Needle Carrier Assembly for Safe Hidden Needle Attachment

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Solution Overview

Problem

Users of drug delivery devices face challenges in conveniently and safely attaching and detaching needle assemblies without direct contact or visibility, especially in disposable or reusable pens.

Innovation Solution

A drug delivery device with a needle assembly that includes a needle carrier, hub, and cam mechanism, allowing for remote attachment and detachment through a drive gear system, enabling needle extension and retraction without direct user contact or visibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a needle assembly is attached to a drug delivery device, then medication can be administered, but the user must directly contact or view the needle which creates safety hazards

Engineering Contradiction:

Improveneedle attachment convenienceVSAvoiduser safety risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The device is divided into separate components: a reusable drug delivery device and a disposable needle assembly. The needle assembly can be attached and detached as a complete unit, eliminating the need for users to handle loose needles. The needle is enclosed within a carrier that provides protection during attachment and detachment operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The needle is nested within a protective carrier housing. The carrier contains the needle in a retracted position and provides a outer shell that users can safely grasp and manipulate. This nested structure allows the needle to be protected while still enabling its function when needed.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If a needle assembly is designed for single-use to prevent re-use, then safety is improved, but device complexity increases

Engineering Contradiction:

Improveprevention of needle re-useVSAvoidneedle assembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The needle assembly is pre-configured with a use indicator mechanism that is activated during the first use. The indicator changes state (such as a window changing from opaque to transparent, or a mechanical flag moving) to permanently mark that the needle has been used, preventing any subsequent re-use attempts.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The needle assembly is designed as a disposable component that is discarded after a single use. This eliminates the need for complex reusable mechanisms and ensures safety by preventing re-use. The simplicity of the disposable design reduces overall system complexity while maintaining reliability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Object-affected harmful factors

If the needle is kept retracted for safety, then user safety is improved, but the time required for needle extension and medication delivery increases

Engineering Contradiction:

Improveneedle exposure riskVSAvoidneedle extension time

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The needle is designed to be dynamically positionable between retracted and extended states. A drive mechanism allows rapid transition from the safe retracted position to the functional extended position, and back again. This dynamic capability maintains safety during storage and transport while enabling quick deployment when needed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The needle follows a periodic cycle of being retracted (safe state) and extended (functional state). The drive mechanism enables this periodic action to occur quickly, with the needle spending most time in the retracted safe position and briefly extending for medication delivery, then returning to retracted position.

Inventive Principle:

Principle #19Periodic action

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

Facilitates safe and convenient attachment and detachment of needle assemblies, enhancing user safety and ease of use by minimizing direct contact with the needle.

Implementation Method 1

A cam is within the needle carrier and the cam has a driven gear. A needle hub is coupled to the cam and is movable relative to the needle carrier. In response to rotating the driven gear of the cam, the cam is configured to drive the needle hub to at least one of to move the needle in an extension direction and to drive the needle hub to move the needle in a retraction direction.

Methodology Applied

Scientific EffectCam mechanism: Cam

Implementation Method 2

actuating the drive gear to rotate the cam to drive the needle hub distally to move the needle to an extended position

Methodology Applied

Scientific EffectGear mechanism: Gear

Implementation Method 3

the needle carrier is coupleable to the drug device to position the proximal end of the needle inserted through a septum in fluid communication within a container of the drug delivery device

Methodology Applied

Scientific EffectMechanical coupling: Mechanical Fastener

Data Source

PatentUS12611508B2Medication delivery device with needle carrier

Publication Date: 2026.04.28 ELI LILLY & CO

AI summary

Drug delivery devices are provided having a needle assembly portion and a drug device portion, where the needle assembly portion is removably coupleable to the drug device portion. In some embodiments, the needle of the needle assembly may be moveable between a retracted position and an extended position for piercing into a subjects skin.