Radially Compressible BFS Vial for Single-Pinch Dose Delivery
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Solution Overview
Problem
Existing BFS vial designs do not adequately address the need for precise compressibility to ensure that a single dose of fluid agent is extracted via a radial compression action, which is crucial for human-pinch-squeezable injector devices, as they often require additional syringes or vacuum forces for fluid extraction.
Innovation Solution
The BFS vials are specifically configured with geometric and dimensional parameters such as length, wall thickness, cross-sectional geometry, and fill-orientation to achieve a designed squeeze-force range between 30-40 N, allowing for a single dose to be expelled through radial compression without the need for syringes or vacuum forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional BFS vial designs are used, then manufacturing simplicity is maintained, but fluid extraction requires additional syringes or vacuum forces
Solution Approach 1:
The patent modifies the physical parameters of the BFS vial by introducing a radially compressible membrane with specific geometric and dimensional parameters. This changes the mechanical properties of the vial wall, enabling direct fluid extraction through radial compression without requiring syringes or vacuum forces. The membrane's compressibility parameter is specifically engineered to allow controlled deformation under manual pinch force.
Solution Approach 2:
The radially compressible membrane enables the vial to perform the fluid extraction function itself through direct manual compression. The membrane's design allows it to deform radially inward when pinched, directly expelling the fluid dose through the needle without requiring external extraction devices. The vial structure serves its own extraction function, eliminating the need for separate syringes or vacuum systems.
2Ease of operation
If BFS vials are made more compressible to enable single-pinching extraction, then ease of operation improves, but control over squeeze-force becomes difficult
Solution Approach 1:
The patent introduces specific geometric and dimensional parameters for the radially compressible membrane, including thickness, radius, and material properties, to engineer the squeeze-force within the 30-40 N range. These parameter changes allow the membrane to be sufficiently compressible for single-pinching operation while maintaining controlled force requirements. The parameters are optimized to balance compressibility with force control.
Solution Approach 2:
The membrane design incorporates dynamic characteristics that allow it to respond to applied force in a controlled manner. The geometric parameters are designed so that the membrane deforms progressively under compression, providing tactile feedback to the user and enabling intuitive control of the squeeze-force. The dynamic response ensures that the membrane can be compressed with manageable force while still achieving complete fluid extraction.
3Measurement precision
If geometric and dimensional parameters are precisely configured for compressibility, then dose delivery accuracy improves, but manufacturing complexity increases
Solution Approach 1:
The patent defines specific geometric and dimensional parameters for the radially compressible membrane, including thickness (e.g., 0.1-0.5 mm), inner radius, outer radius, and material elastic properties. These parameter changes enable precise control over the compression behavior and fluid expulsion characteristics. The parameters are selected to achieve at least 90% dose extraction accuracy while remaining manufacturable using standard BFS processes with modified mold designs.
Solution Approach 2:
The patent applies different geometric and material properties to specific regions of the vial structure. The radially compressible membrane has localized geometric features (such as varying thickness or reinforcement zones) that optimize compression behavior in critical areas while maintaining overall structural integrity. This localized quality approach allows precise dose delivery control without requiring complex specifications throughout the entire vial structure.
4Ease of operation
If radially compressible membrane is introduced, then single-dose extraction is enabled, but structural integrity may be compromised
Solution Approach 1:
The patent designs the radially compressible membrane with localized geometric features that concentrate the compression deformation in specific regions away from critical structural areas. The membrane may have varying thickness or stiffness zones that allow controlled deformation during pinching while maintaining overall vial strength. Reinforcement ribs or strategic thickness variations ensure that the membrane remains structurally sound during both compression and non-compression states.
Solution Approach 2:
The patent employs composite material structures for the radially compressible membrane, combining materials with different mechanical properties to achieve both compressibility and structural integrity. The membrane may consist of layered structures or composite polymers that provide controlled deformation characteristics while maintaining sufficient strength to contain the fluid under normal conditions and resist rupture during compression. The composite structure allows the membrane to be both soft enough for pinching and strong enough for structural stability.
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 configured BFS vials ensure that at least 90% of the fluid dose is expelled with a single pinch, providing reliable and accurate dose delivery for injectable medicines, enhancing the usability and safety of single-dose, pre-filled delivery systems.
Implementation Method 1
a radially compressible membrane configured to deform in response to a designed squeeze-force level
Implementation Method 2
a spring and associated mechanical components form a linear actuating or axial compression mechanism
Data Source
AI summary
Systems and methods for Blow-Fill-Seal (BFS) vials configured to expel a desired quantity of medicament in response to a designed range of radially inward squeeze-force applications received via a compressible fluid reservoir.