Hydroforming Container Method Using Cleanable Liquid
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Solution Overview
Problem
The hydroforming technique is not compatible with sugary or easily non-cleanable liquids, as high-pressure injection can cause bursting or spilling, leading to contamination and reduced production rates due to complex machine cleaning requirements.
Innovation Solution
A method involving a forming station that uses a cleanable liquid to shape containers, followed by a separate concentrate filling station for adding a non-cleanable concentrated liquid, minimizing contamination risks and simplifying machine cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydroforming technique is used with sugary or non-cleanable liquids, then container forming and filling can be performed simultaneously, but the liquid may burst or spill causing contamination and requiring complex cleaning operations
Solution Approach 1:
The patent divides the forming and filling operations into two separate stages: first forming the container with a cleanable liquid (water or alcohol), then transferring it to a filling station where the concentrated liquid is added. This segmentation prevents contamination of the forming station while maintaining high production rates.
Solution Approach 2:
The patent introduces an intermediary substance (cleanable liquid like water or alcohol) that serves as a placeholder during forming, then is replaced by the concentrated liquid in a separate filling step. This intermediary prevents direct contact between the non-cleanable concentrated liquid and the forming station machinery.
2Manufacturing precision
If high pressure is applied during hydroforming with sugary liquid, then the container shape is improved, but the container may burst or the liquid may spill
Solution Approach 1:
The patent separates the high-pressure forming operation (using cleanable liquid) from the filling operation (adding concentrated liquid). This allows applying high pressure during forming without risking bursting, as the container is then filled with the concentrated liquid under controlled conditions in a separate station.
Solution Approach 2:
The patent uses a cleanable liquid as a cushioning medium during the high-pressure forming stage, protecting the container walls from damage. After forming, this cushioning liquid is drained and replaced by the concentrated liquid, preventing spillage and contamination.
3Reliability
If the forming station is cleaned after contamination, then the machine can continue operation, but the production rate is greatly reduced
Solution Approach 1:
The patent uses a cleanable liquid as an intermediary during forming operations, ensuring that even if spillage occurs, the liquid can be easily cleaned from the forming station. This eliminates the need for lengthy cleaning operations that would reduce production rates, as the cleanable liquid does not adhere to the complex mechanical structure.
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 approach reduces the risk of spilling and contamination, simplifies cleaning operations, and increases production rates by using a cleanable liquid for shaping and a separate station for filling the concentrated liquid, ensuring efficient and safe container production.
Implementation Method 1
In the field known as 'hydroforming', it is known to use a pressurized liquid injected inside a preform placed in a mold to shape a container according to the shape of the mold and fill the shaped container with the liquid at the same time.
Implementation Method 2
the end product is obtained by mixing a first liquid with a second liquid
Data Source
AI summary
A method of forming and filling a container. The method includes the steps of placing a preform in fluidic communication with an outlet of an injection device of a forming station and forming a container by expanding the preform during a forming step, wherein a forming liquid is injected into the preform through the outlet to expand the preform into the container. The forming liquid is a cleanable liquid. The method further includes a step of transferring the formed container to a concentrate filling station, separate from the forming station and a step of filling the concentrated liquid in the container already containing the cleanable liquid. The step of filling the concentrated liquid is performed in the concentrate filling station.