Plasma Sterilization System for Container Caps
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Solution Overview
Problem
Existing sterilization methods for container caps, such as those using hydrogen peroxide, face challenges in completely removing the sterilizing agent and can cause thermal contraction issues due to high-temperature processes, leading to potential residual sterilizing agent and deformation.
Innovation Solution
A sterilization system that generates plasma and reactive oxygen by reacting oxygen plasma with steam, producing hydroxy radicals for sterilization, which naturally dissipates and does not require high temperatures, along with an ozone collection and reuse system to optimize oxygen use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydrogen peroxide sterilizing agent is used, then sterilization effect is achieved, but residual sterilizing agent remains on the cap
Solution Approach 1:
The patent changes the chemical parameters of the sterilizing agent from hydrogen peroxide to a plasma-based system generating reactive oxygen species (ROS) such as hydroxyl radicals, singlet oxygen, and ozone. This parameter change ensures complete decomposition of the sterilizing agent into oxygen and water, eliminating residuals while maintaining sterilization effectiveness
Solution Approach 2:
The patent employs short-lived reactive oxygen species that naturally decompose into harmless substances (oxygen and water) within seconds to minutes. These transient sterilizing agents perform their function and then disappear completely, preventing any residual accumulation on the sterilized cap
2Loss of substance
If high temperature cleaning is applied to remove sterilizing agent, then cleaning effect is improved, but thermal contraction and deformation of the cap occur
Solution Approach 1:
The patent replaces the thermal-mechanical cleaning system with a chemical-plasma sterilization system. Instead of using high-temperature thermal energy to remove sterilizing agents, the system uses plasma-generated reactive oxygen species that chemically decompose and eliminate contaminants at low temperatures, thereby avoiding thermal contraction and deformation of the cap
Solution Approach 2:
The patent fundamentally changes the temperature parameter from high temperature (required for thermal cleaning) to low temperature (ambient or slightly elevated). This parameter change enables effective sterilization without subjecting the cap to thermal stress that would cause deformation
3Reliability
If hydrogen peroxide sterilization is performed, then sterilization is achieved, but subsequent cleaning operation is required
Solution Approach 1:
The patent merges the sterilization and cleaning functions into a single integrated plasma treatment step. The reactive oxygen species generated by plasma simultaneously sterilize the cap surface and decompose organic contaminants, eliminating the need for separate cleaning operations and improving overall process efficiency
Solution Approach 2:
The patent implements continuous plasma treatment that simultaneously performs sterilization and surface cleaning in one uninterrupted process. The reactive oxygen species continuously generate and decompose, maintaining constant sterilization and cleaning action without requiring sequential operations
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 effectively sterilizes without leaving residues and avoids thermal contraction, ensuring efficient and safe sterilization of container caps by using reactive oxygen and reusing ozone, thus enhancing operational efficiency.
Implementation Method 1
oxygen (O2) is supplied and this oxygen is converted into plasma, whereby oxygen plasma containing oxygen radical and ozone (O3) is produced
Implementation Method 2
as this is reacted with steam, reactive oxygen is produced. In particular, through the reaction between oxygen plasma and steam, there is mainly produced hydroxy radical (•OH)
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
In a sterilizing system (100), a sterilizing device (1) receives a supply of oxygen and steam. The sterilizing device (1) produces oxygen plasma containing ozone from the supplied oxygen and discharges the produced oxygen plasma and reactive oxygen produced through reaction between the supplied steam and the oxygen plasma as a sterilizing agent. The sterilizing system (100) also includes an ozone collecting unit (120) for collecting ozone contained in the discharged oxygen plasma.