Modular Vial Nest for Freeze-Drying Heat Transfer
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Solution Overview
Problem
Existing packaging solutions for medical and pharmaceutical containers, such as vials, are not flexible enough to accommodate containers of different sizes, and they often require removal from the supporting structure for further processing, leading to inefficiencies and potential contamination during handling and freeze-drying processes.
Innovation Solution
A supporting structure with a flat, rectangular carrier and releasably coupled supporting members that provide a positive-fit to accommodate containers of varying sizes, allowing them to be handled and processed while still supported, with features like radial clearance and deformability to ensure proper alignment and prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If containers are removed from the supporting structure for further processing, then individual processing is possible, but processing speed decreases and contamination risk increases
Solution Approach 1:
The patent merges the supporting structure with the processing capability by allowing the entire nest with multiple containers to be processed as a single unit. The conveyor system is designed to transport the nest structure itself, enabling simultaneous processing of multiple containers without requiring individual removal and handling, thus maintaining high processing speed while enabling individual container access when needed.
Solution Approach 2:
The supporting structure is segmented into a modular nest design where containers are individually positioned in separate cavities or slots within a common support framework. This segmentation allows the system to process the entire nest as one unit while still providing access to individual containers for specific operations, balancing bulk processing efficiency with individual container handling capability.
2Ease of operation
If containers are isolated and placed on conveyor individually, then processing can be performed, but abrasion and contamination occur
Solution Approach 1:
The nest supporting structure serves as an intermediary carrier between the container filling/storing stage and the processing stage. Instead of directly placing containers on the conveyor (which causes abrasion and contamination), the nest acts as a protective intermediary that holds multiple containers in a stable arrangement during transport and processing, reducing direct contact and damage risk.
Solution Approach 2:
The nest structure provides beforehand cushioning and protection for containers during handling and transport. The designed cavity shapes and support surfaces within the nest prevent container-to-container contact and minimize exposure to harmful mechanical stresses before processing begins, thereby reducing abrasion and contamination risks.
3Object-affected harmful factors
If supporting structure acts as isolation between freeze-dryer and vials, then vials are protected, but heat transfer is impaired
Solution Approach 1:
The nest structure is designed with local quality variations where different regions serve different functions. The outer structure provides protection and isolation, while specific contact regions (such as the bottom surfaces of vial-holding cavities) are designed with thermally conductive properties or direct contact features to enable efficient heat transfer to the freeze-dryer cooling surface, thus simultaneously achieving protection and thermal coupling.
Data Source
AI summary
Disclosed is a supporting structure for concurrently supporting a plurality of containers for substances for medical, pharmaceutical or cosmetic applications, comprising a flat, rectangular-shaped carrier having a plurality of apertures or receptacles and at least one supporting member, which is releasably coupled to the carrier, wherein the respective supporting member is configured to support a plurality of containers to said carrier by a positive-fit.According to the invention the positive-fit is formed by coupling the respective supporting member with the carrier such that the containers supported on the container extend into the apertures or receptacles of the carrier.By means of the supporting members tolerances, in particular with respect to the outer radius or the outer contour of the containers and to their length, can be compensated for in a simple manner. Because the containers extend through the apertures of the carrier, the bottoms of the containers are freely accessible from the underside of the carrier even if these are supported on the carrier. This offers significant advantages when processing or further processing the containers. Since the supporting means are clipped into the carrier, these are retained to the carrier in axial direction and thus are supported very reliably on the carrier.