Syringe Plug Insertion by Sleeve Depressurization
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Solution Overview
Problem
Existing methods for inserting a plug into a syringe barrel require large vacuum chambers, increasing the size of the device when manufacturing multiple prefilled syringes.
Innovation Solution
A chemical solution enclosing device and method that uses a barrel holder, a sleeve, a push rod, and a suction depressurization device to insert a plug into a barrel without increasing the device size, by depressurizing the barrel through a gap between the sleeve and barrel, maintaining the depressurized state, and ensuring fluid-tight contact of the plug with the barrel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch processing of plug insertion is performed in a vacuum chamber, then multiple syringes can be manufactured at once, but the device size increases due to the need for large vacuum chambers
Solution Approach 1:
The invention divides the plug insertion process into two independent stages: (1) plug insertion into the sleeve at atmospheric pressure, and (2) barrel depressurization and plug ejection into the barrel. This segmentation allows each stage to be performed in a compact space rather than requiring a large vacuum chamber for the entire process, thereby maintaining productivity while reducing device size.
Solution Approach 2:
The plug is preliminarily inserted into the sleeve at atmospheric pressure before the barrel is depressurized. This preliminary action allows the plug to be positioned and secured in the sleeve in advance, so that when the barrel is later depressurized and the plug is ejected, the process is rapid and efficient. This eliminates the need to perform plug insertion during the vacuum state, reducing the required vacuum chamber size.
2Ease of manufacture
If plug insertion is performed at atmospheric pressure, then the process is simple, but air bubbles form in the chemical solution
Solution Approach 1:
The process is segmented into two pressure environments: plug insertion into the sleeve occurs at atmospheric pressure (simple process), while plug ejection into the barrel occurs after barrel depressurization (prevents air bubbles). This segmentation allows each operation to be performed under optimal pressure conditions without requiring the entire process to occur in a vacuum.
Solution Approach 2:
The plug is preliminarily inserted into the sleeve at atmospheric pressure, which is simple to perform. Then, the barrel is depressurized before the plug is ejected into it. This sequence ensures that when the plug enters the barrel, the low pressure inside the barrel prevents air from being trapped in the chemical solution, thus preventing air bubble formation while maintaining process simplicity.
3Productivity
If a large vacuum chamber is used for batch processing, then multiple syringes can be processed simultaneously, but the manufacturing cost increases
Solution Approach 1:
By segmenting the plug insertion and ejection processes into separate pressure environment stages, the invention eliminates the need for a large vacuum chamber that would be required to accommodate multiple syringes simultaneously for batch processing. Each syringe can be processed sequentially in a compact device, reducing the overall manufacturing cost while maintaining productivity.
Solution Approach 2:
The sleeve acts as an intermediary device that holds the plug before ejection. The plug is inserted into the sleeve at atmospheric pressure, and then ejected into the depressurized barrel. This intermediary mechanism allows the process to be performed in a compact space without requiring a large vacuum chamber for batch processing, thereby reducing manufacturing costs.
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 plug insertion into a barrel without enlarging the device, allowing efficient manufacturing of prefilled syringes without the need for large vacuum chambers.
Implementation Method 1
a suction depressurization device that draws air inside of the barrel that is isolated from outer air, the air being drawn through a gap between an outer peripheral surface of the sleeve and an inner peripheral surface of the barrel to depressurize inside of the barrel
Implementation Method 2
the sleeve is withdrawn from the barrel after at least a part of an outer peripheral surface of the plug comes into fluid-tight contact with the inner peripheral surface of the barrel
Data Source
AI summary
A chemical solution enclosing device that inserts a plug into a barrel containing a chemical solution includes, a sleeve inserted into a barrel in such a manner that a tip end of the sleeve comes near a liquid surface of the chemical solution, a push rod pushing the plug inserted in the sleeve; and a suction depressurization device that draws air inside of the barrel that is isolated from outer air through a gap between an outer peripheral surface of the sleeve and an inner peripheral surface of the barrel to depressurize inside of the barrel. After the suction depressurization device depressurizes the inside of the barrel to a predetermined pressure, the push rod is advanced to push the plug from inside of the sleeve into the barrel, with a depressurized state maintained. The sleeve is withdrawn from the barrel after at least a part of an outer peripheral surface of the plug comes into fluid-tight contact with the inner peripheral surface of the barrel.