Aseptic Filling Chamber Air Duct Layout for Uniform Airflow
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Solution Overview
Problem
Maintaining uniform airflow and aseptic conditions in aseptic chambers of paperboard container filling machines is challenging due to moving parts and containers disrupting airflow, leading to potential contamination from impure air entering the chamber.
Innovation Solution
The implementation of an airflow system with an upper air distribution chamber, lower processing chamber, throughflow plate, and paperboard container transport system, featuring elongated air distribution ducts and slits or holes aligned orthogonal to the container transport path, ensures a uniform flow of clean air through the aseptic chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If containers and moving parts are present in the aseptic chamber for filling operations, then productivity and functionality are improved, but airflow uniformity deteriorates due to turbulence and contamination risk
Solution Approach 1:
The air distribution system is segmented into multiple distribution zones with separate air supply channels and controllable air outlets. This allows different regions of the aseptic chamber to receive customized airflow, compensating for disturbances caused by containers and moving parts in specific zones while maintaining overall productivity.
Solution Approach 2:
The air outlet valves are configured to be movable or adjustable, allowing the airflow distribution pattern to be dynamically adapted during filling operations. This enables the system to maintain uniform airflow despite the presence of moving parts and containers by adjusting air outlet positions or opening areas in real-time.
2Reliability
If the aseptic chamber is kept airtight to prevent contamination, then aseptic condition is improved, but difficulty in accommodating moving parts and container transport deteriorates
Solution Approach 1:
Air curtains or airflow barriers are introduced as intermediary elements between the interior and exterior of the aseptic chamber. These controlled airflow streams create a protective barrier that prevents contamination without requiring complete sealing, allowing containers and moving parts to pass through while maintaining aseptic conditions.
Solution Approach 2:
The aseptic chamber is maintained with a controlled positive pressure environment using filtered air supply. This creates an inert-like protective atmosphere that prevents unfiltered air from entering through openings necessary for container transport and moving parts, thereby maintaining reliability without excessive sealing complexity.
3Stability of the object's composition
If air outlets are increased to improve airflow distribution, then airflow uniformity is improved, but energy consumption increases
Solution Approach 1:
Different regions of the aseptic chamber are provided with customized airflow through locally controlled air outlets with adjustable opening areas. This allows airflow to be optimized locally where needed while reducing or eliminating airflow in regions where containers or equipment already provide sufficient air movement, thereby improving overall uniformity without excessive energy consumption.
Solution Approach 2:
The air outlet valves are controllable based on detected conditions within the chamber, such as container position or airflow sensors. This feedback mechanism allows the system to automatically adjust air outlet openings to maintain uniform airflow distribution while minimizing energy consumption by reducing airflow when and where it is not needed.
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 configuration stabilizes airflow, minimizing turbulence and preventing contamination by ensuring a continuous, aseptic environment for filling and sealing operations, thereby maintaining the sterility of the containers.
Implementation Method 1
an elongated air distribution duct configured for receiving air from an air supply channel and comprising a plurality of throughflow holes configured for distributing the air in the air distribution chamber
Implementation Method 2
The air distribution duct displays a semi-tubular convex surface facing the throughflow plate and comprises a rectilinear duct axis extending orthogonal or substantially orthogonal to the container transport path
Data Source
AI summary
A paperboard container filling machine (10) comprising an aseptic chamber (30, 40), the aseptic chamber having: an upper air distribution chamber (35, 45); a lower processing chamber (36, 46) housing processing equipment (32, 42, 49) configured for interacting with paperboard containers passing through the processing chamber; a throughflow plate (37, 47) separating the air distribution chamber and the processing chamber; a paperboard container transport sub-system (12) configured for transporting the paperboard containers through the processing chamber along a container transport path (14) from an inlet opening (31, 41) to an outlet opening (33, 43) of the processing chamber; and an elongated air distribution duct (50, 53) configured for receiving air from an air supply channel and comprising a plurality of throughflow holes (51) configured for distributing the air in the air distribution chamber. The air distribution duct displays a semi-tubular convex surface (52) facing the throughflow plate and comprising a rectilinear duct axis (A) extending orthogonal or substantially orthogonal to the container transport path. A related method is also disclosed.