Dispensing Tip Filling via Vacuum Suction
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Solution Overview
Problem
Current methods for filling dispensing tips with powdered or liquid materials are unreliable, often requiring multiple attempts, leading to material loss and variability in fill reproducibility, especially for small volumes, and involve manual processes that are time-consuming and inaccurate.
Innovation Solution
A device and method utilizing a vacuum manifold with a set screw and limit element to create negative pressure, allowing precise filling of dispensing tips by pulling material through a narrow clearance, ensuring accurate and reliable filling of small volumes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If powder is blown into the dispensing end of the cartridge using a gas stream, then the tip can be filled with powdered agent, but the method is unreliable and requires multiple attempts resulting in material loss and compacted powder
Solution Approach 1:
Instead of blowing powder into the tip using gas pressure from the dispensing end, the invention reverses the approach by applying vacuum at the proximal end to suction the powder into the tip. This inversion of the filling direction eliminates the need for manual plunger adjustment and prevents compacted powder, achieving reliable filling in a single attempt.
Solution Approach 2:
The invention replaces the manual mechanical process of plunger adjustment and gas stream blowing with an automated vacuum suction system. The vacuum manifold and vacuum pump create controlled negative pressure to draw powder into the tip through the exit opening, eliminating manual intervention and improving reliability.
2Measurement precision
If manual plunger setting is performed from the dispensing end, then the plunger can be positioned, but the process is time-consuming and reduces productivity
Solution Approach 1:
The invention performs plunger positioning automatically as part of the vacuum filling process rather than as a separate manual step. The vacuum suction simultaneously fills the tip with powder and positions the plunger at the correct depth, eliminating the need for separate manual plunger adjustment and significantly improving productivity.
Solution Approach 2:
The vacuum system automatically positions the plunger during the filling process without requiring external manual intervention. The plunger is drawn into the tip along with the powder under vacuum pressure, and the process self-regulates to achieve proper positioning, making the system self-sufficient and faster.
3Quantity of substance
If large volumes of powdered material are used to fill the syringe body, then the powdered material can be inserted, but insertion of the plunger displaces air and disrupts the powdered material
Solution Approach 1:
The invention divides the filling process into two distinct stages: first filling only the tip with small volumes of powder under vacuum, then separately positioning the plunger. This segmentation prevents the plunger from displacing air and disrupting large volumes of powder, maintaining powder integrity while achieving accurate filling.
Solution Approach 2:
The invention applies different filling conditions to different regions: the tip is filled with small volumes of powder under vacuum suction, while the plunger positioning is controlled separately. This local differentiation ensures that powder in the tip is not disrupted by plunger insertion, preserving powder stability and composition.
4Adaptability or versatility
If additive manufacturing is used to create the tip, then complex geometries can be achieved, but the outer surface roughness may affect material passage through the clearance
Solution Approach 1:
The invention changes the critical parameter from outer surface roughness to inner surface smoothness. By focusing quality control on the inner surface that contacts the powder and defining the clearance, the invention allows additive manufacturing flexibility in outer geometry while ensuring proper material passage through controlled inner surface specifications.
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 solution achieves reliable and precise filling of dispensing tips with powdered or liquid materials, improving reproducibility and reducing material loss, especially for small volumes, by using suction to fill the tips through a controlled clearance.
Implementation Method 1
a vacuum source for creating a negative pressure in the vacuum manifold
Implementation Method 2
the negative pressure created in the vacuum manifold by the vacuum pump is sufficient to pull the material through the exit opening and into the axial bore of the at least one container
Data Source
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AI summary
A device for filling a container, such as a dispensing tip, with a powdered or liquid material, and methods of use of the device are disclosed. The device generally includes a vacuum manifold having at least one port, and a vacuum source for creating a negative pressure in the vacuum manifold. The device may further include at least one container having an axial bore therethrough, a proximal end, and a distal end which includes a stop positioned therein. The negative pressure created in the vacuum manifold by the vacuum pump is sufficient to pull the powdered or liquid material through the distal end into the axial bore of the at least one container. A clearance between an outer surface of the stop and an inner wall of the container is configured to prevent passage of the powdered or liquid material.