Aseptic Chamber Entry Section Emission Control
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Solution Overview
Problem
Existing aseptic chambers in package producing machines face challenges in preventing unwanted emissions, especially through the entry section, due to locally protruding features like pre-applied closures, which compromise the seal and affect the sterilization process.
Innovation Solution
The aseptic chamber design includes an entry section with an infeed gasket and inner gasket, each with cutouts to accommodate pre-applied opening devices, and an evacuation pipe connected to the entry chamber to reduce emissions, along with a venting system that maintains a controlled environment using a Y-connector to minimize turbulent kinetic energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the packaging material is provided with pre-applied closures that protrude from the planar surface, then the package functionality is improved, but the sealing at the entry section of the aseptic chamber deteriorates allowing emissions to leak out
Solution Approach 1:
The entry section is divided into multiple sealed chambers (first entry chamber, second entry chamber, and sterilization chamber) separated by gaskets. This segmentation allows the system to accommodate protruding closures while maintaining sealing integrity at each segment boundary, preventing emissions from leaking through the entry section.
Solution Approach 2:
The protruding closures are accommodated within the sealed entry chambers rather than being blocked by gaskets. The gaskets seal around the periphery of the entry section while the closures pass through the sealed chambers, creating a nested configuration where the closures are contained within the sealed environment without compromising the gasket seal.
2Reliability
If a ventilation system is used to maintain positive pressure in the aseptic chamber, then safety is improved by containing ozone, but emissions from the machine are drawn towards the electron beam emitters causing unwanted effects
Solution Approach 1:
The ventilation system is segmented with separate evacuation lines for the entry chambers and the sterilization chamber. This allows independent pressure control and emission management in each chamber, enabling the system to maintain positive pressure for safety while evacuating emissions before they reach the electron beam emitters.
Solution Approach 2:
The sealed entry chambers act as intermediary zones between the external environment and the sterilization chamber. Emissions are evacuated from the entry chambers through dedicated evacuation lines before the packaging material enters the sterilization chamber, preventing harmful emissions from reaching the electron beam emitters while maintaining the safety benefits of pressure control.
3Reliability
If gaskets are used to seal the entry section, then sealing is achieved for planar material, but the protruding closures damage the gaskets and compromise the seal
Solution Approach 1:
The sealing system is segmented into multiple gaskets (infeed gasket, inner gasket, exit gasket) that seal at different locations. The gaskets seal at the periphery of the entry section where they are not exposed to protruding closures, while the closures pass through sealed chambers. This segmentation protects gasket integrity while maintaining sealing effectiveness.
Solution Approach 2:
The sealed entry chambers serve as intermediary spaces that accommodate the protruding closures without requiring the gaskets to directly seal around them. The gaskets seal the periphery of the entry section while the closures are contained within the sealed chambers, preventing direct contact between gaskets and closures that would cause damage.
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 design effectively reduces emissions by approximately 50% through the entry section, ensuring a controlled environment and preventing leaks, while allowing pre-applied opening devices to pass without damage, thereby enhancing the sealing and sterilization efficiency.
Implementation Method 1
systems for sterilization/disinfection using electron beam irradiation have reached the market. One or more electron beam emitters are arranged in an aseptic chamber which forms part of the package producing machine. The packaging material enters the aseptic chamber and passes the one or more electron beam emitters in order to be exposed to a sufficient dose of electrons.
Implementation Method 2
The entry section comprises an entry chamber arranged between an infeed gasket and an inner gasket... The aseptic chamber design includes an entry section with an infeed gasket and inner gasket... and an evacuation pipe connected to the entry chamber to reduce emissions
Data Source
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AI summary
An aseptic chamber (100) of a package producing machine (10) is provided. The aseptic chamber comprises an entry section (110) for allowing a web of packaging material (20) to enter the aseptic chamber (100), and at least one electron beam emitter (152) arranged downstream the entry section (110) for treating the web of packaging material (20) as it runs through the aseptic chamber (100). The entry section (110) comprises an entry chamber (125) arranged between an infeed gasket (120) and an inner gasket (130).