Plastic Preassembled Closure for Lyophilized Product Bottles
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Solution Overview
Problem
Current closure systems for lyophilized products, particularly aluminum and plastic multi-component capsules, are complex, prone to instability, and cause economic losses due to handling issues, contamination risks, and increased production costs, with aluminum capsules generating powder contamination and plastic systems being mechanically less efficient.
Innovation Solution
A closure device comprising a perforable elastomer cap, an inner capsule with elastically deformable tabs, and an outer tab that forms a preassembled unit, allowing air passage and simplifying the lyophilization and sealing process by handling the components as a single unit, made entirely of plastic materials to avoid powder generation and ensure sterility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If aluminum capsules are used for closing bottles, then the closure function is achieved, but powder contamination is generated during handling and mounting
Solution Approach 1:
The invention replaces durable aluminum capsules with disposable plastic capsules that are designed for single-use. These plastic capsules perform the closure function effectively but are discarded after use, eliminating the powder contamination issue inherent in aluminum capsules while maintaining sterilization conditions.
Solution Approach 2:
The invention changes the material parameter from aluminum to plastic, fundamentally altering the properties of the capsule. This material substitution eliminates the powder generation problem while preserving the essential closure and sealing functions required for lyophilized product bottles.
2Object-generated harmful factors
If multi-component plastic capsules are used, then the closure function is achieved, but the number of components increases leading to handling complexity and potential loss
Solution Approach 1:
The invention merges multiple capsule components (outer tab, cage, and sealing elements) into a single integrated plastic capsule structure. This unified design eliminates the need to handle multiple separate components, reducing the risk of loss and simplifying the closing operation while maintaining effective sealing and closure functions.
3Productivity
If rubber cap is partially inserted in bottle mouth during lyophilization, then air can be extracted, but the cap position becomes unstable and may fall or escape
Solution Approach 1:
The invention incorporates preliminary positioning features into the plastic capsule design, such as engagement ribs and sealing flanges that pre-establish stable contact with the bottle mouth. This preliminary structural arrangement ensures the capsule remains securely in position during air extraction and lyophilization without requiring complex retention mechanisms.
4Ease of manufacture
If aluminum capsules are folded and cut during manufacturing, then the capsule shape is formed, but aluminium powders are produced that contaminate the product
Solution Approach 1:
The invention adopts disposable plastic capsules manufactured through injection molding or similar processes that do not involve folding or cutting metal sheets. This manufacturing approach eliminates aluminum powder generation entirely while maintaining ease of production and capsule formation.
Solution Approach 2:
The invention changes the manufacturing parameter from mechanical folding and cutting of metal to mold-based forming of plastic. This fundamental process change eliminates the harmful aluminum powder byproduct while achieving the same capsule shaping objective through a cleaner, more controlled manufacturing method.
Data Source
Figure 1~2
Figure 3~4
Figure 4a~4c
AI summary
The present finding relates to a closure device (1), particularly for bottles of lyophilized products, comprising: - a perforable closure cap (3) adapted for closing the mouth (5) of a bottle (7); - an inner capsule (9), fittable at least on said closure cap (3), comprising a plurality of elastically deformable tabs (29) protruding radially towards the inside said inner capsule (9) and further comprising an opening (13) adapted for allowing access to said closure cap (3); - an outer tab (15) fittable on said inner capsule (9) and comprising an upper portion (17), at least partially removable, adapted for closing said closure (13) of said inner capsule (9). The closure device (1) has a closing configuration wherein said outer tab (15) is fixedly fitted to said inner capsule (9), said inner capsule (9) is fitted to the neck (11) of said bottle (7) and said tabs (29) engage at the bottom with the lip (31) of said bottle (7) so as to retain said closure cap (3) in a closing configuration to seal said mouth (5) of said bottle (7). The closure device (1) also has a preassembly configuration wherein: - said inner capsule (9) rests, with said tabs (29), on the mouth (5) of said bottle (7), - a slit (30) is present between said closure cap (3) and said mouth (5) of said bottle (7) adapted for allowing the passage of air. According to the finding, at least one air passage channel (90) is obtained in the inner capsule (9), said channel (90) extending, in the axial direction (A) towards said opening (13), beyond said tabs (29); in said preassembly configuration said outer tab (15) is fixedly fitted to said inner capsule (9) to form a preassembled closure assembly (2). Furthermore, the at least one air passage channel (90) putting the internal volume (70) of said bottle (7) in fluid communication with the external environment through said slit (30).