Cap Sterilization Chamber with Exhaust Manifold
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Solution Overview
Problem
Existing methods for sterilizing packaging components, such as caps, often fail to ensure thorough sterilization of all accessible surfaces, leading to potential reinfection or contamination, especially when there are interruptions in sterilant supply.
Innovation Solution
A cap sterilization device with a sterilization chamber, nozzle for injecting gaseous sterilants like hydrogen peroxide, and exhaust outlets to maintain a consistent sterilant concentration, ensuring all cap surfaces are exposed to effective sterilization, even during intermittent cap movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydrogen peroxide is directed into an exhaust pipe and redirected to the sterilization chamber after interruption, then the sterilization process can continue, but there is a time delay in reaching the desired H2O2 concentration
Solution Approach 1:
The system pre-positions hydrogen peroxide in a reservoir connected to the exhaust pipe, ready to be redirected immediately upon interruption. This preliminary preparation allows rapid resumption of sterilization without waiting for external H2O2 supply, eliminating the time delay while maintaining process continuity.
2Ease of operation
If caps are moved intermittently through the sterilization chamber, then handling is simplified, but sterilization consistency may be compromised
Solution Approach 1:
The nozzle provides continuous sterilant injection throughout the chamber while caps move intermittently. This ensures that even when caps are stationary or moving slowly, the sterilant concentration remains high and consistent, maintaining sterilization quality without requiring continuous cap motion.
Solution Approach 2:
The system monitors cap position and sterilant concentration, adjusting the nozzle injection rate dynamically. This feedback mechanism ensures consistent sterilization exposure regardless of cap movement speed or interruptions, maintaining manufacturing precision while allowing easy intermittent handling.
3Reliability
If sterilant concentration is increased to ensure thorough sterilization, then sterilization effectiveness improves, but sterilant release into the atmosphere increases
Solution Approach 1:
The exhaust pipe is dedicated to removing excess sterilant and gases from the chamber, separating the sterilization function from the atmosphere. By continuously evacuating the chamber, the system maintains high sterilant concentrations for effective sterilization while preventing release into the atmosphere, addressing both requirements simultaneously.
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
The device ensures thorough sterilization of cap surfaces by maintaining a consistent sterilant concentration within the chamber, preventing contamination and reinfection, while minimizing sterilant release into the atmosphere.
Implementation Method 1
a vaporizer arranged upstream the nozzle, the nozzle being able to selectively redirect a flow from the vaporizer into an exhaust manifold instead of to the nozzle
Implementation Method 2
a nozzle for injecting a sterilant into the sterilization chamber and at least two exhaust outlets for evacuation of gases from the sterilization chamber
Implementation Method 3
at least two exhaust outlets for evacuation of gases from the sterilization chamber
Data Source
Figure 1~3
AI summary
A cap sterilization device has a sterilization chamber (101) with a cap inlet (106) and a cap outlet (108). Guide means (104) are arranged for guiding caps (102) through the sterilization chamber (101). The device also has a nozzle (110) for injecting a sterilant into the sterilization chamber (101) and at least two exhaust outlets (112, 114) for evacuation of gases from the sterilization chamber (101).