US20060168916A1 - Method and apparatus to insert stoppers into prefilled syringes - Google Patents
Method and apparatus to insert stoppers into prefilled syringes Download PDFInfo
- Publication number
- US20060168916A1 US20060168916A1 US10/982,373 US98237304A US2006168916A1 US 20060168916 A1 US20060168916 A1 US 20060168916A1 US 98237304 A US98237304 A US 98237304A US 2006168916 A1 US2006168916 A1 US 2006168916A1
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- US
- United States
- Prior art keywords
- stopper
- tube
- vacuum
- stoppers
- movement
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 24
- 239000007788 liquid Substances 0.000 claims abstract description 18
- 238000007789 sealing Methods 0.000 claims description 21
- 238000013022 venting Methods 0.000 claims description 2
- 230000003213 activating effect Effects 0.000 claims 2
- 238000003780 insertion Methods 0.000 abstract description 31
- 230000037431 insertion Effects 0.000 abstract description 31
- 230000032258 transport Effects 0.000 abstract 2
- RRLHMJHRFMHVNM-BQVXCWBNSA-N [(2s,3r,6r)-6-[5-[5-hydroxy-3-(4-hydroxyphenyl)-4-oxochromen-7-yl]oxypentoxy]-2-methyl-3,6-dihydro-2h-pyran-3-yl] acetate Chemical compound C1=C[C@@H](OC(C)=O)[C@H](C)O[C@H]1OCCCCCOC1=CC(O)=C2C(=O)C(C=3C=CC(O)=CC=3)=COC2=C1 RRLHMJHRFMHVNM-BQVXCWBNSA-N 0.000 description 5
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000004320 controlled atmosphere Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000009972 noncorrosive effect Effects 0.000 description 1
- 230000008520 organization Effects 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B3/00—Packaging plastic material, semiliquids, liquids or mixed solids and liquids, in individual containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, or jars
- B65B3/003—Filling medical containers such as ampoules, vials, syringes or the like
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B7/00—Closing containers or receptacles after filling
- B65B7/16—Closing semi-rigid or rigid containers or receptacles not deformed by, or not taking-up shape of, contents, e.g. boxes or cartons
- B65B7/28—Closing semi-rigid or rigid containers or receptacles not deformed by, or not taking-up shape of, contents, e.g. boxes or cartons by applying separate preformed closures, e.g. lids, covers
- B65B7/2821—Closing semi-rigid or rigid containers or receptacles not deformed by, or not taking-up shape of, contents, e.g. boxes or cartons by applying separate preformed closures, e.g. lids, covers applying plugs or threadless stoppers
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M2207/00—Methods of manufacture, assembly or production
Definitions
- the syringes and stoppers are often standardized by the use of ISO (International Organization for Standardization), e.g. ISO 11040-4 and 5 for glass barrels and plungers for injectables. It is therefore possible to manufacture apparatus to accommodate the various size barrels or syringes and plungers or stoppers.
- ISO International Organization for Standardization
- a stopper insertion system can include one stopper tube 16 and stopper ram 20 for sealing one syringe 12 at once or more sets for sealing two or more syringes at the same time. The following description is simplified for only one set. A description of one cycle will refer to FIGS. 3, 4 and 5 .
Abstract
An apparatus and method for inserting a stopper into a medical syringe minimizing the amount of entrapped air between the stopper and the contained liquid. The apparatus in a first embodiment utilizes a vacuum to assist inserting the stopper within the syringe. In a second embodiment a vacuum is used to transport the stopper and cause the insertion into the syringe. This method eliminates a mechanical device that transports the stopper to the syringe.
Description
- The present invention relates to an apparatus and method for inserting stoppers under a vacuum into a syringe filled with liquid.
- In order to prepare a medical syringe that will be used to inject liquid into a patient, it is critical that the syringe and fluid are free of contamination, biological and chemical. Apparatus used in the process must be made from non-corrosive materials and be located within a controlled atmosphere. Important to the process and apparatus is the prevention of air being retained within the syringe after the filling and stopper insertion processes. The presence of air in the syringe and its possible injection into a patient is undesirable. One of the objectives of syringe filling and closing systems is to minimize the trapped air above the liquid.
- The syringes and stoppers are often standardized by the use of ISO (International Organization for Standardization), e.g. ISO 11040-4 and 5 for glass barrels and plungers for injectables. It is therefore possible to manufacture apparatus to accommodate the various size barrels or syringes and plungers or stoppers.
- All apparatus described herein is typically part of a larger machine that precisely locates multiple syringes below a series of one or more stopper insertion apparatuses and then delivers and inserts the stoppers within the previous filled syringes. Syringes processed by the traditional method contain a relatively large amount of air or gas above the liquid after filling and stopper insertion. This method also requires moving machinery parts to move stopper rams and stopper tubes, inject the stoppers and place the syringes. This machinery releases particles by wear and interferes with the flow of clean air through the machine.
- A description of a typical prior stopper insertion apparatus will be described by referring to
FIG. 1 . The basic function of this system is the insertion of stoppers 1 (also called pistons or plungers) into filledsyringes 2. The syringes are filled with aliquid medium 3. The main functional elements for this insertion arestopper tubes 4 and stopperrams 5. Each functional element is moved relative to each other according to a specific timing. The movement and timing ofstopper tubes 4 andstopper rams 5 is driven for example by mechanical cams, servos or a robot system. A stopper insertion system includes onestopper tube 4 and stopperram 5 for sealing onesyringe 2 at once or more sets for sealing two or more syringes at the same time. The following description of operation is simplified for only one set. - The
stopper 1 is placed concentric above thestopper tube 4. By a vertical movement of thestopper ram 5, thestopper 1 is inserted into thestopper tube 4. Thestopper 1 is compressed inside thestopper tube 4. Then thestopper tube 4 and stopperram 5 move down into thesyringe 2 up to a specific depth. As long as thestopper 1 remains in thestopper tube 4, air above the filling level of the fillingliquid 3 can escape out of thesyringe 2 by passing the gap betweenstopper tube 4 and the inner surface of the syringe body. The pressure inside the syringe remains almost equal to the system's environment pressure (P1≈P2). By starting to move up first, thestopper tube 4 releases thestopper 1 above the filling level. After that release thestopper ram 5 also starts moving up. Both functional elements move back to their home position, and the next cycle can start. - According to the described function of the system, the final position of the
stopper 1A after the insertion into the filledsyringe 2 depends on the lowest position of thestopper tube 4 movement and thestopper ram 5 movement. A gas volume between thestopper 1A and fillingliquid 3 remains. The pressure of this gas volume is close to the system's environment pressure (P1≈P2). - It is the purpose of this invention to disclose an apparatus and method for inserting a stopper into a syringe using simplified machinery having less moving parts and that permits a minimum volume of air to remain within the syringe after stopper insertion. In a first embodiment the apparatus provides a stopper insertion system that uses vacuum to assist the insertion of the stopper. This method and apparatus reduces the air entrapped above the liquid in a syringe. A preferred embodiment improves this process by eliminating the stopper ram mechanism and causes insertion of the stopper by controlled use of vacuum. This method and apparatus reduces entrapped air and reduces the moving machinery parts required to insert the stoppers.
-
FIG. 1 is a side section schematic view of a prior art apparatus for inserting a stopper into a syringe. -
FIG. 2 is a side section of a first embodiment of the present invention for an apparatus for inserting a stopper into a syringe. -
FIG. 3 is a view of theFIG. 2 apparatus at the start of the stopper insertion cycle. -
FIG. 4 is a view of theFIG. 2 apparatus after the start of the stopper insertion cycle. -
FIG. 5 is a view of theFIG. 2 apparatus near completion of the stopper insertion cycle. -
FIG. 6 is a side section schematic of a preferred embodiment of the present invention at the start of the stopper insertion cycle. - This first embodiment will be described by referring to
FIG. 2 . The basic function of this system is the insertion of stoppers 10 (also called pistons or plungers) into filledsyringes 12 with vacuum assist. The syringes are filled with aliquid medium 14. The main functional elements for this insertion arestopper tubes 16 and stopperrams 20. Thestopper tubes 16 have one or moreradial ports 18 which are connected to a vacuum system. A vacuum system, for example, could include a vacuum pump and a vacuum valve. Each functional element is moved relative to each other according to a specific timing. Vacuum supplied by the vacuum system is activated and deactivated according to the stopper tube's 16 and stopper ram's 20 movement. Themovements stopper tubes 16 andstopper rams 20 are driven for example by mechanical cams, servos, or a robot system. A stopper insertion system can include onestopper tube 16 and stopperram 20 for sealing onesyringe 12 at once or more sets for sealing two or more syringes at the same time. The following description is simplified for only one set. A description of one cycle will refer toFIGS. 3, 4 and 5. - Referring to
FIG. 3 : Thestopper 10 is placed concentric above thestopper tube 16. By a vertical movement of thestopper ram 20, thestopper 10 is inserted into thestopper tube 16 up to a specific depth as shown. Thestopper 10 is compressed inside thestopper tube 16. By reaching this specific depth, thestopper 10 seals the upper opening of thestopper tube 16 but remains above the radial vacuum port(s) 18. - Referring to
FIG. 4 : Thestopper tube 16 and stopperram 20 move down until thesealing element 26 touches the syringe's 12 body. Thestopper tube 16 follows the movement of thestopper ram 20, so there is no relative movement between these two components. Thestopper 10 remains in its specific position proportional to thestopper tube 16. The sealingelement 26 seals the stopper tube against thesyringe 12. A vacuum chamber is formed including thestopper tube 16 andsyringe 12. After the vacuum chamber is formed, the vacuum is activated for the duration of 0.01 seconds to 4 seconds. The vacuum chamber is evacuated up to a pressure between 0.01 millibar and 300 millibar. During the evacuation thestopper tube 16,stopper ram 20 andstopper 10 remain in position as shown. - Referring to
FIG. 5 : After that specific duration of evacuation thestopper tube 16 and sealingelement 26 remain in position. Thestopper ram 20 moves down until thestopper 10 is released out of thestopper tube 16. When thestopper 10 reaches thevacuum connection port 18, no further vacuum in thesyringe 12 can be reached by evacuating the vacuum chamber. After thestopper 10 has passed the depth of thevacuum connection port 18 the stopper tube's 16 section above the stopper 10 (including the vacuum connection port 18) is vented up to the system's environment pressure P1. A force which is caused by the pressure difference between inside thesyringe 12 and the environment (P1>P2) moves thestopper 10 down to a final position where the pressure difference is almost equalized with ambient pressure by the compression of the remaining gas volume between the fillingliquid 14 and thestopper 10. Thestopper ram 20 andstopper tube 16 return to their home position byupward movements - According to the described function of the system, the final position of the
stopper 10A after the insertion into the filledsyringe 12 does not depend on the lowest position of thestopper tube 16 movement and thestopper ram 20 movement. After thestopper 10 is released out of thestopper tube 16, different forces act on thestopper 10. The first resultant force is caused by the pressure difference between inside the syringe 12 (F Inside=P2*A) and the system's environment pressure (F Outside=P1*A). “A” is the cross-sectional area of the insertedstopper 10A. The second force is friction between thesyringe 12 and the movingstopper 10. Thestopper 10 is forced to move down until these forces are balanced. By this way the remaining gas volume between the fillingliquid 14 and thestopper 10 can be reduced in comparison to the stopper insertion prior art. - The preferred embodiment vacuum stopper insertion apparatus description refers to
FIG. 6 . The apparatus can have one or more devices, but one will be described for simplicity. The basic function of this system is the insertion ofstoppers 30 into filledsyringes 32 using a vacuum. The syringes are filled with aliquid medium 34. The main functional elements for this insertion are astopper tube 36 and a flexiblestopper transport device 38. Thestopper tube 36 has one or moreradial ports 40 which are connected to a vacuum system. A vacuum system, for example, can include a vacuum pump and a vacuum valve. Thestopper tube 36 is moved according to a specific timing. Vacuum is supplied by the vacuum system and is activated and deactivated according to thestopper tube 36 movement and the flexiblestopper transport device 38 movement. The movement and timing of thestopper tube 36 and flexiblestopper transport device 38 is driven, for example, by mechanical cams, servos, or a robot system. A stopper insertion system can include onestopper tube 36 and flexiblestopper transport device 38 for sealing onesyringe 32 at one time or more sets for sealing two or more syringes at the same time. The following operational description is simplified for only one set. A description of one cycle follows: - The
stopper tube 36 is moved down until a sealingelement 44 touches thesyringe 32 body. The sealingelement 44 seals thestopper tube 36 against thesyringe 32. Astopper 30 is fed into the flexible stoppertransport device entrance 46. Vacuum between 10 and 800 millibars is activated atport 40. In comparison to the environment's pressure P1, the pressure P2 inside the flexiblestopper transport device 38 is reduced (P1>P2) by evacuation. This pressure difference forces thestopper 30 to move through the flexiblestopper transport device 38. Thestopper 30 is compressed as shown at 30A when it enters thestopper tube 36. Thestopper 30A seals thestopper tube 36 from the flexiblestopper transport device 38. In that stage, an optional higher vacuum between 0.01 and 300 millibars, P3 (P1>P2>P3) can be provided by the vacuum system. Also in that stage, thestopper 30A can be held on this position by an optional holding device for a specific duration of evacuation. After the evacuation of the smaller vacuum chamber between thestopper 30A,stopper tube 36 and thesyringe 32, the pressure difference between inside thesyringe 32 and above thestopper 30A (inside the flexiblestopper transport device 38 and the upper section of the stopper tube 36) forces thestopper 30A to move down through thestopper tube 36 into thesyringe 32 to position 30B. As an option, the pressure inside the flexiblestopper transport device 38 and the upper section of thestopper tube 36 can be increased by venting or providing an additional air pressure supply atport 40 at that stage. Thestopper tube 36 returns to its home position bymovement 42, and a new cycle can start. Similar to the vacuum assisted stopper insertion previously described, the final position of thestopper 30B after the insertion into the filledsyringe 32 depends also on the pressure difference P1>P4. After thestopper 30B reaches the lowest position, a gas volume between thestopper 30B and fillingliquid 34 can remain. The pressure P4 of this gas volume would be close to the system's environment pressure P1. Also similar to the vacuum assisted stopper insertion previously described, the final position of thestopper 30B after the insertion into the filledsyringe 32 depends on different forces that act on thestopper 30B. The first resultant force is caused by the pressure difference between inside the syringe 32 (F Inside=P4*A) and the system's environment pressure (F Outside=P1*A). “A” is the cross-sectional area of the insertedstopper 30B. The second force is friction between thesyringe 32 and the movingstopper 30B. Thestopper 30B is forced to move down until these forces are balanced. In this way the remaining gas volume between the fillingliquid 34 and thestopper 30B is reduced in comparison to the traditional stopper insertion previously described. - The above embodiments describe a simplified apparatus and method for closing a filled syringe with a stopper that has a minimum of entrapped air.
Claims (14)
1. An apparatus for inserting stoppers into prefilled syringes comprising:
(a) a stopper tube movement within a base;
(b) a stopper tube attached to the stopper tube movement;
(c) at least one radial vacuum port in the stopper tube, said ports connecting to a vacuum means;
(d) a sealing element attached to the circumference of the stopper tube;
(e) a stopper ram movement within the base, mounted adjacent to the stopper tube movement;
(f) a stopper ram affixed to the stopper ram movement, aligned within the stopper tube; and
(g) stoppers temporarily affixed to the stopper ram movement, wherein sequential timed motion of the stopper tube movement and the stopper ram movement, with vacuum application, inserts the stoppers into the syringe above a prefilled liquid.
2. The apparatus of claim 1 wherein the apparatus comprises two or more of the following elements: stopper tubes, stoppers, sealing elements, stopper rams, and syringes; thereby able to insert stoppers into multiple syringes simultaneously.
3. The apparatus of claim 1 wherein the vacuum application to insert the stoppers is between 0.01 and 4 seconds duration and to an absolute pressure of 0.01 to 300 millibars.
4. A method for inserting stoppers into prefilled syringes in an apparatus comprising a stopper tube having a vacuum means port and a sealing element, a stopper tube movement affixed to the stopper tube, a stopper ram, and a stopper ram movement affixed to the stopper ram, the method comprising the steps of:
(a) inserting the stopper into the stopper tube above the vacuum means port by lowering the stopper ram movement, stopper tube movement and attached stopper;
(b) lowering the stopper tube movement and the stopper ram movement until the sealing element seals against the syringe thereby creating a vacuum chamber including the syringe and stopper tube;
(c) evacuating the chamber to a vacuum;
(d) lowering the stopper ram and stopper below the vacuum means port and out of the stopper tube into the syringe;
(e) venting to atmospheric pressure, the stopper tube and space above the stopper thereby forcing the stopper to a position close to a prefilled liquid; and then
(f) raising the stopper ram and stopper tube up to the home position immediately prior to step (a).
5. The method of claim 4 wherein the chamber is evacuated for a period between 0.01 and 4 seconds to an absolute pressure of 0.01 to 300 millibars.
6. The method of claim 4 wherein the apparatus comprises two or more of the following elements: stopper tubes, stoppers, sealing elements, stopper rams, and syringes; thereby able to insert stoppers into multiple syringes simultaneously.
7. An apparatus for inserting stoppers into prefilled syringes using a vacuum, the apparatus comprising:
(a) a stopper tube movement within a base;
(b) a stopper tube attached to the stopper tube movement;
(c) at least one radial vacuum port in the stopper tube, said ports connecting to vacuum means;
(d) a sealing element attached to the circumferences of the stopper tube;
(e) stopper transport device having a first end attached to the top of the stopper tube; and
(f) means for feeding stoppers into a second end of the stopper transport device, wherein sequential operation of the stopper tube movement and application of vacuum and atmospheric pressure inserts the stoppers into the syringes.
8. The apparatus of claim 7 wherein the apparatus comprises two or more of the following elements: stopper tubes, stoppers, sealing elements, syringes, and stopper transport devices, thereby able to insert stoppers into multiple syringes simultaneously.
9. The apparatus of claim 7 wherein the vacuum application is to an absolute pressure of between 0.01 and 800 millibars.
10. A method for inserting stoppers into prefilled syringes in an apparatus comprising a stopper tube having a vacuum means port and a sealing element, a mechanical arm affixed to the stopper tube, and a stopper transport device affixed to the top of the stopper tube, the method comprising the steps of:
(a) lowering the mechanical arm and stopper tube until the sealing element seals at the top of the syringe;
(b) feeding a stopper into an open end of the stopper transport device;
(c) activating a vacuum in the stopper tube, syringe and transport device thereby transporting the stopper to the top of the stopper tube;
(d) activating a higher vacuum in the stopper tube and syringe thereby inserting the stopper into the syringe above a prefilled liquid; and then
(e) raising the mechanical arm and stopper tube up to the home position immediately prior to step (a).
11. The method of claim 10 wherein the apparatus comprises two or more of the following elements: stopper tubes, stoppers, sealing elements, syringes, and stopper transport devices, thereby able to insert stoppers into multiple syringes simultaneously.
12. The method of claim 10 wherein a step is added after step (d) to increase the pressure in the stopper tube transport device thereby forcing the stopper further into the syringe.
13. The method of claim 10 wherein the actuating vacuum of step (c) is between 10 and 800 millibars.
14. The method of claim 10 wherein the actuating higher vacuum of step (d) is between 0.01 and 300 millibars.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US10/982,373 US20060168916A1 (en) | 2004-11-05 | 2004-11-05 | Method and apparatus to insert stoppers into prefilled syringes |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US10/982,373 US20060168916A1 (en) | 2004-11-05 | 2004-11-05 | Method and apparatus to insert stoppers into prefilled syringes |
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US20060168916A1 true US20060168916A1 (en) | 2006-08-03 |
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US10/982,373 Abandoned US20060168916A1 (en) | 2004-11-05 | 2004-11-05 | Method and apparatus to insert stoppers into prefilled syringes |
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Cited By (12)
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US20150283030A1 (en) * | 2012-12-21 | 2015-10-08 | Peter Skufca | Primary Packaging for Storage and Administration of Medical and Pharmaceutical Compounds |
EP2995333A4 (en) * | 2013-05-10 | 2017-01-04 | Terumo Kabushiki Kaisha | Production method for pre-filled syringe, and pre-filled syringe production device |
WO2019005072A1 (en) * | 2017-06-29 | 2019-01-03 | Regeneron Pharmaceuticals Inc. | Devices and methods for overfilling drug containers |
WO2019011960A1 (en) * | 2017-07-11 | 2019-01-17 | Becton Dickinson France | Device for vacuum and vent tube stoppering a medical container |
WO2019215235A3 (en) * | 2018-05-08 | 2019-12-26 | Akroswiss Ag | Bi-dose nasal spray |
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Owner name: BASCO TECHNOLOGIES, INC., CONNECTICUT Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:GRIEBEL, ROBERT A.E.;RINK, MARKUS;MANZ, STEFAN;AND OTHERS;REEL/FRAME:016098/0407 Effective date: 20041207 |
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