UV-C LED Container Disinfection System
Solution Overview
Problem
Current disinfection systems for containers, particularly those used in blowing and filling systems for microbiologically sensitive products, face issues such as residue contamination, operator risk, incompatibility with narrow-necked containers, high energy consumption, and environmental concerns due to mercury vapors, and inefficiencies in germicidal radiation emission.
Innovation Solution
A blowing and filling system equipped with a disinfection unit utilizing UV-C radiation LED emitters that emit a narrow spectrum of germicidal radiation, minimizing energy dispersion and operating at lower power, while being environmentally friendly by avoiding mercury vapors, and incorporating a carousel system for efficient disinfection of containers and preforms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If oxidizing and germicidal substances are used for container disinfection, then disinfection effectiveness is improved, but risk of residues contaminating the food product increases
Solution Approach 1:
The patent replaces chemical disinfection methods with physical UV-C radiation LED emitters. The LED emitters emit UV-C radiation that sterilizes containers through photonic action without leaving chemical residues, thus maintaining disinfection effectiveness while eliminating residue contamination risks.
Solution Approach 2:
The patent changes the disinfection parameter from chemical concentration to UV-C radiation wavelength (200-280 nm). By operating LEDs at specific wavelengths within this range, the system achieves effective sterilization while avoiding the harmful effects associated with chemical substances.
2Reliability
If pulsed light systems are used for container disinfection, then disinfection capability is improved, but energy consumption and device complexity increase
Solution Approach 1:
The patent employs LED emitters with relatively short operational lifetimes (typically 10,000-50,000 hours) that can be easily replaced. These LEDs consume significantly less energy than pulsed light systems while providing adequate disinfection capability, making them economically and energetically favorable despite their limited lifespan.
Solution Approach 2:
The patent changes from high-power pulsed light operation to continuous low-power LED operation at UV-C wavelengths. This parameter change reduces energy consumption by orders of magnitude while maintaining effective sterilization through the narrow spectral emission of UV-C LEDs.
3Loss of energy
If low-pressure UV lamps are used for container disinfection, then germicidal spectrum efficiency is improved, but energy output and compatibility with automated systems deteriorate
Solution Approach 1:
The patent replaces mercury-vapor low-pressure UV lamps with solid-state LED emitters. The LEDs provide comparable or superior germicidal efficiency with immediate full-power operation, eliminating the warm-up time required by mercury lamps and enabling compatibility with high-speed automated bottling lines.
4Power
If high-pressure UV lamps are used for container disinfection, then energy emission is improved, but safety risks and environmental harm increase
Solution Approach 1:
The patent employs solid-state LED emitters that are inherently safe, containing no mercury or other hazardous materials. While individual LEDs have limited lifetimes, they can be easily replaced and pose no explosion or environmental contamination risks, unlike high-pressure mercury lamps.
Solution Approach 2:
The patent replaces high-pressure mercury vapor lamps with LED technology, eliminating the glass envelope under high pressure that creates explosion risks. The solid-state LED structure is inherently safer while providing sufficient UV-C energy for effective sterilization.
5Reliability
If conventional disinfection systems are used, then disinfection coverage is improved, but adaptability to narrow-necked containers deteriorates
Solution Approach 1:
The patent divides the disinfection function into multiple LED emitters arranged in arrays that can be configured to match different container geometries. This segmentation allows the system to adapt to various bottle sizes and neck diameters while maintaining complete internal surface coverage through strategic emitter placement.
Solution Approach 2:
The patent employs LED emitters with specific directional emission characteristics tailored to illuminate different regions of the container interior. By positioning LEDs at strategic locations and using appropriate optical elements, the system achieves uniform disinfection coverage adapted to the specific geometry of each container type.
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
The system effectively sterilizes containers and preforms with reduced contamination risk, lower energy requirements, and compliance with environmental standards, ensuring reliable disinfection and efficient processing in automated bottling machines.
Implementation Method 1
disinfection elements comprising germicidal UV-C radiation LED emitters
Implementation Method 2
emit a narrow spectrum of germicidal radiation
Data Source
AI summary
The present invention relates to a system for the disinfection of containers in a blowing and filling system of the containers with a product, in particular a system for the internal disinfection of the containers by means of ultraviolet-C radiation LED emitters.