Autoinjector Cap and Needle Shield Integration
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Solution Overview
Problem
Current autoinjectors are complex, costly, and environmentally impactful due to their multiple components, large size, and complex assembly processes, which hinder efficient and reliable activation for medicament dispensing.
Innovation Solution
A simplified autoinjector design featuring a pre-filled syringe with a needle shield and axially moveable needle guard, where the cap serves as a protective cover and snap-fit connection to minimize components, reduce size, and facilitate easy activation by automatically removing the needle shield upon cap removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If multiple components are used to protect the needle (cap, needle shield, needle guard), then the needle is well protected, but the device complexity increases
Solution Approach 1:
The patent combines the cap and needle shield into a single integrated component. The cap serves dual functions: protecting the needle guard and automatically removing the needle shield upon removal. This merging eliminates separate components while maintaining comprehensive needle protection throughout storage and activation.
Solution Approach 2:
The cap is designed as a multi-functional component that not only protects the needle guard during storage but also automatically removes the needle shield when taken off. This universal design allows one component to perform multiple protective and activation functions, reducing overall device complexity.
2Object-affected harmful factors
If multiple components are used in the autoinjector, then the protective functions are comprehensive, but the manufacturing cost increases
Solution Approach 1:
The integration of cap and needle shield into one component reduces the total number of parts that need to be manufactured, assembled, and quality-checked. This merging simplifies the manufacturing process and reduces costs while maintaining all necessary protective functions through the cap's dual role.
Solution Approach 2:
The multi-functional cap design allows manufacturers to produce fewer unique components, reducing tooling costs and assembly complexity. The single cap performs both protective and activation functions, eliminating the need for separate mechanisms and reducing overall manufacturing expenditure.
3Object-affected harmful factors
If multiple components are used, then the protective coverage is complete, but the assembly process becomes complex
Solution Approach 1:
By combining the cap and needle shield into one integrated component, the assembly process is simplified from multiple separate assembly steps into a single assembly operation. The cap is assembled once with the pre-filled syringe and needle guard, eliminating the need for separate needle shield assembly while maintaining complete protective coverage.
4Object-affected harmful factors
If a traditional multi-component design is used, then the protective functions are separate and distinct, but the device size increases
Solution Approach 1:
The integration of cap and needle shield into a single component eliminates the space required for separate components and their interfaces. This merging reduces the overall device volume while maintaining all protective functions within the compact cap structure that fits over the needle guard.
5Reliability
If traditional activation processes are used, then the activation steps are clear, but the activation time increases
Solution Approach 1:
The needle shield is pre-attached to the pre-filled syringe in a ready-to-release configuration. When the cap is removed, the needle shield automatically detaches and falls away, eliminating manual removal steps. This preliminary positioning enables swift activation while maintaining clear indication of the activation process through the cap removal action.
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
The design reduces manufacturing costs, environmental impact, and complexity while ensuring reliable and swift activation, minimizing material usage and storage volume, and enhancing user safety through a compact, versatile device.
Implementation Method 1
The cap is removably held in place in the storage state of the autoinjector via one or more snap fit connections acting between the cap and the needle guard
Data Source
AI summary
An autoinjector includes a pre-filled syringe arranged within a housing of the autoinjector, a needle shield covering a needle of the pre-filled syringe in a storage state of the autoinjector, an axially moveable needle guard arranged to cover the needle of the pre-filled syringe at least after use of the autoinjector and to move relative to the pre-filled syringe during use of the autoinjector, and a removable cap in which the needle guard is stored in the storage state of the autoinjector, and, on removal of the cap, the needle shield is removed from the autoinjector.