Filling apparatus

Abstract

An apparatus for filling containers with a product, includes a product supply, a pre-filling chamber having a controlled outlet, a movable sealing arrangement having a closed position for isolating the product supply from the pre-filling chamber, and a displacer arrangement that extends into the pre-filling chamber and that has an elastically deformable wall. The displacer arrangement is interactively connected to a control medium in such a way that an elastic volume change in the displacer arrangement changes a volume of the pre-filling chamber, thereby permitting control over an amount of product delivered through the outlet.

Claims

1. An apparatus for filling containers with a material, said apparatus comprising a product supply, a pre-filling chamber, a movable sealing-arrangement, a displacer arrangement, an elastically-deformable wall, a controllable outlet, a control surface, and a dual-piston arrangement comprising an inner piston and an outer piston, wherein said pre-filling chamber is isolatable from said product supply, wherein said pre-filling chamber comprises said controllable outlet, wherein said movable sealing-arrangement has a closed position for isolating said product supply from said pre-filling chamber, wherein said displacer arrangement is extendible into said pre-filling chamber, wherein said displacer arrangement comprises said elastically-deformable wall, wherein said displacer arrangement is interactively connected to said control surface in such a way that deformation of said elastically-deformable wall causes a volume change in said displacer arrangement that changes a volume of said pre-filling chamber, thereby permitting control over an amount of product delivered through said outlet, wherein said inner and outer pistons are concentric, and wherein said inner and outer pistons are arranged to interact telescopically.

2. The apparatus of claim 1, further comprising a bellows, wherein said bellows forms said elastically-deformable wall and wherein said bellows protrudes into said pre-filling chamber.

3. The apparatus of claim 1, wherein said movable sealing-arrangement comprises said dual-piston arrangement.

4. The apparatus of claim 1, wherein said outer piston isolates said pre-filling chamber from said product supply when said movable sealing-arrangement is in said closed position, and wherein said inner piston forms said displacer arrangement.

5. The apparatus of claim 4, wherein, when said movable sealing-arrangement is in said closed position, said inner piston is movable into said pre-filling chamber so as to displace a predefined amount of product.

6. The apparatus of claim 4, further comprising a bellows, wherein said bellows seals said inner piston from said outer piston.

7. The apparatus of claim 4, wherein said inner piston is configured as a bellows.

8. The apparatus of claim 4, further comprising a bellows, wherein said bellows isolates said outer piston from said product supply.

9. The apparatus of claim 5, further comprising an actuator that is configured to move said inner piston.

10. The apparatus of claim 9, wherein a resistance that hinders relative movement between said inner piston and said outer piston exceeds a resistance that hinders relative movement between said outer piston and said product supply.

11. The apparatus of claim 9, further comprising a piston element, wherein said actuator connects to said piston element, wherein said outer piston comprises an axial bore in which said piston element is moveable, wherein said inner piston is arranged at one end of said outer piston, wherein said inner piston is connected to said bore, and wherein the arrangement of the piston element and the inner piston results in an ability to have fluid be arranged between said piston element and said inner piston.

12. The apparatus of claim 1, further comprising an actuator, wherein said actuator lowers said outer piston to isolate said product container from said pre-filling chamber.

13. The apparatus of claim 1, wherein said product supply comprises a product container, wherein said outer piston extends vertically through said product container, and wherein a lower end of said outer piston seats against an opening into said pre-filling chamber.

14. The apparatus of claim 1, further comprising a valve, an outlet opening, and an actuator, wherein said valve comprises a closing element and an elastic membrane, wherein said elastic membrane is arranged around said outlet opening, and wherein said actuator is configured to move said elastic membrane relative to said closing element.

15. The apparatus of claim 1, wherein said displacement arrangement comprises a mechanical piston and a bellows, and wherein said piston actuates said bellows.

16. The apparatus of claim 1, wherein said displacement arrangement comprises a fluid-actuated bellows.

17. The apparatus of claim 1, wherein said displacement arrangement is configured such that increasing a volume of said displacement arrangement causes discharge of a corresponding volume of said material from said pre-filling chamber.

18. The apparatus of claim 1, wherein said deformation of said elastically-deformable wall causes ejection of product through said outlet and wherein displacement of said elastically-deformable wall also causes product to be sucked into said chamber from said product supply.

19. The apparatus of claim 1, wherein said elastically-deformable wall protrudes into said pre-filling chamber.

20. An apparatus for filling containers with a material, said apparatus comprising a product supply, a pre-filling chamber comprising a controllable outlet, a movable sealing-arrangement that transitions into a closed position in which said product supply is isolated from said pre-filling chamber, said movable sealing-arrangement comprising concentric inner and outer pistons that are arranged for telescopic interaction with each other, a displacer arrangement that extends into said pre-filling chamber and that comprises an elastically-deformable wall, and a control surface that is interactively connected to said displacer arrangement so as to cause deformation of said wall, said deformation resulting in an increase and then a decrease in volume of said displacer arrangement while said displacer arrangement is within said pre-filling chamber, wherein an extent of said increase in said volume of said displacer arrangement results in a corresponding decrease in volume of said pre-filling chamber, which then results in ejection of a corresponding volume of said material through said controllable outlet.

21. The apparatus of claim 1, wherein said inner and outer pistons are configured such that as said outer piston lifts off to connect said pre-filling chamber to said product supply, said inner piston extends further into said pre-filling chamber thereby avoiding a pressure differential that would otherwise hinder said outer piston from lifting off.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIGS. 1 to 8 show partial-section side views of a first embodiment of a filling apparatus having a dual-piston arrangement in different phases of a filling operation,

(2) FIG. 9 shows a partial-section side view of an alternative embodiment of a filling apparatus having a fluid-operated displacer arrangement,

(3) FIG. 10 shows a partial-section side view of another embodiment of a motor-operated filling apparatus that has an additionally arranged load cell for monitoring and regulating the pre-filling,

(4) FIG. 11 shows a partial-section side view of another embodiment of a motor-operated filling apparatus that has an aseptic pre-filling chamber,

(5) FIG. 12 shows a partial-section side view of an embodiment of a motor-operated filling apparatus according to FIG. 10 during a closed CIP operation,

(6) FIG. 13 shows a partial-section side view of another embodiment of the invention that has a balloon as part of the displacer arrangement, and

(7) FIG. 14 shows a partial-section side view of another embodiment of the invention that has a bellows as part of the displacer arrangement.

(8) In the drawings, parts that are identical or have the same functions are indicated by identical reference numbers.

DETAILED DESCRIPTION

(9) As shown in FIG. 1, a filling apparatus 10 includes a product container 12 having a base 22. This product container 12 acts as a product supply. Attached beneath the product container 12 is a pre-filling chamber 14.

(10) The filling apparatus 10 includes a dual-piston arrangement 16 having an outer piston 18 and an inner piston 36 that are arranged concentrically relative to one another. The inner piston 36 and the outer piston 18 can be moved axially relative to the product supply 12 and to one another. For this purpose, a guide 15 holds the dual-piston arrangement 16 on the product container 12 or on a construction element connected to the product container 12.

(11) An actuator 17 adjusts the outer piston 18 axially relative to the product container 12. Examples of a suitable actuator 17 include a hydraulic cylinder, a pneumatic cylinder, and an electric motor.

(12) A first bellows 24 encloses the outer piston 18, thus sealing it off from the product container 12. In some embodiments, the first bellows 24 is made from an elastic material.

(13) A lower end 20 of the outer piston 18 permits the outer piston to seal off the pre-filling chamber 14 from the product container 12. This lower end 20 faces the pre-filling chamber 14 that is being pressed against the product container's base 22. The resulting sealing arrangement has no sliding seal-faces. As a result, the outer piston 18 isolates the pre-filling chamber 14 from the product container 12 in a way that avoids having any sliding seal-faces provided anywhere in the entire product region.

(14) Meanwhile, a second bellows 38 seals off the inner piston 36 from the outer piston 18. This second bellows 38 is smaller than the first bellows 24 and also more resistant to deformation than the first bellows 24. It acts as a displacer arrangement as soon as the outer piston 18 has sealed off the pre-filling chamber 14 from the product container 12.

(15) A valve 28 forms an outlet on an underside of the pre-filling chamber 14. A suitable valve 28 is an electrically or pneumatically controllable valve having a permanently arranged seal 32 that is arranged over an outlet 34 in the center of an elastic membrane 30. In some embodiments, the seal 32 is spherical. An adjustable control cylinder 31 holds or encloses the membrane 30. This control cylinder 31 causes the membrane 30 to be pressed against or to be moved away from the seal 32, thereby closing or opening the outlet 34.

(16) A pushrod 40 connected to an end of the inner piston 36 moves the inner piston 36 relative to the product container 12. As it moves, the inner piston 36 entrains the outer piston 18, provided the movement is enabled by the actuator 17, or both pistons move together.

(17) At its upper end, the pushrod 40 carries a roller 42 that travels along a guide surface 44 of a control element 45. As a result, the pushrod 40 deflects by an amount that corresponds to the vertical profile of the guide surface 44.

(18) The second bellows 38 transmits the inner piston's movement to the outer piston 18 via the second smaller bellows 38. Because the second bellows 38 is more resistant to deformation than the first bellows 24, when the pushrod 40 moves, the outer piston 18 is first moved by way of the inner piston 36 and its bellows 38 until the bottom end 20 of the outer piston 18 lies against the base 22 of the product container 12. In this state, the pre-filling chamber 14 is sealed off from the product container 12.

(19) In an alternative implementation, the actuator 17 moves the outer piston 18 and the pushrod 40 moves either the inner piston 36 or the bellows 38. This embodiment includes a fixed-position guide sleeve with sealing elements between it and the outer moving piston 18. In some of these implementations, a space between the fixed-position guide sleeve and the piston 18 can also be purged with a liquid or gas. In others of these implementations, appropriate connections connect this space to a cleaning circuit.

(20) Upon a further movement of the pushrod 40, the inner piston 36 moves forward out of the lower end 20 of the outer piston 18. This brings about a corresponding displacement of product in the pre-filling chamber 14. The resulting displacement causes a product discharge of a corresponding volume through the valve 28 and into a container that is to be filled. The container can be a can, a bottle, or a keg.

(21) FIGS. 1-8 show positions of the individual components of the filling apparatus 10 as the filling operation progresses.

(22) The sequence begins, as shown in FIG. 1, with the outer piston 18 in the open position at the start of the filling operation. With the outer piston 18 in this position, a feed 26 forms between the lower end 20 of the outer piston 18 and the product container's base 22. Product passes through this feed 26.

(23) The control cylinder 31 presses the movable membrane 30 against the seal 32. As a result, the seal 32 closes the outlet 34 at the membrane's center. Product continues to flow until it completely fills the pre-filling chamber 14.

(24) In FIG. 2, the roller 42 has already rolled along part of the guide surface 44, thereby deflecting the pushrod 40 downward. Because the second bellows 38 is usually stiffer than the first bellows 24, as the pushrod 40 moves, the inner piston 36 and the second bellows 38 move the outer piston 18 downwards. This continues until the lower end 20 comes to rest against the product container's base 22. This isolates the pre-filling chamber 14 from the product container 12. The valve 28 that forms the pre-filling chamber 14 remains closed.

(25) In an alternative implementation, the actuator 17 causes the entire movement, and in particular, the downward movement. Meanwhile, suitable stops entrain the inner piston 36. This implementation makes it easier to adapt a control cam to different movement sequences.

(26) FIG. 3 shows the configuration after a controller causes a drive to move the control cylinder 31 downward. This causes the outlet 34 to open, thus permitting product delivery through the outlet 34.

(27) In FIG. 4, the roller 42 has reached the lowest section of the guide surface 44. In this position, the inner piston presses into the pre-filling chamber 14 and the second bellows 38 expands. The resulting displacement ejects a defined amount of product through the open outlet 34.

(28) Referring now to FIG. 5, at the end of the product delivery operation shown in FIG. 4, the control cylinder 31 moves back upward and closes the outlet 34. The membrane 30 comes to rest against the seal 32 and the valve 28 closes.

(29) Referring now to FIGS. 6 and 7, the actuator 17 moves the outer piston 18 from its closed position up into its open position so that its lower end 20 lifts off from the product container's base 22. This re-opens the feed 26 from the product container 12 to the pre-filling chamber 14. Since, according to FIG. 7, the roller 42 of the pushrod also slides back upward along the guide surface 44, the inner piston 36 also returns to its retracted position as shown in FIG. 8. This, in turn, is the starting position for a new filling sequence as shown in FIG. 1.

(30) It is especially advantageous if, either before or as the outer piston 18 lifts off, the inner piston 36 moves downward a little further so as to create an equal or positive pressure or prevent a negative pressure that would hinder or even prevent the outer piston 18 from lifting-off. Such a pressure differential at this location would also cause the product to be sucked into the pre-filling chamber 14.

(31) FIG. 9 shows an embodiment of a filling apparatus 60 that is broadly analogous with that shown in FIGS. 1 to 8. In this embodiment, the pushrod 62 has, at its bottom end, a piston element 64 that slides axially in a central bore 65 of the outer piston 18.

(32) In the embodiment shown in FIG. 9, an incompressible fluid 66, such as water or oil, fills a space between the piston element 64 and the second bellows 38. This fluid 66 causes the piston element 64 to deflect the bellows 38 into the pre-filling chamber 14. As a result, this deflection is essentially wear-free and subject to only a minimum of friction. The fluid 66 presses against the entire inner surface of the bellows 38, thereby ensuring that it remains unconstricted.

(33) In the embodiment shown in FIGS. 1-8, a guide surface 44 deflects the push rod 40. However, it is also possible to deflect the push rod 40 using a drive 52, as shown in FIG. 10. Examples of such a drive 52 include a linear motor or control cylinder. In this embodiment, it is possible to precisely set the displaced volume by exercising precise control over the drive 52.

(34) This embodiment also includes an optional load cell 56 to check the correctness of the filled volume and/or to establish a control circuit. In addition, the pushrod 40 is optionally driven by a single drive 52 such as a linear motor or control cylinder.

(35) FIG. 11 shows an aseptic version of the embodiment shown in in FIG. 10. In this aseptic version, the membrane 30 extends into an inlet tube that covers the mouth of a container to be filled. A tight attachment between the membrane 30 and the bottom of the pre-filling chamber 14 assures separation between the sterile space and other filling elements.

(36) A sterile space in which all or some of the containers are arranged and conveyed during filling operations is ideally provided under the filling valve, with essentially only the container carriers being provided within this sterile space as handling elements. The filling elements and all other elements that are part of the filler are located either above or outside the sterile space.

(37) FIG. 12 shows an embodiment analogous to that of FIG. 10 with a closed CIP operation (cleaning-in-place) in progress. As illustrated, the outer piston 16 is in the open position relative to the product container 12, while the seal 32 is in the open position relative to and spaced apart from the elastic membrane 30. Consequently all parts that come into contact with the product can be cleaned under pressure. Because of the two bellows, no sliding seal faces come into contact with the product. As shown in FIGS. 9 to 11, a single drive 52 operates the pushrod 40. However it is also possible to actuate the pushrod 40 with a roller 42 rolling on a guide surface 44 of a control element 45, as shown in FIGS. 1 to 8.

(38) Among the advantages of the illustrated embodiments is that the displacer arrangement 36, which in this case comprises the second bellows, projects in a free-hanging or protruding manner into the pre-filling volume 14. Accordingly, in the filling step, volume expansion by the displacer arrangement 36 multilaterally displaces the filling volume out of the pre-filling volume. In some embodiments, the displacer arrangement 36 is held or mounted on only one surface of the pre-filling volume 14 or on one side of the pre-filling volume 14.

(39) FIG. 13 shows a further embodiment of a filling apparatus 70 having a pre-filling chamber 72, a product supply 74, a product container 75, and a stop valve 76 arranged between the product supply 74 and the pre-filling chamber 72. The product present in the product container 75 can be a liquid that has product pieces and/or a liquid having a viscosity greater than that of water.

(40) A displacer arrangement 78 projects down into the pre-filling chamber 72 from above. The displacer arrangement 78 has an outlet pipe or supply pipe 80 and a rubber layer or elastic polymer layer 82. The polymer layer 82, which is attached to the top of the pre-filling chamber 72 and sealed, defines a balloon that surrounds the supply pipe 80. When the pressure within the fluid container 88 is less than the pressure within the product container 75, the polymer layer 82 lies up against the supply pipe 80.

(41) A proportioning valve 84 and a flow meter 86 are arranged in the supply pipe 80 above the pre-filling chamber 72, with the flow meter 86 being above the proportioning valve 84. Preferably, the flow meter 86 measures flow in either direction. A suitable type of flow meter 86 is a magnetic induction flow meter.

(42) The upper end of the supply pipe 80 ends in a fluid container 88 that draws the pressure fluid that is used to expand the space within the polymer layer 82. A filling valve 89 is arranged at the lower end of the pre-filling chamber 72. Control over the filling apparatus 70 includes alternately using the stop valve 76, the proportioning valve 84 and the filling valve 89 to apply three different pressure levels: a pressure-fluid pressure, a product pressure, and atmospheric pressure, with the pressure-fluid level being between the product pressure and atmospheric pressure.

(43) Embodiments that use a coupling fluid to hydraulically cause displacement include a fluid container 88 with suitable actuators and control elements. In some of these embodiments, all filling elements or their respective displacer elements connect to just one central fluid container 88. In some embodiments, the central fluid container 88 is an annular channel or tank. Only one central unit, such as a pump or infeed, is needed to set the desired pressure level in the respective fluid container.

(44) During the filling operation, the stop valve 76 closes and the proportioning valve 84 and the filling valve 89 open. This pushes a defined quantity of pressure fluid into the interior defined by the polymer layer 82. The flow meter 86 measures the relevant amount. The pressure fluid itself can be oil or water.

(45) In response, the polymer layer 82 expands and forms a balloon, as indicated by the broken line. As it does so, a defined volume of the product is delivered from the pre-filling chamber 72 through the filling valve 89 and into a container 96, such as a bottle.

(46) After the filling operation, the filling valve 89 closes and the stop valve 76 opens. This exposes the pressure fluid to pressure in the product container 75, which is higher than that in the fluid container 88. As a result, pressure fluid that had been pushed into the interior inside the polymer layer 82 is now pushed back into the fluid container 88. This causes the polymer layer 82 to lies against the supply pipe 80 once again. In some embodiments, a pump can be used to achieve the same function.

(47) By using a pump or suitable pressure ratios in the corresponding containers, the defined amount of product is delivered from the product container 75 into the pre-filling chamber 72, thus readying the filling apparatus 70 for the next filling operation.

(48) FIG. 14 shows an embodiment of a filling apparatus 90 that is broadly identical to that shown in FIG. 13, in which identical parts that have the same functions are indicated by the same reference numbers. Unlike the embodiment 70 in FIG. 13, the filling apparatus 90 does not use a balloon-like polymer layer 82. Instead, it relies on a bellows 92 that forms part of the displacer arrangement 94. This bellows 92 has the same function as the polymer layer 82 in the embodiment 70 shown in FIG. 13.

(49) In some embodiments, the bellows 92 consists of a relatively rigid material because in this case the change in volume can be realized by the relative movement of the parts of the bellows relative to one another. As in FIG. 13, a pressure fluid is applied to the bellows 92. The operation is controlled as was explained in conjunction with FIG. 13.