Aseptic Sterilisation Unit with Movable Carrier
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Solution Overview
Problem
Existing devices for treating plastic containers, such as blow molding machines, face challenges in ensuring thorough sterilization, particularly in inaccessible areas, due to limitations in the diffusion of sterilization gases and the maintenance of aseptic conditions, which can lead to contamination and inefficiencies in the production process.
Innovation Solution
A device with a movable carrier in an isolator space that allows for the supply of sterilizing agents as gases or fine mists, using a combination of stationary and movable nozzles and a rotary distributor, ensuring uniform distribution and access to all areas, including those difficult to reach, within the isolator chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sterilizing agents are supplied into the isolator chamber, then sterilization effectiveness is improved, but uniform distribution to all areas including inaccessible areas is difficult to achieve
Solution Approach 1:
The sterilizing agent supply device is divided into multiple nozzles positioned at different locations and angles within the isolator chamber. This segmentation allows the sterilizing agent to be distributed from multiple points simultaneously, ensuring comprehensive coverage including inaccessible areas that would be difficult to reach from a single supply point.
Solution Approach 2:
Different nozzles are positioned to target specific areas within the isolator chamber, including hard-to-reach zones. Each nozzle is strategically located to optimize local sterilization effectiveness, with particular attention to areas that would otherwise be inaccessible to sterilizing agents.
2Adaptability or versatility
If the isolator chamber contains moving parts, then operational flexibility is improved, but maintaining aseptic conditions becomes more difficult
Solution Approach 1:
The isolator chamber and all its components, including moving parts, undergo preliminary sterilization before operation. The sterilizing agent is supplied to ensure all surfaces and areas are sterilized in advance, creating an aseptic environment that is maintained throughout operation. This preliminary action ensures that even moving parts start in a sterile state.
Solution Approach 2:
The sterilizing agent supply operates continuously or periodically to maintain aseptic conditions throughout the operational cycle. This continuous action ensures that as moving parts traverse different positions within the isolator chamber, they remain exposed to the sterilizing atmosphere, maintaining sterility throughout the entire operational sequence.
3Reliability
If sterilization is performed on finished containers, then hygiene is improved, but production time and sterilizing agent consumption increase
Solution Approach 1:
Sterilization is performed on plastic preforms before they are formed into finished containers. This preliminary sterilization of the smaller preforms eliminates the need for subsequent sterilization of the larger finished containers, significantly reducing both production time and sterilizing agent consumption while maintaining hygiene standards throughout the manufacturing process.
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 enables efficient and uniform sterilization of all parts within the isolator space, reducing the risk of contamination and enhancing the overall efficiency of the sterilization process by ensuring that all areas, including stationary and moving parts, are adequately exposed to the sterilizing agents, thereby improving the hygiene and quality of the treated containers.
Implementation Method 1
limitations in the diffusion of sterilization gases
Implementation Method 2
supply of sterilizing agents as gases or fine mists
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The device (7) has a movable carrier (2) that is arranged in insulated chamber (10) and supplied with sterilizing agent. The insulated chamber is comprised with a fixed inner boundary region (14) and movable outer boundary region (15) with respect to movement of the movable carrier. The sterilizing agent is supplied to the movable carrier by one of the feeding units (12,13) which are relatively moved with respect to the carrier. An independent claim is included for method for sterilizing insulated chamber of device for treating plastic container.