Retractable Needle Assembly Universal Barrel Mounting
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Solution Overview
Problem
Existing safety syringes require complex manufacturing processes and specific barrel configurations, making them difficult to adapt to varying syringe shapes and materials, particularly glass barrels, and often include non-standard components that are costly and pose regulatory challenges.
Innovation Solution
A barrel-adaptable needle retraction system that integrates a retractable needle assembly with a plunger mechanism, allowing flexible attachment to standard barrels, including straight-glass barrels, using off-the-shelf components and minimizing the number of components to reduce interaction with therapeutic fluids and enhance safety features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If relatively complicated retractable needle assemblies are devised for a particular syringe barrel shape or configuration, then needle retraction function is achieved, but adaptability to different barrel shapes and configurations is reduced
Solution Approach 1:
The needle assembly is designed with a universal mounting interface that can be attached to syringe barrels of various shapes and configurations. The retainer component features a generic attachment mechanism that accommodates different barrel geometries, allowing the same needle assembly design to function across multiple syringe types without requiring specifically-tailored retraction mechanisms for each barrel configuration.
Solution Approach 2:
The needle assembly is divided into separable components including a needle, retainer, and mounting interface. This segmentation allows the needle assembly to be independently designed for reliable retraction while the mounting interface adapts to different barrel configurations, resolving the contradiction between functional reliability and adaptability.
2Reliability
If specifically-tailored retraction mechanisms and barrel configurations are required, then needle retraction reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
A single, standardized needle assembly design with universal mounting capabilities eliminates the need for multiple specifically-tailored retraction mechanisms. This universality simplifies manufacturing processes and reduces complexity while maintaining reliable needle retraction function across different syringe configurations.
Solution Approach 2:
The needle assembly incorporates self-aligning and self-retaining features that eliminate the need for complex adjustment mechanisms during manufacturing. The design allows for straightforward attachment to barrels of various configurations without requiring specialized assembly procedures, thereby reducing manufacturing complexity.
3Reliability
If non-standard components are used to achieve needle retraction, then safety function is improved, but regulatory approval difficulty and cost increase
Solution Approach 1:
The needle assembly uses standardized, off-the-shelf components where possible, particularly in the mounting interface and retainer mechanisms. This approach facilitates regulatory approval by demonstrating compliance with existing medical device standards while still achieving the safety function of reliable needle retraction.
Solution Approach 2:
The needle assembly is designed as a disposable component that integrates safety function into a single-use device. This approach simplifies regulatory considerations compared to reusable components requiring sterilization and maintenance protocols, while maintaining high safety standards through consistent manufacturing of the disposable unit.
Data Source
AI summary
Needle assemblies for retractable needle syringes include a needle, a needle seal, and a needle retainer, wherein the needle includes one or more barbs substantially at its proximal end. The needle retainer engages an optional needle-over-mold component that is fixedly attached to the needle. The needle-over-mold may be connected to the distal surface of the needle seal and may travel, such as by being a couple component, with the needle during the operation of the syringe. A safety syringe includes a barrel having a needle assembly mounted at a distal end and a plunger assembly mounted at a proximal end. A drug may be contained in a drug chamber of barrel, between the plunger assembly and needle assembly, proximally of the needle seal for drug delivery to a user. The plunger assembly includes a plunger seal having a needle-engaging portion to capture the needle at the barb for retraction.