Thermoplastic Preform Decontamination via External Plasma-Precursor Mixing
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Solution Overview
Problem
Existing methods for decontaminating thermoplastic preforms using precursor agents like hydrogen peroxide face challenges such as insufficient heat for complete decomposition, potential degradation of preforms, increased manufacturing costs, and toxic residue issues, while plasma-based methods suffer from electrode corrosion due to high reactive species concentration.
Innovation Solution
The method involves mixing the precursor agent with plasma outside the reactor and confining the reactive species within the preform using a mandrel or laminar air flow, ensuring complete decomposition and confinement without electrode contact, using a decontamination device with a plasma reactor and confinement means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the preform is heated for longer to decompose more precursor agent into reactive oxygen species, then the sterilization effectiveness is improved, but the manufacturing cost increases and preform degradation risk increases
Solution Approach 1:
The patent applies preliminary action by injecting the precursor agent into the preform before heating, so that the agent is already in position to decompose into reactive oxygen species during the heating process. This ensures that the sterilization effectiveness is achieved without requiring extended heating time, thus maintaining manufacturing efficiency and reducing costs.
2Reliability
If the preform is heated for longer to decompose more precursor agent into reactive oxygen species, then the sterilization effectiveness is improved, but the preform may be degraded
Solution Approach 1:
The precursor agent is injected into the preform in advance before heating, allowing it to be positioned within the preform structure. During the standard heating process, the agent decomposes into reactive oxygen species that sterilize the preform internally without requiring extended heating that would degrade the preform material.
Solution Approach 2:
The precursor agent acts as an intermediary substance that carries out the sterilization function. It decomposes into reactive oxygen species during heating, enabling effective sterilization without direct prolonged exposure of the preform to high temperatures that would cause degradation.
3Productivity
If plasma is injected directly into the reactor to generate reactive species, then the decomposition efficiency is improved, but the electrodes are corroded due to high reactive species concentration
Solution Approach 1:
The patent extracts the precursor agent from the plasma generation process by injecting it separately into the preform before heating. The plasma is generated in the reactor to create reactive species, but the precursor agent is introduced independently, allowing decomposition without direct plasma-precursor interaction that would corrode electrodes.
Solution Approach 2:
The precursor agent serves as an intermediary that receives the beneficial effects of plasma-generated reactive species without being directly exposed to the high-energy plasma environment. This separation protects the electrodes from corrosion while still achieving efficient decomposition and sterilization.
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 approach achieves nearly complete decomposition of the precursor agent, reduces toxic residue, prevents electrode corrosion, and maintains manufacturing efficiency by minimizing maintenance, ensuring effective decontamination of preforms without additional processing steps.
Implementation Method 1
a plasma reactor (40) which generates a plasma (P) by injecting a carrier gas (G)
Implementation Method 2
Decomposition of the precursor agent into reactive oxygen species is carried out for example by heating the precursor agent to a high temperature
Data Source
AI summary
The invention relates to a method for decontaminating a preform made of thermoplastic material by exposing at least part of the preform to reactive species obtained by mixing a precursor agent with a plasma, the plasma being generated by injection of a carrier gas into a reactor, the method including mixing of the precursor agent with the plasma is carried out exclusively outside the reactor before it is in contact with the preform. The invention also relates to a decontamination device for carrying out the method.