Catalytic Hydrogen Peroxide Concentration Measurement
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Solution Overview
Problem
Existing methods for sterilizing packaging materials, particularly for carton bottles, face challenges in accurately controlling hydrogen peroxide concentration, leading to risks of insufficient sterilization or residual peroxide due to the uncertainty of concentration determination methods and the use of bulky and costly sensors.
Innovation Solution
A device with a ceramic catalyst body dipped in a precious metal solution, housed in a stainless steel structure, is used within the heating chamber to measure hydrogen peroxide concentration by decomposing it into water and oxygen, allowing for precise temperature measurements and calculation of concentration using thermometers, thereby ensuring accurate sterilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chemical sterilization using hydrogen peroxide solution and heating chamber is used, then sterilization effectiveness is improved, but accurate control of hydrogen peroxide concentration becomes difficult leading to insufficient sterilization or residual peroxide
Solution Approach 1:
The patent changes the measurement parameter from direct hydrogen peroxide concentration measurement to temperature measurement. By measuring the temperature increase caused by catalytic decomposition of hydrogen peroxide on the ceramic catalyst surface, the system indirectly determines peroxide concentration with high precision, resolving the concentration control issue.
Solution Approach 2:
The patent introduces a ceramic catalyst as an intermediary substance that facilitates the decomposition of hydrogen peroxide. This catalyst enables temperature-based indirect measurement and also serves as a sterilization mechanism, converting the harmful peroxide into water and oxygen while providing measurement capability.
2Reliability
If gas phase sterilization with gaseous hydrogen peroxide is used for carton bottles, then sterilization is achieved, but accurate concentration control remains problematic with similar risks of insufficient sterilization or excessive residues
Solution Approach 1:
The patent applies the same parameter transformation approach to gas phase sterilization - converting direct concentration measurement into temperature measurement through catalytic decomposition. The ceramic catalyst decomposes gaseous hydrogen peroxide, and the resulting temperature change provides accurate indirect concentration measurement for both sterilization monitoring and control.
3Device complexity
If theoretical calculation methods are used to determine hydrogen peroxide concentration, then no additional sensors are needed, but the determination becomes uncertain leading to false alarms or insufficient sterilization
Solution Approach 1:
The patent replaces complex electronic concentration sensors with a simple thermal measurement system using a thermometer or temperature sensor. The ceramic catalyst converts chemical energy (hydrogen peroxide decomposition) into thermal energy, which is easily measurable and provides reliable concentration data without complex electronics.
4Measurement precision
If IR-sensors or UV-sensors are used to measure hydrogen peroxide concentration in gassing chamber, then concentration measurement is achieved, but the sensors become bulky, fragile and costly
Solution Approach 1:
The patent replaces expensive, fragile IR or UV sensors with a simple, robust ceramic catalyst combined with a basic temperature sensor. The ceramic catalyst can be replaced if needed, but the overall system becomes much simpler, cheaper, and more durable, eliminating the need for sensitive electronic sensors.
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 provides precise control over hydrogen peroxide concentration, reducing the risk of inadequate sterilization or residual peroxide, improving the efficiency and accuracy of the sterilization process while avoiding the limitations of existing methods.
Implementation Method 1
a ceramic catalyst (70) dipped in a precious metal solution
Implementation Method 2
The device further has at least two thermometers (88) for measuring a first temperature inside the housing at the inlet (80) of the catalyst (70) and a second temperature inside the catalyst body (70)
Implementation Method 3
passing the packaging material through a bath of hydrogen peroxide solution and then through a heating chamber. In the heating chamber, hot sterile air is introduced for heating the packaging material
Implementation Method 4
the hydrogen peroxide is evaporated and thus removed from the surface of the packaging material
Data Source
Figure 1
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Figure 4
AI summary
A device (36, 100, 200) for measurement of concentration of an oxidizable gas is disclosed, which comprises a catalyst (102) inside a housing (101, 201). The catalyst is surrounded by insulation (105) inside the housing. The device (100, 200) further comprises at least two thermometers, one of which is located at the inlet of the device, and one being located inside the catalyst (102). The device also has means for calculating a concentration based on the temperature measurements. A sterilization chamber and a filling machine having a device according to the main claim are also disclosed.