Cowboy assembly and manufacturing method

Abstract

An assembly for mixing materials, comprising a rigid carrier manufactured by placing a polymer inside a mold and expanding the polymer relative to the interior of the mold. A tank plate and auxiliary components are positioned on the interior of the mold, and the polymer may expand relative to portions of the tank plate and auxiliary components. Openings may be formed within the polymer to align with the auxiliary components. Furthermore, the assembly may further comprise a mixing element disposed on the interior of the rigid body aligned with the tank plate.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application is a non - provisional application of pending provisional patent application No. 63 / 498,912, filed on April 28, 2023, the entire content of which is incorporated herein by reference.

[0002] The present disclosure generally relates to assemblies for agitating, stirring, or mixing materials, and more specifically, to methods of manufacturing assemblies for agitating or mixing materials. In some aspects, the present disclosure includes blow - molding and / or clamshell - molding techniques for manufacturing carboys.

Background Art

[0003] A carboy is a container used for multiple purposes such as storage, mixing, and transportation of materials in various industries including pharmaceutical manufacturing. A carboy includes a container of a rigid or semi - rigid polymeric material capable of holding a fluid material, an internal mixer, and ports for receiving raw materials or discharging mixed materials via one or more connectors. To assemble and join components to a carboy (e.g., internal mixer, ports), conventional carboy manufacturing includes forming a rigid container, creating openings in the walls of the carboy, for example by machining or drilling, and joining and sealing various components within the openings, for example by welding or adhesion. However, machining of carboys often generates particles and introduces contaminants that can remain inside the carboy or adhere to the carboy body even after strict chemical and mechanical cleaning.

[0004] Furthermore, molding, milling, welding, and other techniques used to manufacture the cowboy may introduce variations in shape and dimensions due to manufacturing tolerances, which may result in tolerances in the form, orientation, or location of the cowboy's features. Therefore, when the cowboy is placed on a support rack or platform and / or connected to the corresponding drive mechanism (as described in more detail below), misalignment and / or misalignment may occur in the cowboy and / or its features. This may result in difficulties in mounting or adhesion for fixed connections, as well as uneven or excessive wear on movable connections.

[0005] This disclosure aims to overcome one or more of the drawbacks mentioned above and / or other drawbacks in the art. For example, aspects of the manufacturing process may reduce or eliminate the generation of particles and contaminants inside the cowboy. Another example is that a flexible drive mount may accommodate larger tolerances during manufacturing. [Overview of the project]

[0006] Embodiments of the present disclosure include assemblies for storing, mixing, and / or transporting one or more materials. The assembly may comprise a rigid carrier, e.g., a Cowboy, manufactured by expanding a polymer into the interior of a mold, and may include integrating pre-formed components into the walls of the carrier and / or forming at least one opening in the expanded polymer. For example, a tank plate and / or auxiliary components, e.g., a port, may be positioned on the interior wall of the mold, and at least one opening may be aligned with at least one auxiliary component. The assembly may further comprise a mixing element disposed on the interior of the rigid carrier. In some embodiments, the mixing element is rotatably supported on a tank plate and / or positioned within the rigid carrier by the tank plate. In some embodiments, the mixing element is rotatably supported by the tank plate via one or more friction bearing configurations, via one or more fluid bearing configurations and / or magnetically driven and / or levitated. The position of the tank plate, and consequently the position of the mixing elements, may be based entirely or partially on the desired mixing characteristics, depending on the shape and size of the rigid carrier.

[0007] Embodiments of the present disclosure include a method for manufacturing a rigid carrier. The method includes placing a polymer inside a mold, expanding the polymer relative to the mold, and forming at least one polymer relative to the mold. A tank plate and at least one auxiliary component are positioned on the inside of the mold, with at least one opening aligned with the at least one auxiliary component. It is intended that the rigid carrier may have any desired shape and size, such that it is formed by the shape and size of the mold, in particular by the contour of the inner surface of the mold.

[0008] Embodiments of the present disclosure include a rigid container. The rigid container comprises a wall section, a tank plate, a mixing element, and an auxiliary component, such as a port. The tank plate is integrated with the wall section of the rigid container without any welded seams between the tank plate and the wall section. The mixing element is disposed on the interior of the rigid container. The auxiliary component, such as a port, is integrated with the wall section without any welded seams between the port and the wall section. [Brief explanation of the drawing]

[0009] The accompanying drawings incorporated herein and constituting part thereof illustrate the embodiments disclosed and serve to illustrate the subject matter disclosed in conjunction with the description.

[0010] [Figure 1A] This is a front view of an exemplary assembly for stirring materials, consistent with various embodiments of the present disclosure.

[0011] [Figure 1B] This is a schematic representation of a cross-section of the assembly in Figure 1A, consistent with various embodiments of the present disclosure.

[0012] [Figure 2] This is a flowchart of a method for manufacturing a rigid carrier, consistent with various embodiments of this disclosure.

[0013] [Figure 3A] This figure shows a cross-section of an exemplary tank plate placed within a mold, consistent with various embodiments of the present disclosure.

[0014] [Figure 3B] Figure 3A is a schematic representation of the connection area consistent with various embodiments of this disclosure.

[0015] [Figure 3C] An example of a tank plate consistent with various embodiments of this disclosure is shown.

[0016] [Figure 4] A diagram showing an exemplary shaping technique including auxiliary components that conforms to various embodiments of the present disclosure.

[0017] [Figure 5] A diagram showing an exemplary spring suspension drive unit that conforms to various embodiments of the present disclosure.

[0018] [Figure 6] A diagram showing a portion of the spring suspension drive unit of FIG. 5 that conforms to various embodiments of the present disclosure. [Figure 7] A diagram showing a portion of the spring suspension drive unit of FIG. 5 that conforms to various embodiments of the present disclosure.

Mode for Carrying Out the Invention

[0019] Embodiments of the present disclosure generally relate to rigid carriers and mixing equipment used in pharmaceutical manufacturing. In particular, embodiments of the present disclosure relate to devices and methods for manufacturing rigid carriers (e.g., carboys) used when storing, transporting, mixing, agitating, or stirring pharmaceutical materials. Additionally, or alternatively, embodiments of the present disclosure may also be used in non-pharmaceutical material applications.

[0020] The disclosed embodiments may include an assembly for storing, transporting, and / or agitating materials. This assembly may embody a pharmaceutical mixer, a compound mixing device, or any other device for storing, transporting, and / or mixing materials. In some embodiments, this assembly may be used to agitate, mix, or blend the components of pharmaceuticals, drugs, and other compounds in pharmaceutical dosage forms.

[0021] Referring to FIG. 1A, an exemplary assembly 100 is provided that conforms to various embodiments of the present disclosure. Assembly 100 may include a rigid container such as a carboy 110, a plurality of connectors 120, and be configured to be supported by a platform 130.

[0022] The cowboy may be related to a rigid container used to transport, carry, store, or otherwise contain a liquid or other material. Examples of materials can include, but are not limited to, water or other chemicals, one or more powders, active ingredients, resins, dyes, or other liquids, gels, or solid materials. In some embodiments, the cowboy may contain a gas (e.g., oxygen, carbon dioxide). For example, the cowboy 110 may contain a powdery substance, water, and oxygen. The assembly 100 may include a mixer 140, as shown in FIG. 1B. For example, the powdery substance may be contained within the cowboy 110 and dissolved or dispersed into water or other liquid using the mixer 140. Oxygen, nitrogen, ambient air, or other gases may fill the remaining space in the cowboy 110.

[0023] Furthermore, the cowboy 110 may be made from any suitable material for transporting, carrying, storing, or containing a liquid, including polymers. Plastic materials may include, but are not limited to, polypropylene (PP), high-density polyethylene (HDPE), polycarbonate (PC), and polyethylene terephthalate (PET). It is contemplated that the type of material, e.g., polymer, may be selected based on its properties for manufacturing (e.g., melting temperature, liquid-phase viscosity, solid-phase hardness, etc.) and its properties for use (e.g., biocompatibility or chemical compatibility, inertness, permeability, etc.).

[0024] Figure 1B shows a schematic cross-sectional representation of the exemplary assembly 100 of Figure 1A, consistent with various embodiments of the present disclosure. As shown in Figure 1B, the mixer 140 and the tank plate 150 may be housed and integrated within the wall of the cowboy 110, respectively. As shown in Figure 1B, the cowboy 110 may be supported by the platform 130 via the integrated tank plate 150 of the cowboy 110 and the spring suspension drive unit 510 of the platform 130 (for example, the cowboy 110 may be positioned on the platform 130).

[0025] Referring to Figure 2, embodiments of the present disclosure may include a method 200 for manufacturing a rigid carrier such as a cowboy 110. Method 200 may include, in step 210, placing a polymer inside a mold, and components configured to be integrated into the walls of the cowboy 110 are placed inside the mold. In some embodiments, the polymer may be viscous, molten, or in any malleable state that can facilitate blow molding or clamshell molding of the polymer against the inner surface of the mold. In addition, or alternatively, the polymer may be extruded directly into the mold. Furthermore, in some embodiments, a tank plate 150 and / or auxiliary components, such as a port 122 or connector 120, may be housed or held in place inside the mold.

[0026] Method 200 may include, in step 220, expanding the polymer relative to the mold. In some embodiments, expanding the polymer may include blowing compressed gas into the interior of the mold and expanding the polymer relative to and in contact with the interior surface of the mold. Method 200 may include, in step 230, forming at least one opening in the polymer, the at least one opening being aligned with a port or component. The opening may relate to an opening, hole, channel, or gap formed in the wall of the cowboy to provide a desired opening inside the cowboy after molding. In addition, or alternatively, the opening may be formed by any suitable tool, including, but not limited to, a stylus or needle, a hollow needle with or without compressed gas, or other suitable tool for forming an opening in the wall of the expanded polymer. The tool is intended to be relatively cold and configured to displace the malleable polymer to form the opening. Alternatively, the tool may be configured to be relatively hot (i.e., at or above a temperature configured to melt the polymer) and displace a malleable, partially solid, or solid polymer to form an opening in the expanded polymer wall. For example, a stylus may be inserted through the mold wall and through the inside of the port connection to displace a portion of the expanded polymer that would otherwise cover the port opening.

[0027] Figures 3A to 3C and Figure 4 provide examples of methods for manufacturing rigid carriers, such as the Cowboy 110, which have internally integrated components.

[0028] Figure 3A shows an exemplary tank plate 150 positioned within the mold 340. In some embodiments, the tank plate 150 includes a port (identified as 414a and shown in Figure 4(A)). Furthermore, in some embodiments, the mixer 140 may be assembled to the tank plate 150 before or after the tank plate 150 is positioned in the mold 340. The mixer 140 may be rotatably supported on the tank plate 150.

[0029] As shown in Figure 3A, the tank plate 150 may be placed on or held by a fixture 310. The fixture 310 may include, but is not limited to, any tool capable of holding the tank plate 150 during the manufacturing process, such as a mandrel. Furthermore, as shown in Figure 3A, the polymer (identified as reference no. 330) may be extruded into the mold 340 or otherwise placed. Compressed gas may be blown into the mold 340 so that the polymer expands relative to the interior of the mold 340 and comes into contact with the interior surface of the mold 340.

[0030] The tank plate 150 is pre-formed and may include a plurality of lateral projections. The lateral projections may be configured to engage with, melt into, or otherwise capture the polymer during manufacturing, thereby creating a seamless connection (or joint) between the tank plate 150 and the expanded polymer, and consequently between the wall of the cowboy 110 after manufacturing. In some embodiments, the lateral projections may include protrusions projecting from the tank plate. In addition, or alternatively, in some embodiments, the lateral projections may include a relatively thin rim projecting from the periphery of the tank plate. The lateral projections may be configured to be any suitable shape for engaging with, melting into, or otherwise capturing the polymer during manufacturing, thereby intended to allow the tank plate to be integrated into the body or wall of the cowboy. Furthermore, in some embodiments, the tank plate 150 may be formed from a material that is chemically compatible with the polymer 330. Non-limiting examples of tank plate materials include polypropylene (PP), high-density polyethylene (HDPE), polycarbonate (PC), and polyethylene terephthalate (PET).

[0031] Figure 3B shows a schematic representation of the connection area 320 shown in Figure 3A, consistent with various embodiments of the present disclosure. As shown in Figure 3B, the tank plate 150 may include lateral projections 350. The lateral projections 350 may be in contact with the fixture 310. In some embodiments, the lateral projections 350 and / or the tank plate 150 may be made from the same material as the expanded polymer, and the lateral projections 350 may be melted and chemically bonded to the polymer. In other embodiments, the lateral projections 350 and / or the tank plate 150 may be made from a different material than the polymer. Figure 3C shows an example of a tank plate 150 having lateral projections 350, consistent with various embodiments of the present disclosure. The connection between the tank plate 150 and the polymer 330 is intended to be seamless and form a leak-proof (or leak-resistant) joint.

[0032] As shown in Figure 4(A), the polymer (identified as reference no. 330) may be expanded into a port 414a held in place within the wall portion 330 of the mold. The port 414a may include any suitable shape and may be configured to connect to auxiliary equipment (e.g., a tube) for supplying or removing material from the manufactured cowboy. The port 414a may be pre-formed and may be made from any suitable plastic material, but is not limited to polypropylene (PP), high-density polyethylene (HDPE), polycarbonate (PC), and polyethylene terephthalate (PET). Any auxiliary components, including but not limited to ports, barbs, plates, lugs, handles, supports, or fixture devices, may be integrated into the wall portion of the cowboy 110.

[0033] As shown in Figure 4(B), the polymer may expand with respect to at least a portion of the port 414a. In some embodiments, the port 414a may include lateral projections similar to those of the tank plate 150 as discussed above, for engaging with, dissolving into, or otherwise capturing by the polymer and integrating with the wall of the cowboy.

[0034] As shown in Figure 4(C), a tool such as the stylus 440 shown may be inserted through port 414a (or any other optional auxiliary component) to displace or remove the expanded polymer material beyond the opening of port 414a. Any suitable device may be inserted through port 414a (or any other optional auxiliary component) so that the opening can be formed to align with the opening of port 414a (or any other optional auxiliary component). In some embodiments, a hollow needle may be inserted through port 414a, and compressed gas may be blown through the hollow needle so that the opening is formed and / or assist in the expansion or other displacement of the expanded polymer.

[0035] Embodiments of the present disclosure may include a spring suspension drive unit. The cowboy 110 may be supported on a platform 130, which may include a spring suspension drive unit. As shown in Figure 5, the drive unit 510 may be mounted to the platform 130 via one or more spring suspensions 520. When in use, the cowboy (not shown in Figure 5) may be positioned on the platform 130 such that the drive unit 510 aligns with a tank plate integrated into the wall of the cowboy. The drive unit may be configured to impart or transmit rotational motion to a mixer head supported within the cowboy by the integrated tank plate. The drive unit is intended to impart or transmit rotational motion via one or more magnets interacting with a magnet or magnetic material disposed on the mixer head. In addition, or alternatively, the spring suspension drive unit 510 is intended to accommodate manufacturing tolerances in the form, orientation, or location of the tank plate (not shown) or other features of the cowboy. This arrangement can help align the rotation axis of the drive unit with the rotation axis of the mixer head, which can help reduce or eliminate wear between the rotating surfaces.

[0036] As shown in Figure 5, the spring suspension drive unit 510 may include a flange 510a and one or more spring suspensions 520. Each spring suspension 520 may include a first spring (not referenced in Figure 5) disposed between the upper surface of the platform 130 or the flange supported by the platform 130 (i.e., between the platform 130 and the cowboy, as shown in Figure 7) to allow restricted movement of the spring suspension drive unit 510 toward the platform 130. Multiple spring suspensions (e.g., three or four spring suspensions spaced evenly or unevenly apart from one another) are intended, each of which may be adjusted by different amounts depending on alignment, tolerances, and load, to allow the spring suspension drive unit 510 to tilt. In other words, each spring suspension of the multiple spring suspensions may be adjusted by a different amount (e.g., height) to allow the spring suspension drive unit 510 to tilt in multiple degrees of freedom, thereby allowing the spring suspension drive unit 510 to accommodate manufacturing tolerances in the form, orientation, or location of the cowboy's tank plate (not shown) or other features. Furthermore, the springs of the multiple spring suspensions 520 may be of the same type, have the same spring constant, be of different types, or have different spring constants, depending on the desired application. In some embodiments, the spring suspension may include one or more springs, e.g., conical springs, corrugated springs, or other arbitrary biasing members. Two spring suspensions 520 are shown in Figure 5.

[0037] As shown in Figure 6, each spring suspension 520 may include a second spring (not referenced in Figure 6) disposed between the lower surface of the platform 130 or flanges supported by the platform 130 (i.e., on the side of the platform 130 opposite to the cowboy, as shown in Figure 7) to allow restricted movement of the spring suspension drive unit 510 away from the platform 130. As will be described in more detail below, the spring suspension 520 may include rods and bolts for holding the ends of the second spring. Four spring suspensions 520 are shown in Figure 6.

[0038] The spring suspension drive unit 510 may be made from any suitable material, including stainless steel, aluminum, copper, bronze, brass, or any other corrosion-resistant metal. The platform 130 may be made from any suitable plastic material, including, but not limited to, polyethylene terephthalate (PET or PETE), high-density polyethylene (HDPE), polyvinyl chloride (PVC or vinyl), low-density polyethylene (LDPE), or polystyrene (PS). Furthermore, in some embodiments, the platform 130 may be made from any suitable corrosion-resistant metal, including, but not limited to, stainless steel, aluminum, copper, bronze, or brass.

[0039] As shown in Figure 7, the mixer head 140 may be supported on a tank plate 150, which may be integrated with the wall of the cowboy 110. The tank plate 150 may be configured to house a drive unit, such as a spring suspension drive unit 510. The flange 510a may be mounted to the platform 130 via one or more spring suspensions 520 (two of which are shown in Figure 7). Each spring suspension 520 may include a first spring disposed between the upper side of the platform 130 and the spring suspension drive unit 510. Each spring suspension 520 may include a second spring disposed between the lower side of the platform 130 and the end of the suspension rod. The first and second springs may be supported on their respective ends by the platform 130 directly or by one or more flanges 560. Each of the spring suspensions 520 may include a rod, one end of which is connected to a flange 510a of a spring suspension drive unit 510, and the other end of which is cantilevered under the platform 130. The cantilevered end of each rod may include a flange 580a and / or a bolt 580b to hold one end of the end of each second spring.

[0040] While exemplary embodiments have been described herein, their scope includes all embodiments having equivalent elements, modifications, omissions, combinations (e.g., combinations of aspects across various embodiments), adaptations, and / or changes based on this disclosure. Elements in the claims should be interpreted broadly in accordance with the language used in the claims and should not be limited to the examples described herein or during the examination of the application, and these examples should be interpreted as non-exclusive. Furthermore, the steps of the disclosed method may be modified in any way, including changing the order of steps and / or inserting or deleting steps.

[0041] Other embodiments will become apparent from considerations herein and from the practice of the embodiments disclosed herein. This specification and examples are to be considered merely illustrative, and the true scope and spirit of the disclosed embodiments are intended to be shown by the following claims.

Claims

1. An assembly configured to store materials, wherein the assembly is: It is a rigid carrier: Placing the polymer inside the mold; Expanding the polymer against at least a portion of the inner surface of the mold, at least a portion of the tank plate, and at least a portion of the auxiliary components, wherein the tank plate and the auxiliary components are pre-disposed within the mold; and To form at least one opening in the polymer, wherein the at least one opening is aligned with the at least one auxiliary component. Rigid carriers manufactured by An assembly comprising:

2. The assembly according to claim 1, further comprising a mixing element disposed inside the rigid carrier.

3. The assembly according to claim 2, wherein the mixing element is rotatably supported by the tank plate.

4. The assembly according to claim 2, further comprising a spring suspension drive unit disposed on the outside of the rigid carrier, wherein the spring suspension drive unit is configured to interact with the mixed element and transmit rotational motion to it.

5. The assembly according to any one of claims 1 to 4, wherein the tank plate is pre-formed and includes at least one lateral projection.

6. The assembly according to claim 5, wherein the at least one lateral projection is configured to blend into the wall.

7. The assembly according to claim 5, wherein the at least one lateral projection is configured to interact with the polymer.

8. The assembly according to any one of claims 1 to 4, wherein the auxiliary component is pre-formed.

9. The assembly according to any one of claims 1 to 4, wherein the auxiliary component is a port.

10. The assembly according to any one of claims 1 to 4, further comprising extruding the polymer into the mold.

11. The assembly according to any one of claims 1 to 4, wherein the rigid carrier is further manufactured by supplying compressed gas into the mold to expand the polymer.

12. The assembly according to any one of claims 1 to 4, wherein the rigid carrier is further manufactured by inserting a stylus through the mold and the auxiliary component, and forming an opening with the stylus.

13. The assembly according to claim 12, wherein the stylus is a hollow needle, and the rigid carrier is further manufactured by blowing compressed gas through the hollow needle.

14. A method for manufacturing a rigid carrier, the method being: The step of placing the polymer inside the mold; A step of expanding the polymer on at least a portion of the inner surface of the mold, at least a portion of the tank plate pre-disposed within the mold, and at least a portion of the auxiliary components pre-disposed within the mold; and A step of forming at least one opening in the polymer, wherein the at least one opening is aligned with the auxiliary component. A method that includes [a certain feature].

15. The method according to claim 14, further comprising the step of supplying compressed gas into the mold to expand the polymer.

16. The method according to claim 14 or 15, wherein the tank plate includes at least one lateral projection.

17. The method according to claim 14 or 15, wherein the at least one auxiliary component includes a barb.

18. It is a rigid container: A wall that defines the internal region; The tank plate is integrated with the wall portion, and the wall portion does not have a welded joint between the tank plate and the wall portion; and The port is integrated into the wall portion, and the wall portion does not have a welded joint between the port and the wall portion. A rigid container equipped with [a specific feature / feature].

19. The rigid container according to claim 18, further comprising a mixing element disposed on the internal region.

20. The rigid container according to claim 19, wherein the mixing element is rotatably supported on the tank plate.

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