Patent Description:
Various products are distributed in plastic containers, such as containers formed from one or more polymers. Common polymers used to form containers include polyesters, such as polyethylene terephthalate (PET), high and low density polyethylenes, polycarbonate, and polypropylene, among others. Plastic containers can be made using various blow molding processes including injection blow molding and extrusion blow molding.

Injection blow molding can be used to form certain plastic containers in one or more stages and can involve use of a stretch rod. In a two-stage injection stretch blow molding process, the plastic is first molded into a preform using an injection molding process. The preform can include the neck and finish of the container to be formed, which can include threading thereon, and a closed distal end. The preform can then be heated above the plastic glass transition temperature, longitudinally stretched with a stretch rod, and blown using high-pressure gas (e.g., air) into a container conforming to a mold. As the preform is inflated, it elongates and stretches, taking on the shape of the mold cavity. The plastic solidifies upon contacting the cooler surface of the mold and the finished hollow container is subsequently ejected from the mold. The injection stretch blow molding process can be used to form plastic containers for packaging consumer beverages, as well as other liquids and materials. However, the process has some inherent limitations, which include undesirable gate wells or discontinuities on the bottom portions of containers, as well as limitations on the possible spectrum of designs that can be realized using the stretch blow molding process, such as containers incorporating a handle or void space therein.

Extrusion blow molding can be used to form certain plastic containers where a continuously extruded hot plastic tube or parison is captured within a mold and inflated against the inner surfaces of the mold to form a container blank. The mold can be designed to travel at the speed at which the extruded parison is moving when it closes on the parison so that the process can operate on a continuous basis. There are several different types of extrusion blow molding machines, including shuttle molds that are designed to travel in a linear motion and extrusion blow molding wheels that travel in a rotary or circular motion. While extrusion blow molding processes have addressed a need for an improved plastic container that obviates some of the disadvantages inherent to containers fabricated using the stretch blow molding process, the extrusion blow molding processing requires a number of steps to form the container then later fill and cap the container. As a result, significant costs can be incurred while separately performing the container forming and filling processes, including transport and time commitments.

Blow molding containers and subsequent filling of containers have consequently developed as two independent processes, in many instances occurring at different facilities. In order to make container filling more cost effective, some filling facilities have installed blow molding equipment on site, in certain cases integrating blow molders directly into filling lines. Equipment manufacturers have recognized this advantage and are selling "integrated" systems that are designed to insure that the blow molder and the filler are fully synchronized. Despite the efforts in bringing the two processes together, blow molding and filling continue to be two independent, distinct processes. As a result, significant costs may be incurred in separately performing these two processes. There is also a concern in aseptically filling containers where transport, handling, and/or time between preparing the container and filling the container can result in additional opportunities for introducing contamination into the system. For example, such integrated systems can require maintaining the subject liquid in a clean or sterile state prior to filling the container and/or require introduction of a sterilizing step and associated equipment prior to filling the container.

Thus, there is a need for a liquid or hydraulic blow molding system suitable for forming and filling a container in a single operation to optimize packaging of a liquid product by minimizing transport and time demands, that can provide aseptic filling of the container, and that can improve the resulting container appearance and performance.

<CIT> discloses a method and a device for producing containers by filling preforms with a liquid filling material. The preform is stretched axially and radially by filling material supplied from a feed line under a lower pressure until the preform has substantially formed the shape of the container. A stretch rod is used to support the axial stretching of the preform. The filling material feed is then separated so a closed volume is created downstream of the feed line, and the container is completely formed without further supply of filling material by pressure build-up in the closed volume.

<CIT> discloses an apparatus and a method for simultaneously forming and filling a plastic container. The apparatus comprises a mold cavity with an internal surface adapted to accept a preform, a stretch rod for initiating mechanical stretching of the preform, a pressure source including an inlet and a piston-like device, and a blow nozzle adapted to receive liquid from the pressure source and transfer the liquid at high pressure into the preform, thereby urging the preform to expand toward the internal surface of the mold cavity and creating a resultant container, wherein the liquid remains within the container as an end product.

<CIT> discloses an apparatus for forming containers comprising a plurality of mold segments which define a mold cavity substantially in the form of a container and accommodates a preform having a preform cavity in communication with an open end. The apparatus further comprises an injection cylinder having a chamber with a piston mobile therein, which is configured to inject a volume of liquid into the preform when the piston is advanced in the chamber to form the containers. A stretching rod is urged against the surface of the preform cavity to induce the preform to deform in the longitudinal axis.

<CIT> discloses a station for forming a container from a preform. The station has a main body including a preform seat adapted to receive a preform and an injection assembly including an injection nozzle, an injection device, and a source of incompressible fluid. The injection device is arranged to inject liquid to the inlet of the injection nozzle and into the preform to form a container. A stretch rod is used to assist in the deformation of the preform into a container.

<CIT> discloses a blow molding machine for blow molding plastic containers with at least one blow molding unit for stretch blow molding preforms using compressed air. The blow molding unit comprises a pressure piston and a pressure cylinder and has a force balance such that at least part of the compression force that occurs is compensated for.

The present technology includes articles of manufacture, systems, and processes that relate to use of a liquid to fill and form a container under certain pressure conditions, where the liquid remains in the container thereby merging formerly separate processes and enabling aseptic liquid packaging and transfer of fine mold details to the resulting filled container.

Systems for simultaneously forming and filling a container include a mold cavity, a hydraulic intensifier, a blow nozzle, and a stretch rod. The mold cavity defines an internal surface and is configured to accept a preform. The hydraulic intensifier is configured to receive a first liquid and dispense the first liquid at a first pressure, where the hydraulic intensifier includes a moveable member having a first surface contacting the first liquid and a second surface contacting a second liquid. The second liquid is configured to provide a second pressure on the second surface so that the first pressure is applied to the first liquid by the first surface. The first surface has a smaller area than the second surface and the first pressure is greater than the second pressure. The blow nozzle is configured to transfer the first liquid at the first pressure into the preform to urge the preform to expand toward the internal surface of the mold cavity and form a resultant container, where the first liquid remains within the container as an end product. The stretch rod is configured to mechanically stretch the preform within the mold cavity prior to the first liquid at the first pressure being transferred into the preform by the blow nozzle, where the stretch rod is vented.

Aspects of such systems can further include a pressure source providing the first liquid to the hydraulic intensifier and to the blow nozzle. The pressure source can be configured to provide the first liquid to the hydraulic intensifier and to the blow nozzle at a third pressure, the third pressure being less than the first pressure. Embodiments of the pressure source can have an inlet, a chamber, an outlet, and a mechanically driven piston-like device moveable within the chamber in a first direction to draw a liquid into the chamber through the inlet and moveable in a second direction to urge the liquid out of the chamber through the outlet as the first liquid. The piston-like device can be one of a piston, a pump, and an accumulator. In some embodiments, the first pressure at which the first liquid is dispensed from the hydraulic intensifier can be greater than about <NUM>,<NUM> psi (<NUM> MPa), in other embodiments can be from about <NUM>,<NUM> psi (<NUM> MPa) to about <NUM>,<NUM> psi (<NUM> GPa), and in further embodiments can be from about <NUM>,<NUM> psi (<NUM> MPa) to about <NUM>,<NUM> psi (<NUM> GPa). Certain embodiments of the hydraulic intensifier can use a ratio of a first area of the first surface to a second area of the second surface that is greater than about <NUM>: <NUM> and other embodiments can use a ratio of a first area of the first surface to a second area of the second surface that is from about <NUM>:<NUM> to about <NUM>:<NUM>.

Methods of simultaneously forming and filling a container include applying a first pressure to a first liquid using a hydraulic intensifier. The hydraulic intensifier includes a moveable member having a first surface contacting the first liquid and a second surface contacting a second liquid. The second liquid is configured to provide a second pressure on the second surface so that the first pressure is applied to the first liquid by the first surface, where the first surface has a smaller area than the second surface resulting in the first pressure being greater than the second pressure. The first liquid at the first pressure is dispensed from the hydraulic intensifier to a blow nozzle, where the blow nozzle is configured to transfer the first liquid at the first pressure into a preform within a mold cavity. The mold cavity defines an internal surface where the preform is expanded toward the internal surface of the mold cavity using the first liquid to form a resultant container. The first liquid remains thereafter within the container as an end product. Prior to dispensing the first liquid at the first pressure from the hydraulic intensifier to the blow nozzle, a stretch rod is used to mechanically stretch the preform within the mold cavity. Expanding the preform toward the internal surface of the mold cavity using the first liquid to form a resultant container includes venting the preform through the stretch rod.

Aspects of such methods can further include where, prior to applying the first pressure to the first liquid using the hydraulic intensifier, the first liquid is provided to the hydraulic intensifier and the blow nozzle using a pressure source. The pressure source can provide the first liquid to the hydraulic intensifier and to the blow nozzle at a third pressure, the third pressure being less than the first pressure. Providing the first liquid to the hydraulic intensifier and to the blow nozzle using the pressure source can further include where the blow nozzle transfers a portion of the first liquid into the preform to partially expand the preform toward the internal surface of the mold cavity. Embodiments of the pressure source can have an inlet, a chamber, an outlet, and a mechanically driven piston-like device moveable within the chamber in a first direction to draw a liquid into the chamber through the inlet and moveable in a second direction to urge the liquid out of the chamber through the outlet as the first liquid.

Methods of simultaneously forming and filling a container are also provided that include mechanically stretching a preform using a stretch rod to form a stretched preform. A first liquid is provided to a hydraulic intensifier and to a blow nozzle using a pressure source and a portion of the first liquid is transferred from the blow nozzle into the stretched preform to partially expand the stretched preform toward an internal surface of a mold cavity to form a partially expanded preform. A first pressure is applied to the first liquid using the hydraulic intensifier, where the hydraulic intensifier includes a moveable member having a first surface contacting the first liquid and a second surface contacting a second liquid. The second liquid is configured to provide a second pressure on the second surface so that the first pressure is applied to the first liquid by the first surface. The first surface has a smaller area than the second surface and the first pressure is greater than the second pressure. The first liquid is dispensed at the first pressure from the hydraulic intensifier to the blow nozzle, where the blow nozzle transfers the first liquid at the first pressure into the partially expanded preform within the mold cavity. The partially expanded preform is expanded toward the internal surface of the mold cavity using the first liquid to form a resultant container, where the first liquid remains within the container as an end product.

The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as can be filed claiming priority to this application, or patents issuing therefrom. Regarding methods disclosed, the order of the steps presented is exemplary in nature, and thus, the order of the steps can be different in various embodiments. "A" and "an" as used herein indicate "at least one" of the item is present; a plurality of such items can be present, when possible. Except where otherwise expressly indicated, all numerical quantities in this description are to be understood as modified by the word "about" and all geometric and spatial descriptors are to be understood as modified by the word "substantially" in describing the broadest scope of the technology. "About" when applied to numerical values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by "about" and/or "substantially" is not otherwise understood in the art with this ordinary meaning, then "about" and/or "substantially" as used herein indicates at least variations that can arise from ordinary methods of measuring or using such parameters.

Although the open-ended term "comprising," as a synonym of non-restrictive terms such as including, containing, or having, is used herein to describe and claim embodiments of the present technology, embodiments can alternatively be described using more limiting terms such as "consisting of" or "consisting essentially of. " Thus, for any given embodiment reciting materials, components, or process steps, the present technology also specifically includes embodiments consisting of, or consisting essentially of, such materials, components, or process steps excluding additional materials, components or processes (for consisting of) and excluding additional materials, components or processes affecting the significant properties of the embodiment (for consisting essentially of), even though such additional materials, components or processes are not explicitly recited in this application. For example, recitation of a composition or process reciting elements A, B and C specifically envisions embodiments consisting of, and consisting essentially of, A, B and C, excluding an element D that can be recited in the art, even though element D is not explicitly described as being excluded herein.

As referred to herein, all compositional percentages are by weight of the total composition, unless otherwise specified. Disclosures of ranges are, unless specified otherwise, inclusive of endpoints and include all distinct values and further divided ranges within the entire range. Thus, for example, a range of "from A to B" or "from about A to about B" is inclusive of A and of B. Disclosure of values and ranges of values for specific parameters (such as amounts, weight percentages, etc.) are not exclusive of other values and ranges of values useful herein. It is envisioned that two or more specific exemplified values for a given parameter can define endpoints for a range of values that can be claimed for the parameter. For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that Parameter X can have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if Parameter X is exemplified herein to have values in the range of <NUM>-<NUM>, or <NUM>-<NUM>, or <NUM>-<NUM>, it is also envisioned that Parameter X can have other ranges of values including <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and so on.

When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it can be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers can be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to" or "directly coupled to" another element or layer, there can be no intervening elements or layers present.

Although the terms first, second, third, etc. can be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms can be only used to distinguish one element, component, region, layer or section from another region, layer or section.

Spatially relative terms, such as "inner," "outer," "beneath," "below," "lower," "above," "upper," and the like, can be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms can be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The device can be otherwise oriented (rotated <NUM> degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The present technology allows for simultaneously forming and filling a container using liquid pressurized by a hydraulic intensifier to rapidly and aseptically provide a liquid-filled container. Apparatus, systems, and methods provided herein make use of a mold cavity that defines an internal surface and that is configured to accept a preform. A hydraulic intensifier operates to receive a first liquid and dispense the first liquid at a first pressure, where the hydraulic intensifier includes a moveable member having a first surface contacting the first liquid and a second surface contacting a second liquid. The second liquid provides a second pressure on the second surface so that the first pressure is applied to the first liquid by the first surface. The first surface has a smaller area than the second surface and the first pressure is greater than the second pressure. A blow nozzle operates to transfer the first liquid at the first pressure into the preform to urge the preform to expand toward the internal surface of the mold cavity and form a resultant container, where the first liquid remains within the container as an end product. The hydraulic intensifier can output the first liquid at a pressure that results in sterilization of the first liquid. Sterilization of a liquid in this manner can be referred to as sterilization by Pascalization or high pressure processing. The pressure provided to urge the preform to expand or to further expand toward the internal surface of the mold cavity and form the resultant container can improve transfer of mold details, including fine texture, that maximizes distinctness of image and can provide crispness and detail permitting fonts as small as four typography points.

With reference to the several figures, an embodiment of a system according to the present technology is shown and generally referred to as reference numeral <NUM>. <FIG> show an embodiment of a sequence for simultaneously forming and filling a container C using the system <NUM> in accordance with the present technology. As will be appreciated from the following description, the system <NUM> and associated method utilize a first liquid <NUM> to impart the pressure required to expand or further expand a preform <NUM> to take on the shape of a mold cavity <NUM>, thus simultaneously forming and filling a resultant container C with the first liquid <NUM>.

With initial reference to <FIG>, the system <NUM> will be described in greater detail. The system <NUM> generally includes a mold <NUM> having a mold cavity <NUM>, a pressure source <NUM>, a hydraulic intensifier <NUM>, a blow nozzle <NUM>, and a stretch rod <NUM>. The exemplary mold cavity <NUM> illustrated in the figures includes two mold halves <NUM>, <NUM> that cooperate to define an interior surface <NUM> corresponding to a desired outer profile of the resultant container C. The mold cavity <NUM> can be moveable from an open position (<FIG>) to a closed position (<FIG>) such that a support ring <NUM> of the preform <NUM> can be captured at an upper end of the mold cavity <NUM>. The preform <NUM> can be formed of a polyester material, such as polyethylene terephthalate (PET), can have a shape similar to a test-tube with a generally cylindrical cross section, and can have a length approximately fifty percent (<NUM>%) of a height of the resultant container C. The support ring <NUM> can be used to carry or orient the preform <NUM> through and at various stages of manufacture. For example, the preform <NUM> can be carried by the support ring <NUM>, the support ring <NUM> can be used to aid in positioning the preform <NUM> in the mold cavity <NUM>, and an end consumer can use the support ring <NUM> to carry the plastic container C once manufactured.

In the example shown, the pressure source <NUM> can be in the form of a filling cylinder, manifold, or chamber <NUM> that generally includes a mechanical piston-like device <NUM> that can be configured in various embodiments as a piston, a pump (e.g., a hydraulic pump), or any other such similarly suitable device, where the piston-like device <NUM> is moveable within the filling cylinder, manifold, or chamber <NUM>. The pressure source <NUM> can have an inlet <NUM> for accepting the first liquid <NUM> and an outlet <NUM> for delivering the first liquid <NUM> to the hydraulic intensifier <NUM>. It is appreciated that the inlet <NUM> and the outlet <NUM> can have respective valves <NUM>, <NUM> incorporated thereat. The piston-like device <NUM> can be moveable in a first direction (e.g., upward as viewed in the figures) to draw the first liquid <NUM> from the inlet <NUM> into the filling cylinder, manifold, or chamber <NUM>, and in a second direction (e.g., downward as viewed in the figures) to deliver the first liquid <NUM> from the filling cylinder, manifold, or chamber <NUM> to the hydraulic intensifier <NUM> and to the blow nozzle <NUM>. The piston-like device <NUM> can be moveable by any suitable means, such as pneumatically, mechanically, electromagnetically, and/or hydraulically, for example. The inlet <NUM> of the pressure source <NUM> can be connected, such as by tubing or piping, to a reservoir or container (not shown) that contains the first liquid <NUM>.

It is understood that the pressure source <NUM> can be configured differently in various embodiments and that the system <NUM> can be configured with other means than the pressure source <NUM> as shown to provide the first liquid <NUM> to the hydraulic intensifier <NUM>. For example, in certain embodiments the hydraulic intensifier <NUM> can directly draw the first liquid <NUM> from a reservoir or container. The pressure source <NUM> can also be configured as a reservoir or container of pressurized liquid that can provide the first liquid <NUM> to the remainder of the system <NUM> by actuation of valve <NUM>, for example.

The hydraulic intensifier <NUM> can be configured to receive the first liquid <NUM> and dispense the first liquid <NUM> at a first pressure. Receipt of the first liquid <NUM> can coincide with opening valve <NUM> at the outlet <NUM> of the pressure source and having valve <NUM> open. The hydraulic intensifier <NUM> can include a moveable member <NUM> having a first surface <NUM> that can contact the first liquid <NUM> and a second surface <NUM> that can contact a second liquid <NUM>. As shown, for example, the moveable member <NUM> can be configured as a stepped piston where a smaller first piston head <NUM> provides the first surface <NUM> and a larger second piston head <NUM> provides the second surface <NUM>, where the first piston head <NUM> has a smaller diameter than the second piston head <NUM>. The second liquid <NUM> can be introduced into the hydraulic intensifier <NUM> to provide a second pressure on the second surface <NUM> so that the first pressure is applied to the first liquid <NUM> by the first surface <NUM>. The first surface <NUM> has a smaller area than the second surface <NUM> that results in the first pressure being greater than the second pressure. For example, a ratio of a first area of the first surface <NUM> to a second area of the second surface <NUM> can be greater than about <NUM>:<NUM> and can be at or between about <NUM>:<NUM> to about <NUM>:<NUM>, in various embodiments. Accordingly, the second pressure provided by the second liquid <NUM> is intensified by the moveable member to provide the first pressure to the first liquid <NUM>. The hydraulic intensifier <NUM> can therefore be configured to receive the first liquid <NUM> and dispense the first liquid <NUM> at a first pressure that is greater than about <NUM>,<NUM> psi (<NUM> MPa). Embodiments further include where the first pressure is from about <NUM>,<NUM> psi (<NUM> MPa) to about <NUM>,<NUM> psi (<NUM> GPa) and where the first pressure is from about <NUM>,<NUM> psi (<NUM> MPa) to about <NUM>,<NUM> psi (<NUM> GPa). In this way, the hydraulic intensifier <NUM> can output the first liquid <NUM> at a pressure that results in sterilization of the first liquid <NUM> by Pascalization or high pressure processing.

The blow nozzle <NUM> generally defines an inlet <NUM> for accepting the first liquid <NUM> from the hydraulic intensifier <NUM> and an outlet <NUM> for delivering the first liquid <NUM> into the preform <NUM>. Receipt of the first liquid <NUM> can coincide with opening valve <NUM> at the outlet <NUM> of the pressure source. A valve <NUM> can be positioned within the blow nozzle <NUM> to control delivery of the first liquid <NUM> into the preform <NUM>, where valve <NUM> is open when the blow nozzle <NUM> transfers a portion of the first liquid <NUM> into the preform <NUM> to partially expand the preform <NUM> toward the internal surface <NUM> of the mold cavity <NUM>. It is appreciated that the outlet <NUM> can define a shape complementary to the preform <NUM> near the support ring <NUM> such that the blow nozzle <NUM> can be coupled or easily engage or mate with the preform <NUM> during the forming/filling process. In certain embodiments, the blow nozzle <NUM> can define an opening <NUM> for slidably accepting the stretch rod <NUM> used to initiate mechanical stretching of the preform <NUM>.

The first liquid <NUM> can be introduced into the plastic container C during a thermal process, typically a hot-fill process. For hot-fill bottling applications, the plastic container C can be filled with a liquid or product at an elevated temperature between approximately <NUM>°F to <NUM>°F (approximately <NUM> to <NUM>) and sealed with a closure (not illustrated) before cooling. In various configurations, the first liquid <NUM> can be heated within, en route to, and/or after leaving the pressure source <NUM>. The first liquid <NUM> can also be heated within, en route to, and/or after leaving the hydraulic intensifier <NUM>. It is further possible to heat the first liquid <NUM> relative to the pressure source <NUM> by circulating the first liquid <NUM> within the filling cylinder, manifold, or chamber <NUM> through the inlet <NUM> whereby the first liquid <NUM> can be heated to a preset temperature; e.g., using a heat source (not illustrated) upstream of the inlet <NUM>. In addition, the plastic container C can be suitable for other high-temperature pasteurization or retort filling processes, as well as other thermal processes. In another example, the first liquid <NUM> can be introduced into the plastic container C under ambient or cold temperatures. Accordingly, by way of example, the plastic container C can be filled at ambient or cold temperatures such as between approximately <NUM> °F to <NUM> °F (approximately <NUM> to <NUM>), and more preferably at approximately <NUM> °F (approximately <NUM>° C). In examples where the liquid commodity is filled at ambient or cold temperatures, the preform can be subjected to a sterilization process before introducing the first liquid <NUM>.

With reference to the several figures, an exemplary method of simultaneously forming and filling the plastic container C will be described. In certain embodiments, the preform <NUM> can be sterilized by steam or other means prior to being introduced into the mold cavity <NUM>. By subjecting the preform <NUM> to a sterilizing technique (e.g., steam and/or heat), an aseptic preform and resulting container can be created as the first liquid <NUM> can be sterilized by the first pressure generated by the hydraulic intensifier <NUM>. The container C therefore need not be formed by a hot-filling process. Other examples of sterilizing the preform <NUM> include contact with one or more various sterilizing mediums, such as liquid peroxide. The preform <NUM> can also be passed through an oven in excess of <NUM>°F (<NUM>° C) and nearly immediately subjected to forming and filling and the resultant filled container C can then be capped. In this way, the opportunity for an empty container to be exposed to the environment where it might become contaminated is minimized and the cost and complexity of aseptic filling can be reduced.

The preform <NUM> can be placed into the mold cavity <NUM>; see <FIG>. For example, a machine (not illustrated) can transfer the preform <NUM>, heated to a temperature between approximately <NUM>°F to <NUM>°F (approximately <NUM> to <NUM>), to the mold <NUM> where the preform <NUM> is enclosed within the mold cavity <NUM>. As the preform <NUM> is placed into the mold cavity <NUM>, the piston-like device <NUM> of the pressure source <NUM> can begin to draw the first liquid <NUM> into the filling cylinder, manifold, or chamber <NUM> through the inlet <NUM> while valve <NUM> is open and valve <NUM> is closed. The mold halves <NUM>, <NUM> of the mold cavity <NUM> can then close thereby capturing the preform <NUM>; see <FIG>. The blow nozzle <NUM> can form a seal at a finish of the preform <NUM>. The mold cavity <NUM> can be heated to a temperature between approximately <NUM>°F to <NUM>°F (approximately <NUM> to <NUM>) in order to impart increased crystallinity levels within the resultant container C. In other embodiments, the mold cavity <NUM> can be provided at ambient or cold temperatures, between approximately <NUM>°F to <NUM>°F (approximately <NUM> to <NUM>). The first liquid <NUM> can continue to be drawn into the filling cylinder, manifold, or chamber <NUM> by the piston-like device <NUM>.

Turning now to <FIG>, the stretch rod <NUM> can extend into the preform <NUM> to initiate mechanical stretching. At this point, the first liquid <NUM> can continue to be drawn into the filling cylinder, manifold, or chamber <NUM>. With reference to <FIG>, the stretch rod <NUM> continues to stretch the preform <NUM> thereby thinning the sidewalls of the preform <NUM> and forming a stretched preform <NUM>. The volume of the first liquid <NUM> within the filling cylinder, manifold, or chamber <NUM> can increase until a desired charge or appropriate volume suitable to form and fill the resultant container C is reached. At this point, the valve <NUM> disposed at the inlet <NUM> of the pressure source <NUM> can be closed.

With specific reference to <FIG>, the piston-like device <NUM> of the pressure source <NUM> can then begin to drive downward to initiate transfer of the first liquid <NUM> from the filling cylinder, manifold, or chamber <NUM> to the hydraulic intensifier <NUM> and the hydraulic intensifier <NUM> and to the blow nozzle <NUM>. Again, the piston-like device <NUM> can be actuated by any suitable means such as pneumatic, mechanical, electromagnetic, and/or hydraulic pressure. In various embodiments, the hydraulic pressure of the first liquid <NUM> being transferred to the hydraulic intensifier <NUM> and the blow nozzle <NUM> from the pressure source <NUM> can be between approximately <NUM> psi (<NUM> kPa) to <NUM> psi (<NUM> GPa). Providing the the first liquid <NUM> from the pressure source <NUM> to the hydraulic intensifier <NUM> and the blow nozzle <NUM> can occur with valves <NUM>, <NUM>, <NUM> in an open state. In this way, a portion of the first liquid <NUM> passes from the blow nozzle <NUM> through valve <NUM> into the stretched preform <NUM> to partially expand the stretched preform <NUM> toward the internal surface <NUM> of the mold cavity <NUM> to form a partially expanded preform <NUM>. As the first liquid <NUM> causes the stretched preform <NUM> to partially expand toward the interior surface <NUM> of the mold cavity <NUM>, residual air within the preform <NUM> can be vented through a passage <NUM> defined in the stretch rod <NUM>. The pressure source <NUM> can be configured to provide the first liquid <NUM> to the hydraulic intensifier <NUM> and to the blow nozzle <NUM> at a third pressure, where the third pressure is less than the first pressure. Accordingly, the preform can be expanded by the first liquid <NUM> at the third pressure obtained from the pressure source <NUM> and can be expanded or further expanded by the first liquid <NUM> at the first pressure obtained from the hydraulic intensifier <NUM>, as described herein.

As the first liquid <NUM> is also provided to the hydraulic intensifier <NUM> from the pressure source <NUM>, the first pressure can be applied to the first liquid <NUM> using the hydraulic intensifier <NUM>. Application of the first pressure to the first liquid <NUM> can occur with valve <NUM> in a closed state. The first surface <NUM> of the moveable member <NUM> can contact the first liquid <NUM>. The second surface <NUM> of the moveable member <NUM> can be contacted by the second liquid <NUM>, where the second liquid <NUM> provides the second pressure on the second surface <NUM>. The second pressure on the second surface <NUM> of the moveable member <NUM> results in application of the first pressure by the first surface <NUM> to the first liquid <NUM>. The hydraulic intensifier <NUM> thereby transfers and intensifies the lower second pressure into the higher first pressure, as the first surface <NUM> has a smaller area than the second surface <NUM>. The first liquid <NUM> is then dispensed at the first pressure from the hydraulic intensifier <NUM> to the blow nozzle <NUM>, where the blow nozzle <NUM> is configured to transfer and direct the first liquid <NUM> at the first pressure into the preform <NUM> within the mold cavity <NUM>; see <FIG>. Valves <NUM>, <NUM> are in an open state and valve <NUM> is in a closed state for transfer of the first liquid at the first pressure into the preform <NUM>. The first liquid <NUM> at the first pressure thereby further expands the partially expanded preform <NUM> toward the internal surface <NUM> of the mold cavity <NUM> using the first liquid <NUM> to form the resultant container C, where the first liquid <NUM> remains within the container C as an end product. As the first liquid <NUM> causes the partially expanded preform <NUM> to further expand toward the interior surface <NUM> of the mold cavity <NUM>, any residual air within the preform <NUM> can be further vented through the passage <NUM> defined in the stretch rod <NUM>.

As shown in <FIG>, the hydraulic intensifier <NUM> has completed the dispensing of the charge of first liquid <NUM> at the first pressure, where transfer of the appropriate volume of the first liquid <NUM> to the newly formed plastic container C is complete. Concomitant with or thereafter, the stretch rod <NUM> can be withdrawn from the formed and filled container C within the mold cavity <NUM> while continuing to vent any residual air through passage <NUM>. In certain embodiments, the stretch rod <NUM> can be designed to displace a predetermined volume of the first liquid <NUM> when it is withdrawn from the mold cavity <NUM> thereby allowing for a desired fill level of the first liquid <NUM> within the resultant plastic container C. Generally, the desired fill level can correspond to a level at or near the level of the support ring <NUM> of the plastic container C.

With reference to <FIG>, the fill cycle is shown completed. The mold halves <NUM>, <NUM> can separate and the blow nozzle <NUM> can be withdrawn. The resultant filled plastic container C can now be subjected to various post-forming steps, such as capping, labeling, and packing. At this point, the piston-like device <NUM> of the pressure source <NUM> can begin the next cycle by drawing more of the first liquid <NUM> through the inlet <NUM> in preparation for the next fill/form cycle. While not specifically shown, it is appreciated that the system <NUM> can include a controller for communicating signals to one or more of the various components. In this way, the pressure source <NUM>, the hydraulic intensifier <NUM>, the mold <NUM>, the blow nozzle <NUM>, the stretch rod <NUM>, and various valves can operate according to one or more signals communicated by the controller. It is also contemplated that the controller can be utilized to adjust various parameters associated with these components according to a given application.

The ability of the hydraulic intensifier <NUM> to generate pressures for sterilizing by Pascalization or high pressure processing further provides various ways to sterilize and clean portions of the system <NUM>. For example, the first fluid <NUM> or another fluid can be in fluid communication with the hydraulic intensifier <NUM> and isolated by closure of valve <NUM> and closure of valves <NUM>, <NUM>, <NUM>, and/or <NUM> to subject certain portions of the system to high pressure and sterilization. For example, closure of valves <NUM>, <NUM>, and <NUM> can sterilize the portions of the system <NUM> allowing fluid communication between the hydraulic intensifier <NUM>, the blow nozzle <NUM>, and the pressure source <NUM>. Sub-portions can also be sterilized; e.g., where valves <NUM>, <NUM>, and <NUM> are closed to sterilize the portions of the system <NUM> allowing fluid communication between the hydraulic intensifier <NUM> and the blow nozzle <NUM>. It should be noted that the hydraulic intensifier <NUM> can be fluidly coupled to other portions of the system <NUM> and other components incorporated into the system <NUM> where sterilization by high pressure processing is desired. As shown in the figures, valve <NUM> can control fluid communication with line <NUM> that is part of a recirculation or fluid recovery system (not shown). In this way, valve <NUM> can be opened to withdraw the first fluid <NUM> out of the system <NUM> at different stages for maintenance, for cleaning, and/or for recovery through line <NUM>. Likewise, line <NUM> can be used to introduce another fluid into the system <NUM> when valve <NUM> is opened to clean or sterilize various portions of the system, including by use of the hydraulic intensifier <NUM>.

The following benefits and advantages can be realized by the present technology. Pressures achieved by the hydraulic intensifier in forming and filling the container can sterilize the liquid used to form and fill the container and can result in improved transfer of mold details to the resulting filled container. Sterilization by Pascalization or high pressure processing provides a method of preserving and sterilizing food where the liquid used to form/fill the container is processed under very high pressure, which can lead to the inactivation of certain microorganisms and enzymes in the liquid. Such high pressure processing has a limited effect on covalent bonds within the liquid, thereby minimizing any changes in the liquid. During Pascalization, more than <NUM>,<NUM> pounds per square inch (<NUM> MPa, <NUM> kbar) can be applied for a given time to the liquid, which can lead to the inactivation of any yeast, mold, and/or bacteria present in the liquid. Such high pressure sterilization processing is regarded as a "natural" liquid preservation method, as there is no use chemical preservatives.

The high forming/filling pressure can further result in improved transfer of mold details to the resultant filled container. Sharpness and distinctness of mold features can be improved and the size of mold features that can be effectively transferred can be reduced. The systems and processes provided by the present technology can accordingly impart fine details and textures to the resultant filled container. For example, indicia and/or text in sizes down to <NUM> pt. font can be effectively transferred. The height or distance of projections on the resultant container surface can also be increased as the high forming/filling pressure can force polymer of the preform into deeper mold recesses or features than previously obtainable.

The present technology serves to optimize the forming and filling of containers in various ways. As forming and filling are integrated closer, but remain two separate processes (such as conventional methods of blow molding then subsequently filling the blow molded container), the overall efficiency of such a system is the product of the individual efficiencies of the two parts. In particular, compressed air is an inefficient means of transferring energy. Using the final product to provide hydraulic pressure, as per the present technology, to form the container can employ the equivalent of a positive displacement pump. As a result, it is a more efficient way to transfer energy. Other efficiencies can be driven largely by the number of transitions as parts move through the various systems and machines. Integrating the container forming and filling processes into a simultaneous event can minimize the number of transitions of components (e.g., containers and liquid to be placed therein) and therefore increase the overall process efficiency. The process described herein can eliminate intermediary work-in-process and therefore can avoid the cost associated with warehousing and/or container silos and/or forklifts and/or product damage, sterile storage, sterilizing equipment, etc. In addition, without work-in-process inventory, the overall working capital can be reduced.

Other advantages of the present technology including lowering some of the processing parameters while still achieving desired results. For example, the requirements for preform conditioning can be reduced because the crystallinity requirements can be lowered. In addition, mold conditioning requirements can be reduced which can reduce the amount of oils and/or other surface preparation materials used on the interior surface of the mold cavity. The concurrent blowing and filling process described herein can also facilitate the formation of a super-lightweight container. As noted above, in traditional hot-fill containers, the container can require a suitable wall thickness to accommodate vacuum pressures. By sterilizing the preform prior to introducing the liquid and by using high pressure processing or Pascalization, the resultant wall thickness can be much thinner relative to a traditional hot-filled container. In a super-lightweight container, the liquid itself can give structural support to the container. The walls of a super-lightweight container can therefore be extremely flexible.

The combination of both the forming and filling processes into a integrated or unitary system can reduce handling parts and therefore lead to reduced capital cost per resultant plastic container C. In addition, the space required by a process that simultaneously forms and fills the resultant plastic container C can be significantly reduced over the space required when the processes are separate. This can also result in lower infrastructure cost. Integrating the two processes into a single step can reduce labor and additional costs (both capital and expense) associated with handling containers after they are produced and before they are filled. Integrating the blowing and filling processes into a single process eliminates the need to ship containers. The shipping of empty, formed containers is inherently inefficient and expensive. Shipping preforms, on the other hand, is much more efficient. As one example, a trailer load of empty <NUM> water bottles contains approximately <NUM>,<NUM> individual bottles. The same size trailer loaded with preforms required to make <NUM> water bottles can carry approximately <NUM>,<NUM>,<NUM> individual preforms, a <NUM>:<NUM> improvement.

In instances where products are hot filled, the package must be designed to accommodate the elevated temperature that it is exposed to during filling and the resultant internal vacuum it is exposed to as a result of the product cooling. A design that accommodates such conditions can require added container weight. Liquid/hydraulic blow molding offers the potential of eliminating the hot fill process and as a result, lowering the package weight.

The present technology further overcomes issues associated with liquid products that are susceptible to contamination. One predominant method for filling contaminant susceptible liquids is through hot filling, where the liquid is introduced to the container at a temperature that will pasteurize the liquid and can kill any microorganisms that are present. The resulting container can be sealed while the product is hot. However, one drawback to this technology is that the containers usually need to have a heavier weight design to sustain the elevated filling temperature and the vacuum that eventually develops in the container as the liquid product cools. The forming process can also be somewhat more complex and therefore more costly than non-heat set blow molding. The present technology offers the opportunity to reduce the cost and complexity of filling liquid products susceptible to contamination, including various liquid foods and beverages. By combining the forming and filling processes, there is an ability to heat the preform to over <NUM>°F (<NUM>) for a sufficient period of time necessary to kill any biological contaminants. And the high pressure provided by the hydraulic intensifier can sterilize the liquid (by Pascalization or high pressure processing) substantially at the point the liquid is used to form the container, where the resultant container can be immediately sealed thereafter. The present technology can therefore provide an inexpensive and aseptic filling process with minimized opportunity for contamination.

The method described herein can be particularly useful for filling applications using liquids such as isotonic, juice, tea and other liquid commodities that are susceptible to biological contamination. In particular, by optionally sterilizing the preform as described herein, an aseptic preform and resulting container can be created without requiring the end liquid to be the sterilizing medium. These liquid commodities are typically filled in a controlled, sterile environment that can be established in various ways. One method for filling these types of liquids is by performing the process an aseptic filling environment; e.g., a clean room. All of the components of the product including the packaging are sterilized prior to filling. Once filled, the product can be sealed until it is consumed preventing any potential for the introduction of bacteria. The process is expensive to install and operate and there is always the risk of a bacterial contaminant breaking through the operational defenses and contaminating the product. This is one reason why the present technology, providing aseptic filling via Pascalization or high pressure processing with a hydraulic intensifier, realizes a significant advantage over having to maintain sterile fields and conditions; e.g., a clean room.

In other embodiments, the integrated blowing and filling processes described herein can be used to form containers including liquids such as carbonated beverages (i.e., soda, etc.). With respect to carbonated liquids, liquid carbon dioxide can be used in solution as part of, or in addition to, the liquid used for the simultaneous blowing and filling process. Liquid carbon dioxide prevents foaming that could otherwise occur when blowing with a liquid commodity having gaseous carbon dioxide. Carbon dioxide can exist in liquid form at a given pressure and temperature.

Many beverages, including juices, teas, beer, etc., are sensitive to oxygen and need to be protected when packaged. Many plastics do not have sufficient barrier characteristics to protect the contents from oxygen during the life of the packaged product. There are a number of techniques used to impart additional barrier properties to the container to slow down oxygen transmission and therefore protect the packaged contents. One of the most common techniques is to use an oxygen scavenger in the container wall. Such a scavenger can be molded directly into the preform. The relatively thick wall of the preform protects the scavenger from being consumed prior to blowing it into a container. However, once the container has been blown, the surface area of the wall increases and the thickness decreases. As such, the path that the oxygen has to travel to contact and react with the active scavenging material is shorter. Significant consumption of oxygen scavengers can begin as soon as the container is blown. If the container is formed and filled at the same time, then the scavenger is protecting the product through its entire useful life and not being consumed while the container sits empty waiting to be filled.

There are many other bottled products where this technology can be applicable. Consumable products such as dairy products, liquor, salad dressings, sauces, spreads, ketchups, syrups, edible oils, and others can be bottled utilizing such methods. Furthermore, the liquid used to form and fill a container can also include non-consumable liquid goods such as household cleaners, detergents, personal care items such as toothpaste, etc. Many of these products are currently found in blow molded PET containers but are also in extrusion molded plastic containers, glass bottles, and/or cans. The present technology can therefore optimize the economics of package manufacture and filling for such products.

While much of the description has focused on the production of PET containers, it is contemplated that other polyolefin materials (e.g., polyethylene, polypropylene, polyester, etc.) as well as a number of other plastics can be processed using the present technology.

Claim 1:
A system (<NUM>) for simultaneously forming and filling a container (C) comprising:
a mold cavity (<NUM>) defining an internal surface (<NUM>) and configured to accept a preform (<NUM>);
a hydraulic intensifier (<NUM>) configured to receive a first liquid (<NUM>) and dispense the first liquid (<NUM>) at a first pressure, the hydraulic intensifier (<NUM>) including a moveable member (<NUM>) having a first surface (<NUM>) contacting the first liquid (<NUM>) and a second surface (<NUM>) contacting a second liquid (<NUM>), the second liquid (<NUM>) configured to provide a second pressure on the second surface (<NUM>) so that the first pressure is applied to the first liquid (<NUM>) by the first surface (<NUM>), the first surface (<NUM>) having a smaller area than the second surface (<NUM>), where the first pressure is greater than the second pressure;
a blow nozzle (<NUM>) configured to transfer the first liquid (<NUM>) at the first pressure into the preform (<NUM>) to urge the preform (<NUM>) to expand toward the internal surface (<NUM>) of the mold cavity (<NUM>) and form a resultant container (C), where the first liquid (<NUM>) remains within the container (C) as an end product; and
a stretch rod (<NUM>) configured to mechanically stretch the preform (<NUM>) within the mold cavity (<NUM>) prior to the first liquid (<NUM>) at the first pressure being transferred into the preform (<NUM>) by the blow nozzle (<NUM>);
characterized in that the stretch rod (<NUM>) is vented.