Filling Valve Pressure Equalization to Prevent Product Loss
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Solution Overview
Problem
Existing filling valves result in product loss due to product entering the relief gas channel during the filling process, leading to a total loss of one to two milliliters per filling process, and residues being drawn into the vacuum channel during subsequent suction.
Innovation Solution
A filling valve design with a connecting path for pressure equalization between the pressurizing and relief gas paths, ensuring product flows past the relief gas path opening and preventing product loss by maintaining a static differential pressure, utilizing a valve seat and closure part with a separate pressurizing and relief gas path, and incorporating a connecting path that is open during product flow but can be closed when the product valve is closed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a relief gas path is formed in the filling valve below the outlet-side product valve, then relief gas can escape from the head space into a relief channel, but product partially enters the relief gas channel and is lost during the relief process
Solution Approach 1:
A connecting path is introduced as an intermediary element between the pressurizing gas path and the relief gas path. This connecting path enables pressure equalization, allowing the pressurizing gas to counterbalance the product pressure in the relief gas path, thereby preventing product from entering the relief gas channel while maintaining the relief gas discharge function.
Solution Approach 2:
The pressure parameter in the relief gas path is dynamically adjusted through the connecting path. During filling, the connecting path allows pressure equalization between the pressurizing gas path and relief gas path, changing the pressure conditions to prevent product intrusion. The connecting path is configured to be open during product flow and closable when the product valve is closed, dynamically adapting pressure conditions.
2Loss of substance
If the connecting path is permanently open for pressure equalization, then product loss is prevented, but product may enter the pressurizing gas channel through the connecting path
Solution Approach 1:
The connecting path is designed with dynamic control capability through a shut-off device. The connecting path is open at least when the product valve is open to enable pressure equalization and prevent product loss. When the product valve is closed, the connecting path can be closed to prevent product residues from entering the pressurizing gas channel. This dynamic configuration adapts the connecting path's state based on the filling cycle phase.
3Reliability
If separate gas paths are used for pre-pressurizing gas and relief gas, then dry pre-pressurizing is achieved, but product residues in the relief hole are drawn into the vacuum channel during subsequent suction
Solution Approach 1:
The connecting path acts as an intermediary pressure equalization channel that prevents product residues from being drawn into the vacuum channel. By maintaining pressure balance between the pressurizing gas path and relief gas path through the connecting path, the system prevents negative pressure conditions that would otherwise draw product residues into the vacuum channel during suction operations.
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
Significantly reduces product loss during the filling process, preventing product from entering the relief gas channel and minimizing residues drawn into the vacuum channel, thereby optimizing the filling efficiency.
Implementation Method 1
a connecting path formed in addition to the product path for pressure equalization between the clamping gas path and the relief gas path
Data Source
Figure 1
Figure 2
AI summary
A filling valve (1) for filling a liquid product (2) into containers (3) and a filling machine equipped with it are described. The filling valve comprises a valve seat (4) and an associated closure element (5) for opening/closing a product path (7) on the outlet side, the closure element being centrally located in the product path. The filling valve further comprises a pressurization gas path (8) extending upwards through the closure element and separately from the product path, and a relief gas path (9) opening into the product path downstream of the valve seat. The additional provision of a connecting path (10, 11) for pressure equalization between the pressurization gas path and the relief gas path prevents both product losses through the relief gas path and the introduction of unwanted moisture from the relief gas path into the pressurization gas path.