Sequential Filling of Multi-Viscosity Media in Blow-Moulded Containers
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Solution Overview
Problem
Existing blow molding and filling processes struggle to efficiently fill containers with multiple media of different viscosities without mixing, especially when high-viscosity products like ointments are involved, as they often result in air pockets and cratering, which can lead to incomplete separation and inefficient extraction.
Innovation Solution
A process using independent metering units for each medium, with a drive mechanism to move the units in a slanted guide, allowing for sequential filling through a clear opening in the mold tool, ensuring separation and compact, air-free filling by controlling the filling pressure and movement to prevent mixing, and using a capillary effect for hermetic sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional blow molding and filling processes are used to fill containers with multiple media of different viscosities, then the filling process can be completed, but the media mix and form air pockets and cratering, leading to incomplete separation
Solution Approach 1:
The filling process is segmented into sequential steps with independent metering units for each medium. Each medium is filled separately through the same clear opening in a controlled sequence, preventing mixing while maintaining process efficiency. The metering units are independently controllable and can be positioned sequentially to fill different media into distinct zones within the container.
2Manufacturing precision
If high-viscosity products like ointments are filled using conventional processes, then filling can be achieved, but air pockets and cratering occur, compromising fill quality
Solution Approach 1:
The container is pre-formed with a clear opening that remains open during the filling process, allowing for controlled sequential filling of high-viscosity media. The metering units are positioned and prepared in advance, and the filling sequence is pre-planned to ensure that each medium is introduced at the appropriate time and pressure, preventing air pocket formation and cratering while maintaining filling efficiency.
3Volume of stationary object
If multiple media are filled sequentially through the same opening, then container space is utilized efficiently, but media may transfer between compartments
Solution Approach 1:
A separating element or interface is introduced between different media during the sequential filling process. This intermediary barrier prevents direct contact and transfer between media of different viscosities while allowing each medium to occupy its designated zone within the container. The separating interface maintains media integrity despite the shared filling opening.
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
Enables the simultaneous and separate filling of multiple media within a single container, maintaining separation even when closed, ensuring efficient and air-free filling without cratering, and facilitating easy application by preventing the transfer of media between compartments.
Implementation Method 1
The connection point between the metering chamber as the one further container part and the container head part of the container is formed from a bottleneck, which is designed such that a capillary effect results. The capillary effect prevents a transfer of the discharge medium from the metering chamber into the container head part holding the expulsion medium in any case, regardless of the spatial position of the container.
Data Source
AI summary
A method produces a filled and closed container by the blow-moulding, filling and closing method. An initially open container part (52) is held in a mould (46) and has been vacuum-moulded and/or blow-moulded by a blow pin and is filled successively with media (74, 76) of different types, in particular viscosity, by metering units (12, 14) via its free, upwardly directed container-part opening (54). The filled-in media (74, 76) are separated from one another in the container part (52), and subsequently, by closing of the top mould halves (56, 58) of the mould (46). A container top part (60) is moulded, and the container part (52) is closed, forming the container.