Prefilled Syringe Barrel Geometry for Lower Glass Material Use
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Solution Overview
Problem
Standardized glass pre-filled syringes result in underutilization of volumetric capacity for low dose applications, contributing significantly to waste due to their energy-intensive production and disposal, and are not optimized for reduced material content.
Innovation Solution
Syringes with optimized dimensions and configurations, including reduced wall thickness, outer diameter, and form factor, to minimize material usage while maintaining structural integrity, thereby reducing waste and improving sustainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If standardized syringe specifications are used, then procurement and storage are optimized, but volumetric capacity is underutilized for low dose applications
Solution Approach 1:
The patent applies parameter changes by modifying the syringe barrel dimensions (outer diameter, height, wall thickness) to create multiple standardized specifications (e.g., 0.5ml, 1.0ml, 1.5ml, 2.0ml, 3.0ml, 5.0ml, 10.0ml, 20.0ml, 30.0ml, 50.0ml, 60.0ml, 80.0ml, 100.0ml). This allows optimization of volumetric capacity utilization for different dose requirements while maintaining standardization benefits for procurement and storage.
2Strength
If traditional glass syringes are used, then structural integrity is maintained, but material consumption and energy use are high
Solution Approach 1:
The patent optimizes the wall thickness parameter (T1) to be between 0.5mm and 1.5mm, and adjusts the ratio of material volume to fluid volume (V2/V1) to be between 0.3 and 2.0. These parameter changes reduce glass material consumption and associated energy use while maintaining sufficient structural integrity for drug administration.
3Loss of energy
If wall thickness is reduced to minimize material usage, then sustainability improves, but structural integrity may be compromised
Solution Approach 1:
The patent establishes an optimized wall thickness range (T1: 0.5mm to 1.5mm) and material-to-fluid volume ratio (V2/V1: 0.3 to 2.0) that balances material reduction with structural integrity. This parameter optimization ensures the barrel maintains sufficient strength for its function while minimizing glass material usage and associated energy consumption.
4Manufacturing precision
If standardized syringe geometry is used, then manufacturing consistency is maintained, but material efficiency is reduced
Solution Approach 1:
The patent defines multiple standardized specifications with precise dimensional parameters (outer diameter D1, height H1, wall thickness T1, form factor FF) that maintain manufacturing consistency while optimizing material efficiency. Each specification is engineered to achieve the appropriate balance between structural integrity and material reduction for its intended dose volume.
Data Source
Figure 1
AI summary
A syringe, comprising: a barrel defining a proximal end, a distal end, and an interior cavity, wherein the barrel defines: an outer diameter (D1), an inner diameter (D2), a wall thickness (T1), a height (H1) extending from the proximal end to the distal end, a form factor (FF) defined as H1/D1, a first volume (V1) of the interior cavity of at least 0.5 ml, a second volume (V2) of a material constituting the barrel, and a weight (W1) of the barrel, wherein: V2/V1 is between 0.5 and 1.6, W1/V1 is less than 4.2 g/ml, T1 is less than 1.0 mm, H1 is less than 62 mm, and FF is less than 6.0.