Prefilled Medical Injection Device with Detachable Needle

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Solution Overview

Problem

Prefilled hypodermic syringes face challenges such as chemical interactions with lubricants and adhesives, pressure changes leading to contamination risks, and the need for recapping, which increases the risk of needle sticks for healthcare workers.

Innovation Solution

A prefilled medical injection device designed for the Blow-Fill-Seal manufacturing process, featuring a bellows, valve, needle assembly, and needle cap, which provides a compact, sterile design with a hermetic seal and a frangible engagement mechanism to prevent contamination and accidental needle sticks, allowing for directional fluid flow and pressure resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a prefilled hypodermic syringe is used, then medication delivery efficiency is improved, but the risk of needle stick injury to healthcare workers increases due to recapping requirements

Engineering Contradiction:

Improvemedication delivery efficiencyVSAvoidneedle stick injury risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The needle is extracted from the syringe body by designing a detachable needle assembly that can be removed before disposal, eliminating the need for recapping and reducing needle stick injury risk while maintaining prefilled efficiency

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The syringe is segmented into separate components including a removable needle assembly, plunger, and syringe body, allowing the needle to be detached and disposed of separately from the medication delivery system

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If traditional hypodermic syringe design is used, then ease of manufacture is improved, but chemical interactions with silicone lubricant and adhesives occur

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidchemical interactions

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

Different materials are used in different regions of the syringe components. The needle assembly uses stainless steel with specific surface treatments, the syringe body uses chemically inert plastic, and lubricants are applied only to specific friction surfaces, minimizing overall chemical interactions while maintaining manufacturability

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The syringe employs composite material construction with chemically inert plastics for the barrel, stainless steel for the needle, and specialized coatings on friction surfaces, reducing harmful chemical interactions between components and medications

Inventive Principle:

Principle #40Composite materials

3Productivity

If prefilled syringe format is used, then healthcare worker efficiency is improved, but pressure changes during transportation cause contamination risks

Engineering Contradiction:

Improvehealthcare worker efficiencyVSAvoidcontamination risk

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The syringe is packaged in an inert atmosphere environment that prevents chemical reactions and contamination during transportation, while the sealed design maintains internal pressure equilibrium despite external pressure changes

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The syringe design includes pressure compensation mechanisms and cushioning packaging that anticipate and counteract pressure changes during transportation, preventing contamination before it can occur

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Ease of operation

If needle cap is removed for injection, then injection function is achieved, but accidental needle stick risk increases

Engineering Contradiction:

Improveinjection functionVSAvoidaccidental needle stick risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The needle is completely extracted from the syringe body and removed before disposal, eliminating the need for recapping operations that create accidental needle stick risks, while the injection function is achieved during the controlled administration phase

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS9265889B2Prefilled medical injection device

Publication Date: 2016.02.23 ADAR MEDTECH

AI summary

A prefilled medical injection device with production specific elements is provided as a single use disposable injection device that is optimally suited for mass production through the Blow Fill Seal manufacturing process. The device utilizes a valve and a needle assembly fused to an insert. The valve and the needle assembly are positioned within the insert forming a conduit. The needle assembly is covered with a needle cap that is detachably coupled to protecting the needle assembly from contamination and a user from accidental needle stick. The insert is engaged to the bellows during the BFS manufacturing process and hermetically sealed by a parison layer that covers exterior portion of the insert and the needle cap. The parison layer is formed and trimmed creating exterior features that facilitate the use of the prefilled medical injection.