Autoinjector Needle Shield Remover With Drop-Actuation Lock

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Solution Overview

Problem

Existing autoinjectors face challenges in reliably removing needle shields without excess force or slippage and are prone to unintended actuation when dropped.

Innovation Solution

A cap assembly with a retainer and cap remover that securely engages the needle cover, preventing its movement to the use position and featuring a design that allows easy removal of the needle shield and prevents unintended actuation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rigid cap assembly with retainer is used to prevent unintended actuation, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improveprevention of unintended actuationVSAvoidcap assembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cap assembly is segmented into distinct functional components: a retainer with radially extending protrusions for preventing needle cover movement, and a cap remover with openings for user manipulation. This segmentation allows each component to perform its specific function independently, improving reliability while maintaining manageable complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The retainer is nested within the cap remover, with the retainer's protrusions extending through openings in the cap remover. This nested arrangement allows the cap remover to serve dual purposes: protecting the retainer during storage/transport and providing user access for shield removal, thereby reducing overall device complexity while maintaining the anti-droop function.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If the retainer protrusions are rigid to prevent needle cover movement, then reliability is improved, but ease of operation deteriorates

Engineering Contradiction:

Improveprevention of needle cover movementVSAvoidshield removal

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The retainer protrusions are designed with elastic properties, allowing them to flex radially outward when force is applied through the cap remover. This dynamic behavior enables the rigid-looking structure to temporarily deform during operation, facilitating easy shield removal, then return to its original position to maintain reliability during normal use and transport.

Inventive Principle:

Principle #15Dynamics

3Reliability

If the cap assembly is designed for secure engagement, then reliability is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvesecure engagement of retainer with needle coverVSAvoidalignment of protrusions with openings

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The retainer protrusions are designed with elastic compliance, allowing them to deform and accommodate variations in manufacturing tolerances. This parameter change from rigid to elastic behavior enables secure engagement without requiring extremely precise alignment between the protrusions and the needle cover flange, thereby reducing manufacturing precision requirements while maintaining reliability.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12569625B2Rigid needle shield remover with drop test feature for autoinjector

Publication Date: 2026.03.10 BECTON DICKINSON FRANCE SAS

AI summary

Provided herein is a subassembly for a drug delivery device, including a housing, a displaceable needle cover having a distal end having a flange, the needle cover being received within the housing and configured to have a pre-use position in which the needle cover extends from the housing and a use position in which the needle cover is at least partially displaced into the housing. Displacement of the needle cover into the housing actuates the drug delivery device. The subassembly further includes a cap assembly, comprising configured to prevent movement of the needle cover to the use position.