Cleanroom Blow Molding Ejection for Defective Container Removal

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Solution Overview

Problem

Existing blow molding machines with sterile isolators face challenges in managing defective plastic containers during production, as the isolator volume is limited, necessitating the opening of the cleanroom to remove rejected containers, which compromises sterility and disrupts the production process.

Innovation Solution

A device and method for ejecting defective plastic containers from a cleanroom using a transport device with a movable carrier and ejection mechanism, employing a suction device to create a local negative pressure for removal without disrupting the sterile environment, and a receiving chamber for non-sterile storage of rejected containers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the isolator volume is kept small to maintain sterility, then the sterile environment is preserved, but the space for storing defective containers is insufficient

Engineering Contradiction:

Improvesterility maintenanceVSAvoidisolator volume

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The isolator is segmented into a sterile production area and a non-sterile storage area. The ejection device creates a localized non-sterile zone within the isolator where defective containers can be stored without compromising the sterility of the main production area. This segmentation allows the isolator to maintain its small overall volume while providing dedicated space for defective container storage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The ejection device extracts defective containers from the sterile environment and transfers them to a non-sterile storage area within the isolator. This extraction mechanism removes the harmful elements (defective containers) from the sterile zone, allowing the isolator to maintain sterility while accommodating defective containers in a segregated area.

Inventive Principle:

Principle #2Taking out (Extraction)

2Quantity of substance

If the isolator is opened to remove defective containers, then the storage space for defective containers is utilized, but the sterility of the isolator is compromised and production is disrupted

Engineering Contradiction:

Improvedefective container storage capacityVSAvoidsterility maintenance

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The ejection device acts as an intermediary mechanism that enables the removal of defective containers without opening the isolator. It creates a controlled ejection path that transfers containers from the sterile production area to a non-sterile storage area within the isolator, maintaining the isolator's sealed state and sterility while providing defective container storage capacity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The manual opening and physical removal of defective containers is replaced by an automated ejection device that uses mechanical forces (ejection nozzles, suction devices) to remove and store defective containers internally. This substitution eliminates the need to open the isolator, maintaining sterility while providing continuous defective container storage capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Volume of stationary object

If the isolator volume is increased to store more defective containers, then the storage capacity is improved, but the complexity and cost of maintaining sterility increases

Engineering Contradiction:

Improvedefective container storage spaceVSAvoidisolator maintenance complexity

Core Design Contradiction:

Volume of stationary objectVSDevice complexity

Solution Approach 1:

Instead of increasing the overall isolator volume, the invention creates a localized non-sterile storage area within the existing isolator volume. This local quality change allows defective containers to be stored in a specific zone without requiring the entire isolator to be larger or more complex. The sterile production area remains unchanged, maintaining simple sterility maintenance requirements.

Inventive Principle:

Principle #3Local quality

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

Enables the removal of defective containers during ongoing operation without compromising the cleanroom's sterility, maintaining production continuity and efficiency by using a vacuum-based ejection system integrated with air recirculation and filtration.

Implementation Method 1

employing a suction device to create a local negative pressure for removal without disrupting the sterile environment

Methodology Applied

Scientific EffectNegative pressure: Pressure Drop

Data Source

PatentEP3473406B1Blow moulding machine with clean room and outward transfer of containers

Publication Date: 2025.12.03 KRONES AG

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Figure 3

AI summary

A device (1) for forming plastic preforms (10) into plastic containers (20) with a transport device (2, 12) which transports the plastic preforms (10) along a predetermined transport path (P), wherein this transport device has a movable carrier (2) on which a plurality of forming stations (4) are arranged, each of which is suitable and intended for forming the plastic preforms (10) into the plastic containers (20), with a cleanroom (6) which surrounds the transport path of the plastic preforms (10) at least section by section and which is delimited from its environment by means of at least one wall. According to the invention, the device (1) has an ejection device (40) which is suitable and intended for ejecting plastic containers (20) from the cleanroom (6).