Multilayer Syringe Barrel Nozzle Cutting Without Burrs or Peeling
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Solution Overview
Problem
Existing methods for cutting the nozzle portion of multilayer syringe barrels result in the generation of burrs, rolled-up parts, and peeling of the multilayer structure, leading to potential damage to the cap and contamination of the medicament.
Innovation Solution
A manufacturing method involving ultrasonic cutting with a mechanism to suppress abnormal vibration, followed by laser beam irradiation of the corner portion to prevent burrs, rolled-up parts, and peeling, ensuring a smooth cut surface without pointed corners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ultrasonic cutting is used to cut the remaining gate of the nozzle portion, then the generation of burrs is reduced compared to other known technologies, but burrs and rolled-up parts cannot be completely eliminated and the multilayer structure may peel
Solution Approach 1:
The patent replaces the purely mechanical ultrasonic cutting process with a combined process that incorporates laser beam irradiation. The laser beam (optical/thermal energy) is applied to the corner portion of the nozzle tip after ultrasonic cutting to melt and smooth the cut surface, eliminating burrs and rolled-up parts that mechanical cutting alone cannot remove. This substitution of mechanical action with thermal/optical action resolves the contradiction by achieving complete burr elimination while maintaining the benefits of ultrasonic cutting.
Solution Approach 2:
The patent employs a composite approach by combining two different cutting/finishing technologies: ultrasonic cutting and laser beam processing. The ultrasonic cutting blade (mechanical) removes the bulk of the remaining gate material, while the laser beam (thermal/optical) finishes the corner portion to eliminate burrs and prevent peeling. This composite method achieves superior cut surface quality without the harmful effects of burr generation and multilayer structure peeling.
2Ease of manufacture
If the remaining gate of the nozzle portion is cut with a cutting blade, then the nozzle tip is separated from the syringe barrel, but pointed corner portions are formed that may damage the cap
Solution Approach 1:
The patent replaces the mechanical cutting action alone with a combined mechanical-thermal process. After the cutting blade separates the nozzle tip, laser beam irradiation is applied to the corner portion to melt and smooth the sharp edges. This substitution of pure mechanical cutting with thermal processing eliminates pointed corner portions while maintaining the ease of nozzle tip separation, preventing cap damage.
3Device complexity
If conventional cutting methods are used without vibration suppression, then the cutting process is simpler, but abnormal vibration causes increased burr generation and multilayer structure peeling
Solution Approach 1:
The patent replaces the need for complex vibration suppression mechanisms with a thermal processing step. Instead of relying solely on mechanical vibration control to prevent burrs and peeling, the invention uses laser beam irradiation to melt and smooth the cut surface after cutting. This substitution transforms the problem from mechanical vibration control to thermal finishing, achieving superior cut surface integrity without requiring complex vibration suppression apparatus.
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 method effectively eliminates burrs, rolled-up parts, and peeling of the multilayer structure, preventing cap damage and ensuring the integrity of the cut surface, thereby enhancing the quality and safety of the syringe barrel.
Implementation Method 1
a finish cutting step of cutting a remaining gate of a nozzle portion of the multilayer syringe barrel that is injection-molded from a nozzle tip, with a cutting blade of an ultrasonic cutting apparatus including a mechanism for suppressing abnormal vibration
Implementation Method 2
an irradiation step of irradiating a laser beam to a corner portion of the nozzle portion, the corner portion being formed in the finish cutting step
Data Source
AI summary
A manufacturing method of a multilayer syringe barrel is provided and includes: a finish cutting a remaining gate of a nozzle portion of a multilayer syringe barrel that is injection-molded from a nozzle tip, with a cutting blade of an ultrasonic cutting apparatus including a mechanism for suppressing abnormal vibration; and irradiating a laser beam to a corner portion of the nozzle portion, the corner portion being formed during the finish cutting.