Electromagnetic Sealing of Pharmaceutical Vials

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Solution Overview

Problem

Existing capping technologies for metal caps on vials, such as mechanical crimping, fail to prevent particle contamination, cause cosmetic damage, and result in inferior seals, leading to potential harm and rejection of pharmaceutical products.

Innovation Solution

High velocity electromagnetic metal forming is used to seal metal caps onto non-metallic containers like vials without physical contact, employing electromagnetic forces to create a secure seal while maintaining aseptic conditions and preventing contamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanical crimping is used to seal metal caps, then sealing function is achieved, but particle contamination occurs

Engineering Contradiction:

Improvesealing functionVSAvoidparticle contamination

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the mechanical crimping system with an electromagnetic forming system. Electromagnetic forces are used to deform and seal the metal cap onto the container without physical contact between forming tools and the cap, thereby eliminating particle generation from mechanical blade contact while achieving the same sealing function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If mechanical blades are used for crimping, then sealing is achieved, but cosmetic damage occurs

Engineering Contradiction:

ImprovesealingVSAvoidcosmetic damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The electromagnetic forming process substitutes mechanical blade contact with contactless electromagnetic force application. This eliminates scratching, marring, and slicing of the container surface that occurs with mechanical blades, while still achieving secure sealing of the cap.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If rotation during sealing is used, then sealing process is completed, but container breakage occurs

Engineering Contradiction:

Improvesealing process completionVSAvoidcontainer breakage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent eliminates the need for rotation during sealing by using electromagnetic forces that can be applied axially without requiring the container or head to rotate. This contactless forming process avoids scratching and breakage that occurs when mechanical components rotate against glass containers with poor tolerances.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If extensive manual adjustments are used, then sealing precision is achieved, but container damage occurs

Engineering Contradiction:

Improvesealing precisionVSAvoidcontainer scratching

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The electromagnetic forming system replaces manual adjustment mechanisms with electronically controlled electromagnetic field generation. The positioning and force application are controlled through electromagnetic parameters rather than mechanical adjustments, eliminating contact that would cause scratching while maintaining precise sealing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This method provides a contamination-free, high-speed sealing process that ensures a secure cap seal without damaging the containers, reducing rejection rates and ensuring product integrity.

Implementation Method 1

applying electromagnetic forces from the actuator to the metal portion of each cap

Methodology Applied

Scientific EffectElectromagnetic forces: Electromagnetic Induction

Data Source

PatentUS8316677B2Method and apparatus for high velocity electromagnetic sealing of containers

Publication Date: 2012.11.27 ANTHENAT ALAN S

AI summary

Methods and apparatus for high velocity electromagnetic metal forming are described for sealing containers. The methods include applying an electromagnetic field to the container to seal a metal containing cap to the container. One or more containers may be simultaneously sealed. The apparatus includes an actuator that emits the electromagnetic field to seal the caps to the containers. The containers may contain a medicine.