Pre-filled Vial With Integral Plunger Assembly

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Solution Overview

Problem

Conventional syringe assemblies, particularly pre-filled syringes, face challenges in reducing storage space requirements and minimizing contamination risks during the transfer of medications from small vials or ampoules, where glass shards can contaminate the injected fluid.

Innovation Solution

A pre-filled vial assembly with an integral plunger assembly and a regulator that allows direct attachment to a standard syringe, featuring a transitionable stopper and a luer connection for controlled fluid dispensing, reducing the need for manual fluid transfer and minimizing contamination risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional pre-filled syringes are used, then medication can be delivered directly, but storage space requirements increase and contamination risks arise during manual transfer from vials

Engineering Contradiction:

Improvecontamination riskVSAvoidstorage space

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The patent combines the vial and syringe into a single integrated pre-filled syringe assembly, eliminating the need for separate vial storage and manual transfer operations. This merging reduces total storage volume while eliminating contamination risks associated with manual fluid transfer from separate containers.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The pre-filled syringe serves multiple functions: it acts as both the storage container and the delivery device. The single-use design integrates medication storage, plunger mechanism, and injection function into one universal device, reducing the need for multiple separate components and minimizing contamination opportunities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If manual transfer of medication from vials to syringes is performed, then flexibility is maintained, but contamination risk increases due to potential glass shard incorporation

Engineering Contradiction:

ImproveflexibilityVSAvoidcontamination

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The syringe is pre-filled with medication at the manufacturing stage under controlled conditions, eliminating the need for manual transfer operations at the point of use. This preliminary action ensures that the fluid path is established before any potential contamination can occur, while still maintaining flexibility through the single-use design.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent employs a single-use disposable pre-filled syringe that is discarded after one use. This eliminates the need for cleaning and sterilization processes, and ensures that each device is used only once, preventing cross-contamination and glass shard incorporation while maintaining operational flexibility.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Stability of the object's composition

If pre-filled syringes are stored in controlled environments, then medication integrity is maintained, but storage space requirements increase

Engineering Contradiction:

Improvemedication integrityVSAvoidstorage space

Core Design Contradiction:

Stability of the object's compositionVSVolume of stationary object

Solution Approach 1:

By combining the medication and delivery mechanism into a single integrated unit, the patent reduces the total volume required for controlled storage. The merged design eliminates the need for separate vial and syringe storage spaces, while the sealed construction maintains medication integrity throughout the storage period.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent optimizes the physical parameters of the pre-filled syringe, including the size of the barrel, plunger dimensions, and overall geometry, to minimize storage volume while maintaining sufficient space for the medication dose and proper plunger operation. This parameter optimization allows compact storage without compromising medication integrity.

Inventive Principle:

Principle #35Parameter changes

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 solution provides a compact storage solution and reduces contamination by allowing direct and controlled dispensing of fluids from the vial to the syringe, maintaining the integrity of the medication and minimizing the risk of glass shards entering the injection fluid.

Implementation Method 1

A regulator for regulating the release of air from the pre-filled vial assembly is also disclosed

Methodology Applied

Scientific EffectPressurisation: Pressurisation

Data Source

PatentUS9375385B2Pre-filled active vial having integral plunger assembly

Publication Date: 2016.06.28 BECTON DICKINSON FRANCE SAS

AI summary

A pre-filled vial assembly adapted for dispensing and delivering a fluid includes: a body member having a distal end, a proximal end, and a sidewall extending therebetween defining an interior; and a transitionable stopper disposed within the interior of the body member. At least a portion of the body member is engageable with a source of air or fluid for advancing the transitionable stopper from an initial position to an activated position in which at least a portion of a fluid contained within the interior of the body member is advanced therefrom.