Low-Profile IV Catheter Protector Assembly for Passive Needle Retraction
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Solution Overview
Problem
Conventional catheter protective devices are difficult to operate, prone to improper use due to cumbersome design, and require tedious assembly, increasing the risk of needle sticks and assembly time and cost.
Innovation Solution
A system and method for quickly assembling a passive protector for an intravenous catheter involves forming a hardened tip, connecting a ferrule, attaching a hub, inserting a vent plug, and completing the assembly using a mandrel and pressing machine to facilitate easy and secure attachment of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional protective devices are used, then needle protection is provided, but the devices are difficult to operate and prone to improper use
Solution Approach 1:
The passive protector is designed to automatically engage and secure the needle without requiring active manipulation by the medical technician. The retractable needle mechanism automatically retracts the needle into the sheath after catheter insertion, eliminating the need for manual operation and reducing the risk of improper use.
Solution Approach 2:
The active actuation mechanism and power source have been removed from the protective device, leaving only the passive structural components. This extraction of active elements simplifies the device design, reduces operational complexity, and eliminates the learning curve associated with operating complex mechanisms.
2Reliability
If conventional protective devices are used, then needle protection is provided, but assembly is tedious and time-consuming
Solution Approach 1:
Multiple assembly steps have been combined into a single integrated process. The sheath, needle, connector, and hub are assembled together in one continuous operation using the pressing machine, eliminating the need for separate assembly steps and reducing overall assembly time.
Solution Approach 2:
Components are pre-positioned on the mandrel in their final assembly configuration before the pressing operation. This preliminary positioning ensures that all components are correctly aligned and ready for assembly, eliminating the need for adjustments or repositioning during the assembly process.
3Reliability
If conventional protective devices are used, then needle protection is provided, but the design is cumbersome and increases needle stick risk
Solution Approach 1:
The passive protector relies on the inherent mechanical properties of its components rather than complex active mechanisms. The spring-loaded needle retraction and friction-based securing mechanisms automatically perform their functions without requiring additional control systems, sensors, or power sources.
Solution Approach 2:
The device uses localized structural features rather than complex overall mechanisms. The tapered needle tip, friction-fit connections, and localized spring mechanisms provide the necessary functionality through simple geometric and material properties at specific locations rather than through complex system-wide mechanisms.
4Reliability
If conventional protective devices are used, then needle protection is provided, but assembly cost increases due to tedious assembly
Solution Approach 1:
Multiple assembly operations have been merged into a single pressing cycle. The pressing machine performs insertion, securing, and sealing operations simultaneously, reducing the number of manual assembly steps and lowering labor costs while maintaining component integrity.
Solution Approach 2:
Manual assembly operations have been replaced with automated pressing and sealing mechanisms. The pressing machine and sealing device perform assembly tasks automatically, reducing reliance on skilled manual labor and consistent assembly quality while lowering overall manufacturing costs.
Data Source
AI summary
A low-profile universal passive protector for an IV catheter includes a connector having a tubular body and a pair of arms pivotally connected thereto. The tubular body defines an end face and the connector includes a cavity extending from the end face. An elongate sheath is snap engageable to the tubular body. A spring is insertable within the connector cavity to extend between at least one of the pair of arms and the elongate sheath when received within the cavity. A slider is moveably coupled to the sheath. The slider includes a flashback chamber formed therein. A hypodermic needle is connected to the slider and is in fluid communication with the flashback chamber. The slider is moveable along the sheath between a first position and a second position, with the hypodermic needle being drawn into the sheath as the slider moves from the first position toward the second position.