Single-Piece Liquid Applicator Frangible Tip Design
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Solution Overview
Problem
Existing liquid applicators for antiseptic skin preparation are complex and costly to assemble, with multiple components and weld seams that are susceptible to failure, making them difficult to manufacture and use effectively.
Innovation Solution
A single-piece, unitary body liquid applicator with a closed container that can be easily activated by fracturing a frangible connection, eliminating the need for secondary assembly steps and reducing the number of parts, and utilizing a blow-fill-seal process for manufacturing to integrate multiple components into a single, sterile unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple assembly components are used to create the applicator body, then the applicator can provide functional features (container, frangible tip, end cap), but the assembly becomes complex and costly with multiple weld seams and joints susceptible to failure
Solution Approach 1:
The patent merges the container body, frangible tip, and end cap into a single integrated applicator body formed by one continuous piece of biocompatible material. This eliminates the need for separate assembly components, weld seams, and joints, thereby reducing complexity while maintaining all necessary functional features. The integrated design prevents leakage and structural failure associated with multiple connection points.
Solution Approach 2:
The single-piece applicator body performs multiple functions simultaneously: it serves as the container structure, includes the frangible tip for controlled opening, and incorporates the end cap for sealing. This multi-functional design eliminates the need for separate components, reducing assembly complexity while maintaining versatility.
2Reliability
If glass ampoules are used to house the liquid, then the applicator is impermeable to ethylene oxide during sterilization, but the applicator requires numerous parts including components to prevent glass shards from reaching the patient
Solution Approach 1:
The patent replaces the reusable glass ampoule system with a disposable biocompatible polymer applicator body. This single-use design eliminates the need for complex glass shard prevention mechanisms while maintaining sterilization integrity. The polymer material provides inherent safety by not generating sharp shards upon activation.
Solution Approach 2:
The patent changes the material parameter from glass to biocompatible polymer, which fundamentally alters the safety profile. The polymer material is inherently safer as it does not produce sharp fragments upon fracturing, eliminating the need for additional protective components while maintaining sterilization barrier properties.
3Ease of manufacture
If plastic applicators with frangible plastic tips are used, then the applicator body functions as the container eliminating the glass ampoule, but the construction becomes complex requiring multiple assembly components
Solution Approach 1:
The patent merges the container body, frangible tip, and end cap into a single integrated structure formed from one continuous piece of biocompatible material. This eliminates the multiple assembly components required in conventional plastic applicators, simplifying manufacturing while maintaining the ease of manufacture benefits of plastic materials.
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 costs, and eliminates potential leak points, while providing a reliable and controlled mechanism for applying antiseptic solutions, enhancing both manufacturing efficiency and user experience.
Implementation Method 1
the container includes a closed proximal end and a closed distal end and is configured to be changed from a closed state in which the reservoir is not in fluid communication with ambience to an open state in which the reservoir is in fluid communication with ambience
Data Source
AI summary
A liquid applicator comprising an absorbent member, and a single-piece, unitary body. The body can include a closed container defining a reservoir, and a tab. The container can include a main portion, a transition portion, a rib, and a chamber located in the tab and coupled to the transition portion via a frangible connection. The main portion, the transition portion, the rib, and the chamber can each define a portion of the reservoir, and at least the main portion, the transition portion, and the rib can have a uniform wall thickness. The tab can include the chamber and can be coupled to the transition portion at least by the frangible connection, the tab being movable with respect to the transition portion between a first position in which the frangible connection is intact and a second position in which the frangible connection is fractured.