Bi-Material Vial Locking Cap Housing for Stopper-Safe Sealing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing locking caps for pharmaceutical vials risk damaging the elastomer stopper due to projecting edges and suffer from dimension and hardness variations that affect sealing, leading to potential contamination and compromised closure integrity.

Innovation Solution

A bi-injection molded housing for the locking cap, composed of two materials, where a first material forms the upper ring, legs, and bridges, and a second elastomer material forms the stopper, with precise connections ensuring sealing and mechanical integrity, using polycarbonate for the first material and silicone or thermoplastic elastomer for the second, with hardness between 20 and 45 Shore A.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a locking cap with separate housing and stopper is used, then the housing can provide structural support and locking function, but the projecting edges of the housing may damage the elastomer stopper

Engineering Contradiction:

Improvestructural supportVSAvoidstopper damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent combines the housing and stopper into a single integrated component made of elastomeric material. The stopper is formed as an integral part of the housing, eliminating separate parts and their interface. This merging resolves the damage issue by removing the projecting edges of a separate housing that could harm the stopper, while maintaining both structural support and sealing functions in one piece.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses a multi-layer elastomeric structure with different hardness zones. The housing portion has higher hardness for structural support and locking function, while the stopper portion has lower hardness for sealing and compliance. This composite material approach within a single piece provides both strength and protection against self-damage.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If the stopper dimensions and hardness vary from supplier to another, then manufacturing flexibility is improved, but the compression of the stopper against the flange is modified, impacting the sealing

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidsealing integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent implements a gradient hardness structure within the elastomeric material, with the stopper portion having controlled lower hardness and the housing portion having higher hardness. This parameter variation within a single material piece ensures consistent sealing performance regardless of supplier variations, as the softer stopper portion compensates for dimensional variations while the harder housing provides stable structural support.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies different material properties to different regions of the same component. The stopper region is designed with specific lower hardness for compliant sealing, while the housing region has higher hardness for structural integrity. This local differentiation of material properties within the integrated component ensures reliable sealing while maintaining manufacturing flexibility.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If a single-material housing is used, then manufacturing simplicity is improved, but the ability to provide both rigid structural support and compliant sealing is reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidfunctional integration

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent uses a multi-layer elastomeric structure with different hardness zones within a single integrated component. The housing portion has higher hardness for structural support, while the stopper portion has lower hardness for sealing. This composite material approach maintains manufacturing simplicity through a single-piece construction while achieving functional differentiation through material property variation.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12589916B2Bi-injection molded housing of a locking cap for a pharmaceutical vial, and locking cap including such a housing

Publication Date: 2026.03.31 A RAYMOND & CO SCS

AI summary

A bi-injection molded housing of a locking cap for a pharmaceutical vial includes a first material forming an upper ring, legs having upper ends rigidly connected to the upper ring, and bridges connecting lower ends of the legs in pairs, at least some bridges comprising a flexible tab configured to engage under a flange of the vial. The housing further includes a second elastomer material forming a stopper configured to seal the vial when the flexible tabs engage under the flange. At least one inner face of the upper ring made of the first material is rigidly connected to the stopper made of the second material.