Glass Container Precursor Particle Coating for Breakage Reduction
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Solution Overview
Problem
The pharmaceutical glass container production process faces challenges such as increased production line disruptions due to glass container breakage, contamination risks, and the need for complex multilayer coatings that are costly and inefficient, particularly in high-temperature and mechanical stress environments, which hinder processing speed and optical inspection capabilities.
Innovation Solution
A glass container precursor with a wall partially coated with particles via Van-der-Waals forces, allowing for reduced friction and enhanced scratch resistance, eliminating the need for multilayer coatings and simplifying the production process by applying a composition with particles that adhere to the glass surface without embedding them in a matrix, thus reducing contamination risks and maintaining performance through high-temperature treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex multilayer coatings are applied to the container surface, then scratch resistance and contamination protection are improved, but device complexity and production cost increase
Solution Approach 1:
The patent extracts the essential protective function from complex multilayer coatings and implements it through a single layer of particles applied to the glass container surface. This single-layer particle coating provides scratch resistance and contamination protection without requiring multiple layers, thereby reducing structural complexity while maintaining reliability.
Solution Approach 2:
The patent changes the protective mechanism from a continuous coating layer to discrete particles with specific size parameters (0.1-10 μm). This parameter change allows the particles to provide protection through their physical presence and friction characteristics rather than forming a continuous barrier, simplifying the overall structure while maintaining protective functions.
2Productivity
If high processing speeds are implemented on the filling line, then productivity increases, but the risk of glass container breakage and production disruptions increases
Solution Approach 1:
The patent applies a particle coating to the glass container surface before the containers enter the high-speed filling line. This pre-applied particle layer acts as a cushioning protective layer that absorbs mechanical stresses and impacts during high-speed handling, preventing glass breakage and maintaining container integrity throughout the processing sequence.
3Object-affected harmful factors
If coatings are applied to the container surface, then contamination protection is improved, but the risk of coating particles contaminating the container interior increases
Solution Approach 1:
The patent uses a single layer of particles that provides contamination protection without requiring the container to pass through multiple coating applications. The particles remain on the surface during processing and are removed in a single subsequent step, eliminating the risk of intermediate coating particles contaminating the container interior while maintaining protective functions.
4Strength
If multiple coating layers are applied to withstand high temperatures and mechanical stress, then durability is improved, but production time and cost increase
Solution Approach 1:
The patent extracts the essential thermal and mechanical resistance properties and concentrates them in a single particle layer rather than distributing them across multiple coating layers. The particles withstand high temperatures during depyrogenisation and mechanical stress during handling without requiring additional protective layers, thereby reducing production time and processing steps.
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 significantly reduces the risk of glass container breakage and contamination, increases production line efficiency, and allows for reliable optical inspection and post-treatment processes like depyrogenisation and freeze drying without compromising the container's integrity.
Implementation Method 1
the wall of glass is at least partially superimposed by a plurality of particles
Data Source
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AI summary
The invention refers to a container precursor (100), comprising a wall of glass (101) which at least partially encloses an interior volume (102) of the container precursor (100); wherein, on a side of the wall of glass (101) which faces away from the interior volume (102), the wall of glass (101) is at least partially superimposed by a plurality of particles (1201). Further, the invention refers to an arrangement (200), comprising a packaging and a multitude of the container precursors (100); to a process (400) for preparing a functionalised container precursor; to a functionalised container precursor, obtainable by that process (400); to a container (500); to a process (600) for preparing a functionalised container; to a functionalised container, obtainable by that process (600); to a closed container (700); to a process (800) for packaging a pharmaceutical composition (701); to a closed container obtainable by this process (800); and to uses of a container precursor (100) for making a packaging container, of a container (500) for packaging a pharmaceutical composition (701), and of a plurality of particles (1201).