In-Mold Beverage Filling Volume Control
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Solution Overview
Problem
The existing manufacturing processes for PET bottles often result in inconsistent filling volumes, leading to product loss and precision issues, as they typically overfill to ensure high production rates.
Innovation Solution
A method and device that inject a predetermined volume of beverage into a thermoplastic container preform, using a stretch rod and suction system to expand and then precisely adjust the volume within the mold, minimizing losses through recirculation and turbulence reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high pressures are used to ensure high production rates, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The preform is heated beforehand to a temperature above the glass transition temperature before being placed in the mold, preparing it for subsequent precise stretching and filling operations
Solution Approach 2:
The patent uses controlled parameter changes including heating the preform to specific temperature ranges (above glass transition temperature), applying controlled air pressures (3-40 bar) during stretching, and maintaining mold temperatures to achieve precise volume control while maintaining high production rates
2Reliability
If the volume of beverage introduced into containers is increased to ensure stipulated volume, then reliability is improved, but loss of substance increases
Solution Approach 1:
The patent implements a feedback mechanism where the actual volume of beverage in the container is measured and compared with the target volume, allowing for real-time adjustments to ensure precise volume control and minimize product loss
Solution Approach 2:
The patent controls the beverage volume by adjusting filling parameters including injection pressure, flow rate, and total volume introduced, maintaining precise control to match the stipulated volume without overfilling
3Productivity
If high pressures are applied during filling, then productivity is improved, but object-generated harmful factors increase
Solution Approach 1:
The patent uses pneumatic principles by injecting air at controlled pressures (3-40 bar) through a nozzle to expand the preform and facilitate beverage filling, managing the harmful effects of high pressure through controlled pneumatic delivery
Solution Approach 2:
The patent controls the harmful effects of high pressure by adjusting filling parameters including injection pressure, flow rate, and duration, maintaining productivity while minimizing turbulence and harmful pressure effects
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
Ensures accurate and consistent filling volumes, reducing product loss and improving operational stability by using a suction and injection system with a bell-shaped nozzle to manage high pressures and turbulence.
Implementation Method 1
a step of sucking out a fraction of said volume of beverage component introduced until the volume of beverage component remaining in the container is approximately equal to said predetermined volume
Implementation Method 2
a step of injecting at least some beverage component into a recess in the preform so as to promote expansion of the preform inside the mold
Data Source
AI summary
An apparatus for forming a thermoplastic container from a cylindrical preform and for delivering a predetermined volume of a beverage component into the container. The apparatus includes: a mold defining a shape of the container; a member configured to inject at least one beverage component into a recess in the preform so as to promote expansion of the preform inside the mold into the shape of the container, the member being further configured to inject the at least one beverage component in a first volume intentionally greater than the predetermined volume; and the member also being configured to remove a fraction of the first volume of the beverage component until a second volume of beverage component remaining in the container is equal to the predetermined volume.