Container Assembly Fluidic Network for Rapid Sterile Filling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing drug filling systems for vials, such as crimp-top vials, are inefficient in filling large quantities of containers due to the sequential nature of the process, leading to prolonged filling times and potential bottlenecks.
Innovation Solution
A container assembly system that integrates an array of containers with a framework and fluidic network, allowing for parallel or series filling through a network of fluidic channels, coupled with a liquid source and sealing mechanism to rapidly fill and isolate drugs within containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sequential filling process is used for individual vials, then each vial can be filled with proper sealing, but the filling speed and productivity are very slow
Solution Approach 1:
The system segments the filling process into multiple parallel fluidic channels, each serving one or more vials. The array is divided into groups where each group has dedicated fluidic pathways, allowing simultaneous filling of multiple vials while maintaining individual control over each filling operation.
Solution Approach 2:
Multiple vials are merged into a single integrated array structure that shares common framework and fluidic network components. The system combines individual filling operations into a unified parallel processing system, where multiple vials are filled simultaneously through the integrated fluidic network, dramatically increasing throughput.
2Productivity
If parallel filling of multiple containers is implemented, then filling throughput increases significantly, but the fluidic network complexity and manufacturing difficulty increase
Solution Approach 1:
The fluidic network employs universal components and standardized connection interfaces that can serve multiple functions. The same fluidic channel design and connection mechanisms are reused across different parts of the array, simplifying manufacturing while enabling parallel filling of many vials.
Solution Approach 2:
The system transitions from sequential one-dimensional filling to parallel multi-dimensional filling by arranging vials in a two-dimensional array with fluidic channels extending in multiple directions. This spatial arrangement allows simultaneous filling operations without proportionally increasing channel complexity.
3Productivity
If rapid filling is achieved through parallel processing, then productivity improves, but ensuring sterility and proper sealing becomes more challenging
Solution Approach 1:
The system performs preliminary sealing operations before the filling process begins. Vials are pre-sealed with stoppers and crimped with metallic sleeves while still mounted on the array, creating a sterile barrier before rapid parallel filling occurs. This preliminary preparation ensures sterility is maintained even during high-speed operations.
Solution Approach 2:
The framework acts as an intermediary structure that maintains sterile barriers between the fluidic network and the vial interiors during filling. The integrated framework provides controlled interfaces that prevent contamination while enabling rapid fluid transfer to multiple vials simultaneously.
Data Source
AI summary
Filling systems and related container assemblies and methods are disclosed. In an implementation, a container assembly includes a container array, covers, a framework, and a fluidic network. The container array includes containers having distal ends and the covers are coupled to the respective distal ends of the containers. The framework is integral with: 1) the containers, 2) the covers and couples the containers together, or 3) both. The fluidic network includes fluidic channels that are defined by the framework and enable the containers to be filled in series or in parallel.