Laser Marking Frozen Vials at Cryogenic Temperatures
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Solution Overview
Problem
Current methods for labeling vials or ampoules containing frozen veterinary and pharmaceutical medications, such as vaccines, are unable to maintain the integrity and biological activity of the contents when applying labels or markings, as raising the temperature for labeling reduces the biological activity and direct marking methods subject the material to heat stress.
Innovation Solution
A method involving the use of blank laser-ablatable labels applied to vials or ampoules, which are then placed in a temperature-controlled enclosure filled with dry nitrogen gas, allowing for laser marking at cryogenic temperatures without exposing the biological material to heat, using a polymer binder and pigment coating that maintains the integrity and efficacy of the contents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the temperature of frozen vials is raised to apply labels or markings, then labeling can be performed, but the biological activity of the contents is reduced
Solution Approach 1:
The patent changes the temperature parameter from conventional labeling temperatures (room temperature or higher) to cryogenic temperatures (-70°C to -196°C). This parameter change allows labeling to be performed on frozen vials without thawing, thereby maintaining the biological activity of the contents while enabling labeling capability.
Solution Approach 2:
The patent replaces conventional thermal labeling methods (heating, adhesive application) with laser ablation technology. The laser directly ablates the frozen label material through photothermal conversion, eliminating the need for heating the vial contents. This substitution allows labeling at cryogenic temperatures without subjecting biological material to heat stress.
2Ease of manufacture
If direct laser marking is applied to frozen vials, then labeling is achieved, but the biological material is subjected to heat stress
Solution Approach 1:
The patent introduces an intermediary layer (label material with laser-active coating) between the laser and the vial contents. The laser energy is absorbed by the label material, which then transfers the marking effect without directly heating the biological contents. This intermediary protects the sensitive material from direct laser-induced heat stress.
Solution Approach 2:
The patent employs pulsed or intermittent laser application rather than continuous heating. By controlling the laser duty cycle and pulse duration, the system achieves sufficient ablation of the label material while allowing thermal dissipation that prevents heat accumulation and stress on the biological material.
3Ease of manufacture
If conventional labeling methods are used on frozen vials, then labeling can be applied, but the labeling quality and regulatory compliance are compromised
Solution Approach 1:
The patent replaces mechanical/adhesive labeling systems with laser ablation technology. The laser directly removes or modifies the label material to create permanent markings, eliminating issues associated with adhesive failure, label peeling, or poor print quality on cold surfaces. This ensures high labeling quality and durability.
Solution Approach 2:
The patent utilizes the optical properties of laser-active coatings at cryogenic temperatures to achieve precise control over label ablation. By adjusting laser parameters (wavelength, power, pulse duration) and exploiting the material's optical absorption characteristics at low temperatures, the system achieves high-precision markings that meet regulatory requirements.
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 the application of writings and graphics to frozen vials or ampoules while preserving the biological activity and potency of the contents, with the method ensuring that the labeled products meet regulatory specifications and maintain their immunological effectiveness.
Implementation Method 1
applying laser light to the laser-ablatable labels
Implementation Method 2
applying a sufficient amount of energy to an outer layer of the blank label to ablate away portions of the outer layer
Implementation Method 3
loading the plurality of vials into a temperature-controlled marking enclosure, which is substantially filled with dry nitrogen gas to reduce or eliminate the presence of moisture inside the enclosure
Data Source
Figure 1
Figure 2~3
Figure 4A~5C
AI summary
This invention relates to an apparatus and method for applying writings and other markings to a frozen vial or ampoule, which is filled with biological material, and which is held at temperatures between about -70 °C and about -196 °C. More particularly, the invention relates to a laser marking method that allows frozen vials to be labeled, while maintaining the integrity of the biological material contained therein.