Liquid Loading Device with Air Extraction for Filling Saturation
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Solution Overview
Problem
The existing liquid loading process in product manufacturing is inefficient due to trapped air in the product's internal space, leading to poor filling saturation and reduced impact resistance, as the fluidity of viscous liquids is poor and air is easily trapped during the loading process.
Innovation Solution
A liquid loading device equipped with a loading module, air extraction module, pressure sensor, and controller that controls the loading and air extraction processes to create a negative pressure environment, ensuring efficient liquid filling by continuously extracting air and monitoring pressure values to prevent air from being trapped, thereby enhancing filling saturation and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If liquid is loaded into the product in an air environment, then the loading process is simple, but air is easily trapped inside the liquid resulting in poor filling saturation
Solution Approach 1:
The air extraction module is activated before liquid loading begins to pre-evacuate air from the product's internal space. This preliminary action creates a vacuum environment that prevents air entrapment during subsequent liquid filling, ensuring high filling saturation without requiring complex multi-stage equipment
Solution Approach 2:
The air extraction module continues to operate throughout the entire liquid loading process, maintaining continuous air removal while liquid is being injected. This continuous action ensures that air is constantly evacuated as liquid fills the space, preventing air pockets from forming and ensuring complete saturation
2Productivity
If liquid is loaded quickly to improve productivity, then the loading speed increases, but air is easily trapped due to poor fluidity of viscous liquid
Solution Approach 1:
The air extraction module operates continuously throughout the rapid liquid loading process, maintaining constant air removal even at high injection speeds. This continuous vacuum action compensates for the poor fluidity of viscous liquid, allowing fast loading without air entrapment and maintaining high filling saturation
Solution Approach 2:
The system uses pneumatic pressure differential created by the air extraction module to drive viscous liquid into the product cavity. The negative pressure environment facilitates smooth liquid flow and complete cavity filling even at high speeds, overcoming the limitations of liquid viscosity
3Manufacturing precision
If air extraction is performed to improve filling saturation, then air is removed from the liquid, but the device complexity increases with additional modules
Solution Approach 1:
The air extraction module and liquid loading module are integrated into a single coordinated system controlled by one controller. The modules share common components such as the product fixture and sensing systems, merging multiple functions into a unified device that achieves high filling saturation without proportionally increasing overall device complexity
Solution Approach 2:
The air extraction module serves multiple functions: it removes air before loading, maintains vacuum during loading, and continues extraction after loading to ensure complete saturation. This multi-functionality allows a single additional module to address all air-related issues throughout the entire process, maximizing benefit while minimizing added complexity
4Strength
If traditional liquid loading is used to maintain simple operation, then the operation is easy, but the impact resistance of the product is weak due to poor compactness
Solution Approach 1:
The pressure sensor provides real-time feedback on the internal pressure of the product during air extraction and liquid loading. The controller uses this feedback to automatically adjust the extraction and loading rates, ensuring optimal filling conditions without requiring complex manual operation. This automated feedback control maintains ease of operation while achieving high compactness for improved impact resistance
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 device effectively loads liquids into the product, improving filling saturation and impact resistance by ensuring air is extracted, allowing the liquid to flow smoothly and evenly distribute within the product's cavity, thus enhancing the product's structural integrity.
Implementation Method 1
the air extraction module extracts air from the product to be loaded... creates a negative pressure environment... allowing the liquid to flow smoothly and evenly distribute within the product's cavity
Data Source
AI summary
The present disclosure provides a liquid loading device for loading liquid into a product. The product includes a cavity and a liquid inlet communicated with the cavity. The liquid loading device includes a loading module to load liquid into the cavity through the liquid inlet. A sensor senses a pressure in the cavity and generates at least one pressure value. A controller is coupled to the sensor and the loading module, and controls the loading module to operate based on related data. In addition, the present disclosure also provides a liquid loading method.