Method of removing headspace from a filled container and container comprising a valve

Abstract

The invention relates to a method of removing headspace (3) from a filled container (1). The method comprises providing a container that is filled with a product (2) and that further holds a gas containing headspace. The container comprises a valve (100) that allows gas to be expelled from the container. The method further comprises applying a pressure difference over the one-way valve to remove gas contained in the headspace through the valve to reduce the headspace.

Claims

1. A method of removing headspace from a filled container, said method comprising: a) providing a container that is filled with a product and that further holds a gas containing headspace, wherein the container is at least partially deformable and comprises an opening for dispensing the product, said container comprising a valve that allows gas to be expelled from the container; and the container is made of an elastically deformable material, the container having a deformed shape, the deformed shape being deformed with respect to an undeformed shape, wherein the container inclines to return to its undeformed shape and wherein the internal volume in the deformed shape is less than the internal volume of the container in the undeformed shape, wherein the valve comprises an inner layer and an outer layer positioned on top of each other, the inner layer and outer layer each comprising at least one perforation that are positioned off-set with respect to each other, wherein the inner layer and outer layer are made of a flexible material, the outer layer having a higher modulus of elasticity, and wherein the inner layer and the outer layer are formed by one or more sublayers, the inner layer comprising a first sub-layer made of thermoplastic styrene, the inner layer further comprising a second sub-layer being a conductive layer, such as an aluminum layer, which heats up when an oscillating electromagnetic field is applied, the inner layer further comprising a third sub-layer being made of a thermoplastic material like expanded polyethylene, the outer layer comprising a first sub-layer made of thermoplastic styrene, the outer layer further comprising a second sub-layer forming a protection layer, for instance made of polyethylene terephthalate, and wherein the one-way valve may be closed by induction sealing, by generating an oscillating electromagnetic field, for instance by an induction coil, to heat up the second sub-layer, leading to melting of the first sub-layer facing the inner layer and attaching to the inner layer, and b) applying a pressure difference over the valve to remove gas contained in the headspace through the valve to reduce the headspace.

2. A method according to claim 1, wherein the container is a deformable container and a positive pressure is applied to the container by deforming the container.

3. A method according to claim 1, wherein in between the sub-layers of the inner layer and in between the sub-layers of the outer layer, adhesive layers are provided.

4. A method according to claim 1, wherein valve comprises a filter layer.

5. A method according to claim 1, wherein b) comprises monitoring the applied pressure difference not to exceed a predetermined value.

6. A method according to claim 1, wherein the method further comprises; c) permanently dosing the valve.

7. A method according to claim 6, wherein the valve comprises an inner layer and an outer layer positioned on top of each other, wherein action c) comprises sealing the inner and outer layer together.

8. A method according to claim 6, wherein action c) comprises sealing the valve.

9. A method of filling a container with a product, the method comprising: filling a container with the product, providing a valve that allows gas to be expelled from the container; and applying the method according to claim 1.

10. A method according to claim 9, wherein the method comprises labelling the container before applying the method of removing headspace from a filled container.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will be described in more detail below with reference to a number of drawings which show a few exemplary embodiments. The drawings are only intended for illustrative purposes and do not limit the scope of protection which is defined by the claims.

(2) FIGS. 1a-e schematically show an embodiment of a method of filling a container,

(3) FIGS. 2a-c schematically depict a one-way valve in more detail,

(4) FIGS. 3a-b schematically depict a conveyor belt according to embodiments,

(5) FIG. 4 schematically depicts a one-way valve according to a further embodiment.

DETAILED DESCRIPTION

(6) The embodiments provide a method of filling a container with a pourable product and method of removing the headspace from a container (such as a bottle). A container may be filled with a product, leaving some headspace. A (one-way) valve may be provided, for instance in the opening of the container. Next, pressure may be exerted on the container squeezing out the gas forming the headspace. The valve prevents gas or air from flowing into the container.

(7) The methods are explained with reference to FIGS. 1a-1e.

(8) FIG. 1a shows a container 1. The container 1 may be bottle or the like which can be filled with a product 2. The container 1 comprises an opening 4, for instance shaped as a spout.

(9) The container 1 may be an elastically deformable container meaning that the container 1 may be deformed into a deformed shape by exerting a force or applying over/underpressure, and the container 1 inclines to return to its undeformed shape.

(10) The container 1 may be made of PET (Polyethylene terephthalate) or PP (Polypropylene), PE (Polyethylene) or may a multilayer container of different materials.

(11) FIG. 1b schematically depicts the filling of a container with the product. The product 2 may be a food product. The product may be a liquid, a gel-like or a paste-like product. Examples of products are ketchup, mayonnaise, sauces. The product may also be a granular product, like flour or grain. The product may also be a non-food product, like soap, cleaning agent, washing powder, etc.

(12) FIG. 1c schematically shows the container 1 now filled with the product 2. As shown in FIG. 1c, the container 1 comprises a headspace 3 comprising gas or air and which may be up to 10 vol. % of the total volume of the container 1.

(13) Further shown in FIG. 1c, a one-way valve 100 is provided, positioned in the opening 4 of the container 1. The one-way valve 100 may be a pressure activated one-way valve 100. The one-way valve 100 is arranged to allow gas and air to flow out of the container 1, but prevents air and gas from entering the container 1. The one-way valve 100 is further arranged to prevent the product from flowing in or out of the container 1. The details of the one-way valve 100 will be explained in more detail below with reference to FIGS. 2a-2c. The details of an alternative valve 100 will be explained in more detail below.

(14) Next, a pressure difference is applied over the one-way valve 100, as schematically shown in FIG. 1d. This may be done by deforming the container 1, e.g. by squeezing the container 1. Different ways of applying the pressure difference will be explained in more detail below with reference to FIGS. 3a-3b.

(15) Alternatively, the pressure difference is applied by providing a low pressure at an outside of the one-way valve thereby causing the container 1 to deform.

(16) By applying the pressure difference, the gas in the headspace 3 is pushed out of the container 1 via the one-way valve 100, as shown in FIG. 1d. As the one-way valve 100 does not let through the product 2, the product is not squeezed out of the container 1. As a result, the headspace is significantly reduced without spilling product 2.

(17) Optionally, the one-way valve 100 may be closed, as schematically shown in FIG. 1e. This is also explained in more detail below with reference to FIG. 2c.

(18) The method as explained with reference to FIGS. 1a-1e may be employed with any suitable valve, such as the valves explained with reference to FIGS. 2a-2c.

(19) FIG. 2a schematically depicts a one-way valve 100 as may be used.

(20) The one-way valve 100 comprises at least two layers: an inner layer 110 and an outer layer 120, as shown in FIG. 2a. When attached to the container 1, for instance in the opening 4, the inner layer 110 faces the inside of the container 1.

(21) The inner and outer layer 120 are made of a flexible material, such as a flexible foil, with a different modulus of elasticity (tendency to be deformed elastically when a force is applied to it).

(22) The inner layer 110 has a relatively low modulus of elasticity and the outer layer 120 has a relatively high modulus of elasticity.

(23) Both layers 110, 120 each comprise at least one perforation 118, 128 in different positions, i.e. not in line with respect to each other.

(24) The inner and outer layers 110, 120 may be joint along an edge region 130, leaving non-joint surfaces remaining in the middle. The non-joint surfaces are completely surrounded by the joint edge region 130. When a force is exerted to the layer 110, 120 in a direction from the inner layer 110 to the outer layer 120, for instance generated by a pressure difference, both layers 110, 120 deform as schematically depicted in FIG. 2b.

(25) The outer layer 120 deforms more than the inner layer 110 as a result of the different moduli of elasticity. As a result a small open volume is created between both layers. When at the same time a force, which may also be created by a pressure difference is applied to the content of the container 1, the gas forming the headspace 3 is forced through the one-way valve 100 out of the container 1.

(26) The product, which will have a higher viscosity than the gas, requires more force to go flow through the one-way valve 100 and will therefore not flow through the one-way valve 100.

(27) This way, a one-way valve 100 is created which only let's trough gasses (e.g. air in the headspace) and not the product, such as pourable and/or viscous products.

(28) Also, when the force is applied to the one-way valve from the outside to the inside of the container 1, thereby deforming the inner and outer layer 110, 120 in the direction of the inner layer 110, the outer layer 120 is pushed onto the inner layer 110 creating a gas-tight closure.

(29) Optionally, after the headspace 3 is removed the one-way valve may be closed. This may be done to provide an even more fail-safe closure of the container 1 ensuring that no air or contamination can enter the container 1. Such a closed one-way valve seals the container 1 providing tamper evidence to a user.

(30) So, according to the embodiment, a seal is provided that provides tamper evidence. The seal is also formed as one-way valve which let's through air in a direction out of the container 1 without letting through the product. With this one-way venting seal, the container 1 can be squeezed to push out all the air in the headspace which results in a container 1 with a no or at least a reduced headspace.

(31) An embodiment of such a one-way valve which may be sealed is provided below with reference to FIG. 2c. By using layer materials that can be sealed trough for example heat sealing or induction sealing, the one-way valve can be constructed in such a way that it can be closed.

(32) The inner layer 110 and/or the outer layer 120 may be formed by one or more sublayers.

(33) The inner layer 110 comprises a first sub-layer 111 made of TPS (thermoplastic styrene), forming a sealing layer which may be sealed to the top of the neck of the container 1 forming the opening 4 to attach the one-way valve 100 to the container 1 by induction or heat sealing. The neck may have a flat surface on top to which the sealing layer is sealed.

(34) The inner layer 110 further comprises a second sub-layer 112 being a conductive layer, such as an aluminum layer, which heats up when an oscillating electromagnetic field is applied.

(35) The inner layer 110 further comprises a third sub-layer 113 being made of a thermoplastic material like expanded PE (Polyethylene) which is provided as a cushioning layer. This layer makes sure that the first sub-layer 111 fully touches the neck of the container so it is sealed well.

(36) The outer layer 120 may comprise a first sub-layer 121 made of TPS (thermoplastic styrene), forming a sealing layer which may be sealed to the inner layer 110 by induction or heat sealing.

(37) The outer layer 120 may further comprise a second sub-layer 122 forming a protection layer, for instance made of Polyethylene terephthalate. This layer prevents tearing of the seal tear when it is removed.

(38) In between the sub-layers 111, 112, 113 of the inner layer 110 and in between the sub-layers 121, 122 of the outer layer 120, adhesive layers 140 may be provided.

(39) The one-way valve 100 may be closed by induction sealing. By generating an oscillating electromagnetic field, for instance by an induction coil, the second sub-layer 112 heats up, the first sub-layer 121 facing the inner layer 110 melts and attaches to the inner layer 110.

(40) The one-way valve 100 may go through a sealer, such as an induction or heat sealer, in which the second sub-layer 112 being a conductive layer heats up and seals the sealing layer 121 to an adjacent layer.

(41) Of course, the number and order of the sub-layers may be varied. In order to provide a one-way valve 100 which can be closed by induction or heat sealing, the one-way valve 110 at least comprises: a heat-generating sub-layer 112 which generates heat under the influence of an oscillating electromagnetic field, a seal sub-layer 113 which melts by the heat generated by the heat-generating sub-layer 112 provided at the interface between the inner layer 110 and the outer layer 120.

(42) The filter layer may be one of a paper filter, a cellulose filter, a glass microfiber filters (GMF), a membrane filter or a synthetic foil with micro-perforations.

(43) The filter layer comprises relatively small openings which allow gas or air to travel through the filter layer, but which are too small to allow the product to travel through the filter layer. The filter layer allows gas to be removed from the headspace through the valve 100 to reduce the headspace, until the product reaches the filter layer.

(44) In case a paper filter/cellulose filter layer is used, gas or air will no longer be able to travel through the filter layer once the filter layer is wetted by the product. This prevents gas or air from re-entering the container after the pressure difference has been removed. In that case, the valve 100 also functions as a one-way valve 100.

(45) The filter layer may be a Grade 589/3 filter as supplied by Whatman, having a particle retention in liquid of <2 m, a thickness of 160 m and weighs 84 g/m.sup.2.

(46) According to an embodiment, the valve 100 comprises a first sub-layer similar to the first sub-layer 111 described above, made of TPS (thermoplastic styrene). The first sub-layer may now comprise a plurality of holes which allows gas and/or air to pass. This first sub-layer faces the content of the container.

(47) The valve 100 further comprises a second sub-layer provided on top of the first sub-layer, which is a conductive layer, such as an aluminum layer, which heats up when an oscillating electromagnetic field is applied. This second layer is similar to second sub-layer 112 described above, now comprising a plurality of holes which allows gas and/or air to pass, which are aligned with respect to the holes in the first sub-layer.

(48) On top of the second sub-layer the filter layer is provided, which only allows gas and/or air to pass, but doesn't let through the product.

(49) On top of the filter layer a third sub-layer is provided, made of TPS (thermoplastic styrene), forming a sealing layer. This third sub-layer is similar to first sub-layer 121 described above, now comprising a plurality of holes which allows gas and/or air to pass and which are aligned with respect to the holes in the first sub-layer and the second sub-layer.

(50) The valve 100 further comprises a fourth sub-layer forming a protection layer, for instance made of Polyethylene terephthalate. This layer prevents tearing of the seal tear when it is removed and is similar to the second sub-layer 122 described above, but now comprises a plurality of holes, which are all not aligned with respect to the other holes. This allows to permanently close the valve 100 after sealing the third sub-layer to the fourth sub-layer.

(51) According to this embodiment, all sub-layers and the filter layer may be joined together by a seal provided along the circumference of the valve 100, which may be a heat seal or an adhesive seal.

(52) Different ways of applying the pressure difference will be explained in more detail below with reference to FIGS. 3a-3b.

(53) FIG. 3a schematically depicts a top view of a conveyor belt 200 transporting a plurality of containers 1. The containers 1 are filled with the product, comprise a headspace 3 and a suitable valve 100, such as a one-way valve 100. The conveyor belt moves in the direction indicated by arrow A.

(54) Alongside the conveyor belt 200 a pressure applying device may be provided. The pressure applying device may comprise flexible bags 210 which can be inflated, for instance with air or foam. Two airbags 210 may be provided on opposite sides of the conveyor belt 200 in between which the containers 1 are transported.

(55) The airbags 210 are arranged to move at substantially the same speed as the conveyor belt 200 along a predetermined portion of the conveyor belt 200 to reduce friction between the airbags 210 and the containers 1. As shown in FIG. 3a, the airbags 210 may be provided on an outside of an air bag conveyor belt 222, the air bag conveyor belt 222 being rotated by pulleys 221 in a direction indicated by arrow B.

(56) The airbags 210 may further be connected to an air supply to inflate the air bags 210 to a predetermined pressure. In case the bags are to be filled with foam, the bags may be connected to a foam supply. In general, the bags may be connected to a source which can inflate the bags.

(57) The airbags 210 are arranged in such a way that the space in between the airbags on opposite sides of the conveyor belt 200 is such that a pressure is applied to the containers 1 when travelling in between the airbags 210. The closest distance D between the two airbags is smaller than the corresponding size C of the containers 1. This way, the containers 1 are squeezed and the headspace is reduced or even removed.

(58) Other pressure applying devices may be conceived as well, such as a pressure applying device in which members are pushed against the container by a spring. The members may move together with the containers. The members may also be static and comprise roller elements to prevent damage to the containers. The containers may also be stopped temporarily to apply pressure without the risk of damaging the containers.

(59) According to an embodiment labels are attached to the container before the headspace is removed. By applying pressure by using bags, the risk of damaging labels attached to the container 1 is reduced.

(60) After the headspace is removed, the one-way valve 100 may be permanently sealed, for instance by heat or induction sealing.

(61) By using bags, such as airbags 210, pressure can be exerted in a controlled way without the risk of damaging the containers 1.

(62) The amount of gas flowing through the one-way valve 100 out of the container 1 in relation to the applied pressure or force and the required pressure force to let through product depends on the elasticity moduli of the inner and outer layer 110, 120 and the differences between them, the size of the perforations 118, 128, the relative position of the perforations 118, 128 (distance between them), the size of the non-joint surface of the inner and outer layer 110, 120.

(63) By optimizing these parameters, a one-way valve 100 can be created that for example let's through large amounts of air in high speed but prevents viscous liquids like ketchup or mayonnaise from going through.

(64) According to an embodiment a pressure monitor may be provided monitors the pressure inside the airbags 210 to prevent the pressure exceeding a predetermined value. The predetermined value may be chosen such that it is ensured that no product can be squeezed out of the container 1.

(65) Other embodiments to apply the pressure difference over the one-way valve 100 may be conceived. A further embodiment is shown in FIG. 3b, wherein the air bags 210 are replaced by two guiding elements 240 positioned on both sides of the conveyor belt 200. The guiding elements 240 may be hingeable about respective hinge axes 241. The guiding elements 240 may be actuated to apply a pressure to the containers 1. Alternatively, the guiding elements 240 may have a rest position in which their mutual closest distance is smaller than the corresponding size C of the containers 1. Two guiding elements 240 may be spring loaded such that a pressure is applied to the containers 1 when passing in between the guiding elements and pushing the guiding elements 240 further apart.

(66) Advantages

(67) A liquid tight one-way valve is provided that allows gas through in one-way but does not allow liquid or viscous materials to travel through the one-way valve.

(68) The one-way valve may also be used to seal the container. The one-way valve is used once after the container is filled. The one-way valve is provided in the opening of the container 1 which will be used by users to obtain the product, so no additional opening is needed in the container.

(69) It will also be obvious after the above description and drawings are included to illustrate some embodiments of the invention, and not to limit the scope of protection. Starting from this disclosure, many more embodiments will be evident to a skilled person which are within the scope of protection and the essence of this invention and which are obvious combinations of prior art techniques and the disclosure of this patent.