Disposable Funnel for Precise Container Fill Level Control
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Solution Overview
Problem
Existing methods for filling containers to a specific level, especially in applications like micro-lipoinjection, require manual control and are not suitable for low-volume or limited-scale operations due to their complexity and cost.
Innovation Solution
A funnel system with a securement and reduced section that fits into a container, allowing partial filling by creating a reserved volume, enabling automatic and controlled filling without constant operator attention, and can be part of a manifold assembly for filling multiple containers in series.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sensors or valves are used to control fill level, then filling precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent introduces a funnel as an intermediary object that physically defines the fill level. The funnel acts as a mediator between the material source and the container, using its geometric structure (height and cross-sectional area) to automatically limit the fill level without requiring sensors or active control valves. This resolves the contradiction by achieving precise fill level control through a simple passive geometric constraint rather than complex active control systems.
Solution Approach 2:
The funnel is designed as a simple, inexpensive, disposable component that can be discarded after use. This eliminates the need for expensive, complex, and potentially contaminated sensors or electronic control systems. The funnel achieves the fill level control function at minimal cost and complexity, perfectly resolving the contradiction between precision and device complexity for single-use applications.
2Manufacturing precision
If manual control is used to manage fill level, then filling precision is improved, but ease of operation deteriorates
Solution Approach 1:
The funnel enables the filling system to be self-regulating. As material flows into the container through the funnel, the funnel's geometry automatically prevents overfilling. The system serves itself by using the funnel's physical structure to control the fill level without requiring operator intervention, monitoring, or adjustment. This resolves the contradiction by making the precision control automatic and self-regulating.
Solution Approach 2:
The funnel serves as an automatic mediator that takes over the fill level control function from the operator. Instead of requiring manual monitoring and intervention, the funnel's geometric constraints automatically enforce the desired fill level, dramatically improving ease of operation while maintaining precision control.
3Manufacturing precision
If complex filling mechanisms are used, then filling precision is improved, but productivity deteriorates due to setup and cleaning time
Solution Approach 1:
The disposable funnel eliminates time-consuming cleaning and sterilization procedures associated with complex reusable filling mechanisms. Each funnel is pre-sterilized and discarded after single use, allowing rapid container changes and filling operations without interrupting production for cleaning cycles. This resolves the contradiction by achieving precision control through a disposable component that maximizes productivity.
Solution Approach 2:
The filling control function is extracted from complex mechanical or electronic systems and embodied in the simple geometric structure of the funnel. This extraction creates a minimalist solution that requires no setup, calibration, or cleaning, thereby eliminating productivity losses associated with complex mechanisms while maintaining precise fill level control.
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 efficient, automatic, and controlled filling of containers to a desired level, reducing manual intervention and operational costs, while maintaining sterility and facilitating the use of the filled material in applications like micro-lipoinjection.
Implementation Method 1
The dimensions of the funnel, including the extent to which the funnel occupies a portion of the container volume to create a reserved volume, are selected to leave an unfilled or head space volume after the funnel has been removed from the container
Implementation Method 2
The securement section forms an interconnection with the interior of the container by friction
Implementation Method 3
the material held by the funnel partially fills the reserved volume, leaving the container partially filled
Data Source
AI summary
Methods and systems for filling a container with material to a desired level are provided. In particular, a container to be filled is associated with a funnel. The funnel occupies a selected or reserved amount of the container volume. Moreover, the volume of the funnel is less than the reserved volume of the container. Accordingly, by filling the container and the attached funnel to the top of the funnel, and then removing the funnel, the container is filled to less than a maximum level.