Blow-Fill-Seal Syringe with Radial Compression Collar
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Solution Overview
Problem
Conventional syringes and injector pens face challenges in aseptic manufacturing, dosage accuracy, and ease of use, particularly for chronic illness management, due to their complex structure and the need for precise filling and finishing processes, which complicates the production and deployment of prefilled syringes and injector pens.
Innovation Solution
A syringe design featuring a one-piece body with a hollow tubular section that is partially or completely non-longitudinally flattenable, allowing for radial compression via a slideable collar, ensuring accurate dosing and ease of use, combined with a needle-containing piece for secure needle attachment and communication, facilitating aseptic filling and finishing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional syringes use a rigid non-compressible barrel with internal plunger, then the structure is simple and easy to manufacture, but dosage accuracy deteriorates due to plastic expandability and the complex structure makes aseptic manufacturing difficult
Solution Approach 1:
The syringe is divided into two functional segments: a rigid non-compressible barrel for structural integrity and aseptic manufacturing, and a compressible hollow tubular section for dosage delivery. This segmentation allows each part to optimize its specific function while simplifying the overall manufacturing process.
Solution Approach 2:
The invention changes the compressibility parameter of the tubular section from rigid (conventional) to compressible, enabling radial compression for dosage delivery while maintaining longitudinal rigidity for manufacturing stability. This parameter change resolves the contradiction between dosage accuracy and manufacturing simplicity.
2Manufacturing precision
If prefilled syringes are manufactured aseptically with complex filling processes, then dosage accuracy improves, but production time and manufacturing complexity increase
Solution Approach 1:
The syringe is pre-filled with formulation during the manufacturing process before sterilization and packaging. This preliminary action eliminates the need for complex post-manufacturing filling operations, enabling aseptic manufacturing with high production speed.
Solution Approach 2:
The manufacturing process merges the filling, sterilization, and packaging operations into a single integrated aseptic process. This combination eliminates sequential steps and reduces production time while maintaining dosage accuracy.
3Ease of operation
If conventional syringes require manual preparation and administration steps, then ease of manufacture is maintained, but ease of operation deteriorates due to complex administration procedures and dosing errors
Solution Approach 1:
The syringe is designed as a self-contained prefilled unit that requires no manual preparation. The formulation is pre-loaded during manufacturing, and the device is ready for immediate use, eliminating complex administration steps while maintaining manufacturing simplicity.
Solution Approach 2:
All preparation actions including formulation loading, plunger positioning, and sealing are performed preliminarily during manufacturing. This eliminates the need for complex manual preparation steps at the point of use, significantly improving ease of operation.
4Measurement precision
If plastic syringes are used for dosing, then ease of manufacture is improved, but measurement precision deteriorates due to plastic expandability
Solution Approach 1:
Different parts of the syringe have different mechanical properties: the barrel is made rigid and non-compressible for manufacturing stability and aseptic processing, while the tubular section is made compressible for accurate dosage delivery through radial compression. This local quality differentiation resolves the contradiction between manufacturing ease and dosage precision.
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 solution enables efficient, aseptic manufacturing and easy deployment of prefilled syringes and injector pens, enhancing patient compliance and adherence by ensuring accurate dosing and reducing the complexity of administration, while minimizing waste and production time.
Implementation Method 1
a slideable collar... adapted to slide longitudinally along the longitudinal flanges and the outer surface of the hollow tubular section to flatten, preferably, compress radially, (i.e., inwardly collapse) the hollow tubular section so that when a needle containing piece is piercing the distal end of the hollow tubular section, at least a portion of any contents of the hollow tubular section passes through the needle discharge end
Data Source
AI summary
The present invention is directed to syringes that can be manufactured by blow molding and can be aseptically filled and finished, i.e., Blow-Fill-Seal (“BFS”). The present invention is also directed to pen-type injectors that accommodate cartridges that can be manufactured by BFS technology.