Alternating Gripper Decontamination Unit for Containers and Caps
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Solution Overview
Problem
Existing decontamination units for plastic container manufacturing are costly, bulky, and increase the cycle time and electrical consumption of the manufacturing process, as they require separate decontamination paths for containers and caps.
Innovation Solution
A single decontamination unit that simultaneously decontaminates both plastic containers and caps using a bundle of electrons, with a conveyor system that alternates gripping mechanisms to ensure efficient exposure to the decontamination radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate decontamination units are used for containers and caps, then each component can be decontaminated independently, but the manufacturing machine's electricity consumption increases significantly
Solution Approach 1:
The patent combines two separate decontamination units (one for containers and one for caps) into a single shared decontamination unit. Both containers and caps are conveyed through the same electron beam radiation source, allowing simultaneous decontamination of both components using one electron beam generator, thereby significantly reducing electricity consumption while maintaining decontamination effectiveness.
Solution Approach 2:
The single decontamination unit is designed to handle multiple types of objects (both containers and caps) through the same electron beam radiation field. The unit performs the universal function of decontaminating any microcontaminated object that passes through it, regardless of whether it is a container or a cap, eliminating the need for separate specialized units.
2Use of energy by moving object
If a single decontamination unit is used for both containers and caps, then electricity consumption is reduced, but containers and caps must be stored in a sterile environment after decontamination
Solution Approach 1:
The patent implements continuous conveyance systems that move containers and caps directly from the decontamination unit to the filling and capping stations without interruption. The gripping means continuously transfer decontaminated items along the production line, eliminating the need for sterile storage areas by maintaining an unbroken sterile pathway from decontamination to final assembly.
Solution Approach 2:
The patent introduces specialized gripping means as intermediary devices that handle both containers and caps during conveyance. These gripping mechanisms serve as mediators that can securely hold different types of objects (containers by their body, caps by their rim) and transfer them through the decontamination zone and along the production line, enabling the single-unit system to manage multiple item types without complex sterile storage infrastructure.
3Productivity
If separate decontamination paths are used for containers and caps, then decontamination can be performed simultaneously, but the manufacturing machine becomes more bulky and expensive
Solution Approach 1:
The patent merges the decontamination paths for containers and caps into a single shared electron beam radiation zone. Both item types are conveyed through the same compact decontamination unit in an alternating sequence, reducing the overall footprint and cost of the manufacturing machine while maintaining the capability to decontaminate both containers and caps simultaneously.
Solution Approach 2:
The patent employs periodic action by alternating the conveyance of containers and caps through the shared decontamination unit. The gripping means sequentially transfer containers and caps in an alternating pattern (container, cap, container, cap) through the electron beam radiation zone, allowing both item types to be decontaminated in the same space without requiring separate parallel paths, thus reducing machine size and cost.
4Volume of stationary object
If containers and caps are conveyed through the same decontamination zone with alternating gripping, then the decontamination unit size is reduced, but the conveyor system requires precise alternating positioning
Solution Approach 1:
The patent uses specialized gripping means as intermediary devices that simplify the coordination of alternating conveyance. These gripping mechanisms are designed to automatically alternate between holding containers and caps, transferring them sequentially through the decontamination zone. The gripping means act as intelligent mediators that manage the alternating pattern, reducing the complexity of conveyor system coordination while enabling compact unit design.
Solution Approach 2:
The patent implements dynamic positioning of the gripping means within the decontamination zone. The gripping devices can adjust their positions and timing dynamically to accommodate the alternating conveyance of containers and caps, optimizing the use of space within the compact decontamination unit while maintaining precise coordination. This dynamic approach allows the system to adapt to different item types and maintain ease of operation despite the alternating pattern requirement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the cycle time and electrical consumption of the manufacturing process, while also reducing the size and cost of the decontamination unit, and ensures that both containers and caps are decontaminated in a single sterile circuit.
Implementation Method 1
the containers, once in their final form, pass through a decontamination unit in which they are decontaminated, for example by being moved in front of decontamination radiation in the form of an electron beam which eliminates all or part of the microorganisms
Data Source
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AI summary
The invention relates to a method for decontaminating a series of caps and a series of plastic containers (2) each intended to be sealed by one of the caps (6) in the series of caps, the method comprising the following steps: - emitting of decontamination radiation (15) by emitting means (14), - conveying of the series of containers by first gripping means (13) to the emitting means (14) along a conveying path and - conveying of the series of caps by second gripping means (17) to the emitting means (14) along the conveying path, characterised in that when the series of caps and the series of containers are being conveyed, the second gripping means (17) alternates with the first gripping means (13) along the conveying path in front of the emitting means (14).