A dry powder inhaler gravity filling apparatus and method

Abstract

The present application relates to the technical field of dry powder inhaler filling, and discloses a dry powder inhaler gravity filling device and method, which comprises a storage device feeding unit, a conveying unit, a filling station unit, a powder pretreatment unit, a filling unit, a sealing unit and a discharge unit; the storage device feeding unit is used for rotating and positioning the storage device placed in the feeding port, and then conveying the storage device to the filling station unit through the conveying unit; the filling station unit rotates and alternates the storage device; the powder pretreatment unit pretreats the powder into 100-500 micron particles, and then conveys the particles into the filling unit through a pipeline; and the filling unit releases the powder through a servo motor. In the present application, the filling station adopts a station rotating system controlled by a servo motor to realize the rotation and filling of multiple filling positions, so as to improve the existing dry powder inhaler filling technology, which is prone to dose deviation when processing light and fluffy powder, and thus has the problem of insufficient precision.

Description

Technical Field

[0001] This invention relates to the field of dry powder inhaler filling technology, specifically to a gravity filling device and method for dry powder inhalers. Background Technology

[0002] Dry powder inhaler filling is a crucial process in modern pharmaceutical manufacturing. It involves precisely metered dry powder medication being filled into specialized inhalation devices to ensure accurate drug delivery to patients. Before filling, the dry powder medication undergoes rigorous quality testing and pretreatment to ensure its particle size, flowability, and other properties meet requirements. The filling process typically takes place in a highly clean and controlled environment. Advanced automated filling equipment allows for the rapid and accurate filling of dry powder into the inhaler's compartment or capsule according to preset dosages. The precision and stability of the equipment are paramount, effectively preventing dosage deviations and ensuring consistent drug efficacy. Furthermore, to prevent the dry powder from becoming damp, clumping, or contaminated during filling, environmental parameters such as temperature, humidity, and cleanliness must be strictly controlled. After filling, subsequent processes such as sealing and packaging are performed to facilitate storage, transportation, and use, ultimately providing safe, efficient, and convenient dry powder inhalation therapy for patients with respiratory diseases.

[0003] Existing dry powder inhaler filling technologies are prone to dosage deviations when handling lightweight, fluffy powders, resulting in insufficient precision. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a gravity filling device and method for dry powder inhalers, which solves the problem that existing dry powder inhaler filling technologies are prone to dosage deviations when handling lightweight and fluffy powders, thus resulting in insufficient accuracy.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a gravity filling device for dry powder inhalers, comprising a material storage device feeding unit, a conveying unit, a filling station unit, a powder pretreatment unit, a filling unit, a sealing unit, and a discharging unit. The material storage device feeding unit rotates and positions the material storage device placed at the inlet, and then conveys it to the filling station unit via the conveying unit. The filling station unit rotates and rotates the material storage device. Simultaneously, the powder pretreatment unit pre-agglomerates the powder into particles of 100-500 micrometers and then conveys it to the filling unit through a pipeline. The filling unit releases the powder into the material storage device within the filling station unit via a servo motor. After filling, the powder is conveyed to the sealing unit via the conveying unit. The sealing unit fixes the sealing cap on the upper part of the material storage device. After sealing, the powder is conveyed to the discharging unit via the conveying unit, and the material storage device is unloaded via the discharging unit.

[0006] Preferably, the feeding unit of the storage device includes a camera and a rotating device. The camera is used to identify the position and orientation of the storage device, and the rotating device is used to change the position and orientation of the storage device.

[0007] Preferably, the conveying unit includes a conveyor belt and a clamp, the conveyor belt being used to move the position of the storage device, and the clamp being used to fix the storage device.

[0008] Preferably, the filling station unit includes a servo motor and a multi-station rotating device. The servo motor is used to drive the multi-station rotating device to rotate, and the multi-station rotating device is used to change the angle and sequence of the material storage device.

[0009] Preferably, the sealing unit includes a vibratory feeder, a feed channel, grippers, and a cylinder. The vibratory feeder is used to continuously supply the sealing caps, the feed channel is used to transport the sealing caps to the bottom of the grippers, the grippers are used to hold the sealing caps and move them to the top of the storage tank, and the cylinder is used to press down the sealing caps.

[0010] Preferably, the discharge unit includes a detection system and a discharge port. The detection system is used to inspect the sealing status and filling integrity of the storage device, and the discharge port is used to unload the storage device.

[0011] A filling method for a gravity filling device for dry powder inhalers includes the following steps:

[0012] S1. Feeding: The storage device is placed at the feed inlet, and its position and orientation are captured and identified by a camera. Then, it is precisely positioned by a rotating device.

[0013] S2. Conveying: After the storage device is clamped and positioned by the clamps, it is conveyed to the filling station by the conveyor belt;

[0014] S3. Filling: The filling station uses a multi-station rotating device to control the rotation angle and station rotation according to the filling requirements to fill the storage device. Before filling, the powder is pre-agglomerated.

[0015] S4. Sealing: The filled storage device is conveyed to the sealing station by a conveyor belt, and the sealing cap is precisely sealed to the top of the storage device by a cylinder.

[0016] S5. Discharge: The sealed storage device is conveyed to the discharge port and the sealing status and filling integrity are confirmed by the detection unit.

[0017] Preferably, the pre-agglomeration treatment of the powder involves first preparing a solution with a mass fraction of 10%-30% using a solvent. The solution is then pumped to a pressure atomizer via a peristaltic pump, with the pump feed rate controlled between 5-20 L / h. Simultaneously, the pressure atomizer is adjusted to 5-8 MPa and sprayed, atomizing the solution into a dryer. The hot air in the dryer is controlled to flow at a velocity of 10-30 m / s, with the inlet temperature set between 150-250°C and the outlet temperature between 70-100°C. The atomized solution solidifies in the dryer to form pre-agglomerated powder. The pre-agglomerated powder, ranging from 100-500 micrometers, is then separated and collected using a sieve.

[0018] Working principle: The storage device is placed on the conveyor belt surface below the feeding unit of the storage device. The position and orientation of the storage device are identified by a camera. Then, the position and orientation of the storage device are adjusted by a rotating device. The storage device is then clamped by a clamp. The conveyor belt is started to transport the storage device to the filling station unit. The storage device is placed on the upper part of the multi-station rotating device. The angle and sequence of the storage device are adjusted by a servo motor driving the multi-station rotating device. Then, the pre-agglomerated powder is filled into the storage device by the filling unit. Then, it is transported to the sealing unit by the conveyor belt. The sealing cap is continuously transported to the bottom of the clamp by a vibrating feeder. The clamp moves the sealing cap to the upper part of the storage device. Then, the sealing cap is fixed to the top of the storage device by a cylinder. Then, the storage device is transported to the discharge unit by the conveyor belt. After being detected by the detection unit, it is unloaded through the discharge port, completing the filling work.

[0019] This invention provides a gravity filling device and method for dry powder inhalers. It has the following beneficial effects:

[0020] 1. In this invention, a servo motor-controlled station rotation system is used at the filling station to achieve alternating filling at multiple filling positions. Compared with the traditional single-station filling method, this design allows other stations to complete preparation work while one station is filling, improving filling efficiency. At the same time, the servo-controlled precision rotation system can ensure the consistency of filling volume at each station, making the filling process more efficient and accurate. This improves the existing dry powder inhaler filling technology, which is prone to dosage deviation when handling light and fluffy powders, thus causing insufficient accuracy.

[0021] 2. In this invention, by introducing a camera and image recognition algorithm, the storage device is accurately positioned by capturing and analyzing images when it enters the feed inlet. This image recognition-based positioning method, combined with a PLC-controlled servo motor and a friction-controlled rotating device, enables the storage device to automatically rotate to the correct filling position, greatly improving the automation level and positioning accuracy of the feeding process.

[0022] 3. In this invention, the powder is pre-agglomerated to form small spherical particles of several hundred micrometers, which greatly improves the flowability and stability of the powder. This pretreatment method not only improves the accuracy of filling, but also reduces powder loss during the filling process, avoids dust pollution, and prevents damage to the powder structure during filling.

[0023] 4. In this invention, the sealing station design combines a vibratory feeder and a feeding module to ensure efficient material supply and precise sealing of the sealing caps. The cylinder-driven sealing device precisely positions and seals the storage device after filling, ensuring a tight seal and preventing powder leakage. The multi-stage automated sealing system improves the efficiency and sealing effect of the sealing operation. Attached Figure Description

[0024] Figure 1 This is a diagram of the device apparatus of the present invention;

[0025] Figure 2 This is a flowchart of the method of the present invention. Detailed Implementation

[0026] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] Please see the appendix Figure 1This invention provides a gravity filling device for dry powder inhalers, including a material storage device feeding unit, a conveying unit, a filling station unit, a powder pretreatment unit, a filling unit, a sealing unit, and a discharging unit. The material storage device feeding unit rotates and positions the material storage device placed at the inlet, and then conveys it to the filling station unit via the conveying unit. The filling station unit rotates and rotates the material storage device. Simultaneously, the powder pretreatment unit pre-agglomerates the powder into particles of 100-500 micrometers and then conveys it to the filling unit through a pipeline. The filling unit releases the powder into the material storage device in the filling station unit via a servo motor. After filling, the powder is conveyed to the sealing unit via the conveying unit. The sealing unit fixes the sealing cap on the upper part of the material storage device. After sealing, the powder is conveyed to the discharging unit via the conveying unit, and the material storage device is unloaded by the discharging unit.

[0028] Specifically, the material feeding unit rotates and positions the material storage device placed at the inlet, achieving precise positioning through a camera and rotating mechanism, laying the foundation for the subsequent filling process. The conveying unit utilizes conveyor belts and clamps to ensure stable movement of the material storage device between various workstations, guaranteeing the smooth completion of the entire process from feeding to filling, sealing, and discharging. The filling station unit uses a servo motor to drive a multi-station rotating device, precisely controlling the rotation angle and workstation rotation sequence according to the location of the material storage device and filling volume requirements, achieving efficient and accurate powder filling. The powder pretreatment unit pre-agglomerates the powder into particles of 100-500 microns, improving powder flowability and stability. This system reduces waste and dust pollution, protects the loose structure of the powder, and facilitates subsequent filling operations. The filling unit utilizes a specially designed control system that combines the pre-agglomeration characteristics of the powder with precise control via a servo motor to gradually release the powder into the storage device, ensuring accurate and stable filling volume and avoiding dosage deviation. The sealing unit uses components such as a vibrating feeder, grippers, and cylinders to achieve precise feeding, positioning, and sealing of the sealing cap, ensuring a tight seal, preventing powder leakage, and guaranteeing product quality. The discharge unit transports the sealed storage device to the discharge port via a conveyor belt, and a detection system confirms the sealing status and filling integrity, ensuring product quality and completing the final stage of the entire filling process.

[0029] The material storage device feeding unit includes a camera and a rotating device. The camera is used to identify the position and orientation of the material storage device, and the rotating device is used to change the position and orientation of the material storage device.

[0030] Specifically, the camera can capture images of the storage device placed at the feed inlet, and the image recognition technology can be used to analyze its position and orientation, providing a basis for the precise positioning of the subsequent rotating device. After the camera and algorithm module determine the position and orientation of the storage device, the rotating device can be driven by a servo motor and adjusted to the appropriate position using friction control, ensuring that it enters the filling station in the correct orientation.

[0031] The conveying unit includes a conveyor belt and a clamp. The conveyor belt is used to move the position of the storage device, and the clamp is used to fix the storage device.

[0032] Specifically, the conveyor belt can operate at a constant speed, enabling the storage device to move smoothly between different workstations on the equipment. This includes the conveying process from the inlet to the filling station, from the filling station to the sealing station, and from the sealing station to the outlet. The clamps can clamp and fix the storage device after it is positioned, ensuring that the storage device remains stable during the conveyor belt conveying process and preventing positional deviation from affecting subsequent filling, sealing and other operations.

[0033] The filling station unit includes a servo motor and a multi-station rotating device. The servo motor is used to drive the multi-station rotating device to rotate, and the multi-station rotating device is used to change the angle and sequence of the material storage device.

[0034] Specifically, the servo motor in the filling station unit can precisely drive the multi-station rotating device to rotate. According to the position of the storage device and the filling volume requirements, the rotation angle and the station rotation sequence are precisely controlled to ensure the consistency of the filling volume of each station, thereby achieving efficient and high-precision filling operations. Under the precise control of the servo motor, the multi-station rotating device in the filling station unit can realize the rotation of multiple filling positions, so that when one station is filling, other stations can prepare for the next filling, which greatly improves filling efficiency and production cycle, while ensuring that the filling volume of each station is consistent and improving the overall filling accuracy.

[0035] The sealing unit includes a vibratory feeder, a feed channel, grippers, and a cylinder. The vibratory feeder is used to continuously supply the sealing caps, the feed channel is used to transport the sealing caps to the bottom of the grippers, the grippers are used to hold the sealing caps and move the sealing caps to the top of the storage tank, and the cylinder is used to press down the sealing caps.

[0036] Specifically, the vibrating feeder in the sealing unit continuously vibrates to move the sealing caps in an orderly manner, thus providing a stable supply of sealing caps for the sealing operation. This ensures the timely and continuous supply of sealing caps and guarantees the efficient operation of the sealing process. The material channel in the sealing unit acts as a conveying channel, accurately conveying the sealing caps provided by the vibrating feeder to the bottom of the gripper, ensuring that the gripper can smoothly grasp the sealing caps. This achieves accurate transfer of the sealing caps in the sealing process. The gripper in the sealing unit can accurately grasp the sealing caps conveyed by the material channel and move them stably to the top of the storage tank. This provides accurate positioning for the subsequent cylinder pressing down on the sealing caps to achieve precise sealing, ensuring the accuracy and stability of the sealing. The cylinder in the sealing unit provides downward pressure, driving the sealing device to press down the sealing cap positioned by the gripper on top of the storage device, making the sealing cap fit tightly against the storage device, completing the sealing operation, ensuring a tight seal, and preventing powder leakage.

[0037] The discharge unit includes a detection system and a discharge port. The detection system is used to check the sealing status and filling integrity of the storage device, and the discharge port is used to unload the storage device.

[0038] Specifically, the detection system in the discharge unit can perform comprehensive inspection on the sealed storage device, including checking whether the sealing is tight and whether the filling integrity meets the standards, thereby ensuring product quality and preventing defective products from flowing out. The discharge port in the discharge unit can provide an unloading channel for the sealed and inspected storage device, allowing it to leave the equipment smoothly. At the same time, its design facilitates the automatic completion of the unloading operation, realizing the final step of the entire filling process.

[0039] A gravity filling method for dry powder inhalers includes the following steps:

[0040] S1. Feeding: The storage device is placed at the feed inlet, and its position and orientation are captured and identified by a camera. Then, it is precisely positioned by a rotating device.

[0041] S2. Conveying: After the storage device is clamped and positioned by the clamps, it is conveyed to the filling station by the conveyor belt;

[0042] S3. Filling: The filling station uses a multi-station rotating device to control the rotation angle and station rotation according to the filling requirements to fill the storage device. Before filling, the powder is pre-agglomerated.

[0043] S4. Sealing: The filled storage device is conveyed to the sealing station by a conveyor belt, and the sealing cap is precisely sealed to the top of the storage device by a cylinder.

[0044] S5. Discharge: The sealed storage device is conveyed to the discharge port and the sealing status and filling integrity are confirmed by the detection unit.

[0045] To pre-agglomerate the powder, the powder is first mixed with a solvent to form a solution with a mass fraction of 10%-30%. The solution is then pumped to a pressure atomizer via a peristaltic pump, with the feed rate controlled between 5-20 L / h. Simultaneously, the spray pressure of the pressure atomizer is adjusted to 5-8 MPa and the spray is activated, spraying the atomized solution into a dryer. The hot air in the dryer is controlled to flow at a velocity of 10-30 m / s, with the inlet temperature set between 150-250℃ and the outlet temperature set between 70-100℃. The atomized solution solidifies in the dryer to form pre-agglomerated powder. The pre-agglomerated powder, ranging from 100-500 micrometers, is then separated and collected through a sieve.

[0046] Specifically, preparing a 10%-30% (w / w) solution with a solvent allows for better subsequent atomization and pre-agglomeration of the powder, improving its flowability and stability, facilitating the formation of uniform small spherical particles to meet high-precision filling requirements, while reducing losses and dust pollution during the filling process. Controlling the peristaltic pump feed rate between 5-20 L / h ensures a stable and appropriate flow rate into the pressure atomizer, making the atomization process uniform and controllable. This promotes the generation of pre-agglomerated powder with uniform particle size and stable quality, ensuring the accuracy and consistency of subsequent filling. Adjusting the spray pressure to 5-8 MPa provides sufficient energy for solution atomization, enabling the solution to form fine and uniform droplets in the pressure atomizer. This promotes rapid drying and agglomeration of the droplets into 100-500 micrometer particles in the drying tower, ensuring the quality and particle size requirements of the pre-agglomerated powder for subsequent filling operations. Controlling the hot air pressure at 10⁻³... A flow rate of 0 m / s can quickly remove moisture from the atomizing solution, promoting rapid drying of the droplets. Simultaneously, the dried powder particles are fully agglomerated into suitable particle sizes (100-500 micrometers) under the influence of the airflow, ensuring good flowability and stability of the agglomerated particles, which is beneficial for subsequent filling processes. By setting the inlet temperature between 150-250℃, sufficient heat can be provided to the atomizing solution, allowing hot air to quickly evaporate the solvent in the solution, promoting the drying of droplets into particles. This also helps maintain the temperature environment within the drying tower, ensuring a stable and efficient formation process for the pre-agglomerated powder, guaranteeing that the powder quality and performance meet the requirements of subsequent filling processes. By setting the outlet temperature between 70-100℃, while ensuring sufficient dehydration of the dried powder particles, excessive temperature can prevent powder deterioration or other adverse effects, ensuring the stable quality of the pre-agglomerated powder and meeting the requirements for powder state and performance in subsequent filling processes.

[0047] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A gravity filling device for dry powder inhalers, comprising a material storage device feeding unit, a conveying unit, a filling station unit, a powder pretreatment unit, a filling unit, a sealing unit, and a discharging unit, characterized in that, The feeding unit of the storage device is used to rotate and position the storage device placed at the inlet. The feeding unit includes a camera and a rotating device. The camera is used to identify the position and orientation of the storage device, and the rotating device is used to change the position and orientation of the storage device. The camera and rotating device are combined with a PLC controller for positioning control. After being positioned, the storage device is conveyed to the filling station unit by a conveying unit. The filling station unit rotates and rotates the storage device. The powder pretreatment unit pre-agglomerates the powder into particles of 100-500 micrometers and then conveys it to the filling unit through a pipeline. The filling unit releases the powder into the storage device in the filling station unit through a servo motor. After filling, the powder is conveyed to the sealing unit by a conveying unit. The sealing unit fixes the sealing cap on the upper part of the storage device. After sealing, the powder is conveyed to the discharge unit by a conveying unit. The discharge unit unloads the storage device. The sealing unit includes a vibrating feeder, a feed channel, grippers, and a cylinder. The vibrating feeder is used to continuously supply the sealing caps. The feed channel is used to transport the sealing caps to the bottom of the grippers. The grippers are used to hold the sealing caps and move them to the top of the storage device. The cylinder is used to press down the sealing caps. The powder pretreatment unit pre-agglomerates the powder. First, the powder needs to be mixed with a solvent to form a solution with a mass fraction of 10%-30%. Then, the solution is delivered to a pressure atomizer via a peristaltic pump. The feed rate of the peristaltic pump is controlled between 5-20 L / h, and the spray pressure of the pressure atomizer is adjusted to 5-8 MPa to start spraying. The atomized solution is sprayed into a dryer. The hot air in the dryer is controlled to flow at a velocity of 10-30 m / s. The inlet temperature of the hot air is set between 150-250℃, and the outlet temperature is set between 70-100℃. The atomized solution is solidified in the dryer to form pre-agglomerated powder. The pre-agglomerated powder in the range of 100-500 micrometers is separated by a sieve and then collected.

2. The gravity filling equipment for dry powder inhalers according to claim 1, characterized in that: The conveying unit includes a conveyor belt and a clamp. The conveyor belt is used to move the position of the storage device, and the clamp is used to fix the storage device.

3. The gravity filling equipment for dry powder inhalers according to claim 1, characterized in that: The filling station unit includes a servo motor and a multi-station rotating device. The servo motor is used to drive the multi-station rotating device to rotate, and the multi-station rotating device is used to change the angle and sequence of the storage device.

4. The gravity filling equipment for dry powder inhalers according to claim 1, characterized in that: The discharge unit includes a detection unit and a discharge port. The detection unit is used to check the sealing status and filling integrity of the storage device, and the discharge port is used to unload the storage device.

5. A filling method for a gravity filling device for dry powder inhalers according to any one of claims 1-4, characterized in that, Includes the following steps: S1. Feeding: Place the storage device at the feed inlet, identify the position and orientation of the storage device through a camera, and rotate and position the storage device in conjunction with the PLC controller and the rotating device. S2, Conveying: After the storage device is clamped and positioned by the clamp, it is conveyed to the filling station unit by the conveying unit; S3. Filling: Before filling, the powder is pre-agglomerated into particles of 100-500 microns by the powder pretreatment unit and conveyed by the conveying unit. The filling station unit controls the rotation angle and station rotation according to the filling requirements to perform gravity filling of the storage device. S4. Sealing: The filled storage device is conveyed to the sealing unit by the conveying unit, and the sealing cap is precisely sealed to the top of the storage device by the cylinder. S5. Discharge: The sealed storage device is conveyed to the discharge unit through the conveying unit and the sealing status and filling integrity are confirmed by the detection unit. The material is then unloaded through the discharge port.

Images