Preform Sterilization via Adsorbed Hydrogen Peroxide Activation
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Solution Overview
Problem
Conventional bottle sterilization methods using hydrogen peroxide can lead to damage of blow-molding machine components and result in uneven heating and defective products due to hydrogen peroxide condensation and mist issues.
Innovation Solution
A method and apparatus where a preform adsorbs a sterilizer, such as hydrogen peroxide, is heated to activate it, and then blow-molded into a bottle, with excess sterilizer removed by air blasting to prevent damage and ensure even heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydrogen peroxide mist or gas is blasted to the preform for sterilization, then the sterilization effect is improved, but the hydrogen peroxide may condense and adhere unevenly to the preform, causing uneven heating and defective products
Solution Approach 1:
The patent changes the physical state parameter of hydrogen peroxide from liquid/mist to gas phase, and controls the concentration parameter in the range of 1-100 ppm. This parameter transformation allows uniform distribution without condensation, resolving the contradiction between sterilization effectiveness and uniformity.
Solution Approach 2:
The patent utilizes the phase transition of hydrogen peroxide from liquid to gas state through heating or vaporization. The gaseous state enables uniform penetration and distribution on the preform surface without condensation issues, thereby achieving both effective sterilization and uniform coverage.
2Reliability
If a lot of condensed mist of hydrogen peroxide is blasted to the preform, then the sterilization coverage is improved, but the amount of hydrogen peroxide adhering to the preform becomes uneven, causing defective products
Solution Approach 1:
The patent transforms the delivery form of hydrogen peroxide from condensed mist to gas phase, controlling the concentration at 1-100 ppm. This parameter change ensures wide coverage while maintaining uniform distribution, preventing both insufficient sterilization and uneven adhesion.
3Reliability
If hydrogen peroxide adhering to the preform is introduced into the blow-molding machine, then the sterilization is maintained, but the hydrogen peroxide may damage various members or components such as seal members
Solution Approach 1:
The patent extracts and removes the harmful condensed hydrogen peroxide from the system before the preform enters the blow-molding machine. By eliminating the excess liquid hydrogen peroxide while maintaining the protective sterilization layer, it prevents damage to machine components while preserving sterilization effectiveness.
Solution Approach 2:
The patent introduces air or inert gas as an intermediary medium to blow off excess hydrogen peroxide from the preform surface. This intermediary gas removes the harmful condensed liquid while allowing the controlled gaseous sterilization layer to remain, thus protecting machine components.
4Device complexity
If conventional sterilization methods are used, then the sterilization process is simple, but the heating uniformity deteriorates due to condensation and mist issues
Solution Approach 1:
The patent maintains process simplicity while improving heating uniformity by changing the delivery parameter of hydrogen peroxide to gas phase at controlled concentration (1-100 ppm). This eliminates condensation-related heating non-uniformity without significantly complicating the sterilization process.
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
Prevents damage to blow-molding machine components, ensures uniform heating, and improves sterilization effectiveness by controlling the sterilizer's presence, reducing defects like bleaching and distortion in the bottle molding process.
Implementation Method 1
a preform (1) made of resin is allowed to adsorb a sterilizer
Implementation Method 2
sterilizing the preform (1) by heating the preform (1) having adsorbed the sterilizer to a temperature suitable for a blow-molding treatment to activate the sterilizer
Implementation Method 3
air blasting to a preform on which the sterilizer is allowed to adhere, thereby removing an excess of the sterilizer from the preform
Data Source
AI summary
A step of letting a preform made of resin adsorb a sterilizer, a step of sterilizing the preform by heating the preform having adsorbed the sterilizer to a temperature suitable for a blow-molding treatment to activate the sterilizer adsorbed by the preform and a step of shaping the preform into a bottle by blowing aseptic air into the preform in a mold are performed sequentially. According to the above-mentioned steps, the sterilizer does not enter a blow-molding machine.