Dynamic Filling Profile for In Situ Liquid Mixing
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Solution Overview
Problem
Traditional industry-scale methods for forming liquid consumer products lack flexibility, generating waste and requiring extensive cleaning between product changes, which hampers efficient production and raw material utilization.
Innovation Solution
An in situ liquid mixing method where two or more liquid raw materials are mixed directly inside a container using a dynamic filling profile with increasing and decreasing flow rates to ensure homogeneity and stability, reducing waste and improving throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional batch mixing or continuous in-line mixing methods are used, then high throughput and satisfactory mixing homogeneity are achieved, but production line flexibility deteriorates and significant waste liquid is generated
Solution Approach 1:
The mixing process is segmented into two distinct phases: (1) a high-speed filling phase for rapid container filling, and (2) a low-speed mixing phase for thorough homogenization. This segmentation allows the system to achieve both high throughput during filling and excellent mixing quality during the subsequent mixing phase, while eliminating the need for production line cleaning between different products.
Solution Approach 2:
The patent applies preliminary action by performing the mixing operation after the filling operation is complete, rather than mixing before filling. The container is first filled with the liquid composition at high speed, then the same filling mechanism is used to introduce additional liquid that acts as a mixing medium, automatically homogenizing the contents without requiring separate mixing equipment or production line reconfiguration.
2Productivity
If traditional batch mixing or continuous in-line mixing methods are used, then high throughput and satisfactory mixing homogeneity are achieved, but significant waste liquid is generated during cleaning or purging
Solution Approach 1:
The system uses the filling mechanism itself to perform the mixing function, eliminating the need for separate cleaning operations. The additional liquid introduced during the mixing phase serves dual purposes: it acts as a mixing medium to homogenize the contents and simultaneously cleans the filling mechanism, thereby eliminating waste-generating cleaning or purging steps entirely.
3Productivity
If high-speed filling is used, then filling time is reduced and system throughput is improved, but splashing, rebounding, and aeration occur inside the container
Solution Approach 1:
The patent employs a dynamic filling profile that transitions from high-speed filling to low-speed mixing. The system starts with high-speed filling to maximize throughput, then automatically transitions to a low-speed phase where the same mechanism gently introduces additional liquid to homogenize the contents without causing splashing, rebounding, or excessive aeration.
Solution Approach 2:
The filling process is divided into periodic phases: an initial high-speed filling period for rapid container filling, followed by a low-speed mixing period for thorough homogenization. This periodic action allows the system to achieve both high throughput during the first phase and minimal harmful effects during the second phase.
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
The method achieves high-speed filling with reduced splashing and rebounding, resulting in improved homogeneity, stability, and increased system throughput while minimizing waste and optimizing raw material use.
Implementation Method 1
two or more liquid feed compositions are mixed together inside the container to form a liquid composition that is homogenous and stable
Implementation Method 2
two or more liquid feed compositions are mixed together inside the container to form a liquid composition that is homogenous and stable
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
Methods for in situ mixing of two or more different liquid compositions by employing a dynamic flow profile characterized by a ramping-up section and/or a ramping-down section.