Curved Needle Hub Collapsible Support for Septum Insertion
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Solution Overview
Problem
Existing disposable needle hubs for injector devices face challenges with high-gauge needles buckling when inserting into the septum of a drug reservoir due to the hardness of the septum and rapid forces applied, especially when the needle is not aligned linearly, leading to potential misalignment and increased psychological stress in flat application scenarios.
Innovation Solution
A needle hub design with a single-needle length and a needle aligning device that provides controlled movement through a support member, which collapses to allow insertion and provide frictional resistance, preventing buckling and misalignment, and uses sonic or laser welding for securement without chemical adhesives, reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a high-gauge needle is used for both distal and proximal ends, then manufacturing cost is reduced, but the needle may buckle and bend when pressed into the septum due to its flexibility and the hardness of the septum
Solution Approach 1:
The needle is pre-curved to follow the arc of the collar, and the collar is designed with a specific arc geometry that guides the needle into proper alignment with the septum before insertion occurs. This preliminary geometric configuration prevents buckling by ensuring the needle is properly supported and aligned throughout the insertion process.
Solution Approach 2:
The collar acts as an intermediary structure between the needle and the septum. It provides a curved guide surface that the needle follows during insertion, distributing forces and preventing direct buckling of the flexible high-gauge needle against the hard septum material.
2Ease of operation
If the needle is intended to curve around an arc with the proximal end not in line with the distal end, then the device can be applied flat on the skin reducing psychological impact, but the needle portion piercing the skin is not aligned with the needle portion entering the drug cartridge
Solution Approach 1:
The collar is designed with a specific arc curvature that matches the needle's bend radius. This curved geometry allows the needle to maintain proper alignment throughout its length, ensuring that even when curved at 90 degrees or other angles, the needle portions at both ends remain properly aligned for their respective functions.
Solution Approach 2:
The collar and needle are designed with asymmetric curvature to accommodate the specific angular relationship between the proximal and distal needle ends. This asymmetric geometric configuration ensures proper alignment while enabling flat application on the skin surface.
3Productivity
If rapid and high forces are applied when the cartridge and needle hub are pushed together, then insertion speed is increased, but the needle may buckle due to the hardness of the septum and the flexibility of the high-gauge needle
Solution Approach 1:
The collar is designed to provide gradual, controlled resistance during needle insertion rather than allowing sudden force application. The curved geometry and frictional engagement create a cushioning effect that distributes the insertion forces over time, preventing buckling while maintaining insertion speed.
Solution Approach 2:
The collar serves as a mechanical intermediary that mediates the interaction between the needle and septum during insertion. It controls the force transmission, preventing sudden high forces from causing buckling while still enabling rapid insertion through its guided geometry.
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 ensures the needle remains firm and aligned during insertion, reducing the risk of buckling and misalignment, while eliminating the need for additional materials and process steps, thus enhancing the integrity and cost-effectiveness of the device.
Implementation Method 1
The support member is collapsible to allow movement of the needle into the septum and provides frictional resistance to movement of the needle into the septum
Implementation Method 2
uses sonic or laser welding for securement without chemical adhesives
Implementation Method 3
uses sonic or laser welding for securement without chemical adhesives
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
An injector device comprises a needle support member (6,13) for supporting a distal end of a needle (4) within a collar region (3) of the device. On insertion of the neck of a drug cartridge (10) into the collar region (3), the tip of the needle (4B) pierces a septum (9) in the drug cartridge and is thereafter supported by the septum (9). The needle support member (6, 13) is then displaced by the drug cartridge (10) as it moves further into the collar region (3). The displacement may comprise hinging or sliding of the support member (6, 13). By supporting the needle (4B) as it pierces the septum (9) and by providing controlled resistance to rapid or violent insertion of the drug cartridge (10), the needle support member (6,13, 15) enables a single, fine needle (4) to be used for both the distal end and the proximal end without buckling, even if the needle (4) is curved so that the two ends are mutually inclined.