Ejection Tool Piston Gap for Bubble-Free Viscous Filling
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Solution Overview
Problem
Filling containers with small nozzle diameters, especially those for viscous materials, requires high pressure, leading to material separation and quality deterioration, and existing methods struggle to release air without forming bubbles or causing leakage.
Innovation Solution
An ejection device with a cylindrical member and a discharge portion where the piston's outer diameter matches the member's inner diameter, allowing a gap for air flow and pressure application, enabling filling without high pressure and preventing material separation or air bubbles, with optional elastic members to adjust volume and prevent leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high pressure is applied to fill a small diameter nozzle container with viscous material, then filling efficiency is improved, but material separation and quality deterioration occur
Solution Approach 1:
The filling process is segmented into two distinct phases: a high-pressure initial filling phase that quickly fills the majority of the container, followed by a low-pressure final filling phase that completes the filling without exceeding material pressure limits. This segmentation allows the system to achieve both high productivity and material quality by applying appropriate pressure at different stages of the filling process.
Solution Approach 2:
The filling operation uses periodic action by switching between high-pressure and low-pressure modes. The high-pressure phase operates periodically to fill the container rapidly, then transitions to a low-pressure phase to complete filling, creating a periodic cycle that optimizes both efficiency and quality.
2Reliability
If the piston fits tightly against the container wall to prevent leakage, then sealing is improved, but air cannot be released during filling
Solution Approach 1:
The piston design applies local quality by creating different fit characteristics at different locations. The piston fits tightly against the container wall at the rear end to prevent leakage, while maintaining a controlled gap at the front end to allow air release. This localized differentiation of fit quality enables simultaneous achievement of sealing performance and air venting capability.
3Ease of operation
If the piston is disposed at the front end to prevent air trapping, then air release is improved, but material leakage occurs with low viscosity materials
Solution Approach 1:
The system uses dynamics by adjusting the piston position and fit characteristics based on the filling stage and material properties. During initial filling, the piston is positioned to allow air escape; as filling progresses and pressure increases, the piston's tight fit prevents leakage. The dynamic adjustment of piston positioning and pressure application enables the system to handle both air release and leakage prevention.
4Device complexity
If a single filling port is used, then device complexity is reduced, but high pressure is required to fill viscous materials
Solution Approach 1:
The filling process is segmented into two pressure stages through a single filling port. The high-pressure initial filling stage quickly fills the container, followed by a low-pressure final filling stage. This temporal segmentation of pressure application allows the use of a simple single-port structure while avoiding the need for sustained high pressure that would cause material separation.
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 device allows for efficient filling of viscous materials without high pressure, preventing separation and air bubbles, and effectively releasing air to maintain material quality, especially for low viscosity materials.
Implementation Method 1
the material contained in the stock container is pressurized and is poured into the disposable container through the nozzle
Implementation Method 2
the material flows from the opening on the rear end side toward the filling surface on the front end side
Implementation Method 3
an outer diameter of the piston is nearly the same as the inner diameter of the cylindrical member so that a gap between the outer periphery surface of the piston and the inner periphery surface of the cylindrical member is so formed as to maintain sealing to a degree that permits an air to flow
Implementation Method 4
optional elastic members to adjust volume and prevent leakage
Data Source
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AI summary
[Problems] To fill a container with a material without applying a high pressure to the material that is to be filled. [Means for Solution] An ejection device 1 comprises a filling chamber 24 formed in a cylindrical member for containing a material to be filled, a discharge portion 7 having a discharge nozzle 12 for pouring out the filled material to the exterior, and a piston 4 that pushes the filled material toward the front end side of the filling chamber 24 to discharge the filled material through the discharge nozzle 12. In the ejection device 1, the discharge portion 7 is formed separately from the filling chamber 24 and in a manner to be fitted to an opening on one end side of the cylindrical member 24, the opening serving as a filling port for filling the material to be filled, and after the material to be filled is poured into the filling chamber 24 through the filling port, the discharge portion 7 is coupled to the filling chamber 24.