Pharmaceutical Packaging Laser Welding via Internal Scattering Interface
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Solution Overview
Problem
Current medical packaging materials require additives like absorber and scatter pigments for laser welding, which are not approved for pharmaceutical packaging, leading to contamination issues and costly cleaning procedures with other welding methods.
Innovation Solution
A medical packaging material with internal interfaces that scatter laser light, allowing for welding without absorber or scatter pigments, using a connecting body made of the same material as the components, which reflects and scatters laser light to achieve the necessary heat for bonding, eliminating the need for additives and reducing contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If absorber and scatter pigments are added to plastic components for laser welding, then laser welding capability is improved, but material approval for pharmaceutical packaging is lost
Solution Approach 1:
A connecting body made of the same approved plastic material is introduced as an intermediary element between the two plastic components. This connecting body contains the laser-absorbing particles, allowing the main components to remain free of contaminants while still enabling laser welding through the mediator that converts laser energy to heat for bonding.
Solution Approach 2:
The welding structure is segmented into three distinct parts: two laser-transparent plastic components and one connecting body that contains the laser-absorbing particles. This segmentation isolates the contaminants to a specific component (the connecting body) that can be removed, allowing the main components to maintain their approval status.
2Reliability
If other welding methods (ultra-welding, vibration welding, high frequency welding, heated tool welding) are used, then welding without additives is possible, but expensive cleaning procedures are required to remove contaminations
Solution Approach 1:
The connecting body acts as a sacrificial intermediary that contains all the laser-absorbing particles and potential contaminants. After laser welding, this connecting body can be easily removed, taking all contaminants with it, thereby eliminating the need for expensive cleaning procedures on the main components while maintaining their approval status.
3Reliability
If laser-transparent plastics are used for medical packaging, then material approval is maintained, but laser welding is not possible due to low absorption of laser radiation
Solution Approach 1:
The connecting body serves as a mediator that absorbs the laser radiation and converts it to heat. This heat is then transferred to the laser-transparent plastic components, enabling welding without requiring the components themselves to absorb laser radiation, thus maintaining both weldability and material approval.
Solution Approach 2:
The optical properties are changed locally in the connecting body by adding laser-absorbing particles, while the main components remain laser-transparent. This parameter change is confined to the mediator, allowing the system to be weldable while the main components retain their approved status.
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
Enables laser welding of pharmaceutical packaging components without altering their approved composition, reducing contamination risks and avoiding expensive cleaning procedures, while maintaining the integrity of the packaging material.
Implementation Method 1
at least one internal interface having a scattering effect is arranged between a first thermoplastic plastic component body and a second thermoplastic plastic component body
Implementation Method 2
the internal interface with scattering effect is formed by the first material of the first thermoplastic plastic component and/or the second material of the second thermoplastic plastic component
Implementation Method 3
Thermoplastic plastics are fused through laser radiation. During cooling, the plastics combine and are fused together.
Implementation Method 4
two components can be joined with the assistance of laser welding
Implementation Method 5
During cooling, the plastics combine and are fused together
Data Source
AI summary
A medical packaging material, in particular a pharmaceutical packaging material, comprising a first thermoplastic plastic component body consisting of a first material, a second thermoplastic plastic component body consisting of a second material, wherein between the first plastic component body and the second plastic component body at least one internal interface having a scattering effect is arranged that results preferably in an extended wavelength of radiated light.