Patent Publication Number: US-2021179300-A1

Title: Micro-auger powder filling apparatus

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application No. 62/596,407 filed Dec. 8, 2017, entitled “MICRO-AUGER POWDER FILLING APPARATUS,” which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     Syringes are filled with various fluids or powders. For example, powder syringes, such as hemostatic syringes dispense fluids or powders, such as wound sealant (e.g., hemostatic powder) through their dispensing ends. The dispensing ends may be luer tips that interface with other components such as fluid lines and containers. Syringes are typically filled from the plunger end using various techniques including vacuum filling, powder feeding, etc. 
     An improved syringe filling system and method is needed accordingly. 
     SUMMARY 
     The present disclosure provides improved syringe filling systems and methods. In one example embodiment, a syringe filling system includes a syringe, a powder source, a funnel, a rotatable auger, and a motor. The syringe has a dispensing end and a barrel chamber. The funnel is configured to hold powder from the powder source. The rotatable auger is positioned within the funnel and is configured to transport powder from the funnel through the dispensing end of the syringe to fill the barrel chamber of the syringe with a predetermined quantity of powder. Additionally, the motor is configured to rotate the auger to cause powder to be transported from the funnel to the syringe. 
     In another example embodiment, a syringe filling system includes a syringe, a powder source, a funnel, a rotatable auger, and a motor. The syringe has a dispensing end and a barrel chamber. The funnel has an inlet end and an outlet end. Additionally, the funnel has an inside diameter and the funnel is configured to hold powder from the powder source. The rotatable auger is positioned within the funnel, and the auger has a conveying portion with a first diameter, a transition portion, and a filling portion with a second diameter. The auger is configured to transport powder from the funnel through the dispensing end of the syringe to fill the barrel chamber of the syringe with a predetermined quantity of powder. The motor is configured to rotate the auger to cause powder to be transported from the funnel to the syringe. 
     In another example embodiment, a method for filling a syringe includes positioning a rotatable auger within a funnel. The rotatable auger has a filling portion. Powder is added from a powder source to the funnel, and the outlet end of the funnel is coupled to a dispensing end of the syringe. Additionally, at least a portion of a filling portion of the filling portion of the auger is positioned within the dispensing end of the syringe. The rotatable auger is rotated to convey powder from the funnel to the syringe. 
     In another example embodiment, a container filling system includes a container, a powder source, a funnel configured to hold powder from the powder source, a rotatable auger, and a motor. The rotatable auger is positioned within the funnel, and the auger is configured to transport powder from the funnel to the container to fill the container with a predetermined quantity of powder. The motor is configured to rotate the auger, and the rotation of the auger causes powder to be transported from the funnel to the container. 
     It is accordingly an advantage of the present disclosure to improve the quality of powder filled syringes by reducing caking and clogging of the bulk material. 
     It is another advantage of the present disclosure to reduce the amount of time needed to process and produce luer tip filled syringes. 
     It is a further advantage of the present disclosure to improve the manufacturing process by reducing syringe contamination. 
     Additional features and advantages of the disclosed syringe filling systems and methods are described in, and will be apparent from, the following Detailed Description and the Figures. The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the figures and description. Also, any particular embodiment does not have to have all of the advantages listed herein. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject matter. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a schematic view of a syringe filling system according to an example embodiment of the present disclosure. 
         FIG. 2A  is a front view of a funnel according to an example embodiment of the present disclosure. 
         FIG. 2B  is a top view of the funnel of  FIG. 2A , according to an example embodiment of the present disclosure. 
         FIG. 2C  is a cross-sectional view of the funnel of  FIG. 2A , according to an example embodiment of the present disclosure. 
         FIG. 3A  is a front view of an auger according to an example embodiment of the present disclosure. 
         FIG. 3B  is a top view of the auger of  FIG. 3A , according to an example embodiment of the present disclosure. 
         FIG. 3C  is a cross-sectional view of the auger of  FIG. 3A , according to an example embodiment of the present disclosure. 
         FIG. 4  illustrates a flowchart of an example process for filling a syringe, according to an example embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS 
     As discussed above, syringe filling systems and methods are provided to improve the manufacturing process, quality of the finished filled syringe product, and processing speed. Empty containers (e.g., syringes) are moved down a production line to final packing. A filling station is configured such that the containers are filled through their dispensing ends with powder. A funnel and rotatable auger convey powder from a powder source to the container. For example, the rotatable auger may convey power through the dispensing end of the syringe to fill the syringe barrel. 
     Referring to the drawings and in particular to  FIG. 1 , in one embodiment, a syringe filling system  100  of the present disclosure is provided to fill containers, such as syringes  102 . In one embodiment, the syringe filling system  100  includes a syringe  102 , a funnel  110 , an auger  120 , a control unit  130 , a motor  140 , a power source  150 , and a powder source  160 . Control unit  130  may include one or more processor (e.g., CPU  132 ) and one or more memory (e.g., memory device  134 ). 
     As used herein, the term, “processor” may refer to a device capable of executing instructions encoding arithmetic, logical, and/or I/O operations. As used herein, the term, “memory” may refer to a volatile or non-volatile memory device, such as RAM, ROM, EEPROM, or any other device capable of storing data. 
     Control unit  130  may be programmed to store multiple selectable programs to cause the syringe  102  to be transported along a production line to different filling systems  100 . For example, a filling system  100  may be configured for a specific powder  152  or medication and/or a specific syringe size. Additionally, selectable programs may include various predetermined quantities of powder  162  to fill syringes  102 . For example, the control unit  130  may be programmed to store multiple programs based on syringe size, powder sources  160 , etc. 
     As illustrated in  FIG. 1 , syringe  102  includes a dispensing end  182 , such as a luer tip. Additionally, syringe  102  includes a barrel chamber  182  and a seal  192  with a leading ring  194  and a trailing ring  196 . Syringe  102  also includes a plunger  186 , barrel flange  188 , and plunger flange  190 . The syringe filling system  100  is configured to fill the barrel chamber  182  with a predetermined quantity of powder  162  from powder source  160 . 
     Specifically, auger  120  is configured to convey powder  162  from funnel  110  through the dispensing end  182  and into barrel chamber  184  of syringe  102 . For example, auger  120  engages powder in funnel  110  to convey or transport powder towards syringe  102 . The powder  162  is carried by the auger through the dispensing end  182  of the syringe and falls into barrel chamber  184 . Motor  140  continues to drive (e.g., rotate) auger  120  until the predetermined quantity exits funnel  110  and fills barrel chamber  182  of syringe  102 . Filling through the syringe&#39;s dispensing end  182  may advantageously eliminate caking of the powder  162 . For example, if filled through the barrel end of syringe  102 , the powder  162  may cake on lubricating material applied to seal  192 . As the plunger  186  and seal  192  are removed from the barrel chamber  182 , residue may be left on the inner barrel chamber wall, and powder  162  may stick and/or cake to the wall of barrel chamber  182 . 
     In another example, syringe filling system  100  may be used to fill a barrel end of syringe  102 . For example, with plunger  186  removed, the syringe filling system  100  may fill the barrel chamber  182  through the barrel end of syringe  102  with a predetermined quantity of powder  162  from powder source  160 . Additionally, filling system  100  may be used to fill other containers, for example, vials. Filling system  100  is adapted to provide precise and accurate filling for a wide variety of powder containers. For example, as discussed in more detail below, delivery tube  288  (as illustrated in  FIG. 2A  and  FIG. 2C ), may extend into barrel chamber  184  far enough to avoid any residual residue or lubrication material left on the inner wall of barrel chamber  182  when removing the plunger  186  and seal  192 . 
     Referring now to  FIGS. 2A, 2B, and 2C , an example funnel  110  is illustrated. Funnel  110  includes an inlet end  212  and an outlet end  222 . In an example, funnel  110  includes a bulk section  230 , a conveying section  240 , a transition section  250 , and a delivery section  260 . In the illustrated example, bulk section  230  is adjacent inlet end  212  and in fluid communication with conveying section  240 . Conveying section  240  is in fluid communication with delivery section  260  via transition section  250 . Delivery section  260  is adjacent outlet end  222 . Additionally Funnel  110  may include a delivery tube  288 . In an example, delivery tube may be coupled to funnel  110 . In another example, delivery tube  288  may be integrated into funnel  110 . Delivery tube  288  may be sized and arranged such that it can be inserted into the dispensing end of a syringe  102 . Additionally, the delivery tube  288  may extend beyond the end of auger  120  (discussed in more detail below) to provide a barrier between the external environment and the powder conveyed to the syringe. In an example, funnel  110  may be made from stainless steel. 
     In an example embodiment, bulk section  230  may have an inside diameter (D B )  234  that changes as it moves from a first end to a second end. For example, diameter  234  may linearly decrease from an initial inside diameter  243 A at its first end (e.g., the inlet end  212  of funnel  110 ) to a final inside diameter  234 B at its second end. The inside diameter  234  may decrease from approximately 0.90 inches to 0.25 inches. In an example embodiment, the initial inside diameter  234 A at the first end may be 0.9005 inches with a tolerance of 0.0005 inches and the final inside diameter  234 B at the second end may be 0.252 inches with a tolerance of 0.001 inches. 
     In an example embodiment, conveying section  240  may have a constant inside diameter (D C )  244 . For example, inside diameter  244  of the conveying section  240  may be substantially the same as the final inside diameter  234 B of the bulk section  230 . For example, inside diameter  244  may be approximately 0.25 inches. In an example embodiment, the inside diameter  244  may be 0.252 inches with a tolerance of 0.001 inches. Transition section  250  may have an inside diameter (D T )  254  that changes. For example, diameter  254  may linearly decrease from an initial inside diameter  254 A at its first end (e.g., end adjacent to conveying section  240 ) to a final inside diameter  254 B at its second end (e.g., end adjacent to delivery section  250 ). The inside diameter  254  may decrease from approximately 0.25 inches to 0.08 inches. In an example embodiment, the initial inside diameter  254 A may be 0.252 inches with a tolerance of 0.001 inches and the final inside diameter  254 B may be 0.077 inches with a tolerance of 0.001 inches. In an example embodiment, delivery section  260  may have a constant inside diameter (D F )  264 . For example, inside diameter  264  of the delivery section  260  may be substantially the same as the final inside diameter  254 B of the transition section  250 . For example, inside diameter  264  may be approximately 0.08 inches. In an example embodiment, the inside diameter  264  may be 0.077 inches with a tolerance of 0.001 inches. 
     In an example embodiment, funnel  110  may have an overall height of approximately 3.175 inches. In the illustrated example, bulk section  230  has a height (H B ) of approximately 1.542 inches, conveying section  240  has a height (HO of approximately 1.0 inches, transition section  250  has a height (H T ) of approximately 0.24 inches, and delivery section  260  has a height (H D ) of approximately 0.188 inches. 
     It should be appreciated that the sizes and dimensions discussed herein are merely for explanation. In various alternative embodiments, the sizing (e.g., diameters, lengths, and heights) of the auger  120  and funnel  110  is different. It should be appreciated that the relative dimensions of the constituent features discussed herein may be ratios rather than strict unitary dimensions. For example, the relationship between bulk section  230  inside diameter (D B )  234 , conveying section  240  inside diameter (D C )  244 , transition section  250  inside diameter (D T )  254 , and delivery section  260  inside diameter (D F )  264  may be described in terms of a ratio(s). Additionally, the varying diameters (D B )  234  and (D T )  254  may be described as a slope or as a percent diameter reduction per unit length. The diameters may also be related to the heights of the funnel  110 . Similarly, the relationship between the various funnel  110  section heights may be described in terms of one or more ratios. For example, bulk section  230  height (H B ), conveying section  240  height (H C ), transition section  250  height (H T ), and delivery section  260  height (H D ) may be described in terms of a ratio(s). Additionally, the sizes and dimensions discussed herein may be based on syringe size, syringe application, syringe dispensing tip geometry (e.g., luer tip geometry), powder properties (e.g., particle quantity, particle size, bulk particle viscosity), and manufacturing parameters, including but not limited to, rotational speed of auger  120 , speed of processing line or fill line, etc. Accordingly, though not all calculated and discussed in detail herein, it should be appreciated that the ratios of respective example dimensions discussed above can be calculated and scaled for alternative goals and embodiments. 
     Referring now to  FIGS. 3A, 3B, and 3C , an example auger  120  is illustrated. Auger  120  includes a shaft  376  and threads or flight  378 . Auger  120  may also include a shank  372  and a tang  374 . In the illustrated example, the threaded portion of auger  120  includes a conveying portion  340 , a transition portion  350 , and a filling portion  360 . In the illustrated example, transition portion  350  is positioned between the conveying portion  340  and filling portion  360 . During filling operations, filling portion  360  may partially extend into delivery tube  288 . For example, during filling operations, both a portion of the delivery tube  288  and the filling portion  360  of auger  120  may be inside dispensing end  182  of syringe  102 . In an example, auger  120  may be made from stainless steel. 
     Threads or flight  378  have pitch  382  and a thread height  384 . In an example embodiment, the pitch  382  may be 0.25 inches and thread height  384  may be approximately 0.045 inches in the conveying portion  340 . At the filling portion  360 , thread height  384  may be reduced to 0.012 inches. In an example, the thread height may be adjusted to change the quantity or amount of powder that the auger conveys per rotation. For example, taller threads (e.g., larger thread heights) may convey larger quantities of powder  162  per rotation since the additional height supports or carries more powder (e.g., there is more thread or flight surface to support the powder). Additionally, smaller thread heights may convey less powder  162  per auger  120  rotation because there is less thread surface to support the powder. 
     Conveying portion  340  may have a constant shaft diameter  390 A. For example, shaft diameter  390 A may be approximately 0.160 inches. Shaft diameter  390 B of the transition portion  350  may change as it transitions from conveying portion  340  to filling portion  360 . Filling portion  360  may have a constant shaft diameter  390 C. For example, shaft diameter  390 C may be approximately 0.040 inches. For example, inside diameter  264  may be approximately 0.08 inches. In an example embodiment, the inside diameter  264  may be 0.077 inches with a tolerance of 0.001 inches. 
     The threaded portion of auger  120  may have an overall length of approximately 3.0 inches. In the illustrated example, conveying portion  340  has a length (L C ) of approximately 2.173 inches, transition portion  350  has a length (L T ) of approximately 0.262 inches, and filling portion  360  has a length (L F ) of approximately 0.490 inches. 
     As discussed above, thread height  384 , pitch  382 , shaft diameter  290 , screw diameter (e.g., diameter of shaft accounting thread height), shaft length, conveying portion  340  length (L C ), transition portion  350  length (L T ), and filling portion  360  length (L F ) can vary based on one or more of the complimentary funnel  110 , filling apparatus, and syringe  102  appropriate for perspective application of the filling device or system  100 . Similarly, as discussed above, the relative dimensions of the auger  120  features may be ratios rather than strict unitary dimensions. 
       FIG. 4  illustrates a flowchart of an example method  400  for filling a syringe in accordance with an example embodiment of the present disclosure. The flowchart of  FIG. 4  may be implemented at control unit  130 . Although the example method  400  is described with reference to the flowchart illustrated in  FIG. 4 , it should be appreciated that many other methods of performing the acts associated with the method  400  may be used. For example, the order of some of the blocks may be changed, certain blocks may be combined with other blocks, and some of the blocks described are optional. The method  400  may be performed by processing logic that may include hardware (circuitry, dedicated logic, etc.), software, or a combination of both. 
     At oval  402 , method  400  begins. At block  410 , example method  400  positions a rotatable auger  120  within a funnel  110 . For example, rotatable auger  120  is positioned such that the filling portion  360  partially extends beyond the outlet end  222  of funnel  110 . At block  420 , example method  400  adds powder  162  from a powder source  160  to the funnel  110 . At block  430 , example method  400  couples the outlet end  222  of the funnel  110  to a dispensing end  182  of the syringe  102 . For example, funnel  110  may be fitted with a luer lock connection that engages a luer tip of the syringe  102 . At block  440 , example method  400  positions a portion of the filling portion  360  of the auger  120  within the dispensing end  182  the syringe  102 . For example, as the outlet end  222  of the funnel  110  is coupled to the syringe  102 , the filling portion  360  of the auger extends into the dispensing end  182  of the syringe  102 . At block  450 , example method  400  also rotates the rotatable auger  120  to convey powder  162  from the funnel  110  to the syringe  102 . As the auger  120  rotates, powder  162  is carried along threads or flight  378  from the conveying portion  340  of the auger  120  towards to filling portion  360 . The auger  120  and funnel  110  are configured and arranged such that the powder  162  in contact with auger  120  is conveyed downward towards syringe  102 . As the auger rotates, powder traveling along the threads or flight  378  falls off the end of the filling portion  360  and into the syringe  102 . At oval  462 , method  400  ends. Powder  162  is prevented from exiting funnel  110  when the auger  120  is stationary from the viscosity of the powder and the interactions between the powder  162 , auger  120 , and/or funnel  110 . For example, the powder  162  may have sufficient viscosity such that the powder  162  does not exit funnel  110 . Additionally, friction between particles of powder  162 , auger  120 , and/or funnel  110  may prevent the powder  162  from existing funnel  110 . Other interactions such as mechanical interlocking and inter-particulate cohesion may also prevent powder  162  from exiting funnel  110  when auger  120  is stationary. 
     In another example, method  400  may be used to fill a syringe  102  through its barrel end, which may advantageously eliminate caking of the powder  162 . Additionally, method  400  may be used to fill other containers, such as a medical vial. For example, method  400  may be used to provide precise and accurate filling for a wide variety of powder containers. 
     Aspects of the subject matter described herein may be useful alone or in combination with one or more other aspects described herein. In an exemplary aspect of the present disclosure, a syringe filling system includes a syringe having a dispensing end and a barrel chamber, a powder source, a funnel configured to hold powder from the powder source, a rotatable auger positioned within the funnel, and a motor. The auger is configured to transport powder from the funnel through the dispensing end of the syringe to fill the barrel chamber of the syringe with a predetermined quantity of powder. The motor is configured to rotate the auger. Additionally rotation of the auger causes powder to be transported from the funnel to the syringe. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the dispensing end includes a luer tip. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the powder is configured to seal a wound. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the powder is a hemostatic powder. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the funnel has an outlet end having an inside diameter, the auger having a filling portion with an outside diameter, the outside diameter being smaller than the inside diameter. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the funnel is configured to present powder to the auger. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the auger has a conveying portion, a transition portion, and a filling portion. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the conveying portion has a first diameter and the filling portion has a second diameter, the second diameter small than the first diameter. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the transition portion has a first end having the first diameter and a second end having the second diameter. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the transition portion has a first end having the first diameter and a second end having the second diameter. 
     Aspects of the subject matter described herein may be useful alone or in combination with one or more other aspects described herein. In an exemplary aspect of the present disclosure, a syringe filling system includes a syringe having a dispensing end and a barrel chamber, a powder source, a funnel, a rotatable auger, and a motor. The funnel has an inlet end and an outlet end. Additionally, the funnel has an inside diameter and the funnel is configured to hold powder from the powder source. The rotatable auger is positioned within the funnel. The auger has a conveying portion with a first diameter, a transition portion, and a filling portion with a second diameter. The auger is configured to transport powder from the funnel through the dispensing end of the syringe to fill the barrel chamber of the syringe with a predetermined quantity of powder. The motor is configured to rotate the auger, where rotation of the auger causes powder to be transported from the funnel to the syringe. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the dispensing end includes a luer tip. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the powder is configured to seal a wound. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the powder is a hemostatic powder. 
     Aspects of the subject matter described herein may be useful alone or in combination with one or more other aspects described herein. In an exemplary aspect of the present disclosure, a method for filling a syringe includes positioning a rotatable auger within a funnel, the rotatable auger having a filling portion, adding powder from a powder source to the funnel, coupling the outlet end of the funnel to a dispensing end of the syringe, positioning at least a portion of the filling portion of the auger within the dispensing end of the syringe, and rotating the rotatable auger to convey powder from the funnel to the syringe. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the method further includes ceasing rotation of the rotatable auger once a predetermined quantity of the powder is conveyed to the syringe. 
     Aspects of the subject matter described herein may be useful alone or in combination with one or more other aspects described herein. In an exemplary aspect of the present disclosure, a container filling system includes a container, a powder source, a funnel configured to hold powder from the powder source, a rotatable auger positioned within the funnel, and a motor. The auger is configured to transport powder from the funnel to the container to fill the container with a predetermined quantity of powder. The motor is configured to rotate the auger. Additionally, rotation of the auger causes powder to be transported from the funnel to the container. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the container is one of a syringe and a vial. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the container is a syringe and the syringe has a dispensing end and a barrel end. 
     In another exemplary aspect of the present disclosure, which may be used in combination with any one or more of the preceding aspects, the rotation of the auger causes powder to be transported from the funnel to the syringe through the barrel end of the syringe. 
     To the extent that any of these aspects are mutually exclusive, it should be understood that such mutual exclusivity shall not limit in any way the combination of such aspects with any other aspect whether or not such aspect is explicitly recited. Any of these aspects may be claimed, without limitation, as a system, method, apparatus, device, medium, etc. 
     The many features and advantages of the present disclosure are apparent from the written description, and thus, the appended claims are intended to cover all such features and advantages of the disclosure. Further, since numerous modifications and changes will readily occur to those skilled in the art, the present disclosure is not limited to the exact construction and operation as illustrated and described. Therefore, the described embodiments should be taken as illustrative and not restrictive, and the disclosure should not be limited to the details given herein but should be defined by the following claims and their full scope of equivalents, whether foreseeable or unforeseeable now or in the future.