Protective Cap Mechanical Membrane Attachment
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Solution Overview
Problem
Existing protective injection devices for medical devices face challenges with production complexity and cost due to temperature-dependent ultrasonic welding of resilient barrier members, which requires precise tensioning and is prone to aging-related tension loss, leading to leakage issues.
Innovation Solution
A protective cap with a membrane holder using a resilient membrane made from medical-grade elastomeric polymers, where the membrane is mechanically attached and tensioned only upon application, eliminating the need for ultrasonic welding and reducing aging-related issues by maintaining a non-tensioned state during storage and transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to attach the resilient barrier member, then the membrane can be securely affixed, but the production process becomes complicated and costly due to temperature dependence and tight tolerances
Solution Approach 1:
The patent replaces the thermal ultrasonic welding process with a mechanical attachment system consisting of a holding flange and clamping structure. The membrane is mechanically clamped between the holding flange and the device body, eliminating the need for temperature-dependent welding processes and associated quality control complexities.
Solution Approach 2:
The patent extracts the membrane attachment function from the complex ultrasonic welding process and implements it through a simple mechanical clamping mechanism. The holding flange structure separates the membrane securing function from the main device body, allowing for straightforward assembly without specialized equipment.
2Reliability
If the barrier member is highly tensioned during mounting, then the piercing site closes completely, but the piercing member may punch out a piece of the membrane
Solution Approach 1:
The patent implements a dynamic tensioning system where the membrane tension is adjusted based on the operational state. During storage and transport, the membrane is held in a relaxed state by the holding flange. When the device is activated and the piercing member is inserted, the membrane automatically tensions to provide complete sealing, preventing both premature punching and incomplete closure.
Solution Approach 2:
The holding flange structure is designed to pre-position the membrane in a relaxed state during manufacturing and storage. The membrane is tensioned only when needed during actual use, after the piercing member has been inserted and begun to pull the membrane taut. This preliminary positioning prevents excessive tension during handling while ensuring adequate tension during operation.
3Ease of operation
If the barrier member is mounted with predetermined tensioning compression, then the membrane is ready for use, but the membrane loses tension over time due to aging
Solution Approach 1:
The patent transitions from a static pre-tensioned mounting system to a dynamic tensioning system. The holding flange maintains the membrane in a relaxed state during storage and transport, preventing aging-related tension loss. When the device is activated, the membrane automatically tensions to the required level, ensuring consistent performance throughout the product lifecycle without degradation from prolonged tensioning.
4Ease of operation
If the piercing member is movable with respect to the sealing member, then the piercing can be performed, but the sealing member may not close completely after removal
Solution Approach 1:
The patent implements a self-service sealing mechanism where the membrane automatically tensions and seals the piercing site without requiring additional components or complex mechanisms. The holding flange structure allows the piercing member to move freely during insertion, and the membrane's elastic properties enable it to automatically return to its sealed state after the piercing member is removed, ensuring complete closure.
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 simplifies the assembly process, reduces production costs, and enhances the membrane's lifespan by applying tension only when needed, ensuring a reliable seal against leakage and contamination.
Implementation Method 1
a resilient membrane (18) arranged to cover the opening (15), the resilient membrane (18) comprising a piercing portion (20) and a sealing portion (22)
Implementation Method 2
the attachment means being an adhesive attachment means or a mechanical attachment means or a combination of an adhesive attachment means and a mechanical attachment means
Data Source
AI summary
A protective cap (1) for application on a medical device such as a medical vial (2) comprising a membrane holder (3) in which a resilient membrane (18) is mounted. The protective cap (1) is provided with connection means (10) for connecting the cap (1) to the medical device (2). The resilient membrane (18) comprises a piercing portion (20) and a sealing portion (22) and is mechanically and/or adhesively held in the protective cap (1) and is arranged to be brought into sealing contact with a receiving portion of the medical device (2) when the protective cap (1) is applied on the medical device (2).