Patent Application
20170253355
Apparatus, and methods of using the same, for dispensing fluid.
Unit dose articles filled with compositions, particularly household care compositions such as laundry detergent, are becoming more popular with consumers. Generally, such articles are made in part by forming compartments in a web, for example, a web of water-soluble film, filling the compartments with a composition, and then sealing and separating the articles. The webs are often disposed on a moving surface, such as on a rotary drum or on a horizontal conveyor belt, and the compartments are filled as they move past filling nozzles. In larger scale manufacturing lines there are typically multiple filling nozzles in a lane in the machine direction MD and multiple lanes in parallel with one another in the cross direction CD. For example, a manufacturer may have twelve lanes, each lane having four nozzles, for a total of forty-eight nozzles. The nozzles are typically crowded closely together to allow more nozzles to fit within compact space. The lanes are typically crowded closely together to allow more lanes to fit within compact space. Having more nozzles allows for an increase in the number of compartments that can be filled simultaneously. Manufacturers are continually looking for ways to increase the speed and efficiency of the process of filling compartments with fluid compositions.
The type of composition being dispensed can provide filling challenges. During manufacture, the time it takes to fill a compartment with a fluid depends a great deal on the rheological properties of the fluid. Higher-viscosity compounds may result in a filament or string that forms and hangs down from the filling nozzle at the end of the filling event, and this filament or string takes some time to break up. The time to break up is typically longer than desired and imposes a limitation to the speed at which consecutive filling events can take place. The time to break up sometimes can be the controlling factor for selecting the maximum speed at which the filling operation can run, as speeding up the filling operation before the filament or string breaks up will cause fluid to fall on the web in between the compartments. Lower-viscosity compounds may splash out of cavities when dispensed quickly which will also cause fluid to fall on the web in between the compartments. Fluid located on the web in between the compartments causes difficulty in sealing and separating the articles.
To compensate for the problem associated with stringing, a valve can be joined to the tip of the filling nozzle that only opens when filling is needed and closes rapidly at the end of the filling event. In a compact filling apparatus, there is little space to install valves next to all of the nozzles. Furthermore, adding valves would also add extra weight to reciprocating shuttles that are often employed to enable continuous web motion. Starting and stopping a heavy shuttle can result in over stressing and fatigue of the driving motor and moving parts. Additionally, having a valve does not always solve the problem because there are physical parts on the exit side of the valve that can become wetted with fluid and can give rise to further stringing and dripping.
In view of the above, there is a continuing unaddressed need for lightweight apparatus and processes that are capable of quickly filling a succession of compartments with minimal stringing and dripping of the fluid and that are capable of cleanly shutting off the flow of fluid to avoid stringing and dripping the fluid outside of the compartments.
An apparatus providing a filling cycle comprising: a nozzle comprising a nozzle inlet and a fluid flow discharge opening in fluid communication with the nozzle inlet, wherein the fluid flow discharge opening has a fluid flow discharge opening area; a fluid flow conduit in fluid communication with the nozzle inlet, the fluid flow conduit in fluid communication with a fluid source; a fluid flow valve in line with the fluid flow conduit, wherein the fluid flow valve has a fluid flow valve open position and a fluid flow valve closed position; a vacuum conduit in fluid communication with a vacuum source, the vacuum conduit comprising a vacuum opening, wherein the vacuum opening is spatially proximate to the fluid flow discharge opening, wherein the vacuum opening has a vacuum opening area, wherein the vacuum opening area to the fluid flow discharge opening area has a ratio of less than or equal to 1; and a vacuum valve in line with the vacuum conduit, wherein the vacuum valve has a vacuum valve open position and a vacuum valve closed position.
As used herein, the term “compartment” is used in the broadest scope to include any bottle, chamber, vessel, box, pouch, such as thermoformed water-soluble film, water-soluble film, plastic bottles, glass bottles, soluble-unit dose pouches, or the like including a breadth of sizes. Compartments can be (but not necessarily) empty, i.e., devoid of fluid, when conveyed through the dispensing processes or partially filled compartments can be of any discrete size.
As used herein, the term “cross direction” (CD) refers to a direction perpendicular to the machine direction (MD).
As used herein, the term “dosing amplitude” refers to the measurement of the width of the fluid stream at the widest part leaving the nozzle at a pre-determined distance from the fluid flow discharge opening.
As used herein, the term “joined to” encompasses configurations in which an element is directly secured to another element by affixing the element directly to the other element; configurations in which the element is indirectly secured to the other element by affixing the element to intermediate member(s) which in turn are affixed to the other element; and configurations in which one element is integral with another element, i.e., one element is essentially part of the other element. The term “joined to” encompasses configurations in which an element is secured to another element at selected locations, as well as configurations in which an element is completely secured to another element across an entire surface of one of the elements.
As used herein, the term “machine direction” (MD) refers to the direction of material flow through a process. In addition, relative placement and movement of material may be described as flowing in the machine direction through a process from upstream in the process to downstream in the process.
In operation, fluid may flow from the fluid source 175 through a single fluid flow conduit 30. At a point where the fluid reaches the fluid flow manifold 90 the fluid may branch into more than one fluid flow conduits 30. The fluid in each fluid flow conduit 30 may flow from each fluid flow conduit 30 into a respective nozzle 10 and is then dispensed. A vacuum may flow from the vacuum source 55 through a single vacuum conduit 50. At a point where the vacuum reaches the vacuum manifold 100 the vacuum may branch into more than one vacuum conduit 50. The vacuum in each vacuum conduit 50 may flow from the vacuum conduit 50 through the vacuum opening 60 to suction residual fluid that may otherwise form a string, drip, or otherwise leave residue within or around the nozzle 10. This residual fluid may flow through the vacuum conduit 50 into a reservoir and may be further used for purposes of re-blend, may be recycled through a separate purification process, or may be discarded. The fluid flow valve 35 controls when fluid first starts to flow from the fluid source 175 into the fluid flow conduit 30. The vacuum valve 70 controls when a vacuum starts to flow from the vacuum source 55 into the vacuum conduit 50.
The rotary drum 165 may rotate in the machine direction MD about a rotational axis RA. The rotary drum 165 may have a surface 170 positioned radially outward from the rotational axis RA. Rotary drums are described in U.S. Pat. No. 3,057,127. A plurality of molds 160 may be disposed on the surface 170 of the rotary drum 165. A web 140 may be fed from a roll 145 onto the surface 170 of the rotary drum 165 and drawn into the molds 160 by a vacuum applied to the face of the mold 160, forming a plurality of compartments 150. In the non-limiting illustration shown, the compartments 150 are cavities that are circumferentially spaced and aligned to form a lane in the machine direction MD.
The fluid filling assembly 180 may encompass one or more vacuum assisted nozzle apparatus 135 mounted on a shuttle 155. Each vacuum assisted nozzle apparatus 135 may comprise a plurality of nozzles 10 that are each positioned above one or more of the compartments 150 ready to dispense a composition into the compartment 150. The shuttle 155 may start at a first position. The shuttle 155 may systematically move in concert with the rotary drum 165 or a horizontal conveyor belt to align each nozzle 10 with a respective compartment 150 for dispensing of fluid into a compartment 150 during a single filling cycle. After the dispensing of fluid in a single filling cycle, the shuttle 155 may return to the first position in a reciprocating fashion, moving in a direction opposite to the machine direction MD, to prepare for the next filling cycle if a rotary drum 165 is employed. Fluid is typically dispensed into the compartments 150 on a substantially horizontal portion of the rotary drum 165, e.g., when the compartments 150 are at or near the top of the rotary drum 165. The filled compartments 150 may continue to move along the machine direction MD to later be covered by a second web.
In simple form, the vacuum assisted nozzle apparatus 135 may comprise a nozzle 10 having a fluid flow discharge opening 20 having a fluid flow discharge opening area, and a vacuum opening 60 having a vacuum opening area, wherein the vacuum opening area to the fluid flow discharge opening area may have a ratio of less than or equal to 1. The vacuum opening 60 may be operatively coupled with the nozzle 10 to provide suction.
Alternatively stated, the vacuum assisted nozzle apparatus 135 may provide a fluid flow system and a vacuum system wherein the fluid flow system and vacuum system each alternatively transition back and forth between on and off to have a single filling cycle.
Nozzle
The vacuum assisted nozzle apparatus 135 may comprise a nozzle 10. A variety of configurations for the nozzle 10 may be suitable depending on the application. In a simple form, the nozzle 10 may comprise a nozzle inlet 15 and a fluid flow discharge opening 20. The fluid flow discharge opening 20 may be in fluid communication with the nozzle inlet 15. The fluid flow discharge opening 20 may have a fluid flow discharge opening area.
The nozzle 10 may be any instrument, often a pipe or tube of varying cross-sectional area, designed to direct or modify the flow, such as the speed, direction, mass, shape, and pressure, of a fluid upon exit of the nozzle 10.
The nozzle inlet 15 may be any opening where fluid may flow into the nozzle 10. The nozzle inlet 15 may be of any suitable shape to conduct fluid and is not limited to the embodiments shown. The nozzle inlet 15 has a cross-sectional area. The cross-sectional area of the nozzle inlet 15 may be dependent upon the rheological properties of the fluid being dispensed.
The fluid flow discharge opening 20 may be any opening where fluid flows out from the nozzle 10. The fluid flow discharge opening 20 may be of any suitable shape to conduct fluid and is not limited to the embodiments shown. The fluid flow discharge opening 20 may have an outward facing surface and an inward facing surface. The fluid flow discharge opening 20 may be void of any surface.
The nozzle inlet 15 may be in fluid communication with the fluid flow discharge opening 20. In some embodiments, the nozzle inlet 15 and the fluid flow discharge opening 20 may be in a substantially parallel relationship. In other embodiments, the nozzle inlet 15 may be positioned at a slope relative to the fluid flow discharge opening 20. The location of the nozzle inlet 15 relative to the fluid flow discharge opening 20 is not limited to the embodiments shown and may be of any suitable configuration to conduct fluid flow.
The nozzle inlet 15 is located at a distance from the fluid flow discharge opening 20. This distance may be any suitable distance to conduct fluid. This distance may be between 0 mm and about 300 mm. This distance may be between about 5 mm and about 100 mm, for example, specifically reciting all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby.
The fluid flow discharge opening 20 may have a fluid flow discharge opening area. The fluid flow discharge opening area is a measurement of the cross-sectional area of the fluid flow discharge opening 20 measured at the fluid flow discharge opening 20. The fluid flow discharge opening area may have a circular cross-section as shown in
The nozzle 10 may be of any shape as known in the art to conduct fluid. In one embodiment, the nozzle 10 may have a cylindrical shape. The nozzle 10 may have a nozzle outer surface 14 and a nozzle inner surface 12 to form a wall of the nozzle 10. The nozzle outer surface 14 and nozzle inner surface 12 may be separated by a distance that may be known as the thickness. The thickness may vary about the length of the nozzle 10. In one embodiment, when the thickness is the same throughout the length of the nozzle, the nozzle outer surface 14 and nozzle inner surface 12 may be said to be in a substantially parallel relationship. The diameter of the nozzle inner surface 12 at the nozzle inlet 15 may be the same diameter of the nozzle inner surface 12 at the fluid flow discharge opening 20. The diameter of the nozzle inner surface 12 at the nozzle inlet 15 may be a different diameter of the nozzle inner surface 12 at the fluid flow discharge opening 20. In one embodiment, the diameter of the nozzle inner surface 12 at the nozzle inlet 15 may be about 4 mm and the diameter of the nozzle inner surface 12 at the fluid flow discharge opening may be about 4 mm. In another embodiment, the diameter of the nozzle inner surface 12 at the nozzle inlet 15 may be about 5 mm and the diameter of the nozzle inner surface 12 at the fluid flow discharge opening may be about 4 mm, for example, specifically reciting all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby.
As shown in
The nozzle 10 may be made of any suitable material as known in the art. Such materials may include, but are not limited to, stainless steel, titanium, metal alloys, aluminum, plastic, polymers, hardened resins, or polytetrafluoroethylene (e.g., Teflon®) material.
Fluid Flow Conduit
The vacuum assisted nozzle apparatus 135 may further comprise a fluid flow conduit 30. The fluid flow conduit 30 may be in fluid communication with the nozzle inlet 15. The fluid flow conduit 30 may be in fluid communication with a fluid source 175. In an embodiment, the fluid flow conduit 30 may be in fluid communication at a first end with a fluid source 175 and may be in fluid communication at a second end with the nozzle inlet 15. In such embodiment, fluid may flow from the fluid source 175 into the fluid flow conduit 30 first end, flow through the fluid flow conduit 30, flow out of the fluid flow conduit 30 by exiting through the fluid flow conduit 30 second end, then flow into the nozzle inlet 15. In operation, the fluid flow conduit 30 provides a pathway for fluid to flow from a fluid source 175 into the nozzle 10.
The fluid flow conduit 30 may be of any suitable shape to conduct fluid and is not limited to the embodiments shown. In one embodiment, the fluid flow conduit 30 may be of a cylindrical shape. The shape of the fluid flow conduit 30 may be dependent upon the rheological properties of the fluid being dispensed, the spatial constraints of the surrounding machinery, and/or other considerations.
The fluid flow conduit 30 may be of a certain length. The length of the fluid flow conduit 30 may be dependent upon the rheological properties of the fluid being dispensed, the spatial constraints of the surrounding machinery, and/or other considerations.
The fluid flow conduit 30 may have a certain cross-sectional area. The cross-sectional area may vary along its length. The cross-sectional area of the fluid flow conduit 30 may be dependent upon the rheological properties of the fluid being dispensed, the spatial constraints of the surrounding machinery, and/or other considerations.
The fluid flow conduit 30 may be made of any suitable material as known in the art. Such materials may include, but are not limited to, stainless steel, titanium, metal alloys, aluminum, plastic, polymers, hardened resins, or polytetrafluoroethylene (e.g., Teflon®) material.
The fluid flow conduit 30 may be of any suitable shape, length, cross-sectional area, and material suitable to conduct fluids that may include but are not limited to detergent compositions such as those sold under the tradenames TIDE, GAIN, ARIEL, TIDE PODS, GAIN FLINGS, FAIRY and CASCADE manufactured by The Procter & Gamble Company, Cincinnati, Ohio, USA.
Fluid Flow Valve
The vacuum assisted nozzle apparatus 135 may further comprise a fluid flow valve 35. The fluid flow valve 35 may be in line with the fluid flow conduit 30. The fluid flow valve 35 may have a fluid flow valve open position and a fluid flow valve closed position. The fluid flow valve 35 may be any such suitable instrument known by one skilled in the art that may alter the fluid flow. In operation, the fluid flow valve 35 regulates the flow of fluid into the fluid flow conduit 30 by allowing for fluid to flow into the fluid flow conduit 30 when the fluid flow valve 35 is in the fluid flow valve open position and halting or restricting fluid from flowing into the fluid flow conduit 30 when the fluid flow valve 35 is in the fluid flow valve 35 closed position. The fluid flow valve 35 may be by way of non-limiting example a valve selected from the group consisting of ball valve, a butterfly valve, a piston valve, a membrane valve, a plunger valve, a spool valve, a pinch valve, solenoid valve and a gate valve.
The fluid flow valve 35 may have a fluid flow valve open position. The fluid flow valve open position may be a position in which the fluid flow valve 35 permits fluid to flow through the fluid flow conduit 30. The fluid flow valve 35 may further have a fluid flow valve closed position. The fluid flow valve closed position may be where the fluid flow valve 35 restricts or halts fluid from flowing through the fluid flow conduit 30.
Vacuum Conduit
The vacuum assisted nozzle apparatus 135 may further comprise a vacuum conduit 50 in fluid communication with a vacuum source 55. The vacuum conduit 50 may comprise a vacuum opening 60. The vacuum opening 60 may be spatially proximate to the fluid flow discharge opening 20. The vacuum opening 60 may have a vacuum opening area. The vacuum opening area to the fluid flow discharge opening area may have a ratio of less than or equal to 1.
The vacuum conduit 50 may be in fluid communication with a vacuum source 55 to draw a vacuum into the vacuum conduit 50. In operation, the vacuum conduit 50 provides for a vacuum to suction the residual fluid dispensed from the fluid flow discharge opening 20 into the vacuum conduit 50 to prevent stringing and dripping on the fluid flow discharge opening 20.
The location of the vacuum opening 60 relative to the fluid flow discharge opening 20 is further described hereinafter. More than one vacuum conduit 50 may be joined to one nozzle 10. The vacuum opening 60 may have a vacuum opening area. The vacuum opening area is a measurement of the cross-sectional area of the vacuum opening 60 measured at the inward facing surface of the vacuum opening 60. The vacuum opening area may have a circular cross-section as shown in
The vacuum conduit 50 may be of a certain length. The length of the vacuum conduit 50 may be dependent upon the rheological properties of the residual fluid being dispensed through the fluid flow discharge opening 20 and then suctioned through the vacuum conduit 50, the spatial constraints of the surrounding machinery, and/or other considerations.
The vacuum conduit 50 may have a certain cross-sectional area. The cross-sectional area may vary along its length. The cross-sectional area of the vacuum conduit 50 may be dependent upon the spatial constraints of the surrounding machinery, and/or other considerations.
The vacuum opening area to the fluid flow discharge opening area may have a ratio of less than or equal to 1. The vacuum opening area to the fluid flow discharge opening area ratio may be calculated by dividing the measurement of the vacuum opening area by the measurement of the fluid flow discharge opening area. The vacuum opening area to the fluid flow discharge opening area may have a ratio of between about 0.1 and 1. The vacuum opening area to the fluid flow discharge opening area may have a ratio of between about 0.2 and about 0.9. The vacuum opening area to the fluid flow discharge opening area may have a ratio of between about 0.4 and about 0.7, for example, specifically reciting all 0.1 increments within the specified ranges and all ranges formed therein or thereby. The vacuum opening area may be less than or equal to the fluid flow discharge opening area. The vacuum opening area to the fluid flow discharge opening area having a ratio of less than or equal to 1 provides greater efficiency of the vacuum in suctioning fluid from the fluid flow discharge opening 20 because, without wishing to be bound by theory, as the diameter of a pipe increases, the velocity of the fluid flowing through the pipe decreases. Here, as the vacuum opening area increases, the velocity of the air in the vacuum decreases, resulting in decreased suction, which is unfavorable and inefficient. Conversely, as the vacuum opening area decreases, the velocity of the air in the vacuum increase, resulting in increased suction, which provides greater efficiency in suctioning fluid from the fluid flow discharge opening 20. The vacuum opening area to the fluid flow discharge opening area having a ratio of less than or equal to 1, or, alternatively said, the vacuum opening area being less than or equal to the fluid flow discharge opening area provides the additional benefit of taking up a smaller space in an already compact and crowded space.
Vacuum Valve
The vacuum assisted nozzle apparatus 135 may further comprise a vacuum valve 70. The vacuum valve 70 may be in line with the vacuum conduit 50. The vacuum valve 70 may have a vacuum valve open position, and a vacuum valve closed position. In operation, the vacuum valve 70 regulates the flow of vacuum through the vacuum conduit 50 by allowing for application of vacuum at the vacuum opening 60 when the vacuum valve 70 is in the vacuum valve open position and halting or restricting application of vacuum at the vacuum opening 60 when the vacuum valve 70 is in the vacuum valve closed position.
The vacuum valve 70 may be in line with the vacuum conduit 50. The vacuum valve 70 may be by way of non-limiting example a valve selected from the group consisting of ball valve, a butterfly valve, a piston valve, a membrane valve, a plunger valve, a spool valve, a pinch valve, a solenoid valve, and a gate valve.
The vacuum valve 70 may have a vacuum valve open position. In the vacuum valve open position, a vacuum can be applied to the vacuum opening 60. When the vacuum valve 60 is in the vacuum valve open position, the vacuum applied to the vacuum valve opening 60 can suck residual fluid into the vacuum opening 60. The vacuum valve 70 may have a vacuum valve closed position where the vacuum may not be applied to the vacuum opening 60. Where the vacuum valve 70 is in the vacuum valve closed position, suction of fluid into the vacuum opening 60 may not be occurring.
In a single filling cycle the vacuum valve 70 may transition from the vacuum valve closed position to the vacuum valve open position before the fluid flow valve 35 may transition from the fluid flow valve open position to the fluid flow valve closed position. In other words, the fluid flow valve 35 and the vacuum valve 70 may be coupled so that the fluid flow valve 35 may be in the fluid flow valve closed position after the vacuum valve 70 may be in the vacuum valve open position in a single filling cycle. Coupling is further described herein.
Proximity of Vacuum Opening to Fluid Flow Discharge Opening
The vacuum opening 60 may be spatially proximate to the fluid flow discharge opening 20. The fluid flow discharge opening 20 may be any opening where fluid flows out from the nozzle 10. The fluid flow discharge opening 20 may be of any suitable shape to conduct fluid and is not limited to the embodiments shown.
The vacuum opening 60 and the fluid flow discharge opening 20 may be separated by 0 mm to about 100 mm. The vacuum opening 60 and the fluid flow discharge opening 20 may be separated by 0 mm to about 60 mm. The vacuum opening 60 and the fluid flow discharge opening 20 may be separated by 0 mm to about 40 mm, for example, specifically reciting all 0.1 mm increments within the specified ranges and all ranges formed therein or thereby. The vacuum opening 60 and the fluid flow discharge opening 20 may be separated by any suitable distance that allows for the vacuum assisted nozzle apparatus 135 to deliver its intended benefits. The vacuum opening 60 may be located closer to the fluid flow discharge opening 20 than to the nozzle inlet 15. The vacuum opening 60 may be located closer to the nozzle inlet 15 than to the fluid flow discharge opening 20. The separation distance is measured from the closer edge of the vacuum opening 60 to the closer edge of the fluid flow discharge opening 20.
The nozzle 10 may comprise a nozzle outer surface 14 and a nozzle inner surface 12. As shown in a non-limiting embodiment in
There may be more than one vacuum opening 60 spatially proximate to one fluid flow discharge opening 20.
Manifolds
In an alternative embodiment, the vacuum assisted nozzle apparatus 135 may comprise a plurality of nozzles 10, a plurality of fluid conduits 30, and a plurality of vacuum conduits 50. In such an embodiment as shown in
In operation, fluid may flow from the fluid source 175 through a single fluid flow conduit 30. At a point where the fluid reaches the fluid flow manifold 90 the fluid may branch into more than one fluid flow conduits 30. The fluid in each fluid flow conduit 30 may flow from each fluid flow conduit 30 into a respective nozzle 10 and is then dispensed. A vacuum may flow from the vacuum source 55 through a single vacuum conduit 50. At a point where the vacuum reaches the vacuum manifold 100 the vacuum may branch into more than one vacuum conduit 50. The vacuum in each vacuum conduit 50 may flow from the vacuum conduit 50 through the vacuum opening 60 to suction residual fluid that may otherwise form a string, drip, or otherwise leave residue within or around the nozzle 10.
The fluid flow manifold 90 may be any instrument known to one skilled in the art to facilitate the branching of fluid into the plurality of fluid flow conduits 30. The fluid flow manifold 90 may have as many openings as needed. The vacuum manifold 100 may be any instrument known to one skilled in the art to facilitate the branching of vacuum into the plurality of vacuum conduits 50. The vacuum manifold 100 may have as many openings as needed.
In such an embodiment, the vacuum assisted nozzle apparatus 135 may comprise more than one vacuum conduit 50 per individual nozzle 10 to better facilitate vacuum suction. The vacuum assisted nozzle apparatus 135 may have more than one vacuum opening 60 spatially proximate to one fluid flow discharge opening 20 to better facilitate suction of a fluid string, drip, or residual fluid in the nozzle 10.
Having a fluid flow manifold 90 and a vacuum manifold 100 may be beneficial in operations where there are multiple filling lanes, such as on a horizontal conveyor belt or on a rotary drum 165. For example, as shown in
Process
The present invention encompasses a process of dispensing fluid using the apparatus according to the present invention. The vacuum assisted nozzle apparatus 135 may be used to dispense fluid as described herein. In some aspects, the process may comprise the steps of: providing a vacuum assisted nozzle apparatus 135 wherein the vacuum assisted nozzle apparatus 135 comprises a nozzle 10 wherein the nozzle comprises a fluid flow discharge opening 20; dispensing fluid from the fluid flow discharge opening 20; and applying a vacuum while the fluid is dispensed. The nozzle 10 can further comprise a nozzle inlet 15 in fluid communication with the fluid flow discharge opening 20. The vacuum assisted nozzle apparatus 135 may further comprise a fluid flow conduit 30 in fluid communication with the nozzle inlet 15 and a fluid flow valve 35 in line with the fluid flow conduit 30, wherein the fluid flow valve 35 may have a fluid flow valve open position and a fluid flow valve closed position. The vacuum assisted nozzle apparatus may further comprise a vacuum conduit 50 in fluid communication with a vacuum source 55 wherein the vacuum conduit 50 may comprise a vacuum opening 60 wherein the vacuum opening 60 is spatially proximate to the fluid flow discharge opening 20. The vacuum assisted nozzle apparatus 135 may further comprise a vacuum valve 70 in line with the vacuum conduit 50, wherein the vacuum valve 70 may have a vacuum valve open position and a vacuum valve closed position. The fluid flow valve 35 and the vacuum valve 70 may be coupled.
The process may further comprise the step of placing the fluid flow valve 35 in the fluid flow valve open position before the step of dispensing fluid from the fluid flow discharge opening 20 in a single filling cycle. Fluid may be dispensed by a pump. Fluid may be dispensed gravitationally. Fluid may be dispensed by any means known to one skilled in the art to facilitate the dispensing of fluid from the fluid flow discharge opening 20 into a compartment 150. When the fluid flow valve 35 is in the fluid flow valve open position, fluid may flow into the fluid flow conduit 30 from the fluid source 175. Placing the fluid flow valve 35 in the fluid flow valve open position may allow for fluid to flow into the fluid flow conduit 30, through the fluid flow conduit 30 into the nozzle 10, and be dispensed into a compartment 150 below the vacuum assisted nozzle apparatus 135.
A single filling cycle can be thought of as follows. First, the fluid flow valve 35 is opened. Fluid flows through the fluid flow conduit 30 into the nozzle 10. Over time, fluid flow through the nozzle 10 develops. Fluid is dispensed from the nozzle 10 for a desired increment of time. The trailing quantity of fluid between the fluid flow valve 35 and the fluid flow discharge opening 20 is dispensed. At a desired time, the vacuum valve 70 is opened. Vacuum develops in the vacuum conduit 50. Proximate in time to the vacuum valve 70 being opened, the fluid flow valve 35 is closed. The vacuum then suctions the residual fluid from the fluid flow discharge opening 20 to remove any string filament, dripping, or residue. The vacuum valve 70 then closes. Alternatively, a single filling cycle may be described by a singular transition of the vacuum valve 70 from the vacuum valve closed position to the vacuum valve open position and a singular transition of the fluid flow valve 35 from the fluid flow valve open position to the fluid flow valve closed position.
The process may comprise the step of placing the vacuum valve 70 in the vacuum valve open position while the fluid is dispensed from the fluid flow discharge opening 20. By keeping the vacuum valve 70 in the vacuum valve open position while fluid is dispensed from the fluid flow discharge opening 20, any stringing may be removed before the nozzle 10 moves. Without the vacuum valve 70 in the vacuum valve open position, residual fluid may string together, drip, and/or become residue on the nozzle 10.
The process may further comprise the step of placing the vacuum valve 70 in the vacuum valve open position before placing the fluid flow valve 35 in the fluid flow valve closed position. The benefit of placing the vacuum valve 70 in the vacuum valve open position before the step of placing the fluid flow valve 35 in the fluid flow valve closed position is that this order can provide for more accurate dosing to account for the amount of time taken between when the vacuum valve 70 is in the vacuum valve open position and when the fluid flow valve is in the fluid flow valve closed position, due to the residual fluid from the fluid source 175 that still flows through the fluid flow conduit 30 after the fluid flow valve 35 is in the fluid flow valve closed position.
In a single filling cycle the vacuum valve 70 may transition from the vacuum valve closed position to the vacuum valve open position before the fluid flow valve 35 may transition from the fluid flow valve open position to the fluid flow valve closed position. In other words, the fluid flow valve 35 and the vacuum valve 70 may be coupled so that the vacuum valve 70 is in the vacuum valve open position before the fluid flow valve 35 is in the fluid flow valve closed position in a single filling cycle. In operation, the fluid flow valve 35 and the vacuum valve 70 can be coupled in so that the functioning of each valve is linked to the other so that the change in position of one valve may be associated with a change in the position of the other valve. The fluid flow valve 35 and the vacuum valve 70 may be coupled by any means known to one skilled in the art. The fluid flow valve 35 and vacuum valve 70 may be mechanically coupled. The fluid flow valve 35 and the vacuum valve 70 may be electronically coupled. The fluid flow valve 35 and the vacuum valve 70 may be manually coupled. The fluid flow valve 35 and the vacuum valve 70 may be coupled by a programmable logic controller. The fluid flow valve 35 and the vacuum valve 70 may be coupled by a coupling element 190. The coupling element 190 may be electromechanical. The coupling element 190 may be mechanical. The coupling element 190 may be electrical. The coupling element 190 may be any instrument to known to one skilled in the art used for automation of processes and is not limited to the examples described. The coupling element 190 may be operatively connected to both the fluid flow valve 35 and to the vacuum valve 75. The coupling element 190 may be connected to the fluid flow valve 35 and to the vacuum valve 75 by a coupling connector connected to the coupling element 190 and to the fluid flow valve 35 and further connected to the coupling element 190 and to the vacuum valve 70. The coupling connecter may be by way of non-limiting example a coupling connector selected from the group consisting of a signal cable, a wire, an electronic signal, a cable, a fiber optic cable, a communication cable, and combinations thereof. The amount of set time chosen between when the vacuum valve 70 is in the vacuum valve open position and when the fluid flow valve 35 is in the fluid flow valve closed position may depend upon, but is not limited to, the rheological properties of the fluid, the geometry of the vacuum assisted nozzle apparatus 135, and the time response due to any inertia, including but not limited to mechanical inertia and fluid inertia, both fluid in the nozzle 10 and application of the vacuum. In operation, when the vacuum valve 70 changes from the vacuum valve closed position to the vacuum valve open position, the coupling mechanism causes the fluid flow valve 35 to change from the fluid flow valve open position to the fluid flow valve closed position at a set time thereafter. For example, in the dispensing of small amounts of fluid such as several milliliters, the fluid flow valve 35 will move to the fluid flow valve closed position only a few milliseconds after the vacuum valve 70 moves to the vacuum valve open position.
The process may further comprise the step of placing the vacuum valve 70 in the vacuum valve closed position as the fluid approaches a dosing amplitude of 0 mm. At a dosing amplitude of 0 mm, fluid is not stringing and the dosing of a single filling cycle is complete. When the fluid flow valve 35 is in the fluid flow valve closed position, further fluid flow from the fluid source 175 is shut off, however, there may be residual fluid flowing through the fluid flow conduit 30 and through the nozzle 10 and then dispensed from the fluid flow discharge opening 20. As the remaining fluid moves through the fluid flow conduit 30 and through the nozzle 10, the dosing amplitude decreases as the quantity of residual fluid decreases, and eventually the dosing amplitude may approach 0 mm. This residual fluid may string, drip, or leave a residue within the fluid flow conduit 30 and/or within the nozzle 10. The residual fluid may string, drip, or leave a residue around the fluid flow discharge opening 20. The residual fluid may form a filament or string that forms and hangs down from the nozzle 10. This residual filament may take some time to release from the fluid flow discharge opening 20. To reduce dripping and residue stringing, the vacuum valve 70 is placed in the vacuum valve open position while the residual fluid is dispensed from the fluid flow discharge opening 20 and is approaching a dosing amplitude of 0 mm so that the vacuum may suction the residual fluid that has formed a string filament through the vacuum opening 60.
In some aspects, the vacuum assisted nozzle apparatus 135 may dispense the fluid into compartments 150 located below the vacuum assisted nozzle apparatus 135. Suitable compartments 150 may be soluble-unit dose pouches, such as those sold under the tradenames TIDE, GAIN, ARIEL, TIDE PODS, GAIN FLINGS, FAIRY and CASCADE manufactured by The Procter & Gamble Company, Cincinnati, Ohio, USA. In some aspects, the vacuum assisted nozzle apparatus 135 may dispense the fluid into soluble-unit dose pouches located below the vacuum assisted nozzle apparatus 135. The compartments 150 may be selected from the group consisting of thermoformed water-soluble film, water-soluble film, plastic bottles, glass bottles, and soluble-unit dose pouches. The vacuum assisted nozzle apparatus 135 may dispense fluid into compartments 150 on a rotary drum 165. The vacuum assisted nozzle apparatus 135 may dispense fluid into compartments 150 on a horizontal conveyor belt. The quantity of fluid dispensed into a compartment 150 may be between about 0.1 mL and about 100 mL. The quantity of fluid dispensed into a compartment 150 may be between about 1 mL and about 30 mL, for example, specifically reciting all 0.1 mL increments within the specified ranges and all ranges formed therein or thereby. The quantity of fluid dispensed into a compartment 150 may be of any suitable quantity known by one skilled in the art to fill the compartment 150 in use.
The fluid dispensed may have a viscosity from about 10 mPa·s to about 2000 mPa·s measured at 20° C. and at a shear rate of 1000 s−1. The fluid dispensed may have a viscosity from about 50 mPa·s to about 1000 mPa·s measured at 20° C. and at a shear rate of 1000 s−1. More preferably, the fluid dispensed may have a viscosity from about 100 mPa·s to about 900 mPa·s measured at 20° C. and at a shear rate of 1000 s−1. The fluid may be Newtonian or non-Newtonian (shear thinning) fluids. The fluid dispensed may have any suitable viscosity known by one skilled in the art to fill the compartment 150 in use when the fluid is measured at a particular temperature. Viscosity may be measured using a rotational rheometer. Viscosity may be measured at ambient conditions. Suitable fluids may include, but are not limited to, detergent compositions, such as those sold under the tradenames TIDE, GAIN, ARIEL, TIDE PODS, GAIN FLINGS, FAIRY and CASCADE manufactured by The Procter & Gamble Company, Cincinnati, Ohio, USA.
In some aspects, the absolute pressure upstream from the vacuum opening 60 may be between about 10 kPa and about 90 kPa. The absolute pressure upstream from the vacuum opening 60 may be between about 20 kPa and about 80 kPa. The pressure at the vacuum opening 60 may be dependent upon the rheological properties of the fluid being dispensed from the nozzle 10, the quantity of fluid being dispensed from the nozzle 10, the size of the fluid flow discharge opening area, and/or other considerations.
In this test, data from a single filling cycle of 1.6 mL of fluid was collected from the use of a nozzle without vacuum and data from a single filling cycle of 1.6 mL of the same fluid was collected from the use of a vacuum assisted nozzle apparatus 135 to determine the amount of time taken from when the fluid first had a positive dosing amplitude to when the fluid approached a dosing amplitude of 0 mm, which is when the fluid string breaks. Both the nozzle without vacuum and the vacuum assisted nozzle apparatus 135 had a length of 30 mm and had a fluid flow discharge opening area of 6.16 mm2. The vacuum conduit 50 attached to the vacuum assisted nozzle apparatus 135 had a length of 20 mm and had a vacuum opening area of 3.14 mm2. The vacuum source 55 attached to the vacuum assisted nozzle apparatus 135 applied an absolute pressure of 50 kPa upstream from the vacuum opening 60. The included angle defined by the fluid flow conduit axis and vacuum conduit axis was 90 degrees. The fluid dispensed had a viscosity of 500 mPa·s measured at 20° C. and at a shear rate of 1000 s−1. The viscosity of the fluid dispensed was measured using a rotational rheometer at ambient conditions. The fluid used was liquid detergent, more specifically, the liquid detergent contained in the marketed TIDE PODS manufactured by The Procter & Gamble Company, Cincinnati, Ohio, USA.
For both the nozzle without vacuum dispensing cycle and the vacuum assisted nozzle apparatus 135 dispensing cycle, the fluid flow valve 35 was placed in the fluid flow valve open position allowing fluid to be dispensed from a fluid source 175. Fluid was dispensed using a pump. For the nozzle without vacuum, the fluid flow valve 35 was placed in the fluid flow valve closed position after 1.6 mL of fluid was dispensed into the compartment 150 below the nozzle without vacuum. For the vacuum assisted nozzle apparatus 135, the vacuum valve 70 was placed in the vacuum valve open position and then the fluid flow valve 35 was placed in the fluid flow valve closed position. For the vacuum assisted nozzle apparatus 135, the vacuum valve 70 and the fluid flow valve 35 were electronically coupled using conventional electronic means using a programmable logic controller (PLC) so that the vacuum valve 70 was placed in the vacuum valve open position with the precise time for the vacuum to manifest itself at the fluid flow discharge opening 20 to allow suction for when 1.6 mL was dispensed into the compartment 150 below the vacuum assisted nozzle apparatus 135.
For both the nozzle without vacuum dispensing cycle and the vacuum assisted nozzle apparatus 135 dispensing cycle, data was recorded of the dosing amplitude as a function of the time until the dosing amplitude was 0 mm. As the fluid flow valve 35 was placed in the fluid flow valve open position and fluid began to flow, a timer was immediately turned on and the fluid exiting the fluid flow discharge opening 20 was recorded using a Mako U-029B high-speed camera from Graftek Imaging, Austin, Tex., USA, with a frame rate of 350 frames per second. Graftek Image software from Graftek Imaging, Austin, Tex., USA, was used to calculate the data using a grayscale of 256 bits. The software played the video in slow motion and measured the dosing amplitude through knowledge of the number of pixels in the image which were calibrated to the diameter stream of the fluid. The recorded points were plotted on a graph as shown. The dosing amplitude was recorded every 2.85 ms.
As shown in
This decrease in time taken to reach a dosing amplitude of 0 mm enables a decrease in the amount of time to fill compartments 150. This can correspond in an increase in the number of compartments 150 that can be filled in a given time increment.
For illustration, a single horizontal conveyor belt line filling one compartment 150 at a time with 1.6 mL of fluid using a nozzle without vacuum could fill approximately 345,600 compartments 150 per day, if running constantly for a twenty-four hour period, measured at 250 milliseconds (ms) per filling cycle. A single horizontal conveyor belt line filling one compartment 150 at a time with 1.6 mL of fluid using the vacuum assisted nozzle apparatus 135 could fill approximately 864,000 compartments per day, if running constantly for a twenty-four hour period, measured at 100 ms per filling cycle. The vacuum assisted nozzle apparatus 135 could allow a 250% increase in the productivity for a single lane when compared to a nozzle without vacuum. This reduction in time spent per filling cycle is greatly beneficial for companies like The Procter & Gamble Company, Cincinnati, Ohio, USA, who produce millions of fluid filled compartments, such as soluble-unit dose compartments of those sold under the tradenames TIDE, GAIN, ARIEL, TIDE PODS, GAIN FLINGS, FAIRY and CASCADE manufactured by The Procter & Gamble Company, Cincinnati, Ohio, USA, where time and efficiency on the manufacturing filling line is of the essence.
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
It should be understood that every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
Every document cited herein, including any cross-referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
