Filling Cylinder Insert for Variable Volume Adjustment

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Solution Overview

Problem

Existing container forming and filling systems require complex and time-consuming changes to the entire filling cylinder assembly to accommodate different container sizes, leading to increased downtime and costs due to the need for multiple assemblies for various sizes.

Innovation Solution

A filling cylinder assembly with a removable insert and interchangeable piston heads that adjust the cavity volume and piston stroke, allowing for the formation and filling of multiple container sizes without replacing the entire assembly, featuring a piston rod assembly with adjustable stroke and velocity to achieve optimal pressure and control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If dedicated filling cylinder assemblies are used for each container size, then the filling process is simple and reliable, but the device complexity increases and changeover time increases

Engineering Contradiction:

Improvefilling process reliabilityVSAvoidcylinder assembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The filling cylinder assembly is segmented into modular components: a cylinder body, removable inserts with different volumes, and interchangeable piston heads with different stroke lengths. This segmentation allows the system to be reconfigured for different container sizes without replacing the entire assembly, maintaining reliability while reducing device complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cylinder assembly is designed with universal compatibility through interchangeable inserts and piston heads. A single cylinder body can accommodate multiple inserts and piston heads to handle various container sizes (e.g., 8oz, 16oz, 32oz), making the system multi-functional and eliminating the need for dedicated assemblies for each size.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If multiple dedicated cylinder assemblies are maintained for different container sizes, then each assembly is optimized for its specific size, but the loss of time increases due to assembly replacement

Engineering Contradiction:

Improvecontainer forming precisionVSAvoidchangeover time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system transitions from static dedicated assemblies to a dynamic reconfigurable assembly. The piston stroke length and cavity volume can be dynamically adjusted by changing piston heads and inserts during operation, allowing the same physical assembly to adapt to different container sizes without time loss.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes operational parameters (cavity volume and piston stroke length) by swapping inserts and piston heads rather than replacing entire assemblies. This parameter adjustment approach maintains manufacturing precision for different container sizes while eliminating the time loss associated with assembly replacement.

Inventive Principle:

Principle #35Parameter changes

3Stress or pressure

If the cavity volume is reduced for smaller containers, then the forming pressure increases, but the device complexity increases due to volume adjustment mechanisms

Engineering Contradiction:

Improveforming pressureVSAvoidvolume adjustment complexity

Core Design Contradiction:

Stress or pressureVSDevice complexity

Solution Approach 1:

The system uses inexpensive, easily replaceable inserts with different volumes and piston heads with different stroke lengths. These components can be quickly swapped to adjust cavity volume and achieve optimal forming pressure for different container sizes without adding complex adjustment mechanisms to the main assembly.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 solution reduces changeover time and costs by enabling the formation and filling of various container sizes with a single assembly, achieving higher forming pressures and more consistent control over the filling process, thereby improving efficiency and reducing the need for multiple cylinder assemblies.

Implementation Method 1

a piston, which actuates in a cavity defined by a fill cylinder

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

Existing container forming and filling systems pump fluid into a preform to simultaneously form a container from the preform and fill the container with the fluid

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentUS11141907B2Filling cylinder insert to reduce volume

Publication Date: 2021.10.12 LIQUIFORM GRP LLC

AI summary

A filling cylinder assembly for a container forming and filling system that simultaneously forms and fills a container from a preform with fluid. The filling cylinder assembly includes a cylinder having an inner wall defining a cavity. A piston head is at a distal end of a piston rod. An insert is configured to be seated in the cavity to provide the cavity with a reduced volume such that with the insert seated within the cavity the cavity has a first volume, and without the insert seated in the cavity the cavity has a second volume that is greater than the first volume.