Oxygen-Free Atmosphere in Vials via Absorbing Envelope
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge is to create an oxygen-free atmosphere within containers, particularly vials and syringes, during the sterile filling process without the need for large assembly robots and oxygen-free assembly machinery, which is costly and inconvenient.
Innovation Solution
The process exploits the oxygen-permeability of container walls and closures, using oxygen-absorbing materials to remove oxygen from the container interior and replace it with other gases, reducing the oxygen concentration to 1% or less, allowing for the sterile filling of medicinal substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional sterile filling methods are used with oxygen-free atmosphere requirements, then oxidation protection is achieved, but device complexity and manufacturing cost increase due to large assembly robots and oxygen-free machinery
Solution Approach 1:
The patent applies preliminary action by pre-enclosing the container within an envelope that contains oxygen-absorbing material before the filling process. This preliminary setup creates the oxygen-free environment automatically, eliminating the need for complex oxygen-free assembly machinery and large assembly robots during the filling operation.
Solution Approach 2:
The patent introduces an intermediary element - the envelope containing oxygen-absorbing material - that mediates between the container and the external environment. This envelope acts as a buffer that absorbs oxygen, creating the necessary oxygen-free atmosphere without requiring complex active control systems or specialized machinery.
2Object-affected harmful factors
If oxygen-free assembly environments are implemented, then oxidation protection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent employs a disposable envelope containing oxygen-absorbing material that is inexpensive compared to complex oxygen-free assembly equipment. This low-cost intermediary device provides effective oxidation protection during the filling process without requiring expensive specialized machinery, thereby reducing manufacturing costs while maintaining product safety.
3Object-affected harmful factors
If complex oxygen-free assembly machinery is used, then oxygen removal is effective, but ease of operation decreases
Solution Approach 1:
The patent implements self-service by using an oxygen-absorbing material that automatically removes oxygen from the envelope interior without requiring external control systems or complex machinery. The oxygen absorption occurs passively through the inherent chemical properties of the absorbing material, making the filling process simpler to operate while still achieving effective oxygen removal and protection against oxidation.
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
This method effectively minimizes oxidative damage to medicinal substances by reducing oxygen levels within the containers, making the process more efficient and cost-effective by eliminating the need for complex oxygen-free assembly environments.
Implementation Method 1
using oxygen-absorbing materials to remove oxygen from the container interior
Implementation Method 2
The process exploits the oxygen-permeability of container walls and closures
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A process for reducing the oxygen concentration in a container (17) prior to filling the container with a liquid by passing a hollow filling needle (40) through a puncturable part (16) of the container wall, in which the empty container (17) is enclosed within an envelope (21) which is less permeable to oxygen than the container wall (11). The process is suitable for use with vials having a puncturable closure.