Systems and methods for filling a collapsible container

A system and method for filling a collapsible container are provided. Such a collapsible container may be made of a relatively rigid portion and a collapsible portion, with the collapsible portion having a collapsed condition and an expanded condition. An obstruction maintains the collapsible portion in the collapsed condition while the container is filled with contents. The obstruction may remain in place until the container is capped and sealed with the contents stored inside the container.

TECHNICAL FIELD

The invention is generally applicable to semi-collapsible containers. More specifically, the invention is applicable to systems and methods for maintaining a semi-collapsible container in a collapsed or partially collapsed condition during a filling operation.

BACKGROUND

Many consumer and industrial products are composed of active ingredients or concentrates dissolved in solvents, such as water. To reduce the weight and volume of such a product, the product may be offered in concentrate form, allowing the end user to add a solvent to the concentrate prior to use. Either the concentrate or the solvent may be in solid, liquid, or gaseous form, or a combination of these three. To provide the end user with a container gaseous form, or a combination of these three. To provide the end user with a container adaptable to hold the subsequently diluted product (including both the concentrate and the solvent), the concentrate may be provided in a collapsible or semi-collapsible container. Such a container minimizes packaging space in an initial collapsed state, in which only the concentrate is contained, and then expands or distends to contain the diluted product upon the addition of the solvent.

In one such container, an interior or hollow portion is defined by a relatively rigid portion including a base, sides, and a dispenser, and a collapsible portion joined with the rigid portion and movable with respect to the rigid portion between a collapsed state and a distended state. To make the collapsible portion of the container more pliable, the collapsible portion may be provided with a thinner wall thickness, or be made from a softer or more flexible material, than the more rigid portion. In doing so, the collapsible portion may be adapted to be pliable enough to automatically expand to the distended state when solvent is added to the concentrate in the container, as the filling operation provides sufficient outward force against the collapsible portion to expand the collapsible portion to the distended state.

FIGS. 1 and 2show a representative container100as described in co-pending U.S. application Ser. No. 11/217,088, entitled “Semi-Collapsible Container,” the entire disclosure of which is incorporated herein by reference.FIG. 1illustrates the container100in a collapsed state, in which collapsible portion130is concave or inverted towards the interior of the container100.FIG. 2illustrates the container100in a distended state, in which the collapsible portion130is convex or expanded from the interior of the container100. The collapsible portion130may be joined to a more rigid support portion120by a hinge portion250having one or more bends to allow the collapsible portion130to flex between collapsed and expanded states. In other embodiments the collapsible portion130may be flexible enough to not require a hinge portion, or may be constructed of an elastic material that stretches to expand when the container is filled.

Due to the flexibility of the collapsible portion130or hinge portion250of such a container100, which allows the container to expand when filled with a solvent or other fluid, the potential exists for premature expansion or other deformation of the collapsible portion130. This may occur, for example, when a concentrate or other substance is being deposited into the collapsed container prior to shipment to distribution or retail outlets for being sold to end users. Depositing the concentrate into the container100through the dispenser140, many times done at a high rate of speed, may result in an outward force applied to the collapsible portion130, due to, for example, an increase in the internal pressure within the container100or the impact of the concentrate being deposited. This may undesirably cause the collapsible portion130to prematurely expand or otherwise deform in an unintended fashion. This expansion or deformation may result in an increased volume and/or irregular appearance for the packaged product, potentially detracting from the space-saving and aesthetic features of the collapsible container. In addition, maintaining each container in its collapsed state helps to ensure each bottle in the assembly line has substantially the same configuration and shape. Maintaining such consistency from container to container makes the containers more easy to handle in a mass distribution context and also helps to improve their presentation on retail shelves.

DETAILED DESCRIPTION

The present invention will now be described with occasional reference to specific embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will fully convey the scope of the invention to those skilled in the art.

The invention is directed, in various embodiments, to devices and methods for filling, to varying degrees, a collapsible container. As used herein, “filling” includes depositing any amount of a solid, liquid, or gaseous substance into a container. “Collapsible containers” include containers of varying degrees of collapsibility, and the terms “collapsible” and “semi-collapsible” are used to refer to any space within a container that is effectively reducible in its size or internal volume by the application of mechanical force to distort its shape, such as by inverting a portion of the container.

According to one aspect of the invention, the systems and methods for filling the collapsible container include the use of an obstruction, adapted to engage a collapsible portion of the container in a collapsed or partially collapsed state, to prevent undesired expansion or other outward movement of the collapsible portion. Such an obstruction may be engaged with the collapsible portion during filling of the container, such as, for example, when a concentrate is being deposited into the collapsed container for future dilution. Engagement of the obstruction with the collapsible portion may involve bringing the obstruction and collapsible portion into physical contact. Or, such engagement may involve merely placing the obstruction close enough to the collapsible portion such that in the event the collapsible portion begins to expand (whether or not it actually does so), such expansion will be prevented by the obstruction, and the collapsible portion will remain in its collapsed state. Once the container is capped or sealed, such as after a filling operation is complete, an air-tight seal between the container and the environment may be sufficient to prevent expansion or deformation of the collapsible portion, and the obstruction may be removed from engagement with the collapsible portion of the container.

In some instances it may be desirable to permit some expansion or outward movement of the collapsible portion during or after a filling operation. For example, such an expansion may increase the available volume within the partially collapsed container for holding concentrate. This permits using the same container design to hold varying amounts of concentrate, to allow for different solvent-to-concentrate ratios in the final solution. As a representative example, a gallon size container (in the expanded state) may be able to hold enough concentrate in the collapsed state to form a 3:1 solvent-to-concentrate solution when expanded to hold a gallon of the solution. Using the same container to form a 2:1 solvent-to-concentrate solution requires storing more concentrate in the collapsed condition, which may require more available volume.

In some applications, engaging an obstruction with a collapsible portion of a container only during a filling operation may be sufficient to prevent unwanted premature deformation of the collapsible portion. In other applications, it may be desirable to engage an obstruction with the collapsible portion from a filling operation until the container is capped or sealed. In still other applications, it may be desirable to engage an obstruction with the collapsible portion through the entire filling, capping and packaging operations to avoid any undesirable deformation resulting from any impact or forces against the collapsible portion.

It may be desirable to incorporate a device or method for maintaining the collapsed condition of a collapsed container into automated or high production packaging equipment. Such equipment may include, for example, conventional in-line and rotary conveyors, in which containers are moved through separate forming, filling, capping, and packaging stations, often in a matter of seconds. Where the collapsed portion of a container forms a concave or bowl-shaped structure, as shown inFIG. 1, engagement of a rigid obstruction with the collapsed portion may involve insertion and subsequent removal of the obstruction from the collapsed portion. As such, a flat plate or wall adjoining the conveyor, which cannot be inserted into the concave collapsed portion, may be inadequate for maintaining the collapsed condition. Also, in packaging systems in which containers are moved between stations, as is the case with many packaging systems, a stationary press, ram or other extendable obstruction may undesirably impede this movement. Such obstructions may also be bulky and/or mechanically complex.

Therefore, according to an aspect of the present invention, a packaging system may be adapted to provide an obstruction for maintaining the collapsed condition of a collapsible container, in which the obstruction is able to move with the container as the container is conveyed in a filling station, and/or between a filling station and a capping or sealing station.

In one such embodiment, the obstruction is affixed to a conveyor on which the container is transported. Such a conveyor may include, shown for example inFIG. 3A, a base support portion such as a tray or car10, with upstanding walls12and an open top. In another embodiment, shown inFIG. 3B, the conveyor may include one or more portions of a continuous conveyor belt. Like the conveyor10ofFIG. 3A, the conveyor20ofFIG. 3Bmay include one or more support walls, ribs, or other extensions22, to prevent a container placed on the conveyor from sliding or tipping over. Once one or more containers have been loaded onto the conveyor, conventional automated equipment may then be used to move the conveyor to and from different stations.

To enable engagement and subsequent disengagement between the container and the obstruction, the container may be moved relative to the obstruction. As one example, shown inFIG. 4A, the base portion41of a conveyor40may tilt in one direction to shift a collapsible container100against a fixed obstruction45. The conveyor40may tilt in the opposite direction to shift the container100away from the obstruction45to be supported by side wall42, as shown inFIG. 4B. As another example, shown inFIG. 5A, a conveyor50may include a first conveyor belt51driven by a pulley or gear53. The conveyor belt51may be provided with a fixed obstruction55and side wall52for supporting a container100. To disengage the container100from the obstruction55, the conveyor belt51may transport the container to an edge defined by the gear53. As the side wall52and obstruction55are driven around the gear53(FIG. 5B), the container100is dropped or transferred to a second conveyor portion51′, which may be a conveyor belt or some other conveying mechanism. The second conveyor portion may then move the container100to a packaging location or to some other station (not shown). As yet another example, shown inFIG. 6, a conveyor60may utilize a separate obstruction65, unattached to the base portion61of the conveyor60. The obstruction65may be wedged between the container100and a second side wall63, such that the container100is supported by the obstruction65and first side wall62.

In other embodiments, the obstruction may be selectively moved in and out of engagement with the collapsible portion. For example, the obstruction may be pivoted, flexed, expanded, or otherwise shifted into and out of engagement with the collapsible portion.

In one such embodiment, an expandable or inflatable obstruction may be provided, wherein the obstruction engages the collapsed portion of a container in an expanded or inflated state, and the obstruction disengages the collapsed portion in an unexpanded or deflated state.FIGS. 7A-Cillustrate an exemplary embodiment of such an obstruction adapted for selective engagement with a collapsible portion of a container. Referring toFIG. 7A, a frame310, against which a collapsible container100(not shown) may be positioned, extends from a base portion305of conveyor300. The container100(not shown) may be held in place between the frame310and one or more side walls308. Attached to the frame310is a balloon-type inflatable member320, which surrounds a port330in the base portion305. As the container100reaches a filling station, a solenoid or other valve schematically represented by reference character “V” inFIG. 7Aattached to the port330may be opened, allowing compressed gas to fill and expand the inflatable member320and bringing the inflatable member into engagement with the collapsed portion of the container, as shown inFIG. 7B. Concentrate (or any other substance) may then be deposited into the container100through a spout or dispenser140in the container100. The engagement of the inflatable member320with the collapsible portion130of the container100during filling prevents the collapsible portion130from deforming in an undesired manner under forces resulting from the filling operation.

At the same time, varying inflation of the inflatable member320from container to container allows the user to control permitted deformation of the collapsed portion. As discussed above, for example, this may facilitate using the same container design to hold varying amounts of concentrate to control ratios of solvent-to-concentrate in the final solution.

As the filled container is moved from the filling station to a capping station, the inflatable member320may remain expanded and in engagement with the collapsed portion130until the container100is capped, maintaining the container in a collapsed state. When engagement between the inflatable member320and the collapsible portion130is no longer desired, which may be after capping the container or at any other stage during the filling, capping and packaging operations, the port330may be opened to atmosphere to evacuate compressed gas from the inflatable member320, allowing the inflatable member to deflate and disengage from the collapsed portion130of the container100. This disengagement allows the container to be more easily packaged, for example, by allowing the container to freely slide down an inclined conveyor or to drop into a box or crate, after filling and capping are complete.

As shown inFIG. 7C, two containers100,100′ may be positioned on either side of the frame310, and the inflatable member320may be adapted to distend into engagement with opposed collapsed portions of both containers. This may provide for more efficient use of the packaging arrangement.

Various methods may be used to inflate and deflate the inflatable member320through the port330(FIG. 7A). For example, a source of compressed gas such as air may be disposed near the filling station. A fluidic connection can then be established between the source of compressed gas and the port330, such as with a tube, as the conveyor300approaches the filling station. With the valve attached to the port330being open, compressed gas may be forced through the port330and into the inflatable member320. The valve may then be closed by interference between the valve and a closure member disposed near the conveyor's path upstream of the filling station. Similarly, an opening member may be placed near the conveyor's path downstream of the filling station, such that interference between the opening member and the valve attached to the port330opens the valve. One of ordinary skill will readily appreciate various other methods by which the inflatable member320may be inflated and deflated in conjunction with high speed automated packaging equipment, without need for human intervention.

In another embodiment, a flexing obstruction may be provided, wherein the obstruction engages the collapsed portion of a container by flexing into engagement with the collapsed portion, and the obstruction disengages the collapsed portion by straightening or flexing away from the collapsed surface.FIGS. 8A-Dillustrate an exemplary embodiment of such an obstruction adapted for selective engagement with a collapsible portion of a container. Referring toFIG. 8A, telescoping frame members410,415, against which a collapsible container may be positioned, extend from a base portion405of a conveyor400. The container100may be held in place between the frame members410,415and one or more side walls408. Attached to the frame members410,415are one or more flexible members or slats420, which are in an essentially straight or un-flexed condition when frame members410,415are extended with respect to each other, as shown inFIG. 8A. As the container100reaches a filling station, the upper frame member410may be contracted into or onto the lower frame member415(FIGS. 8B and 8C), causing the slats420to bow or flex into engagement with the collapsed portion130of the container100. Concentrate (or any other substance) may then be deposited into the container100through a spout or dispenser140in the container100. The engagement of the flexed slats420with the collapsible portion130of the container100during filling prevents the collapsible portion130from deforming under forces in an undesired manner resulting from the filling operation. It may be desirable to have some relatively small amount of flexure of the slats420in the extended position ofFIG. 8A, in the direction of the container100, to insure they flex toward the container in the contracted positions ofFIGS. 8B and 8C.

Flexure of the slats420may be varied to allow the user to control permitted deformation of the collapsed portion from container to container. As discussed above, for example, this may facilitate using the same container design to hold varying amounts of concentrate to control solvent-to-concentrate ratios in the final solution.

As the filled container100is moved from the filling station to a capping station, the frame members410,415may remain in a contracted state to maintain flexure of the slats420against the collapsed portion130of the container100. When engagement between the slats420and the collapsible portion130is no longer desired, which may be upon capping the container100or at any other stage during the filling, capping and packaging operations, the frame members410,415may be extended, allowing slats420to straighten and disengage from the collapsed portion130of the container100.

Many different mechanisms or arrangement may be used to contract the frame members, such as actuated pistons or gears. In one embodiment, as shown inFIG. 8B, an inclined upper surface430, such as a track or plate, is positioned to engage upper frame member410to push the upper frame member downward when the container reaches the filling station. This upper surface430may extend to the capping station to maintain the frame members410,415in the contracted state until the container is sealed. Once the upper frame member410disengages from the upper surface430, springs (not shown) disposed between the frame members may return the frame members to the extended condition, straightening the slats420and disengaging them from the container100.

As shown inFIG. 8D, two containers100,100′ may be positioned on either side of the frame members410,415. The slats420may be adapted to flex in opposite directions, with some of the slats420aflexing toward a first container100and the remaining slats420bflexing toward a second container100′. This arrangement provides engagement with opposed collapsed portions of both containers, which may provide for more efficient use of the packaging arrangement.

In yet another embodiment, a pivoting obstruction may be provided, wherein the obstruction engages the collapsed portion of a container by pivoting into engagement with the collapsed portion, and the obstruction disengages the collapsed portion by straightening or flexing away from the collapsed surface.FIGS. 9A-9Cillustrate an exemplary embodiment of such an obstruction adapted for selective engagement with a collapsible portion of a container. A rigid obstruction, such as, for example, the ball shaped obstruction520ofFIGS. 9A-B, may be pivotally attached to a portion505of a conveyor500on which a container100is supported. The obstruction520may be either directly connected to the conveyor500, or connected by a linking member510, as shown inFIGS. 9A-B. As the container100reaches a filling station, the obstruction520may be pivoted into engagement with the collapsed portion130of the container100. As the filled container is moved from the filling station to a capping station, the obstruction520may remain pivoted against the container100to hold the filled container in the collapsed condition. Once the container is capped, the obstruction may be pivoted away from the container100to disengage from the collapsed portion.

Many different mechanisms or arrangements may be used to pivot the obstruction into and out of engagement with the container, such as motorized mechanisms or a contoured track on the conveyor which guides the linking member. In one embodiment, shown inFIGS. 9A-9C, an angled side surface530, such as a plate or wall, is positioned a first distance d1from the conveyor500to engage the obstruction520to push the obstruction toward the container100when the container reaches the filling station. This side surface530may extend to the capping station to maintain engagement between the obstruction520and the container100until the container is sealed. Once the side surface530is disposed at a greater distance d2from the conveyor500, the obstruction520may pivot away from the container100through any number of mechanisms, such as a spring-loaded linking member.

While several embodiments of the invention has been illustrated and described in considerable detail, the present invention is not to be considered limited to the precise constructions disclosed. Various adaptations, modifications and uses of the invention may occur to those skilled in the arts to which the invention relates. It is the intention to cover all such adaptations, modifications and uses falling within the scope or spirit of the described invention.

For example, it is not necessary that the obstruction be attached or otherwise mounted to a conveyor. Thus, another embodiment as shown for example inFIG. 10includes a round-shaped obstruction600which is held between two containers100,100′. When the two containers are tied or otherwise held together with the obstruction600in between, the obstruction will extend into the concavities defined by the collapsible portions130of the respective containers. These two containers100,100can then be packaged and shipped together as a unit, if desired. The obstruction600will thus maintain both containers in their collapsed condition until they are untied or otherwise pulled apart from each other, at which time the obstruction600may be re-used or discarded.

In yet another alternative embodiment, the container100ofFIGS. 1 and 2may be modified so that a convex bulbous portion extends out of the side of the container opposite from the collapsible portion. This is shown, for example, inFIG. 11. The container101ofFIG. 11is identical to the container100ofFIG. 1except that it has a convex portion102on the face of the rigid support portion120opposite the collapsible portion130. Two containers101,101′ may then be placed side-by-side, with the convex portion102of one container101fitting into the concave collapsible portion130of the adjacent container101′ (not shown). With this and similar embodiments, of course, any number of containers101,101′,101″, . . . may be held side-by-side to be filled, capped and perhaps even shipped as one unit. A separate obstruction similar to the obstruction600may be used to maintain the collapsed condition of the container on the end of such an assembly, if desired.