Adapter Caps with Segmented Needle Bore for Universal Engagement

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Solution Overview

Problem

Current adapter caps for collecting biological fluids are not cost-effective and do not accommodate needles from different manufacturers, leading to inconsistent sealing and engagement issues.

Innovation Solution

The development of adapter caps with a monolithic elongate body featuring a needle bore with circumferentially spaced, longitudinally extending flat surfaces and inwardly extending threads, allowing for secure engagement of needles with varying dimensions, fabricated using injection molding techniques that eliminate the need for spinning to form threads.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional adapter caps are used, then manufacturing cost is reduced, but compatibility with needles from different manufacturers is poor and sealing consistency deteriorates

Engineering Contradiction:

Improvecompatibility with needles from different manufacturersVSAvoidsealing consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The needle bore is segmented into multiple longitudinally extending flat surfaces (typically 3-6 surfaces) circumferentially spaced around the bore. This segmentation allows the adapter cap to accommodate needles with varying outer diameters and tolerances by providing multiple contact points, thereby improving compatibility while maintaining consistent sealing through the distributed flat surface geometry.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inner surface of the needle bore features localized flat surfaces with specific dimensional tolerances and orientations, while other portions of the adapter cap maintain standard manufacturing tolerances. This local quality enhancement ensures precise engagement and sealing with needles from different manufacturers without requiring high precision throughout the entire adapter cap, thus resolving the contradiction between adaptability and manufacturing precision.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If adapter caps with multiple flat surfaces are manufactured using traditional spinning techniques, then needle engagement accuracy is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveneedle engagement accuracyVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The traditional mechanical spinning process for forming threads and flat surfaces is replaced with injection molding technology. The injection mold incorporates core pins with pre-formed flat surfaces and threads, allowing the adapter cap to be molded directly with the required geometric features. This substitution eliminates complex spinning operations while maintaining needle engagement accuracy through precise mold design and injection molding process control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The flat surfaces and thread geometries are pre-formed on the injection mold core pins before the actual production of adapter caps. This preliminary action ensures that each adapter cap receives the precise geometric features needed for accurate needle engagement during the injection molding process, eliminating the need for post-molding spinning operations and reducing manufacturing complexity.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If adapter caps are designed to accommodate various needle dimensions, then versatility is improved, but device complexity increases

Engineering Contradiction:

Improveaccommodation of needles with varying dimensionsVSAvoidadapter cap structural complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The adapter cap is designed with a universal needle bore configuration featuring multiple longitudinally extending flat surfaces that can accommodate needles from different manufacturers with varying dimensions and tolerances. This universal design achieves multi-functionality by providing a single adapter cap structure that works with multiple needle types, thereby improving versatility without increasing device complexity through additional components or mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10172545B2Adapter caps for sample collection containers and associated molds with core pins and related methods

Publication Date: 2019.01.08 BIOMERIEUX INC

AI summary

Adapter caps for sample collection containers have a monolithic elongate body with an upper neck portion that merges into a larger lower body portion with an open internal cavity. The upper neck portion has an open needle bore that is concentrically aligned with the open internal cavity. The monolithic elongate body has an axially extending centerline. The needle bore has a downwardly extending wall with an inner surface that comprises a plurality of circumferentially spaced apart longitudinally extending flat surfaces.