Container Filling by External Volume Adjustment for Level Control
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Solution Overview
Problem
Existing blow molding and filling processes for plastic containers are often separate and inefficient, leading to high costs and challenges in accurately controlling the final product level within the container.
Innovation Solution
A system and method for simultaneously forming and filling containers, where a force is applied to the exterior surface of the container to adjust the product level, allowing for precise control of the volume and final product level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If blow molding and filling are performed as separate processes, then each process can be optimized independently, but transport costs and time commitments increase significantly
Solution Approach 1:
The patent combines blow molding and filling operations into a single integrated process where the container is formed and filled simultaneously in one mold cavity, eliminating the need for separate transport steps and reducing overall processing time while maintaining independent process optimization benefits
2Loss of time
If integrated blow molding and filling systems are used, then transport costs are eliminated, but synchronization complexity and equipment complexity increase
Solution Approach 1:
The patent integrates the filling system directly into the blow molding press, allowing the filler to be positioned within or adjacent to the mold cavity, thereby eliminating transport needs while reducing synchronization complexity through spatial integration rather than complex temporal coordination
Solution Approach 2:
The patent uses the mold cavity itself as an intermediary structure that serves both forming and filling functions, with the cavity acting as both the shaping boundary and the receiving container for the fill material, simplifying the overall system architecture
3Device complexity
If separate blow molding and filling processes are used, then equipment simplicity is maintained, but manufacturing precision of final product level deteriorates
Solution Approach 1:
The patent incorporates feedback mechanisms where the filling process is controlled based on real-time monitoring of container formation progress and product level detection, allowing precise control of the final product level while maintaining relatively simple equipment through intelligent control algorithms
4Productivity
If simultaneous forming and filling is implemented, then productivity increases, but control of final product level becomes more difficult
Solution Approach 1:
The patent performs preliminary actions by pre-positioning the filler and pre-programming the filling sequence to occur at specific stages of container formation, allowing simultaneous operation while maintaining precision through advance planning and coordinated timing of filling relative to container expansion
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 efficient and accurate control of the product level in containers, optimizing packaging by eliminating separate transport and time demands, and ensuring uniformity and accuracy in product fill levels.
Implementation Method 1
The preform can then be heated above the plastic glass transition temperature, longitudinally stretched with a stretch rod, and blown using high-pressure gas
Implementation Method 2
blown using high-pressure gas (e.g., air) into a container conforming to a mold. As the preform is inflated, it elongates and stretches
Implementation Method 3
The plastic solidifies upon contacting the cooler surface of the mold and the finished hollow container is subsequently ejected from the mold
Data Source
AI summary
Ways for controlling a level of a product in a container are provided that include engaging an exterior surface of the container containing the product at a first product level. A pulling force is applied to the exterior surface of the container to cause the container to change from a first volume to a second volume. Cessation of the force results in the container containing the product at a second product level. The second product level can provide an accurate and reproducible final product level in the container.