Injection Molded Vial With Desiccant Insert and Hinged Cap
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Solution Overview
Problem
Existing processes for forming vials with integral caps and tubes lack reliability in achieving airtight seals due to manufacturing defects, particularly in the sealed portions, which compromises the protection of contents within the vials.
Innovation Solution
A process involving separate injection molding of a tube, an insert, and a cap, where each component is formed independently and then assembled, with the insert being made from a desiccant and polymer blend to absorb environmental gases, and the cap secured to the tube using a hinge mechanism to enhance sealing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the tube and cap are integrally formed in a single injection molding operation, then the manufacturing process is simplified and productivity is improved, but the reliability of the seal and manufacturing precision deteriorate due to defects in sealed portions
Solution Approach 1:
The vial is divided into separate components (tube, cap, insert) that are manufactured independently in separate injection molding operations. This segmentation allows each component to be produced with optimized precision, particularly in sealed portions, while maintaining overall manufacturing efficiency through parallel production processes.
Solution Approach 2:
The insert is pre-formed and prepared before assembly, allowing for quality control and precision verification of the sealing surfaces beforehand. This preliminary action ensures that when the tube and cap are assembled, the sealing portions are already optimized, thereby improving seal reliability without sacrificing productivity.
2Ease of manufacture
If the tube and cap are integrally formed, then the manufacturing process is simpler, but the manufacturing precision of sealed portions deteriorates leading to unreliable seals
Solution Approach 1:
By segmenting the vial into separate tube, cap, and insert components manufactured in different injection molding operations, the patent enables precise control of sealing surfaces in each component. This allows for optimized mold designs and process parameters for each part, achieving higher seal precision while maintaining ease of manufacture through standardized separate production processes.
3Manufacturing precision
If separate injection molding machines are used for tube, cap and insert, then manufacturing precision and quality control are improved, but device complexity and production time increase
Solution Approach 1:
The manufacturing system is segmented into separate injection molding machines for each component, allowing independent optimization of precision for tube, cap, and insert. This segmentation enables specialized equipment for each part, improving manufacturing precision while managing system complexity through modular architecture and automated assembly.
Solution Approach 2:
An automated assembly system acts as an intermediary between the separate injection molding machines and the final vial assembly. This intermediary coordinates the precise positioning and assembly of tube, cap, and insert components, managing the complexity of multiple machines through centralized control while maintaining high manufacturing precision.
4Reliability
If separate injection molding machines are used, then quality control and manufacturing precision are improved, but production time and process complexity increase
Solution Approach 1:
By segmenting the production process into parallel independent injection molding operations for tube, cap, and insert, the patent enables simultaneous manufacturing of all components. This segmentation improves quality reliability through dedicated production lines for each component while reducing total production cycle time compared to sequential assembly processes.
Solution Approach 2:
Components are prepared in advance through separate injection molding operations, allowing for quality inspection and adjustment before final assembly. This preliminary action ensures high quality reliability while optimizing production time by pre-positioning components for rapid assembly rather than requiring sequential production and assembly steps.
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 significantly improves the reliability of the seal by allowing for precise control and quality assurance of each component before assembly, reducing the risk of damage during the manufacturing process and ensuring a leak-proof vial.
Implementation Method 1
an insert, which insert absorbs gaseous compositions that are present in the environment, particularly moisture
Data Source
AI summary
A process for forming a vial consisting of a tube, an insert secured within the tube, and a cap secured to the tube, which includes injection molding of the insert, removing the insert from the injection molding machine and placing it over a pin on a moving pallet by use of a manipulator, injection molding of the tube by a separate injection molding machine and moving the injection molded tube to a position where it is placed over the insert on the moving pallet by use of a manipulator, wherein a cap for the tube is formed at a separate injection molding machine where the cap is secured to the tube, wherein the joined tube with insert and cap are moved to a cap closing station wherein, after closing of the cap onto the tube, the assembled vial is inspected, tested and packaged.