Aseptic Bottle Molding with Dynamic Sterilizer Nozzle
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Solution Overview
Problem
Existing methods for molding and aseptic filling of PET bottles face inefficiencies due to variable sterilization concentration, prolonged processing times, and high hydrogen peroxide consumption, with inadequate sterilization of the bottle's interior, particularly at the bottom.
Innovation Solution
A method involving a heated preform being clamped in a molding die, where a mist or gas of a sterilizer is blasted in, followed by primary and secondary blow molding air to expand and sterilize the preform into a bottle, with used air discharged to remove the sterilizer, allowing for simultaneous molding and sterilization while maintaining a consistent sterilizer concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple nozzles are arranged at fixed positions to eject large amount of mist for thorough sterilization, then sterilization coverage is improved, but hydrogen peroxide consumption increases
Solution Approach 1:
The nozzle is made movable to follow the bottle along the conveying path, dynamically adjusting its position to maintain optimal distance and angle for mist ejection. This ensures thorough sterilization coverage throughout the bottle interior while using a single nozzle instead of multiple fixed nozzles, thereby reducing hydrogen peroxide consumption.
Solution Approach 2:
A blowing air nozzle is introduced as an intermediary to enhance the distribution of sterilizer mist into the bottle. The blowing air acts as a mediator that propels and disperses the mist more effectively throughout the bottle interior, improving sterilization coverage without requiring increased mist flow rate or multiple nozzles.
2Productivity
If traveling velocity of bottles is increased to improve production efficiency, then productivity is improved, but mist flow rate must be increased leading to higher hydrogen peroxide consumption
Solution Approach 1:
The nozzle is designed to move synchronously with the bottle at its traveling velocity, maintaining a constant relative position. This dynamic positioning allows effective sterilization to be maintained regardless of the line speed, enabling increased productivity without proportionally increasing hydrogen peroxide consumption.
Solution Approach 2:
A blowing air system is used to enhance mist distribution into the bottle. The pneumatic action of blowing air propels the sterilizer mist more effectively throughout the bottle interior, compensating for reduced exposure time at higher velocities without requiring proportional increases in mist flow rate.
3Reliability
If dry heat sterilization is used with hot gas blow molding, then sterilization is achieved, but processing time is prolonged and apparatus structure becomes complicated
Solution Approach 1:
The sterilization method is changed from dry heat sterilization at high temperatures (135-180°C) to chemical sterilization using hydrogen peroxide mist. This parameter change allows sterilization to occur at lower temperatures and shorter times, reducing processing time while maintaining sterilization effectiveness.
Solution Approach 2:
The sterilization function is merged with the blow molding process itself. The hydrogen peroxide mist is introduced during the blow molding operation, combining two previously separate steps (sterilization and molding) into one integrated process, thereby reducing total processing time and simplifying apparatus structure.
4Manufacturing precision
If different molding dies are used for primary and secondary blow molding, then molding quality is maintained, but production efficiency decreases
Solution Approach 1:
The sterilization function is merged with both primary and secondary blow molding operations. By introducing hydrogen peroxide mist during these molding steps, the patent eliminates the need for a separate sterilization process, thereby improving production efficiency while maintaining molding quality through proper integration of sterilization into the existing molding sequence.
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 approach enhances sterilization efficiency, reduces hydrogen peroxide usage, and simplifies the apparatus structure, ensuring thorough bottle sterilization and improved production efficiency.
Implementation Method 1
a mist or gas of a sterilizer or a mixture thereof is blasted into the preform (1)
Implementation Method 2
a blow molding air is blasted into the preform (1) to expand the preform (1) into an intermediate molded product
Implementation Method 3
the used blow molding air is discharged from the container (2) to remove the sterilizer in the container (2)
Implementation Method 4
a heated preform (1) is put in a molding die (6)
Data Source
Figure 1(A)~1(D)
Figure 2(E)~2(I)
Figure 3
AI summary
An aseptic filling method, wherein after a heated preform (1) is put in a molding die (6), the molding die (6) is clamped, and a mist or gas of a sterilizer or a mixture thereof is blasted into the preform (1), a blow molding air is blasted into the preform (1) to expand the preform (1) into a container (2) as a finished product, the used blow molding air is discharged from the container (2) to remove the sterilizer in the container (2), and the container (2) is removed from the molding die (6), filled with a content and sealed,wherein after the mist or gas of the sterilizer or the mixture thereof is blasted into the preform (1), a primary blow molding air (PI) is blasted into the preform (1) to expand the preform (1) into an intermediate molded product (2a) and at the same time sterilize an interior of the intermediate molded product (2a),characterized in thata secondary blow molding air (P2) is then blasted into the intermediate molded product (2a) to expand the intermediate molded product (2a) into the container (2) as the finished product, the used blow molding air is discharged from the container (2) to remove the sterilizer in the container (2), and the container (2) is removed from the molding die (6), filled with the content and sealed.