U.S. patent application number 13/128880 was filed with the patent office on 2011-09-01 for apparatus and method for delivering a product into a receptacle.
This patent application is currently assigned to Polynest Technologies Ltd.. Invention is credited to Shlomo Nevo.
Application Number | 20110210120 13/128880 |
Document ID | / |
Family ID | 41692233 |
Filed Date | 2011-09-01 |
United States Patent
Application |
20110210120 |
Kind Code |
A1 |
Nevo; Shlomo |
September 1, 2011 |
APPARATUS AND METHOD FOR DELIVERING A PRODUCT INTO A RECEPTACLE
Abstract
An apparatus for delivering a product into a receptacle having a
feeding aperture. The apparatus comprises a mixing chamber having a
plurality of inlets each configured for separately receiving at
least one of a plurality of component materials and at least one
outlet, the mixing chamber being configured for forming the product
by mixing the plurality of component materials and injecting the
product to the feeding aperture via the at least one outlet and a
feeding element configured for being secured in a feeding channel
for allowing the injecting.
Inventors: |
Nevo; Shlomo; (Tel-Aviv,
IL) |
Assignee: |
Polynest Technologies Ltd.
Tel-Aviv
IL
|
Family ID: |
41692233 |
Appl. No.: |
13/128880 |
Filed: |
November 12, 2009 |
PCT Filed: |
November 12, 2009 |
PCT NO: |
PCT/IL09/01070 |
371 Date: |
May 12, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61114078 |
Nov 13, 2008 |
|
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|
Current U.S.
Class: |
220/23.83 ;
53/266.1 |
Current CPC
Class: |
B29B 7/7615 20130101;
B29C 44/182 20130101; B01F 15/00123 20130101; B65B 55/20 20130101;
B01F 13/1055 20130101; B65D 75/527 20130101; B65B 3/326 20130101;
B01F 5/0077 20130101; B65D 75/42 20130101 |
Class at
Publication: |
220/23.83 ;
53/266.1 |
International
Class: |
B65D 25/00 20060101
B65D025/00; B65B 1/00 20060101 B65B001/00 |
Claims
1. An apparatus for delivering a product into a receptacle having a
feeding aperture, comprising: a mixing chamber having a plurality
of inlets each configured for separately receiving at least one of
a plurality of component materials and at least one outlet, said
mixing chamber being configured for forming the product by mixing
said plurality of component materials and injecting the product to
the feeding aperture via said at least one outlet; and a feeding
element configured for being secured in a feeding channel for
allowing said injecting.
2. The apparatus of claim 1, wherein the distance between said
mixing chamber and said aperture during said injecting is less than
5 centimeters.
3. The apparatus of claim 1, wherein each said inlet being
separately connected to a hydraulic tube configured for conducting
respective said component material from a pump, wherein the
distance between said mixing chamber and said pump is more than 10
centimeters.
4. The apparatus of claim 1, wherein each said inlet being
separately connected to a hydraulic tube configured for conducting
respective said component material from a container, wherein the
distance between said mixing chamber and said container is more
than 10 centimeters.
5. The apparatus of claim 1, wherein at least one of said feeding
element and said mixing chamber is detachable.
6. The apparatus of claim 1, wherein the distance between said
mixing chamber and said aperture during said injecting is less than
1 centimeter.
7. The apparatus of claim 1, wherein said feeding element is
configured for containing said mixing chamber.
8. The apparatus of claim 1, wherein the product is formed as an
outcome of a chemical reaction between at least two of said
plurality of component materials.
9. The apparatus of claim 1, wherein said mixing chamber having a
volume of less than 5 cubic millimeter for performing said
mixing.
10. The apparatus of claim 4, further comprising a motor unit
configured for motivating at least one of said mixing chamber and
the receptacle to said distance before said injecting.
11. The apparatus of claim 10, further comprising a control unit
configured for synchronizing between said motivating and said
injecting.
12. The apparatus of claim 1, further comprising a pumping unit
configured for directing said plurality of component materials into
said mixing chamber, said directing being controlled by at least
one user instruction.
13. The apparatus of claim 1, further comprising a feeding element
configured for supporting the positioning of said aperture in front
of said at least one outlet before said injecting.
14. The apparatus of claim 13, wherein said receptacle is a member
of a roll of a plurality of receptacles connected to a feeding
channel, further comprising a motor unit configured for conducting
said feeding element in said feeding channel for supporting the
positioning of respective said aperture of each member of said
roll.
15. The apparatus of claim 14, wherein said feeding element
comprises a wedge configured for cutting said feeding channel
during said conducting.
16. A roll of a plurality of receptacles for storing a product,
comprising: a plurality of receptacles each comprises a container
configured for storing the product of a mixture of a plurality of
components and a feeding aperture configured for receiving the
product; and a feeding channel configured for covering each said
feeding aperture and supporting the positioning of each said
feeding aperture in front of an injection unit having a mixing
chamber during a filling of respective said container.
17. The receptacle of claim 16, wherein said feeding channel is
configured for being cut to allow the filling of respective said
container with the product.
18. A method for creating a packaging element, comprising: using a
feeding element for feeding a receptacle having a feeding aperture
to a distance of less than 5 centimeter from an injection unit
having a mixing chamber; separately conveying a plurality of
component materials intosaid mixing chamber; mixing said plurality
of component at said mixing chamber to form a mixing product;
injecting the mixing product via said feeding aperture into said
receptacle; and allowing said mixing product to solidified in said
receptacle according to a shape of a packaged item.
19. The method of claim 18, further comprising using said
receptacle with said solidified mixing product for packaging said
packaged item without closing said aperture.
20. The method of claim 19, wherein said feeding comprising
actuating a roll of a plurality of receptacles to allow the
positioning of the receptacle in front an injection unit performing
said injecting.
21. The method of claim 18, further comprising: getting at least
one user instruction, before said separately conveying; and
separately conveying said plurality of component materials
according to said at least one user instruction.
22. The method of claim 18, wherein said plurality of component
materials comprises isocyanate and polyol, said mixing product
comprises polyurethane.
Description
FIELD AND BACKGROUND OF THE INVENTION
[0001] The present invention, in some embodiment thereof, relates
to packaging of component materials, and more particularly, but not
exclusively, to the mixing and storage of component materials
before and during the packaging.
[0002] Various materials are formed by mixing two or more chemical
components. For example foam, which is a mixture of isocyanate and
polyol, expands and hardens within about 10-30 seconds. In many
cases, a foam dispensing gun is used to generate the foam at the
packaging site.
[0003] U.S. Pat. No. 3,178,157 by Cole, U.S. Pat. No. 6,691,898 by
Hurray et al., and U.S. Pat. No. 5,462,204 by Finn, the disclosures
of which are incorporated herein by reference, describe dispensing
guns used in the making of foams, such as urethane foams.
[0004] As foam materials harden within a short time, remnants of
the foam may harden within the dispensing apparatus and clog flow
passageways. One solution to the clogging of passages is to include
a solvent flushing path in the gun, which provides a solvent that
cleans out portions of the gun that require cleaning, after every
use. U.S. Pat. No. 4,262,847 by Stitzer et al. describes one such
gun.
[0005] Other dispensing guns include a mechanical cleaning device
that passes through the mixing chamber between uses. U.S. Pat. No.
5,405,083 by Moses, the disclosure of which is incorporated herein
by reference, describes another dispensing gun in which, a
disposable mixing tube is replaced, each time the gun is used.
[0006] U.S. Pat. No. 5,429,308 to Brown describes a mixing gun
having a replaceable nozzle including a mixing chamber. Those parts
of the gun that come in contact with the mixed chemicals are
included in the replaceable nozzle. In the non-disposable part of
the gun, respective valves are used to control the flow of each of
the chemical components into the mixing chamber.
[0007] U.S. Pat. No. 6,375,096 by Rashidi describes a foam gun with
a disposable nozzle attachment including a mixing chamber in which
the chemicals mix. The disposable nozzle includes one way valves
for each of the chemicals entering the nozzle attachment, so as to
prevent backflow of the chemicals into the non-disposable part of
the gun. The cost of the disposable nozzle attachments is not
negligible and their replacement is time consuming. It is therefore
desired to reduce and even eliminate the need for replacement of
the disposable nozzle attachments, without incurring the costs and
inconvenience involved in a solvent flushing system or a mechanical
cleaning system.
[0008] U.S. Pat. No. 4,262,848 to Chabria describes a dispensing
gun, which does not have a mixing chamber at all. The chemicals are
mixed a short distance distal from the dispensing gun. Such mixing
in the air, may result in a reduced quality of the foam. A flexible
extension is suggested to be used to separately lead the chemicals
before they are mixed to a location forward of the gun.
SUMMARY OF THE INVENTION
[0009] The present invention, in some embodiments thereof, relates
to the delivery of fluids comprising a plurality of fluidic
components into one or more receptacles, by directing the fluidic
components into a mixing chamber located at a proximity of the
receptacle. In the mixing chamber, the fluidic components are mixed
and/or react together to form the fluid that is delivered into the
receptacle.
[0010] According to an aspect of some embodiments of the present
invention there is provided an apparatus for delivering a product
into a receptacle having a feeding aperture. The apparatus
comprises a mixing chamber having a plurality of inlets each
configured for separately receiving at least one of a plurality of
component materials and at least one outlet, the mixing chamber
being configured for forming the product by mixing the plurality of
component materials and injecting the product to the feeding
aperture via the at least one outlet and a feeding element
configured for being secured in a feeding channel for allowing the
injecting.
[0011] Optionally, the distance between the mixing chamber and the
aperture during the injecting is less than 5 centimeters.
[0012] Optionally, each the inlet being separately connected to a
hydraulic tube configured for conducting respective the component
material from a pump, wherein the distance between the mixing
chamber and the pump is more than 10 centimeters.
[0013] Optionally, each the inlet being separately connected to a
hydraulic tube configured for conducting respective the component
material from a container, wherein the distance between the mixing
chamber and the container is more than 10 centimeters.
[0014] Optionally, at least one of the feeding element and the
mixing chamber is detachable.
[0015] Optionally, the distance between the mixing chamber and the
aperture during the injecting is less than 1 centimeter.
[0016] Optionally, the feeding element is configured for containing
the mixing chamber.
[0017] Optionally, the product is formed as an outcome of a
chemical reaction between at least two of the plurality of
component materials.
[0018] Optionally, the mixing chamber having a volume of less than
5 cubic millimeter for performing the mixing.
[0019] More optionally, the apparatus further comprises a motor
unit configured for motivating at least one of the mixing chamber
and the receptacle to the distance before the injecting.
[0020] More optionally, the apparatus further comprises a control
unit configured for synchronizing between the motivating and the
injecting.
[0021] Optionally, the apparatus further comprises a pumping unit
configured for directing the plurality of component materials into
the mixing chamber, the directing being controlled by at least one
user instruction.
[0022] Optionally, the apparatus further comprises a feeding
element configured for supporting the positioning of the aperture
in front of the at least one outlet before the injecting.
[0023] More optionally, the receptacle is a member of a roll of a
plurality of receptacles connected to a feeding channel, further
comprising a motor unit configured for conducting the feeding
element in the feeding channel for supporting the positioning of
respective the aperture of each member of the roll.
[0024] More optionally, the feeding element comprises a wedge
configured for cutting the feeding channel during the
conducting.
[0025] According to an aspect of some embodiments of the present
invention there is provided a roll of a plurality of receptacles
for storing a product. The roll comprises a plurality of
receptacles each comprises a container configured for storing the
product of a mixture of a plurality of components and a feeding
aperture configured for receiving the product. The apparatus
further comprises a feeding channel configured for covering each
the feeding aperture and supporting the positioning of each the
feeding aperture in front of an injection unit having a mixing
chamber during a filling of respective the container.
[0026] Optionally, the feeding channel is configured for being cut
to allow the filling of respective the container with the
product.
[0027] According to an aspect of some embodiments of the present
invention there is provided a method for creating a packaging
element. The method comprises using a feeding element for feeding a
receptacle having a feeding aperture to a distance of less than 5
centimeter from an injection unit having a mixing chamber,
separately conveying a plurality of component materials into the
mixing chamber, mixing the plurality of component at the mixing
chamber to form a mixing product, injecting the mixing product via
the feeding aperture into the receptacle, and allowing the mixing
product to solidified in the receptacle according to a shape of a
packaged item.
[0028] Optionally, the method further comprises using the
receptacle with the solidified mixing product for packaging the
packaged item without closing the aperture.
[0029] More optionally, the feeding comprising actuating a roll of
a plurality of receptacles to allow the positioning of the
receptacle in front an injection unit performing the injecting.
[0030] Optionally, the method further comprises getting at least
one user instruction, before the separately conveying and
separately conveying the plurality of component materials according
to the at least one user instruction.
[0031] Optionally, the plurality of component materials comprises
isocyanate and polyol, the mixing product comprises
polyurethane.
[0032] Unless otherwise defined, all technical and/or scientific
terms used herein have the same meaning as commonly understood by
one of ordinary skill in the art to which the invention pertains.
Although methods and materials similar or equivalent to those
described herein can be used in the practice or testing of
embodiments of the invention, exemplary methods and/or materials
are described below. In case of conflict, the patent specification,
including definitions, will control. In addition, the materials,
methods, and examples are illustrative only and are not intended to
be necessarily limiting.
[0033] Implementation of the method and/or system of embodiments of
the invention can involve performing or completing selected tasks
manually, automatically, or a combination thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] Some embodiments of the invention are herein described, by
way of example only, with reference to the accompanying drawings.
With specific reference now to the drawings in detail, it is
stressed that the particulars shown are by way of example and for
purposes of illustrative discussion of embodiments of the
invention. In this regard, the description taken with the drawings
makes apparent to those skilled in the art how embodiments of the
invention may be practiced.
[0035] In the drawings:
[0036] FIG. 1 is a schematic illustration of an exemplary apparatus
having a mixture chamber designed for mixing a plurality of
component materials to form a fluid, and for delivering the fluid
into one or more receptacles placed at a proximity of the mixture
chamber, according to some embodiments of the invention; the
apparatus is shown to receive the component materials from two
reservoirs.
[0037] FIG. 2 is a schematic illustration of an apparatus through
which component materials flow for forming a product, and through
which the product is delivered into a receptacle, according to some
embodiments of the invention;
[0038] FIG. 3 is a schematic illustration of an exemplary apparatus
for forming a product from the component materials and delivering
the product into a receptacle, where the apparatus is characterized
by external gear pumps, according to some embodiments of the
invention;
[0039] FIG. 4 is a schematic illustration of two receptacles,
according to some embodiments of the present invention;
[0040] FIGS. 5A and 5B are schematic illustrations of an apparatus
for forming a product from the component materials and delivering
the product into a plurality of receptacles, according to some
embodiments of the invention;
[0041] FIGS. 5C and 5D are schematic illustrations of a feeding
element in a rail of a receptacle and an exemplary apparatus for
forming a product from the component materials, according to some
embodiments of the invention;
[0042] FIG. 5E is a schematic illustration of an exemplary
apparatus that comprises the mixing chamber and the feeding channel
of FIGS. 5C and 5D, according to some embodiments of the
invention;
[0043] FIG. 5F is a schematic illustration of a feeding element in
a rail of a receptacle and an exemplary apparatus for forming a
product from the component materials, according to some embodiments
of the invention; and
[0044] FIG. 6 is a flowchart of a method for delivering a product
into receptacles, according to some embodiments of the
invention.
DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION
[0045] The present invention, in some embodiment thereof, relates
to packaging of component materials, and more particularly, but not
exclusively, to the mixing and storage of component materials
before and during the packaging.
[0046] As used herein, to mix two or more materials means to induce
a chemical reaction, to blend, and/or to bring the materials into
contact with each other. As used herein, the term "delivery time"
refers to the time between the formation of a product, from mixing
two or more component materials, and the delivery of the product to
a receptacle.
[0047] According to an aspect of some embodiments of the present
invention, an apparatus for forming a fluidic product by mixing
fluidic component materials together and for delivering the newly
formed product to a receptacle is provided. The mixing of the
component materials occurs in a mixing chamber that is positioned
at proximity of the receptacle--for example, less than 5
centimeters from the receptacle, for example between 0.01 and 2
millimeters. In such a manner, the product is delivered into the
receptacle substantially immediately after the mixing. For example,
the product may be delivered to the receptacle approximately
between 1 and 50 milliseconds after being formed. The apparatus
comprises a feeding element that allows the feeding of one or more
receptacles toward a position about the mixing chamber. Optionally,
in use, the feeding element is placed in a feeding channel that is
attached to the one or more receptacles. The feeding channel
supports the feeding of the one or more receptacles in front of the
mixing chamber that delivers the product thereto.
[0048] The short time between the mixing of the component materials
within the mixing chamber and the delivery of the product to the
receptacle makes the apparatus useful for mixing isocyanate and
polyol, for forming and delivering polyurethane. Polymers, such as
polyurethane, are known to solidify relatively short time after
being formed.
[0049] The short time between the formation and the delivery of the
product allows the delivery of the product to take place when the
product is still in fluid form. This may reduce or eliminate any
clogging which may be formed as a result of the hardening of
packaging material inside the apparatus.
[0050] Optionally, the above apparatus is designed for being
conveyed by a motor unit to a position at which a delivering
element of the apparatus is aligned with an inlet, such as a
receiving aperture, of the receptacle.
[0051] Optionally, the above apparatus is designed for moving the
receptacle, for example by using rollers, to a point in which the
inlet of the receptacle is aligned with the delivering element,
such as a nozzle, of the apparatus. For example the apparatus
and/or receptacle may be moved so that the delivering element is
aligned with the inlet. Optionally, the apparatus and/or
receptacles may be moved relative to each other, in order to
deliver the product to a plurality of receptacles, one by one.
[0052] According to an aspect of some embodiments of the present
invention, a receptacle is provided. The receptacle includes a
container, designed for storing a product, an inlet, designed for
receiving a product in a fluidic state, and a feeding channel, for
supporting the motivation of the receptacle toward an element that
delivers the product into the receptacles. Optionally, the inlet is
covered by the feeding channel. In use, the feeding channel may be
torn, for example by a wedge, to allow a delivering element to
directly access the inlet. The inlet may be sealed after being
opened, for example by heating the open sides thereof and joining
them together.
[0053] Before explaining at least one embodiment of the invention
in detail, it is to be understood that the invention is not
necessarily limited in its application to the details of
construction and the arrangement of the components and/or methods
set forth in the following description and/or illustrated in the
drawings and/or the Examples. The invention is capable of other
embodiments or of being practiced or carried out in various
ways.
[0054] FIG. 1 is a schematic illustration of an apparatus 110 for
mixing a plurality of component materials at a proximity of a
receptacle 112 that is designed for storing the product of the
mixing, according to some embodiments of the invention. The
apparatus 110 is designed to be attached and/or contained in a
feeding element that allows the feeding of one or more receptacles
toward a position about the mixing chamber, for example to a
position at a distance of less than 5 millimeter.
[0055] In FIG. 1, apparatus 110 separately receives a plurality of
component materials 104, 108 from respective reservoirs 102, 106.
Component materials 104 and 108 are conveyed to a mixing chamber
114 in which component materials 104 and 108 are mixed. The
conveying is done by conveyers, for example pipes, tubes, and
capillaries. The product of the mixing is delivered to a receptacle
112, which is positioned at proximity of the mixing chamber 114,
optionally in a distance of less than 5 centimeters therefrom.
[0056] Optionally, the mixing chamber 114 comprises a plurality of
inlets each configured for receiving another component material and
one or more outlets configured for injecting the product via an
aperture in the receptacle. Optionally, the diameter of the
aperture is less than 5 centimeters. Optionally, the diameter of
the aperture is less than 2 centimeters. Optionally, the diameter
of the aperture is less than 1 centimeter. As the component
materials which are conducted via the plurality of inlets may
accumulate in a manner that blocks the mixing chamber 114 the
inlets and/or the outlets of the mixing chamber 114, the mixing
chamber 114 may be detachable. In such a manner, the mixing chamber
114 may be replaced in order to ensure a continuous functioning of
the apparatus 110. Optionally, the apparatus 110 and/or the mixing
chamber 114 comprises one or more coupling fitments that allows the
replacement, cleaning, and/or repositioning of the mixing chamber
114. Optionally, the apparatus 110 may be detachable and/or
replaceable, allowing the user to maintain a system that uses the
apparatus 110 for filling receptacles, such as a packaging
system.
[0057] Optionally, apparatus 110 is connected to a motor unit that
is designed to move apparatus 110 to face receptacle 112 or vice
versa. Such an actuation allows apparatus 110 to deliver the
product into receptacle 112, which is optionally a member of a roll
of a plurality of receptacles, without a conduit or any other
piping device. For example, apparatus 110 may be placed on a rail
and moved along the rail by a motor. Optionally, apparatus 110
includes actuators for the moving one or more receptacles 112 into
a delivery position, in which the product is delivered into
receptacle 112. As further described below, apparatus 110 may
include rollers for actuating the roll's receptacles, for example
the receptacle shown at 112.
[0058] As mixing chamber 114 is brought to proximity of receptacle
112, the delivery time of the mixed product is reduced. Apparatus
110 may therefore be used to mix fluids which harden and/or
solidify shortly after being mixed. Reducing the product's delivery
time allows the delivery of the product to take place when the
product is still fluidic. In such a manner, the clogging of the
product conveyers is reduced or eliminated.
[0059] The presence of apparatus 110 allows first and second
component materials 104 and 108 to be stored separately. In such a
state, each one of the component materials 104 and may be contained
in their respective reservoirs for an extended period of time, such
as half a year, a year and/or any other shelf life at inert state
and/or before crystallizing. Therefore, reservoirs 102 and 106 may
hold large amount of component materials.
[0060] According to exemplary embodiments of the present invention,
apparatus 110 is designed for forming polyurethane. In such
embodiments, the first component material 104 is isocyanate, and
the second component material 108 is polyol. According to exemplary
embodiments of the present invention, apparatus 110 may be used for
forming polyurethane bags for packaging. In use, the apparatus 110
may be used for mixing components in a liquid state of aggregation
to form polyurethane foam which is spread around the shape of a
packaged item. The mixture solidified to form a hardened wraparound
that is adjusted to the dimensions of the packaged item.
[0061] It must be noted that apparatus 110 is not limited to be
used with any specific component materials. Apparatus 110 (and
consequently apparatus 200 of FIG. 2, apparatus 300 of FIG. 3, and
apparatus 500 of FIG. 5) may be used with many component materials,
to form a large range of desired products.
[0062] Optionally, more than two component materials are needed for
forming the desired product. Apparatus 110 is optionally designed
for receiving more than two component materials and housing a
mixing of the component materials, for obtaining the desired
product. Optionally, the component materials may form the desired
product through a series of sequential mixing processes. For
example, a first component material combines with a second
component material, forming an intermediate product, and the
intermediate product combines with a third component material, to
form the desired product.
[0063] FIG. 2 is a schematic illustration of an apparatus through
which component materials flow for forming a product and, and
through which the product is delivered into a receptacle, according
to some embodiments of the invention.
[0064] Apparatus 200 includes conveyers 202 and 204, for receiving
component materials from reservoirs and conveying the component
materials to mixing chamber 206, a mixing chamber 206, for mixing
the component materials, and a delivering element 208, such as a
nozzle, for directing the product formed in mixing chamber 206 to
the receptacle. Optionally, conveyers 202 are pipes, tubes,
capillaries, or a combination thereof.
[0065] Optionally, apparatus 200 further includes a pumping unit,
which for example includes pumps 210 and 212. Pumps 210 and 212 are
placed along conveyers 202 and 204, respectively, for regulating
the flow of the component materials out of the reservoirs and into
mixing chamber 206. Optionally, pump drivers 214 and 216 are
provided, for driving pumps 210 and 212, respectively. Optionally,
pump drivers 214 and 216 are motors. Optionally, a control unit
(not pictured) is provided to control the operation of pump drivers
214 and 216, and consequently, of pumps 214 and 216. Optionally,
the control unit is controlled by a user, and the pumping unit is
controlled by at least one user instruction.
[0066] Conveyer 202 is connected to a reservoir, for example
reservoir 102 of FIG. 1, at an entry point 202a, for receiving a
component material, for example component material 104 of FIG. 1.
The component material flows through conveyer 202 and into mixing
chamber 206. Similarly, a second component material, for example
component material 108 of FIG. 1, flows to mixing chamber 206
through conveyer 204. Optionally, at least one flow parameter of
the component materials is regulated by pumps 210 and 212. In
mixing chamber 206, a mixing between the component materials takes
place, and a product is formed. The product exits apparatus 200
through delivering element 208, and enters the receptacle where the
product is to be stored. Since the flow of the product out of
mixing chamber 206 through delivering element 208 is related to the
flow of the component materials into mixing chamber 206, the flow
properties of the product through delivering element 208 depends on
the settings of pumps 210 and 212. The flow of the product out of
delivering element 208 is therefore regulated by pumps 210 and
212.
[0067] Optionally, pumps 210 and 212 control the pressure at which
the component materials are directed into mixing chamber 206.
Optionally, pumps 210 and 212 control the quantities of the
component materials directed into mixing chamber 206.
[0068] Optionally, pumps 210 and 212 are external gear pumps.
Optionally pumps 210 and 212 are internal gear pumps. Optionally
pumps 210 and 212 are gerotor pump. Optionally pumps 210 and 212
are peristatic pump. Optionally pumps 210 and 212 are positing
displacement pumps. Pumps 210 and 212 may be placed at any location
that allows them to control the flow of the component materials,
for example, anywhere along pipes 202 and 204, respectively.
[0069] Optionally, mixing chamber 206 is constructed according to
the mixing chamber described in PCT Applications WO2005IL00355 and
WO2005IL00356 by Malik et al., which are herein incorporated by
reference. According to some embodiments of the present invention,
mixing chamber 206 is characterized by a small volume, for example
20 mm.sup.3. A small-sized mixing chamber may reduce the time
between the formation of the desired product and the delivery of
the product into the receptacle.
[0070] Optionally, delivering element 208 is an integral part of
mixing chamber 206. Optionally, delivering element 208 is an
aperture on the surface of mixing chamber 206, through which the
product formed in mixing chamber 206 leaves apparatus 200.
Optionally, delivering element 208 comprises a hollow tubular
element, such as a needle, for injecting the product via the inlet
of the receptacle. Optionally, delivering element 208 is a narrow
element having a cross sectional area of between 0.5 and 1
mm.sup.2. Optionally, delivering element 208 partially or fully
protrudes from apparatus 200. Protruding delivering element 208 may
enter the receptacle, for example through an inlet of the
receptacle. In such a manner, protruding delivering element 208
delivers the product to the receptacle from the inside of the
receptacle, and therefore reduces or eliminates a spillage of the
product during delivery. A narrow delivering element 208 may
produce a precise delivery of the product into the receptacle, by
causing the product to exit apparatus 200 at a narrow stream.
[0071] According to some embodiments of the present invention, a
conveyer is provided for each component material. Optionally, a
pump is also provided for each component material. For example, if
three, four, or six component materials are needed to be mixed in
order to form a desired product, then three, four, or six conveyers
are provided, such that each conveyer is connected to a different
reservoir. Optionally, three, four, or six pumps are provided, each
pump regulating the flow of a different component material.
[0072] FIG. 3 is a schematic illustration of an apparatus 300 for
forming a product from the component materials and delivering the
product into a receptacle, where the apparatus is characterized by
external gear pumps, according to some embodiments of the
invention. Apparatus 300 is an embodiment of apparatus 110 of FIG.
1, and of apparatus 200 of FIG. 2.
[0073] Apparatus 300 includes the same elements and units as
apparatus 200 depicted in FIG. 2. Apparatus 300 is an exemplary
embodiment of apparatus 200, as apparatus 300 is characterized by a
first and a second external gear pumps.
[0074] An external gear pump is characterized by two gears
connected to each other. One of the gears is rotated by a user,
either manually or automatically, for example through a motor. The
connection between the gears causes the second gear to rotate as
well. The rotation of the gears forces the fluid to flow from the
entrance area of the pump to an outlet area of the pump. The rate
of rotation of the gears affects the pressure at which the fluid
enters and exits the pump.
[0075] An exemplary external gear pump measures about 2 cm by 3 cm
by 4 cm. This pump pumps a fluid of a viscosity of about 200
mPa.times.s out of a conveyer, for example conveyer 202, and into
mixing chamber 206, at a pressure which may be varied between about
5 BAR and 15 BAR, leading the newly formed product out of
delivering element 208 at a pressure between 5 and 15 BAR. The
fluid of viscosity 200 mPa.times.s is, for example isocyanate,
which is a typical component material of packaging material.
[0076] A first external gear pump is associated with conveyer 202.
The entrance area of first external pump is connection point 202b
between conveyer 202 and pump cover 302, and the outlet area of the
first external pump is the continuation of conveyer 202. The first
external gear pump includes a pump cover 302 to house the two
interconnected gears, a gear casing 304, to connect the pump cover
to the continuation of conveyer 202, and a drive shaft 306, which
is connected to one gear and is designed for rotating the one gear.
Optionally, the first external gear pump also includes a motor-gear
coupling element 308, designed for coupling drive shaft 306 to a
motor, and allowing the motor to apply a torque upon drive shaft
306, which in turn applies a torque upon one of the gears. For
example, motor-gear coupling element may be used to couple drive
shaft 306 to pump driver 214 shown in FIG. 2.
[0077] Similarly to the first external gear pump, a second external
gear pump, associated with conveyer 204, is characterized by a
second pump cover 310, a second gear casing 312, a second drive
shaft 314, and optionally a second motor-gear coupling 316.
[0078] As the gears of the first external gear pump are rotated,
first component material 104 contained in reservoir 102 of FIG. 1
is directed through conveyer 202 into pump cover 302. The gears
within pump cover 302 direct the component material via gear casing
304 to the continuation of pipe 202 and to mixing chamber 206. In a
similar manner, second component material 108, contained in
reservoir 106 of FIG. 1, reaches mixing chamber 206, and a mixing
between the first and second component materials occur, to form the
desired product. The product exits mixing chamber 206, flows
through delivering element 208, and enters the receptacle.
[0079] It should be noted that such an external gear pump builds up
a relatively high pressure in a relatively small mixing chamber
206.
[0080] FIG. 4 is a schematic illustration of two receptacles,
according to some embodiments of the present invention.
[0081] Receptacle 400 is characterized by an feeding aperture 402,
designed for receiving a product, a container 403, for storing the
product, and a feeding channel 404 for covering feeding aperture
402 and supporting the motivation of receptacle 400 toward a
filling apparatus, such as apparatus 110 of FIG. 1, apparatus 200
of FIG. 2, and/or apparatus 300 of FIG. 3.
[0082] Optionally, feeding aperture 402 is positioned on the
perimeter of the container and allows the delivering of the product
after receptacle 400 has been moved to align feeding aperture 402
with a filling apparatus. According to some embodiments of the
present invention, feeding channel 404 is interposed between
feeding aperture 402 and the filling apparatus, and therefore
prevents access to feeding aperture 402 by the filling apparatus.
Optionally, feeding channel 404 is designed to be torn, for example
by a wedge, such as a blade, that is connected to the filling
apparatus, during the delivery process, as described below, in
FIGS. 5A and 5B. Such a tear allows access by a delivering element
of the filling apparatus to feeding aperture 402. Optionally, the
inlet is closed and the product is delivered to receptacle 400
after the feeding aperture 402 is punctured, for example using the
delivering element. Optionally, feeding aperture 402 may be sealed
after the product's delivery, for example by heating the sides of
feeding aperture 402 to a temperature of about 120.degree., causing
a partial melting of the heated areas, and joining the sides
together. Optionally, the melted material is a high-density
polyethylene (PEHD).
[0083] Feeding channel 404 is tubular and is designed for being
traversed, for example by feeding element, such as a rod or a rail.
Optionally, feeding channel 404 is replaced by a series of loops
designed to be traversed by the feeding element. The feeding
element may enter feeding channel 404 through opening 406, thereby
actuating receptacle 400 to face the filling apparatus, which
delivers a product to receptacle 400. The actuating may be
achieved, for example, by supporting the motivation of, or
constraining the movement of receptacle 400 along the feeding
element.
[0084] Optionally, receptacle 400 is collapsible. Optionally,
receptacle 400 is made out of PEHD. Optionally, receptacle 400 is
rigid. Optionally, receptacle 400 is shaped to determine the shape
of a product, like packaging material, which solidifies shortly
after being formed by the component materials thereof. It should be
noted that as the product is injected into a receptacle having a
relatively limited feeding aperture, optionally with a diameter of
less than 2 centimeters, the receptacle 400 may not be seamed,
welded, and/or otherwise closed. The product, which is injected in
a fluid state of aggregation and solidified in the receptacle to a
solid state of aggregation does not, or substantially does, not
extend beyond the sides of the walls of the receptacle 400. The
product solidifies before or substantially before it extends beyond
the sides of the walls of the receptacle 400 and therefore the
closing of the receptacle 400 may not be required in order to
create a packaging element therefrom.
[0085] Optionally, receptacle 400 is used as a packaging element,
to be filled with packaging material--for example polyurethane.
Optionally, receptacle 400 is used as a polyurethane packaging
element.
[0086] According to some embodiments of the present invention, a
roll 401 is provided, in which receptacle 400 is joined on a side
thereof to a second receptacle 408, having an inlet 412, and
feeding channel 414. On the side that is common to receptacles 400
and 408, a line of perforations 410 is optionally provided, in
order to allow an easy separation between the receptacles,
following the product delivery to the receptacles. Optionally,
channels 404 and 414 are joined together to assemble a central
feeding channel. Optionally, the roll includes a plurality of
receptacles joined at the sides and assembling the central feeding
channel. The roll is optionally fed to a filling apparatus, which
delivers a product to the receptacles, by inserting a feeding
element into opening 406 of feeding channel 404. Optionally, the
apparatus moves along the feeding element and delivers the product
to each receptacle in turn. Optionally, the apparatus is fixed, and
the receptacles are moved along the feeding element toward the
apparatus, so that the apparatus delivers the product to each
receptacle in turn, as illustrated below (FIGS. 5A and 5B).
[0087] FIGS. 5A and 5B are schematic illustrations of an apparatus
500 with a feeding element 502 for forming a product from component
materials and delivering the product into a plurality of
receptacles, according to some embodiments of the present
invention. FIG. 5A is a front view of apparatus 500, and FIG. 5B is
an isometric view of apparatus 500.
[0088] Apparatus 500 includes all the elements of apparatus 300,
for forming a desired product and delivering to a receptacle, the
feeding element 502, designed for being inserted into a feeding
channel 404 described in FIG. 4, and rollers 504, for moving the
receptacles along feeding element 502. Optionally feeding element
502 is a rod or a rail. Optionally, feeding element 502 includes a
wedge, such as a blade wedge, for example as shown at 506 of FIG.
5A. The wedge cuts feeding channel 404, thereby allowing continued
movement of the receptacles along rod 502. Optionally, the blade
also cuts open the inlets of the receptacles, thereby allowing
feeding of the receptacles and the delivery of the product to the
receptacles.
[0089] Optionally, apparatus 500 further comprises a sealing device
(not shown), for sealing the receptacles once the product delivery
is complete. Optionally, sealing device seals the receptacles, by
heating the open sides of the inlet and joining them together, as
explained above. Optionally, the sealing device includes a resistor
based heater.
[0090] In FIGS. 5A and 5B, feeding element 502 is inserted into a
central feeding channel of a roll which includes receptacles 400
and 408. Rollers 504 move the receptacles in direction 508, along
feeding element 502. The wedge 506 on feeding element 502 cuts the
central feeding channel, to allow access to feeding aperture 402 by
apparatus 500, and to prevent the kit from getting stuck on feeding
element 502, thus ensuring that the receptacles can continue to be
moved. Optionally, the wedge 506 on feeding element 502 also cuts
open feeding aperture 402, if feeding aperture 402 is closed. When
a delivering element of apparatus 500 is aligned with open feeding
aperture 402, the rollers stop moving, therefore stopping the
movement of the receptacles and the delivery of the product takes
place, as previously described. After the delivery to receptacle
400 is complete, the rollers resume their movement, and the
receptacles resume moving in direction 508. Feeding aperture 402
passes by sealing device, and receptacle 400 is sealed, in the
manner described above. As the movement continues, inlet 412 of
receptacle 408 is cut open, and the process is repeated.
[0091] Optionally, the receptacles are fixed, and apparatus 500
moves along a feeding channel, such as a rail, inserted into the
central feeding channel of the roll of receptacles, to deliver the
product to the receptacles. Optionally, rollers 504 are substituted
by different means for moving the receptacles, such as pneumatic
manipulators.
[0092] Optionally, the product delivery is synchronized with the
movement of the receptacle. This may be done, for example, by
connecting flow control units to rollers 504. Exemplary flow
control units are the pumps of apparatus 500 and/or pump drivers
214 and 216, as described above. According to some embodiments of
the present invention, product delivery is not executed when
rollers 504 move. Optionally, a control unit 512 is provided, to
control the operation of rollers 504 and of pump drivers 214 and
216.
[0093] Optionally, control unit 512 is programmable by a user, in
order the set the parameters of the synchronization between rollers
504 and pump drivers 214 and 216. For example, the user may change,
via control unit 512, the speed of rotation of the rollers and/or
the torque provided by pump drivers 214 and 216 to the pumps of
apparatus 500. Optionally, if apparatus 500 moves and the
receptacles are fixed, the motor unit for moving apparatus 500 is
synchronized with pump drivers 214 and 216. Optionally, control
unit 512 controls the operation of the motor unit for moving
apparatus 500 and of pump drivers 214 and 216. Optionally, control
unit 512 is programmable by a user, in order the set the parameters
of the synchronization between the motor unit and pump drivers 214
and 216. For example, the user may change, via control unit 512,
the speed at which apparatus 500 moves and/or the torque provided
by pump drivers 214 and 216 to the pumps of apparatus 500.
[0094] Optionally, control unit 512 is designed to receive at least
one instruction from a user, for example through a computer
program. Optionally, the instruction is given in order to set
quantities and/or pressures of the component materials directed
into the mixing chamber and the quantity and/or the pressure of the
product formed by the component materials as the product is
directed into the receptacles. Optionally, control unit 512
includes a computer.
[0095] Optionally, apparatus 500 includes a sensor placed next to
delivering element 208, shown in FIGS. 2 and 3. The sensor detects
the position of feeding aperture 402 in relation to the outlet of
the mixing chamber, which may be referred to herein as a delivering
element 208. Optionally, the sensor is designed to send a signal to
control unit 512, when feeding aperture 402 is in a position
suitable for product delivery by apparatus 500, and cause the
moving means to stop the movement of the receptacles, and/or the
movement of apparatus 500.
[0096] Optionally, the sensor is part of an image capturing device,
such as a charge coupled device (CCD) sensor, or a complementary
metal oxide semiconductor (CMOS) sensor. The position of the
feeding aperture 402 is determined according to an analysis of the
image captured by the sensor. The analysis is optionally performed
by control unit 512.
[0097] Optionally, the sensor is part of a photo detector, which
includes a light source, and a sensor. Light emitted by the light
source illuminates the receptacle, and is reflected back to the
sensor. When the emitted light illuminates feeding aperture 402,
light is reflected in a different manner toward the sensor. For
example, a higher percentage, or a lower percentage may be
reflected. The position of the inlet is determined according to the
change in the properties of light detected by the sensor.
[0098] Reference is now made to FIGS. 5C and 5D which are schematic
illustrations of a feeding element 601 in a feeding channel 602 of
a receptacle 613 and an exemplary mixing chamber 607 for forming a
product from the component materials which is connected to
hydraulic tubes 604 and designed to be contained in the feeding
element, according to some embodiments of the invention. Reference
is also made to FIG. 5E, which is a schematic illustration of an
exemplary apparatus 650 that comprises the mixing chamber 607 and
the feeding channel 602, according to some embodiments of the
invention. In the exemplary apparatus 650, the mixing chamber 607
is contained in the feeding channel 602. Optionally, the hydraulic
tubes 604 have valves for adjusting the streaming of the material
components therein. The hydraulic tubes may be flexible, rigid,
and/or having flexible and rigid segments. The hydraulic tubes may
be covered by one or more heating sleeves to maintain the
temperature of the streamed component materials. Optionally,
different tubes are coated with different heating sleeves to
maintain different temperatures of different streamed component
materials.
[0099] The feeding element 601 is optionally defined as described
above in relation to feeding element 502. In addition, the feeding
element 601 is designed to contain apparatus 603 that is depicted
in FIG. 5D, for example as depicted in FIG. 5F. As depicted in FIG.
5D, apparatus 603 comprises two inlets 606 configured for
separately receiving different component materials for injecting
the product via an aperture in the receptacle, such as the inlet
shown at 412 of FIG. 4. The apparatus 603 comprises a mixing
chamber 607 for mixing the received component materials, for
example as described above in relation to FIG. 1. Each one or the
inlets 606 is connected to a conducting element 608, such as a
conveyer, for example a tube, which is designed to conduct the
respective component material thereto. The conducting element 608
is stretched along the feeding element 601. The feeding element 601
has an injecting aperture (not shown) for allowing the apparatus
603 to inject the product via the receptacle's aperture. In such a
manner, the product is injected directly to the receptacle 613. The
direct injection reduces the waste of component materials as it
assures that the product is injected directly into the receptacle
613. In addition, the cleaning frequency may be reduced.
[0100] Optionally, the apparatus 603 comprises a blade 651 for
cutting the feed channel 404 to allow the aforementioned injection.
As described above, the feeding channel 404 is designed to be torn
by the blade 651 during the delivery process. Such a tear allows
the delivering of the product via the delivering element of the
mixing chamber 607 to the receptacle 613.
[0101] It should be noted that the hydraulic tubes 604 allows the
positioning of the mixing chamber in a distance from the pumps
and/or the containers. For example, the distance may be 1, 2, 3, 4,
5, 10, 20, 30, 40, 50, 100, 200, and 500 centimeter(s). In such a
manner, the mixing chamber 607 can easily replaced when plugged.
Furthermore, the hydraulic tubes 604 allows the positioning of the
mixing chamber 607 in feeding elements having different structures
which are adapted for feeding different receptacles. In such a
manner, different feeding elements may be attached to the apparatus
603 to allow the feeding of receptacles from different materials
and/or of various forms.
[0102] FIG. 6 is a flowchart of a method 700 for delivering a
product into receptacles, according to some embodiments of the
invention.
[0103] At 702, component materials of the product are provided, for
examples inside reservoirs. Optionally, the component materials are
the component materials needed for forming packaging material, as
described above. Optionally, two component materials are needed for
forming the desired product. Optionally, more than two component
materials are needed for forming the desired product.
[0104] At 704, an access is opened to the receptacle. For example,
a closed inlet of the receptacle may be opened. Optionally the
feeding aperture 402 is punctured by a needle, as described above.
Optionally, the feeding aperture 402 is cut open by a blade, as
described above. Optionally, a channel covering the feeding
aperture 402 is cut, for example as shown at numeral 651 in FIG. 5E
and described above.
[0105] At 706, at least one user instruction is received.
Optionally, the instruction is sent via a control unit to a pumping
unit, as described above. Optionally, the instruction is used to
set one or more flow parameters of one or more component materials.
For example, a pressure and/or a quantity of a component material
is chosen.
[0106] At 708, the component materials flow out of the reservoirs
and are received conveyers described above. Optionally, the
component materials are pumped out of the reservoirs and into the
conveyers. At this stage, the component materials do not come in
contact with each other.
[0107] At 610, the flow of the component materials is adjusted, if
needed, according to the user instruction of 706. The adjustment
may be performed, for example by monitoring the flow properties of
the component materials and/or the product, and changing the flow
properties, according to the user instruction. This may be
accomplished, for example, by changing a torque provided by a pump
driver to a gear of an external gear pump, as described above.
[0108] At 712, the component materials reach a mixing chamber. In
the mixing chamber, the component materials are mixed, and a
product is formed, as described above.
[0109] At 714, the product formed in the mixing chamber is directed
by a delivering element to the receptacle, for example through the
inlet opened at 604.
[0110] At 718, another receptacle is moved into position, and the
process is repeated, starting from step 704.
[0111] Method 700 may be used with the apparatuses shown in FIGS.
1, 2, 3, 5A, and 5B. Method 700 is useful for quickly forming and
delivering products which harden and/or solidify within a short
period of time after being formed, and need to be delivered to a
receptacle while still in fluid form. Such a product is packaging
material, which solidifies about 10-30 seconds after being formed.
Method 700 is also useful for forming and delivering products that
are affected by contact with air, while the component materials of
the products are not affected by being exposed to air.
[0112] It is expected that during the life of a patent maturing
from this application many relevant products and component
materials will be developed and the scope of the term "product" and
"component material" is intended to include all such new
technologies a priori.
[0113] As used herein the term "about" refers to .+-.10%.
[0114] The terms "comprises", "comprising", "includes",
"including", "having" and their conjugates mean "including but not
limited to".
[0115] The term "consisting of" means "including and limited
to".
[0116] The term "consisting essentially of" means that the
composition, method or structure may include additional
ingredients, steps and/or parts, but only if the additional
ingredients, steps and/or parts do not materially alter the basic
and novel characteristics of the claimed composition, method or
structure.
[0117] As used herein, the singular form "a", an and the include
plural references unless the context clearly dictates otherwise.
For example, the term "a compound" or "at least one compound" may
include a plurality of compounds, including mixtures thereof.
[0118] Throughout this application, various embodiments of this
invention may be presented in a range format. It should be
understood that the description in range format is merely for
convenience and brevity and should not be construed as an
inflexible limitation on the scope of the invention. Accordingly,
the description of a range should be considered to have
specifically disclosed all the possible subranges as well as
individual numerical values within that range. For example,
description of a range such as from 1 to 6 should be considered to
have specifically disclosed subranges such as from 1 to 3, from 1
to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as
well as individual numbers within that range, for example, 1, 2, 3,
4, 5, and 6. This applies regardless of the breadth of the
range.
[0119] Whenever a numerical range is indicated herein, it is meant
to include any cited numeral (fractional or integral) within the
indicated range. The phrases "ranging/ranges between" a first
indicate number and a second indicate number and "ranging/ranges
from" a first indicate number "to" a second indicate number are
used herein interchangeably and are meant to include the first and
second indicated numbers and all the fractional and integral
numerals therebetween.
[0120] It is appreciated that certain features of the invention,
which are, for clarity, described in the context of separate
embodiments, may also be provided in combination in a single
embodiment. Conversely, various features of the invention, which
are, for brevity, described in the context of a single embodiment,
may also be provided separately or in any suitable subcombination
or as suitable in any other described embodiment of the invention.
Certain features described in the context of various embodiments
are not to be considered essential features of those embodiments,
unless the embodiment is inoperative without those elements.
[0121] Although the invention has been described in conjunction
with specific embodiments thereof, it is evident that many
alternatives, modifications and variations will be apparent to
those skilled in the art. Accordingly, it is intended to embrace
all such alternatives, modifications and variations that fall
within the spirit and broad scope of the appended claims.
[0122] All publications, patents and patent applications mentioned
in this specification are herein incorporated in their entirety by
reference into the specification, to the same extent as if each
individual publication, patent or patent application was
specifically and individually indicated to be incorporated herein
by reference. In addition, citation or identification of any
reference in this application shall not be construed as an
admission that such reference is available as prior art to the
present invention. To the extent that section headings are used,
they should not be construed as necessarily limiting.
* * * * *