Foaming Unit for Oxygen Removal in Foamable Liquid Containers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Oxygen present in the headspace of filled containers can impair the quality of foamable liquids, as existing technologies fail to effectively remove it before closure.
Innovation Solution
A device comprising a foaming unit, optoelectrical sensor units, and an ejection station is used to introduce a foaming medium into containers, monitor foam formation and fill levels, and adjust energy input to achieve optimal foam formation, ensuring the removal of oxygen by displacing it with carbon dioxide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a foaming medium is introduced into containers to remove oxygen from headspace, then oxygen removal effectiveness is improved, but device complexity increases due to addition of foaming unit, sensor units, and ejection station
Solution Approach 1:
The device is divided into functionally independent modules: a foaming unit for oxygen removal, optoelectrical sensor units for monitoring, and an ejection station for defect detection. Each module operates semi-independently, allowing the oxygen removal function to be enhanced without requiring complete system redesign, thus managing complexity through modular segmentation.
Solution Approach 2:
The foaming unit introduces foaming medium into containers before closing to preemptively remove oxygen from the headspace. The sensor units monitor foam formation in advance, and the ejection station identifies defects before final product completion. These preliminary actions prevent oxygen contamination before it can affect the liquid quality.
2Manufacturing precision
If optoelectrical sensor units are added to monitor foam formation and fill levels, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Mechanical measurement methods for monitoring foam formation and fill levels are replaced with optoelectrical sensor units. These sensors use optical fields to detect and measure foam characteristics and liquid levels, providing higher precision without mechanical contact and enabling non-invasive monitoring that simplifies the overall measurement system.
Solution Approach 2:
The optoelectrical sensor units provide real-time feedback on foam formation and fill levels to the control system. This feedback loop enables automatic adjustment of the foaming process parameters, ensuring manufacturing precision while reducing the need for complex manual monitoring and adjustment mechanisms.
3Manufacturing precision
If energy input to foaming unit is dynamically adjusted based on sensor feedback, then foam formation quality is improved, but use of energy increases
Solution Approach 1:
The energy input to the foaming unit is made dynamically adjustable based on real-time feedback from optoelectrical sensor units. The system can increase energy input when foam formation is insufficient and decrease it when adequate foam is achieved, optimizing foam quality while adapting energy consumption to actual process requirements rather than using constant high energy input.
Solution Approach 2:
The system changes operational parameters (energy input levels) of the foaming unit based on monitored foam formation characteristics. By adjusting parameters such as foaming medium flow rate, pressure, or injection timing in response to sensor feedback, the system achieves optimal foam quality while minimizing unnecessary energy consumption.
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 effectively removes oxygen from the headspace by producing the correct amount and type of foam, ensuring the quality of the liquid by expelling all air and maintaining minimal residual oxygen, thereby preventing impairment.
Implementation Method 1
the foaming unit (10) is configured so as to introduce a foaming medium into the container (2) in a jet form, in each case in such a way that foaming occurs in the container (2)
Implementation Method 2
at least one first optoelectrical sensor unit (12.1) of a monitoring unit (13) downstream of the foaming unit (10) in the transport direction (A)
Data Source
AI summary
A container-treatment machine includes a foaming unit that introduces foaming medium into a container that is filled with a foamable liquid. This causes a foam to form in the container. A sensor downstream obtains an image of the foam and provides it to a controller. The controller decides whether or not to eject the container based on the extent of a foam nose that forms on the container's outer surface.