Aseptic Valve Assembly Switching Valve Integration
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Solution Overview
Problem
Existing aseptic valve arrangements in sterile process engineering are structurally and technically complex, making them difficult to operate and maintain, especially in applications requiring high sterility and simplicity.
Innovation Solution
A simplified valve arrangement is introduced, replacing the leakage valve with a switching valve that couples the functions of leakage and steam valves, eliminating the need for a sequence valve and reducing control technology requirements, while maintaining sterility through separate actuation of closing elements and bellows for enhanced cleanliness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional valve arrangement with separate leakage valve and steam valve is used, then sterility and safety are ensured, but the structural complexity and control system complexity increase significantly
Solution Approach 1:
The patent combines the leakage valve and steam valve functions into a single integrated valve unit. The valve housing contains both a steam chamber for sterilization and a leakage detection chamber, with a single actuator controlling both functions. This merging eliminates the need for separate leakage valves and steam valves, reducing structural complexity while maintaining sterility through the integrated design.
Solution Approach 2:
The integrated valve serves multiple functions simultaneously: it acts as both a steam valve for sterilization and a leakage valve for detecting product leaks. The single valve unit can switch between admitting steam into the product line and detecting leaks in the sealed product flow, providing universal functionality that reduces the overall number of components needed in the system.
2Reliability
If separate leakage valve and steam valve are installed, then functional redundancy provides safety, but the number of components and installation work increase
Solution Approach 1:
The patent merges the leakage valve and steam valve into one integrated component, reducing the total number of parts that need to be installed. The single valve unit incorporates both the steam admission mechanism and the leakage detection mechanism, eliminating the need for separate installations while maintaining the safety functions of both valves through their integrated design.
3Adaptability or versatility
If multiple valves (steam valve, leakage valve, sequence valve) are used, then comprehensive control is achieved, but the control technology outlay and operational complexity increase
Solution Approach 1:
The patent combines multiple valve functions into a single integrated valve with one actuator. The actuator controls both the steam admission and leakage detection functions through the integrated valve housing, eliminating the need for separate control systems for multiple valves. This reduces operational complexity while maintaining comprehensive control capability through the unified design.
Solution Approach 2:
The single integrated valve performs multiple control functions: it can admit steam for sterilization, detect leaks in the product flow, and control the sealed product transfer. This multi-functionality reduces the number of control signals and operations needed while maintaining comprehensive control over the aseptic process.
4Reliability
If traditional valve arrangement with multiple components is used, then functional requirements are met, but the cleanability and maintenance difficulty increase
Solution Approach 1:
The patent merges multiple valve components into a single integrated unit with fewer internal passages and surfaces. The streamlined design of the integrated valve housing reduces the number of crevices and complex geometries that are difficult to clean, making the valve easier to maintain sterility while still providing comprehensive control functions.
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 simplifies the valve arrangement, reduces installation and control complexity, ensures safe fluid handling, and enhances cleanability, achieving economic and technical advantages by eliminating the risk of incorrect switching and reducing the number of components and control outlay.
Implementation Method 1
A first bellows can be arranged between the first and second closing element. A second bellows can be arranged between the second closing element and a housing bushing. The bellows or bellows improve the properties of the valve assembly for use in applications with high sterility requirements.
Data Source
Figure 1~2
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AI summary
The invention relates to a valve assembly (1; 1') comprising: a housing (19), a chamber (5) having a first product opening (40), a second product opening (42), a first closable secondary opening (45), which can be connected to a steam line (7), and a second closable secondary opening (46); a first closing element (21), by means of which the first product opening (40) can be closed; a second closing element (22), by means of which the second product opening (42) can be closed; and an outlet (33; 33') associated with the second secondary opening (46). In order to simplify the physical design of the valve assembly, a switching valve (18; 18') is arranged between the second secondary opening (46) and the outlet (33; 33') such that a fluid connection between the outlet (33; 33') and the second secondary opening (46) can be switched over by switching the switching valve (18; 18') to a fluid connection between the outlet (33; 33') and an inlet (32; 32'), which is provided on the switching valve (18; 18') and which can be connected to a steam line (7), while simultaneously closing the second secondary opening (46). The invention further relates to a system comprising said valve assembly and to a method for operating said system.