Dual-Jet Filling Element Radial Offset Design
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Solution Overview
Problem
Existing filling elements for free-jet filling of containers are limited in their filling capacity and often result in foaming or spattering of the filling material, which impairs the filling process and quality.
Innovation Solution
A filling element design that combines two partial jets of filling material, one outer and one inner, where the inner jet acts as a guiding flow to the outer jet, with the discharge openings offset radially, forming an annular gap to create a combined jet that enters the container, enhancing filling capacity without foaming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single jet of filling material is used, then the structure is simple, but the filling capacity is limited and foaming occurs
Solution Approach 1:
The filling material jet is segmented into two separate partial jets (inner and outer) that are delivered through distinct liquid channels (first and second liquid channels) with separate discharge openings. This segmentation allows each jet to be controlled independently and combined downstream, increasing filling capacity while maintaining manageable structural complexity through modular valve bodies.
Solution Approach 2:
Two separate partial jets of filling material are merged into a single combined jet after traveling through different paths. The inner partial jet and outer partial jet converge and combine before entering the container, effectively doubling the filling capacity while using a unified valve structure that integrates both liquid channels.
2Productivity
If the jet velocity is increased to improve filling speed, then filling capacity increases, but foaming and spattering occur
Solution Approach 1:
The high-velocity filling material is segmented into two controlled partial jets with different velocity profiles. The inner partial jet from the first liquid channel and the outer partial jet from the second liquid channel can be delivered at optimized velocities, allowing the combined jet to achieve high filling speed without the excessive velocity that causes foaming and spattering.
Solution Approach 2:
The outer partial jet acts as an intermediary that surrounds and guides the inner partial jet. This configuration allows the inner jet to maintain higher velocity for efficient filling while the outer jet provides a stabilizing boundary that prevents spattering and reduces foaming by containing the inner jet's energy.
3Object-generated harmful factors
If a fine-running valve is used to control the jet, then foaming is reduced, but the filling capacity is limited
Solution Approach 1:
Two liquid valve systems are merged into a single integrated valve body, allowing both fine-running control (to prevent foaming) and high-capacity delivery (to maintain filling speed). The first liquid valve controls the inner partial jet with fine adjustment capability, while the second liquid valve controls the outer partial jet, and their combined output achieves both foaming control and high filling capacity.
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 design significantly increases the filling capacity by up to 20% without relevant foaming, ensuring a clean and efficient filling process, even under centrifugal forces during rotation.
Implementation Method 1
The inner partial jet of filling material forms a kind of guiding or guiding flow, with which the at least one outer partial jet of filling material preferably connects before it enters the respective container
Data Source
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AI summary
A filling element includes a housing that forms a first dispensing opening. The first dispensing opening and a second dispensing opening provide corresponding filling jets. These jets combine to create a new jet for entry into a container to be filled. The first dispensing opening is offset outward radially opposite the second dispensing opening.