Filling machine

Abstract

The present invention addresses the problem of providing a filling machine having a simple structure and capable of preventing material filled into a syringe from largely remaining in flow paths or the like, thus ending up being wasted. As a means to solve the problem, this filling device (1) is for filling a syringe (50) interior with a material in paste form, and comprises: a stage (12); a support section (14) which is provided extending downward from the stage (12) and inside of which the syringe (50) is detachably accommodated; a pressing section (30) for pressing down on from above and fixing the syringe (50) accommodated in the support section (14); and a material supply section (40) in which a reservoir container (42) for holding material in reserve is arranged. The support section (14) is provided with a through-hole (18) bored therethrough and has at the lower end thereof a valve element (16) for advancing into and out of the reservoir container (42).

Description

filling equipment

[0001] The present invention relates to a filling device, and more particularly to a filling device for filling a syringe with a paste-like material.

[0002] A filling device for filling a syringe with a paste-like material is known. Examples of such materials include paste-like materials, i.e., fluids with higher viscosity than liquids, used in fields such as pharmaceuticals, chemical materials, food products, paints, and semiconductor device materials.

[0003] However, if air bubbles are mixed in the material, this can cause variations in the amount of material dispensed from the syringe, or cause product defects. Therefore, research has been conducted into filling devices and methods that prevent air bubbles from being mixed in when filling syringes. As an example, a filling device equipped with a rotary table has been developed (see Patent Document 1: International Publication WO 2022 / 153816).

[0004] International Publication No. WO2022 / 153816

[0005] The filling device disclosed in the above-mentioned Patent Document 1 has a configuration in which a rotary table is provided on a stage, and thereby a series of processes such as degassing the inside of a syringe and filling the material can be performed continuously, thereby improving production efficiency. However, since the structure is complicated, there has been a demand for a device with a simple structure.

[0006] As the inventors of the present application continued their research to solve the above-mentioned problems, a new problem arose: the material remains in the flow path (piping, etc.), resulting in waste, mainly due to the syringe structure in which the opening (filling port) is located far from the material storage section. It became clear that this problem was particularly pronounced when the syringe capacity was small, as a relatively large amount of material remained.

[0007] The present invention has been made in consideration of the above circumstances, and aims to provide a filling device with a simple structure that can prevent a large amount of material being filled into a syringe from remaining in a flow path, etc., and being wasted.

[0008] The present invention solves the above problems by the means described below.

[0009] This filling device is a filling device that fills a syringe with a paste-like material, and is equipped with a stage, a support section that extends downward from the stage and has the syringe detachably housed inside, a pressing section that presses from above to fix the syringe housed in the support section, and a material supply section in which a storage container for storing the material is disposed, and is required to have a through hole drilled in the support section and a valve body at its lower end that advances into and advances out of the storage container.

[0010] According to the present invention, it is possible to realize a filling device with a simple structure that can prevent a large amount of material being filled into a syringe from remaining in a flow path, etc., and is particularly suitable for use with syringes with small capacities.

[0011] FIG. 1 is a perspective view showing an example of a filling device according to a first embodiment of the present invention. FIG. 2 is a front cross-sectional view of the filling device shown in FIG. 1. FIG. 3 is an enlarged view (front cross-sectional view) showing an example of a state in which a first adapter is attached alone in the filling device shown in FIG. 1. FIG. 4 is an enlarged view (front cross-sectional view) showing an example of a state in which a first adapter and a second adapter are attached in a stacked manner in the filling device shown in FIG. 1. FIGS. 5A and 5B are explanatory diagrams illustrating the operation of the operating mechanism of the filling device shown in FIG. 1. FIG. 6 is a front cross-sectional view showing an example of a syringe to be filled with a material using the filling device shown in FIG. 1. FIG. 7 is an enlarged view (front cross-sectional view) showing an example of a filling device according to a second embodiment of the present invention. FIG. 8 is a perspective view showing an example of a locking jig in the filling device shown in FIG. 7.

[0012] (First embodiment) A filling device 1 according to the present invention is a device that fills a syringe 50 with a paste-like filling material (hereinafter, sometimes simply referred to as "material") stored in a storage container 42. Hereinafter, a first embodiment of the present invention will be described in detail with reference to the drawings. FIG. 1 is a perspective view (schematic diagram) showing an example of the configuration of the filling device 1 according to this embodiment, and FIG. 2 is a front cross-sectional view (schematic diagram) thereof. In all drawings used to explain each embodiment, components having the same function are designated by the same reference numerals, and repeated description thereof may be omitted. Furthermore, unless otherwise specified, general structural materials (metallic materials, resinous materials) are used as structural materials for the device.

[0013] First, the configuration of syringe 50 to be filled with a material using filling device 1 according to this embodiment will be described in detail. As shown in Fig. 6, syringe 50 has small-diameter section 51 having relatively small outer and inner diameters at one end and large-diameter section 52 having relatively large outer and inner diameters at the other end. An opening (first opening) 51a is formed in small-diameter section 51, and an opening (second opening) 52a is formed in large-diameter section 52.

[0014] In this embodiment, the syringe 50 is configured so that the material is filled into the small-diameter portion 51 through the first opening 51a (although it may be filled through the second opening 52a). A plunger 60 is slidably inserted into the small-diameter portion 51 through the second opening 52a. The plunger 60 is a member that is pushed to discharge the filled material from the first opening 51a while sealing the second opening 52a. The materials for the syringe 50 and the plunger 60 are not particularly limited, and they may be formed using a resin material appropriately selected depending on the properties of the filling material, etc. In some cases, the syringe 50 does not include a plunger.

[0015] A threaded portion 51b is provided around the first opening 51a of the small diameter portion 51, and a cap (not shown) for sealing the first opening 51a can be fitted onto the threaded portion 51b. As an example of the threaded portion 51b, the first opening 51a may be formed into a single cylinder (single cylinder) and the threaded portion 51b may be provided on the inner or outer periphery thereof, or the first opening 51a may be formed into a double cylinder and the threaded portion 51b may be provided on the inner periphery of the outer cylinder. In this embodiment, the latter configuration is shown as an example.

[0016] Next, the configuration of the filling device 1 according to this embodiment will be described in detail. As shown in FIGS. 1 and 2 , the filling device 1 includes a substantially plate-shaped stage 12 having an entrance 13 with an opening through which the syringe 50 enters (in this embodiment, from the small diameter portion 51 side). The filling device 1 also includes a support portion 14 extending downward from the stage 12 (i.e., attached to the stage 12 so as to extend downward from the stage 12) and removably housing the syringe 50 therein. Here, "housed inside" does not necessarily mean that the entire longitudinal length of the syringe 50 is housed therein, but also includes the case where a portion of the syringe 50 (in this embodiment, the side of the large diameter portion 52, which is the upper end) is disposed outside the support portion 14. In this embodiment, not only the syringe 50 but also the support portion 14 are configured to enter the entrance 13.

[0017] The filling device 1 also includes a holding unit 17 that holds the syringe 50 so as not to move in the radial direction (i.e., restricts the radial movement of the syringe 50). The holding unit 17 is fixed to the upper part of the stage 12 (or the lower part, or both).

[0018] The filling device 1 also includes a pressing unit 30 that presses from above to fix the syringe 50 housed in the support unit 14. The filling device 1 also includes a material supply unit 40 in which a storage container 42 is disposed at a position below the stage 12.

[0019] First, the support unit 14 has a valve element 16 attached to its lower end. The valve element 16 moves up and down inside a storage container 42, which is moved up and down by a material supply unit 40 (moving mechanism 44) described below. As an example, the support unit 14 is cylindrical (including cases where the inner and outer peripheries have different diameters), with a cutout in the circumferential surface to provide an interior viewing window 15. The storage container 42 is cylindrical with a bottom. The valve element 16 is disk-shaped, and a seal member (e.g., an O-ring) 19 with an outer diameter that can slide against the inner wall of the storage container 42 is fitted to the outer periphery. Furthermore, the valve element 16 has a through-hole 18 drilled at a predetermined position (in this embodiment, a radially central position). This allows the material supply unit 40 (moving mechanism 44) described below to be driven to raise the storage container 42, and the valve element 16 to enter the storage container 42 and press the material, thereby discharging the material through the through-hole 18.

[0020] Support part 14 is provided with fitting part 23 into which small diameter part 51 of syringe 50 is fitted, and which connects the opening of small diameter part 51 (first opening 51a in this embodiment) with through-hole 18. This allows through-hole 18 of valve body 16, which enters storage container 42, and first opening 51a of syringe 50, which serves as the material filling port, to be disposed close to each other, thereby reducing the amount of material remaining between them.

[0021] More specifically, the valve body 16 has a fitting portion 23 (23A). Without an adapter (described below), a syringe 50 with a relatively long length (axial dimension) can be accommodated in the support portion 14 and filled with a material. The adapter also has fitting portions 23 (23B, 23C). With the adapter attached, a syringe 50 with a relatively short length (axial dimension) can be accommodated in the support portion 14 and filled with a material. As an example, the valve body 16 and the adapter are formed using a metal material or a resin material. Furthermore, the fitting portion 23 has a seal portion 26 (26A, 26B, 26C) made of rubber or elastomer to enhance sealing performance, which can be tightly pressed against the syringe 50 (a predetermined position on the small-diameter portion 51) (however, the seal portion 26 may be omitted). As a modified example, a seal may be achieved by threading the threaded portion 51b of the small-diameter portion 51 (not shown).

[0022] A specific example of the adapter includes a first adapter 21 and a second adapter 22, which may be identical or different in shape, and can be attached either alone or both stacked together. Fig. 3 shows the first adapter 21 attached alone (note that Fig. 2 also illustrates this state). Fig. 4 shows the first adapter 21 and the second adapter 22 attached in a stacked configuration. The first adapter 21 has a through-hole 24 at its radial center, penetrating vertically so as to communicate with the through-hole 18 of the valve body 16. Similarly, the second adapter 22 has a through-hole 25.

[0023] According to the above configuration, by appropriately changing the attachment state of the adapter (i.e., single state or stacked state), syringes 50 of different lengths can be accommodated in the support part 14 and can be pressed and fixed by the pressing part 30. In particular, even syringes 50 with small volumes (e.g., 5 ml, 10 ml, etc.) and short lengths can be accommodated and fixed.

[0024] Furthermore, since the syringe 50 can be fitted into the fitting portion 23 while being checked through the internal viewing window 15 of the support portion 14, a secure fit can be achieved, and accidents such as leakage of material can be prevented.

[0025] Next, the pressing unit 30 has a syringe abutment portion 32 that abuts against the large diameter portion 52 of the syringe 50 and presses it in the axial direction. The syringe abutment portion 32 is configured to be movable toward and away from the large diameter portion 52 (up and down movement (including forward and backward movement)) by an operating mechanism 31 attached to the stage 12 (or another member). This allows the syringe 50 to be clamped and held (removably fixed) in the axial direction by the fitting portion 23 of the support unit 14 (valve body 16 or adapters 21, 22) and the syringe abutment portion 32. Note that if the large diameter portion 52 of the syringe 50 has a flange 52b, the syringe abutment portion 32 abuts against the flange 52b, and if the large diameter portion 52 does not have a flange, the syringe abutment portion 32 abuts against the end of the large diameter portion 52.

[0026] The operating mechanism 31 according to this embodiment is configured such that, when the lever 36 is tilted from the vertical to the horizontal direction, the syringe abutment portion 32 moves away from the large diameter portion 52 (moves upward) (see FIG. 5A), and, when the lever 36 is raised from the horizontal to the vertical direction, the syringe abutment portion 32 moves toward the large diameter portion 52 (moves downward) (see FIG. 5B). Note that the operating mechanism 31 is not limited to a configuration including the lever 36, and may be configured to include a cylinder or the like (not shown).

[0027] Next, the filling device 1 includes a distance measurement unit 45 in which a distance measurement sensor 46 is disposed, which measures the distance to the target (i.e., the target position). As an example, the distance measurement sensor 46 is a laser-type distance measurement sensor, but is not limited thereto. Here, the target according to this embodiment includes a measurement pin 38 that is inserted into the second opening 52a of the large-diameter portion 52 of the syringe 50 and rises as the material is filled. Specifically, the measurement pin 38 is inserted into an insertion hole 34 formed in the syringe contact portion 32 and is held so as to be movable up and down. At this time, the tip (lower end) of the measurement pin 38 is held in a state in which it abuts against the upper surface of the material being filled into the syringe 50 (since this embodiment is an example in which a plunger 60 is provided, the tip is not in direct contact, but in a state in which it abuts against the upper surface of the plunger 60, which rises in conjunction with the upper surface of the material).

[0028] The syringe 50 to be filled has a problem that, particularly when the capacity is small (e.g., 5 ml, 10 ml, etc.), the inner diameter of the syringe 50 (large diameter portion 52) is small (e.g., 10 mm, 15 mm, etc.), making it impossible for the distance measuring sensor to detect the upper surface (liquid level) of the material, i.e., the amount filled. In contrast, the configuration including the above-mentioned target solves this problem, i.e., makes it possible to detect the amount filled in the syringe 50.

[0029] Next, the material supply unit 40 according to this embodiment will be described. As shown in Figures 1 and 2, the material supply unit 40 includes a storage container 42 for storing the material to be filled into the syringe 50, and a movement mechanism 44 for moving the storage container 42 up and down.

[0030] As an example, the moving mechanism 44 uses a known linear motion mechanism equipped with a stepping motor, but is not limited to this.

[0031] Furthermore, storage container 42 according to this embodiment is detachably attached to material supply unit 40, positioned directly below valve body 16 (although it may also be a fixed, non-detachable type). For example, if storage container 42 with a relatively large shape (diameter, height) is used, the replacement work can be reduced, and if storage container 42 with a relatively small shape (diameter, height), the material can be used up before it changes or deteriorates. In this way, the optimal storage container 42 can be selected depending on the number of syringes 50 to be filled, the properties of the material, and the like.

[0032] As an option suitable for the above configuration, the support unit 14 according to this embodiment is configured such that multiple types with different heights are prepared, and one type corresponding to the height of the storage container 42 attached to the material supply unit 40 is selected from the multiple types and detachably attached to the stage 12. By selecting a support unit 14 with an appropriate height depending on the shape (particularly the height) of the storage container 42, the valve body 16 can be properly advanced to a predetermined position (the bottom or its vicinity) within the storage container 42 without the upper end of the storage container 42 abutting the underside of the stage 12. This further prevents material from remaining in the storage container 42. However, the support unit 14 does not have to be configured such that multiple types are prepared and selectable.

[0033] Next, an outline of the process of filling the syringe 50 with the paste-like material contained in the storage container 42 using the filling device 1 having the above-described configuration will be described.

[0034] First, an empty syringe 50 (one syringe) is inserted into the entry portion 13 of the stage 12 (in this embodiment, the support portion 14 inserted into the entry portion 13) from the small diameter portion 51 side, and housed inside the support portion 14, and the small diameter portion 51 is fitted into the fitting portion 23 of the first adapter 21. Note that even when the empty syringe 50 is held by the valve body 16 without using the first adapter 21, or when the first adapter 21 and the second adapter 22 are stacked and held, it is sufficient to fit the empty syringe 50 into the fitting portion 23 provided on the valve body 16 or the second adapter 22 in the same manner as described above.

[0035] Next, the lever 36 of the operating mechanism 31 of the pressing unit 30 is operated (tilted in this embodiment) to bring the underside of the syringe abutting portion 32 into contact with the large diameter portion 52 (in this embodiment, flange 52b) of the syringe 50 and press it downward. This action causes the syringe 50 to be clamped and held (fixed) in the axial direction between the syringe abutting portion 32 and the fitting portion 23 of the first adapter 21. At this time, the small diameter portion 51 (at a predetermined position) and the fitting portion 23 (seal portion 26) are in close contact (pressed together) to ensure sealing, and the first opening 51a and the through-hole 18 are in communication with each other (in this embodiment, they are in communication with each other via the through-hole 24 of the first adapter 21).

[0036] Next, the movement mechanism 44 is driven to raise the storage container 42. This action causes the valve body 16 to enter the storage container 42 (relatively enter due to the movement of the storage container 42), and the lower surface of the valve body 16 presses against (the upper surface of) the material in the storage container 42. Therefore, the material is pressurized, and an action occurs to send out the material through the through-hole 18 of the valve body 16, and the material begins to be filled into the interior from the first opening 51 a of the syringe 50 through the through-hole 18 (and also through-hole 24 in this embodiment).

[0037] At this time, as the filling of the material into the syringe 50 progresses, the upper surface (liquid surface) of the material inside rises. In this embodiment, in response to this, the plunger 60, which is in contact with the upper surface, rises.

[0038] The position of the top surface of plunger 60 (the distance to the top surface) is measured by distance measuring sensor 46 of distance measuring unit 45 using measuring pin 38 described above, thereby detecting the position of the top surface of the material being filled into syringe 50 (i.e., the filling amount). When the filling amount reaches a set value, driving of movement mechanism 44 is stopped, i.e., the lifting of storage container 42 is stopped. This completes the filling operation into syringe 50.

[0039] Second Embodiment Next, a filling device 1 according to a second embodiment of the present invention will be described. The filling device 1 according to this embodiment has the same basic configuration as the first embodiment described above, but differs in particular in the configuration for holding the syringe 50. This embodiment will be described below, focusing on these differences. Here, Fig. 7 is a front cross-sectional view (enlarged view of the periphery of the support portion 14) showing an example of the configuration of the filling device 1 according to this embodiment.

[0040] The filling device 1 according to this embodiment includes a locking jig 20 that is detachably attached (so that their circumferential surfaces are in close contact) to the inside of the holding portion 17 (see a perspective view in FIG. 8 ). The locking jig 20 according to this embodiment is formed in a generally cylindrical shape with a locking portion 20a at one end (the lower end) that can lock onto the large-diameter portion 52 of the syringe 50 and a flange portion 20b at the other end (the upper end). As an example, the locking portion 20a is configured as a fitting groove into which the flange 52b of the large-diameter portion 52 of the syringe 50 is inserted and rotated circumferentially to secure the locking portion 20a (although this configuration is not limited). This allows the syringe 50 locked by the locking jig 20 to be accommodated inside the support portion 14. Furthermore, the flange portion 20b, which is the other end (the upper end) of the locking jig 20, can be pressed by the syringe abutment portion 32 of the pressing portion 30. Therefore, the syringe 50 can be clamped and fixed between the fitting portion 23 and the syringe abutment portion 32 while regulating lateral movement of the syringe 50 .

[0041] In particular, in the case of a syringe 50 having a relatively short overall length, whereas in the first embodiment ( FIG. 4 ) described above, the first adapter 21 and the second adapter 22 had to be stacked to hold the small diameter portion 51 side, the syringe 50 (small diameter portion 51 side) can be held by the first adapter 21 alone (single unit) or the valve body 16 alone (without an adapter). In other words, the length of the flow path occupied by the adapter can be made shorter, and the amount of material remaining in the flow path can be further reduced.

[0042] Other configurations of the filling device 1 according to this embodiment and the filling process using the filling device 1 are basically the same as those of the first embodiment described above, so repeated explanations will be omitted.

[0043] As described above, the filling device according to the present invention can realize a filling device with a simple structure that can prevent a large amount of material being filled into a syringe from remaining in a flow path, etc. In particular, even when a syringe with a small capacity is used, the amount remaining in the reservoir container or flow path can be reduced, and the filling amount can be reliably detected to accurately fill the syringe.

[0044] The present invention is not limited to the above-described embodiment, and various modifications are possible without departing from the scope of the present invention.

Claims

1. A filling device for filling a syringe with a paste-like material, comprising: a stage; a support section extending downward from the stage and detachably housing the syringe inside; a pressing section that presses from above on the syringe housed in the support section to fix it in place; and a material supply section in which a storage container for storing the material is disposed, wherein the support section has a through-hole formed therein and a valve body at its lower end that advances into and advances out of the storage container.

2. The filling device according to claim 1, wherein the support part has a fitting part into which the small diameter part of the syringe is fitted, connecting the opening of the small diameter part with the through-hole, and the fitting part is provided on at least one of the valve body or an adapter that is detachably attached onto the valve body.

3. The filling device according to claim 1, characterized in that the large diameter part of the syringe has a locking part that can be locked, and a locking jig that is pressed by the pressing part is detachably attached.

4. A filling device as claimed in any one of claims 1 to 3, further comprising a distance measuring unit for measuring the distance to a target, wherein the distance measuring unit has a measuring pin which is inserted into the opening of the large diameter part of the syringe as the target and is held with its tip in contact with the top surface of the material being filled into the syringe either directly or via a plunger, and which rises as the material is filled.

5. The filling device according to claim 4, characterized in that the pressing part has a syringe contact part that has an insertion hole through which the measuring pin can be inserted and that contacts and presses the large diameter part of the syringe directly or via another member.

6. A filling device according to any one of claims 1 to 3, characterized in that the storage container is detachably attached to the material supply unit, and a plurality of types of support units with different height dimensions are prepared, and one corresponding to the height dimension of the storage container attached to the material supply unit is selected and detachably attached to the stage.

7. The filling device according to claim 2, characterized in that the adapters comprise a first adapter and a second adapter, each of which may be identical or different in shape, and either one of which may be attached alone or both of which may be attached in a stacked state.

8. The filling device according to any one of claims 1 to 3, characterized in that the support part is formed in a cylindrical shape with an internal viewing window formed by cutting out the circumferential surface.

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