Laser Sealing Elastomer for Vial Closures

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Solution Overview

Problem

Existing elastomer materials used in pharmaceutical vial closures and hypodermic syringe plungers generate smoke and allow significant laser power penetration when heated, potentially contaminating contents and damaging them.

Innovation Solution

A thermoplastic elastomer material with a laser light absorption coefficient of 0.5-2.5 mm−1, compounded with a colourant to absorb laser light, is used for sealing puncture holes in vial closures and syringe plungers, ensuring minimal smoke emission and reduced laser power transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If known elastomer materials are used for vial closures and syringe plungers, then the material can be sealed with laser heating, but the material generates smoke and allows significant laser power penetration

Engineering Contradiction:

Improvesealing effectivenessVSAvoidsmoke emission and laser power penetration

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the optical parameters of the elastomer by compounding it with laser-absorbing pigments, achieving an absorption coefficient of 0.5-2.5 mm⁻¹. This parameter modification enables effective laser sealing while minimizing smoke emission and laser power penetration to the contents.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite elastomer material combining base thermoplastic elastomer with laser-absorbing pigments and optional fillers. This composite structure provides both the sealing functionality and the controlled laser energy absorption needed to prevent harmful effects.

Inventive Principle:

Principle #40Composite materials

2Object-generated harmful factors

If the elastomer material absorbs more laser light, then smoke emission is reduced, but the sealing efficiency may be compromised

Engineering Contradiction:

Improvesmoke emissionVSAvoidsealing speed and efficiency

Core Design Contradiction:

Object-generated harmful factorsVSProductivity

Solution Approach 1:

The patent optimizes the absorption coefficient to a specific range of 0.5-2.5 mm⁻1, balancing laser energy absorption for smoke prevention with sufficient energy transmission for effective sealing. This optimized parameter range resolves the contradiction between reducing smoke and maintaining sealing efficiency.

Inventive Principle:

Principle #35Parameter changes

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 material effectively seals puncture holes without emitting significant smoke and minimizes laser power penetration, maintaining the integrity and purity of the contents within vials and syringes.

Implementation Method 1

an absorption coefficient for laser light of 0.5-2.5 mm−1

Methodology Applied

Scientific EffectOptical absorption: Absorption (EM radiation)

Implementation Method 2

sealing by melting the elastomer material adjacent the residual puncture hole

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS7851538B2Laser sealing elastomer

Publication Date: 2010.12.14 ASEPTIC TECH

AI summary

A novel elastomer material having an absorption coefficient for laser light of 0.5-2.5 mm−1, preferably being a base thermoplastic elastomer compounded with a colorant which comprises a Pantone 4597C pigment mixed with a carrier material. The elastomer is suited for use as a pharmaceutical vial closure which can be punctured by a filling needle and the puncture hole heat sealed by a focused laser.