Variable shape syringe package system

Abstract

A syringe and syringe package system comprising: a syringe barrel having a distal end and an open proximal end; and a syringe stopper disposed at the open proximal end of the syringe barrel. The system includes a variable shape package within which a syringe barrel and a syringe stopper are housed, where the variable shape package includes a web of material sized and arranged to house the syringe barrel and the syringe stopper and configured to be transformed into a plunger rod engaged with the syringe stopper, and is translatable within the open proximal end of the syringe barrel.

Description

Technical Field

[0001] The present disclosure relates generally to medical syringes and packaging, and in particular, to syringes packaged in shape-shifting packages. Background Art

[0002] Disposable medical devices and medical device packaging made of plastic are an important source of landfill waste. The increase in plastic usage over the past few decades has led to an impact on the increased capacity of landfills and the depletion of resources based on fossil fuels. Syringes include syringe barrels, plungers, and stoppers, which are typically packaged in blister packs or clamshell blister packs made of plastic. Plastic medical devices and plastic packaging for medical devices have caused an increase in the level of environmental pollution, related carbon footprints, and other environmental impacts. Although medical waste can be incinerated, incineration may produce potential air pollution problems.

[0003] While recycling of some medical device products (e.g., syringes) and packaging may be feasible, not all healthcare facilities (e.g., hospitals, urgent care facilities, medical offices, and long-term care facilities) may be able or willing to comply with used medical device recycling. Cost and convenience issues associated with complying with used medical device recycling may hinder widespread adoption of used medical device and packaging recycling. Furthermore, a supply chain must be established for the collection of used devices and packaging, as well as for the packaging, transportation, shredding, sterilization, and reuse of recycled plastics from used medical devices.

[0004] It would be desirable to provide alternative solutions to the problem of waste generated by the use of medical devices, including syringes and their associated packaging. Summary of the Invention

[0005] In a first embodiment, a syringe and syringe packaging system includes: a syringe barrel having a distal end and an open proximal end; a syringe stopper placed in the open proximal end of the syringe barrel; and a shape-shifting package, wherein the syringe barrel and the syringe stopper are contained within the shape-shifting package, wherein the shape-shifting package includes a web of material sized and arranged to accommodate the syringe barrel and the syringe stopper and configured to transform into a plunger rod that engages the syringe stopper and is capable of translating within the open proximal end of the barrel.

[0006] In a second embodiment, a syringe and syringe packaging system includes: a syringe barrel having a distal end and an open proximal end; a syringe stopper placed in the open proximal end of the syringe barrel; and a shape-shifting package, wherein the syringe barrel and the syringe stopper are contained within the shape-shifting package, wherein the shape-shifting package includes a wound web of biodegradable material, the wound web of biodegradable material being sized and arranged to accommodate the syringe barrel and the syringe stopper and configured to transform into a plunger rod that engages the syringe stopper and is capable of translating within the open proximal end of the syringe barrel. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] In order that the manner in which the above-recited features of the present invention may be understood in detail, a more particular description of the invention may be had by reference to embodiments, some of which are illustrated in the accompanying drawings. It should be noted, however, that the drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

[0008] Figure 1 is a perspective view of a syringe and a shape-variable package according to a first embodiment;

[0009] Figure 2 yes Figure 1 a side view of the syringe and the shape-shifting package shown with the syringe partially removed from the shape-shifting package;

[0010] Figure 3 yes Figure 1 a side view of the syringe and the shape-shifting package shown with the syringe completely removed from the shape-shifting package;

[0011] Figure 4A yes Figure 1 a front left perspective view of the illustrated shape-flexible package;

[0012] Figure 4B yes Figure 1 a front right perspective view of the illustrated shape-flexible package;

[0013] Figure 5 is a partial perspective view of a shape-shifting package configured as a plunger rod and prior to assembly with a stopper;

[0014] Figure 6 is a partially cutaway side view of a syringe stopper and a plunger rod inserted into the syringe stopper;

[0015] Figure 7 is a front perspective view of a second embodiment of a syringe and a shape-shifting package;

[0016] Figure 8A yes Figure 7 a front perspective view of the illustrated shape-shifting package;

[0017] Figure 8B yes Figure 8A A front perspective view of a shape-variable package configured as a plunger rod is shown;

[0018] Figure 9A Inserted into the stopper of the syringe Figure 8B A perspective view of a shape-variable package configured as a plunger rod is shown;

[0019] Figure 9B Shown is the stopper inserted into the syringe Figure 9A A detailed view of a package configured as a variable shape plunger rod is shown;

[0020] Figure 10 Shown Figure 7 A side view of the shape-flexible package is shown;

[0021] Figure 11 is a perspective view of a third embodiment of a syringe and a plunger rod formed from a shape-variable package;

[0022] Figure 12A is in the assembled configuration Figure 10 a perspective view of the plunger rod shown; and

[0023] Figure 12B is in disassembled configuration and ready for assembly Figure 11 A is a perspective view of the plunger rod shown.

[0024] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. The figures are not drawn to scale. DETAILED DESCRIPTION

[0025] Before describing several exemplary embodiments of the present disclosure, it should be understood that the present disclosure is not limited to the details of construction or process steps set forth in the following description, and the present disclosure is capable of other embodiments and can be practiced or carried out in various ways.

[0026] The matters illustrated in this specification are provided to help understand the exemplary embodiments of the present disclosure. Before describing several exemplary embodiments of the present disclosure, it should be understood that the present disclosure is not limited to the details of the construction or process steps set forth in the following description. The present disclosure can have other embodiments and can be practiced or implemented in various ways.

[0027] With respect to terms used in this disclosure, the following definitions are provided: As used herein, the use of "a," "an," and "the" includes both the singular and the plural.

[0028] Reference to a "medical device" refers to any device intended for medical purposes, such as a syringe. Reference to a "syringe" includes references to syringes used with a needle, nozzle, tubing, or in an irrigation system. As used herein, the term "syringe" refers to a simple pump-like device consisting of a plunger rod mounted in a barrel or tube. The plunger rod can be pulled or pushed inside the barrel, allowing the syringe to draw in and expel liquid or gas through an opening at the open end of the barrel. The open end of the syringe can be equipped with a needle, nozzle, or tubing to help guide fluid in and out of the barrel. Depending on the needs of the technician, the syringe can be sterile or non-sterile.

[0029] As used herein, the term "package" or "packaging" includes any material used to wrap or protect a good or product (e.g., a syringe). As used herein, "shape-shifting" means that the package can change shape or size in one or more ways, including but not limited to collapsing, rolling, rearranging, folding, etc.

[0030] Aspects of the syringes and syringe packaging systems described herein facilitate the disposal of packaging and syringe waste. The syringes and syringe packaging systems disclosed herein also.

[0031] The following non-limiting description illustrates the principles of one or more embodiments according to the present disclosure. Figure 1-6 , a first embodiment of a syringe and syringe package system 100 is shown, which includes a syringe barrel 102 having an open proximal end 104 and a distal end 106. The distal end 106 of the syringe barrel 102 can be configured for connection to a medical device, catheter, or needle (not shown).

[0032] The syringe and syringe package system 100 also includes a syringe stopper 108 positioned in the open proximal end 104 of the syringe barrel 102. Additionally, the syringe and syringe package system 100 also includes a shape-shifting package 120, and the syringe barrel 102 and the syringe stopper 108 are contained within the shape-shifting package 120. The shape-shifting package 120 includes a web of material 122 sized and arranged to contain the syringe barrel 102 and the syringe stopper 108 and configured to transform into a plunger rod 140 that engages the syringe stopper 108 and is capable of translating within the open proximal end 104 of the syringe barrel 102. The plunger rod 140, according to one or more embodiments, engages the stopper via a lug 142 extending from the web of material 122, as will be further described below.

[0033] In one or more embodiments of the syringe and syringe package system 100, the web of material 122 includes a distal end 121 and a proximal end 123. As shown in the figures, the lugs 142 extend radially outward from the distal end 121 of the web of material.

[0034] like Figure 4A and Figure 4B As best shown, the web of material 122 further includes a first edge 124 extending from the distal end 121 to the proximal end 123, the first edge 124 including a fold 127, and a second edge 126 extending from the distal end 121 to the proximal end 123 and opposite the first edge 124. The second edge 126 includes a locking element 129 configured to engage the fold 127. In one or more embodiments, the web of material 122 is in the form of a sheet of material that can be bent to form the fold 127, and the locking element 129 can be a protrusion or corrugation extending outward from the web of material 122. The fold 127 can be a recess of any suitable size to allow the locking element 129 to fit therein. The locking element 129 is pushed into the fold 127, thereby forming the web of material into a tubular housing that, in a first configuration, is sized to accommodate the syringe barrel 102 and the syringe stopper 108, thereby forming a shape-shifting package 120 that maintains the syringe barrel 102 and the syringe stopper 108 in a clean and sterile condition until the syringe barrel and the syringe stopper are ready to be removed from the shape-shifting package 120. The shape-shifting package 120 also includes a distal cap 125 and a proximal cap 131.

[0035] Thus, the syringe and syringe package system 100 in the illustrated embodiment includes a locking element 129 comprising a radial protrusion extending outwardly from the web of material 122 that is configured to releasably engage the fold 127. This arrangement facilitates transitioning the shape-shifting package 120 into a plunger rod 140.

[0036] In the syringe and syringe package system 100, the shape-shifting package 120 is configured to be collapsible from a first coiled configuration having a first diameter to a second coiled configuration having a second diameter smaller than the first diameter. Figures 1 to 4A - Figure 4B The first diameter is sized so that the cavity formed by the web of material 122 can receive the syringe barrel 102 and the syringe plunger. The second diameter is sized so that when in Figure 5 and Figure 6When in the second, coiled configuration shown, the lugs 142 engage the receiving grooves 109 in the syringe stopper 108. The receiving grooves 109 can be in the form of threads, and the lugs 142 can be angled so that the plunger rod 140 (which has been transformed from the shape-shifting package 120 to the plunger rod 140 by coiling the material web 122 to reduce the diameter of the coiled material web 122) can be screwed into the syringe stopper. In other embodiments, the lugs 142 can be press-fit into the grooves 109 in the syringe stopper 108.

[0037] Thus, in one or more embodiments, the first diameter is sized and arranged to accommodate the syringe barrel 102 and the syringe stopper 108 , and the second diameter is sized such that the distal end 121 of the plunger rod 140 fits within the syringe stopper 108 and the syringe barrel 102 .

[0038] In the illustrated embodiment, the syringe and syringe packaging system 100 further includes a flange 135 extending from the proximal end, which provides a thumb press for the plunger rod 140. In one or more embodiments, the web of material 122 comprises a biodegradable material. As used herein, according to one or more embodiments, biodegradable refers to a material that is decomposed by living organisms (e.g., bacteria) and that the decomposed material is harmless. Thus, biodegradable materials avoid contamination and are environmentally friendly.

[0039] In one or more embodiments, the biodegradable material is soluble in a solvent (e.g., alcohol). In certain embodiments, the biodegradable material comprises, consists essentially of, or consists of zein. Zein is a protein polymer obtained from corn by extracting the polymer from corn. By replacing the packaging material and plunger rods with plastic materials currently used for packaging and plunger rods (e.g., polypropylene materials), landfill waste is significantly reduced. Plastic materials such as polypropylene are not biodegradable and are not environmentally sustainable. According to one or more embodiments, the biodegradable material used for the material web should have sufficient tensile and compressive strength to withstand the forces applied to the plunger rod used to draw fluid into and expel fluid from the syringe. It has been determined that a web material made of zein can be used as a plunger rod according to the embodiments described herein.

[0040] Now refer to Figures 7 to 10, shows a syringe and syringe package system 200 according to a second embodiment, which includes a syringe barrel 102 having an open proximal end 104 and a distal end 106 similar to those of the first embodiment. The distal end 106 of the syringe barrel 102 is configured for connection to a medical device, catheter, or needle (not shown). Similar to the first embodiment, the syringe and syringe package system 200 also includes a syringe stopper 108 positioned within the open proximal end 104 of the syringe barrel 102. The shape-shifting package 220 also includes a distal cap 225 and a proximal cap 231.

[0041] In a second embodiment, a shape-shifting package 220 has a different configuration than the shape-shifting package 120 shown in the first embodiment. Only the components that differ are described herein. The syringe barrel 102 and the syringe stopper 108 are housed within the shape-shifting package 220. The shape-shifting package 220 includes a web of material 222 sized and arranged to house the syringe barrel 102 and the syringe stopper 108 and configured to transform into a plunger rod 240 that engages the syringe stopper 108 and is capable of translating within the open proximal end 104 of the syringe barrel 102. The plunger rod 240, according to one or more embodiments, engages the stopper via a keying surface 242 extending from the web of material 122, as will be further described below.

[0042] In the second embodiment of the syringe and syringe package system 200, the web of material 222 includes a distal end 221 and a proximal end 223. The web of material 222 also includes a first edge 224 and a second edge 226 extending from the distal end 221 to the proximal end 223 and opposite the first edge 224. There is a first elongated protrusion 251 extending radially inwardly adjacent to the second edge 226, which is configured to extend when the web of material is in the Figure 8A The illustrated embodiment is sized and shaped to engage the first edge 224 when accommodating the syringe barrel 102 and syringe stopper 108 in the first coiled configuration. Figure 8A In the illustrated configuration, the web of material 222 is configured as a shape-shifting package 220 .

[0043] Figure 7 and Figure 8AThe deformable package 220 is configured to collapse from a first rolled configuration having a first diameter to a second rolled configuration having a second diameter less than the first diameter. In a second embodiment, the web of material 222 further includes a second elongated protrusion 252 adjacent to the second edge 226 and extending outwardly, and a third elongated protrusion 253 adjacent to the first edge 224 and extending radially outwardly. The first edge 224 and the first elongated protrusion 253 are positioned to engage each other when the deformable package is in the first rolled configuration. In the second embodiment, the second elongated protrusion 252 provides a keying surface 242 at the distal end 221 for engaging the syringe stopper 108. In the second embodiment, the web of material further includes a flange 235 that acts as a thumb press when the deformable package 220 collapses and transforms into the plunger rod 240.

[0044] In a second embodiment, the biodegradable material is soluble in a solvent (e.g., alcohol). In certain embodiments, the biodegradable material comprises, consists essentially of, or consists of zein. Zein is a protein polymer obtained from corn by extracting the polymer from corn. By replacing the packaging material and plunger rods with currently used plastic materials (e.g., polypropylene materials) for packaging and plunger rods, landfill waste is significantly reduced. Plastic materials such as polypropylene are not biodegradable and are not environmentally sustainable. According to one or more embodiments, the biodegradable material used for the material web should have sufficient tensile and compressive strength to withstand the forces applied to the plunger rod used to draw fluid into and expel fluid from the syringe. It has been determined that a web material made of zein can be used as a plunger rod according to the embodiments described herein.

[0045] exist Figure 11 and Figures 12A-12B In the illustrated third embodiment of a syringe and syringe packaging system 300, a web of material 322 for the packaging is configured to be assembled into a T-shaped plunger rod 340, as shown. In this embodiment, the web of material 322 is provided in a configuration in which a portion of the web of material 322 made of a biodegradable material (e.g., zein) includes fold lines and / or perforations and slots formed in the web of material. Instructions for assembling the web of material into a T-shaped plunger rod having a thumb press 335 and a stopper-engaging portion 337 are provided within the packaging.

[0046] It will be appreciated that the syringe and syringe packaging system addresses the urgent need to reduce plastic waste generated by syringes and packaging. The proposed syringe and syringe packaging system will help reduce the carbon footprint of medical device disposal. The present disclosure utilizes biodegradable packaging materials, one example being zein. Zein is a member of a class of prolamin-rich alcohol-soluble proteins and is generally considered safe for use in drug coatings.

[0047] References throughout this specification to "one embodiment," "some embodiments," "one or more embodiments," or "an embodiment" mean that the particular features, structures, materials, or characteristics described in connection with the embodiment are included in at least one embodiment of the present disclosure. Thus, phrases such as "in one or more embodiments," "in some embodiments," "in an embodiment," or "in an embodiment" that appear in various places throughout this specification are not necessarily referring to the same embodiment of the present disclosure. Furthermore, the particular features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments.

[0048] Although the present disclosure has been described herein with reference to specific embodiments, it should be understood that these embodiments are merely illustrative of the principles and applications of the present disclosure. It will be apparent to those skilled in the art that various modifications and variations may be made to the methods and apparatus of the present disclosure without departing from the spirit and scope of the present disclosure. Therefore, the present disclosure is intended to include modifications and variations that fall within the scope of the appended claims and their equivalents.

Claims

1. A syringe and syringe packaging system comprising: a syringe barrel having a distal end and an open proximal end; a syringe stopper disposed in the open proximal end of the syringe barrel; as well as A shape-shifting package, the syringe barrel and the syringe stopper being contained within the shape-shifting package, wherein the shape-shifting package comprises a web of material sized and arranged to contain the syringe barrel and the syringe stopper and configured to transform into a plunger rod that engages the syringe stopper and is capable of translating within the open proximal end of the syringe barrel.

2. The syringe and syringe packaging system of claim 1, wherein: The material web includes a distal end, a proximal end, a first edge extending from the distal end of the material web to the proximal end of the material web, and a second edge extending from the distal end of the material web to the proximal end of the material web and opposite the first edge, the first edge including a fold, and the second edge including a locking element configured to engage with the fold.

3. The syringe and syringe packaging system of claim 2, wherein: The shape-shifting package is configured to be collapsible from a first rolled configuration having a first diameter to a second rolled configuration having a second diameter that is smaller than the first diameter.

4. The syringe and syringe packaging system of claim 3, wherein: The first diameter is sized and arranged to receive the syringe barrel, and the second diameter is sized to fit within the syringe stopper and the syringe barrel.

5. The syringe and syringe packaging system of claim 4, wherein: The locking element includes a radial protrusion extending outwardly from the web of material and configured to releasably engage the fold.

6. The syringe and syringe packaging system of claim 2, further comprising a lug extending radially outward from a distal end of the web of material and configured to engage the syringe stopper.

7. The syringe and syringe packaging system of claim 6, wherein: The syringe stopper includes threads configured to engage the lugs.

8. The syringe and syringe packaging system of claim 6, further comprising a flange extending from the proximal end, the flange providing a thumb press for the plunger rod.

9. The syringe and syringe packaging system of claim 2, wherein: The web of material comprises a biodegradable material.

10. The syringe and syringe packaging system of claim 9, wherein: The biodegradable material includes zein.

11. The syringe and syringe packaging system of claim 1 , wherein: The material web includes a distal end, a proximal end, a first edge extending from the distal end of the material web to the proximal end of the material web, a second edge extending from the distal end of the material web to the proximal end of the material web and opposite the first edge, and a first elongated protrusion extending radially inward adjacent to the second edge, the first elongated protrusion being configured to engage with the first edge when the material web is in a first wound configuration sized and shaped to accommodate the syringe barrel and the syringe stopper.

12. The syringe and syringe packaging system of claim 11, wherein: The shape-shifting package is configured to be collapsible from a first rolled configuration having a first diameter to a second rolled configuration having a second diameter that is smaller than the first diameter.

13. The syringe and syringe packaging system of claim 12, wherein: The material web also includes a second elongated protrusion adjacent to the second edge and extending outwardly, and a third elongated protrusion adjacent to the first edge and extending outwardly, wherein the first elongated protrusion and the first are positioned to engage each other when the shape-changing package is in the first rolled configuration.

14. The syringe and syringe packaging system of claim 13, wherein: The second elongated protrusion provides a keying surface configured to engage the syringe stopper.

15. The syringe and syringe packaging system of claim 14, further comprising a flange extending from the proximal end, the flange providing a thumb press for the plunger rod.

16. The syringe and syringe packaging system of claim 15, wherein: The web of material comprises a biodegradable material.

17. The syringe and syringe packaging system of claim 16, wherein: The biodegradable material includes zein.

18. The syringe and syringe packaging system of claim 1, wherein: The web of material is configured to be assembled into a T-shaped plunger rod.

19. A syringe and syringe packaging system comprising: a syringe barrel having a distal end and an open proximal end; a syringe stopper disposed in the open proximal end of the syringe barrel; as well as A shape-shifting package, the syringe barrel and the syringe stopper contained within the shape-shifting package, wherein the shape-shifting package comprises a wound web of biodegradable material sized and arranged to contain the syringe barrel and the syringe stopper and configured to transform into a plunger rod that engages the syringe stopper and is capable of translating within the open proximal end of the syringe barrel.

20. The syringe and syringe packaging system of claim 19, wherein: The biodegradable material includes zein.

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