Pivoting Cap Sterilization via Electron Beam
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Solution Overview
Problem
Conventional methods for sterilizing and filling containers do not achieve a high enough level of sterility, as they separate the sterilization, filling, and capping processes, which can lead to contamination and residual traces.
Innovation Solution
A method that assembles a cap with a pivoting cover on the container, allowing it to be opened during filling and closed for sealing, enabling simultaneous sterilization of the container and cap surfaces, and subsequent heat sealing for a secure, sterile closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separate sterilization, filling, and capping processes are used, then the process is simple to implement, but the sterility level is insufficient and contamination risk increases
Solution Approach 1:
The patent combines sterilization, filling, and capping operations into an integrated sequence where the cap with pivoting cover serves multiple functions. The cap structure merges protection, sealing, and sterility maintenance functions, while the process integrates these operations that were previously separate, achieving higher sterility (Log 6) without proportionally increasing complexity
Solution Approach 2:
The cap is segmented into two functional parts: a base that provides structural support and sealing, and a pivoting cover that can open for filling and close for protection. This segmentation allows the cover to be opened during filling to enable sterilization of internal surfaces, then closed to maintain sterility and provide sealing, resolving the contradiction between maintaining sterility and enabling filling access
2Reliability
If the cap cover is kept closed during filling, then sterility is maintained, but filling cannot be performed
Solution Approach 1:
The cap cover is designed as a dynamic element that can pivot between closed and open positions. During transfer and sterilization, the cover remains closed to maintain sterility. During filling, the cover opens to allow product access. This dynamic behavior resolves the contradiction by adapting the cap's state to the operational requirements at each stage
Solution Approach 2:
The cap with its pivoting cover is assembled on the container before sterilization begins. The cover is positioned in closed state initially, then opened at the appropriate moment for filling. This preliminary assembly ensures that the sterility-maintaining structure is in place before contamination risks arise, while enabling controlled access when needed
3Reliability
If chemical sterilization is used, then the process is simple, but residual traces remain and sterilization effectiveness is reduced
Solution Approach 1:
The patent replaces chemical sterilization methods with electron beam irradiation. The electron beam emitter passes through the container opening and irradiates internal surfaces, providing effective sterilization without leaving chemical residues. This substitution maintains simplicity of operation while eliminating harmful residual traces and improving sterilization effectiveness
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 method ensures a high level of sterility by maintaining the cap in a sealed position during transfers and ensuring the internal and external surfaces are sterilized, achieving a sterility level of Log 6, while maintaining simplicity in design and implementation.
Implementation Method 1
each treatment station comprising means of sterilising which comprise an electron-beam emitter, and supporting means in order to support a container under said emitter, said emitter being able to emit an electron beam passing through the upper opening of a container supported by said supporting means, in order to sterilise the container, in particular the internal wall of said container
Implementation Method 2
said step d) of fastening is carried out via heat sealing, for example via ultrasound, of the cover on the base
Data Source
AI summary
A method for processing containers includes, for each container to be processed: a) an assembling step of assembling a cap having a cover on a container, the cap including a tubular base and a cover pivotably connected to the base, between an open position and a closed position, the cap being assembled via the base thereof onto the container at an opening of the container, b) a step of sterilizing the container provided with the cap having a cover, and c) a step of filling the container, the filling step including filling the container with a filling product while the cap having the cover is in the open position, and moving the cover into the closed position.