Auto-Injector Actuation Lock and Needle Guard Inversion
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Solution Overview
Problem
Existing auto-injectors can be actuated inadvertently, have needle covers that interfere with penetration, and require expensive sterile manufacturing processes, leading to user confusion and increased costs.
Innovation Solution
An auto-injector design featuring a housing with a needle that moves between positions, an energy storage member, an actuator, and a locking member, where the needle guard is removably coupled to prevent actuation until the needle cover is removed, ensuring consistent penetration and reducing manufacturing costs through non-sterile assembly of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking cap is placed at the proximal end and needle cover at the distal end, then inadvertent actuation is prevented, but user confusion occurs regarding which end is the needle end and which is the actuation end
Solution Approach 1:
The patent inverts the conventional configuration by placing the locking cap at the distal end (needle end) and the needle cover at the proximal end. This inversion resolves the user confusion problem because the locking cap is now located where users expect the active component to be, while the needle cover is at the opposite end. The actuator is positioned at the distal end, allowing users to easily identify the correct orientation without confusion.
2Adaptability or versatility
If the locking cap can be removed prior to needle cover removal, then device flexibility is improved, but the auto-injector can be actuated before needle cover removal allowing injection into wrong site
Solution Approach 1:
The patent implements a preliminary action mechanism where the needle cover must be removed first before the locking cap can be removed. The locking cap is designed to remain in place until the needle cover is removed, at which point the locking cap can then be removed to enable actuation. This sequence ensures that the needle is exposed before the device can be actuated, preventing premature injection into wrong sites while maintaining flexibility in the overall device design.
3Productivity
If the needle cover collapses or buckles during actuation, then the needle breaks through the cover, but the bunched needle cover interferes with needle penetration into the user
Solution Approach 1:
The patent extracts the needle cover from the actuation process itself. Instead of the needle cover being present during needle penetration, the design requires that the needle cover be removed first as a separate preliminary action. This extraction eliminates the problem of the needle cover collapsing or bunching during actuation, ensuring consistent and reliable needle penetration into the user without interference from the cover material.
Data Source
AI summary
A method includes moving an actuation lock of a medical injector from a first position to a second position. The actuation lock has an extended portion disposed between a shoulder of a housing and the base when the actuation lock is in the first position. The extended portion is spaced apart from the base when the actuation lock is in the second position. A distal end portion of a base, which is movably coupled to an end portion of the housing, is placed into contact with a body. The base is actuated after the placing to release an energy from an energy storage member within the housing to produce a force to move a needle from a first needle position to a second needle position. At least a portion of the needle extends through the base when the needle is in the second needle position.