Sealability evaluation method and the like and standard artificial leak device
11408795 · 2022-08-09
Assignee
Inventors
Cpc classification
International classification
G01M3/26
PHYSICS
G01M3/28
PHYSICS
Abstract
It is an object of the present invention to enhance reliability of an allowable limit conductance used for setting a threshold value for evaluating sealability of a test object, and further, enhance reliability of the sealability evaluation. By leak testing a test object 9A with a sealing defect 9g, a leakage characteristic that shows a relationship between an internal-external pressure difference and a leak flow rate is obtained. A conductance of a test object with a similar artificial leak 9B having a similar artificial leak device 29 disposed therein, conducting the leak-detected substance is measured. The similar artificial leak device 29 has a leakage characteristic similar to the obtained leakage characteristic. An allowable limit conductance is obtained based on results of the measurement. Sealability of a test object 9 is evaluated based on a threshold value set with a standard artificial leak device 9S having the allowable limit conductance.
Claims
1. A method for evaluating sealability of a test object as an object of evaluation, the method comprising steps of: obtaining a leakage characteristic showing a relationship between an internal-external pressure difference and a leak flow rate of a test object with a sealing defect by leak-testing the test object with the sealing defect; determining which among a turbulent flow characteristic, a laminar flow characteristic and a molecular flow characteristic the leakage characteristic has; measuring a conductance with respect to the leak-detected substance in a test object with a similar artificial leak, the test object with the similar artificial leak having a similar artificial leak device disposed therein, the similar artificial leak device having a leakage characteristic similar to the obtained leakage characteristic; selecting an orifice as the test object with the similar artificial leak when the leakage characteristic has the turbulent flow characteristic; selecting a capillary as the test object with the similar artificial leak when the leakage characteristic has the laminar flow characteristic; selecting a micropipette as the test object with the similar artificial leak when the leakage characteristic has the molecular flow characteristic; obtaining an allowable limit conductance at which leakage of a leak-detected substance to an inside or an outside of the test object as the object of evaluation reaches an allowable limit based on results of the measurement; and evaluating the sealability of the test object against a threshold value set with a standard artificial leak device having the allowable limit conductance.
2. The method according to claim 1, wherein a fluid pressure of a fluid in a same phase state as the leak-detected substance is applied to the test object with the sealing defect in the step of obtaining a leakage characteristic.
3. A method for setting a threshold value for a sealability evaluation of a test object as an object of evaluation, the method comprising steps of: obtaining a leakage characteristic showing a relationship between an internal-external pressure difference and a leak flow rate of a test object with a sealing defect by leak-testing the test object with the sealing defect; determining which among a turbulent flow characteristic, a laminar flow characteristic and a molecular flow characteristic the leakage characteristic has; measuring a conductance with respect to the leak-detected substance in a test object with a similar artificial leak, the test object with the similar artificial leak having a similar artificial leak device disposed therein, the similar artificial leak device having a leakage characteristic similar to the obtained leakage characteristic; selecting an orifice as the test object with the similar artificial leak when the leakage characteristic has the turbulent flow characteristic; selecting a capillary as the test object with the similar artificial leak when the leakage characteristic has the laminar flow characteristic; selecting a micropipette as the test object with the similar artificial leak when the leakage characteristic has the molecular flow characteristic; obtaining an allowable limit conductance at which leakage of a leak-detected substance to an inside or an outside of the test object as the object of evaluation reaches an allowable limit based on results of the measurement; and setting the threshold value with a standard artificial leak device having the allowable limit conductance.
4. The method according to claim 3, wherein a fluid pressure of a fluid in a same phase state as the leak-detected substance is applied to the test object with the sealing defect in the step of obtaining a leakage characteristic.
5. A method for manufacturing a standard artificial leak device for a sealability evaluation, the method comprising steps of: obtaining a leakage characteristic showing a relationship between an internal-external pressure difference and a leak flow rate of a test object with a sealing defect by leak-testing the test object with the sealing defect; determining which among a turbulent flow characteristic, a laminar flow characteristic and a molecular flow characteristic the leakage characteristic has; measuring a conductance of a test object with a similar artificial leak conducting the leak- detected substance, the test object with the similar artificial leak having a similar artificial leak device disposed therein, the similar artificial leak device having a leakage characteristic similar to the obtained leakage characteristic; selecting an orifice as the test object with the similar artificial leak when the leakage characteristic has the turbulent flow characteristic; selecting a capillary as the test object with the similar artificial leak when the leakage characteristic has the laminar flow characteristic; selecting a micropipette as the test object with the similar artificial leak when the leakage characteristic has the molecular flow characteristic; obtaining an allowable limit conductance at which leakage of a leak-detected substance to an inside or an outside of the test object reaches an allowable limit based on results of the measurement; manufacturing a standard artificial leak device comprising an orifice when the test object with the similar artificial leak is an orifice, manufacturing a standard artificial leak device comprising a capillary when the test object with the similar artificial leak is a capillary, and manufacturing a standard artificial leak device comprising a micropipette when the test object with the similar artificial leak is a micropipette; and setting a flow passage cross-sectional area and a flow passage length of the standard artificial leak device such that a conductance of the standard artificial leak device is the allowable limit conductance.
6. The method according to claim 5, wherein a fluid pressure of a fluid in a same phase state as the leak-detected substance is applied to the test object with the sealing defect in the step of obtaining a leakage characteristic.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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MODE FOR CARRYING OUT THE INVENTION
(12) One embodiment of the present invention will be described hereinafter with reference to the drawings.
(13) As shown in
(14) The leak-detected substance is a substance that affects quality of contents of the test object 9, which may include oxygen, water vapor and air, for example. The leak-detected substance may be bacteria.
(15) A variety of the leak-detected substance is not limited to one. Multiple components such as oxygen and water vapor may be selected as the leak-detected substance.
(16) The test object as an object of a sealability evaluation is not limited to the vial container, but may be a blister package, an eye lotion container, a gasoline tank, an engine component, an electronic component and any other goods for which sealability is required.
(17) For example, leakage of a specific leak-detected substance from an inside of a test object, which may include leakage of pharmaceutical ingredients from an inside of a vial container and leakage of gasoline from a gasoline tank, to an outside may be evaluated.
(18) To evaluate the sealability mentioned above, a threshold value for the evaluation is set in the following manner:
(19) <Leakage Characteristic Obtaining Step>
(20) As shown in
(21) Further, as shown in
(22) The leakage characteristic testing apparatus 10 includes a test path 11, an internal-external pressure difference setter 12 and a leak flow rate measuring instrument 13. A pressure source 2 such as an air compressor is connected to an upstream end of the test path 11. A chamber 3 is disposed at a downstream end of the test path 11.
(23) The internal-external pressure difference setter 12 and the leak flow rate measuring instrument 13 are disposed on the test path 11. The internal-external pressure difference setter 12 is a pressure control valve (regulator), for example. The leak flow rate measuring instrument 13 may be a flow rate sensor or may be a pressure sensor. In a case where the leak flow rate measuring instrument 13 is a pressure sensor, a flow rate is calculated from inner volumes and measured pressures of the test path 11 and the chamber 3. Further, a temperature correction may be performed. The pressure sensor may be a gauge pressure sensor or may be a differential pressure sensor.
(24) For the sake of accuracy and reliability, it is preferable to use a differential pressure type air leak tester (see
(25) A leakage characteristic is obtained using the test object with the sealing defect 9A and the leakage characteristic testing apparatus 10 in the following manner:
(26) The test object with the sealing defect 9A is placed inside the chamber 3 and the chamber 3 is sealed. An internal pressure of the test object with the sealing defect 9A is an atmospheric pressure, for example.
(27) A secondary pressure of the internal-external pressure difference setter 12 is introduced into the chamber 3 via the test path 11. Thereby, an internal-external pressure difference ΔP.sub.9A is generated between an internal space of the test object 9A and a space-surrounding-test object 3a (space outside of the test object 9A) between an inner wall of the chamber 3 and an outer surface of the test object with the sealing defect 9A. The internal-external pressure difference ΔP.sub.9A can be adjusted by a secondary pressure setting of the internal-external pressure difference setter 12. Due to the internal-external pressure difference, air leakage is generated from the space-surrounding-test object 3a to an inside of the test object 9A via the sealing defect 9g. The leak flow rate Q.sub.9A is measured with the leak flow rate measuring instrument 13.
(28) Leakage may be generated from the inside of the test object 9A to the space-surrounding-test object 3a via the sealing defect 9g by making a pressure of the space-surrounding-test object 3a negative by using a vacuum pump as the pressure source 2.
(29) By using a test object 9A similar to the actual test object 9 (
(30) The internal-external pressure difference ΔP.sub.9A is changed by the internal-external pressure difference setter 12 and for each internal-external pressure difference, the leak flow rate Q.sub.9A is measured with the leak flow rate measuring instrument 13.
(31) Thereby, as shown in
(32) The leakage characteristic tends to be different according to a configuration of the sealing defect 9g. For example, when the sealing defect 9g has an orifice configuration (pinhole configuration), the leak flow rate Q.sub.9A varies linearly or logarithmically with respect to the internal-external pressure difference ΔP.sub.9A. That is, as the internal-external pressure difference ΔP.sub.9A is increased, the leak flow rate Q.sub.9A is increased in a proportional manner or as the internal-external pressure difference ΔP.sub.9A is increased, a gradient of increase of the leak flow rate Q.sub.9A is gradually decreased (thin line of
(33)
(34) Expression 1 is applicable to a choked flow and Expression 2 is applicable to a subsonic flow. In Expression 1 and Expression 2, Q denotes a flow rate (L/min), C denotes a sonic conductance (dm.sup.3/(s.Math.bar)), P.sub.1 denotes an inlet pressure, i.e. a pressure (MPa abs) set by the internal-external pressure difference setter 12, P.sub.2 denotes an outlet pressure, i.e. an internal pressure (MPa abs) of the test object with the sealing defect 9A, T denotes an absolute temperature (K) and b denotes a critical pressure rate.
(35) In the sealing defect 9g having an orifice configuration, the flow of the leak is a turbulent flow, showing a leakage characteristic specific to a turbulent flow.
(36) In the sealing defect 9g having a capillary configuration (elongated hole configuration), a leakage characteristic is quadric. That is, as the internal-external pressure difference ΔP.sub.9A is increased, a gradient of increase of the leak flow rate Q.sub.9A is gradually increased (thick line of
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(38) In Expression 3, Q.sub.G denotes a flow rate (Pa.Math.m.sup.3/s), D denotes a diameter of pipe, i.e. sealing defect 9g (m), η.sub.G denotes viscosity coefficient of gas (Pa.Math.s), L denotes a length of pipe, i.e. sealing defect 9g (m) and P.sub.1 and P.sub.2 are same as in Expression 1.
(39) In the sealing defect 9g having a capillary configuration, the flow of the leak is a laminar flow, showing a leakage characteristic specific to a laminar flow.
(40) Further, when a hole diameter of the sealing defect 9g is minute, the flow of the leak is a molecular flow, showing a leakage characteristic specific to a molecular flow.
(41) <Similar Artificial Leak Device Selecting Step>
(42) As shown in
(43) For example, when the leakage characteristic is that of a turbulent flow, an artificial leak device 29A that is an orifice is selected (
(44) When the leakage characteristic is that of a laminar flow, an artificial leak device 29B that is a capillary is selected (
(45) When the leakage characteristic is that of a molecular flow, an artificial leak device 29C that is a micropipette is selected (
(46) Further, a plurality of the selected kind of similar artificial leak devices 29 having different hole dimensions, and further different conductance, are prepared.
(47) In a case where the artificial leak device 29A is an orifice, a plurality of the artificial leak devices 29A that are different only in hole diameter (flow passage cross-sectional area) may be prepared.
(48) In a case where the artificial leak device 29B is a capillary or where the artificial leak device 29C is a micropipette, a plurality of the artificial leak devices that have a same hole diameter (flow passage cross-sectional area) and different hole lengths (flow passage lengths) may be prepared, a plurality of the artificial leak devices that have a same hole length (flow passage length) and different hole diameters (flow passage cross-sectional areas) may be prepared, or a plurality of the artificial leak devices that have different hole diameters (flow passage cross-sectional areas) and different hole lengths (flow passage lengths) may be prepared.
(49) <Test Object with Similar Artificial Leak Preparing Step>
(50) As shown in
(51) The test object 9 having the similar artificial leak device 29 disposed therein is referred to as a “test object with a similar artificial leak 9B” hereinafter.
(52) Further, a plurality of test objects with the similar artificial leak 9B are made by preparing a plurality of test objects 9 and respectively disposing a plurality of similar artificial leak devices 29 that are different in the conductance in the test objects 9.
(53) <Conductance Measurement Step>
(54) As shown in
(55) Further, a plurality of test chambers 21 are prepared and a plurality of test objects with the similar artificial leak 9B that are different in the conductance are respectively placed in the test chambers 21.
(56) An atmosphere gas in an inner space of the test chamber 21, i.e. in a space-surrounding-test object 21a between an inner wall of the test chamber 21 and an outer surface of the test object with the similar artificial leak 9B is replaced with a gas containing the leak-detected substance. An inside of the test object with the similar artificial leak 9B and the space-surrounding-test object 21a are communicated via the hole of the similar artificial leak device 29.
(57) By using the test object with the similar artificial leak 9B having the similar artificial leak device 29 disposed therein, artificial leakage can be generated in equivalent conditions to those of the actual test object 9 (
(58) As shown in
(59) A measuring time T.sub.9B is from a few days to several months, for example.
(60) The leak flow rate can be calculated from an initial concentration (0%) of the leak-detected substance inside the test object with the similar artificial leak 9B and a concentration thereof after the passage of the measuring time.
(61) A plurality of thin lines a, b, c, d in the graph of
(62) <Allowable Limit Conductance Obtaining Step>
(63) An allowable limit conductance at which leakage of the leak-detected substance reaches an allowable limit is obtained from the results of the measurements of the conductance. An allowable limit of a leak flow rate is a maximum leak flow rate at which quality of contents such as pharmaceuticals to be contained in the test object 9 can be maintained until an end of a quality assurance period, for example. The quality assurance period is an effective period in which quality and efficacy of the contents such as pharmaceuticals can be maintained, for example.
(64) For example, in the graph of
(65) When there are a plurality of leak-detected substances such as oxygen and water vapor, the test chamber 21 is prepared for each kind of the leak-detected substances, and the allowable limit conductance is obtained for each leak-detected substance. Preferably, among the obtained allowable limit conductance, the most restrictive one is selected as the allowable limit conductance to be used in steps given below.
(66) <Standard Artificial Leak Device Manufacturing Step>
(67) Subsequently, a standard artificial leak device 39 having the allowable limit conductance is prepared as shown in
(68) The standard artificial leak device 39 in
(69) A flow passage cross-sectional area (hole diameter) and a flow passage length of the standard artificial leak device 39 are determined such that a conductance of the standard artificial leak device 39 is the allowable limit conductance while referring to the flow passage cross-sectional area (hole diameter) and the flow passage length of the similar artificial leak device 29 and the measured conductance mentioned above (
(70) <Threshold Value Setting Step>
(71) As shown in
(72) The test object 9 with the standard artificial leak device 39 disposed therein is referred to as a “test object with the standard artificial leak 9S” hereinafter.
(73) Further, a leak testing apparatus 30 is prepared. A differential pressure type air leak tester may be used as the leak testing apparatus 30, for example. The leak testing apparatus 30 includes a test pressure setter 32 that is a pressure control valve (regulator), a leakage measuring instrument 33 that is a differential pressure sensor, a work capsule 34, a master tank 35, valves 36, 37, 38 and a test path 31 connecting them. The pressure source 2 is connected to an upstream end of the test path 31.
(74) The test object with the standard artificial leak 9S is placed in the work capsule 34 and the work capsule 34 is sealed. An inner space of the work capsule 34, that is a space-surrounding-test object 34a between an inner wall of the work capsule 34 and an outer surface of the test object with the standard artificial leak 9S, and an inside of the test object with the standard artificial leak 9S are communicated via the hole of the standard artificial leak device 39.
(75) A test pressure is set by the test pressure setter 32. The valves 36, 37, 38 are opened to introduce the test pressure to the work capsule 34 and the master tank 35. Subsequently, the valves 37, 38 are closed to make the work capsule 34 and the master tank 35 closed systems independent from each other. In the work capsule 34, gas enters the test object with the standard artificial leak 9S via the hole of the standard artificial leak device 39. Thereby, a pressure difference is generated between the work capsule 34 and the master tank 35. A time variation of the pressure difference is measured by the leakage measuring instrument 33. Based on the measured value, an entrance flow rate into the test object with the standard artificial leak 9S, i.e. a leak flow rate Q.sub.9S of the test object with the standard artificial leak 9S, can be calculated. A threshold value S is set based on the leak flow rate Q.sub.9S. The leak flow rate Q.sub.9S as it is may be used as the threshold value S. A value may be obtained by arithmetic processing such as multiplying the leak flow rate Q.sub.9S by a predetermined coefficient, and the value may be used as the threshold value S.
(76) <Sealability Evaluation Step>
(77) Sealability of the actual test object 9 is evaluated against the set threshold value S.
(78) As shown in
(79) When the leak flow rate Q.sub.9 is not greater than the threshold value S, the sealability of the test object 9 is judged to be acceptable. When the leak flow rate Q.sub.9 is greater than the threshold value S, the test object 9 is judged to be not-acceptable.
(80) As described above, in the sealability evaluation method according to the present invention, the allowable limit conductance of the standard artificial leak device 39 is derived from the measured conductance of the test object with the similar artificial leak 9B having a leakage characteristic similar to that of the test object with the sealing defect 9A. Therefore, reliability of the allowable limit conductance can be enhanced and further, reliability of the standard artificial leak device 39 can be enhanced. Furthermore, reliability of the sealability evaluation can be enhanced.
(81) The present invention is not limited to the embodiments described above. Various modifications can be made without departing from the scope and spirit of the invention.
(82) For example, when the leak-detected substance is liquid such as chemical solution contained in the test object 9, leakage of water from the inside of the test object 9A to the space-surrounding-test object 3a via the sealing defect 9g may be generated in the leakage characteristic obtaining step by filling the inside of the test object 9A with water and making the pressure of the space-surrounding-test object 3a negative, and thereby making a water pressure of the inside of the test object 9A (fluid pressure by a fluid in a same phase state as the leak-detected substance) relatively high. The fluid pressure may be applied by liquid such as chemical solution contained in the test object 9.
(83) The threshold value S may be obtained by disposing an artificial leak path in the test path 31 of the leak testing apparatus 30 and connecting the standard artificial leak device 39 to the artificial leak path. In this case, preparation of the test object with the standard artificial leak 9S is not required.
INDUSTRIAL APPLICABILITY
(84) The present invention may be applied to a sealability evaluation of a vial container containing pharmaceutical agents and a PTP package, for example.
EXPLANATION OF REFERENCE NUMERALS
(85) 3a space-surrounding-test object (space outside of the test object) 9 test object 9A test object with a sealing defect 9B test object with a similar artificial leak 9S test object with a standard artificial leak 9g sealing defect 10 leakage characteristic testing apparatus 12 internal-external pressure difference setter 13 leak flow rate measuring instrument 21 test chamber 21a space-surrounding-test object (space outside of the test object) 29 similar artificial leak device 29A orifice (similar artificial leak device) 29B capillary (similar artificial leak device) 29C micropipette (similar artificial leak device) 30 leak testing apparatus 31 test path 32 test pressure setter 33 leakage measuring instrument 34a space-surrounding-test object (space outside of the test object) 39 standard artificial leak device