Continuous Vacuum Cooling Chambers with Dynamic Pressure Control
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Solution Overview
Problem
Existing thermoforming packaging machines require multiple vacuum cooling stations and intermittent vacuum processes, leading to complex designs, high energy consumption, and potential product damage due to repeated vacuum interruptions.
Innovation Solution
A continuous vacuum cooling apparatus with independently controllable vacuum cooling chambers, each equipped with a control circuit device for dynamic vacuum pressure generation, allowing continuous vacuum cooling without interruptions and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple vacuum cooling stations are used for intermittent operation, then vacuum cooling can be performed in stages, but the device complexity increases and energy consumption rises
Solution Approach 1:
The vacuum cooling chamber is divided into multiple independently controllable zones along the transport direction, each zone equipped with its own vacuum control system. This allows different sections to operate at different vacuum levels simultaneously, enabling staged cooling without requiring multiple separate chambers, thus maintaining productivity while reducing device complexity
Solution Approach 2:
The vacuum cooling system transitions from static intermittent operation to dynamic continuous operation. The vacuum pressure in each zone can be dynamically adjusted based on product temperature and cooling requirements, allowing the system to adapt to varying cooling demands without interrupting the continuous product flow, thereby improving productivity without proportionally increasing device complexity
2Productivity
If vacuum cooling stations are opened and closed repeatedly for intermittent feed, then cooling can be performed in stages, but energy consumption increases due to repeated vacuum buildup and release
Solution Approach 1:
The system maintains continuous vacuum action throughout the cooling chamber while products move through it. Instead of repeatedly creating and releasing vacuum in intermittent cycles, the vacuum is sustained continuously, eliminating the energy-wasting repeated compression and expansion cycles while maintaining effective cooling throughout the continuous product feed process
Solution Approach 2:
Multiple vacuum cooling zones are merged into a single continuous vacuum environment. The separate vacuum stations are combined into one integrated vacuum system that operates continuously, allowing products to be cooled along the entire transport path without the energy-intensive repeated vacuum cycling required by separate intermittent stations
3Productivity
If intermittent vacuum cooling is used, then cooling can be performed in stages, but products are unnecessarily stressed and possibly damaged due to repeated pressurization
Solution Approach 1:
The vacuum pressure in each zone is dynamically controlled to match the cooling requirements at different positions along the transport path. Products experience a gradual, controlled pressure change as they move through zones with progressively adjusting vacuum levels, rather than sudden repeated pressurization events, thereby reducing mechanical stress and damage while maintaining cooling flexibility
Solution Approach 2:
The vacuum cooling process is prepared in advance by establishing appropriate vacuum levels in each zone before products enter. The cooling zones are pre-configured with optimal vacuum pressures, allowing products to undergo smooth, predictable pressure transitions without sudden changes that cause stress and damage
4Temperature
If several vacuum cooling stations are used for longer cooling times, then desired temperature level can be achieved, but the manufacturing cost increases
Solution Approach 1:
The cooling chamber is segmented into multiple zones, each contributing to the overall cooling process. Products receive cumulative cooling effect as they pass through successive zones with progressively lower temperatures, achieving the desired final temperature level within a single integrated station rather than requiring multiple separate stations
Solution Approach 2:
The vacuum pressure and cooling conditions in each zone are dynamically optimized to maximize cooling efficiency. By adjusting vacuum levels and cooling parameters in real-time across different zones, the system achieves extended effective cooling time and lower final temperatures within a single station, eliminating the need for multiple separate cooling stations
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, gentle vacuum cooling of products with increased output and reduced energy consumption by eliminating intermittent vacuum steps, ensuring consistent product quality.
Implementation Method 1
vacuum cooling the product received therein
Implementation Method 2
each vacuum cooling chamber comprises its own control circuit device configured for dynamic vacuum pressure generation
Data Source
AI summary
The disclosure relates to an apparatus comprising at least one vacuum cooling station comprising a plurality of vacuum cooling chambers, each of which, while being moved along a cooling path together with at least one product received therein, is controllable for vacuum cooling the at least one product received therein. Each vacuum cooling chamber has its own control circuit device configured for dynamic vacuum pressure generation. The disclosure further relates to a method for vacuum cooling products.