Patent Grant
9849470
A variable size hole multi-hole nozzle and components thereof for a filling machine.
Liquid products, particularly household and fabric care compositions such as dishwashing soap, hand soap, and surface cleansers, are a popular choice among consumers. Generally such liquids are sold within plastic containers. These plastic containers oftentimes have a body with a larger bottom end and an opposing tapered neck connecting to a smaller top end. The larger bottom end allows for a container to stand upright on a surface such as for storage purposes. The smaller top end can be attached to a cap or to a dispenser for dispensing purposes. The smaller top end is oftentimes a round opening. This opening is usually relatively small in area to make it easier for a consumer to control the amount of liquid that poured out of the container. During the manufacturing process of the container holding the liquid, manufacturers will use a container filling system to dispense liquids through the opening into the container.
High-speed container filling systems are well known and used in many different industries. In many of the systems, the containers are filled through a series of pumps, pressurized tanks and flow meters and/or valves to help ensure that the correct amount of liquid is dispensed into the containers. These pumps, pressurized tanks, flow meters, and/or valves are typically connected to a nozzle having an opening above or within the container opening. The liquid flows through this nozzle opening into the container. Manufacturers are continually looking for ways to increase the volumetric flow rate of the liquid during the filling process, which in turn increases the speed and efficiency of the process of filling containers with liquids.
Filling containers through small top openings can be challenging to do quickly due to size constraints of the top opening and the neck coupled with the rheological properties of the liquid. To compensate for slower filling speeds associated with conventional size, single orifice nozzles, the nozzle orifice size can be made larger, allowing higher volumetric flow rates and faster filling cycles. However, when filling containers, especially at high volumetric flow rates, the large opening can create a surge of liquid at the end of the filling event that can cause the liquid in the container to splash in a direction generally opposite to the direction of filling and often out of the container being filled. This is especially true for lower viscosity liquids such as hard surface cleaners, examples of which are under the tradenames MR. CLEAN, SWIFFER WETJET, and VIAKAL manufactured by The Procter & Gamble Company. Higher viscosity liquids, such as dishwasher liquids, such as, for example, those sold under the tradename DAWN and laundry detergents such as, for example, those sold under the tradenames TIDE and GAIN manufactured by The Procter & Gamble Company may result in a filament or string that forms and hangs down from the filling nozzle at the end of the filling event, this filament or string taking some time to break up after flow to the nozzle ceases.
Alternatively, a nozzle can have a multitude of smaller openings through which liquid flows during the filling process. However, there is a limitation on the number and size of openings that can be placed in one constrained area. If the openings are spaced too close to one another, the liquid may join together to form one stream, which in turn, can result in the same aforementioned stringing and/or splashing problems. If the openings are spaced too far apart, fewer openings will be able to fit on the nozzle surface resulting in reduced volumetric flow rate and slower filling speed. Stringing and splashing can waste liquid, contaminate the outer surface of the container and/or contaminate the filling equipment itself. Having a nozzle with too large an opening or a nozzle with openings spaced too closely to one another may result in an increase in the velocity of the liquid. An increase in the velocity of the liquid stream may result in greater entrapment of air which in turn causes undesirable foaming of the liquid near the impinging jet when the liquid hits the bottom surface of the container. In order to mitigate or avoid splash-back and air entrapment, manufacturers can use oversized containers to provide enough head space to prevent any back-splash from exiting the container. This creates waste in terms of the amount of material used to make the containers, which can be costly, and can result in containers that appears to be less than completely filled. Manufacturers also slow the filling line rate down to compensate for splash-back and for air entrapment which may result in a decrease in number of containers that can be filled on a single filling line during a given time.
In view of the above, there is a continuing unaddressed need for nozzles for filling machines that are capable of quickly filling a succession of containers with liquid by increasing the volumetric flow rate of the liquid while lessening or avoiding splashing, stringing, dripping, and foaming of the liquid, and that are capable of cleanly shutting off the flow of liquid between containers to avoid dripping of the liquid outside of the containers at the end of a filling event.
A multi-hole nozzle component comprising: a periphery, an inlet side having an inlet surface, and an opposing outlet side having an outlet surface, wherein the nozzle component has a longitudinal axis extending from the inlet side to the outlet side; a plurality of first passageways extending through the nozzle component from the inlet side to the outlet side, wherein the plurality of first passageways form a plurality of first openings at the outlet surface, wherein the plurality of first openings are arranged about the longitudinal axis of the nozzle component, wherein each of the first openings has a first opening area; a plurality of second passageways extending through the nozzle component from the inlet side to the outlet side, wherein the plurality of second passageways form a plurality of second openings at the outlet surface, wherein the plurality of second openings are arranged about the plurality of first openings, wherein each of the second openings has a second opening area, wherein the second opening area is greater than the first opening area; and a plurality of third passageways extending through the nozzle component from the inlet side to the outlet side, wherein the plurality of third passageways form a plurality of third openings at the outlet surface, wherein the plurality of third openings are arranged about the plurality of second openings, wherein each of the third openings has a third opening area, wherein the third opening area is about equal to the second opening area.
Nozzle Assembly
The air cylinder 22 may comprise an air cylinder housing 30 having an interior hollow space 32 therein. The air cylinder 22 further comprises an air cylinder rod 34, a piston 36, and a spring 38. In its usual orientation, during operation, the air cylinder 22 will move the air cylinder rod 34 upward in order to open the nozzle component 52, and downward to close the nozzle component 52. The spring 38 may hold the stopper 28 against the openings in the nozzle body 26 and may keep liquid from running out of the nozzle component 52 in the event air pressure to the filling machine is turned off, for instance for an emergency, maintenance, air tubing failure, or any other such event. The air cylinder 22 may comprise any suitable commercially available air cylinder. The optional connecting body 24 may comprise an element of any configuration that is suitable for connecting the air cylinder 22 to the nozzle body 26.
The nozzle body 26 may be joined to the other portion(s) of the nozzle assembly 20, and may form the outlet of the nozzle assembly 20. The nozzle body 26 may comprise a nozzle body housing 42 and may have at least one inlet conduit 40 joined thereto so that it is in fluid communication with the inner chamber 44 of the nozzle body 26. The nozzle assembly 20 may further comprise an optional stem 46 that may be joined to the air cylinder rod 34. A flexible diaphragm 48 may encircle at least a portion of the length of the air cylinder rod 34 or stem 46.
The nozzle body 26 may have a plurality of spaced passageways 50 that pass through the nozzle body 26. The passageways 50 may be integrally formed in a portion of the nozzle body 26 itself, such as the nozzle body housing 42, or the passageways 50 may be formed in a separate nozzle component 52, such as an insert or an attachment, that is joined to the remainder of the nozzle body 26. For example, such a separate nozzle component 52 may be removably affixed, such as by a clamp, to the nozzle body housing 42. The term nozzle component 52 will be used herein to describe either of the following nozzle constructions: the portion of the nozzle body 26 that has the passageways 50 formed therein; or a separate nozzle piece that has the passageways 50 formed therein. The nozzle body 26 may have a stopper 28 therein at the end of the air cylinder rod 34 or optional stem 46 for closing the passageways 50 and shutting off the nozzle component 52.
The multi-hole nozzle assembly 20 may function as follows. The liquid to be filled into containers is delivered under pressure to the nozzle inlet 40. The air cylinder rod 34 is in the closed position. In this position, the liquid is contained inside the inner chamber 44 of the nozzle body 26. After a container is in position to be filled, a machine program sends a signal to a conventional solenoid valve that shifts and sends air pressure to the air cylinder 22. The air cylinder rod 34 moves upward allowing the liquid to flow through the passageways 50 into the bottle. When the program detects that the correct amount of liquid has been delivered to the container, a signal is sent to the valve that shifts and moves the air cylinder rod 34 downward closing off the passageways 50 and preventing any additional liquid from flowing out of the nozzle component 52. The liquid may be any liquid.
Multi-Hole Nozzle Component
The multi-hole nozzle component 52 may have a plurality of first passageways 64 extending through the multi-hole nozzle component 52 from the inlet side 56 to the outlet side 58, in order to provide passageways for liquid to flow therethrough. The plurality of first passageways 64 may form a plurality of first openings 65 at the outlet surface 59. The plurality of first openings 65 may be where liquid ultimately exits the nozzle component 52. The plurality of first openings 65 may be arranged about or arranged around the longitudinal axis L. Each first opening 65 has a first opening 65 area.
The multi-hole nozzle component 52 may have a plurality of second passageways 67 extending through the multi-hole nozzle component 52 from the inlet side 56 to the outlet side 58, in order to provide passageways for liquid to flow therethrough. The plurality of second passageways 67 may form a plurality of second openings 68 at the outlet surface 59. The plurality of second openings 68 may be where liquid ultimately exits the nozzle component 52. The plurality of second openings 68 may be arranged about or arranged around the plurality of first openings 65. Each second opening 68 has a second opening 68 area. The second opening 68 area may be greater than the first opening 65 area.
The multi-hole nozzle component 52 may have a plurality of third passageways 70 extending through the multi-hole nozzle component 52 from the inlet side 56 to the outlet side 58, in order to provide passageways for liquid to flow therethrough. The plurality of third passageways 70 may form a plurality of third openings 71 at the outlet surface 59. The plurality of third openings 71 may be where liquid ultimately exits the nozzle component 52. The plurality of third openings 71 may be arranged about or arranged around the plurality of second openings 68. Each third opening 71 has a third opening 71 area. The third opening 71 area may be about equal to the second opening 68 area. The third opening 71 area may be greater than the second opening 68 area.
As shown in
Each of the first openings 65, each of the second openings 68, and each of the third openings 71 may be sized and configured so that when liquid is dispensed through the nozzle component 52, the liquid exits the outlet side 58 in the form of separate streams from each opening.
The plurality of first openings 65, the plurality of second openings 68, and the plurality of third openings 71 may be concentric about the longitudinal axis L. The term concentric is used herein to denote circles, arcs, or other shapes that share the same center. The plurality of first openings 65 may be arranged concentrically about the longitudinal axis L. The plurality of second openings 68 may be arranged concentrically about the plurality of first openings 65. The plurality of third openings 71 may be arranged concentrically about the plurality of second openings 68. The plurality of first openings 65, plurality of second openings 68, and the plurality of third openings 71 may be arranged about or arranged around the same center, the longitudinal axis L. Arranged around may encompass a substantially circular arrangement, not limited to a full circle. A concentric arrangement may provide the benefit of centering the liquid stream when the nozzle component 52 is placed above or within the top opening of the container. A concentric arrangement may provide the benefit of balancing the nozzle component 52. A concentric arrangement may provide the benefit of the liquid streams being less likely to come into contact with the sides of the container which could lead to uneven flow. The multi-hole nozzle component 52 may have at least three pluralities of openings. The multi-hole nozzle component 52 may have at least three pluralities of openings arranged concentrically about the longitudinal axis L.
The plurality of first openings 65, the plurality of second openings 68, and the plurality of third openings 71 may be substantially circular, as shown in
The first passageways 64, second passageways 67 and third passageways 70 extending through the nozzle component 52 may be substantially parallel to each other and may also be parallel to the longitudinal axis of the nozzle component 52. The passageways being generally parallel to each other may provide the benefit of allowing for the liquid to move in a substantially linear motion for faster delivery through the passageways and the passageways to not cross each other.
As shown in
As shown in
The first passageways 64, second passageways 67, and third passageways 70 may be sized so that when liquid is dispensed through the nozzle component 52, the liquid exits the outlet side 58 in the form of separate streams from each opening. Each of the individual passageways has a cross-section. Each individual passageway of the plurality of first passageways 64 may have the same cross-sectional size and configuration. Each individual passageway of the plurality of second passageways 67 may have the same cross-sectional size and configuration. Each individual passageway of the plurality of third passageways 70 may have the same cross-sectional size and configuration. Each individual passageway of the plurality of second passageways 67 and each individual passageway of the plurality of third passageways 70 may have the same cross-sectional size and configuration. The inner diameter of each passageway may stay the same throughout the length of the passageway. The inner diameter of each passageway may vary throughout the length of the passageway. The inner diameter of each individual passageway of the plurality of first passageways 64 may be about 2 mm. The inner diameter of each individual passageway of the plurality of second passageways 67 may be about 3 mm. The inner diameter of each individual passageway of the plurality of third passageways 70 may be about 3 mm. The plurality of first passageways 64, plurality of second passageways 67 and/or the plurality of third passageways 70 may have substantially circular cross-sections.
The first openings 65, the second openings 68, and the third openings 71 may be sized so that when liquid is dispensed through the nozzle component 52, the liquid exits the outlet side 58 in the form of separate streams from each opening.
The first opening 65 area, second opening 68 area, and third opening 71 area is each a measurement of the cross-sectional area of the respective opening measured at the opening at the distal end 82. As shown in
Each first opening 65 may have a first opening 65 diameter measured at the inner surface of the opening. Each second opening 68 may have a second opening 68 diameter measured at the inner surface of the opening. Each third opening 71 may have a third opening 71 diameter measured at the inner surface of the opening. The third opening 71 diameter may be about equal to the second opening 68 diameter. The third opening 71 diameter may be greater than the second opening 68 diameter.
The first opening 65 diameter may be about 2 mm. The second opening 68 diameter may be about 3 mm. The third opening 71 diameter may be about 3 mm. The first opening 65 diameter to the second opening 68 diameter may have a ratio of about 2:3. The second opening 68 diameter to the third opening 71 diameter may have a ratio of about 1:1. The first opening 65 diameter to the third opening 71 diameter may have a ratio of about 2:3. The first opening 65 diameter to the second opening 68 diameter to the third opening 71 diameter may have a ratio of about 2:3:3. Without being bound by theory, a first opening 65 diameter to second opening 68 diameter ratio of about 2:3 may provide the benefit of less foaming given the lower surface tension each droplet of liquid forms. Without being bound by theory, a first opening 65 diameter to second opening 68 diameter ratio of about 2:3 may provide a benefit of less splashing and less dripping contamination given the lower surface tension each droplet of liquid forms. Alternatively, the first opening 65 diameter may be about 2.5 mm. The second opening 68 diameter may be about 3.5 mm. The first opening 65 diameter to the second opening 68 diameter may have a ratio of between about 2:3 and about 2.5:3.5.
The plurality of first openings 65 may comprise about five or more first openings 65, the plurality of second openings 68 may comprise about ten or more second openings 68, and the plurality of third openings 71 may comprise about fifteen or more third openings 71.
As shown in
The grooves 62 may each be sized and configured to reduce dripping of liquid after the nozzle component 52 is closed by separating the first openings 65, second openings 68, and third openings 71 at the outlet surface 59 such that any individual meniscus formed at the first openings 65, second openings 68, and third openings 71 at the outlet surface 59 of the nozzle component 52 cannot combine to produce a large drop. The grooves 62 in the outlet surface 59 of the nozzle component 52 may each be of any suitable configuration and be arranged in any suitable pattern to keep the aforementioned individual menisci from combining to produce a large drop. The grooves 62 may be substantially rectilinear, curvilinear, rectangular, rounded, oval, v-shaped or combinations thereof at the cross section. Grooves 62 that are substantially rectangular at the cross section may provide the benefit of having a sharp edge at the top portion of the groove 62 where the groove 62 meets the outer surface 59 that may keep liquid from being pulled into the groove 62.
The grooves 62 may, thus, at least partially surround the openings to separate the openings. The number of openings that are separated from each other by the grooves 62 can range from two to more, depending on characteristics, such as viscosity, of the liquid being dispensed, as shown in
As shown in
As shown in
The grooves 62 may have a width and a depth as illustrated in
As shown in
The arrangements of the plurality of grooves 62 as shown in
Passageways of Predetermined Magnitudes of Projection
As shown in
The predetermined magnitude or magnitudes of projection can range from about 1 mm to about 6 mm, depending on characteristics of the liquid such as the liquid's viscosity and on characteristics of the container the liquid is being dispensed into such as the size and depth of the container neck, and also depending on the dispensing rate.
Centering Feature
As shown in
Stopper
The components of the multi-hole nozzle assembly 20 may be made in any suitable manner from any suitable materials. The various components (other than any compressible material used for the stopper) can be machined or cast from metal, such as stainless steel, or from plastic, or certain components may be made out of metal, and certain components may be made out of plastic.
Process
In some aspects, the present disclosure relates to a process of dispensing liquid. The process may comprise the steps of: providing a low viscosity liquid hard surface cleaner, providing a container, and filling the container with a multi-hole nozzle component 52.
Combinations:
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 the entire surface of one of the elements.
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.
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