System for precise dispensing of fluids contained within disposable syringes using high stiffness plunger
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- AVAY BIOSCIENCES PTE LTD
- Filing Date
- 2026-01-31
- Publication Date
- 2026-08-06
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Figure IN2026050172_06082026_PF_FP_ABST
Abstract
Description
[0001] SYSTEM FOR PRECISE DISPENSING OF FLUIDS CONTAINED WITHIN DISPOSABLE SYRINGES USING HIGH STIFFNESS PLUNGER RELATED PATENT APPLICATION
[0002] This application claims the priority to and benefit of Indian Patent Application No.
[0003] 202541008651 filed on February 03, 2025 the disclosures of which are incorporated herein by reference
[0004] FIELD OF THE INVENTION
[0005] The present invention relates to a field of precision liquid dispensing systems. More particularly, it pertains to a system utilizing a disposable syringe with enhances accuracy and precision, suitable for applications in healthcare, liquid handling, flexible electronics manufacturing, prototyping, and chemical and biological processes.
[0006] BACKGROUND OF THE INVENTION
[0007] In conventional mass-manufactured syringes are ubiquitously used for the administration of vaccines, drugs, and other medications to humans and animals. These syringes, typically made from polymer plastics like polypropylene, offer several advantages in terms of low cost, ease of mass production, and disposability. However, the material properties and design limitations of such syringes make them unsuitable for applications requiring high precision.
[0008] Polypropylene, while being cost-effective and easily moldable, is a relatively soft material compared to metals or ceramics. Under mechanical stress, components made from polypropylene are prone to flexing and deformation, which can lead to variations in the precision of movement. In syringe designs, the polymer plunger and cylinder assembly often suffer from tolerances and inconsistencies that affect the linear motion of the plunger, leading to inaccuracies in fluid dispensing. For healthcare applications, these shortcomings are not critical because the tolerances are within acceptable limits for medication dosing. However, for applications such as dispensing conductive inks, adhesives, or other specialized materials, these inaccuracies become a significant challenge.
[0009] Existing high-precision dispensing systems often rely on entirely metallic or ceramic cylinders and pistons to achieve the necessary stiffness and accuracy. While effective, these systems have significant drawbacks. Metallic systems are expensive to manufacture, increasing the cost of acquisition for users. Furthermore, they require extensive cleaning and maintenance after each use to preventcontamination, which is both labor-intensive and material-cost-intensive. In research and development settings, where multiple materials or fluids are tested iteratively, the need to clean and maintain reusable systems after each trial adds significant overhead in terms of time and resources.
[0010] On the other hand, while disposable syringes offer the advantage of being easily replaceable and cost-effective, they lack the precision required for advanced dispensing applications. The flexible nature of the polymer stalk in conventional syringes adversely affects the transfer of motion from a motor or actuator, resulting in inconsistent linear displacement. Additionally, without structural modifications, disposable syringes cannot provide the high stiffness and fine tolerances needed for controlled fluid deposition.
[0011] Recognizing these limitations, the present invention seeks to address the dual challenges of accuracy and affordability in fluid dispensing systems. By introducing a novel method for repurposing disposable syringes, this invention combines the cost-efficiency and disposability of mass-manufactured syringes with the precision of metallic or high-stiffness components. The key innovation lies in the integration of a metallic shaft to actuate the polymer plunger within the syringe. This design enables the use of disposable syringes for high-precision applications while maintaining the stiffness and accuracy of a metallic system.
[0012] The addition of the metallic shaft significantly enhances the accuracy of motion transfer, eliminating the inconsistencies caused by the plasticity of the polymer stalk. This hybrid approach ensures that all fluid-contacting surfaces remain disposable, thereby eliminating the need for cleaning and maintenance. In research environments, this feature is particularly advantageous, as it allows researchers to rapidly switch between different materials or fluids without the risk of crosscontamination. By enabling the disposal of tainted syringes after each use, the system saves valuable time and effort that would otherwise be spent on cleaning and preparing reusable components.Furthermore, the invention incorporates additional features to enhance safety and usability. A limit switch is integrated at the distal end of the plunger’s range of motion, serving as a safeguard to prevent overextension or damage to the system. This mechanism ensures reliable and repeatable operation, even in high-stress or continuous-use scenarios.
[0013] In comparison to existing solutions, the present invention offers a unique combination of affordability, precision, and convenience. Conventional metallic dispensing systems are prohibitively expensive for many users and require significant maintenance. Disposable syringes, while cost-effective, lack the structural rigidity needed for high-precision applications. The present invention bridges this gap by leveraging the inherent advantages of both approaches.
[0014] The use of disposable syringes as the primary container for the fluid ensures that all material-contacting surfaces can be discarded after use, addressing concerns of contamination and cross-reactivity. At the same time, the integration of a metallic shaft provides the stiffness and accuracy needed for precise fluid dispensing. This hybrid design not only reduces the overall cost of the system but also makes high-precision fluid dispensing accessible to a wider range of users, including researchers, and small-scale manufacturers.
[0015] The system is particularly well-suited for applications in emerging fields such as flexible electronics manufacturing, where the deposition of conductive inks requires precise control over material flow and placement. It is equally valuable in prototyping and additive manufacturing processes, where accurate dispensing of adhesives, resins, or other materials is critical to achieving desired outcomes. By enabling fine adjustments in material output and delivering consistent results, the invention supports a wide range of applications that were previously constrained by the limitations of existing technologies.The present invention represents a significant advancement in the field of fluid dispensing systems. By repurposing disposable syringes and integrating precise dispensing controls, it addresses the shortcomings of both mass-manufactured syringes and high-cost metallic systems. The invention offers a cost-effective, scalable, and user-friendly solution for high-precision fluid dispensing, making it a valuable tool for a variety of industries and applications. This innovation not only enhances the accuracy and reliability of fluid dispensing but also reduces the overall cost and complexity of operation, paving the way for broader adoption in diverse fields.
[0016] OBJECTS OF THE INVENTION
[0017] The primary object of the present invention is to provide a cost-effective and precise fluid dispensing system.
[0018] Another object of the invention is to enhance the structural integrity and operational precision of disposable syringes.
[0019] Yet another object of the invention is to simplify cleaning and maintenance requirements by retaining the disposable nature of parts that come into direct contact with the fluid.
[0020] A further object of the invention is to incorporate a robust and reliable mechanism with integrated safety features to prevent overrun and potential damage during operation.
[0021] SUMMARY OF THE INVENTION
[0022] The present invention relates to an improved syringe system designed for enhanced precision and accuracy in liquid dispensing. The syringe system is configured with two primary components: a conventional syringe cylinder body and an upgraded piston assembly. The cylinder body retains its standard configuration, incorporatinga Luer-lock or other suitable nozzle or needle adaptor to provide a small-diameter outlet. This design ensures that liquid is dispensed with high precision and accuracy.
[0023] The piston assembly is innovatively modified to replace the conventional polymer-based shaft with a metallic shaft. The metallic shaft provides enhanced rigidity, eliminating the bending or flexing associated with polymer-based stems. This rigidity allows for high-precision linear motion of the plunger, leading to accurate dispensing of liquid volumes. The plunger, typically made of rubber, silicone, or similar soft materials, ensures an effective liquid seal within the cylinder, while the metallic shaft ensures reliable force transfer during operation.
[0024] To further enhance the precision of the dispensing system, the metallic shaft is connected to a plate mounted on a linear rail, enabling controlled one-dimensional motion. The plate is actuated by a threaded shaft, which is rotated by a motor, preferably a stepper or servo motor. The accurate step-based rotation of the motor, combined with the precise pitch of the threaded shaft, facilitates sub -millimeter linear motion accuracy. This precise motion of the metallic shaft translates directly to highly accurate liquid volume dispensing due to the fixed internal diameter of the syringe cylinder, ensuring minimal tolerance variations.
[0025] The invention thus introduces a mechanically robust and highly precise dispensing system suitable for applications requiring controlled and accurate liquid delivery. This enhanced system addresses the limitations of conventional syringe designs by integrating a metallic shaft, a motor-driven actuation mechanism, and a linear rail, ensuring reliability and accuracy across diverse operating conditions.
[0026] BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The drawings described herein are intended to provide a further understanding of the invention and are intended to be a part of the invention. However, the drawings as shown are representative for illustration and are non-limiting the scope of the invention. The drawings are described as below:Figure 1: Depicts various views illustrating the system for precise dispensing of fluids contained within disposable syringes using a high-stiffness plunger.
[0028] • FIG.1A: Shows the proposed system including additional components for contextual reference.
[0029] • FIG.1B: Provides a side perspective view of the proposed system.
[0030] • FIG.1C: Illustrates the front view of the proposed system.
[0031] • FIG.1D: Shows a zoomed-in view of the proposed system to emphasize alignment of plunger to the metallic shaft.
[0032] Figure 2: Represents a schematic cross-sectional view of the metal shaft and the polymer / rubber plunger aligned with a complementary disposable, mass-manufactured syringe, displaying the driving component connected to the threaded shaft located behind.
[0033] • FIG.2A: Illustrates the side perspective view of the cross-sectional schematic of the metal shaft and polymer / rubber plunger
[0034] • FIG.2B: Presents the front view of the cross-sectional schematic, showcasing the alignment of the metal shaft and polymer / rubber plunger with the disposable syringe and the connection to the driving component behind the threaded shaft.
[0035] Figure 3: Depicts a schematic representation of the threaded shaft and motor system that drives the plunger shaft mechanism. The schematic also includes a limit switch to protect the syringe from potential damage due to overrun of the motor.
[0036] • FIG.3A: Shows the side perspective view of the threaded shaft and motor system with the integrated limit switch for overrun protection.
[0037] • FIG.3B: Provides the front view of the same schematic, illustrating the configuration of the plunger shaft mechanism and the safety features incorporated.
[0038] Throughout the drawings, reference numerals are employed to identify various components of the invention. The proposed system for high-precision fluiddispensing is denoted as 100, with the motor used for driving the system, typically but not exclusively stepper or servo motors, identified as 101. A plate mounted on a linear rail is designated as 102, while the linear rail is marked as 103. The lead screw (hereinafter referred as threaded shaft) is labeled as 104, and the metal shaft as 105. The polymer-based disposable gasket (hereinafter referred as plunger) is identified as 106, and the disposable syringe cylinder body is marked as 107. The luer-lock, functioning as a needle adaptor or nozzle, is denoted as 108, and the limit switch positioned at the distal end is identified as 109. A knob, designated as 110, is provided for manual operation, allowing users to rotate it by hand.
[0039] DESCRIPTION OF THE INVENTION
[0040] The present invention provides high-precision fluid dispensing system 100 utilizing disposable syringe cylinder body 107 commonly available in medical, laboratory, and industrial settings. Conventional syringes, made from materials like polypropylene, are prone to flexing under operational stresses, leading to inaccuracies in dispensing volumes. Fully metallic dispensing systems, though more precise, incur significant costs and requires frequent cleaning, making them unsuitable for many disposable or research-intensive applications. This invention bridges the gap by integrating a high-stiffness metallic shaft 105 into a disposable syringe cylinder body 107, ensuring accuracy, ease of use, and cost-effectiveness.
[0041] The existing syringe is reimagined in two parts - the existing syringe cylinder body 107 with a needle adaptor or other style of nozzle or Luer-Lock (hereinafter Luer-Lock 108) in order to provide a small diameter outlet contributing to the accuracy of the liquid dispensed. The second part is the piston, which includes a polymer-based disposable gasket (hereinafter referred as plunger 106) usually made of rubber or silicones or other soft material which can seal liquid within the syringe cylinder body 107, and a stem or shaft (hereinafter referred as shaft) which transfers the pushing force from the actuator (hand or otherwise) to the plunger 106. The invention is to replace this shaft with a metal shaft 105, which would actuate the plunger 106 in the same way, but not bend or flex as a polymer-based shaft would,thereby allowing high accuracy motion of the plunger 106 and subsequently dispensing of liquid volume. This metal shaft 105 is attached to a plate 102 mounted on a linear rail 103 to allow one-dimensional motion. This plate 102 is then actuated by another threaded shaft 104 that is rotated by a motor 101, typically but not exclusively stepper and servo motors, so the accurate step-based rotation combined with the pitch of the screw threading allows for sub-millimeter linear motion accuracy on the syringe metal shaft 105. Since the syringe diameter is fixed, this also directly translates to the accurate liquid volume dispensing based on the motional accuracy of the shaft with minimal tolerance issues.
[0042] Components and Structure
[0043] 1. Syringe Cylinder body 107 and Plunger 106:
[0044] The syringe cylinder body 107 and plunger 106, being components that come into direct contact with the dispensed material, are designed to be disposable, thereby preventing contamination and simplifying maintenance. The syringe cylinder body 107 is further equipped with a Luer-lock 108 interface, enabling seamless compatibility with downstream applications such as needles, pipes, or adhesive nozzles.
[0045] 2. Metal Shaft 105:
[0046] The polymer shaft of conventional syringes is replaced with a high-stiffness metal shaft 105 made from materials such as steel, aluminum, ceramic, or high-strength polymers. The metal shaft 105 provides superior rigidity, eliminating the flexing observed in polymer shafts. This rigidity translates to higher accuracy in motion transfer, enabling precise control over the dispensed fluid volume. The shaft is machined to seamlessly interface with the rubber plunger 106, ensuring a secure fit and consistent operation.
[0047] 3. Linear Rail 103 Mechanism:
[0048] The metal shaft 105 is mounted on a linear rail 103 system, guiding its motion in a single dimension. The linear rail 103 ensures smooth and precise movement, reducing mechanical play and further enhancing accuracy. Theuse of a linear rail 103 also supports the robust operation of the dispensing system, particularly in high-repetition or automated setups.
[0049] Actuation Mechanism:
[0050] The motion of the metal shaft 105 is actuated by a motor 101 connected to a threaded shaft 104. The motor 101, typically a stepper or servo type, translates rotational motion into linear displacement through the threaded shaft 104. The combination of the motor’s step-based control and the threaded shaft’s 104 pitch allows sub -millimeter precision in the metal shaft’s 105 motion. This precision directly correlates with the volume of fluid dispensed, ensuring highly accurate dosing.
[0051] Limit Switch 109 for Safety:
[0052] To prevent damage to the syringe assembly and the dispensing system, a limit switch 109 is positioned at the distal end of the motion. The limit switch 109, which may be optical, mechanical, or of another suitable type, signals the motor controller to halt motion when the shaft reaches its operational limit. This safety feature protects the syringe from overrun, preventing breakage or misalignment during use.
[0053] Manual Rotation Attachment:
[0054] A manual rotation knob, designated as 110, is provided for user-controlled operation. The knob features serrations for improved grip and is directly connected to the threaded shaft 104, which is also driven by the motor 101.
[0055] This integration allows seamless transition between manual and automated operation.
[0056] When manual control is required, the motor 101 can be disengaged, freeing the threaded shaft 104 for direct rotation by hand. Since the threaded shaft 104 is responsible for actuating the plunger 106 via the metal shaft 105, rotating the knob 110 enables precise extrusion of material. This manual functionality is particularly useful for controlled dispensing of small quantities, allowing fine adjustments to the dispensed volume as per the user's needs.Working Principles
[0057] The system operates by converting the motor’s rotational motion into precise linear motion of the metal shaft 105. The linear rail 103 ensures that the shaft moves in a straight path, maintaining alignment with the syringe plunger 106. As the shaft advances, it pushes the plunger 106, forcing fluid out through the syringe’s luer-lock 108. The amount of fluid dispensed corresponds to the shaft’s displacement, which is controlled by the motor’s 101 input signals.
[0058] In addition to motorized operation, the system features a manual rotation attachment that allows users to dispense material manually. The knob 110, directly connected to the threaded shaft 104, enables controlled extrusion when rotated by hand. When manual operation is required, the motor 101 is disengaged, allowing the user to precisely control the plunger’s movement by rotating the knob. This functionality is particularly useful for fine adjustments and dispensing small volumes of material.
[0059] The high-stiffness metal shaft 105 eliminates inaccuracies caused by flexing, ensuring consistent and repeatable results. The disposable nature of the syringe cylinder body 107 and plunger 106 allows for quick replacement, reducing downtime and maintenance costs. The combination of motorized precision and manual control enhances the system’s versatility, making it suitable for both automated and user-controlled dispensing applications.
[0060] Applications
[0061] The invention is highly versatile and applicable across a broad spectrum of industries. In the healthcare sector, it enables precise dosing of medications, vaccines, and other pharmaceutical substances, thereby ensuring accuracy and patient safety. Additionally, it facilitates controlled infusion systems, which are indispensable for both clinical applications and research studies requiring meticulous administration of fluids.In the domain of flexible electronics manufacturing, the invention supports advanced processes such as the deposition of conductive inks used in the fabrication of printed circuit boards and sensors. It is also instrumental in the application of adhesives and coatings during microfabrication, enhancing the reliability and efficiency of production workflows.
[0062] For laboratory research, the invention proves invaluable by enabling accurate pipetting of liquids for chemical and biological experiments. Furthermore, it streamlines the dispensing of small- volume reagents, a critical requirement in high-throughput experimental setups, thereby boosting productivity and reducing human error.
[0063] The invention also finds utility in additive manufacturing, where it can be integrated into 3D printing systems to achieve precise deposition of pastes, resins, and similar materials. This capability not only ensures the creation of intricate designs but also minimizes material wastage, making it ideal for custom prototyping and environmentally sustainable production practices.
[0064] Advantages Over Prior Art
[0065] The present system incorporates a metal shaft 105 with high stiffness, effectively eliminating flexing during operation. This design ensures precise motion transfer, resulting in accurate dispensing volumes, which are critical for applications requiring high precision. The use of such a rigid component enhances the system's reliability and repeatability, making it well- suited for precision-dependent operations.
[0066] The system achieves cost-effectiveness through the use of disposable syringe cylinders body 107 and plunger 106. Unlike fully metallic systems, this configuration significantly reduces manufacturing and maintenance expenses. The ability to replace the syringe components easily without compromisingfunctionality makes the system economical for both large-scale operations and research environments.
[0067] Maintenance is simplified by the disposable nature of the syringe components. This feature is particularly advantageous in scenarios where contamination control is paramount, such as in research facilities or high- sensitivity applications. Cleaning and component replacement are streamlined, minimizing downtime and reducing labor-intensive maintenance procedures.
[0068] To ensure safety and operational reliability, the system is equipped with a limit switch 109 mechanism. This feature prevents damage caused by overrun, thereby enhancing the longevity of the device and ensuring consistent performance. Such built-in safeguards are essential for systems operating in critical environments where reliability cannot be compromised.
[0069] The modular design of the system adds a layer of versatility, making it compatible with a range of syringe sizes and luer-lock types. This adaptability allows the system to cater to diverse applications across various industries, from medical and pharmaceutical to industrial and laboratory settings. The ability to customize the system to specific operational requirements further enhances its utility and broadens its application scope.
[0070] Optional Embodiments
[0071] The metal shaft 105 employed in the system is not limited to a specific material and may be manufactured from alternative high-stiffness materials such as ceramics, carbon composites, or reinforced polymers. These material variations are intended to optimize the shaft's performance, durability, and cost-effectiveness based on the particular requirements of the application. The flexibility in material selection ensures adaptability to diverse operating environments and performance standards.While the system primarily utilizes stepper and servo motors 101 for their high precision and control capabilities, it is not restricted to these motor types. Depending on the application's specific demands, alternative motor types, such as DC motors, may also be implemented. This flexibility in motor selection allows the system to cater to a broader range of functional and economic requirements.
[0072] The operation of the motor 101 may be governed by various advanced control systems, including remote software interfaces, integrated loT devices, or Al-based systems. These control options facilitate automated and adaptive dispensing, thereby enhancing the system's efficiency and usability. The inclusion of such advanced control mechanisms supports customization and scalability for various industrial and commercial applications.
[0073] In addition to the use of limit switches 109, the system is further equipped with enhanced safety mechanisms, including torque limiters and emergency stop buttons. These additional safety measures are designed to protect both the system and its users from operational hazards, thereby ensuring compliance with safety regulations and improving overall reliability.
[0074] Experimental Results
[0075] The invention has been successfully implemented in a syringe pump integrated with a 3-axis motion system, demonstrating significant improvements in precision. Dispensed volumes were consistent within sub-millimeter tolerances, and the disposable syringe components allowed for rapid reconfiguration between tests. The system also proved effective in reducing contamination and maintenance requirements.
[0076] Industrial Applicability
[0077] The system’s versatility, precision, and cost-effectiveness make it highly applicable across industries, including healthcare, electronics, manufacturing, and research. Itsdisposable components and modular design ensure that it can be easily scaled or customized for specific use cases, providing a competitive edge in diverse markets.
Claims
We claim:
1. A system 100 for precise dispensing of fluids from disposable syringes, comprising:a. a commercially available syringe cylinder body 107 with a polymer- based disposable plunger 106;b. a metal shaft 105 operatively connected to the plunger 106, wherein the metal shaft 105 minimizes tolerance and flexing compared to conventional polymer-based shaft;c. a plate 102 mounted on a linear rail 103, the metal shaft 105 being affixed to the plate 102 to facilitate one-dimensional linear motion; d. a threaded shaft 104 actuated by a motor 101, wherein the threaded shaft 104 interact with the plate 102 to enable sub-millimeter accuracy in linear motion; ande. a limit switch 109 at the distal end of the motion to signal the motor controller to halt motion and prevent overrun, thereby protecting the syringe and system components.f. a manual rotation knob 110 operatively connected to the threaded shaft 104, allowing manual actuation of the dispensing mechanism when the motor 101 is disengaged.
2. The system as claimed in claim 1, wherein the motor 101 is a stepper motor or servo motor, allowing precise step-based rotation and motion control.
3. The system as claimed in claim 1, wherein the metal shaft 105 is made of a high- strength material selected from the group consisting of metal, ceramic, bone, or fiber-reinforced polymer.
4. The system as claimed in claim 1, wherein the limit switch 109 is an optical mechanism, providing enhanced longevity and reliability during operation.
5. The system as claimed in claim 1, further comprising:a. a software-controlled interface enabling remote or in-situ programming of the motor 101 to customize the dispensing volume based on user input.
6. The system as claimed in claim 1, wherein the syringe nozzle includes a Luer-lock 108 mechanism or similar adapter to accommodate various outlet configurations for controlled fluid dispensing.
7. The system as claimed in claim 1, wherein the motorized actuation allows for seamless integration with 3-axis motion systems for applications such as 3D printing and high-precision fluid deposition.
8. The system as claimed in claim 1, wherein the disposable syringe cylinder body 107 and plunger 106 eliminate the need for cleaning, ensuring economical and contamination-free operation in research and industrial settings.
9. A method for precise dispensing of fluids using a modified syringe system, comprising the steps of:a. replacing the polymer-based shaft of a commercially available disposable syringe with a metal shaft 105 to minimize flexing and enhance motion accuracy;b. mounting the metal shaft 105 onto a plate 102 secured to a linear rail 103 for controlled linear motion;c. actuating the plate 102 using a threaded shaft 104 driven by a motor 101, wherein the threaded shaft 104 translates rotary motion of the motor 101 into precise linear motion of the metal shaft 105;d. dispensing fluid through the syringe by advancing the metal shaft 105 to push the plunger 106;e. utilizing a limit switch 109 at the distal end of the motion to prevent motor overrun and safeguard the syringe components;f. engaging a manual rotation knob 110, wherein the motor 101 is disengaged to allow the user to rotate knob 110 connected to the threaded shaft 104 for controlled manual dispensing; andg. discarding the disposable syringe cylinder body 107 and plunger 106 after use to ensure contamination-free operation.
10. The method as claimed in claim 9, wherein the motor 101 is controlled by software to enable programmable adjustment of fluid dispensing volumes based on user-defined parameters.
11. The method as claimed in claim 9, further comprising the step of integrating the syringe system with a 3 -axis motion control system for applications such as additive manufacturing or high-precision liquid handling.
12. The method as claimed in claim 9, wherein the metal shaft 105 is manufactured from a material selected from the group consisting of metal, ceramic, bone, or high-strength polymer.
13. The method as claimed in claim 9, further comprising the step of attaching a nozzle or adaptor, such as a Luer-lock 108 mechanism, to the syringe to facilitate controlled and directed dispensing of the fluid.
14. The method as claimed in claim 9, wherein the limit switch 109 is an optical sensor providing feedback to the motor controller to halt motion upon reaching the predefined limit.
15. The method as claimed in claim 9, further comprising the step of calibrating the system to correlate linear motion of the metal shaft 105 with precise volumetric dispensing, based on the syringe diameter and fluid properties.