Funnel Assembly with Integrated Gas Lances for Bulk Filling

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Solution Overview

Problem

Existing funnel designs for bulk product packaging lead to product loss and weight inaccuracies due to the Coanda effect and high gas velocity, as well as the need for oxygen scavengers, caused by the small cross-sectional area and independent movement of gas lances, which also increase complexity and safety risks.

Innovation Solution

A funnel assembly with a coped exit end and integrated gas lances that move together, eliminating the Coanda effect by ensuring gas mixture enters the package directly, reducing the cross-sectional area gradually to prevent product loss and using a coped design to plow open the package, thereby minimizing funnel plugs and residual oxygen levels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a small cross-sectional area funnel is used to consistently get bulk product into the package, then filling consistency is improved, but product loss increases due to the Coanda effect and high gas velocity

Engineering Contradiction:

Improvefilling consistencyVSAvoidproduct loss

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The gas lances are integrated with the funnel structure, merging two previously separate components into one unified assembly. This ensures the lances move with the funnel and maintain proper positioning, eliminating the Coanda effect while preserving filling consistency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The funnel structure serves as an intermediary that guides both the bulk product and the gas mixture into the package simultaneously. The integrated design allows the funnel to mediate between product flow and gas flow, preventing product loss while maintaining filling accuracy.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If gas lances are mounted outside the package to avoid interfering with duckbill movement, then ease of operation is improved, but residual oxygen levels increase due to the Coanda effect

Engineering Contradiction:

Improvelance positioningVSAvoidresidual oxygen

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

The gas lances are merged with the funnel structure, allowing them to move together as a single unit. This integration enables the lances to enter the package with the funnel, effectively displacing oxygen without interfering with duckbill operation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Instead of mounting lances outside the package as conventionally done, the invention inverts the approach by having the lances enter the package through the funnel. This reverse positioning eliminates the Coanda effect and reduces residual oxygen levels.

Inventive Principle:

Principle #13The other way round (Inversion)

3Manufacturing precision

If the funnel shapes the bulk product stream simultaneously in x axis and y axis directions (funnel effect), then filling accuracy is improved, but funnel plugs occur causing manufacturing delays

Engineering Contradiction:

Improvefilling accuracyVSAvoidmanufacturing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The funnel structure is segmented into multiple sections with different shaping functions. The first section shapes the stream in the x-axis direction, while the second section shapes it in the y-axis direction. This segmentation prevents funnel plugs by distributing the shaping action across separate zones.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a dimensional separation in the stream shaping process by using sequential x-axis and y-axis shaping sections rather than simultaneous multi-directional shaping. This dimensional approach eliminates the funnel effect while maintaining filling accuracy.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Productivity

If high velocity gas mixture is blown into the package through a small cross-sectional area, then gas flushing efficiency is improved, but bulk food products are blown out causing product loss

Engineering Contradiction:

Improvegas flushing efficiencyVSAvoidproduct loss

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The gas lances are merged with the funnel, allowing the gas mixture to be introduced at the same location where bulk product enters the package. This integration ensures that gas flow and product flow are coordinated, preventing product from being blown out while maintaining efficient oxygen displacement.

Inventive Principle:

Principle #5Merging (Combining)

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 solution effectively reduces product loss and weight inaccuracies, eliminates the need for oxygen scavengers, simplifies the design, and enhances food safety by ensuring consistent filling and reduced residual oxygen levels, thereby extending shelf life and minimizing manufacturing delays.

Implementation Method 1

a gas lance that direct a gas mixture under pressure into the filled package

Methodology Applied

Scientific EffectGas pressure: Pressure Increase

Implementation Method 2

the Coanda effect which states that in free surroundings, a jet of fluid entrains and mixes with its surroundings as it flows away from a nozzle

Methodology Applied

Scientific EffectCoanda effect: Coanda Effect

Data Source

PatentUS11827399B2Funnels for package filling

Publication Date: 2023.11.28 SARGENTO CHEESE INC

AI summary

Funnels are disclosed for use with filling packages with bulk product.