Sterilization Conduit Wall Heating and Exhaust Control
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Solution Overview
Problem
Existing sterilization apparatuses for container closures are inefficient in using process fluids, leading to energy waste and risk of damaging closures due to excessive heat, and suffer from suboptimal fluid distribution caused by suction forces during exhaust fluid extraction.
Innovation Solution
The apparatus independently heats the conduit wall using a separate heating system and captures exhaust fluids using a draught principle, optimizing fluid distribution and preventing direct suction force on process fluids, allowing for controlled and uniform sterilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If process fluids are used to heat the conduit wall indirectly, then the sterilization of closures is achieved, but energy is wasted heating the conduit wall instead of optimizing fluid treatment
Solution Approach 1:
The heating function is segmented from the sterilization process. A dedicated heating system with heaters coupled to the external surface of the conduit wall separates the wall heating function from the process fluid sterilization function, allowing each to be optimized independently without energy waste
Solution Approach 2:
Heaters act as an intermediary element between the energy source and the conduit wall. These heaters are coupled to the external surface of the conduit wall and provide direct heating, eliminating the need to use process fluids as the heating medium and thus preventing energy waste
2Reliability
If excessive heat is applied to sterilize closures, then sterilization effectiveness is improved, but closures may be damaged
Solution Approach 1:
A control system continuously monitors the temperature of the conduit wall and adjusts the power supplied to the heaters accordingly. This feedback mechanism ensures the wall temperature remains within the optimal range for sterilization without exceeding levels that could damage closures
Solution Approach 2:
The system optimizes the temperature parameter by maintaining it within a specific range (above the activation value of the sterilization fluid but below damage thresholds). The independent heating system allows precise control of this parameter to achieve effective sterilization while preventing closure damage
3Productivity
If suction pump is directly connected to conduit for exhaust fluid extraction, then exhaust removal is achieved, but fluid distribution inside conduit is altered
Solution Approach 1:
The suction force is extracted from the internal conduit environment and applied externally. The suction pump is connected to the exhaust opening through a hood that extends into the conduit, allowing exhaust removal without directly applying suction force to the process fluids inside the conduit, thus maintaining stable fluid distribution
Solution Approach 2:
The exhaust hood acts as an intermediary structure between the suction pump and the conduit interior. It captures exhaust fluids at the exhaust opening and directs them to the suction pump without creating disruptive suction forces within the conduit, preserving the stability of process fluid distribution
4Loss of energy
If independent heating system is added to heat conduit wall directly, then energy waste is reduced, but device complexity increases
Solution Approach 1:
The independent heating system with heaters coupled to the conduit wall serves multiple functions: it heats the conduit wall to maintain sterilization conditions, and its integration with the control system allows it to respond to temperature variations. This multi-functionality justifies the added complexity by significantly improving energy efficiency
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 optimizes the use of process fluids for sterilization, reduces energy waste, and prevents closure damage by maintaining a consistent temperature and fluid distribution, enhancing the sterilization process's efficiency and safety.
Implementation Method 1
spraying means for injecting inside the conduit a sterilization fluid (i.e. a chemical agent) heated and vaporized
Implementation Method 2
drying means for introducing hot air in the conduit. The drying means have the function of eliminating the sterilization fluid condensed on the closures
Implementation Method 3
means for heating the wall (3) of the conduit (2), which are operatively coupled thereto
Implementation Method 4
The apparatus (1) comprises a system for capturing the exhaust fluids which exit from the conduit (2), the system being arranged to capture the exhaust fluids by way of a draught principle
Data Source
AI summary
An apparatus (1) for sterilizing container closures comprises a conduit (2) defining a passage for the closure and having a wall (3) surrounding the passage, spraying means (4) for injecting inside the conduit (2) a sterilization fluid heated and vaporized, drying means for introducing hot air in the conduit (2) and means for heating the wall (3) of the conduit (2) operatively coupled thereto. A method for sterilizing container closures transported inside a conduit (2) having a wall (3) defining internally a passage for the closures comprises the steps of injecting inside the conduit (2) a sterilization fluid heated and vaporized, introducing hot air in the conduit (2) for drying the closures and heating the wall (3) of the conduit (2) by transferring heat directly to the conduit wall (3).