Horizontal Freeze-Drying Valve with Adjustable Aperture
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Solution Overview
Problem
Existing horizontal freeze-drying systems face challenges in achieving uniform freeze-drying due to non-uniform flow conditions within the product chamber, leading to inconsistent drying of materials on upper, middle, and lower shelves, and require separate inspection openings and valves that increase complexity and costs.
Innovation Solution
A horizontal freeze-drying system with a height-adjustable connection opening between the product and condenser chambers, allowing for direct and uniform medium flow, and an intermediate valve with guide rods and lubricant-free bearings for smooth operation and hygiene compliance, along with optional heat exchanger integration for temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the connection opening is positioned at a fixed height, then the structure is simple, but the flow conditions are non-uniform for upper, middle, and lower shelves
Solution Approach 1:
The connection opening height is made adjustable rather than fixed, allowing it to be dynamically positioned to optimize flow conditions. This dynamic adjustment capability enables uniform evacuation across all shelf levels while maintaining structural feasibility, resolving the contradiction between uniformity and complexity.
2Adaptability or versatility
If a separate inspection opening is provided, then inspection function is independent, but the device complexity and production costs increase
Solution Approach 1:
The connection opening serves dual purposes: it functions as both the evacuation pathway for medium flow and as the inspection opening. This multi-functionality eliminates the need for a separate inspection opening and its associated valve, thereby reducing device complexity and production costs while maintaining full inspection capability.
3Productivity
If the medium flow path is long and indirect, then the connection opening can be smaller, but the evacuation speed and uniformity decrease
Solution Approach 1:
The height parameter of the connection opening is optimized to create the shortest possible flow path from all shelf levels to the condenser chamber. By adjusting this geometric parameter, the system achieves fast evacuation and uniform flow conditions without requiring excessively large opening dimensions, thus resolving the contradiction between evacuation speed and path length.
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 design ensures uniform freeze-drying across all shelves with reduced resistance, faster evacuation, and eliminates the need for a separate inspection opening, enhancing product quality and reducing production costs by maintaining consistent flow conditions and temperature control.
Implementation Method 1
a heat exchanger is attached to the intermediate valve, which can be constructed in the form of a surface or a coil, as a result of which the intermediate valve itself can also be cooled
Implementation Method 2
The intermediate valve is moved into the condenser chamber parallel to the intermediate wall by a lifting piston
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A horizontal freeze-drying assembly with shelves (16) has a product chamber (10) whose side or rear face is separated from a condensation chamber (12) by a partition wall (22). The partition wall has an aperture (24) that may be opened and closed by an intermediate valve (26). The aperture is located in the range 70 to 100% of the shelf maximum height. The link aperture is located astride the shelf vertical mid-line and has a width one fifth of its height. The valve is operated by pushrods (30) and moves through lubricant-free guides made of e.g. POM, Teflon, Peak or similar. The valve is co-located with a meandering heat-exchanger tube (28).