Liquid-Expanded Container Forming for Aseptic Filling

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Solution Overview

Problem

Existing blow molding processes for plastic containers face challenges in achieving aseptic conditions without exposing end products to high temperatures, which can affect product properties and require complex container configurations to manage pressure differentials.

Innovation Solution

A method and system using a sterilizing liquid to expand a preform within a mold cavity, sterilizing the interior surface of the container, followed by draining and rinsing, allowing for aseptic filling without heating the end product, using a mold cavity, blow nozzle, and pressure source to introduce and remove the sterilizing liquid.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a hot filling process is used to sterilize the container and end product, then sterilization is achieved, but the end product properties (shelf-life, color, consistency, flavor) are adversely affected

Engineering Contradiction:

Improvesterilization effectivenessVSAvoidheat-induced product degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The container is sterilized in advance during the blow molding process by exposing it to ionizing radiation before the end product is filled. This preliminary sterilization eliminates the need for subsequent hot filling, thereby preserving the end product's quality attributes while ensuring the container is sterile when the product is introduced.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Ionizing radiation serves as an intermediary sterilization method that can sterilize the container without requiring thermal contact with the end product. This intermediary approach allows sterilization to occur independently of the filling process, avoiding direct heat exposure to temperature-sensitive products.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a hot filling process is used, then sterilization is achieved, but complex container configurations are required to manage pressure differentials during cooling

Engineering Contradiction:

Improvesterilization effectivenessVSAvoidcontainer configuration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If gas (air) is used to expand the preform, then the blow molding process is simple, but energy efficiency is reduced compared to liquid expansion

Engineering Contradiction:

Improveblow molding process simplicityVSAvoidenergy efficiency

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The patent utilizes liquid (hydraulic) pressure instead of gas (pneumatic) to expand the preform during blow molding. This hydraulic approach improves energy efficiency compared to traditional pneumatic methods while maintaining the essential blow molding process functionality.

Inventive Principle:

Principle #29Pneumatics and hydraulics

4Productivity

If the end product is used as the liquid expansion means, then intermediate process steps are eliminated, but the end product is exposed to potential contamination before filling

Engineering Contradiction:

Improveprocess integration efficiencyVSAvoidcontamination risk

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The container is sterilized in advance during the blow molding process by exposing it to ionizing radiation before the end product is filled. This preliminary sterilization ensures the container is contamination-free when the end product is introduced, allowing the end product to be used as the expansion medium without compromising product safety.

Inventive Principle:

Principle #10Preliminary action

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 method enables aseptic formation and filling of containers without heat-induced product changes, reducing complexity and ensuring sterile conditions for the container interior and exterior surfaces.

Implementation Method 1

sterilizing the interior surface of the container with the sterilizing liquid

Methodology Applied

Scientific EffectSterilization by liquid contact:

Implementation Method 2

introducing the sterilizing liquid into the preform to expand the preform against the mold cavity

Methodology Applied

Scientific EffectPressure expansion: Pressure Increase

Data Source

PatentUS20250319644A1Method of aseptically forming a container with a fluid

Publication Date: 2025.10.16 DISCMA AG

AI summary

A method of forming and sterilizing a container includes steps of locating a container precursor within a mold cavity having an internal surface, dispensing a sterilizing liquid into the container precursor to expand the container precursor toward the internal surface of the mold cavity to form a resultant container having an interior defined by an interior surface of the resultant container with the sterilizing liquid sterilizing the interior surface of the resultant container during the dispensing of the sterilizing liquid, draining the sterilizing liquid from the interior of the resultant container, rinsing the interior of the resultant container with a rinsing liquid following the draining of the sterilizing liquid, dispensing an end product into the interior of the resultant container following the rinsing of the interior of the resultant container, and sealing the interior of the resultant container following the dispensing of the end product therein.