Preform Sterilization Gasification and Removal
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Solution Overview
Problem
Conventional methods for sterilizing preforms before blow molding introduce hydrogen peroxide into the molding process, risking damage to machine components and leading to uneven sterilization, which can result in defects like whitening, distortion, and uneven heating in the final bottle products.
Innovation Solution
A method involving gasifying a sterilizer, such as hydrogen peroxide, in a chamber with lower pressure than atmospheric, and using hot air to activate and remove the sterilizer from the preform, ensuring it does not enter the blow-molding machine and maintaining even sterilization across the preform's surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydrogen peroxide sterilizer is applied to preforms before blow molding, then sterilization effect is improved, but machine components are damaged and product defects occur
Solution Approach 1:
The patent extracts the harmful sterilizer (hydrogen peroxide) from the system by introducing a removal unit that applies nitrogen gas or air flow to blow off the sterilizer from preforms before they enter the blow molding machine. This ensures sterilization effectiveness is maintained while preventing damage to machine components and product defects.
Solution Approach 2:
The patent introduces nitrogen gas or air as an intermediary substance between the sterilizer-coated preforms and the blow molding machine. This intermediary medium carries away the harmful sterilizer through controlled gas flow, protecting machine components while maintaining the sterilization benefit.
2Reliability
If sterilizer is applied to preforms, then sterilization is achieved, but uneven sterilization occurs leading to product defects
Solution Approach 1:
The patent segments the sterilization process into two distinct stages: first, applying the sterilizer to preforms; second, removing excess sterilizer using nitrogen gas or air flow before blow molding. This segmentation ensures uniform sterilization by preventing localized over-concentration of sterilizer that would cause defects.
Solution Approach 2:
The patent changes the physical state and distribution parameters of the sterilizer by controlling the gas flow rate, temperature, and contact time in the removal unit. These parameter adjustments ensure uniform removal of sterilizer across all preform surfaces, preventing uneven sterilization and associated defects.
3Reliability
If sterilizer adheres to preform and is not removed, then sterilization is maintained, but sterilizer enters blow molding machine causing damage
Solution Approach 1:
The patent implements a rapid sterilizer removal process using high-velocity nitrogen gas or air flow that quickly blows off excess sterilizer from preforms in a short time period. This rushing through approach maintains sterilization effectiveness while preventing sterilizer accumulation and entry into the blow molding machine.
Solution Approach 2:
The patent uses pneumatic principles by introducing compressed nitrogen gas or air into the removal unit to create directional gas flow. This pneumatic force efficiently removes adhered sterilizer from preform surfaces through pressure-driven flow, preventing machine contamination while maintaining 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 prevents damage to blow-molding machine components and reduces the risk of defects in the bottles, ensuring effective sterilization and uniform heating, resulting in higher-quality, defect-free products.
Implementation Method 1
gasifying a sterilizer, discharging a sterilized gas (G) toward a preform (1)
Implementation Method 2
activating the sterilizer adhering to the preform (1) by the heat of hot air (P) blasted to the preform (1)
Implementation Method 3
the preform is heated in the heating furnace to a temperature suitable for forming the preform into a container
Data Source
Figure 1(A)~1(C)
Figure 2(D)~2(G)
Figure 3
AI summary
A method of sterilizing a preform includes steps of: sterilizing bacteria adhering to a preform (1) made of resin by gasifying a sterilizer, discharging a sterilized gas (G) from a nozzle (6) toward a preform (1), now traveling, so as to adhere to the preform (1); activating the sterilizer adhering to the preform (1) by blasting hot air (P) to the preform; and sterilizing bacteria adhering to the preform, and removing the sterilizer adhering to the preform (1), wherein the above steps are performed sequentially in order. According to the above-mentioned steps, the sterilizer does not enter a blow-molding machine.