Blow-Fill-Seal Clean-Zone Partitioning for Safe Die Head Maintenance
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Solution Overview
Problem
Existing continuous blow-fill-seal devices face challenges in maintenance and size replacement due to safety concerns and spatial constraints, with potential risks of cross-contamination and energy inefficiency.
Innovation Solution
A continuous blow-fill-seal device with a base frame and moving mechanism that allows the extrusion die head and filling needle assembly to move between clean zones, utilizing laminar flow assemblies for positive pressure protection and partitioned passages to prevent cross-contamination and reduce energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the extrusion die head and filling needle assembly remain in the molding-filling zone for maintenance and size replacement, then the device structure remains compact, but safety risks increase due to rotating mold activation and spatial constraints prevent proper cleaning
Solution Approach 1:
The device is divided into two distinct zones: a first clean zone for normal molding-filling operations and a second clean zone for maintenance and size replacement. The partition with movable second and third partitions separates these zones, allowing the extrusion die head and filling needle assembly to be moved to the maintenance zone when needed, thereby eliminating safety risks associated with operating in the molding-filling zone during maintenance activities
Solution Approach 2:
The partition structure incorporates movable second and third partitions that can be shifted between positions to seal off passages. This dynamic configuration allows the system to transition between operational modes: during normal operation, the partitions seal the maintenance zone; during maintenance, the partitions are moved to allow access while maintaining contamination barriers
2Ease of repair
If the extrusion die head is cleaned in the molding-filling zone, then maintenance can be performed, but cross-contamination risk increases due to the narrow space between the die head and molding mold
Solution Approach 1:
The device separates cleaning operations from the molding-filling zone by providing a dedicated second clean zone. This segmentation allows the extrusion die head to be moved to the maintenance zone for cleaning, where there is sufficient space to perform thorough cleaning without risk of cross-contamination, while the first clean zone remains dedicated to contamination-free molding operations
Solution Approach 2:
The partition structure acts as an intermediary barrier between the first and second clean zones. The movable second and third partitions can be positioned to seal passages, preventing contamination from the maintenance zone from reaching the molding-filling zone while still allowing the extrusion die head to be moved between zones for cleaning operations
3Object-affected harmful factors
If both clean zones operate simultaneously with laminar flow assemblies, then contamination protection is maximized, but energy consumption increases
Solution Approach 1:
The laminar flow assemblies in the first and second clean zones are operated periodically rather than simultaneously. The control system activates the laminar flow assembly in the zone that requires protection or maintenance at any given time, and deactivates the other. This periodic operation maintains contamination protection when needed while significantly reducing energy consumption during maintenance operations
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
Facilitates safe and efficient maintenance and size replacement by separating clean zones, reducing cross-contamination risks and energy costs while ensuring operational safety and efficiency.
Implementation Method 1
upper sides of both the first clean zone and the second clean zone are provided with a laminar flow assembly
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A continuous blow-fill-seal device, comprising a base frame (1), an extrusion screw assembly (2), an extrusion die head (3), a filling needle assembly (4), a first clean zone (5) and a second clean zone (6), wherein the frame (1) is provided with a moving mechanism (7) to drive the extrusion die head (3) to make a reciprocating motion between the first clean zone (5) and the second clean zone (6), upper sides of both the first clean zone (5) and the second clean zone (6) are provided with a laminar flow assembly (9) , a first partition (81) is disposed between the first clean zone (5) and the second clean zone (6), the first partition (81) is provided with a passage (82), the extrusion screw assembly (2) and the first partition (81) are provided with a second partition (83) and a third partition (84) respectively; when the extrusion die head (3) and the filling needle assembly (4) are within the first clean zone (5), turning on the laminar flow assembly (9) above the first clean zone (5), turning off the laminar flow assembly (9) above the second clean zone (6), sealing the passage (82) by the second partition (83), and separating the third partition (84) from the passage (82); and when the extrusion die head (3) needs to be cleaned or to be replaced, turning on the laminar flow assembly (9) above the second clean zone (6), driving the extrusion die head (3) by the moving mechanism (7) to move to the second clean zone (6), separating the second partition (83) from the passage (82), and sealing the passage (82) by the third partition (84). The continuous blow-fill-seal device ensures that the first clean zone (5) and the second clean zone (6) are partitioned from each other to avoid cross contamination, and also saves energy consumption, reducing operation costs of the device.