One-Piece Synthetic Cap with Jamming Areas for Insulin Pen Sealing
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Solution Overview
Problem
Current sealing methods for drug cartridges, such as crimping with aluminum capsules, generate debris and risk contamination in cleanroom environments and can lead to rotation issues with sealing washers, compromising drug integrity and patient safety, especially in small containers like insulin pens.
Innovation Solution
A one-piece synthetic cap with a skirt and jamming areas to securely hold a circular stopper, featuring release areas for radial expansion, preventing breakage and contamination, and ensuring effective isolation without metal or paint particle release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a crimping tool is used to secure the aluminum capsule on the cartridge neck, then the sealing function is achieved, but particles of aluminum, glass or paint are released causing contamination
Solution Approach 1:
The invention extracts and eliminates the crimping tool and aluminum capsule from the sealing system, replacing them with a one-piece plastic cap that secures the stopper through integrated jamming areas without generating metallic debris or paint particles during installation
Solution Approach 2:
The invention replaces the durable aluminum capsule with a disposable one-piece plastic cap that is molded and discarded after use, eliminating the need for expensive crimping tools and avoiding contamination from metal particles while maintaining effective sealing
2Reliability
If the sealing washer is pre-installed inside the aluminum capsule, then the sealing function is provided, but the sealing washer may rotate in relation to the cartridge compromising isolation
Solution Approach 1:
The invention merges the cap and stopper into a single integrated unit where the stopper is permanently molded within the cap structure, eliminating relative movement and rotation between components while maintaining the sealing function through the integrated design
Solution Approach 2:
The invention segments the sealing function into distinct components: the one-piece cap provides structural support and locking through jamming areas, while the integrated stopper provides the sealing surface, with both components working together without relative movement
3Object-affected harmful factors
If a one-piece plastic cap is used to cover the neck and stopper, then particle contamination is prevented, but the cap may tear under compressive force if dimensions are reduced for small containers
Solution Approach 1:
The invention applies local quality by creating regions of different thickness within the cap structure: thicker walls in stress-bearing areas and thinner walls in non-critical areas, optimizing both strength and contamination prevention without requiring overall dimensional increases
Solution Approach 2:
The invention uses a one-piece molded plastic construction that combines multiple functional elements (cap, jamming areas, stopper housing) into a single homogeneous material structure, eliminating joints and potential failure points while preventing particle contamination through the integrated design
4Adaptability or versatility
If the cap dimensions are reduced to fit small containers like cartridges, then adaptability to small containers is achieved, but the compressive force required to secure the stopper causes radial expansion that may tear the cap
Solution Approach 1:
The invention applies local quality by creating regions of different thickness within the cap structure: thicker walls in stress-bearing areas and thinner walls in non-critical areas, optimizing both strength and contamination prevention without requiring overall dimensional increases
Solution Approach 2:
The invention incorporates dynamic characteristics by designing the cap with controlled flexibility in specific regions, allowing the material to deform elastically under compression and return to its original shape, preventing permanent deformation or tearing while maintaining secure stopper engagement
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 provides a cost-effective, reliable sealing mechanism that maintains drug integrity and prevents contamination, suitable for small containers like insulin pens, ensuring secure sealing without risk of breakage or particle release.
Implementation Method 1
the skirt has at least two jamming areas for jamming the stopper
Implementation Method 2
the skirt has, on the inner radial surface thereof and between the two jamming areas for jamming the stopper, a release area with a diameter strictly greater than the minimum unstressed diameter of the stopper
Data Source
AI summary
A sealing device for a container comprising a circular cap designed to seal the neck of the container and a cover made from a synthetic material capable of covering both the neck and the cap fitted on the neck, the cover being provided with means for locking onto the neck, the cover being in one piece and comprising a skirt capable of radially surrounding a collar of the neck of the container, and an annular portion provided with a central opening allowing permanent access to the cap, and the skirt having at least two jamming areas for jamming the cap and, on the inner radial face thereof between the two jamming areas, a release area with a diameter strictly greater than the minimum unstressed diameter of the cap.