Deformable Engagement Element for Injection Device Cap Removal
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Solution Overview
Problem
Existing injection devices face challenges in maintaining the sterility of the injection needle and medicine during the assembly process, particularly when inserting a prefilled syringe into the device, as force applied during handling can compromise the sterility of the needle protection cap.
Innovation Solution
The injection device incorporates a mechanism with a deformable engagement element that allows for easy insertion of the product container and secure removal of the needle protection cap without exerting force on the cap during assembly, using a hook-shaped engagement element that moves from a spaced-apart position to an engagement position to ensure the cap is not prematurely activated during insertion, thus maintaining sterility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the needle protection cap is securely mounted on the prefilled syringe to maintain sterility, then the sterility of the injection needle and medicine is preserved, but the cap becomes difficult to remove during the pull-off process
Solution Approach 1:
The needle protection cap is divided into two functional zones: a proximal portion with high friction engagement to the syringe body for secure mounting and sterility maintenance, and a distal portion with reduced friction or release features that allow easy removal during the pull-off process. This segmentation enables the cap to remain firmly attached during assembly while being readily removable when needed.
Solution Approach 2:
The engagement between the needle protection cap and the syringe body is designed to be dynamic rather than static. The cap transitions from a tightly engaged state during assembly and storage to a easily removable state during the pull-off process. This is achieved through friction-based engagement that allows controlled slippage or disengagement when pull-off forces are applied.
2Ease of manufacture
If force is applied to the needle protection cap during assembly to secure the prefilled syringe, then the assembly process is simplified, but the sterility of the needle and medicine is compromised
Solution Approach 1:
The engagement mechanism for securing the prefilled syringe is extracted from the needle protection cap itself and placed in a separate component, such as a syringe holder or retention mechanism. This allows the cap to remain passive and force-free during assembly, while the separate mechanism handles the securing function. The cap only engages with the syringe body through gentle friction without requiring assembly forces.
Solution Approach 2:
An intermediary component, such as a syringe holder or retention mechanism, is introduced between the assembly process and the needle protection cap. This intermediary handles all forceful engagement operations, allowing the cap to remain in a neutral, force-free state during assembly. The intermediary secures the syringe body without transmitting forces to the cap, thereby preserving sterility.
3Ease of operation
If the engagement element is designed to engage the needle protection cap during pull-off, then the cap is securely removed, but the cap may be prematurely activated during insertion
Solution Approach 1:
The engagement element is pre-positioned in a retracted or disengaged state during assembly and insertion operations. It only transitions to the engaged state when specific pull-off forces or movements are detected. This preliminary positioning ensures that the cap cannot be prematurely activated during insertion, while still being ready for secure removal when the pull-off action occurs.
Solution Approach 2:
The engagement element employs a dynamic engagement mechanism that responds to the direction and magnitude of applied forces. During insertion, the element remains disengaged or in a low-engagement state. During pull-off, the element transitions to a high-engagement state that securely grasps the cap. This dynamic behavior prevents premature activation while ensuring secure removal when needed.
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
This solution ensures the sterility of the injection needle and medicine is maintained throughout the handling and assembly process by minimizing forces applied to the needle protection cap, reducing the risk of contamination and ensuring secure removal for safe disposal.
Implementation Method 1
The engagement element is deformable in such a manner that the engagement element can move from a spaced-apart position, in which the engagement element is at a radial distance from the needle protection cap, into an engagement position, in which the engagement element is engaged with the needle protection cap, wherein the engagement element is deformed during removal of the device cap
Data Source
AI summary
An injection device comprising a cap for removing a needle protection cap from a product container, and a method for assembling an injection device. The cap comprises an engaging element for removing the needle protection cap from the product container when the cap is removed from the injection device. The engaging element can be deformed in such a way that the engaging element can be moved from a distanced position, in which the engaging element is radially distanced from the needle protection cap, into an engagement position, in which the engaging element engages with the needle protection cap, with the engaging element being deformed when the cap is removed.