Large-scale production system and method for ultra-clean injection-molded medical cryopreservation tubes

Abstract

The invention is suitable for the technical field of medical consumable production, and provides a large-scale production system and method for medical cryopreservation tubes through ultra-clean injection molding, the production system comprises an air purification subsystem, and the production environment reaches the ultra-clean standard through multi-stage filtration; the automatic production subsystem integrates full-process operation modules such as automatic feeding, injection molding and sorting, and efficient and automatic production is achieved; and the intelligent control subsystem coordinates the work of each subsystem and optimizes production. The production method comprises the steps of raw material preparation, injection molding, assembly, detection, packaging and the like, and process parameters of all links are accurately set. The problems that a traditional production environment is not clean, efficiency is low, and quality consistency is poor are solved, large-scale production of the medical cryopreservation tubes through ultra-clean injection molding can be achieved, the product quality and the production efficiency are improved, and the production cost is reduced.

Description

Technical Field

[0001] This invention relates to the field of medical consumables production technology, specifically to a system and method for large-scale production of ultra-clean injection molded medical cryopreservation tubes. Background Technology

[0002] In numerous fields such as biomedicine, scientific research, and medical testing, medical cryovials are commonly used consumables for preserving and transporting biological samples, cells, blood, vaccines, and gene samples. With the rapid development of these fields, the demand for medical cryovials is increasing, and the requirements for their quality and production efficiency are also becoming more stringent.

[0003] Currently, traditional medical cryopreservation tube production systems and methods have many problems. Regarding the production environment, ordinary injection molding environments often fail to meet cleanliness standards, easily leading to the contamination of cryopreservation tubes by dust, microorganisms, and other impurities. This contaminates the biological samples stored inside, affecting subsequent experimental results and medical applications. For example, in cell culture experiments with extremely high microbial density requirements, cryopreservation tubes produced in ordinary environments may introduce contaminants, causing cell culture failure. In terms of production efficiency, most existing production systems cannot achieve true large-scale production. Many production processes rely heavily on manual labor, such as manual loading, sorting, and assembly, which is not only labor-intensive but also inefficient, failing to meet the ever-increasing market demand. For instance, when facing large-scale vaccine storage needs, traditional production methods may not be able to provide a sufficient quantity of high-quality cryopreservation tubes in a short time. Regarding product quality consistency, manual operation inevitably introduces errors. Different operators' techniques and pressures can lead to variations in key indicators such as dimensional accuracy and sealing of the cryopreservation tubes. Taking sealing as an example, poorly sealed cryovials are prone to liquid nitrogen seepage or sample leakage during low-temperature storage, which can not only cause sample loss but also harm the storage equipment and the surrounding environment. Furthermore, traditional production systems are insufficient in terms of automation and intelligence. The lack of effective automated detection and rejection mechanisms makes it difficult to promptly identify and handle defective products during production, resulting in low yields and increased production costs.

[0004] In summary, existing medical cryopreservation tube production systems and methods have significant shortcomings in terms of production environment, production efficiency, product quality consistency, and automation level, failing to meet the large-scale production needs of modern biomedicine and other fields for ultra-clean, efficient, and high-quality medical cryopreservation tubes. Therefore, there is an urgent need to provide an ultra-clean injection molding system and method for large-scale production of medical cryopreservation tubes to overcome the deficiencies in current practical applications. Summary of the Invention

[0005] The purpose of this invention is to provide a system and method for large-scale production of ultra-clean injection molded medical cryopreservation tubes, effectively solving the problems mentioned in the background art.

[0006] This invention is achieved as follows: a large-scale production system for ultra-clean injection-molded medical cryopreservation tubes, comprising: The air purification subsystem is used to filter outside air, enabling the production workshop to reach ultra-clean standards. An automated production subsystem, connected to the air purification subsystem, includes an automatic feeding module, an injection molding module, an automatic sorting and assembly module, a capping module, a coding and labeling module, an detection and rejection module, and an automatic packaging and counting module, used to realize fully automated production of cryopreservation tubes from raw materials to finished products. The intelligent control subsystem is communicatively connected to the air purification subsystem and the automated production subsystem, and is used to coordinate and control the operation of each subsystem and module.

[0007] As a further aspect of the present invention: the air purification subsystem includes a pre-filter, a medium-efficiency filter and a high-efficiency filter connected in sequence, and the air purification subsystem also includes an air circulation device and an air purification and disinfection device installed in the workshop.

[0008] As a further aspect of the present invention: the high-efficiency filter is used to filter out particles and microorganisms with a diameter greater than 0.3 micrometers in the air; The air purification and disinfection equipment includes an ultraviolet disinfection lamp and an ozone generator.

[0009] As a further aspect of the present invention: the automatic feeding module includes a vibratory feeder and a conveyor belt for orderly arranging and conveying raw material particles and cryopreservation tube components to a designated position, and the conveyor belt is equipped with sensors and controllers to control the feeding speed and quantity; The injection molding module includes a high-speed injection molding machine and a multi-cavity mold for injection molding dried raw materials, and is equipped with an automatic cutting device.

[0010] As a further aspect of the present invention: the automatic sorting and assembly module utilizes a robotic arm and a vision recognition system to identify the cryopreservation tube body and cap, employing the following formula: ; Calculate the assembly deviation correction amount, locate and assemble; in, This represents the amount of correction for assembly deviations. This represents the number of image acquisitions used in the calculation. This represents the number of a single image acquisition. This represents the reference length used for normalizing the error term. Represents the geometric error scaling factor. Representing the The normalized Euclidean distance for the second identification. Representing the Normalized weights for the angle deviation of the sub-identification This represents the maximum gripping torque of the robotic arm. Representing the The actual average torque during each grabbing process. Represents torque-length conversion stiffness; The capping module uses an electric capping machine; The detection and rejection module includes a visual inspection system and a laser sensor for detecting cryopreservation tubes.

[0011] As a further aspect of the present invention: the intelligent control subsystem includes a central controller and multiple distributed controllers; The central controller coordinates the work of various subsystems and modules and sends instructions to the distributed controller.

[0012] This invention also provides a method for large-scale production of ultra-clean injection molded medical cryopreservation tubes. This method uses the system described above and includes the following steps: Step 1: Raw material preparation: Select polypropylene or polycarbonate materials that meet medical standards and dry them. Step 2, Injection Molding: Add the dried raw materials to the injection molding machine and perform injection molding according to the set injection parameters to obtain the cryopreservation tube body; Step 3, Automated Sorting and Assembly: The tubes and caps are sorted and assembled using a vision recognition system and a robotic arm; Step 4, Capping: Send the assembled cryopreservation tubes into the electric capping machine for capping. Step 5, Coding and Labeling: Print information on the cryovials and affix labels; Step 6, Inspection: Inspect the cryopreservation tubes for appearance and sealing. Step 7, Automatic Packaging: Pack the qualified cryopreservation tubes according to the set quantity.

[0013] As a further aspect of the present invention: in step 1, the drying conditions for preparing the raw materials are: drying at a temperature of 80-100°C for 4-6 hours.

[0014] As a further aspect of the present invention: in step 2, for polypropylene material, the injection temperature is controlled at 200-230℃, the injection pressure is 80-120MPa, and the holding time is 10-15 seconds. For polycarbonate materials, the injection temperature is 280-320℃, the injection pressure is 100-150MPa, and the holding time is 15-20 seconds.

[0015] As a further aspect of the present invention: in step 4, the capping torque is controlled at 1-2 N·m and the rotation speed is 50-100 rpm.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. Improve product quality Ultra-clean environment guarantee: The ultra-clean production environment effectively avoids contamination of cryovials by dust, microorganisms, and other impurities. This allows the produced medical cryovials to better protect the biological samples stored inside, reducing the risk of sample contamination and ensuring the accuracy of experimental results and the safety of medical applications. For example, in the field of cell therapy, using cryovials produced by this invention to store cells can effectively reduce the chance of cell contamination and improve the success rate of cell therapy.

[0017] High-precision manufacturing: Automated production systems and optimized production methods ensure the dimensional accuracy and consistent quality of the cryovials. Errors in key dimensions such as the tube opening diameter and body thickness are controlled within extremely small ranges, resulting in excellent sealing and meeting the stringent requirements of various biological samples during cryogenic storage and transportation. In long-term cryogenic storage experiments, the cryovials produced by this invention maintain excellent sealing, preventing liquid nitrogen infiltration or sample leakage.

[0018] 2. Improve production efficiency Multi-station parallel operation: The large-scale production system adopts a multi-station parallel operation design, with multiple production stages running simultaneously, greatly shortening the production cycle. Compared with traditional production methods, production efficiency is significantly improved, enabling the production of large quantities of medical cryopreservation tubes in a short time to meet large-scale market demand. For example, in response to public health emergencies, such as large-scale vaccination requiring a large number of cryopreservation tubes to store intermediate and finished products in the vaccine production process, the production system of this invention can respond quickly and provide a sufficient number of cryopreservation tubes.

[0019] Automation reduces human intervention: Highly automated production processes reduce manual operations, not only lowering labor intensity but also avoiding inefficiencies and errors caused by manual labor. The production system can operate 24 / 7, continuously and stably producing high-quality cryopreservation tubes, improving the company's production efficiency and market competitiveness.

[0020] Reduce production costs Improved yield: Advanced detection and rejection mechanisms can promptly identify and remove defective products during the production process, increasing the yield and reducing waste of raw materials and production costs caused by defective products. Through precise production control and quality inspection, the production system of this invention can increase the yield to over 99%, significantly reducing production costs compared to traditional production methods.

[0021] Reduced labor costs: Automated production reduces reliance on manual labor, requiring only a small number of staff for equipment monitoring and maintenance, thus lowering labor costs. Simultaneously, automated production reduces production accidents and product quality issues caused by human error, further mitigating potential cost losses.

[0022] 4. Enhance production flexibility Adjustable parameters: The intelligent control subsystem allows for flexible adjustment of various parameters of the production system according to different production needs and product specifications. Enterprises can quickly switch between producing medical cryopreservation tubes of different specifications and materials based on market demand, meeting diverse customer needs and improving the enterprise's market adaptability and competitiveness.

[0023] Easy to upgrade and expand: The modular design of the production system makes it easy to upgrade and expand. Enterprises can add new production modules or equipment to the existing system according to their own development and market demand, thereby improving production capacity and product quality and achieving sustainable development.

[0024] In summary, the ultra-clean injection molding system and method for large-scale production of medical cryopreservation tubes of the present invention have significant advantages in terms of product quality, production efficiency, production cost and production flexibility. It can bring significant economic and social benefits to medical cryopreservation tube manufacturers and promote the development of related fields such as biomedicine. Attached Figure Description

[0025] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0026] Figure 1 Architecture diagram of a large-scale production system for ultra-clean injection molded medical cryopreservation tubes.

[0027] Figure 2 A flowchart of a method for large-scale production of medical cryopreservation tubes using ultra-clean injection molding.

[0028] Figure 3 It refers to the raw material transportation and pretreatment process.

[0029] Figure 4 This is a flowchart of the quality testing equipment workflow. Detailed Implementation

[0030] 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, not all, of the embodiments of the present invention. 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.

[0031] The present invention will be further explained below with reference to specific embodiments.

[0032] Please see Figure 1 The present invention provides a system for the large-scale production of ultra-clean injection-molded medical cryopreservation tubes, comprising: 1. Large-scale production system for ultra-clean injection molding of medical cryopreservation tubes Air purification subsystem: This system mainly consists of a pre-filter, a medium-efficiency filter, and a high-efficiency filter. Outside air first passes through the pre-filter to remove larger dust particles and impurities; then it enters the medium-efficiency filter, which further filters out smaller dust particles and some microorganisms; finally, it passes through the high-efficiency filter to remove particles larger than 0.3 micrometers and microorganisms, ensuring that the air entering the production workshop meets ultra-clean standards. Simultaneously, the workshop is also equipped with air circulation devices and air purification and disinfection equipment, such as ultraviolet disinfection lamps and ozone generators, to regularly disinfect the air and ensure a continuously clean production environment.

[0033] 2. Automated Production Subsystem Automatic feeding module: This module combines a vibratory feeder and a conveyor belt. The vibratory feeder arranges raw material granules such as medical-grade polypropylene (PP) or polycarbonate (PC), as well as components such as cryovial caps, in an orderly manner, and then transports them to the injection molding machine and assembly station via the conveyor belt. Sensors and controllers are installed on the conveyor belt to automatically control the feeding speed and quantity according to the production progress, ensuring an uninterrupted supply of raw materials and components.

[0034] Injection Molding Module: Utilizing a high-speed injection molding machine and multi-cavity molds. Dried raw material granules are fed into the injection molding machine's barrel, melted into a liquid state at high temperature, and then injected into the multi-cavity mold under high pressure. By precisely controlling parameters such as temperature, pressure, and holding time of the injection molding machine, the liquid raw material is rapidly molded into cryopreservation tubing within the mold. The mold employs high-precision machining technology to ensure consistent dimensional accuracy and surface quality in each cavity, thereby producing cryopreservation tubing with precise dimensions that meet medical standards. After injection molding, an automatic cutting device cuts the tubing opening, ensuring smooth, burr-free edges.

[0035] Automated sorting and assembly module: The automated sorting and assembly module uses a robotic arm and a vision recognition system to identify the cryopreservation tubes and caps, using the following formula: ; Calculate the assembly deviation correction amount, locate and assemble; in, This represents the amount of correction for assembly deviations. This represents the number of image acquisitions used in the calculation. This represents the number of a single image acquisition. This represents the reference length used for normalizing the error term. Represents the geometric error scaling factor. Representing the The normalized Euclidean distance for the second identification. Representing the Normalized weights for the angle deviation of the sub-identification This represents the maximum gripping torque of the robotic arm. Representing the The actual average torque during each grabbing process. This represents torque-length conversion stiffness.

[0036] The automated sorting and assembly module utilizes a robotic arm and a vision recognition system to identify the cryopreservation tubes and caps, employing a formula... To perform the calculation, in this formula This represents the amount of assembly deviation correction, and its unit is millimeters (mm). This represents the total number of image acquisitions used for calculation; it is a preset integer based on assembly accuracy requirements.

[0037] In this embodiment, the setting is , The operation logic is to From 1 to of Sum the results of the calculations (i.e., the absolute value of the deviation), and then divide by . To obtain the arithmetic mean, This represents the number of a single image acquisition. This represents the reference length used for normalizing the error term. Its setting is based on the typical geometry of the object being gripped (such as a cryopreservation tube cap), obtained through prior calibration experiments. , This represents the geometric error scaling factor. The setting of this coefficient is based on regression analysis of the relationship between visual recognition deviations and actual mechanical corrections in a large amount of historical assembly data. (dimensionless) Representing the The normalized Euclidean distance for the second identification is obtained by the vision system identifying the actual center pixel coordinates of the cryopreservation tube cap in a Cartesian coordinate system. and target assembly center pixel coordinates Calculate the pixel Euclidean distance between the two. Then use a calibrated pixel-length reference value. right Normalize, Set as Pixels .

[0038] For example, when At that time, the actual center of identification is The target center is ,but Pixels , Representing the The normalized weights for the angular deviation of the secondary recognition are obtained by measuring the deviation between the actual pose angle of the tube cap and the target pose angle during grasping. (Unit: degree) The setting is based on this angle deviation, through Perform calculations, where Set as the maximum allowable angular deviation of the system. , The closer the value is to 1, the smaller the angular deviation. For example, when At that time, it was measured ,but , This represents the maximum grasping torque of the robotic arm. This value is determined by the robot's hardware specifications and can be obtained by consulting the equipment manual or by actually testing the maximum output. , Representing the The actual average torque during each gripping process is continuously collected by a torque sensor installed on the end effector (gripper) of the robot arm during the gripping and tightening of the cryopreservation tube cap. Torque value And calculate its average value. , Representing torque-to-length conversion stiffness, this is a stiffness coefficient characterizing a system's ability to convert torque differences (force) into equivalent length (displacement). It is determined during the calibration phase by applying a known torque and measuring the resulting displacement deviation, and its unit is 1 / 2 inch. ,set up In the formula The operation represents taking the absolute value. The operation represents taking the square root, the first term The second term represents the equivalent geometric deviation (in mm) measured by the vision system after angle weighting and scaling. This represents the equivalent length deviation (in mm) corresponding to the difference in gripping force measured by the torque sensor. Subtracting the two terms represents the net difference between the visual deviation and the physical force deviation. The advantage of this formula is that it allows for... and Parameters that feed back the actual physical force (torque) during the grasping process. Introduced into geometric deviation In the correction calculation, the fusion of visual information and physical force information was realized. In a specific assembly task, the system executed... The data obtained from the continuous identification and capture attempts is summarized in Table 1 below.

[0039] Table 1 Automatic Assembly Data Collection Table ; As shown in Table 1, data from three collections were obtained, and based on this data and preset parameters... , , , To perform the calculation, first calculate and .

[0040] for : Geometric deviation term Torque deviation item absolute deviation .

[0041] for : Geometric deviation term Torque deviation item absolute deviation .

[0042] for : Geometric deviation term Torque deviation item absolute deviation .

[0043] Finally, calculate The result indicates This is the assembly deviation correction amount calculated for this assembly task. The value is sent to the robot's motion controller, which then incorporates the correction amount. Adjust the end-effector coordinates of the robot arm, calculate the assembly deviation correction, and then position and assemble.

[0044] Capping Module: Utilizing an electric capping machine, precise control of the capping torque and speed ensures consistent cap tightness, further improving the sealing performance of the cryovials. The capping machine's parameters can be adjusted to accommodate different specifications of cryovials, adapting to the production needs of various products.

[0045] Coding and Labeling Module: The online coding machine can print batch numbers, QR codes, or barcodes on the tubes or caps of cryopreservation tubes, enabling product traceability management. The automatic labeling machine accurately affixes pharmaceutical-grade waterproof labels to the tubes or caps, ensuring precise label placement and guaranteeing consistent and standardized product appearance.

[0046] Inspection and Rejection Module: This module utilizes a vision inspection system and laser sensors to perform comprehensive inspection of the cryovials. The vision inspection system primarily detects defects such as scratches, cracks, and deformation on the cryovials' appearance, while the laser sensors are used to check the seal of the caps and the accuracy of the label placement. Once a non-conforming product is detected, an automatic rejection device immediately removes it from the production line, ensuring a high quality pass rate for the finished products.

[0047] Automatic packaging and counting module: This module automatically loads qualified cryovials into trays or plastic bags according to a set quantity, then seals them using an automatic sealing machine and marks the batch. The packaged cryovials can be linked with automatic case packers or palletizers to achieve automated production and packaging across the entire line, facilitating subsequent logistics and management.

[0048] Intelligent Control Subsystem: This system is the core of the entire production system, consisting of a central controller and multiple distributed controllers. The central controller coordinates the work between various subsystems and modules, sending instructions to each distributed controller based on production tasks and preset parameters. The distributed controllers then control specific equipment and devices, such as injection molding machines, robots, and testing equipment, ensuring they operate accurately according to instructions. Simultaneously, the intelligent control subsystem also possesses data acquisition and analysis capabilities, enabling real-time monitoring of various data during the production process, such as production speed and product quality parameters. Based on the data analysis results, it optimizes and adjusts the production process to improve production efficiency and product quality.

[0049] Please see Figure 1 The present invention also provides a method for large-scale production of ultra-clean injection molded medical cryopreservation tubes. The method uses the system described above and includes the following steps: Raw material preparation: Polypropylene (PP) or polycarbonate (PC) materials meeting medical standards are selected as the raw materials for cryovials. The raw materials are dried to remove moisture and impurities to ensure the quality of the injection molding. Drying conditions are set according to the material's characteristics, generally at 80-100℃ for 4-6 hours.

[0050] Injection molding: The dried raw material granules are added to the barrel of the injection molding machine, and the machine's parameters such as temperature, pressure, and holding time are set. For polypropylene, the injection temperature is generally controlled at 200-230℃, the injection pressure at 80-120MPa, and the holding time at 10-15 seconds; for polycarbonate, the injection temperature is typically 280-320℃, the injection pressure at 100-150MPa, and the holding time at 15-20 seconds. The molten raw material is then injected into a multi-cavity mold. After cooling and solidification, the mold is opened, and the formed cryogenic tube is removed. The cooling time depends on the size of the mold and the thickness of the product, generally ranging from 15 to 30 seconds.

[0051] Automated sorting and assembly: The injection-molded cryopreservation tubes and caps are transported to the automated sorting and assembly station via conveyor belt. A vision recognition system and robotic arms are used to sort and assemble the tubes and caps, ensuring that each tube is accurately and tightly fitted with its corresponding cap, without any looseness.

[0052] Capping: Feed the assembled cryopreservation tubes into the electric capping machine. Set the torque and speed of the capping machine according to the specifications and requirements of the cryopreservation tubes. Generally, the capping torque is controlled at 1-2 N·m and the speed is 50-100 rpm to ensure that the caps are tightened in place and achieve good sealing.

[0053] Coding and Labeling: An online coding machine is used to print batch numbers, QR codes, or barcodes on the body or cap of the cryopreservation tubes. Then, an automatic labeling machine affixes the labels to the designated locations. The content and location of the coding and labeling should comply with relevant pharmaceutical standards and customer requirements.

[0054] Inspection: The cryovials are inspected for appearance and sealing using a vision inspection system and a laser sensor. The vision inspection system scans the cryovials at a certain speed and resolution to detect defects such as scratches, cracks, and deformation. The laser sensor emits a laser beam to detect the gap and seal between the cap and the tube body, determining whether the seal is adequate.

[0055] Automated packaging: Qualified cryovials are packed into trays or plastic bags according to a set quantity, sealed using an automatic sealing machine, and the batch number and quantity are labeled on the packaging. The packaged cryovials can be boxed or stacked as needed for storage and transportation.

[0056] In summary, the production system of this invention is equipped with an advanced air purification system, employing a multi-stage filtration device that effectively filters dust, microorganisms, and other impurities from the air, enabling the injection molding workshop to reach a cleanliness standard of 10,000 or even higher. Simultaneously, the surfaces of the production equipment are coated with special antibacterial materials and undergo regular automatic cleaning and disinfection, further reducing the adhesion of impurities and microorganisms. This provides an ultra-clean environment for the production of cryovials, ensuring that the produced cryovials meet high cleanliness requirements and reducing the risk of biological sample contamination.

[0057] The production system integrates modules for the entire process, including automated feeding, injection molding, sorting, assembly, capping, coding, inspection, and packaging. Through an intelligent control system, these modules work collaboratively and seamlessly. For example, the automated feeding device precisely delivers raw materials and components to designated locations according to the production schedule; robotic arms perform high-precision operations during assembly and capping, ensuring the assembly quality and sealing of the cryopreservation tubes. Furthermore, advanced inspection equipment such as vision inspection systems and laser sensors monitor key indicators like product appearance, dimensions, and sealing in real time. Once a defective product is detected, an automatic rejection device immediately removes it from the production line, significantly improving the yield rate.

[0058] The large-scale production system employs a multi-station parallel operation design, enabling it to handle the production of multiple cryovials simultaneously, significantly shortening the production cycle and improving efficiency. For example, in the injection molding process, multi-cavity molds and high-speed injection molding machines are used to mold multiple cryovials in a single injection. Precise temperature and pressure control ensures consistent dimensional accuracy and physical properties for each cryovial. During assembly and capping, robots operate according to preset programs and parameters, avoiding errors caused by manual operation and ensuring high standards of sealing and assembly quality for each cryovial.

[0059] In terms of production methods, the injection molding process parameters were optimized. Based on the material properties and usage requirements of medical cryopreservation tubes, parameters such as injection temperature, pressure, and holding time were precisely adjusted to improve the molding quality of the cryopreservation tubes and reduce defects such as bubbles and deformation. Simultaneously, strict operating procedures and quality standards were established for the assembly and testing stages to ensure that each step is carried out according to specifications, further improving the quality and stability of the product.

[0060] Through the above improvements, the ultra-clean injection molding medical cryopreservation tube mass production system and method of the present invention aims to solve the technical problems existing in the prior art, such as unclean production environment, low production efficiency, poor product quality consistency and insufficient automation, and provide high-quality, large-scale medical cryopreservation tube production solutions for the biomedical and other fields.

[0061] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A system for large-scale production of ultra-clean injection-molded medical cryopreservation tubes, characterized in that, include: The air purification subsystem is used to filter outside air, enabling the production workshop to reach ultra-clean standards. An automated production subsystem, connected to the air purification subsystem, includes an automatic feeding module, an injection molding module, an automatic sorting and assembly module, a capping module, a coding and labeling module, an detection and rejection module, and an automatic packaging and counting module, used to realize fully automated production of cryopreservation tubes from raw materials to finished products. The intelligent control subsystem is communicatively connected to the air purification subsystem and the automated production subsystem, and is used to coordinate and control the operation of each subsystem and module.

2. The large-scale production system for ultra-clean injection-molded medical cryopreservation tubes according to claim 1, characterized in that, The air purification subsystem includes a pre-filter, a medium-efficiency filter, and a high-efficiency filter connected in sequence. The air purification subsystem also includes an air circulation device and an air purification and disinfection device installed in the workshop.

3. The large-scale production system for ultra-clean injection-molded medical cryopreservation tubes according to claim 2, characterized in that, The high-efficiency filter is used to filter out airborne particles and microorganisms with a diameter greater than 0.3 micrometers; The air purification and disinfection equipment includes an ultraviolet disinfection lamp and an ozone generator.

4. The large-scale production system for ultra-clean injection-molded medical cryopreservation tubes according to claim 1, characterized in that, The automatic feeding module includes a vibratory feeder and a conveyor belt for orderly arranging and conveying raw material particles and cryopreservation tube components to a designated position. The conveyor belt is equipped with sensors and controllers to control the feeding speed and quantity. The injection molding module includes a high-speed injection molding machine and a multi-cavity mold for injection molding dried raw materials, and is equipped with an automatic cutting device.

5. The large-scale production system for ultra-clean injection-molded medical cryopreservation tubes according to claim 1, characterized in that, The intelligent control subsystem includes a central controller and multiple distributed controllers; The central controller coordinates the work of various subsystems and modules and sends instructions to the distributed controller.

6. A method for large-scale production of ultra-clean injection-molded medical cryopreservation tubes, the method employing the system described in any one of claims 1-5, characterized in that, The method includes the following steps: Step 1: Raw material preparation: Select polypropylene or polycarbonate materials that meet medical standards and dry them. Step 2, Injection Molding: Add the dried raw materials to the injection molding machine and perform injection molding according to the set injection parameters to obtain the cryopreservation tube body; Step 3, Automated Sorting and Assembly: The tubes and caps are sorted and assembled using a vision recognition system and a robotic arm; Step 4, Capping: Send the assembled cryopreservation tubes into the electric capping machine for capping. Step 5, Coding and Labeling: Print information on the cryovials and affix labels; Step 6, Inspection: Inspect the cryopreservation tubes for appearance and sealing. Step 7, Automatic Packaging: Pack the qualified cryopreservation tubes according to the set quantity.

7. The method for large-scale production of ultra-clean injection molded medical cryopreservation tubes according to claim 6, characterized in that, In step 1, the drying conditions for the raw materials are: drying at a temperature of 80-100℃ for 4-6 hours.

8. The method for large-scale production of ultra-clean injection molded medical cryopreservation tubes according to claim 7, characterized in that, In step 2, for polypropylene material, the injection temperature is controlled at 200-230℃, the injection pressure is 80-120MPa, and the holding time is 10-15 seconds; For polycarbonate materials, the injection temperature is 280-320℃, the injection pressure is 100-150MPa, and the holding time is 15-20 seconds.

9. The method for large-scale production of ultra-clean injection-molded medical cryopreservation tubes according to claim 8, characterized in that, In step 4, the capping torque is controlled at 1-2 N·m, and the rotation speed is 50-100 rpm.

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