Electron Beam Sterilization System with Magnetic Positioning
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Solution Overview
Problem
The electron-beam irradiation continuous sterilization system faces issues with product containers tipping over during sterilization, uneven irradiation times, and contamination of previously sterilized areas due to unstable contact positions and non-uniform irradiation.
Innovation Solution
A continuous sterilization system employing multiple electron beam accelerators and support mechanisms to ensure uniform irradiation by changing the support point during irradiation, using low-energy electron beams to prevent damage and residue formation, and incorporating mechanisms like star wheels and vacuum suction for stable container handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a slide guide is used to make the product container slide laterally on the mesh conveyer, then the electron beam can irradiate the entire bottom surface of the product container, but the product container may be tipped over on the mesh conveyer depending on its shape
Solution Approach 1:
The patent replaces the mechanical slide guide system with a magnetic field-based positioning system. Electromagnets embedded in the mesh conveyer hold the ferromagnetic product container in place during irradiation, eliminating mechanical contact that causes tipping while maintaining precise positioning for uniform electron beam irradiation from below.
2Manufacturing precision
If the product container is made to slide on the mesh conveyer, then different positions of the bottom surface can be irradiated, but the contact position becomes unstable and irradiation time becomes non-uniform
Solution Approach 1:
The patent replaces mechanical sliding with magnetic field positioning using electromagnets that hold the container stationary at precise locations. This eliminates unstable contact and ensures consistent irradiation time across the bottom surface while maintaining irradiation uniformity through controlled container orientation.
3Reliability
If the bottom surface is irradiated while in contact with the mesh conveyer, then sterilization is achieved, but the irradiated surface moves to the mesh upper surface and becomes contaminated again
Solution Approach 1:
The patent introduces a vertical dimension to the sterilization process by using multiple electron beam irradiators positioned at different heights. The bottom surface is irradiated from below through the mesh conveyer, the side surfaces are irradiated from the sides, and the top surface is irradiated from above, ensuring all surfaces are sterilized without contact contamination.
Solution Approach 2:
The patent replaces mechanical contact-based positioning with magnetic field-based suspension and positioning. The electromagnets hold the container in precise positions during multi-angle irradiation, allowing electron beam sterilization from multiple directions without the container surface contacting potentially contaminated mesh surfaces.
4Manufacturing precision
If multiple electron beam accelerators are used to sterilize different portions, then uniform irradiation can be achieved, but the device complexity increases
Solution Approach 1:
The patent makes the mesh conveyer multi-functional by embedding electromagnets that serve both as conveyer support structures and as positioning/molding devices during irradiation. This eliminates the need for separate mechanical positioning systems, reducing overall device complexity while enabling uniform multi-angle electron beam irradiation.
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 system reliably prevents container tipping, ensures uniform irradiation across all surfaces, and maintains sterility by changing support points during electron beam emission, effectively sterilizing both inner and outer surfaces without contamination.
Implementation Method 1
electron beam accelerators E1 to E3 for irradiating electron beams to each portion of the cylindrical container B being conveyed by them for sterilization
Implementation Method 2
a vacuum suction device 31 for supporting the cylindrical container B
Data Source
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AI summary
A continuous sterilization system is provided which reliably supports a sterilization target so that the sterilization target is not tipped over during a sterilization process and can stably ensure uniform irradiation periods on any portion of inner and outer surfaces and moreover, a portion sterilized by electron beam irradiation is not contaminated again. The continuous sterilization system is provided with first conveying means for supporting a cylindrical container from a side surface and continuously conveying the same, a first electron beam accelerator for emitting an electron beam from the bottom surface portion side of the cylindrical container during conveyance by this first conveying means, second conveying means for supporting the cylindrical container from the bottom surface portion side sterilized by the electron beam irradiation by the first electron beam accelerator and continuously conveying the same while rotating the cylindrical container along a cylindrical shaft core of the cylindrical container, a second electron beam accelerator for emitting the electron beam over the entire periphery from the side surface portion side of the cylindrical container during conveyance by this second conveying means, and a third electron beam accelerator for emitting the electron beam from an opening portion side to an inner surface portion of the cylindrical container during conveyance by the first conveying means or the second conveying means.