Reusable Auto-Injector with Fluid Transfer Assembly
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Solution Overview
Problem
Current auto-injector devices require pre-filled syringes, leading to complex and costly manufacturing processes, as well as limited reusability, due to the need for separate production lines for each drug and the disposal of injection components after each use.
Innovation Solution
An auto-injector system that allows for the transfer of drugs from standard vials into a reusable chamber, using a bespoke transfer assembly that increases chamber volume to draw fluid in, reducing manufacturing costs and enabling greater reusability of the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pre-filled syringes are used in auto-injectors, then the device is ready for immediate use, but the manufacturing process becomes more complicated and expensive with separate production lines required for each drug
Solution Approach 1:
The auto-injector is divided into two separate subassemblies: a reusable first subassembly containing the chamber and operating mechanisms, and a disposable second subassembly containing the injection components and pre-filled syringe. This segmentation allows the reusable portion to be manufactured once and used multiple times with different drugs, while the disposable portion handles drug-specific requirements, thereby reducing overall manufacturing complexity and cost.
Solution Approach 2:
The first subassembly with the chamber is designed as a universal reusable component that can accommodate different drugs through the interchangeable second subassembly. This multi-functionality allows a single chamber design to serve multiple drug types, eliminating the need for separate production lines for each drug while maintaining readiness for use.
2Ease of operation
If pre-filled syringes are used in auto-injectors, then the device can be used immediately, but the manufacturing costs increase due to separate production lines for each drug
Solution Approach 1:
By segmenting the auto-injector into reusable and disposable subassemblies, the manufacturer can produce the expensive reusable chamber once and amortize its cost over multiple uses with different drugs. The disposable second subassembly handles drug-specific manufacturing requirements at lower cost, thereby reducing overall manufacturing costs while maintaining immediate readiness for use.
Solution Approach 2:
The disposable second subassembly containing the pre-filled syringe is discarded after single use, while the first subassembly with the chamber is recovered and reused for subsequent injections with different drugs. This approach allows the manufacturer to invest in quality reusable components once and avoid recurring costs of manufacturing multiple complete devices for different drugs.
3Ease of operation
If complete auto-injector units are pre-filled with specific drugs, then the device is ready for use, but the reusability of the device is limited due to disposal requirements
Solution Approach 1:
The auto-injector is segmented into a reusable first subassembly and a disposable second subassembly. This allows the core device with the chamber to be reused across multiple drug types and patients, while only the injection-specific components are discarded, thereby significantly increasing device reusability while maintaining readiness for use.
Solution Approach 2:
The first subassembly is designed as a universal platform that can work with multiple different second subassemblies containing different drugs. This multi-functionality enables a single reusable chamber to serve multiple purposes with different medications, greatly enhancing device reusability and adaptability.
4Ease of manufacture
If standard vials are used instead of pre-filled syringes, then manufacturing costs are reduced and inventory management is simplified, but a mechanism to transfer fluid from vial to chamber is required
Solution Approach 1:
The fluid transfer mechanism is merged with the loading process itself. The second subassembly is designed to be loaded directly from standard vials through a simple transfer process, and the chamber is integrated into the first subassembly to receive the transferred fluid. This merging eliminates the need for separate complex transfer devices while enabling the use of standard vials, thereby reducing manufacturing costs with minimal added complexity.
Solution Approach 2:
The second subassembly acts as an intermediary between the standard vial and the reusable chamber. It receives fluid from the vial and transfers it to the chamber, serving as a mediator that simplifies the overall transfer process and enables the use of standard vials without requiring direct complex transfer mechanisms between the vial and chamber.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies the manufacturing process by allowing a single type of sub-assembly to be used with any drug, reduces costs, and increases the reusability of the auto-injector by allowing standard vials to be used, thereby lowering overall costs and simplifying inventory management.
Implementation Method 1
The transfer assembly is moveably disposed within the chamber such that moving the transfer assembly increases a volume of the chamber to draw fluid into the chamber
Data Source
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AI summary
An injection device comprises a first sub-assembly (110) comprising a chamber (112) for holding a fluid and a transfer assembly (116) moveably disposed within the chamber. The chamber comprises an exit aperture and an inner surface and the transfer assembly has an outer surface substantially in contact with the inner surface about its perimeter. The transfer assembly is adapted to transfer fluid into the chamber when the transfer assembly is moved within the chamber.