Sterilizing Receptacle with Segmented H2O2 and UV Treatment

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Solution Overview

Problem

Current sterilization methods for pharmaceutical packaging are complex, inefficient, and pose risks due to the use of toxic gases, radiation, and uncertainty in maintaining aseptic safety, particularly in high-output systems and uneven regions where germ reduction is insufficient.

Innovation Solution

A sterilizing device and method that uses hydrogen peroxide gas to sterilize the impermeable receptacle body while irradiating the gas-permeable lidding foil with UV radiation, minimizing hydrogen peroxide contact with the primary packaging and ensuring effective germ reduction without additional adhesive processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hydrogen peroxide gas is used to sterilize the receptacle body, then effective germ reduction is achieved, but hydrogen peroxide may remain as residue and have negative effects on sensitive medicines

Engineering Contradiction:

Improvesterilization effectivenessVSAvoidhydrogen peroxide residue

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The sterilization process is segmented into two distinct parts: the receptacle body is sterilized with hydrogen peroxide gas while the lidding foil is sterilized with UV radiation. This segmentation prevents hydrogen peroxide residue from contacting the primary packaging and medicines, eliminating the harmful effect while maintaining sterilization effectiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sterilization methods are applied to different parts of the receptacle based on their specific properties. The gas-impermeable receptacle body receives hydrogen peroxide gas sterilization, while the gas-permeable lidding foil receives UV radiation sterilization. This local quality approach ensures each part is treated with the most appropriate method for its material properties.

Inventive Principle:

Principle #3Local quality

2Productivity

If electron beam irradiation is used for high-output sterilization, then productivity is improved, but X-rays are produced requiring lead shields

Engineering Contradiction:

Improvesterilization outputVSAvoidX-ray radiation

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The electron beam sterilization method is replaced with UV radiation sterilization for the lidding foil. UV radiation achieves effective germ reduction without producing harmful X-rays, eliminating the need for lead shields while maintaining adequate sterilization capability for the foil surface.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If UV irradiation is used for sterilization, then equipment complexity is reduced, but germ reduction is insufficient particularly in uneven regions

Engineering Contradiction:

Improvesterilization system simplicityVSAvoidgerm reduction effectiveness

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Two sterilization methods (hydrogen peroxide gas and UV radiation) are merged into a single integrated process. The hydrogen peroxide gas provides reliable sterilization of the receptacle body including shadowed areas, while UV radiation simultaneously sterilizes the lidding foil. This combination achieves both simplicity and effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

4Object-affected harmful factors

If a foil is adhesively bonded to the lidding foil before sterilization, then hydrogen peroxide contact is prevented, but additional process steps and potential germ contamination at edges are introduced

Engineering Contradiction:

Improvehydrogen peroxide contactVSAvoidprocess steps

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Instead of adding a foil barrier before sterilization, the approach is inverted: the lidding foil itself is directly sterilized with UV radiation before the receptacle body is sterilized with hydrogen peroxide gas. This inversion eliminates the need for additional foils and adhesive bonding processes while preventing hydrogen peroxide contact with the primary packaging through the gas-impermeable property of the lidding foil.

Inventive Principle:

Principle #13The other way round (Inversion)

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 approach provides a safe and effective decontamination method that achieves sufficient germ reduction without exposing sensitive medicines to hydrogen peroxide, ensuring the sterility of both the receptacle body and lidding foil while maintaining aseptic safety.

Implementation Method 1

The receptacle is sterilized in the region of the gas-impermeable receptacle body primarily by exposure to hydrogen peroxide (H2O2) in the gas phase

Methodology Applied

Scientific EffectGaseous hydrogen peroxide sterilization: Hydrogen Peroxide

Implementation Method 2

The region of the gas-permeable lidding foil is sterilized in a radiation-based manner

Methodology Applied

Scientific EffectUV irradiation: Light

Data Source

PatentUS20230056171A1Sterilizing device and method for sterilizing an outer face of a receptacle

Publication Date: 2023.02.23 SYNTEGON TECHNOLOGY GMBH

AI summary

The present invention relates to a sterilizing device (10) and to a method for sterilizing an outer face of a receptacle (22).