Abstract
A dispenser system for a pumpable dispensed product, in particular a cosmetic fluid dispensed product such as a washing lotion, a cream lotion, a perfume liquid or similar includes a rigid or pliable product container and a dispensing device with a pump apparatus. The pump apparatus includes at least one first valve group for conveying the dispensed product out of the product container. The pump apparatus includes a second valve group for feeding air into the product container, wherein the second valve group defines a feed duct in which at least one filter unit for filtering sterile air is arranged. In subsidiary aspect, a filter unit for the dispenser system as well as a manufacturing facility and a manufacturing method for the manufacture of the dispenser system are provided.
Claims
1. Dispenser system for a pumpable dispensed product comprising a rigid or pliable product container and a dispensing device with a pump apparatus, wherein the pump apparatus comprises at least one first valve group for conveying the dispensed product out of the product container, as well as a second valve group for feeding air into the product container, wherein the second valve group defines a feed duct in which at least one filter unit for filtering sterile air is arranged, so that a positive pressure of sterile air is settable in the product container, wherein the pump apparatus is designed as a manually operable double-pump apparatus and comprises a double-piston system for simultaneous conveying of the dispensed product and introduction of the sterile air.
2. Dispenser system according to claim 1, wherein the pump apparatus is connected to the product container in an airtight manner, preferably inextricably connected to the product container, and when not used the dispensed product is sealed in an airtight manner against the surroundings.
3. Dispenser system according to claim 1, wherein the pump apparatus is arranged to introduce a volumetric quantity of sterile air into the product container that is equal to or greater than the volumetric quantity of the dispensed product to be supplied, so that a positive pressure is settable in the product container by sterile air.
4. Dispenser system according to claim 1, wherein the filter unit comprises a sterile air filter with a filter class of H13 or class 100 or higher, and the filter unit comprises a labyrinth-type filter duct.
5. Dispenser system according to claim 1, wherein the pump apparatus is designed according to the principle of a scoop piston pump with a scoop piston, wherein the scoop piston comprises two piston segments, with a first piston segment for conveying the dispensed product and a second piston segment for supplying sterile air, and furthermore that the two piston segments are designed concentric.
6. Dispenser system according to claim 1, wherein the second valve group comprises at least two non-return valve units connected one after another in the feed duct.
7. Dispenser system according to claim 6, wherein the filter unit is arranged in the feed path from the external air to the first non-return valve unit.
8. Dispenser system according to claim 6, wherein the filter unit or a second filter unit is arranged between a first non-return valve unit and a second non-return valve unit or between the second non-return valve unit and a third non-return valve unit.
9. Dispenser system according to claim 1, wherein a non-return valve unit is arranged in the pump apparatus in the outlet duct of the dispensed product in the region of an outlet nozzle.
10. Dispenser system according to claim 1, wherein the product container is pliable, in particular designed as a foil container.
11. Filter unit for use in a dispenser system according to claim 1, wherein the filter unit comprises a sterile air filter, in particular with a filter class of H13 or class 100 or higher.
12. Manufacturing facility for the manufacture and filling of a dispenser system according to claim 1, wherein the manufacturing facility comprises at least a raw material tank, a processing tank and a storage tank for manufacture of the dispensed product, as well as a filling station for filling the dispensed product into the product container and for connecting the product container to the pump apparatus in an airtight manner, wherein a supply of external air takes place through at least one sterile air pressure line to which at least one sterile air filtering apparatus is connected.
13. Manufacturing facility according to claim 12, wherein the filling station comprises a sterilization apparatus for the product container, a filling apparatus and a pump fitting apparatus.
14. Manufacturing facility according to claim 13, wherein the filling apparatus is arranged to fill a product container that opens at the base, wherein the pump fitting apparatus is upstream, and the sterilization apparatus is arranged between the pump fitting apparatus and the filling apparatus and is designed to carry out a sterilization of the open-base product container in an open position of the pump apparatus.
15. Manufacturing facility according to claim 13, wherein the sterilization apparatus comprises a foil welding or foil deep-drawing unit (86) for the manufacture of pliable product containers.
16. Method for the manufacture of a dispenser system according to claim 1, comprising: S1: providing raw material under the cover of sterile air; S2: processing the raw material to create dispensed product under the cover of sterile air; S3: storing the dispensed product under the cover of sterile air, S4: filling the dispensed product into the dispenser system under the cover of sterile air.
17. Method according to claim 16, comprising, in connection with the filling of the dispensed product in step S4, following the filling steps of: M1: fitting of the pump apparatus onto an open-base product container; M2: sterilization of the product container in an open position of the pump apparatus; M3: filling the dispensed product in a locked position of the pump apparatus; M4: closing the product container base; M5: sealing the product container base.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] Further advantages emerge from the drawings and the descriptions of the drawings below. Exemplary embodiments of the invention are illustrated in the drawings. The drawing, the description and the claims contain numerous features in combination. The person skilled in the art will expediently also consider the features individually and combine them to form useful further combinations.
[0053] Here:
[0054] FIG. 1 shows a dispensing apparatus of a dispenser system of the prior art;
[0055] FIG. 2 shows a pliable refillable product container of a dispensed product of the prior art;
[0056] FIG. 3 shows a dispensing apparatus with product container of the prior art;
[0057] FIG. 4 shows a sectional view of a first exemplary embodiment of a dispenser system in accordance with the invention;
[0058] FIGS. 5a, 5b show sectional views of further exemplary embodiments of dispenser system in accordance with the invention;
[0059] FIG. 6 shows schematically a manufacturing facility for the manufacture of a dispenser system in accordance with the invention;
[0060] FIG. 7 shows schematically a sterilization unit for a filling station of a manufacturing facility for the sterilization of rigid product containers;
[0061] FIG. 8 shows in perspective a sterile air filtering apparatus for use in a manufacturing facility according to FIG. 6;
[0062] FIG. 9 shows a detailed view of the sterile air filtering equipment illustrated in FIG. 8;
[0063] FIG. 10 shows an exemplary embodiment of the filling station according to an embodiment of the invention.
DETAILED DESCRIPTION
[0064] The same reference numerals have been used to identify components that are identical or of the same type in the figures.
[0065] FIG. 1 shows a dispensing device 200 of the prior art. The dispensing device 200 comprises a pump actuator 202, a pump unit 204 and a conveying tube 206. The dispensing device 200 is screwed onto a product container by means of a threaded seat 224, as is illustrated in FIG. 3. They dispensed product is guided by means of the conveying tube 206 out of the product container to an outlet nozzle by the pump unit 204. Due to the threaded seat 224, the dispenser system 220 with the product container screwed on cannot be made reliably air-tight, so that ambient air with the corresponding contamination can reach a dispensed product. For this reason, the dispensed product must have a long shelf life, even when in contact with air, which means that the addition of preservatives is unavoidable.
[0066] A pliable product container 212 of a refill pack of a dispensed product from the prior art is shown in FIG. 2. The product container 212 is designed as a foil container 216, and has a screwed closure 214. Its purpose is so that the dispensed product can be refilled into a product container, like the product container 222 illustrated in FIG. 3, in order to provide a refillable dispenser system.
[0067] A dispenser system 220 of the prior art that uses a dispensing device 200 FIG. 1 is illustrated in FIG. 3. A rigid product container 222 is arranged at the threaded seat 224 of the dispensing device 200, in order to be able to release a dispensed product in measured doses. As a result of the removability of the dispensing device 200 and the product container 222, there is no airtight separation between the ambient atmosphere and dispensed product, so that conservation agents in the dispensed product must ensure an extended shelf life.
[0068] A section through an upper region of a dispenser system 10 of a first exemplary embodiment is illustrated in FIG. 4. The dispenser system 10 comprises a product container 14 which can be designed as, for example, a pliable foil container, or also as a rigid plastic, glass, ceramic or metal container. A dispensed product 12, for example a soap lotion, a cream lotion or an atomizable perfume, is stored in the interior of the product container. The dispenser system 10 comprises a dispensing device 16 which is connected in an airtight manner to the product container 14. The dispensing device 16 comprises a pump apparatus 18 with a double-pump system, in which a double-piston system 34 operating according to the principle of a scoop piston with a first piston segment 38 and a second piston segment 40 can both introduce sterile air into the product container 14 and simultaneously convey the dispensed product 12 via an outlet duct 42 to an outlet nozzle 44. The double piston system 34 is driven by hand by means of a pump actuator 56, with an automatic return to position taking place by means of a return spring element 54. On activation of the pump apparatus 18, manual pressure is applied to the pump actuator 56, whereby both the first pump segment 34 and the second pump segment 36 are moved downwards in a hermetically sealed chamber. The first pump segment 38 is used to convey the dispensed product 12 into the outlet duct 42. A first valve group 20, based on two non-return valve units 24, is provided for this purpose. The non-return valve units 24 let through the dispensed product upwards from below as a result of a negative pressure generated by the first pump segment 38, and prevent a return flow. A negative pressure is generated by raising and lowering the scoop piston 36 of the first piston segment 38, so that the dispensed product enters the piston chamber through a conveying tube 26, with the dispensed product passing into the outlet duct 42 of the pump apparatus 18 through the second non-return valve of the first valve group 20. A sterile air feed duct 28 feeds sterile air 46 into the interior of the product container 14 with the same stroke as that with which the dispensed product 12 is removed from the product container 14. Ambient air 50 is first introduced for this purpose via a filter unit 30 into the feed duct 28, and is brought into the interior of the product container 14 by means of a second scoop piston 36 of the second piston segment 40. Three non-return valve units 22a, 22b and 22c of the second valve group 22 are arranged for this purpose in the feed duct 28. Ambient air 50 flows through the filter element 30, through the first non-return valve unit 22a, into the upper region of the second pump segment 40. When the pump segment 40 moves upwards, this sterile air is moved through the non-return valve 22b into the lower region of the sterile air piston chamber, and when the second piston segment 40 moves downwards, this sterile air is introduced via the non-return valve unit 22c into the interior of the product container 14, as is illustrated by the arrows. The double-piston system 34 has dimensions such that with a piston stroke of the pump actuator 56, a larger volumetric quantity of sterile air 46 is introduced than the amount of dispensed product 12 conveyed into the outlet duct 42, so that the product container 14 is under positive pressure.
[0069] FIG. 5a shows a second exemplary embodiment of a dispenser system 10. To a large extent this is identical in design to the exemplary embodiment according to FIG. 4. Them is however a difference from the first exemplary embodiment, in that the filter element 30 is arranged behind the first non-return units of the second valve group 22a, and is thus located in the interior of the sterile air pump chamber. Sterile air is introduced through the sterile air feed duct 28, and reaches the interior of the sterile air piston via the first non-return valve unit of the second valve group 22a, is passed via the second piston segment 40 downwards and through the second valve group 22b and finally through the non-return valve unit 22c into the interior of the product container. As the air passes through the filter element 30, it passes through a labyrinth passage 48, so that the transport path through the filter element 30 is lengthened in order to create an increased filtering effect. This is in particular advantageous with filter units 30 of limited size, since an improved filtering effect, and thereby a greater cleanliness of the sterile air, can be achieved through the longer filter path. In an embodiment of this type, the filter unit 30, in contrast to the exemplary embodiment illustrated in FIG. 4, cannot be exchanged, which allows a reduced physical size of the dispenser system 10 to be achieved. It is furthermore conceivable for additional filter elements to be arranged in front of the inlet to the feed duct 28, or also in the lower region of the pump chamber or at the outlet after the non-return valve unit 22c. In the exemplary embodiment illustrated in FIG. 5a a further non-return valve unit 24 is furthermore arranged in the region of the outlet nozzle 44 in the outlet duct 42. The effect of this is that no external air 50 can enter the outlet duct 42, so that a dispensed product that has been located in the outlet duct 42 for a long time does not come into contact with contaminated external air. A germ-free dispensed product can thus be provided at the first dispensing stroke even after a long period of storage and non-use, so that the risk of contamination or microbial infestation in the dispensed product is effectively prevented.
[0070] An embodiment modified from FIG. 5a is shown in FIG. 5b, in which the filter element is arranged at the inlet to the non-return valve unit 22c. Incoming air is thus not filtered until it crosses the second pump segment 40 in the pressurized region, so that pressurized air instead of drawn air is filtered here. In this way, an increased quantity of air can be conveyed through the filter unit 30 with a settable pressure. In other respects, this embodiment corresponds to the fourth embodiment illustrated in FIG. 5.
[0071] FIG. 6 schematically illustrates a manufacturing facility 60 of an exemplary embodiment of the invention. The manufacturing facility 60 implements a four-stage manufacturing concept, wherein in step S1 initial materials can be stored in raw material tanks 70, in this case up to four raw material tanks. The necessary atmospheric supply with air takes place via a sterile air pressure line 62, wherein a sterile air filter apparatus 64, for example a Sterivent 500 sterile air filtering apparatus, can be provided upstream. Raw materials can thus be stored for a long time under cover of sterile air, and the contamination with microbes, fungi and toxic materials from the ambient air can be prevented. Raw materials can here in particular be water, EDA (ethylenediamine), amide, Purton CFD or other chemicals that can be used for the manufacture of cosmetics, creams, pharmaceutical products or medical products.
[0072] The raw material can be passed on, under cover of sterile air, to reactors in processing tanks 72, which may also be known as reactor tanks, in which the processing steps with physical and chemical processes take place, while sterile air can continue to be provided as a process atmosphere through a pressure line 62 from a sterile air filtering device 64. The dispensed product is manufactured in this process step S2, and is usually passed on in process step S3 for initial storage in storage tanks 74. Coverage with sterile air takes place again here, after which filling takes place in a filling station 76, wherein the dispensed product can be removed from the storage tanks 74.
[0073] Sterile air cover in the raw material tank 70 is not essential, since process temperatures of 85° C. or more prevail in the processing tanks 72, also known as reactor tanks, whereby biological contaminations at least are usually killed. Cooling down to room temperature at about 25° C. however takes place in the processing tanks 72. As a result of the cooling process, external air flows in to the processing tank(s) 72, so that there is a risk that contamination can enter the dispensed product 12 during cooling. Sterile air cover at a slight positive pressure above the normal atmospheric pressure is thus necessary at least following the processing stage of the processing tanks 72.
[0074] Two quite different embodiments can be considered as the filling station 76, namely a filling station 76a in which the rigid product containers can be filled, or a filling station 76b in which the pliable product containers can be filled.
[0075] The filling station 76 is composed of various stations, for example having a blow-molding machine as the first stage in which the hot, and thereby sterile, raw material is formed into a bottle. A laminar flow sterile filter 78 with a mesh size of, for example, 0.45 μm can be arranged on the actual filling apparatus 82. Biocides range in diameter down to a minimum of 0.6 to 0.5 μm, and are therefore retained by the filter. A particle number in tanks secured in that way of 0.3 particles/milliliter is documented in the operating records. The dispensed product remains without any contact with unfiltered external air, from raw material through production to packaging.
[0076] A filling station 76a for rigid product containers comprises a sterilization apparatus 80 in which the product containers that have been manufactured are first cleaned and sterilized, after which the dispensed product is filled in a filling apparatus 82, and finally the dispensing device 16 is placed on the product container 14 and sealed in an airtight manner in a pump fitting apparatus 84. The connection between the product container 14 and the pump apparatus 18 is usually made in an inseparable manner, so that refilling the product container 14 is not possible. It can, however, also be provided that a refillable dispenser system 10 is made available, wherein refilling can, however, be carried out a sterile air cover. One possible design of a sterilization apparatus 80 for the sterilization of rigid product containers is shown in the following illustration in FIG. 7.
[0077] A filling station 76b that is prepared for filling the dispenser product into pliable product containers can alternatively be operated in parallel or independently. The filling station 76b comprises for this purpose both a sterilization apparatus and a foil welding and foil deep-drawing unit 86. The foils to be welded are sterilized in the sterilization apparatus 80, for example by exposure to ozone, after which they are welded together or deep-drawn, so that a pliable product container is formed. A filling with the dispensed product then takes place under sterile air cover, followed by fitting of the dispensing device 16 to the product container 14 in the pump fitting apparatus 84.
[0078] Sterile air cover can be achieved through a central sterile air pressure line 62 with a sterile air pressure line, or via one or more laminar flow filters 78 that can be arranged directly at the filling station 76.
[0079] A part of a filling station 76 for filling rigid product containers 52 is illustrated in FIG. 7. A filling station 76 of this type can be used as a filling station 76a in a manufacturing facility according to FIG. 6. In the filling station 76, rigid product containers 52 are first sterilized in a sterilization apparatus 80 that consists of or comprises three different stages, and filled with dispensed product in a further filling apparatus 82. In the sterilization apparatus 80, a sterilization medium, for example ozone, is first introduced into the product container via a sterilization medium feed line 138, whereby a sterilization medium filling unit 130 is formed. The sterilization medium enters through a lance to the base of the product container 52, and flows at an open end into an exhaust air duct 136 in which the sterilization medium is withdrawn through exhaust air lines 140. The exhaust air duct 136 is sealed by a gasket 144 at the openings of the product container 52. In a further step of a sterilization process unit 132, the product container 52 is subjected to a sterilization process, for example by a mechanical treatment with the filter sterilization medium filling, and in a third step the sterilization medium is removed from the product container via a sterilization medium extraction unit 134 by filling, for example with sterile air, through a sterile air pressure line 62. A withdrawal of the sterilization medium and of the sterile air then takes place through an exhaust air duct 140. After this, the product container 52 leaves the sterilization apparatus 80 and reaches the filling apparatus 82. In the filling apparatus 82, a dispensed product filling line 142 is introduced through a lance, and the dispensed product is filled into the product container 52. Following this, a closure, not illustrated, of the product container 52 by a dispensing device 16 takes place, so that the dispenser system is manufactured.
[0080] An embodiment of the sterile air filter apparatus 64 is illustrated in FIG. 8, being implemented as a sterile air provision apparatus 110 for the manufacture of a sterile air dispenser system 10. The sterile air provision apparatus 10 comprises an ambient air inlet region 112 with a labyrinth duct which can only receive a flow of air from underneath to protect against environmental influences and rain, and a sterile air outlet region 114 arranged on the opposite side, in which filtered sterile air is discharged. The filter equipment 110 is cylindrical in structure, and has at a section of the external wall an electrical sterile air pressure controller 108 in which operating elements and display elements for displaying the operating state plus, for example, an upcoming filter exchange, the current pressure, etc. are arranged.
[0081] A perspective view of the internal design of the sterile air provision apparatus 110 illustrated in FIG. 8 is shown in FIG. 9a, while FIG. 9b shows the air guidance and the electrical components of the sterile air provision apparatus 110 as a schematic block diagram. Ambient air is guided through a labyrinth duct into an ambient air inlet region 112, and subjected to preliminary filtering through a preliminary filter unit 116. The preliminary filter unit can filter air at a flow speed of about 0.35 m/s, and filters coarse materials out of the air. A filter fan 118, which generates an air pressure and is used to establish a desired fluid flow of sterile air, is arranged behind this. The speed of the filter fan 118 is controllable, and can have a rated power between 100 W and 500 W, preferably 200 W, and an air throughput of up to 500 m3/h. A differential manometer 120, which can capture a pressure difference of the filter unit 66, is arranged at the outlet of the filter fan 118. The sterile filter unit 66 is a class 100 filter which does not allow more than 100 particles with a size of 0.5 μm per m3 of air to pass, and has an elimination factor of 99.997% of solid material. It is preferably formed as a HEPA filter or as a ULPA filter of class a H14 or higher. It has an active filter surface area of at least 5 m2, with the differential manometer 120 measuring the pressure drop across the filter 66, and this provides an indication of the degree of soiling, or of a fault or of correct functioning of the filter equipment. A further pressure manometer 122 which can determine the sterile air pressure within the sterile air pressure line 62 is finally arranged at the sterile air outlet region 114, in order to monitor a sufficient sterile air cover.
[0082] As an alternative to the filling station 76 illustrated in FIG. 7, a modified filling station 300 is shown in FIG. 10. The filling station 300 is arranged in a sterile air positive pressure container 320, in which there is a positive pressure of sterile air in order to prevent the ingress of external air into the filling station 300. In step M1, a pump fitting apparatus 304 fastens, in a pressure-tight manner, a pump apparatus 18 to the neck of a product container 306 with an open base, where for example a pressure-proof closure ring 316 on the product container 306 ensures a fluid-proof connection by means of a snap-lock connection and an optional welding of the seam. In step M2, a sterilization apparatus 318 introduces ozone as a sterilization gas from the open base side into the product container by means of a lance. The product containers are upside down during the filling process, so that the open base region of the product container 306 faces upwards. During the introduction of the ozone in step M2, the pump actuator 202 is moved into an open position 312, so that ozone can flow through the pump actuator mechanism and sterilize this too. Both the product container 306 and the pump apparatus 18 are sterilized in this way. The pump apparatus 18 is locked in a locked position 314 during a sterilization period, so that the fluid path is blocked. The duration of the sterilization period during which the ozone disinfects the interior of the product container 306 can be preselected. In the subsequent step M3, a dispensed product is introduced through the open base into the product container 306 by means of a filling apparatus 302. After this, the base opening is closed in a step M4, either by opposite side regions of the product container 306 being bonded together as in a toothpaste tube, or by a product container base 308 being pressed into the base opening. The product container base 308 is adjusted in such a way that the product container 306 is gas-tight. Small amounts of sterile air or ozone can be trapped by the closure, and a positive pressure atmosphere is set in the interior of the product container 306. In the final step M5, welding of the product container 306 or of the base 308 by means of a base welding apparatus 322 takes place, forming a welded seam 310. The dispenser system is thus sterilized and free from germs, and filled under sterile air cover, so that no foreign materials can reach the dispensed product 12.
LIST OF REFERENCE NUMERALS
[0083] 10 Dispenser system [0084] 12 Dispensed product [0085] 14 Product container [0086] 16 Dispensing device [0087] 18 Pump apparatus [0088] 20 First valve group [0089] 22 Second valve group [0090] 24 Non-return valve unit [0091] 26 Conveying tube [0092] 28 Sterile air feed duct [0093] 30 Filter unit [0094] 32 Double-pump apparatus [0095] 34 Double-piston system [0096] 36 Scoop piston [0097] 38 First piston segment [0098] 40 Second piston segment [0099] 42 Outlet duct of the dispensed product [0100] 44 Outlet nozzle of the dispensed product [0101] 46 Sterile air [0102] 48 Labyrinth-type filter duct [0103] 50 Surroundings [0104] 52 Rigid product container [0105] 54 Return spring element [0106] 56 Pump actuator [0107] 60 Manufacturing facility [0108] 62 Sterile air pressure line [0109] 64 Sterile air filter apparatus [0110] 66 Sterile air filter of a sterile air filter apparatus [0111] 70 Raw material tank [0112] 72 Processing tank [0113] 74 Storage tank [0114] 76 Filling station [0115] 78 Laminar flow filter [0116] 80 Sterilization apparatus [0117] 82 Filling apparatus [0118] 84 Pump fitting apparatus [0119] 86 Foil welding or foil deep-drawing unit [0120] 106 Sterile air compression tank [0121] 108 Sterile air pressure controller [0122] 110 Sterile air provision apparatus [0123] 112 Ambient air inlet region [0124] 114 Sterile air outlet region [0125] 116 Preliminary filter unit [0126] 118 Filter fan [0127] 120 Differential manometer [0128] 122 Pressure manometer [0129] 130 Sterilization medium filling unit [0130] 132 Sterilization medium processing unit [0131] 134 Sterilization medium extraction unit [0132] 136 Exhaust air duct [0133] 138 Sterilization medium feed line [0134] 140 Exhaust air line [0135] 142 Dispensed product filling line [0136] 144 Gasket [0137] 146 Transition seal [0138] 200 Dispensing device of the prior art [0139] 202 Pump actuator [0140] 204 Pump unit [0141] 206 Conveying tube [0142] 210 Dispensed product refill pack of the prior art [0143] 212 Pliable product container [0144] 214 Screwed connection [0145] 216 Foil container [0146] 218 [0147] 220 Dispenser system of the prior art [0148] 222 Rigid product container [0149] 224 Threaded seat of the pump apparatus at the product container [0150] 300 Filling station [0151] 302 Filling apparatus [0152] 304 Pump fitting apparatus [0153] 306 Product container with open base [0154] 308 Product container base [0155] 310 Welded seam [0156] 312 Open position of the pump apparatus [0157] 314 Locked position of the pump apparatus [0158] 316 Pressure-proof closure ring [0159] 318 Sterilization apparatus [0160] 320 Sterile air positive pressure container [0161] 322 Base welding apparatus
