Curved Filling Needle with Grid Elements for Low Viscosity Liquids
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Solution Overview
Problem
Existing filling needles fail to accurately and reproducibly fill medicinal liquids with low viscosity, low surface tension, and low density into small containers, often resulting in dripping, air bubble formation, and incomplete sealing due to issues with fluid column support and flow rate.
Innovation Solution
A filling needle with a curved design and grid-elements at the outlet, which reduces the influence of gravity on the liquid column and minimizes foam formation, ensuring laminar flow and precise filling without dripping or leakage, specifically designed for liquids with viscosities less than 6 mPa·s, surface tensions less than 35 mN/m, and densities less than 0.95 g/ml.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a blunt tip needle is used for filling low viscosity liquids, then the needle structure is simple and easy to manufacture, but dripping and foaming occur during filling
Solution Approach 1:
The needle tip is segmented into multiple outlet openings (e.g., 3-5 small holes) arranged in a specific pattern, transforming a single blunt tip into a multi-aperture structure. This segmentation allows controlled liquid distribution while preventing dripping and foaming by reducing the velocity and surface area of liquid discharge.
Solution Approach 2:
The needle exhibits local quality variation with a conical or tapered geometry where the tip region has different properties than the body. The tip is designed with specific angle (e.g., 30-60 degrees) and aperture characteristics optimized for low viscosity liquids, while the body maintains structural integrity and compatibility with filling machinery.
2Reliability
If a basket tip needle is used to support the fluid column, then dripping is reduced, but fluid sprays towards the container walls causing seal leakage
Solution Approach 1:
The basket tip structure is segmented into multiple radial outlets arranged in a circular or rectangular pattern. This segmentation distributes the fluid column support function across multiple points while directing flow inward toward the container center, preventing wall spray and seal leakage.
Solution Approach 2:
The needle geometry transitions from a simple linear tip to a three-dimensional basket structure with radial outlets. This dimensional change allows the fluid to be discharged in a controlled radial pattern that supports the liquid column while directing flow away from the container walls, eliminating the spray problem.
3Reliability
If a showerhead needle is used for high volume fills, then foaming and dripping are prevented, but the needle diameter is too large for small volume fills
Solution Approach 1:
The needle incorporates multiple small aperture outlets (e.g., 3-5 holes with 0.1-0.5mm diameter) in a compact arrangement, providing showerhead-like flow distribution in a small overall diameter (e.g., 0.5-1.0mm). This segmentation achieves foam and drip prevention without requiring a large needle body.
Solution Approach 2:
The needle parameters (aperture size, number of apertures, outlet arrangement) are optimized for small volume fills. The total outlet area is carefully controlled to match the required fill volume while maintaining the multi-aperture configuration that prevents foaming and dripping.
4Device complexity
If a straight needle is used for filling, then the needle structure is simple, but air bubbles form and filling accuracy is poor for low surface tension liquids
Solution Approach 1:
The needle incorporates curved or angled sections in its geometry, particularly at the tip region. The conical taper and angled outlets (e.g., 45-60 degrees from the axis) create smooth fluid transitions that prevent air bubble formation and improve filling accuracy for low surface tension liquids.
Solution Approach 2:
The needle exhibits local quality variation with a conical or tapered geometry where the tip region has different properties than the body. The tip is designed with specific angle (e.g., 30-60 degrees) and aperture characteristics optimized for low viscosity liquids, while the body maintains structural integrity and compatibility with filling machinery.
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
Enables quick and accurate filling of low viscosity, low surface tension, and low density liquids into small containers with minimal product loss, preventing air bubbles and ensuring seal integrity by maintaining a stable liquid column and reducing foam formation.
Implementation Method 1
The needle pipe is curved at an inclination angle beta of between 100 and 170 degrees, in order to reduce the influence of gravity on the liquid column in the filling needle
Implementation Method 2
ensuring laminar flow and precise filling without dripping or leakage
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention discloses a filling needle (1) for dispensing liquid compositions into a container, comprising a connector (6) for connecting a feeding line (22), a needle pipe (2) leading from the connector (6) to an outlet (10) of the filling needle (1), wherein the needle pipe (2) is curved at an inclination angle (β) and/or the outlet (10) comprises at least two grid-elements (3).