Plastic Mono-Dose Vial With Integrated Needle Moulding
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Solution Overview
Problem
Existing machines and methods for producing plastic mono-dose vials with integrated needles are complex, expensive, and often fail to provide optimal results due to critical connections and inadequate needle protection, which can compromise sterility and ease of use.
Innovation Solution
A machine and method that simplify the production process by using fewer components and phases, integrating needle protection, and ensuring reliable mechanical resistance and sterility through a low-temperature connection without excessive volatile emissions, with the protection means being easy to remove.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If known machines and methods are used for producing plastic mono-dose vials with needles, then the container can be filled and sealed, but the production process becomes complex and expensive with many production phases
Solution Approach 1:
The patent combines multiple production operations into a single integrated moulding process. The container, needle, and protection means are formed in one continuous operation using a specialised mould that incorporates all components, eliminating the need for separate production phases and reducing overall process complexity while maintaining production reliability
Solution Approach 2:
The moulding means is designed to perform multiple functions simultaneously: forming the container body, shaping the needle, creating the protection means, and establishing the connection between components. This multi-functional approach reduces the number of separate production phases needed while ensuring reliable production outcomes
2Strength
If the needle is inserted by force in the plastic element, then the connection is achieved, but the connection becomes critical and may cause limitations of use
Solution Approach 1:
The needle connection is integrated into the moulding process itself, where the needle is positioned and connected to the container during the initial forming stage. This preliminary integration ensures proper alignment and connection strength without requiring forceful insertion later, while maintaining container usability through controlled connection geometry
Solution Approach 2:
The patent employs low-temperature connection methods during moulding, changing the thermal parameters of the plastic material to facilitate needle integration. This approach achieves strong mechanical connection without excessive heat that could compromise usability, allowing the connection to be formed at temperatures that maintain material properties and container functionality
3Reliability
If protection means is provided for the needle, then sterility and sharpening are maintained, but the protection means becomes difficult to remove or insufficient for sterility
Solution Approach 1:
The protection means is designed with differentiated local properties: the main body provides robust sterility protection with a secure fit, while the distal end features a localized release mechanism with reduced friction or a breaking seam. This local quality variation ensures reliable sterility maintenance during storage while enabling easy removal by the user through a specific action at the release point
Solution Approach 2:
The protection means is pre-formed as an integral part of the moulding process, with the release mechanism already configured in the correct position and orientation. This preliminary formation ensures that the protection means is properly positioned to maintain sterility while the built-in release feature is ready for easy user activation, eliminating the need for complex removal procedures
4Strength
If the connection is made at high temperatures, then mechanical resistance is improved, but excessive volatile substances are emitted
Solution Approach 1:
The patent changes the temperature parameter of the connection process, forming the needle-to-container connection at low temperatures during the moulding operation. This parameter change achieves sufficient mechanical resistance through controlled material flow and bonding without reaching temperatures that would cause excessive volatile substance emission, thereby eliminating the harmful effect while maintaining connection strength
Data Source
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AI summary
Machine and method for carrying out, starting from at least a tubular element (110) of semi-fluid plastic material, at least a container (100) for a product (P) and provided with a respective accessory (101) ; comprising at least: - production means of the tubular element (110) of semi-fluid plastic material; - moulding means (2) that, in an operational condition of the machine (1), they are fed by the production means of the tubular element and driven between closing and opening conditions ; - moulding means (3) adjacent and nearly coaxial to the moulding means (2) and driven between closing and opening conditions; - support means (4) fit to move the accessory (101) between internal and external conditions in respect to the forming mean (3) and fit to release it in this latter external condition; - filling means (5) moving between internal and external conditions in respect to the forming mean (3) and fit to supply the product (P). The manufactured container is also claimed.