Inline Gas Infusion Pressure Control for Stable Carbonation
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Solution Overview
Problem
Existing beverage carbonation systems fail to maintain consistent carbonation levels due to fluctuations in incoming liquid and gas pressures, lack real-time adjustability, and are not suitable for applications requiring clean-in-place functionality, leading to variable drink quality and sanitation issues.
Innovation Solution
An inline gas/liquid absorption system with pressure sensing devices and an electronic controller that adjusts liquid input pressure in real-time to maintain precise carbonation levels, using a control algorithm to manage differential pressure and ensure consistent gas absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If standard regulators and gauges are used in inline carbonation devices, then the device structure is simple, but the resolution is insufficient to adjust regulator increments fine enough to properly and reliably adjust the set point value
Solution Approach 1:
The patent replaces mechanical regulators and gauges with an electronic control system that includes a pump, pressure sensor, and microcontroller. The microcontroller precisely controls the pump to regulate liquid pressure, achieving fine adjustment resolution that mechanical components cannot provide. This substitution enables accurate differential pressure control (0.5 to 3 psi) necessary for reliable inline nitrogen infusion.
Solution Approach 2:
The patent introduces a pressure sensor as an intermediary between the liquid stream and the control system. The sensor continuously monitors liquid pressure and provides feedback to the microcontroller, enabling precise closed-loop control of the differential pressure. This intermediary component bridges the physical liquid flow and the electronic control, achieving measurement precision unattainable with direct mechanical gauge reading.
2Productivity
If inline carbonation devices operate with low differential pressure (0.5 to 3 psi), then gas absorption efficiency is improved, but standard regulators cannot provide sufficient resolution to maintain reliable set point adjustment
Solution Approach 1:
The patent replaces mechanical pressure regulation with an electronic pump control system. The microcontroller precisely modulates the pump motor speed and pressure output to maintain the required low differential pressure (0.5 to 3 psi) with fine resolution. This electronic control achieves the measurement precision needed for efficient gas absorption, which mechanical regulators cannot provide at such low pressure differentials.
Solution Approach 2:
The patent implements a closed-loop feedback system where the pressure sensor continuously monitors liquid pressure and feeds this information to the microcontroller. The microcontroller adjusts the pump output in real-time to maintain the target differential pressure range (0.5 to 3 psi). This feedback mechanism ensures gas absorption efficiency is optimized while maintaining reliable pressure control, overcoming the resolution limitations of mechanical regulators.
3Quantity of substance
If accumulator tank systems are used for nitrogen infusion, then liquid storage capacity is increased, but flow and pressure vary from 20 to 120 PSI creating variable flow rate output and variable nitrogen infusion levels
Solution Approach 1:
The patent replaces the accumulator tank mechanical storage system with an inline infusion device that processes liquid on-demand through electronic pump control. The microcontroller precisely regulates pump output to maintain consistent flow rate and pressure regardless of storage capacity. This substitution eliminates the pressure variability (20 to 120 PSI) inherent in tank systems, achieving stable nitrogen infusion levels while still providing adequate liquid supply capacity.
Solution Approach 2:
The patent transitions from static accumulator tank storage to dynamic inline infusion processing. The electronic pump and microcontroller continuously adjust liquid flow and pressure in real-time based on system conditions and target parameters. This dynamic control maintains stable flow rate and nitrogen infusion levels, overcoming the inherent instability of fixed-volume tank systems where pressure varies as liquid level changes.
4Quantity of substance
If accumulator tanks are used for premixed beverages, then storage capability is improved, but clean in place functionality is compromised leading to sanitation issues
Solution Approach 1:
The patent extracts the liquid storage function from the infusion system by using separate, easily cleanable reservoirs upstream and performing infusion inline. The inline device itself contains no large accumulator tank that would be difficult to sanitize. This separation allows the infusion mechanism to be simple and cleanable, while storage capability is provided by external containers that can be separately sanitized or replaced.
Solution Approach 2:
The patent introduces an inline infusion device as an intermediary between the beverage storage and dispensing points. This intermediate device processes liquid on-demand through electronic control without requiring large internal storage tanks. The design enables clean-in-place functionality for the infusion mechanism while maintaining beverage storage capability through external, easily sanitizable containers, thus resolving the contradiction between storage and sanitation.
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 real-time adjustable gas infusion levels, maintaining target carbonation levels despite pressure fluctuations, and improves drink quality by allowing precise customization of characteristics like carbonation, nitrogen levels, and flavor, while facilitating clean-in-place operations.
Implementation Method 1
The pump in turn manipulates the pressure of the incoming liquid stream in a way that provides a stable and real-time adjustable inlet pressure to the Inline Gas Liquid Absorption device
Implementation Method 2
The differential pressure between the input gas and liquid streams determines the level of gas absorbed into the liquid at a given temperature
Implementation Method 3
an electronic controller that executes a control algorithm on the pump and/or other system components. The pump in turn manipulates the pressure of the incoming liquid stream
Data Source
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AI summary
An inline gas/liquid infusion system featuring an electronic control logic and subsystem having a signal processor configured to: receive signaling containing information about a liquid pressure of an incoming liquid provided from a pump to an inline gas liquid absorption device and about a gas pressure of an incoming gas provided to the inline gas liquid absorption device; and determine corresponding signaling containing information to control the liquid pressure of the incoming liquid provided from the pump to the inline gas liquid absorption device in order to provide real time adjustable set point output levels of gas absorption in the inline gas liquid absorption device, based upon the signaling received.