stopper 430 then returns to its original position. This position constitutes the end of the container filling step.

After the end of the container filling step, the base controller 118 causes the indexer motor 410 to rotate the flat plate 406 of the Z-axis indexer 402 180° about the Z-axis, as shown in FIG. 25. As a result, the filled container 108 is transferred from the container filling station 400 to the container capping station 500 as the next cleaned empty container 108 is transferred from the container cleansing station 300 to the container filling station 400. Since the rotor 102 is continuously rotating, the resulting centripetal force on the fluid urges the fluid to remain in the container 108 as the filled container 108 is transferred from the container filling station 400 to the container capping station 500.

(iii) Container Capping Step

As mentioned, before the container filling and capping stations 400, 500 are populated with containers 108, the base controller 118 causes the indexer motor 410 of the Z-axis indexer 402 to incline the longitudinal axis of the flat plate 406 relative to the X-axis, as shown in FIG. 25. Upon receipt of the next cleaned empty container 108 at the container filling station 400, the base controller 118 causes the indexer motor 410 to rotate the flat plate 406 about the Z-axis until the longitudinal axis of the flat plate 406 is substantially parallel to the X-axis. As a result, one of the C-shaped grippers 408 grips the neck of the next empty container 108, while the C-shaped grippers 408 at the opposite end of the flat plate 406 transfers the just-filled container 108 from the container filling station 400 to the container capping station 500, as shown in FIG. 23.

In subsequent iterations after the container filling and capping stations 400, 500 are populated with containers 108, the base controller 118 causes the indexer motor 410 to rotate the flat plate 406 of the Z-axis indexer 402 180° about the Z-axis, and also causes the servo motor to rotate the flat plate 306 of the Y-axis indexer 302 180° about the Y-axis. Preferably, the base controller 118 causes the flat plate 406 to rotate in synchronism with the flat plate 306, as shown in FIG. 22. As a result, the next empty container 108 is transferred from the container cleansing station 300 to the container filling station 400 as the just-filled container 108 is transferred from the container filling station 400 to the container capping station 500, as shown in FIG. 22.

Once a filled container 108 is transferred to the container capping station 500, the base controller 118 causes the capping motor 506 to advance the capping head 504 towards the cap magazine 502. The capping head 504 grabs the next container cap 110 from the cap magazine 502, and screws or pressure fits the container cap 110 onto the mouth of the filled container 108, as shown in FIG. 5. The face of the flat plate 406 of the Z-axis indexer 402 may include an anti-rotation mechanism that limits rotation of the container 108 during the container sealing step. Suitable anti-rotation means includes a textured surface on the flat plate 406, or retractable needles which extend from the face of the flat plate 406.

The base controller 118 then causes the capping motor 506 to move the capping head 504 away from the cap magazine 502, leaving the container cap 110 on the filled container 108. The capped container 108 is then released from the capping station 500, as shown in FIG. 26.

As discussed above, the C-shaped grippers 408 may include mechanical jaws, in which case the base controller 118 may cause the mechanical jaws to move apart to thereby facilitate release of the capped container 108 from the capping station 500. Alternately, the capping station 500 may be fitted with a solenoid (not shown) that presses against the neck of the capped container 108, under control of the base controller 118, to thereby force the capped container 108 out of the C-shaped grippers 408.

Since the rotor 102 is continuously rotating, the resulting centripetal force acting on the container 108 causes the released container 108 to land on the container removal station 106, as shown in FIGS. 27 and 28. As shown in FIGS. 26 and 28, the container removal station 106 may include a conveyor belt 140 that receives the capped containers 108 as they are delivered from the container capping stations 500. Further, as shown, the filled containers 108 may be delivered to the container removal station 106 substantially horizontally. Therefore, the container removal station 106 may include a horizontal supporting surface (not shown) that supports the capped containers 108. Alternately, or additionally, the container removal station 106 may include a mechanism (not shown) to re-orient the containers 108 to a substantially vertical orientation upon receipt from the container capping stations 500.

As will be apparent, the processing rate of the centripetal container processing apparatus 100 will vary with the number of container processing stations 200 and container cleansing/filling/capping stations 300, 400, 500. For instance, if the diameter of the container processing rotor 102 of FIG. 1 is 17 feet, and the rotor 102 is rotated at a speed of 30 rpm, the following yields may be realized:

• • 34 container processing stations 200, and 68 cleansing/filling/capping stations: 122,400 containers/hour
  • 17 container processing stations 200, and 34 cleansing/filling/capping stations: 61,200 containers/hour
  • 8 container processing stations 200, and 16 cleansing/filling/capping stations: 28,800 containers/hour

Further, although the containers 108 are typically all of the same size, the containers 108 can be of different sizes with appropriate adjustments to the length of the cleaning and filling steps.

6. Variation #1: Container Processing Station for Rigid Necked Pouches

Thus far, this disclosure has focused on the processing of rigid containers. However, the centripetal container processing apparatus is not so limited. For instance, as will be discussed below, one variation of the centripetal container processing apparatus may be used to fill flexible pouches that have a rigid filler neck.

6.1. Centripetal Container Processing Apparatus—Overview

FIG. 29 depicts a centripetal container processing apparatus, denoted generally by reference numeral 1100. The centripetal container processing apparatus 1100 is substantially similar to the centripetal container processing apparatus 100 and, therefore, like reference numerals will be used to denote like components.

As shown, the centripetal container processing apparatus 1100 comprises a container processing rotor 1102, a container intake station 1104, and the container removal station 106. The container intake station 1104 feeds empty containers 1108 to the rotor 1102, and the container removal station 106 accepts filled containers 1108 from the rotor 1102. The container intake and removal stations 1104, 106 are disposed proximate the outer radius of the container processing rotor 1102.

Typically, the containers 1108 are flexible pouches that have a rigid filler neck. As above, typically the fill material is a liquid (foodstuff or non-foodstuff), such as water, juice or soda. However, the centripetal container processing apparatus 1100 may be used to fill the containers 1108 with granular, shredded, particulate or paste-like material.

The container processing rotor 1102 comprises a base 1112, the turret 114, the hub 116, and at least one container processing station 1200 that is connected to the hub 116 and extends radially outwards from the base 1112. The rotor 1102 also includes the base controller 118 that is mounted within the base 1112 and is configured to control and monitor the operation of the container processing stations 1200.

As shown in FIG. 29, each container processing station 1200 comprises a substantially straight arm 202 that is secured at its inner end to the rotating hub 116, and one or more head assemblies 1212, that are secured to the outer end of the arm 202 and serve to fill and cap the containers 1108. As shown in FIGS. 30 and 31, preferably each arm 202 carries a pair of the head assemblies 1212, which are disposed radially adjacent to each other around a common radius of the container processing rotor 1102. However, each arm 202 need not support only two head assemblies 1212 but may comprise any number of the head assemblies 1212.

Since the containers 1108 are typically received at the container processing stations 1200 already cleaned, the container processing stations 1200 do not include a container cleansing station. Instead, as shown in FIG. 32, typically each head assembly 1212 comprises a container filling station 1400, and the container capping station 500. Further, in each head assembly 1212 preferably the container filling station 400 and container capping station 500 are disposed vertically above one another.

The arm 202 of each container processing station 1200 carries the fluid delivery pipe 204 and the vacuum pipe 208 which are connected to the head assembly/assemblies 1212 of the associated container processing station 1200. Further, each arm 202 carries associated electrical wiring, sensors and control valves that are coupled to the base controller 118 for controlling the operation of the head assemblies 1212.

The base 1112 includes the fluid delivery line 120, the vacuum line 124, the fluid delivery manifold, and a vacuum delivery manifold (not shown). The fluid delivery line 120 is connected to the fluid delivery manifold within the base 1112. The vacuum line 124 is connected to the vacuum delivery manifold within the base 1112.

The fluid delivery pipes 204 of all of the container processing stations 1200 are connected to the fluid delivery manifold. The vacuum pipes 208 of all of the container processing stations 1200 are connected to the vacuum delivery manifold. As a result, as the hub 116 rotates, the fluid delivery line 120 is able to supply fluid (liquid or granular material) to the head assemblies 1212, and the vacuum line 124 is able to apply vacuum to the head assemblies 212, via the respective manifolds.

Typically the centripetal container processing apparatus 1100 will fill all of the containers 1108 with the same fluid. However, as shown in FIG. 38, the base 1112 may be fed with a plurality of fluid delivery lines 120, each connected to a respective fluid supply and a respective fluid delivery manifold. Each fluid delivery manifold may be coupled to a respective portion of the head assemblies 1212. In this variation, the centripetal container processing apparatus 1100 would fill each container 1108 with one of a number of different fluids, depending upon the contents of the respective fluid supplies.

6.2. Z-axis Indexer of Container Filling Station

As shown in FIG. 32, each container filling station 1400 and includes a Z-axis indexer 1402 and an associated filling nozzle 1404. The Z-axis indexer 1402 comprises a substantially flat plate 1406, a pair of gripper arms 1434 which are displaced along the Z-axis (parallel to the axis of the arm 202 of the associated container processing station 1200) from the flat plate 1406, and a tubular member 1436 that is connected to the flat plate 1406 and the gripper arms 1434.

The flat plate 1406 includes a pair of U-shaped grippers 1408 that are disposed at the opposite ends of the flat plate 1406. As shown, the U-shaped grippers 1408 have substantially parallel sides which are parallel to the longitudinal axis of the flat plate 1406 of the Z-axis indexer 1402.

Further, as will be explained, in operation the rotor 1102 continuously rotates about its axis (X-axis) of rotation. As shown in FIG. 29, as the rotor 1102 rotates, the Z-axis indexer 1402 of each container filling station 1400 picks up an empty container 1108 from the container intake station 1104 via the filler neck of the container 1108. Preferably, the width of the U-shaped grippers 1408 is slightly less than the diameter of the filler neck of the container 1108, to thereby allow the Z-axis indexer 1402 to hold the empty container 1108 without a separate mechanical actuator. Alternately, the Z-axis indexer 1402 may include alternate gripping means to grip the container 1108. For example, the U-shaped grippers 1408 may include mechanical jaws (not shown) that grip the filler neck of the container 1108 under control of the base controller 118.

As shown in FIG. 32, the gripper arms 1434 are disposed 180° apart, and extend radially outwards from one end of the tubular member 1436. The tubular member 1436 extends from the gripper arms 1434, through the centre of the flat plate 1406, and is coupled at its opposite end to the vacuum pipe 208 of the container processing station 1200. Each gripper arm 1434 includes a plurality of apertures (not shown) that are connected to the vacuum pipe 208 via the tubular member 1436, and grip the base portion of the empty container 1108 by vacuum when the U-shaped grippers 1408 grip the filler neck of the container 1108.

The Z-axis indexer 1402 also includes an indexer motor (not shown) which is mounted on the arm 202. As will be explained, the indexer motor rotates the flat plate 1406, together with the tubular member 1436 and the gripper arms 1438 about the Z-axis of the centripetal container processing apparatus 1100, under control of the base controller 118.

Preferably, the empty containers 1108 are delivered substantially horizontally from the container intake station 1104 to the container filling stations 1400. The empty containers 1108 may be delivered at a different angle (e.g. vertically) to the filling stations 1400. However, in this variation, preferably the filling stations 1400 re-orient the containers 1108 to the plane of the arms 202 of the rotor 1102 upon receipt from the container intake station 1104.

As shown in FIG. 29, the container intake station 1104 may include a conveyor belt 134 that carries the empty containers 1108, and a star-wheel 1136 that includes a plurality of outwardly-extending gripping channels 138 for lifting the empty containers 1108 from the conveyor belt 134 to the filling stations 1400 via the neck of each container 1108. The star-wheel 1136 also includes a plurality of lift arms 1438 that are displaced (along an axis that is parallel to the axis of rotation of the star-wheel 1136) from the gripping channels 138, and extend radially outwards from the centre of rotation of the star-wheel 1136. The lift arms 1438 are positioned below the Z-axis indexers 1402, in substantial vertical alignment with the gripper arms 1434 thereof. Each lift arm 1438 includes a plurality of apertures (not shown) that are connected to a common vacuum line, and grip the base portion of the pouch by vacuum while the gripping channels 138 of the star-wheel 1136 grip the filler neck of the container 1108.

As above, the pitch of the star-wheel 136 may be selected to deliver an empty container 1108 to each radially-adjacent filling station 1400. However, the centripetal container processing apparatus 1100 is not so limited but may include an odd number of head assemblies 1212, with the pitch of the star-wheel 1136 being selected to deliver an empty container 1108 to each alternate head assembly 1212.

6.3. Filling Nozzle of Container Filling Station

Since the containers 1108 are typically supplied to the container filling station 1400 substantially flat and devoid of air, the filling nozzle 1404 does not include a valve spool or a sliding nozzle tube. Instead, as shown in FIGS. 31 and 32, the filling nozzle 1404 comprises a nozzle tube 1416 and an in-line valve (not shown). The nozzle tube 1416 is fixed relative to the respective arm 202 and terminates at one end in close proximity to the flat plate 1406 of the Z-axis indexer 1402. The other end of the nozzle tube 1416 is coupled to the fluid delivery pipe 204 of the associated container processing station 1200. The in-line valve is disposed between the fluid delivery pipe 204 and the nozzle tube 1416, and controls the movement of fluid from the fluid delivery pipe 204 through the filling nozzle 404.

6.4. Method of Operation

The base controller 118 causes the container processing rotor 1102 to continuously rotate around its axis (X-axis) of rotation. Further, the star-wheel 1136 of the container intake station 1104 rotates in synchronism with the conveyor belt 134 and the container processing rotor 1102. Since the conveyor belt 134 is populated with empty containers 1108, the star-wheel 136 continuously transfers the empty containers 1108 from the conveyor belt 134 to the container processing stations 1200 (via the gripping channels 138 and the lift arms 1438) as each container processing station 1200 moves past the container intake station 104. Similarly, as will be explained, after the empty containers 1108 are filled and capped, the filled containers 1108 are transferred from the container processing stations 1200 to the container removal station 106 as each container processing station 1200 moves past the container removal station 106.

Prior to receipt of an empty container 1108 at a filling station 1400, the base controller 118 causes the indexer motor of the filling station 1400 to orient the Z-axis indexer 402 substantially parallel to the X-axis (vertical orientation if the rotor 1102 is substantially horizontal) to allow the U-shaped grippers 1408 to receive the neck of an empty container 1108, as shown in FIG. 32.

Preferably, the mouth of the container 1108 is directed inwards towards the centre of rotation of the rotor 1102. Therefore, upon receipt of an empty container 1108 at a filling station 1400, the flat plate 1406 of the Z-axis indexer 1402 grips the neck of the container 1108 via the U-shaped grippers 1408, as shown in FIG. 33. As discussed above, the U-shaped grippers 1408 may include mechanical jaws, in which case the base controller 118 may cause the mechanical jaws to close around the filler neck of the container 1108 and thereby grip the container 1108. At the same time, preferably the base controller 118 causes vacuum to be applied to the gripper arm 1434 of the filling station 1400, thereby gripping the base portion of the container 1108.

The base controller 118 then opens the in-line valve, causing fluid to be delivered from the fluid delivery pipe 204 into the filler neck of the empty container 1108 via the nozzle tube 1416. Since the nozzle tube 1416 terminates in close proximity to the flat plate 1406 of the Z-axis indexer 1402, the fluid is directed from the nozzle tube 1416 into the container 1108 without significant loss and without the nozzle tube 1416 touching the mouth of the container 1108. Again, since the rotor 1102 is continuously rotating, the resulting centripetal force on the fluid reduces filling times while also urging the fluid to remain in the container 1108. After a predetermined period of time which is sufficient to fill the container 1108, the base controller 118 closes the in-line valve. This position constitutes the end of the container filling step.

After the end of the container filling step, the base controller 118 causes the indexer motor of the filling station 1400 to rotate the flat plate 1406 180° about the Z-axis, as shown in FIGS. 34 and 35. As a result, the filled container 1108 is transferred from the container filling station 400 to the container capping station 500 as the next empty container 1108 is transferred from the container intake station 1104 to the container filling station 400, as shown in FIG. 36. Since the rotor 1102 is continuously rotating, the resulting centripetal force on the fluid urges the fluid to remain in the container 1108 as the filled container 108 is transferred from the container filling station 400 to the container capping station 500.

Once a filled container 1108 is transferred to the container capping station 500, the base controller 118 causes the capping motor 506 to advance the capping head 504 towards the container cap magazine 502. The capping head 504 grabs the next container cap 110 from the container cap magazine 502, and screws or pressure fits the container cap 110 onto the mouth of the filled container 1108. The base controller 118 then causes the capping motor 506 to pull the capping head 504 away from the container cap magazine 502, leaving the container cap on the filled container 1108. The capped container 1108 is then released from the capping station 500.

As discussed above, the U-shaped grippers 1408 of the Z-axis indexer 1402 may include mechanical jaws, in which case the base controller 118 may cause the mechanical jaws to move apart to thereby facilitate release of the capped container 1108 from the capping station 500. Since the rotor 1102 is continuously rotating, the resulting centripetal force on the container 1108 causes the released container 108 to land on the container removal station 106, as shown in FIG. 37.

7. Variation #2: Container Processing Station for Neckless Pouches

Thus far, this disclosure has focused on the processing of containers having rigid filler necks. However, the centripetal container processing apparatus is not so limited. For instance, as will be discussed below, another variation of the centripetal container processing apparatus may be used to fill flexible pouches that do not have rigid filler necks.

Typically the centripetal container processing apparatus 1100 will fill all of the containers 1108 with the same fluid. However, the base 112 may be fed with a plurality of fluid delivery lines 120, each connected to a respective fluid supply and a respective fluid delivery manifold, to fill each container 1108 with one of a number of different fluids, depending upon the contents of the respective fluid supplies.

7.1. Centripetal Container Processing Apparatus—Overview

FIGS. 39 and 40 depict a centripetal container processing apparatus, denoted generally by reference numeral 2100. The centripetal container processing apparatus 2100 is substantially similar to the centripetal container processing apparatus 1100. Therefore, as shown, the centripetal container processing apparatus 2100 comprises a container processing rotor 2102, a container intake station 2104, and the container removal station 106. The container intake station 2104 feeds empty containers 2108 to the rotor 2102, and the container removal station 106 accepts filled containers 2108 from the rotor 2102. The container intake and removal stations 2104, 106 are disposed proximate the outer radius of the container processing rotor 2102.

Typically, the containers 2108 are flexible neckless pouches (i.e. without rigid filler necks). Preferably, each container 2108 has an internal polymeric layer, which is at least proximate the mouth of the container 2108 and allows the mouth of the container 2108 to be sealed by ultrasonic, heat or laser welding, or other suitable sealing technique. As above, typically the fill material is a liquid (foodstuff or non-foodstuff), such as water, juice or soda. However, the centripetal container processing apparatus 2100 may be used to fill the containers 2108 with granular, shredded, particulate or paste-like material.

The container processing rotor 2102 comprises the base 1112, the turret 114, the hub 116, and at least one container processing station 2200 that is connected to the hub 116 and extends radially outwards from the base 1112. The rotor 2102 also includes the base controller 118 that is mounted within the base 1112 and is configured to control and monitor the operation of the container processing stations 2200.

As shown in FIGS. 41 and 42, each container processing station 2200 comprises a substantially straight arm 202 that is secured at its inner end to the rotating hub 116, and one or more head assemblies 2212, that are secured to the outer end of the arm 202 and serve to fill and cap the containers 2108. As shown in FIG. 40, preferably each arm 202 supports a pair of the head assemblies 2212, which are disposed radially adjacent to each other around a common radius of the container processing rotor 2102. However, each arm 202 need not support only two head assemblies 2212 but may comprise any number of the head assemblies 2212.

As above, since the containers 2108 are typically received at the container processing stations 2200 already cleaned, the container processing stations 2200 do not include a container cleansing station. However, in contrast to the previous variation, typically each head assembly 2212 comprises an integrated container filling/sealing station, as opposed to separate filling and sealing stations.

The arm 202 of each container processing station 2200 carries the fluid delivery pipe 204 and the vacuum pipe 208 which are connected to the head assembly/assemblies 2212 of the associated container processing station 2200. Further, each arm 202 carries associated electrical wiring, sensors and control valves that are coupled to the base controller 118 for controlling the operation of the head assemblies 2212.

Typically the centripetal container processing apparatus 1100 will fill all of the containers 2108 with the same fluid. However, as above, the base 1112 may be fed with a plurality of fluid delivery lines 120, each connected to a respective fluid supply and a respective fluid delivery manifold to fill each container 2108 with one of a number of different fluids.

7.2. Integrated Container Filling/Sealing Station

As shown in FIGS. 43 and 44, each container filling/sealing station (head assembly) 2212 comprises a container filling/sealing head 2402 and an associated filling nozzle 2404. The container filling/sealing station 2402 comprises a support frame 2406, a sealing anvil 2408, and a welding anvil (not shown).

The support frame 2406 is secured to the respective arm 202, and carries the sealing anvil 2408 and the welding anvil. The sealing anvil 2408 comprises a mounting plate 2410, a pair of opposing reciprocating jaws 2412, an anvil rotation servo motor 2414, and a sealing anvil servo motor 2416. The mounting plate 2410 is rotatably coupled to the support frame 2406, and houses the reciprocating jaws 2412. The anvil rotation servo motor 2414 is coupled to the support frame 2406 and the mounting plate 2410, and serves to rotate the mounting plate 2410 about the Z-axis under control of the base controller 118, as shown in FIG. 41.

The sealing anvil servo motor 2416 is coupled to the reciprocating jaws 2412 via a linear screw (not shown) that is disposed within the mounting plate 2410 to thereby move the jaws 2412 between a closed position and an opened position under control of the base controller 118. Preferably, the sealing anvil jaws 2412 include a plurality of apertures (not shown) through which vacuum can be applied (from the associated vacuum pipe 208) to thereby temporarily secure the upper and lower surfaces of the container 2108, at the mouth thereof, to a respective one of the sealing anvil jaws 2412, when the sealing anvil jaws 2412 are opened.

The welding anvil is secured to the mounting plate 2410 of the sealing anvil 2408, and comprises a pair of opposing reciprocating jaws 2418 that are disposed radially inwards from the sealing anvil jaws 2412. The welding anvil jaws 2418 are coupled to the linear screw of the sealing anvil 2408 to thereby move the welding anvil jaws 2418 between a closed position and an opened position in unison with the sealing anvil jaws 2412. At least one of the welding anvil jaws 2418 is configured with an ultrasonic, heat or laser welder to seal the mouth of the container 2108 after the container 2108 has been filled.

As above, in operation the rotor 2102 continuously rotates about its axis (X-axis) of rotation. As the rotor 2102 rotates, each container filling/sealing station 2212 picks up an empty container 2108 from the container intake station 2104. Preferably, the empty containers 2108 are delivered substantially horizontally from the container intake station 2104 to the container filling/sealing station 2212. Therefore, as shown in FIG. 39, the container intake station 2104 may comprise a conveyor belt that carries the horizontal empty containers 2108. Alternately, the container intake station 2104 may comprise an automatic stack dispenser that delivers empty containers 2108 to the container filling/sealing station 2212 substantially horizontally. Alternately still, the container intake station 2104 may comprise a conveyor belt and a star wheel for transferring empty containers 2108 to the container filling/sealing stations 2212.

As shown in FIGS. 41 and 43, preferably the sealing anvil 2408 also comprises a stop arm 2418 that extends in the X-Z plane from the outer surface of the sealing anvil jaws 2412. Alternately, or additionally, the sealing anvil 2408 may include a support plate 2420 that extends in the Y-Z plane from the outer surface of the sealing anvil jaws 2412. As will be explained, the support plate 2420 serves to lift an empty container 2108 from the container intake station 2104, and to support the container 2108 during the filling step. The stop arm 2418 serves to align the mouth of the container 2108 with the sealing anvil jaws 2412 after the head assembly 2212 receives an empty container 2108 from the container intake station 2104.

7.4. Filling Nozzle of Container Filling Station

Since the containers 2108 are typically supplied to the head assembly 2212 substantially flat and devoid of air, the filling nozzle 2404 does not include a valve spool or a sliding nozzle tube. Instead, as shown in FIGS. 42 and 44, the filling nozzle 2404 comprises a flexible nozzle sleeve 2424, a primary nozzle valve 2426, a secondary nozzle valve 2428, and a plurality of servo motors (not shown). As will become apparent, the nozzle sleeve 2424 delivers fluid from the fluid delivery pipe 204 to the container 2108, and the primary and secondary nozzle valves 2426, 2428 control the movement of fluid from the fluid delivery pipe 204 through the filling nozzle 2404.

Preferably, the nozzle sleeve 2424 is fabricated from a flexible polymeric material, and comprises an inlet end and an outlet end. The nozzle sleeve 2424 is coupled at the inlet end thereof to the fluid delivery pipe 204 of the associated head assembly 2212, and is open at the outlet end of the nozzle sleeve 2424. The nozzle sleeve 2424 extends from the fluid delivery pipe 204 to the outlet end of the nozzle sleeve 2424, and terminates at the outlet end in close proximity to the welding anvil jaws, radially inwards of the welding anvil jaws.

The primary nozzle valve 2426 is fixed to the support frame 2406, and comprises a pair of opposing reciprocating jaws that are disposed in close proximity to the welding anvil jaws, radially inwards of the welding anvil jaws. At the outlet end of the nozzle sleeve 2424, the upper outer surface of the nozzle sleeve 2424 is secured (typically by adhesive or welding) to the upper jaw of the primary nozzle valve 2426. Similarly, at the outlet end of the nozzle sleeve 2424, the lower outer surface of the nozzle sleeve 2424 is secured to the lower jaw of the primary nozzle valve 2426. One of the filling nozzle servo motors is configured to move the jaws of the primary nozzle valve 2426 between a closed position and an opened position, under control of the base controller 118, and thereby control the delivery of fluid from the nozzle sleeve 2424 into the container 2108. Preferably, the outlet end of the nozzle sleeve 2424 terminates in close proximity to the radially outer face of the primary nozzle valve 2426 (i.e. the face that is adjacent the sealing anvil 2408). Further, preferably the outlet end of the nozzle sleeve 2424 is positioned on the primary nozzle valve 2426 so to align with the mouth of the container 2108 (when the mouth of a container 2108 is secured via vacuum to the sealing anvil jaws 2412), and the diameter of the outlet end of the nozzle sleeve 2424 is similar to that of the mouth of the container 2108 to thereby allow fluid to be delivered from the nozzle sleeve 2424 into the container 2108 when the sealing anvil jaws 2412 and the primary nozzle valve 2426 are both opened.

The secondary nozzle valve 2428 comprises a pair of opposing reciprocating jaws that are disposed radially inwards of the open end of the nozzle sleeve 2424, between the primary nozzle valve 2426 and the opposite end of the nozzle sleeve 2424. One of the filling nozzle servo motors is configured to move the jaws of the secondary nozzle valve 2428 between a closed position and an opened position, under control of the base controller 118, and thereby control the delivery of fluid from the fluid delivery pipe 204 into the nozzle sleeve 2424.

The volume of the filling nozzle is defined by the distance between the primary nozzle valve and the secondary nozzle valve. Therefore, the secondary nozzle valve 2428 is axially movable along the support frame 2406 between the outlet of the fluid delivery pipe 204 and the primary nozzle valve 2426. A servo motor is coupled to the secondary nozzle valve 2428 via a linear screw (not shown) that is disposed within the support frame 2406, and is configured to move the secondary nozzle valve 2428 axially along the support frame 2406, under control of the base controller 118. Preferably, the axial position of the secondary nozzle valve is adjusted by the base controller 118 so that the maximum volume of fluid that can be maintained in the nozzle sleeve 2424 corresponds to the desired fluid volume of the container 2108 to be filled.

7.3. Method of Operation

As the rotor 2102 rotates, each head assembly 2212 cyclically approaches and departs from the container intake station 2104 and the container removal station 106. After a head assembly 2212 departs from the container removal station 106, the base controller 118 opens the secondary nozzle valve 2428 of the head assembly 2212, while maintaining the primary nozzle valve 2426 closed, thereby causing the filling nozzle 2404 to fill with fluid from the associated fluid delivery pipe 204. The base controller 118 then closes the secondary nozzle valve 2428 after a predetermined period of time which is sufficient to fill the filling nozzle 2404 with fluid.

Typically, the base controller 118 maintains the support plate 2420 of the sealing anvil 2408 substantially horizontal, above the height of the conveyor belt of the container intake station 2104. However, as the head assembly 2212 approaches the container intake station 2104, the controller 118 causes the sealing anvil jaws 2412 and the welding anvil jaws 2418 of the head assembly 2212 to separate enough to capture an empty container 2108 between the sealing and welding anvil jaws 2412, 2418. Further, as shown in FIG. 41, preferably the base controller 118 also rotates the sealing anvil 2408 and the welding anvil clockwise so as to cause the leading edge of the support plate 2420 to drop and engage the upper surface of the conveyor belt of the container intake station 2104.

As the rotor 2102 continues to rotate, the leading edge of the support plate 2420 engages the trailing side of the next empty container 2108, causing the container 2108 to move from the conveyor belt along the support plate 2420 until the trailing side of the container 2108 engages the stop arm 2420 of the sealing anvil 2408. At this stage, the mouth of the container 2108 will be disposed between the sealing and welding anvil jaws 2412, 2418.

The base controller 118 then returns the sealing and welding anvils 2412, 2418 to the substantially horizontal position, and closes the sealing and welding anvil jaws 2412, 2418, thereby capturing the mouth of the container 2108 between the sealing and welding anvil jaws 2412, 2418, as shown in FIG. 45.

After a container 2108 has been captured between the sealing and welding anvil jaws 2412, 2418 of the head assembly 2212, and the head assembly 2212 leaves the container intake station 2104, the base controller 118 applies vacuum to the apertures of the sealing anvil 2408, thereby securing the upper and lower surfaces of the container 2108, at the mouth thereof, to the sealing anvil jaws 2412. As shown in FIG. 46, the base controller 118 then opens the primary nozzle valve 2426 and the sealing and welding anvil jaws 2412, 2418, thereby causing the mouth of the container 2108 and the outlet end of the nozzle sleeve 2424 to open, and the fluid stored in the nozzle sleeve 2424 to be ejected out of the outlet end of the nozzle sleeve 2424 from the centripetal force acting on the stored fluid.

Since the diameter of the outlet end is similar to that of the mouth of the container 2108, and since the outlet end of the nozzle sleeve 2424 will be aligned with the mouth of the container 2108, the fluid that is ejected from the nozzle sleeve 2424 will be directed into the mouth of the container 2108. Again, since the rotor 2102 is continuously rotating, the resulting centripetal force reduces the time required to fill the container 2108. Further, as shown in FIG. 47, the centripetal force acting on the ejected fluid causes the side walls of the container 2108 to separate to accommodate the delivery of the fluid into the container 2108. At the same time, the centripetal force urges the fluid to remain in the container 2108.

After a predetermined period of time which is sufficient to fill the container 2108 with all the fluid in the filling nozzle 2404, the base controller 118 closes the primary nozzle valve 2426 and the sealing and welding anvil jaws 2412, 2418, and then activates the ultrasonic welder to thereby seal the mouth of the container 2108 at the welding anvil jaws 2418.

As the sealed pouch approaches the container removal station 106, the base controller 118 removes the vacuum from the sealing anvil apertures, and opens the sealing and welding anvil jaws 2412, 2418 to thereby allow the filled container 2108 to be ejected from the sealing anvil 2408 and the welding anvil, onto the container removal station 106, by the centripetal force acting on the container 2108, as shown in FIG. 48.

Although each of the foregoing variations of the centripetal container processing apparatus are shown in the attached drawings as comprising only a single container processing rotor, it should be understood that the centripetal container processing apparatus can comprise a plurality of container processing rotors which are stacked vertically over each other. In this latter variation, the container processing rotors would be supported on the same base 112, with each rotor being in communication with a respective set of container intake and container removal stations.

Further, in another variation, the base 112 supports two rotors, with the upper rotor being inverted relative to the lower rotor. In this latter variation, the container intake station for the upper rotor is disposed above the upper rotor, while the container intake station for the lower rotor is disposed below the lower rotor. The container processor stations would be disposed between the upper and lower rotors.

Claims

1-23. (canceled)

24. A rotor for mounting to a rotor support of a centripetal container processing apparatus, the rotor comprising: a plurality of arms extending radially outwards from a central hub; anda container processing station mounted to at least one of the arms, the at least one container processing station being configured to introduce material into the container via a centripetal force, the centripetal force being exerted against the fluid during a rotation of the rotor about the rotor support, the at least one container processing station being further configured to one of cap and seal the container.

25. The rotor according to claim 24, wherein the at least one container processing station comprises a container filling head, the container filling head being configured to introduce the material into the container, and to maintain the introduced material in the container via the centripetal force.

26. The rotor according to claim 24 or 25, wherein the at least one container processing station comprises a container cleansing head, the container cleansing head being configured to clean the container by injecting fluid into the container, and to remove the injected fluid from the container via the centripetal force.

27. The rotor according to claim 24, wherein each said container processing station comprises a container cleansing head, a container filling head, and a container capping head.

28. The rotor according to claim 27, wherein the container filling head is configured to introduce the material into the container, and to maintain the introduced material in the container via the centripetal force.

29. The rotor according to claim 28, wherein the container cleansing head is configured to clean the container by injecting the material into the container, and to remove the injected material from the container via the centripetal force.

30. The rotor according to claim 29, wherein the container capping head is configured to maintain the introduced matter in the container via the centripetal force while capping the container.

31. The rotor according to claim 27, wherein the container cleansing heads all occupy a common cleansing head plane, the container filling heads all occupy a common filling head plane, and the container capping heads all occupy a common capping head plane, and the cleansing head plane is parallel to the filling head plane and the capping head plane.

32. The rotor according to claim 31, wherein the arms extend horizontally from the rotor support, the container processing stations are fixed to the arms, the container filling heads are vertically adjacent the container cleansing heads, and the container capping heads are vertically adjacent the container filling heads.

33. The rotor according to claim 32, wherein the container processing stations are mounted proximate outer ends of the arms.

34. The rotor according to claim 24, configured to supply one of a number of different fluids to the container processing stations.

35. The rotor according to claim 34, wherein the rotor support comprises a plurality of material delivery manifolds, each said manifold being coupled to a respective material delivery line and a respective portion of the container processing stations.

36. The rotor according to claim 24, wherein the at least one container processing station comprises a container filling head, and the container filling head comprises a filling nozzle configured to introduce the material into the container during the rotation of the rotor, the filling nozzle comprising a valve spool, a telescoping nozzle diffuser slidably received within the valve spool, and an actuator coupled to the nozzle diffuser for moving the nozzle diffuser into and out of the valve spool, the valve spool being open at one end thereof, the nozzle diffuser including a stopper for closing the open end when the nozzle diffuser is disposed within the valve spool.

37. The rotor according to claim 36, wherein the nozzle diffuser is coupled to a fluid source proximate one end thereof, the stopper being proximate the other end thereof, the nozzle diffuser including at least one aperture proximate the other end for introducing the fluid into the container when the nozzle diffuser moves out from the valve spool.

38. The rotor according to claim 37, wherein the filling nozzle further comprises a magnetic stop, and the valve spool includes a radially-extending valve spool flange, the magnetic stop being configured to engage the valve spool flange as the nozzle diffuser moves out of the valve spool and enters the container.

39. The rotor according to claim 38, wherein the magnetic stop is configured to release the valve spool flange before the nozzle diffuser is fully withdrawn from the container and after the stopper closes the open end of the valve spool.

40. The rotor according to claim 36, wherein the container filling head comprises a filling nozzle configured to introduce the fluid into the container during the rotation of the rotor, the filling nozzle comprising a valve spool which is fixed relative to the associated arm.

41. The rotor according to claim 36, wherein the container comprises a neckless pouch, and the container filling head comprises a filling anvil and a filling nozzle coupled to the filling anvil, the filling anvil being configured to capture the pouch at a mouth thereof, the filling nozzle being configured to open the neckless pouch via the introduced fluid.

42. The rotor according to claim 41, wherein the filling nozzle comprises a primary nozzle valve, a secondary nozzle valve, and a flexible sleeve extending between the nozzle valves.

43. The rotor according to claim 42, wherein the flexible sleeve has an inlet end and an outlet end, the outlet end being secured to the primary nozzle valve, the primary nozzle valve being configured to align the outlet end with the mouth of the pouch.

44. A rotor for mounting to a rotor support of a centripetal container processing apparatus, the rotor comprising: a plurality of arms extending radially outwards from a central hub; anda container sealing head mounted to at least one of the arms, the container sealing head being configured to maintain fluid in the container via a centripetal force and to seal the container as the fluid is maintained in the container via the centripetal force, the centripetal force being exerted against the fluid during a rotation of the rotor about the rotor support