Textured Surface Pattern for Air Evacuation in Pharmaceutical Packaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current packaging methods for multi-monodose pharmaceutical containers do not effectively evacuate air, leading to suboptimal sealing and potential degradation of pharmaceuticals due to residual gases.
Innovation Solution
A method involving a molded structure with interconnected monodose vials and a textured surface pattern to direct gas flow, where the structure is covered with a hermetically-sealable overwrap, and air is evacuated before forming a hermetic seal, ensuring a gas-tight package.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air evacuation is not performed during packaging, then the sealing process is simpler and faster, but residual gases cause suboptimal sealing and potential pharmaceutical degradation
Solution Approach 1:
Air evacuation is performed before the hermetic sealing process begins. The textured surface pattern is pre-formed on the molded structure to facilitate efficient air removal during the evacuation phase, ensuring that air is systematically extracted from packaging cavities before sealing occurs.
Solution Approach 2:
The molded structure incorporates a textured surface pattern in specific regions (second portion) that is optimized for gas flow direction. This localized texturing creates pathways that enhance air evacuation efficiency from critical sealing areas without requiring complete redesign of the entire packaging system.
2Productivity
If a textured surface pattern is added to direct gas flow, then air evacuation efficiency is improved, but the manufacturing complexity of the molded structure increases
Solution Approach 1:
The textured surface pattern is applied only to the second portion of the molded structure where gas flow direction is critical, rather than the entire structure. This localized approach improves air evacuation efficiency while minimizing the increase in manufacturing complexity.
Solution Approach 2:
The molded structure is divided into functional portions: a first portion containing the monodose vials and a second portion with the textured surface pattern. This segmentation allows the texturing to be applied only where needed for gas flow management, reducing overall manufacturing complexity.
3Stability of the object's composition
If hermetic sealing is performed without air removal, then the packaging process is faster, but pharmaceutical stability is compromised due to residual gases
Solution Approach 1:
Air evacuation is performed as a preliminary step before hermetic sealing. The textured surface pattern facilitates rapid air removal during this pre-sealing phase, minimizing the time required for gas extraction while ensuring thorough air removal to protect pharmaceutical stability.
Solution Approach 2:
The packaging process creates a gas-free or reduced-gas environment within the overwrap before hermetic sealing. By removing air and potential oxidizing gases before sealing, the pharmaceutical products are protected from degradation, and the hermetic seal maintains this protective environment throughout storage and transport.
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 enhances the sealing process by removing air, thereby maintaining the stability and effectiveness of pharmaceuticals within the containers.
Implementation Method 1
evacuating at least a portion of air from around the molded structure covered by the hermetically-sealable overwrap, the evacuated at least a portion of the air at least partially flowing over the textured surface pattern
Implementation Method 2
the evacuated at least a portion of the air at least partially flowing over the textured surface pattern of the second portion of the molded structure
Implementation Method 3
forming a hermetic seal around the row of interconnected monodose pharmaceutical vials by bonding the hermetically-sealable overwrap to at least a portion of the molded structure
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Methods and devices are described for packaging a multi-monodose container including covering a molded structure with a hermetically-sealable overwrap, the molded structure including a first portion and a second portion, the first portion including a row of interconnected monodose pharmaceutical vials, each of the interconnected monodose pharmaceutical vials enclosing a dose of at least one pharmaceutical agent, the second portion affixed to the first portion and including a textured surface pattern positioned to direct gas flow between the first portion and a region adjacent to the second portion; evacuating at least a portion of air from around the molded structure, the evacuated air at least partially flowing over the textured surface pattern of the second portion; forming a hermetic seal around the row of interconnected monodose pharmaceutical vials; and separating the second portion of the molded structure from the first portion of the molded structure.