Drug Delivery Packaging Angled Retention
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Solution Overview
Problem
Conventional blister packaging fails to securely hold drug delivery devices, leading to rattling and premature actuation of the plunger during transport, handling, and storage, which can result in medicament expulsion and render the device ineffective.
Innovation Solution
A packaging system that houses drug delivery devices at a non-zero angle relative to its longitudinal axis, featuring a retaining cavity for secure interference fit and a gripping cavity to prevent movement and actuation, with a transparent design allowing visibility of indicator windows to confirm proper use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional blister packaging is used to package drug delivery devices, then the packaging is simple and easy to manufacture, but the device can rattle and move within the pack, causing potential damage and premature actuation
Solution Approach 1:
The packaging base is divided into multiple functional cavities: a retaining cavity with interference fit features to secure the upper segment of the device, a gripping cavity to hold the lower segment and actuator, and an end cavity to receive the tip. This segmentation allows each cavity to perform a specific function in preventing device movement while maintaining overall packaging simplicity
Solution Approach 2:
The packaging base acts as an intermediary structure between the device and the external environment during transport. The base's cavities and interference fit features mediate the mechanical stresses and movements, preventing direct contact and potential damage between the device and packaging walls, thereby enhancing device stability without requiring complex active stabilization mechanisms
2Ease of operation
If the packaging allows device movement, then the device can be easily removed from the packaging, but the device may be accidentally actuated during handling and storage
Solution Approach 1:
The packaging base provides different local qualities through its cavities: the gripping cavity offers a secure hold on the lower segment and actuator to prevent accidental actuation during storage and handling, while the overall design allows for easy removal by gripping the device body. The local interference fit in the retaining cavity provides selective retention that balances security with ease of removal
3Reliability
If the packaging is designed to securely hold the device, then premature actuation is prevented, but the packaging becomes more complex and difficult to manufacture
Solution Approach 1:
Multiple retention functions are merged into a single packaging base structure. The retaining cavity with interference fit features, the gripping cavity for securing the lower segment, and the end cavity for the tip are integrated into one monolithic base component. This merging achieves comprehensive device security without requiring multiple separate packaging components, thereby maintaining manufacturing simplicity
Solution Approach 2:
The packaging base performs multiple functions simultaneously: it secures the upper segment via interference fit, holds the lower segment and actuator, prevents premature actuation, and allows for easy device removal. This multi-functionality is achieved through a single universal base structure rather than multiple specialized components, simplifying the manufacturing process while enhancing device protection
Data Source
AI summary
Various packaging systems and packaging kits are described. In one exemplary embodiment, a packaging system is provided and includes a base configured to receive a drug delivery device having a device body having an upper segment and a lower segment, and an actuator. The base is configured to house the received drug delivery device therein at a non-zero angle relative to a longitudinal axis of the base. The base includes a retaining cavity and a gripping cavity adjacent the retaining cavity. The retaining cavity is configured to create an interference fit with at least a portion of an upper segment of a drug delivery device received within the base, and the gripping cavity is configured to receive a lower segment of a device body and a portion of an actuator of a drug delivery device received within the base.