Vial holder devices, methods and systems
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Solution Overview
Problem
Current methods for labeling and storing vials are cumbersome, expensive, and require specialized equipment, making them inefficient for bulk handling and storage, especially for cylindrical vials which are fragile and prone to tipping over.
Innovation Solution
A packaging system comprising a primary, secondary, and tertiary packaging holder configuration that allows for secure, irreversible holding and direct access to the vial, with a snap-fit assembly and planar surfaces for labeling, enabling efficient handling, storage, and labeling of cylindrical vials without interfering with the vial cap or integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cylindrical vials are used for storing sterile products, then the vials are easy to manufacture and store, but they are fragile and prone to tipping over, requiring bulky storage equipment
Solution Approach 1:
The packaging system is divided into three hierarchical levels: primary packaging holder (receiving portion) that cradles the vial, secondary packaging holder with base and walls that provides structural support, and tertiary packaging holder that offers outer protection. This segmentation distributes the stability function across multiple components, allowing the cylindrical vial to maintain its manufacturing simplicity while gaining enhanced stability through the nested packaging structure.
Solution Approach 2:
The patent implements a nested packaging structure where the primary packaging holder is placed inside the secondary packaging holder, which is in turn placed inside the tertiary packaging holder. Each level provides increasing structural support and stability, with the base and walls of the secondary holder and the outer structure of the tertiary holder preventing the cylindrical vial from tipping over, eliminating the need for bulky standalone storage equipment.
2Manufacturing precision
If specialized equipment is used for labeling vials, then labeling precision can be improved, but the process becomes cumbersome and expensive
Solution Approach 1:
The patent introduces a planar wall structure in the secondary packaging holder that extends from the base, creating a flat surface dimension. This planar surface serves as an ideal labeling area where labels can be applied directly to the packaging holder rather than the curved vial surface, significantly improving labeling precision and enabling simple manual or automated labeling processes without requiring specialized vial labeling equipment.
3Device complexity
If manual labeling of vials is performed, then equipment cost is reduced, but the labeling process becomes time-consuming and expensive due to labor requirements
Solution Approach 1:
By providing a planar wall surface in the secondary packaging holder, the patent creates an optimized labeling surface that accommodates both manual and automated labeling methods. The flat surface allows for rapid label application and alignment, significantly improving productivity compared to labeling curved vial surfaces manually. This dimensional change enables efficient high-speed automated labeling while also simplifying manual labeling processes.
4Reliability
If the packaging holder completely encloses the vial, then protection is improved, but access to the vial and its contents becomes difficult
Solution Approach 1:
The patent extracts the vial from complete enclosure by designing the primary packaging holder receiving portion with an open top configuration. The vial is held securely by the receiving portion's cradle structure and the secondary holder's base and walls, but remains accessible from the top. This extraction of the vial from full enclosure maintains protection through the packaging structure while enabling easy access for filling, sealing, and retrieval operations.
Solution Approach 2:
The packaging holders are designed with cushioning features including the receiving portion's cradle structure, the base and walls of the secondary holder, and the outer structure of the tertiary holder. These elements provide beforehand cushioning and protection to the vial during handling and storage, securing it in place while allowing access when needed.
5Productivity
If rapid assembly of packaging holders is achieved, then productivity is improved, but the need for specialized assembly equipment increases
Solution Approach 1:
The packaging system is segmented into three distinct holders (primary, secondary, tertiary) that can be manufactured independently using standard manufacturing processes. This segmentation allows for simple, rapid assembly by nesting the holders together without requiring complex specialized assembly equipment. Each holder is designed with features that facilitate easy connection to the next level, enabling high-speed assembly through simple nesting operations.
Data Source
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AI summary
A packaging apparatus is provided for holding a sterile product. In one aspect, a secondary packaging holder is configured with a base and a receiving portion to receive and irreversibly hold a primary packaging holder. The secondary packaging holder can have a substantially planar wall configured to affix an identifying label thereto. The secondary packaging holder can be configured to snap fit to a neck of the primary packaging holder to hold the primary packaging holder such that a portion of the primary packaging holder is exposed outside of the secondary packaging holder based on a height relationship between the secondary packaging holder and the primary packaging holder.