Patent Description:
In liquid food packaging, containers are filled using a filling device. Filling devices normally include a filling nozzle from which the liquid food is dispensed into the container and a filling valve, which controls the flow of the liquid food through the filling nozzle, normally dosing the liquid food according to the size of the container being filled. Common containers that are used for packaging liquid food products include cartons that are made from plastics-coated paperboard. Liquid food products include milk and fruit juice and also more viscous products such as soup and bases for sauces and so on. Different filling devices are used depending upon the type of liquid food product being filled and the rate at which containers are to be filled. A known problem with filling devices that are being used to fill more viscous products is that some amount of product can tend to remain hanging from the filler nozzle and drip down uncontrolled on to the package's outer and inner surfaces, which can lead to problems of food hygiene and container sealing.

United States of America patent application publication <CIT> discloses a device for controlling flow rate. The device for controlling the flow rate of flowable products, in particular of foodstuffs, comprises a valve rod, a sealing element with at least one sealing lip connected to the valve rod, wherein the sealing element comprises a base plane and a contact plane, wherein the sealing lip is arranged on the contact plane and an outlet element with a stop plane and with at least one outlet channel, wherein the stop plane has at least one sealing region assigned to the sealing lip and at least one outlet region connected to the outlet channel. The contact plane is spaced apart from the base plane, so that an offset is created between the sealing lip and the base plane. <CIT> also discloses a filling device according to the preamble of claim <NUM>.

It is therefore an object of the invention to improve upon the known art.

According to a first aspect of the present invention, there is provided a filling device according to claim <NUM>.

According to a second aspect of the present invention, there is provided a method of operating a filling device according to claim <NUM>.

Owing to the invention, it is possible to provide an improved filling device that can be used to fill a partially formed container with a viscous flowable product that will not have the risk of the product dripping uncontrolled from the filler nozzle after dosing from the filling device. The main capillary (or capillaries) of the filler nozzle can have additional pressure provided along its length, which causes more of the product to be expelled through this capillary (or capillaries) compared to other capillaries, which can then be reversed to provide suction along the main capillary (or capillaries), which draws any excess product on the end of the filler nozzle back inside the filler nozzle, thereby preventing any product from dripping uncontrolled from the filling device.

By having not all of the capillaries closed by the sealing component, two significant advantages are delivered. Firstly, the sealing plate, which closes the capillaries not closed by the sealing component, is less likely to suffer the wear and tear that would result if the component is continually sealing all of the capillaries, given the pressure exerted to create a seal of all of the capillaries. Secondly, since there are two different components closing the capillaries, it is possible to run the filling device with only the main capillary open, which has a tendency to draw any excess product on the end of the other capillaries towards that main capillary, making it easier to suck back the product into the filler nozzle, when suction is provided through the main capillary.

Preferably, the main capillary is located centrally within the filler nozzle and the sealing plate, when in contact with the filler nozzle closes a plurality of the capillaries but leaves only one main capillary open. In the preferred embodiment of the filling device there is provide a single main capillary (the one that is left open by the sealing plate) which is located centrally within the filler nozzle. This arrangement provides the simplest way of achieving the overall desired aim of removing the likelihood that a viscous flowable product will have an uncontrolled drip from the filler nozzle, since a single central main capillary is provided that can provide the necessary suck back to draw back any excess product that is left on the end of the filler nozzle.

Advantageously, each capillary closed by the sealing plate, at the end of the filler nozzle adjacent to the sealing plate, includes a tube extending from the filler nozzle, with the main capillary (or capillaries), at the end of the filler nozzle adjacent to the sealing plate, terminating at the filler nozzle and the sealing plate comprising, on its side adjacent to the filler nozzle, a plurality of caps arrange to close each capillary closed by the sealing plate and one or more elongate tubes arranged to engage with the main capillary (or capillaries). In this way, the sealing plate can provide a good seal onto those capillaries that are to be closed by the sealing plate while leaving the main capillary open, with an elongate tube in the sealing plate providing a connection from the main capillary to the other side of the sealing plate, where the main capillary can be closed by the sealing component.

The sealing component of the filler valve comprises a flexible sealing component, for example formed as a silicone rubber cap. The sealing component can be constructed from any suitable material that has the necessary functional properties and is safe for use in a liquid food environment. Any flexible plastics material can be used that is sufficiently robust to be compressible. The flexible sealing component is moveable independently of the sealing plate of the filler valve and serves the purpose of closing the main capillary, which is not closed by the sealing plate. The flexible sealing component can be compressed to create pressure along the main capillary and releasing the compression causes suction to be generated along the main capillary.

<FIG> shows a vertical cross-section through a filling device <NUM>. The filling device <NUM> comprises a filler nozzle <NUM> comprising a plurality of capillaries <NUM>, and a filler valve <NUM> moveable relative to the filler nozzle <NUM>. The filler valve <NUM> is in two parts and comprises a sealing plate <NUM> which, when in contact with the filler nozzle <NUM>, closes a plurality of the capillaries <NUM> but leaves at least one main capillary 14a open, and a sealing component <NUM> (connected to a shaft <NUM>) moveable relative to the sealing plate <NUM>, which, when in contact with the sealing plate <NUM>, closes the at least one main capillary 14a, and is operable to create pressure along the main capillary 14a.

The valve <NUM> operates inside a housing <NUM>, which contains flowable product <NUM>, which is gravity fed through the filling device <NUM> into a partially formed container <NUM> (the top of which is shown in the Figure). The flowable product <NUM> is a liquid food product with a relatively high viscosity, such as a soup which contains some solid food matter. The operation of the valve <NUM> doses the product <NUM> into the partially formed container <NUM>, which, once full, is moved on to a different station to be top-sealed. The operation of the valve <NUM> will be described in more detail below, as the function of the valve <NUM> is to ensure that the product <NUM> is not left dripping from the filler nozzle <NUM>, in addition to its dosing function.

The plurality of capillaries <NUM> are arranged longitudinally within the filler nozzle <NUM>. The main capillary 14a is located centrally within the filler nozzle <NUM>. The capillaries <NUM> are angled so that at the exit end of the filler nozzle <NUM> (which is the end opposite to that closed by the sealing plate <NUM>), the capillaries <NUM> create a single beam of product when the product exits the filler nozzle <NUM>. The sealing plate <NUM>, when in contact with the filler nozzle <NUM> closes a plurality of the capillaries <NUM> but leaves only one main capillary 14a open. In this preferred embodiment of the filling device <NUM>, there is a single main capillary 14a, centrally located in the filler nozzle <NUM>, which has a more complex function that the other capillaries <NUM> that are surrounding the main capillary 14a. However, the nozzle <NUM> can be constructed with multiple main capillaries 14a that operate in the manner described below.

<FIG> shows a more detailed cross-section of the filler valve <NUM>, which is moveable relative to the filler nozzle <NUM>. The valve <NUM> comprises the solid sealing plate <NUM> which, when in contact with the filler nozzle <NUM>, closes a plurality of the capillaries <NUM> but leaves the main capillary 14a open, and a sealing component <NUM> which is moveable relative to the sealing plate <NUM>, and, when in contact with the sealing plate <NUM>, closes the main capillary 14a, and is operable to create pressure along the main capillary 14a. The sealing component <NUM> is a flexible silicone rubber cap, which can be compressed by movement of the shaft <NUM> which is connected to the flexible sealing component <NUM>.

The sealing plate <NUM> comprises, on its side that is adjacent to the filler nozzle <NUM>, a plurality of caps <NUM> arrange to close each capillary <NUM> closed by the sealing plate <NUM> and an elongate tube <NUM> arranged to close the main capillary 14a. The elongate tube <NUM> is arranged to engage with the main capillary 14a and passes through the sealing plate <NUM> and terminates adjacent to the flexible sealing component <NUM>. When the flexible sealing component <NUM> is open, then the product <NUM> can flow through the elongate tube <NUM> of the sealing plate <NUM> and into the main capillary 14a of the filler nozzle <NUM>.

The shaft <NUM> provides the means for compressing the flexible sealing component <NUM>, since as the shaft <NUM> is moved up and down, the sealing component <NUM> also moves up and down. Once the sealing component <NUM> is in contact with the sealing plate <NUM>, as shown in <FIG>, then any additional downwards pressure from the shaft <NUM> will cause the flexible sealing component <NUM> to be compressed, which creates pressure in the elongate tube <NUM> and therefore also in the main capillary 14a, which forces out product <NUM> that is present in the lower part of the main capillary 14a. When the shaft <NUM> is raised, decompressing the sealing component <NUM>, then suck back is created in the main capillary 14a drawing any excess product <NUM> remaining on the exterior of the filler nozzle <NUM> back into the main capillary 14a.

<FIG> shows the starting closed position of the filler valve <NUM> relative to the filler nozzle <NUM> (with the housing <NUM> removed for clarity purposes). In this position no product <NUM> can exit from the filler nozzle <NUM>, since the sealing plate <NUM> is closing all of the capillaries <NUM> apart from the central main capillary 14a and that capillary 14a is closed by the flexible sealing component <NUM>, which is in contact with the sealing plate <NUM>. The shaft <NUM> controls the movement of the flexible sealing component <NUM> and additional components (not shown for ease of understanding) control the movement of the sealing plate <NUM>, which moves independently of the flexible sealing component <NUM> of the filler valve <NUM>.

Additional features of the filler nozzle <NUM> are shown in this Figure. Each capillary <NUM> that is closed by the sealing plate <NUM>, at the end of the filler nozzle <NUM> adjacent to the sealing plate <NUM>, includes a tube <NUM> extending from the filler nozzle <NUM>. The main capillary 14a however, at the end of the filler nozzle <NUM> adjacent to the sealing plate <NUM>, terminates at the filler nozzle <NUM>. The tubes <NUM> match the caps <NUM> of the sealing plate <NUM>, with the sealing plate <NUM> closing the capillaries <NUM> by the action of the caps <NUM> covering the ends of the tubes <NUM>, as can be seen in the Figure.

<FIG> shows the filling device <NUM> in its first position of operation with the flexible sealing component <NUM> moved relative to the sealing plate <NUM> to open the main capillary 14a. The caps <NUM> of the sealing plate <NUM> remain in contact with the filler nozzle tubes <NUM> and still close the remaining capillaries <NUM>. Product <NUM> can flow through the main capillary 14a, as indicated by the arrows in the Figure. All of the other capillaries <NUM> remain closed and there is no flow of product <NUM> through these capillaries <NUM>. This is the start of the dosing procedure for outputting product <NUM> from the filling device <NUM> into the partially formed container <NUM>.

<FIG> shows the filling device <NUM> in its second position of operation with the sealing plate <NUM> moved away from the filler nozzle <NUM> and the separation between the sealing plate <NUM> and the flexible sealing component <NUM> maintained. Product <NUM> can now flow through all of the capillaries <NUM> including the central capillary 14a. The filler valve <NUM> is fully open and the product <NUM> enters the top of the capillaries <NUM> in the filler nozzle <NUM> and passes downwards through the capillaries <NUM> and into the open top of the partially formed container <NUM>. The open tubes <NUM> at the top of the capillaries <NUM> can be clearly seen in this Figure, the central main capillary 14a is not provided with a tube <NUM>.

<FIG> shows the next stage of the operation of the filling device <NUM>, in which the caps <NUM> of the sealing plate <NUM> have been moved into contact with the tubes <NUM> of the filler nozzle <NUM>, closing the capillaries <NUM>. In physical configuration, the position of the different components within the filling device <NUM> is identical to that shown in <FIG>, although at the lower end of the now closed capillaries <NUM>, product <NUM> can be seen forming as a drip at the end of the capillaries <NUM>. The viscous nature of the product <NUM> and the weight of any particles within the product <NUM> tends to lead to such a drip <NUM> forming. Flow through the central capillary 14a continues as before and tends to drag the product <NUM> from the closed capillaries <NUM> towards the centre capillary 14a.

<FIG> shows the next stage in the operation of the filling device <NUM>. The shaft <NUM> is arranged to move the flexible sealing component <NUM> into contact with the sealing plate <NUM> and apply pressure onto the flexible sealing component <NUM>, which causes the flexible sealing component <NUM> to be compressed against the sealing plate <NUM> in order to create pressure through the elongate tube <NUM> and along the main capillary 14a. As can be seen in the Figure, more of the contents <NUM> will flow through and out of the central main capillary 14a, since the compressed sealing component <NUM> reduces the volume between the sealing component <NUM> and the sealing plate <NUM>. This Figure shows the flexible sealing component <NUM> in its most compressed state, with the shaft <NUM> moved as far towards the sealing plate <NUM> as possible.

<FIG> shows the final stage of the operation of the filling device <NUM>. The shaft <NUM> is moved away from the sealing plate <NUM> and this reverses the compression of the flexible sealing component <NUM>, which creates suction along the main capillary 14a. This suction action draws into the capillary 14a any excess product <NUM> that is present on the exterior of the filler nozzle <NUM> and leaves the lower surface of the filler nozzle <NUM> clear of any product <NUM> that might drip uncontrollably from the filler nozzle <NUM>. The final position of the components of the filling device <NUM> is identical to the starting position shown in <FIG>, and the set of <FIG> show one complete cycle of the operation of the filling device <NUM>.

According to invention the filling device <NUM> uses a sealing component <NUM> that is flexible and is operable to create the necessary pressure along the central capillary 14a by being compressed, as described above. The sealing component <NUM> has two primary functions, firstly that the sealing component <NUM> can close the main capillary 14a and that the sealing component <NUM> is operable to create the pressure along the main capillary 14a. The operation of the sealing component <NUM> can also be reversed to create the suction along the length of the main capillary 14a.

<FIG> shows a second embodiment of the filling device <NUM>. The Figure shows a vertical cross-section through the filling device <NUM>. The filling device <NUM> comprises a filler nozzle <NUM> comprising a plurality of capillaries <NUM>, and a filler valve <NUM> moveable relative to the filler nozzle <NUM>. The filler valve <NUM> is in two parts and comprises a sealing plate <NUM> which, when in contact with the filler nozzle <NUM>, closes a plurality of the capillaries <NUM> but leaves at least one main capillary 14a open, and a sealing component <NUM> (connected to a shaft <NUM>) moveable relative to the sealing plate <NUM>, which closes the at least one main capillary 14a, and is operable to create pressure along the main capillary 14a.

The embodiment of the <FIG> differs from the first embodiment of <FIG> in that the design of the two-part filler valve <NUM> is different. The sealing plate <NUM> (which can be formed in one piece or multiple parts) still closes a plurality of the capillaries <NUM> but leaves at least one main capillary 14a open and the sealing component <NUM> still closes the at least one main capillary 14a, and is operable to create pressure along the main capillary 14a. However, the sealing component <NUM> no longer in contact with the sealing plate <NUM> when the sealing component <NUM> closes the at least one main capillary 14a, the sealing component <NUM> is in direct contact with the filler nozzle <NUM>.

The operation of the second embodiment of <FIG> is the same as that of the first embodiment, with the cycle of opening and closing of the two parts of the filler valve <NUM> working in the same way, with both parts being open first to allow product <NUM> to flow into the partially formed container <NUM>. The sealing plate <NUM> then closes all of the capillaries <NUM> apart from the main capillary 14a. This is followed by the closing of the main capillary 14a by the sealing component <NUM> which then creates pressure down the main capillary 14a before reversing and creating suction along the main capillary 14a.

<FIG> show a filler valve <NUM> of a yet further embodiment of the filling device <NUM>. In the previous embodiments, two separate drives are required, one each for the sealing plate <NUM> and the sealing component <NUM>, which have to be raised and lowered by separate drives. However, in the embodiment of <FIG>, only a single drive is required which operates through the shaft <NUM>. The filler valve <NUM> has at the lower end of the shaft <NUM> a flat plate <NUM> which has three connecting pins <NUM> passing through holes in the flat plate <NUM>. The pins <NUM> connect at their lower end to the sealing plate <NUM>. One or more springs <NUM> (or any other resilient and elastic component) are provided which connect at one end to the flat plate <NUM> and at the other end to the sealing plate <NUM>. The sealing component <NUM> is also connected to the underside of the flat plate <NUM>. The view of the filler valve <NUM> shown in <FIG> is of the filler valve <NUM> in its open position with product <NUM> being able to flow through the capillaries <NUM>. In the raised position shown in <FIG>, as the shaft <NUM> is raised, the flat plate <NUM> rises to engage the top of the pins <NUM> which raises the sealing plate <NUM>.

<FIG> shows the filler valve <NUM> after the filler valve <NUM> has been lowered (by the shaft <NUM>) so that the sealing plate <NUM>, which is now in contact with the filler nozzle <NUM>, closes all of the capillaries <NUM> apart from the main capillary. The sealing component <NUM> is still in its open position, so that product <NUM> can flow through the main capillary 14a. The sealing plate <NUM> is pushed downwards with the force acting from the shaft <NUM> and through the spring(s) <NUM> to the sealing plate <NUM>.

<FIG> shows the positions of the components of the filler valve <NUM> after all of the capillaries <NUM> in the filler nozzle <NUM> have been closed. The shaft <NUM> is lowered and this causes the flat plate <NUM> to move downwards which causes pressure through the springs <NUM> to move the sealing plate <NUM> downwards to engage the top of the filler nozzle <NUM>. The sealing component <NUM> has now moved down and into contact with the sealing plate <NUM> which closes the main capillary 14a in the centre of the filler nozzle <NUM>. The relative movement between the various parts has caused the flat plate <NUM> to no longer be engaged with the pins <NUM>. At this point in the operational cycle of the filler valve <NUM>, the only pressure on the sealing plate <NUM> is through the springs <NUM>.

<FIG> shows the filler valve <NUM> in the point in its operation when the sealing component <NUM> has been compressed and is providing pressure through the main capillary 14a. The shaft <NUM> has been lowered to its furthest possible extent, compressing the sealing component <NUM> against the sealing plate <NUM>. The flat plate <NUM> is now at its lowest possible point relative to the pins <NUM>. After the pressure has been generated along the main capillary 14a then the shaft <NUM> is raised slightly, which will allow the sealing component <NUM> to decompress and create suction along the main capillary 14a, returning to the operational configuration shown in <FIG>.

The use of one or more springs <NUM> in the embodiment of <FIG> has a number of different advantages. Firstly the spring(s) <NUM> assist in keeping the sealing plate <NUM> horizontal within the sealing valve <NUM>, ensuring that a good seal is continually made in the operation of the sealing plate <NUM>, as this sealing plate <NUM> is raised and lowered every time a container <NUM> is filled with product. Secondly, the spring(s) <NUM> provide a route for the force required to be delivered to the sealing plate <NUM> from the shaft <NUM>. If the springs <NUM> were not present then the force that pushes down the sealing plate <NUM> would pass through the sealing component <NUM>, which would greatly increase the wear and tear on this component <NUM>.

<FIG> show a yet further embodiment of the filling device <NUM>, not according to the claimed invention, where the configuration of the filler nozzle <NUM> is the same as before, but the configuration of the filler valve <NUM> is different. In this embodiment, the sealing plate <NUM> is connected to the sealing component <NUM> by a flexible membrane <NUM>. The sealing plate <NUM> and the sealing component <NUM> can still move independently of each other although the range of movement is limited by the size of the membrane <NUM>. The sealing component <NUM> seen from above is circular with the sealing plate <NUM> being a ring around the sealing component <NUM>.

<FIG> shows the fully open position of the filler valve <NUM>, with product <NUM> being able to flow through all of the capillaries <NUM>. <FIG> shows the next position of the filler valve <NUM>, in which all of the capillaries <NUM> are now closed and no product <NUM> is flowing from the filler nozzle <NUM>. <FIG> shows the next position of the filler valve <NUM> in which the sealing component <NUM> has been operated to close the main capillaries 14a and to create pressure through these main capillaries 14a. The next position of the filler nozzle <NUM> is that shown in <FIG>, with the sealing component <NUM> being raised relative to the sealing plate <NUM> which creates the suction back along the main capillaries 14a.

Claim 1:
A filling device (<NUM>) comprising:
• a filler nozzle (<NUM>) comprising a plurality of capillaries (<NUM>), and
• a filler valve (<NUM>) moveable relative to the filler nozzle (<NUM>),
wherein the filler valve (<NUM>) comprises:
∘ a sealing plate (<NUM>) which, when in contact with the filler nozzle (<NUM>), closes a plurality of the capillaries (<NUM>) but leaves at least one main capillary (14a) open, and characterized in that the filling device further comprises:
∘ a flexible sealing component (<NUM>) which is compressible and moveable relative to the sealing plate (<NUM>), which is operable to close the at least one main capillary (14a) and, by being compressed, to create pressure along the at least one main capillary (14a), wherein releasing the compression causes suction to be generated along the at least one main capillary.