Prefilled Syringe Delivery Device With Deformable Shoulder Force Isolation

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Solution Overview

Problem

Existing autoinjectors are not configured to handle prefilled syringes effectively, leading to potential breakage of the syringe flange or body due to high forces applied during needle insertion, and can result in medicament leakage or premature injection when a force is applied to the plunger.

Innovation Solution

A medicament delivery device with a housing, medicament container, and movable member, utilizing an energy storage member to control the force applied to the plunger, including a deformable shoulder to isolate the plunger during storage and ensure proper needle insertion and retraction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If a spring-loaded member is placed in contact with the plunger during storage, then the autoinjector can provide stored energy for needle insertion and medicament injection, but this can cause leakage of the medicament due to force applied against the plunger

Engineering Contradiction:

Improvestored energy for needle insertionVSAvoidmedicament leakage

Core Design Contradiction:

Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

The movable member is segmented into distinct functional zones: a first shoulder for engaging the flange during needle insertion, a deformable portion that isolates the plunger from the spring-loaded member during storage, and a second shoulder for engaging the flange during medicament injection. This segmentation allows the spring-loaded member to provide stored energy without applying force to the plunger during storage, preventing medicament leakage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The deformable portion of the movable member acts as an intermediary between the spring-loaded member and the plunger. During storage, this deformable portion absorbs the force from the spring-loaded member, preventing direct force transmission to the plunger and thereby preventing medicament leakage. During injection, the deformable portion deforms to allow proper force transmission.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Force

If high forces are applied to the flange during needle insertion operation, then the needle can be inserted effectively, but this can lead to breakage of the syringe flange or body

Engineering Contradiction:

Improveforce for needle insertionVSAvoidsyringe flange strength

Core Design Contradiction:

ForceVSStrength

Solution Approach 1:

The first shoulder of the movable member is configured to engage the flange beforehand during the needle insertion operation. This engagement distributes the insertion force across a larger area of the flange and provides a mechanical advantage that reduces peak stresses, preventing breakage of the syringe flange or body while still enabling effective needle insertion.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Productivity

If force is applied to the plunger during needle insertion event, then the medicament can be injected, but this can result in premature injection before the needle is inserted to the desired location

Engineering Contradiction:

Improveinjection speedVSAvoidinjection timing control

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The movable member is designed to perform preliminary actions in a specific sequence: first, the first shoulder engages the flange to facilitate needle insertion; second, the deformable portion deforms to establish proper engagement; third, the second shoulder engages the flange to control medicament injection. This preliminary sequencing ensures the needle is properly inserted before any medicament injection occurs, preventing premature injection while maintaining efficient delivery.

Inventive Principle:

Principle #10Preliminary 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

The device ensures controlled medicament delivery with reduced risk of leakage and premature injection, allowing for safe and efficient administration of medicaments using prefilled syringes.

Implementation Method 1

utilizing an energy storage member to control the force applied to the plunger

Methodology Applied

Scientific EffectEnergy storage: Spring

Implementation Method 2

A portion of the first shoulder is configured to deform when the medicament container is in the second position such that at least a portion of the force is exerted upon the plunger

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS12420016B2Medicament delivery devices for administration of a medicament within a prefilled syringe

Publication Date: 2025.09.23 KALEO INC

AI summary

An apparatus includes a housing, a medicament container and a movable member. The medicament container is movable within the housing between a first position and a second position in response to a force produced by an energy storage member. A proximal end portion of the medicament container includes a flange and has a plunger disposed therein. A first shoulder of the movable member exerts the force on the flange to move the medicament container from the first position to the second position. A portion of the first shoulder deforms when the medicament container is in the second position such that at least a portion of the force is exerted upon the plunger. A second shoulder of the movable member exerts a retraction force on the flange to move the medicament container from the second position towards the first position.