Injection Pen Plunger Sensing for Accurate Drug Remaining Detection

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Solution Overview

Problem

Existing medical liquid injection devices, particularly for diabetic patients, face challenges in accurately determining the remaining amount of medical liquid, ensuring safe and convenient operation, and preventing errors due to noise or fluctuations in liquid levels.

Innovation Solution

A medical liquid injection device equipped with a sensor unit that measures the liquid amount through a plunger's movement, using contact and non-contact detection signals to determine the remaining amount, and switches modes based on these signals to ensure accurate liquid delivery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a sensor unit measures liquid amount through plunger movement, then measurement precision is improved, but device complexity increases

Engineering Contradiction:
Improveliquid amount measurementVSAvoidsensor unit and mode switching mechanism
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical sensing mechanisms with a simpler plunger movement-based detection system. The sensor unit detects liquid amount by monitoring plunger position changes, which converts a complex liquid volume measurement problem into a straightforward linear displacement measurement, thereby improving measurement precision while controlling device complexity.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements mode switching between first mode (normal operation) and second mode (error correction) based on detected liquid amount thresholds. This dynamic adaptation allows the device to automatically adjust its measurement and correction strategies, improving overall measurement precision without requiring permanently complex hardware for all operating conditions.

Inventive Principle:
Principle #15Dynamics

2Reliability

If mode switching is implemented based on sensor signals, then reliability is improved, but device complexity increases

Engineering Contradiction:
Improveoperation safetyVSAvoidmode switching control system
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs feedback control where the sensor unit continuously monitors liquid amount and provides signals to the control unit. Based on this feedback, the system automatically switches between operational modes to correct detection errors or noise, thereby improving reliability through a relatively simple feedback loop rather than complex predictive algorithms.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The device performs self-diagnosis and self-correction by automatically detecting when measurement errors or noise occur and switching to correction modes without external intervention. This self-service capability improves reliability while keeping the control system simple, as the device manages its own error correction without requiring complex external monitoring or manual calibration.

Inventive Principle:
Principle #25Self-service

3Measurement precision

If contact and non-contact detection signals are used, then measurement precision is improved, but ease of operation deteriorates

Engineering Contradiction:
Improveliquid amount detection accuracyVSAvoiduser understanding of detection mechanism
Core Design Contradiction:
Measurement precisionVSEase of operation

Solution Approach 1:

The patent extracts and separates the detection mechanism details from the user interface. The complex contact and non-contact detection signals are processed internally by the control unit, which presents simplified information to the user. This extraction allows high measurement precision through multiple detection modes while maintaining ease of operation by hiding the complexity from the user.

Inventive Principle:
Principle #2Taking out (Extraction)

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 device accurately measures and informs the user about the remaining liquid amount, preventing errors and ensuring safe, efficient operation by switching modes based on sensor signals, enhancing user convenience and safety.

Implementation Method 1

a first sensor unit configured to measure the amount of the medical liquid stored in the reservoir according to the movement of the plunger

Methodology Applied
Scientific EffectContact detection:

Implementation Method 2

the connector member is in contact or not in contact with the sensor unit disposed adjacent to the storage unit while moving together with the plunger

Methodology Applied
Scientific EffectNon-contact detection:

Data Source

PatentUS12539362B2Liquid medicine injection device, drug injection device, and method for determining remaining amount of drug thereof
Publication Date: 2026.02.03 IPV
  • US12539362B2 patent drawing
  • US12539362B2 patent drawing
  • US12539362B2 patent drawing

AI summary

Provided is a medical liquid injection device including a base body, a needle assembly mounted on the base body, a reservoir fluidly connected to the needle assembly and having an inner space in which a medical liquid is stored, a plunger disposed inside the reservoir, and configured to move in a longitudinal direction of the reservoir according to an amount of the medical liquid stored in the reservoir, and a first sensor unit configured to measure the amount of the medical liquid stored in the reservoir according to the movement of the plunger.