Aseptic Bottle Blow Molding With Mold Temperature Control
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Solution Overview
Problem
Conventional aseptic filling machines face challenges in accurately maintaining the surface temperature of molded bottles at high filling rates, leading to inadequate sterilization of bottles that may be filled and shipped, especially when the filling rate exceeds 1000 bottles per minute.
Innovation Solution
The method involves controlling the temperature of neck, trunk, and bottom portion molds within a predetermined range by using a mold temperature adjusting apparatus, ensuring the preform is sealed and blow-molded into a bottle with adequate heat retention, and utilizing a sterilizer to contact bottles with insufficient temperature for sterilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the filling rate is increased to exceed 1000 bottles per minute, then productivity is improved, but the surface temperature of molded bottles cannot be accurately maintained, leading to inadequate sterilization
Solution Approach 1:
The patent applies preliminary action by pre-heating the preform before molding and controlling the mold temperature within a specific range (20°C to 80°C) before the filling process begins. This ensures that the bottle surface temperature is maintained at an adequate level (above 40°C) even at high filling rates of 1000 bottles per minute or more, providing sufficient heat for effective sterilization without requiring additional heating during the high-speed filling process
Solution Approach 2:
The patent applies parameter changes by precisely controlling the mold temperature within a specific range (20°C to 80°C) and maintaining the bottle surface temperature above 40°C during the filling process. By adjusting and maintaining these temperature parameters, the system achieves effective sterilization even at high filling rates of 1000 bottles per minute or more, resolving the contradiction between productivity and sterilization reliability
2Reliability
If more sterilizer is used to ensure adequate sterilization at high filling rates, then sterilization effectiveness is improved, but the amount of residual sterilizer in bottles increases
Solution Approach 1:
The patent applies parameter changes by maintaining the bottle surface temperature above 40°C during the filling process through controlled mold temperature (20°C to 80°C). This temperature parameter control enhances the sterilization effectiveness of the sterilizer, allowing adequate sterilization to be achieved with a reduced amount of sterilizer, thereby minimizing residual sterilizer in the bottles while maintaining high filling rates
Solution Approach 2:
The patent applies mechanics substitution by replacing the reliance on large quantities of sterilizer with a thermal field approach. By maintaining adequate bottle surface temperature through controlled mold heating, the system uses heat as a complementary sterilization mechanism, reducing dependence on chemical sterilizer quantity while ensuring effective sterilization even at high filling rates
3Productivity
If the mold temperature is not controlled within a predetermined range, then the filling process can proceed at high speed, but the bottle surface temperature becomes insufficient for effective sterilization
Solution Approach 1:
The patent applies parameter changes by establishing and maintaining the mold temperature within a specific range (20°C to 80°C) during high-speed filling operations. This temperature parameter control ensures that the bottle surface temperature remains above 40°C, providing adequate thermal conditions for sterilization effectiveness while maintaining high filling speeds of 1000 bottles per minute or more
Solution Approach 2:
The patent applies feedback by monitoring and controlling the mold temperature within the predetermined range (20°C to 80°C) to maintain adequate bottle surface temperature during high-speed filling. This temperature feedback control mechanism ensures that even at filling rates of 1000 bottles per minute or more, the bottle surface temperature remains sufficient for effective sterilization
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 effectiveness by maintaining the bottle's surface temperature within an optimal range, reducing the amount of sterilizer needed and minimizing residual sterilizer in the bottles, thereby improving the aseptic filling process.
Implementation Method 1
controlling the temperature of neck, trunk, and bottom portion molds within a predetermined range
Implementation Method 2
utilizing a sterilizer to contact bottles with insufficient temperature for sterilization
Data Source
Figure 1
Figure 2(A)~2(D)
Figure 3(E-1)~3(H)
AI summary
An aseptic filling method, wherein when a preform (1) is heated, the heated preform (1) is sealed in a neck portion mold (20a), a trunk portion mold (20b) and a bottom portion mold (20c) at a temperature in a predetermined temperature range, and the preform (1) sealed in the molds is blow-molded into a bottle (2), any bottle (2) is removed which has been molded in the neck portion mold (20a), the trunk portion mold (20b) and the bottom portion mold (20c) the temperature of any of which is outside the predetermined temperature range, a sterilizer is brought into contact with any bottle (2) that has not been removed to sterilize a surface of the bottle (2), the sterilized bottle (2) is filled with a sterilized content, and the bottle (2) filled with the content is sealed with a sterilized lid member (3), characterized in that the temperature of the neck portion mold (20a), the trunk portion mold (20b) and the bottom portion mold (20c) in the predetermined temperature range is a temperature of a mold temperature adjusting medium circulated through the molds (20a, 20b, 20c).