Softgel Capsule Pre-Fill Wedge to Eliminate Entrained Air Bubbles

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Solution Overview

Problem

Existing encapsulation machines face challenges in synchronizing the operation of components, require mechanical gear changes for adjustments, and produce softgel capsules with air bubbles due to entrained air during the formation of multi-dosage forms, leading to quality issues and potential degradation of incompatible active ingredients.

Innovation Solution

A system with a distributor plate and filling wedge segment, utilizing concave wedge surfaces and synchronized air displacement within the rotary die process, ensures air bubbles are eliminated by injecting pre-fill medicine to displace air chambers, forming air-free softgel capsules with incorporated solid forms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional encapsulation machines are used to form softgel capsules with solid dosage forms inside, then capsules are produced, but air bubbles are entrained during the formation process

Engineering Contradiction:

Improvecapsule productionVSAvoidair bubbles in capsules

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary action by injecting a pre-fill liquid medicine into the capsule cavity before the solid dosage form is inserted. This pre-fill liquid displaces air from the cavity, creating a liquid environment that allows the solid form to be submerged and sealed without trapping air bubbles, thus eliminating the harmful air entrapment issue while maintaining production efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The pre-fill liquid medicine acts as an intermediary substance between the capsule cavity and the solid dosage form. It facilitates the sealing process by providing a liquid medium that prevents air from being trapped, enabling the formation of bubble-free capsules without compromising the encapsulation process

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If mechanical gear changes are used for synchronization adjustments in encapsulation machines, then operational flexibility is achieved, but device complexity increases

Engineering Contradiction:

Improvesynchronization adjustmentVSAvoidmechanical gear system

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system replaces the traditional mechanical gear-based synchronization system with an electronic control system that uses sensors and programmable logic to coordinate the movement of the capsule carrier, pre-fill injection mechanism, and sealing components. This substitution eliminates complex mechanical gear changes while providing flexible digital adjustment capabilities for synchronization

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system implements dynamic synchronization control where the timing and coordination of various components are adjusted in real-time through electronic control signals rather than fixed mechanical gear ratios. This allows the encapsulation process to adapt to different capsule sizes, filling rates, and production speeds without requiring physical gear changes

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If air bubbles are present in softgel capsules, then capsule formation is simplified, but product quality and stability deteriorate

Engineering Contradiction:

Improvecapsule formation processVSAvoidproduct stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The pre-fill injection of liquid medicine occurs as a preliminary step before capsule sealing, proactively displacing air from the capsule cavity. This preliminary action ensures that when the capsule is sealed around the solid dosage form, no air bubbles are trapped, thereby maintaining both manufacturing simplicity and product stability without requiring complex post-processing

Inventive Principle:

Principle #10Preliminary action

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 system provides precise synchronization and eliminates air bubbles, ensuring stable delivery of incompatible substances in softgel capsules, maintaining product quality and shelf stability.

Implementation Method 1

injecting pre-fill medicine to displace air chambers

Methodology Applied

Scientific EffectAir displacement:

Data Source

PatentUS12508232B2Pre-filling system to eliminate bubbles inside capsules having a solid dosage forms within said capsules

Publication Date: 2025.12.30 PROCAPS

AI summary

The invention provides a rotary die mold process for manufacturing softgel capsules incorporating another solid form within said capsule and wherein said softgel capsule is free of air bubbles, in which at least two material strips are brought together by means of counter-running forming rolls and formed into capsules, a liquid and solid filling material being introduced via a filling wedge segment comprising two concave wedge surfaces; a filling medicine inlet; a fill medicine outlet; an output of solids and pre-fill medicine; a solids feed channel and pre-fill medicine; a pre-filling medicine inlet and a solids inlet. A softgel capsule free of air bubbles having incorporated within said capsule a second solid form, said second solid form being the form of a tablet.