ALD pH Protective Coating for Pharmaceutical Barrier Containers
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Solution Overview
Problem
Existing pharmaceutical containers with barrier layers degrade over time when in contact with certain pharmaceutical agents, reducing their shelf life and requiring special handling during transport and storage.
Innovation Solution
A pharmaceutical container with a thin pH protective layer applied using atomic layer deposition (ALD) to protect the underlying gas barrier layer, providing enhanced long-term storage and resistance to pH exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional barrier layer is used to protect pharmaceutical agents, then protection from contamination is provided, but the barrier layer degrades over time when in contact with pharmaceutical agents
Solution Approach 1:
The patent applies a composite coating system consisting of a barrier layer (e.g., aluminum oxide) and a pH protective layer (e.g., zirconium oxide or magnesium oxide) deposited by atomic layer deposition. This composite structure protects the barrier layer from pH degradation while maintaining its protective function, thereby extending the shelf life of the pharmaceutical container without compromising protection effectiveness.
Solution Approach 2:
The pH protective layer acts as an intermediary between the barrier layer and the pharmaceutical agent. It shields the barrier layer from direct contact with pH extremes of the pharmaceutical contents, preventing degradation while allowing the barrier layer to maintain its protective function against contamination.
2Reliability
If a thick pH protective layer is applied to protect the barrier layer, then protection from pH exposure is improved, but the coating thickness increases and production time increases
Solution Approach 1:
The patent utilizes atomic layer deposition to precisely control the thickness of the pH protective layer at the nanometer scale (typically 5-50 nm). This precise parameter control allows achieving adequate pH protection with minimal thickness, thereby reducing production time while maintaining protection effectiveness.
Solution Approach 2:
The patent replaces conventional thick coating applications with a thin-film deposition process (atomic layer deposition). This substitution enables achieving the same protective function with much thinner layers, reducing production time and material usage while maintaining or improving protection quality.
3Productivity
If a thin pH protective layer is applied to reduce production time, then production efficiency is improved, but the protection capability may be insufficient
Solution Approach 1:
The patent achieves sufficient pH protection with thin layers (5-50 nm) by precisely controlling deposition parameters in atomic layer deposition. The high-quality thin films formed by this process provide adequate protection capability while maintaining production efficiency.
Solution Approach 2:
The patent employs thin-film technology to create flexible, ultra-thin pH protective layers that provide sufficient protection despite their minimal thickness. These thin films maintain integrity and protective function while enabling rapid production.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The ALD-applied pH protective layer reduces the rate of gas barrier layer dissolution by >90% when exposed to pH 3 to 9 at 50°C for 72 hours, maintaining the integrity and effectiveness of the container.
Implementation Method 1
the pH protective layer is applied using atomic layer deposition (ALD) technique
Data Source
AI summary
Disclosed is a pharmaceutical container comprising a lumen defined in part by a wall, the wall having an interior surface facing the lumen, an outer surface, and a coating set on the interior surface comprising a pH protective layer, wherein the pH protective layer is applied using atomic layer deposition.