Fluid Forming and Filling for Accurate Product Levels in Containers
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Solution Overview
Problem
Existing blow molding and filling processes for plastic containers are inefficient and costly due to their separation, and simultaneous forming and filling operations often fail to accurately control the product level in the container, leading to issues such as air space, aesthetic concerns, and product identification.
Innovation Solution
A system and method for controlling the product level in a container by engaging its exterior surface, applying a force to change the volume, and ceasing the force to achieve a desired product level, allowing for simultaneous forming and filling with the product remaining in the container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate blow molding and filling processes are used, then each process can be optimized independently, but transport costs and time commitments increase significantly
Solution Approach 1:
The patent merges the blow molding and filling processes into a single integrated operation. The container is formed and filled simultaneously in one continuous process, eliminating the need for separate transport steps between facilities. The mold cavity retains the formed container while filling occurs, allowing both operations to complete in sequence without interruption.
2Loss of time
If simultaneous forming and filling operations are performed, then transport and time costs are eliminated, but accurate control of final product level becomes difficult
Solution Approach 1:
The patent performs preliminary stretching and positioning of the preform during the forming process to prepare for accurate filling. The preform is stretched and positioned within the mold cavity before filling occurs, establishing the correct geometry and orientation for achieving the desired final product level. This preliminary preparation enables precise level control despite the simultaneous nature of the operations.
Solution Approach 2:
The system incorporates feedback mechanisms to monitor and control the filling process. Sensors detect the product level during filling and provide feedback to the control system, which adjusts filling parameters in real-time to achieve the target product level. This closed-loop control ensures manufacturing precision even while performing simultaneous forming and filling operations.
3Productivity
If a continuously extruded hot plastic tube is used in extrusion blow molding, then production can operate continuously, but multiple separate steps are required to form and fill the container
Solution Approach 1:
The patent combines the extrusion blow molding process with the filling operation into a single integrated system. The continuously extruded preform is formed into the container shape within the mold cavity, and the filling operation is performed in sequence without removing the container from the mold. This merging reduces the number of separate steps while maintaining continuous production capability.
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
Enables accurate and reproducible control of the final product level in containers, optimizing packaging by eliminating transport and time costs associated with separate forming and filling processes.
Implementation Method 1
blown using high-pressure gas (e.g., air) into a container conforming to a mold
Implementation Method 2
The plastic solidifies upon contacting the cooler surface of the mold
Data Source
AI summary
Ways for controlling a level of a product in a container are provided that include engaging an exterior surface of the container containing the product at a first product level. A force is applied to the exterior surface of the container to cause the container to change from a first volume to a second volume. Cessation of the force results in the container containing the product at a second product level. The second product level can provide an accurate and reproducible final product level in the container.