Mini-Vial Plunger Overmoulded Membrane Filter Integration
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Solution Overview
Problem
Existing methods for producing mini-vials involve complex production steps, high costs, risk of particle contamination, and significant 'dead' volume for filtration due to separate filter components and mechanical connections, which can deform the filter and increase production costs.
Innovation Solution
The method involves overmoulding the membrane filter directly into the plunger during injection moulding, creating a single, integral component with a support portion to minimize 'dead' space and ensure secure filtration without particle release, using a reduced number of components and simpler machinery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If separate filter components and mechanical connections are used, then the filter can be positioned away from the plunger end, but this creates significant 'dead' volume for filtration
Solution Approach 1:
The patent merges the filter membrane with the plunger body into a single integrated component. The filter is positioned at the very end of the plunger with no intervening support body, eliminating dead volume while maintaining structural integrity through the monolithic design.
2Reliability
If ultrasonic welding is used to connect the support body and plunger, then the components can be joined, but particles are released that may pollute the fluid
Solution Approach 1:
The filter and plunger are molded as a single integral component, eliminating the need for separate joining operations like ultrasonic welding. This prevents particle release while maintaining reliable assembly through the unified structure.
3Manufacturing precision
If a support body is used to hold the filter, then the filter can be secured to the plunger, but this deforms the filter and limits filtering qualities
Solution Approach 1:
The filter membrane is directly integrated into the plunger body without an intervening support body. This eliminates filter deformation caused by mechanical compression while maintaining secure positioning through the monolithic construction.
Solution Approach 2:
The filter is positioned and secured in its final location during the molding process itself, before any assembly operations. This preliminary positioning ensures optimal filtering quality without subsequent deformation from assembly operations.
4Reliability
If multiple production steps are used to assemble the support body and filter, then the components can be properly connected, but this increases production complexity and cost
Solution Approach 1:
The filter and plunger are produced as a single component in one molding operation, eliminating multiple assembly steps while maintaining secure connection. This significantly improves production efficiency and reduces manufacturing cost.
Data Source
Figure 1
Figure 2~4
AI summary
A method for producing a mini-vial (1) of the type comprising a tubular container or vial (2), closed at a first end (5) and open at its second end (6) and capable of containing a product in fluid phase, a plunger (3) sealingly movable in said vial (2) through said second end (6) and having an internal cavity (13) capable of receiving the fluid from said vial (2), the plunger (3) having a first end (9) on which is placed a sealing cap and a second end (11) movably slidable in the vial (2) and at which is located a membrane filter (16), said plunger (3) and vial (2) being obtained by moulding; the plunger (3) being envisaged as overmoulded onto the filter located at its second end, said membrane filter forming a single body with said plunger.