Thermoplastic Container Filling with Internal Gas Pressurization

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for filling thermoplastic containers with gasified liquids, such as carbonated beverages, require a cooling step using water jets to prevent deformation, which adds operational complexity and environmental impact due to water consumption and potential microbial issues.

Innovation Solution

A method involving a filling unit that delivers a small initial volume of a product at atmospheric pressure, followed by pressurization with gas to a pressure similar to the gasified liquid, allowing efficient cooling of the container base without deformation, and subsequent filling under pressurized conditions, reducing the need for water-based cooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If water jets are used to cool the container base during transfer, then deformation of the container is prevented, but operational complexity and environmental impact increase due to water consumption and microbial issues

Engineering Contradiction:

Improvecontainer deformation preventionVSAvoidcooling system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention extracts and eliminates the water-based cooling system from the process. Instead of using water jets to cool the container base, the method uses a purely pneumatic approach where gas is introduced to pressurize and cool the container internally, removing the need for external water cooling infrastructure and associated microbial contamination risks

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention introduces gas as an intermediary cooling and pressurizing medium. This gas serves dual purposes: it cools the container base through internal pressure and phase change, and simultaneously pressurizes the system to prevent deformation, replacing the need for separate water-based cooling and pressurization systems

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If water-based cooling is used during transfer, then container base deformation is avoided, but water consumption and microbial contamination risks increase

Engineering Contradiction:

Improvecontainer base stabilityVSAvoidmicrobial contamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention converts the harmful effect of water-based cooling (microbial contamination) into a beneficial pneumatic process. By using gas pressurization and internal cooling, the system eliminates the harmful water medium while maintaining the protective cooling effect, thus preventing both deformation and microbial contamination

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If conventional cooling step is included in transfer, then container deformation is prevented, but cycle time increases

Engineering Contradiction:

Improvecontainer deformation preventionVSAvoidcooling step duration

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The invention merges the cooling and pressurization functions into a single simultaneous operation. Instead of performing cooling during transfer and then pressurization separately, the gas introduction step does both cooling and pressurization concurrently, eliminating the sequential time loss and reducing total cycle time

Inventive Principle:

Principle #5Merging (Combining)

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 approach effectively cools the container base, prevents deformation during filling, and reduces the cycle time, while eliminating the need for water-based cooling systems, thus simplifying the process and minimizing environmental impact.

Implementation Method 1

The container base cools the container base

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

pressurization with gas to a pressure similar to the gasified liquid

Methodology Applied

Scientific EffectPressurization: Pressurisation

Data Source

PatentEP3697721B1Method for filling container with a gasified liquid and associated devices

Publication Date: 2023.04.19 SOCIETE DES PRODUITS NESTLE SA

Figure 1a~1b
Figure 1c~1d
Figure 1e~1f

AI summary

The invention concerns a method for filling a thermoplastic container (2), comprising a mouth (2a), with a gasified liquid having a pressure (P), said method using a filling unit (1) and comprising the steps of: - Positioning the container (2) under a filling head (3) of the filling unit (1), the filling head (3) comprising a product filling valve (8); - Establishing fluid tight connection between the filling head (3) and the mouth (2a) of the container (2); - Delivering a first volume of a first product (FL) in the container, said first volume being less than 10% of the maximum defined volume of the container; - Pressurizing the container (2) with a pressurized gas (G) at a pressure similar to the pressure (P) of the gasified liquid to be filled, using at least one pressurization valve (9a, 9b); - Filling the container (2) under pressurized condition until its maximum defined volume with the gasified liquid (PL), using the product filling valve (8); - Depressurizing the container (2) using a venting valve (10); - Separating the container(2) from the filling head (3); the resulting gasified liquid in the container (2) being a mixture of the first product (FL) and of the gasified liquid (PL). The invention is also related to the associated devices.