Vial Holder with Open Bases for Uniform Freeze-Drying Heat Transfer
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Solution Overview
Problem
Existing freeze-drying processes for pharmaceutical vials face challenges such as non-homogeneous heat transfer, long processing times, and variations in product quality due to vial position in the freeze-drying chamber.
Innovation Solution
A holder device with housing seats having open bases facing the processing line surface and internal spacer elements that maintain vials in a suspended position, allowing for natural convection and uniform heat transfer during freeze-drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If vials are placed directly on the heating surface of the freeze-drying chamber, then heat transfer is efficient, but heat transfer becomes non-homogeneous and processing time increases
Solution Approach 1:
The patent introduces a holder device as an intermediary between the heating surface and the vials. This holder device includes a base plate with support elements that suspend the vials from the heating surface, allowing uniform heat transfer through natural convection while preventing direct contact that causes non-homogeneous heating. The holder device acts as a mediator that enables both efficient and uniform heat transfer simultaneously.
2Temperature
If vials are suspended from the heating surface, then heat transfer becomes uniform, but the structure becomes more complex
Solution Approach 1:
The holder device is segmented into distinct functional elements: a base plate for support, multiple support elements for suspension, and positioning features for the vials. This segmentation allows each component to perform its specific function simply, avoiding overall structural complexity while achieving uniform heat transfer through the suspended configuration.
Solution Approach 2:
The holder device is designed to be universally applicable to multiple vials simultaneously, with a base plate that can accommodate various numbers and positions of vials. The support elements can be configured to hold different vial sizes and positions, making the device multi-functional for various freeze-drying scenarios without requiring complex specialized structures for each case.
3Temperature
If spacers are used to maintain vial position, then heat transfer uniformity improves, but spacer reliability decreases due to potential collapse or deformation
Solution Approach 1:
The holder device is made from a single piece of thermally conductive material that combines structural support and thermal conduction functions. This composite approach eliminates the need for separate spacers made of thermally insulating materials that may collapse or deform. The unified structure provides both mechanical stability and reliable thermal conduction, preventing the reliability issues associated with multi-material spacer constructions.
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 solution ensures homogeneous freeze-drying of pharmaceutical products, reduces processing time, and maintains product quality by providing ideal conditions for heat exchange and vial support.
Implementation Method 1
heat is transferred evenly from the heating surface to the inside of the vials mainly by natural convection through the base and the side surface of the vials
Implementation Method 2
reducing the pressure and introducing heat to allow the water frozen in the product which is inside the vials to sublime
Data Source
AI summary
A holder device for holding a plurality of vials to be moved in a processing line. The holder device includes a plate having a plurality of housing seats for housing the vials and a plurality of rigid spacer elements arranged within the housing seats and configured to maintain the vials in a suspended position with respect to a substantially horizontal operating surface of the processing line. Each housing seat includes an open base intended to face towards the operating surface.