Collector Cup for Aseptic Nozzle Pre-sterilization
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Solution Overview
Problem
Existing aseptic packaging machines face inefficiencies in pre-sterilization processes, including limited sterilization media options, risk of contamination, and manual handling that can damage packaging tubes and slow down production, due to the need for pre-sterilizing large sterile zones and using aggressive chemicals.
Innovation Solution
An aseptic packaging machine design with a collector cup that encloses the product outlet, sterilization medium outlet, and exhaust inlet portions during pre-sterilization, allowing for efficient and automated sterilization using hotter and more aggressive media without direct contact with the packaging tube, reducing manual handling risks and improving sterilization efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-sterilization is performed on large sterile zones using aggressive chemicals, then sterilization effectiveness is improved, but packaging tubes may be damaged and production speed decreases
Solution Approach 1:
The patent segments the sterilization process into two distinct phases: pre-sterilization of the nozzle assembly (without packaging tube) and sterilization during production. The collector cup isolates the nozzle assembly components (product outlet, sterilization medium outlet, exhaust inlet) to allow aggressive pre-sterilization chemicals to be used without damaging the packaging tube, thereby enabling faster production speeds while maintaining sterilization effectiveness.
Solution Approach 2:
The patent performs pre-sterilization of the nozzle assembly before production begins. The collector cup enables this preliminary sterilization action to be performed with aggressive chemicals (like hydrogen peroxide vapor or hot steam) that would otherwise damage the packaging tube, thus ensuring sterilization effectiveness is achieved beforehand without compromising production speed during actual packaging operations.
2Adaptability or versatility
If manual handling is used to position packaging tubes during pre-sterilization, then flexibility is improved, but contamination risk increases and handling damage occurs
Solution Approach 1:
The patent implements automated handling where the collector cup automatically positions and secures the packaging tube around the nozzle assembly during pre-sterilization, and automatically retrieves it afterward. This self-service mechanism eliminates manual handling, thereby reducing contamination risk while maintaining the flexibility needed for proper positioning and securing of the packaging tube throughout the sterilization process.
3Device complexity
If the same collector cup is used for both pre-sterilization and production phases, then device complexity is reduced, but sterilization medium may leak into the machine
Solution Approach 1:
The patent employs a dynamic collector cup that can move between two positions: engaged with the nozzle assembly during pre-sterilization and disengaged during production. This dynamic positioning allows the same collector cup to serve both phases effectively - enclosing the sterile zone during pre-sterilization to prevent medium leakage, and moving away during production to avoid interfering with packaging operations, thus maintaining reliability while minimizing device complexity.
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 high-speed, efficient, and economic pre-sterilization of the sterilizer-filler nozzle assembly, using diverse sterilization media like hot steam and Hydrogen Peroxide Vapor, reducing contamination risks, and maintaining aseptic conditions during production.
Implementation Method 1
a sterilization medium supply duct (14) that extends at least partly through the form section; has a sterilization medium inlet connector (15) that lies upstream of the distal end of the form section; and has a sterilization medium outlet portion (16) that lies between the distal end of the form section and the product outlet portion (4)
Implementation Method 2
an exhaust duct (20) that extends at least partly through the form section; has an exhaust outlet connector (21) that lies upstream of the distal end of the form section; and has an exhaust inlet portion (22) that lies between the distal end of the form section and the product outlet portion (4)
Implementation Method 3
a collector cup (70) that is movable relative to the nozzle assembly (NA) between an inactive position and a docking position, in which the collector cup (70) delimits one or more interior spaces that are designed to, in the docking position, enclose the product outlet portion (4) to collect and/or drain away pre-sterilization media that during a pre-sterilization of the nozzle assembly (NA) get to flow through and along it
Data Source
AI summary
An aseptic packaging machine includes a web-shaped packaging material feed, a sterilizer-filler nozzle assembly with a form section 40, a product supply duct, a sterilization medium supply duct, and an exhaust duct. One or more pre-sterilization medium supply feeds are connectable to a product inlet connector and a sterilization medium inlet connector. A collector cup 70 is movable relative to the nozzle assembly between an inactive and a docking position. The collector cup delimits one or more interior spaces 71a, 72a designed to, in the docking position, enclose a product outlet portion 4 to collect and/or drain away pre-sterilization media during a pre-sterilization of the nozzle assembly get to flow through and along it, and to also enclose the sterilization medium outlet portion 16 and/or exhaust inlet portion 22 in the docking position inside its one or more interior spaces.