Auto-Injector Syringe

Abstract

To provide an injector that may auto-insert a needle into a patient or user.SOLUTION: An injector 30 comprises a housing 32 having a proximal end 33 and a distal end 35, a shell, a plunger, a needle guard, a first member, and an actuation assembly. The shell is within the housing 32 and has a cavity to receive at least a portion of a medicament chamber. The shell is moveable with respect to the housing 32 from an initial position to an injecting position. The plunger is moveable with respect to the shell. The needle guard is moveable between an extended position and a retracted position. The first member is within the housing 32. The actuation assembly is coupled to the housing 32 and the shell. The needle guard moves the first member with respect to the housing 32 as the needle guard moves from the extended position to the retracted position. The actuation assembly moves the shell from the initial position to the injecting position when the first member moves with respect to the housing 32. The actuation assembly moves the plunger with respect to the shell when the shell is in the injecting position.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 682,816, filed June 8, 2018, entitled "Auto-Insert Injector," which is incorporated herein by reference in its entirety.

[0002]

[0003] The present invention relates generally to syringes, and more particularly to syringes that can automatically insert a needle into a patient or user. Summary of the Invention [Means for solving the problem]

[0003]

[0004] In one embodiment, there is a syringe including a housing having a proximal end and a distal end, a shell, a plunger, a needle guard, a first member, and an actuation assembly. The shell can be within the housing and can have a cavity for receiving at least a portion of the medication chamber. The shell can be movable relative to the housing from an initial position to an injection position. The plunger can be movable relative to the shell. The needle guard can be movable between an extended position and a retracted position. The first member can be within the housing and coupled to the housing. The actuation assembly can be coupled to the housing and the shell. The needle guard can move the first member relative to the housing when the needle guard moves from the extended position to the retracted position. The actuation assembly can move the shell from the initial position to the injection position when the first member moves relative to the housing. The actuation assembly can move the plunger relative to the shell when the shell is in the injection position.

[0004]

[0005] Proximal movement of the needle guard can move the first member proximally relative to the housing. The shell can move relative to the housing in response to movement of the needle guard. Movement of the needle guard can trigger the syringe. The shell can move distally relative to the housing when the first member moves proximally relative to the housing. The first member can include a detent movable from a first position to a second position. The detent can engage with the housing to prevent movement of the first member when the detent is in the first position. The detent can disengage from the housing when the detent is in the second position. The needle guard can prevent movement of the detent from the first position to the second position when the needle guard is in the extended position.

[0005]

[0006] In a further embodiment, the syringe includes a second member secured to the housing, the second member including a catch engageable with the shell to prevent movement of the shell relative to the housing. The second member can at least partially surround the shell. The shell can include a recess, and the catch can be positioned within the recess when the catch is in the first position. The catch can move out of the recess when the first member moves relative to the housing. The actuation assembly can include a first biasing element operably associated with the housing and the shell. The first biasing element can move the shell from an initial position relative to the housing to an injection position when the first member moves relative to the housing. The actuation assembly can include a second biasing element operably associated with the shell and the plunger. The second biasing element can move the plunger relative to the shell when the shell is in the injection position. The shell can include an engagement member movable from an engaged position, which prevents movement of the ram, to a disengaged position, which allows the ram to move relative to the shell. The engagement member can be in the engaged position when the shell is in the initial position. The engagement member may be in a disengaged position when the shell is in the injection position.

[0006]

[0007] In a further embodiment, the syringe includes a second member secured to the housing, the second member including a catch engageable with the shell to prevent movement of the shell relative to the housing. The second member can block movement of the engaging member from the engaged position to the disengaged position when the shell is in the initial position. In a further embodiment, the syringe includes a syringe and a syringe holder. The syringe holder can include a first end, a second end, a longitudinal axis extending from the first end to the second end, and a sidewall extending from the first end toward the second end. The sidewall can define a receiving area for the syringe. The sidewall can include a sidewall opening such that the syringe can be loaded into the syringe holder from a side of the syringe holder. The syringe can be loaded into the syringe holder without axial movement through a rear opening of the syringe holder. The needle shield can be coupled to the syringe, and the syringe can be loaded into the syringe holder without passing the needle shield through the syringe holder. The side wall opening can extend from the first end to the second end. The syringe can include a body defining a medicament chamber, a needle fluidly coupled to the medicament chamber, and a needle shield that receives the needle. The needle shield can have a needle shield diameter. The syringe holder can include an end wall having an end wall opening with an end wall opening diameter smaller than the needle shield diameter. The syringe can include a syringe flange at a proximal end of the syringe, and when the syringe is coupled to the syringe holder, the distal end of the syringe engages the end wall and the syringe flange is spaced from the second end of the side wall.

[0007]

[0008] In a further embodiment, the syringe includes a needle shield remover having a protrusion disposed between the proximal end of the needle shield and the distal end of the syringe. In a further embodiment, the syringe includes a cap coupled to the housing. The needle shield remover can be coupled to the cap such that the needle shield is removed when the cap is uncoupled from the housing. The cap can at least temporarily maintain the needle guard in the extended position. Movement of the plunger can force the medicament from the medicament chamber through the needle. The needle guard can be movable to a locked position, and the needle guard can include a needle guard lock that engages a lockout surface to prevent proximal movement of the needle guard when the needle guard is in the locked position. The needle guard lock can include a lockout arm that flexes radially outward to engage the lockout surface when the needle guard is in the locked position. In a further embodiment, a collar is coupled to the housing, and the collar includes the lockout surface. In a further embodiment, a biasing element is coupled to the collar and the needle guard, and the biasing element biases the needle guard toward the extended position.

[0008]

[0009] The following detailed description of embodiments of an automatic injection syringe will be better understood when read in conjunction with the accompanying drawings of illustrative embodiments. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. For example, features of one or more of the various disclosed embodiments may be incorporated into other disclosed embodiments, although not explicitly stated herein. [Brief explanation of the drawings]

[0009] [Figure 1]

[0011] FIG. 1 is a perspective view of a syringe according to an exemplary embodiment of the present invention. [Figure 2] FIG. 2 is a bottom elevational view of the housing of FIG. 1. [Figure 3] 2 is a top perspective view of the cap of FIG. 1. [Figure 4] FIG. 2 is a perspective view of the syringe of FIG. 1 with the housing removed. [Figure 5] FIG. 2 is an exploded view of the internal assembly of the syringe of FIG. 1. [Figure 6] FIG. 2 is a perspective view of a needle guard of the syringe of FIG. 1; [Figure 7] 2 is an exploded perspective view of a syringe assembly of the injector of FIG. 1. [Figure 8] FIG. 2 is a top plan view of the syringe carrier of FIG. 1. [Figure 9] 2 is a perspective view of the syringe carrier of FIG. 1. [Figure 10] FIG. 2 is a perspective view of the needle shield remover of FIG. [Figure 11] FIG. 2 is a perspective view of a syringe assembly and needle shield remover of the injector of FIG. 1; [Figure 12] 2 is a cross-sectional view of the syringe assembly, needle shield remover, and cap of the injector of FIG. 1 taken along a plane containing line AA. [Figure 13] 2 is a cross-sectional view of the syringe of FIG. 1 taken along a plane containing line AA in a pre-fired configuration. [Figure 14] 2 is a cross-sectional view of the syringe of FIG. 1 taken along a plane containing line BB. [Figure 15] FIG. 15 is an enlarged view of a portion of the cross-sectional view of FIG. [Figure 16] 2 is a cross-sectional view of the syringe of FIG. 1 with the needle guard in a retracted configuration; [Figure 17] FIG. 17 is an enlarged view of a portion of the cross-sectional view of FIG. [Figure 18] 2 is a cross-sectional view of the syringe of FIG. 1 in an injection configuration. [Figure 19] FIG. 19 is an enlarged view of a portion of the cross-sectional view of FIG. [Figure 20] FIG. 19 is an enlarged view of a portion of the cross-sectional view of FIG. [Figure 21] 2 is a cross-sectional view of the syringe of FIG. 1 with the shell in the injection position. [Figure 22]FIG. 22 is an enlarged view of a portion of the cross-sectional view of FIG. [Figure 23]

[0033] FIG. 1 is an enlarged view of a portion of the syringe in a firing configuration. [Figure 24] FIG. 2 is a cross-sectional view of the syringe of FIG. 1 in a lockout configuration. [Figure 25] FIG. 25 is an enlarged view of a portion of the cross-sectional view of FIG. [Figure 26] FIG. 3 is an enlarged cross-sectional view of a second member, a first member, and a shell in a ready position according to another exemplary embodiment of the present invention. [Figure 27] FIG. 27 is an enlarged view of the second member, first member, and shell of FIG. 26 during transition from the ready position to the fired position. DETAILED DESCRIPTION OF THE INVENTION

[0010]

[0038] Referring in detail to the drawings, wherein like reference numerals refer to like elements throughout, Figures 1-27 show a syringe, generally designated 30, in accordance with an exemplary embodiment of the present invention. In some embodiments, syringe 30 is configured to automatically insert a needle into a patient or user in response to activation.

[0011]

[0039] The syringe 30 can be configured to inject a medication into a user or patient. The syringe 30 can be configured to accept a syringe, or the syringe can include a medication chamber. The medication can be, for example, but not limited to, diazepam, haloperidol, lorazepam, methotrexate, testosterone, or recombinant human papillomavirus tetravalent. The syringe 30 can be configured to deliver the medication subcutaneously or intramuscularly. The syringe 30 can be configured to insert a needle to a selected insertion depth. The syringe 30 can include a retractable needle guard, and the insertion depth can be independent of the extension length of the retractable needle guard. The syringe 30 can include an internal assembly insertable into an external housing, and the internal assembly can be assembled before coupling the external housing to the internal assembly. The syringe 30 can move the needle relative to the housing to the insertion depth before delivering the medication through the needle. The syringe 30 can include a needle shield remover configured to engage a portion of a rear surface of a needle shield. The needle shield remover can be part of an internal assembly that can provide visual confirmation that the needle shield remover is engaged with the rear face of the needle shield prior to completing assembly of the syringe 30.

[0012]

[0040] 1-5, the syringe 30 can include a housing 32. The housing 32 includes a cavity for at least partially receiving an inner assembly 36 (FIGS. 4-5). The inner assembly 36 can be configured to move the needle relative to the housing 32 to expel the medicament from the reservoir and out of the needle. One or more alignment structures 37 (e.g., protrusions or The syringe 30 may include a longitudinal axis 31 extending from a proximal end 33 to a distal end 35 of the housing 32. The alignment structure 37 may align the inner assembly 36 relative to the housing 32. In some embodiments, the housing 32 has a cylindrical exterior shape. In other embodiments, the housing 32 has an exterior shape configured to prevent the syringe 30 from rotating when placed on a surface. The syringe 30 may include a longitudinal axis 31 extending from a proximal end 33 to a distal end 35 of the housing 32.

[0013]

[0041] 3-4 and 13, syringe 30 can include a cap 34 configured to prevent unintentional needle guard retraction or unintentional needle exposure (e.g., during manufacturing, shipping, or prior to intended use). Cap 34 can be removably coupled to housing 32 or collar 38 (FIG. 13). Cap 34 can be uncoupled from housing 32 or collar 38 (e.g., by pulling, pushing, or twisting cap 34 relative to housing 32 or collar 38). At least one of cap 34 and collar 38 can include a recess or threads 39 for receiving a protrusion or mating threads 41 on the other of cap 34 and collar 38. Cap 34 can be shaped and dimensioned to prevent syringe 30 from turning when the cap is attached to the syringe and the syringe is placed on a surface. The collar 38 can include a collar protrusion 118 (FIG. 4) configured to be received by a second opening 120 in the housing 32 (e.g., via a snap fit), thereby securing the collar 38 to the housing 32 (FIG. 14). The cap 34 can include a receiver 43. The receiver 43 can be configured to couple to a needle shield remover, as described in more detail below.

[0014]

[0042] Referring to FIG. 5 , the syringe 30 can include an internal assembly 36. The internal assembly 36 can be configured to move the syringe relative to the housing 32 to deliver medication from the syringe to a user or patient. The internal assembly 36 can include a first member 48, a second member 40, and a shell 52. The internal assembly 36 can include a ram 58 and an actuation assembly configured to move at least one of the shell 52 and the ram 58 relative to the housing 32. The first member 48, the second member 40, the shell 52, and the ram 58 can be nested within one another within the housing. Some components of the internal assembly 36 can be fixed to the housing 32, while other components are movable relative to the housing 32. The second member 40 can be fixed relative to the housing 32, and the first member 48 can be movable relative to the second member 40 and the housing 32.

[0015]

[0043] 1, 4, and 13, in some embodiments, the second member 40 is secured to the housing 32 by a protrusion 42 (FIG. 4) that is disposed in an aperture 44 (FIG. 1) in the housing 32. In other embodiments, the second member 40 includes an aperture configured to receive the protrusion on the housing 32. The protrusion 42 can be coupled to the housing 32 via a snap fit. In other embodiments, the second member 40 is secured to the housing 32 via adhesive, welding, or fasteners.

[0016]

[0044] 4, 15, and 19, the second member 40 can include a first arm 46 or catch. The first arm 46 can engage and prevent movement of the shell 52 relative to the housing 32. The first arm 46 can be configured to move from a first position (FIG. 15) to a second position (FIG. 19). The first arm 46 can deflect radially outward as the arm moves from the first position to the second position. In some embodiments, the first arm 46 is biased toward the second position, but the first member 48 blocks movement of the first arm 46 until the syringe 30 is activated. In other embodiments, the first arm 46 remains stationary in the first position but deflects radially outward from the housing 32. Movement of shell 52 relative to 32 urges first arm 46 from the first position to the second position.

[0017]

[0045] 4-5 , the first member 48 can be configured to at least partially receive the second member 40. The first arm 46 of the second member 40 can be in a first position when the second member 40 is received by the first member 48. The first member 48 can at least partially surround the second member 40 such that the first member 48 blocks movement of the first arm 46. The first member 48 can be movable (e.g., axially translatable, rotatable) relative to the housing 32 or the second member 40. The first member 48 can include a recess or opening 50. The first arm 46 can move from a first position to a second position when the first arm 46 aligns with the opening 50. The opening 50 can be aligned with the first arm 46 when the first member 48 moves relative to the second member 40. The second member 40 can remain fixed relative to the housing 32 while the first member 48 moves relative to the second member 40 .

[0018]

[0046] 1 and 15, the safety device 140 can be disposed in the opening 50 when the syringe 30 is in the safe state. The safety device 140 can extend through the opening in the housing 32. The safety device 140 can engage a sidewall of the opening in the housing 32 such that the safety device 140 is prevented from moving axially along the axis 31. The safety device 140 can be removably coupled to the housing 32. The safety device 140 can prevent axial movement of the first member 48. The safety device 140 can be manually removed from the housing 32 so that the syringe 30 can be activated as described herein. In some embodiments, the safety device 140 is coupled to the housing 32 during manufacturing and is removed once the syringe 30 is assembled. The safety device 140 can be removed before the syringe 30 is provided to a user. In other embodiments, the safety device 140 is removed by the user before using the syringe 30.

[0019]

[0047] 1 and 4-5, first member 48 may include a detent 62. Detent 62 may be movable relative to first member 48 from a first position (e.g., a relaxed position) to a second position (e.g., a radially flexed position). Detent 62 may include a cantilevered arm extending from first member 48. Detent 62 may be configured to engage a sidewall of first detent opening 61 or second detent opening 63 in housing 32 ( FIG. 1 ), as described in more detail below.

[0020]

[0048] 4-5 and 15, the shell 52 can be configured to be coupled to a syringe carrier. The shell 52 may be movable relative to the housing 32 from an initial position (FIG. 13) to an injection position (FIG. 18). The shell 52 can be disposed together with the housing 32. The second member 40 can at least partially surround the shell 52. The shell 52 can include a first recess 54 in its outer surface. The first recess 54 can extend through a sidewall of the shell 52. The first recess 54 can be configured to receive a portion of the first arm 46 of the second member 40 to at least temporarily secure the shell 52 to the second member 40. The first arm 46 can be disposed within the recess 54 when the first arm 46 is in the first position.

[0021]

[0049] 4-5 and 15, shell 52 may be movable (e.g., axially translatable, rotatable) relative to housing 32 or second member 40. First arm 46 may engage a sidewall of first recess 54 to prevent shell 52 from moving relative to housing 32. At least one recess 54 and first arm 46 may have a chamfered edge such that axial movement of shell 52 causes radial movement of first arm 46.

[0022]

[0050] 4-5 and 13, the shell 52 can include an internal recess 66 or cavity configured to at least partially receive the ram 58 (FIG. 13). In some embodiments, the internal recess 66 is configured to receive a syringe 72. In other embodiments, the internal recess 66 defines a medicament chamber. The shell 52 can include an engagement member 68 configured to at least temporarily retain the ram 58 in a pre-fire position. The shell 52 can include multiple engagement members 68 circumferentially spaced about the shell 52. The engagement members 68 can include flexible arms that at least temporarily block movement of the ram 58. The engagement members 68 can be biased radially outward. The engagement members 68 can be movable between an engaged position (FIG. 13), in which the engagement members prevent movement of the ram 58, and a disengaged position (FIG. 22), in which the ram 58 can move relative to the shell 52. The second member 40 can prevent movement of the engagement member 68 between the engaged and disengaged positions. The engaging member 68 can be in an engaged position when the shell 52 is in the initial position, and the engaging member 68 can be in a disengaged position when the shell 52 is in the injection position.

[0023]

[0051] 4-5 and 13, the ram 58 can include a rim 64 configured to engage an engagement member 68 when the syringe 30 is in the pre-fired configuration (FIG. 13). The ram 58 can be configured to engage a plunger 70. The plunger 70 can move relative to the shell 32 as the ram 58 moves relative to the shell 52 to force the medication from the medication chamber (e.g., in a pre-filled syringe) out through a needle 74 and into the patient or user. The rim 64 can have a diameter larger than the inner diameter of the medication chamber such that the rim 64 cannot enter the medication chamber. The rim 64 of the ram 58 can be spaced from the flange 106 of the syringe 72 when the plunger 70 is at the end of the medication chamber.

[0024]

[0052] 5 and 13 , the syringe 30 can include an actuation assembly configured to move the shell 52 from an initial position to an injection position. The actuation assembly can be coupled to the housing 32 and the shell 52. The actuation assembly can be operably associated with the housing 32 and the shell 52. The actuation assembly can include a first biasing element 56. The first biasing element 56 can be operably associated with the housing 32 and the shell 52. The first biasing element 56 can urge the shell 52 toward the distal end 35 of the syringe 30.

[0025]

[0053] 13 , the actuation assembly can include a second biasing element 76. The actuation assembly can include a first biasing element 56 and a second biasing element 76. The second biasing element 76 can be disposed within the internal recess 66 of the shell 52. The second biasing element 76 can be operably associated with the shell 52 and the ram 58. The second biasing element 76 can engage the rim 64 of the ram 58 and the end of the shell 52 such that the ram 58 is biased toward the distal end 35 of the syringe 30. In some embodiments, the second biasing element 76 does not move the ram 58 until the shell 52 is in the injection position. The actuation assembly can cause movement of the plunger 70 relative to the shell 52 when the shell 52 is in the injection position.

[0026]

[0054] 13, the internal recess 66 of the shell 52 can include a first portion 66a and a second portion 66b. The second portion 66b can be proximal to the first portion 66a. The first portion 66a can be configured to receive the ram 58 and a portion of the rim 64. The second portion 66b can be configured to receive the proximal end of the ram 58 and the second biasing element 76. The second portion 66b can have a smaller diameter than the first portion 66a. The first portion 66a can have a longer axial length than the second portion 66b. can be done.

[0027]

[0055] 6, 14, and 20, the syringe 30 can include a needle guard 78. The needle guard 78 can surround the needle 74 when the syringe 30 is not in use. The needle guard 78 can be movable relative to the housing 32 from an extended position (FIG. 14) to a retracted position (FIG. 20). The needle guard 78 can be configured to be actuated by a user, where a distal end of the needle guard 78 is positioned relative to an injection site (e.g., against the user's skin) and a force is applied to the distal end of the syringe 30 such that the needle guard 78 moves proximally relative to the housing 32. The needle guard 78 can include a base 80 (FIG. 6). At least a portion of the base 80 can extend from the housing 32 when the syringe 30 is in a pre-fired configuration. The needle guard 78 can include legs 82 extending from the base 80. The legs 82 may include needle guard protrusions 84 configured to engage with the detents 62 of the first member 48, as described in more detail below. The legs 82 may include engagement surfaces 83 configured to engage with the first member 48. The engagement surfaces 83 may be at proximal ends of the legs 82. The legs 82 of the needle guard 78 may extend through openings 91 in a rim 93 ( FIG. 4 ) of the shell 52. The rim 93 may maintain the alignment of the legs 82. The rim 93 may prevent undesired bending of the legs 82 of the needle guard 78.

[0028]

[0056] Referring to FIG. 6 , the needle guard 78 may include a limiting portion 86 configured to engage a protrusion or recess on the housing 32 or the collar 38 to limit distal movement of the needle guard 78 relative to the housing 32 after the syringe 30 is fired. The needle guard 78 may include a cap-engaging structure 88 ( FIG. 6 ) configured to engage a structure (e.g., threads or another protrusion) on the cap 34 to prevent unintended movement of the needle guard 78. The needle guard 78 may be axially fixed relative to the housing 32 when the cap 34 is coupled to the housing 32 and the needle guard 78. The needle guard 78 may include an opening 92 configured to allow the needle 74 to pass therethrough when the syringe 30 is fired. The needle guard 78 may include a lockout arm 94 ( FIG. 6 ) configured to be disposed in a lockout opening 96 in the collar 38 ( FIG. 25 ) after the syringe 30 is fired, as described in more detail below.

[0029]

[0057] Referring to FIG. 7 , the injector 30 can include a syringe 72 (e.g., a pre-filled syringe). The syringe 72 can include a body 100 defining a medicament chamber and a neck 102 adjacent to the body 100. The body 100 can have a first diameter, and the neck 102 can have a second diameter. The first diameter can be larger than the second diameter. A needle 74 can be coupled to the neck 102. The needle 74 can be in fluid communication with the medicament chamber. A plunger 70 can be disposed within the medicament chamber. The plunger 70 can move relative to the medicament chamber to expel the medicament from the medicament chamber through the needle 74 and out. The syringe 72 can include a syringe flange 106. The syringe flange 106 can have a diameter larger than the body 100.

[0030]

[0058] 7-11 , the syringe 72 can be placed in a syringe holder 98. The syringe holder 98 can include a C-shape or a partial cylinder shape so that the syringe 72 can be loaded from the side of the syringe holder 98. The syringe holder 98 can include a first end 99 and a second end 101. A sidewall 103 can extend from the first end 99 to the second end 101. The sidewall 103 can define a receiving area for the syringe 72. The sidewall 103 can include an opening extending from the first end 99 toward the second end 101. The sidewall opening can extend from the first end 99 to the second end 101. The syringe 72 can be moved through the sidewall opening so that the syringe 72 can be loaded into the syringe holder 98 from the side of the syringe holder 98. Syringe Syringe 72 can be loaded into syringe holder 98 without axially moving syringe 72 through the rear opening of syringe holder 98. Syringe 72 can be loaded into syringe holder 98 without passing needle shield 108 through syringe holder 98. In some embodiments, syringe 72 is snap-fit ​​into syringe holder 98. In some embodiments, side wall 103 is flexible such that side wall 103 elastically deforms as syringe 72 moves through the side wall opening.

[0031]

[0059] 7-9 , the syringe holder 98 can include an end wall 104 configured to engage the end of the body 100 of the syringe 72 adjacent the neck 102. The end wall 104 can extend radially inward from the side wall 103 of the syringe holder 98. The end wall 104 can limit or prevent movement of the syringe 72 relative to the syringe holder 98 when the syringe 30 is fired. The end wall 104 can include an end wall opening 107 configured to receive the neck 102 of the syringe 72. The size of the end wall opening 107 can be selected so that a portion of the end wall 104 contacts a lower portion of the syringe 71. The end wall opening 107 can include an opening circumscribing an arc of at least 180 degrees. The end wall opening 107 can include an arcuate portion 113 ( FIG. 9 ) having a radius of about 0.1 inch, about 0.15 inch, about 0.2 inch, about 0.3 inch, about 0.4 inch, or about 0.5 inch. The end wall opening 107 can include a straight portion 115 tangent to the arcuate portion 113. The neck 102 of the syringe 72 can be engaged by the arcuate portion 113 and the straight portion 115 when the syringe 72 is in the syringe holder 98. The end wall opening 107 can include a chamfered edge 117. The chamfered edge 117 can provide a lead-in to facilitate loading of the neck of the syringe 72 into the end wall opening 107 by a user or manufacturer. The end wall 104 may be rigid.

[0032]

[0060] 7-9 , the syringe holder 98 can include a syringe holder arm 105. The syringe holder arm 105 can include a lip 111 configured to hold the syringe 72. A syringe flange 106 can be disposed between the lip 111 and the second end 101 of the syringe holder 98. The syringe flange 106 can be spaced apart from the second end 101 of the syringe holder 98 when the syringe 72 is coupled to the syringe holder 98. Spaced apart from the second end 101 of the syringe holder 98 can reduce or eliminate any impact of the syringe flange 106 against the syringe holder 98 to reduce or eliminate breakage of the syringe 72. The syringe holder 98 can retain the syringe 72 even if the syringe 72 is broken. Syringe holder 98 may include a fastener 124 configured to engage with a ridge 126 (FIGS. 4 and 13) on shell 52 to secure syringe holder 98 relative to shell 52. Fastener 124 may snap-fit ​​onto ridge 126. Arm 105 may include fastener 124 for engaging with ridge 126 on shell 52 and lip 111 for engaging syringe flange 106.

[0033]

[0061] 7-11, the needle shield 108 can cover the needle 74 when the syringe 30 is in the pre-fire configuration. The needle shield 108 can have an outer diameter that is larger than the diameter of the end wall opening 107 of the syringe holder 98 (FIGS. 8-9). The needle shield 108 can have an outer diameter that is equal to or larger than the diameter of the syringe body 100. The end wall opening 107 can have a diameter that is smaller than the outer diameter of the body 100. The diameter of the end wall opening 107 can be smaller than the outer diameter of the needle shield 108.

[0034]

[0062] The existing syringe holder may include a tubular shape, with the syringe and needle shield moving axially through an opening at one end of the syringe holder. The needle shield used in the holder must be smaller in diameter than the syringe because it must pass through the opening in the syringe holder.

[0035]

[0063] In contrast, syringe holder 98 can be used with a needle shield 108 having a larger diameter than syringe 72 because needle shield 108 does not pass through syringe holder 98 or end wall opening 107 when syringe 72 is loaded into syringe holder 98 from the side. Syringe 72 can be snap-fit ​​into syringe holder 98.

[0036]

[0064] 10-11 , the syringe 30 can include a needle shield remover 110. The needle shield remover 110 can include a C-shape or a partial cylinder shape so that the needle shield 108 can be loaded from the side of the needle shield remover 110. The needle shield 108 can be snap-fit ​​into the needle shield remover 110. The needle shield remover 110 can include a sidewall 119 that defines a receiving area for the needle shield 108. The sidewall can include a sidewall opening so that the needle shield can be loaded from the side through the sidewall opening. The sidewall 119 can include a neck 121. The neck 121 can snap-fit ​​onto the needle shield 108 when the needle shield 108 is loaded into the needle shield remover 110. The syringe 72 and the needle shield 108 can be loaded into the syringe holder 98 and the needle shield remover 110 simultaneously. The syringe 72 and needle shield 108 can be side-loaded into the syringe holder 98 and needle shield remover 110 simultaneously.

[0037]

[0065] 10-11 , the needle shield remover 110 can include a circumferential collar 112 at its distal end. The end of the needle shield 108 can be loaded into the circumferential collar 112, and there can be some relative rotation between the needle shield 108 and the needle shield remover 110 when the needle shield 108 is loaded into the needle shield remover 110. In some embodiments, the distal end of the needle shield 108 is loaded into the needle shield remover 110 before the proximal end of the needle shield 108 is loaded into the needle shield remover 110. The thickness of the sidewall 119 or other structure of the needle shield remover 110 can be selected to allow the needle shield remover 110 to accept different sized needle shields 108 without changing the overall dimensions of the needle shield remover 110.

[0038]

[0066] 10-11 , the needle shield remover 110 can include a remover arm 114. The remover arm 114 can be configured to engage the proximal end of the needle shield 108. The remover arm 114 can include a protruding opening 115 having a diameter smaller than the diameter of at least one of the needle shield 108 and the syringe 72. The remover arm 114 can be configured to engage approximately 10%, 20%, 30%, 40%, 50%, 60%, 70%, or 80% of the surface area of ​​the proximal end of the needle shield 108. The remover arm 114 and the end wall 104 can be positioned between an end (e.g., the proximal end) of the needle shield 108 and an end (e.g., the distal end) of the syringe 72 adjacent the neck 102 ( FIG. 11 ).

[0039]

[0067] 3 and 11-12, the needle shield remover 110 can include a remover arm 116 configured to engage with the cap 34. The remover arm 116 can be configured to snap-fit ​​into the receiver 43 of the cap 34 (FIGS. 1 and 12). The remover arm 116 can be a flexible cantilever beam having a protrusion at an end thereof. The protrusion can be configured to engage a ledge on the receiver 43 of the cap 34 such that the needle shield remover 110 is secured relative to the cap 34. In some embodiments, the needle shield 108 can be coupled to the needle shield remover 110 before the needle shield remover 110 is coupled to the cap 34. In other embodiments, the needle shield 108 is coupled to the cap 34 before the needle shield 108 is coupled to the needle shield remover 110. In some embodiments, the needle shield 108 is coupled to the needle shield remover 110 before the syringe 72 is coupled to the syringe holder 98.

[0040]

[0068] 13-15 , in some embodiments, the syringe 30 is provided to a user in a pre-fired state. In other embodiments, the syringe 30 is provided in a safety configuration, and the user can move the syringe 30 to the pre-fired configuration by removing the safety 140. The cap 34 can be removed by pulling or twisting the cap 34 relative to the housing 32 such that the cap 34 is decoupled from the housing 32. The needle shield 108 can be decoupled from the needle 74 and syringe 72 when the cap 34 is removed because a needle shield remover 110 is coupled to the cap 34. The needle guard 78 may be movable relative to the housing 32 when the cap 34 is removed from the housing 32.

[0041]

[0069] 13-15, the needle guard protrusion 84 on the leg 82 of the needle guard 78 can be positioned adjacent to the detent 62 of the first member 48 when the syringe 30 is in the pre-fired configuration and the needle guard 78 is in the extended position (FIG. 15). The detent 62 can be in a first position when the syringe is in the pre-fired configuration. The needle guard protrusion 84 can prevent radial movement of the detent 62 from the first detent position to the second detent position when the needle guard 78 is in the extended position. The detent 62 can engage with the housing 32 (e.g., a sidewall of the first detent opening 61) to prevent movement of the first member 48 when the detent 62 is in the first position. The detent 62 can disengage (e.g., bend radially inward) from the housing 32 when the detent 62 is in the second position.

[0042]

[0070] 16-17 , the engagement surface 83 of the leg 82 can contact the ledge 85 of the first member 48 when the user presses the distal end of the needle guard 78 against the injection site, causing the needle guard 78 to move from the extended position toward the retracted position relative to the housing 32. In some embodiments, the user initiates a trigger sequence by moving the needle guard 78 relative to the housing 32. In some embodiments, the needle guard 78 is a trigger that activates the syringe 30. In some embodiments, movement of the needle guard 78 triggers the syringe 30 to deliver a dose of medication to the user. The needle guard protrusion 84 can move along the length of the detent 62 of the first member 48 as the needle guard 78 moves relative to the housing 32. The needle guard protrusion 84 can no longer block movement of the detent 62 when the engagement surface 83 contacts the ledge 85, allowing the detent 62 to move from the first position to the second position.

[0043]

[0071] 16-17 , the needle guard 78 can move the second member 40 as the needle guard 78 continues to move proximally after engagement surface 83 contacts engagement surface 85. Proximal movement of the needle guard 78 can move the second member 40 proximally. The detent 62 of the first member 48 can move from the first detent opening 61 to the second detent opening 63 as the second member 40 moves proximally relative to the housing 32. The detent 62 can be movable between a first position, a second position, and a third position. The detent 62 can be within the first detent opening 61 in the first position. The detent can be removed from the first detent opening 61 in the second position. The detent 62 can be within the second detent opening 63 in the third position. The first arm 46 of the second member 40 can align with the opening 50 in the first member 48 when the first member 48 moves proximally relative to the housing 32. The first arm 46 can exit the first recess 54 in the shell 52 when the opening 50 aligns with the first arm 46.

[0044]

[0072] 18-19, the first biasing element 56 is configured to bias the first arm 46 toward the shell 44. When the first biasing element 56 disengages the shell 52 from the first recess 54 of the needle guard 78, the shell 52 can be moved distally. The first biasing element 56 can move the shell 52 distally. The first biasing element can move the shell 52 from the initial position relative to the housing 32 to the injection position when the first member 48 moves relative to the housing 32. Proximal movement of the needle guard 78 and the first member 48 can cause distal movement of the shell 52. The shell 52, ram 58, syringe 72, and syringe holder 98 can move distally relative to the housing 32 when the first biasing element 56 moves the shell 52. The needle 74 can extend through the opening 92 in the needle guard 78 when the shell 52 moves to the injection position.

[0045]

[0073] 20 , the syringe 30 can have an insertion depth defined by the length of the needle 74 extending through the opening 92 in the needle guard 78. In some embodiments, the insertion depth of the needle 74 is about 5 mm, about 10 mm, about 15 mm, about 16 mm, about 20 mm, about 25 mm, about 30 mm, about 35 mm, about 40 mm, about 45 mm, or about 50 mm. In some embodiments, the insertion depth of the needle 74 is about 5 mm to about 10 mm, about 10 mm to about 15 mm, about 15 mm to about 20 mm, about 20 mm to about 25 mm, about 25 mm to about 30 mm, about 30 mm to about 35 mm, about 35 mm to about 40 mm, about 40 mm to about 45 mm, or about 45 mm to about 50 mm. In some embodiments, the needle guard is configured to advance approximately 1 mm, approximately 2 mm, approximately 3 mm, approximately 4 mm, approximately 5 mm, approximately 6 mm, approximately 7 mm, approximately 8 mm, approximately 9 mm, approximately 10 mm, approximately 11 mm, approximately 12 mm, approximately 13 mm, approximately 14 mm, or approximately 15 mm. In one embodiment, the needle can extend approximately 20 mm to approximately 25 mm from the distal end of the needle guard 78 in response to needle guard advancement of approximately 1 mm to approximately 5 mm or approximately 5 mm to approximately 10 mm. The insertion depth may be independent of the length of advancement of the needle guard 78. The shell 52 can be moved distally until the end wall 104 of the syringe holder 98 engages the rim 128 of the collar 38 ( FIG. 20 ). The shell 52 can be in an injection position when the syringe holder 98 engages the rim 128 of the collar. In some embodiments, the position of the ram 58 relative to the syringe 72 is fixed so that the medication is not ejected as the shell 52 moves toward the distal end of the injector 30. In other embodiments, the ram 58 can begin to move relative to the syringe 72 before the syringe holder 98 engages the rim 128.

[0046]

[0074] 21-22 , the engagement member 68 of the shell 52 can be disposed distal to the second member 40 when the shell 52 is in the injection position. The engagement member 68 can move radially outward when the engagement member 68 moves past the second member 40. The movement of the engagement member 68 can disengage the engagement member 68 from the rim 64 of the ram 58. The second biasing element 76 can move the ram 58 toward the distal end of the syringe 30 when the rim 64 no longer engages the engagement member 68. The engagement member 68 can be movable from a constrained configuration to an extended configuration. The engagement member 68 can be in the constrained configuration when the engagement member 68 is within a recess defined by the second member 40. The engagement member 68 can move radially outward to the extended configuration when the engagement member 68 disengages the distal end 130 of the second member 40 and the engagement member 68 is no longer constrained by the second member 40. The engagement member 68 may not contact the rim 64 or may allow distal movement of the ram 58 when the engagement member 68 is in the expanded configuration. In some embodiments, the second biasing element 76 does not begin to expand until the shell 52 is in the injection position.

[0047]

[0075] 22 , a second biasing element 76 can apply a force to the rim 64 of the ram 58 to move the ram distally. The second biasing element 76 can move the ram 58 when the engagement member 68 of the shell 52 is in the expanded configuration. The ram 58 can move the plunger 70 to dispense the medication from the syringe 72 through the needle 74 and into the user or patient. In some embodiments, the ram 58 is spaced apart from the plunger 70 prior to movement of the ram 58. In other embodiments, the ram 58 is spaced apart from the plunger 70 prior to movement of the ram 58. The ram 58 is associated with (e.g., in contact with or close proximity to) the syringe 70. The ram 58 can move the plunger toward the end of the syringe 72 to dispense all, most, or a portion of the medication from the syringe 72.

[0048]

[0076] 21 and 23, a third biasing element 122 can be disposed within the needle guard 78. The third biasing element 122 can be operatively associated with the needle guard 78 and the collar 38. The third biasing element 122 can bias the needle guard 78 toward the extended position. The third biasing element 122 can compress when the needle guard 78 moves proximally relative to the housing 32. The needle guard 78 can be configured to translate axially relative to the housing 32 approximately 1 mm, approximately 2 mm, approximately 3 mm, approximately 4 mm, approximately 5 mm, approximately 6 mm, approximately 7 mm, approximately 8 mm, approximately 9 mm, approximately 10 mm, approximately 11 mm, approximately 12 mm, approximately 13 mm, approximately 14 mm, or approximately 15 mm. The needle 74 can remain within a recess defined by the needle guard 78 when the needle guard 78 is initially moved from the extended configuration (FIG. 16). The end of the needle 74 can be exposed when the needle guard 78 moves to the retracted position (FIG. 21). A third biasing element 122 can bias the needle guard 78 toward the extended position. In some embodiments, the progress of the syringe 72 or syringe carrier 98 is not impeded or buffered by the third biasing element 122.

[0049]

[0077] 4 and 24-25, the syringe 30 can be removed from the injection site after the medication has been dispensed from the syringe 72. The needle guard 78 can be movable to a locked position after the syringe 30 has been activated and removed from the injection site. A third biasing element 122 can move the needle guard 78 to the extended, locked position when the needle guard is no longer in contact with or pressed against the injection site. The third biasing element 122 can move the needle guard 78 distally relative to the housing 32. The needle guard 78 can extend farther away from the housing 32 when the needle guard is in the locked position than when the syringe is in the extended position prior to firing. The needle guard 78 can include a lockout arm 94 configured to lock the needle guard 78 in the locked position. The lockout arm 94 can prevent proximal movement of the needle guard 78 when the needle guard 78 is in the locked position. The lockout arms 94 can be biased to flex radially outward. The lockout arms 94 can flex radially outward such that when the needle guard 78 is moved to the locked position, the lockout arms 94 are disposed in the lockout openings 96 of the collar 38 ( FIG. 25 ). The syringe 30 can be in the locked configuration when the lockout arms 94 are within the lockout openings 96. The lockout arms 94 can be configured to contact a lockout surface or sidewall of the lockout openings 96 such that the needle guard 78 cannot move proximally relative to the housing 32 when the syringe 30 is in the locked configuration.

[0050]

[0078] 26-27, a second embodiment of the first member 148 is shown. The first member 148 may be similar to the first embodiment of the first member 48, except that the detents 162 of the first member 148 can engage with the recesses 164 of the shell 52 when the shell 52 is in the initial position. The needle guard protrusions 84 of the needle guard can engage with the detents 162 when the needle guard 78 moves relative to the housing 32. The needle guard protrusions 84 can urge the detents 162 to flex radially outward when the needle guard 78 moves proximally relative to the housing. The detents 162 can disengage from the shell recesses 164 when the detents 162 flex radially outward. The needle guard 78 can move the first member 148 proximally relative to the shell 52 and the second member 40. The opening 50 can be aligned with the first arm 46 when the needle guard 78 moves the first member 148 relative to the housing 32 so that the syringe 30 can move the shell 52 to an injection position to deliver a dose of medication as described above.

[0051]

[0079] Those skilled in the art will understand that changes can be made to the exemplary embodiments shown and described above without departing from the broad inventive concept thereof. It is therefore understood that the present invention is not limited to the exemplary embodiments shown and described, but is intended to cover modifications within the spirit and scope of the invention as defined by the claims. For example, certain features of the exemplary embodiments may or may not be part of the claimed invention, and various features of the disclosed embodiments may be combined. The terms "inwardly" and "outwardly" refer to directions toward and away from the geometric center of the syringe, respectively. Unless otherwise stated herein, the terms "a," "an," and "the" should not be limited to one element but should instead be interpreted to mean "at least one."

[0052]

[0080] It should be understood that at least some of the drawings and descriptions of the present invention have been simplified to focus on elements relevant to a clear understanding of the present invention, while, for purposes of clarity, ignoring other elements that one skilled in the art would appreciate could also be part of the present invention. However, because such elements are well known in the art, and because they do not necessarily facilitate a better understanding of the present invention, descriptions of such elements are not provided herein.

[0053]

[0081] Furthermore, to the extent that the method of the present invention does not rely on the particular order of steps set forth herein, the particular order of steps should not be construed as a limitation on the scope of the claims. Any claims directed to the method of the present invention should not be limited to the performance of those steps in the order written, and one of ordinary skill in the art will readily understand that steps can be varied and still remain within the spirit and scope of the invention.

Claims

1. a housing (32) having a proximal end and a distal end; a shell (52) positioned within the housing (32), the shell (52) having a cavity for receiving at least a portion of the medicament chamber, the shell (52) being movable relative to the housing from an initial position to an injection position; a plunger (70) movable relative to the shell; a needle guard (78) movable between an extended position and a retracted position and having a projection (84) configured to extend radially outward from said housing; a first member (48) within the housing (32); an actuation assembly coupled to said housing and said shell (52); Equipped with the first member (48) includes a detent (62) configured to extend radially outward from the housing and movable from a first position to a second position; The detent (62) When in the first position, the housing (32) engages to prevent movement of the first member; When in the second position, the housing (32) is disengaged; The needle guard (78) when in the extended position, said protrusion (84) prevents movement of said detent (62) from said first position to said second position; moving the first member (48) relative to the housing when moving from the extended position to the retracted position; the actuation assembly includes a first biasing element (56) operably associated with the housing and the shell; the first biasing element (56) moves the shell (52) relative to the housing (32) from the initial position to the injection position when the first member (48) moves relative to the housing (32); the actuation assembly includes a second biasing element (76) operably associated with the shell (52) and the plunger (70); The second biasing element (76) moves the plunger (70) relative to the shell (52) when the shell (52) is in the injection position. syringe.

2. Further comprising a second member (40) fixed to the housing (32); The second member (40) includes a catch (46) engageable with the shell to prevent movement of the shell relative to the housing. The syringe of claim 1.

3. The second member (40) at least partially surrounds the shell.

3. The syringe of claim 2.

4. The shell (52) includes a recess (54); The catch (46) is disposed within the recess when the catch (46) is in the first position.

3. The syringe of claim 2.

5. The catch (46) moves out of the recess (54) when the first member (48) moves relative to the housing (32).

5. The syringe of claim 4.

6. a ram (58) movable relative to the shell; The shell (52) includes an engagement member (68) that is movable from an engaged position; The engagement member prevents movement of the ram (58) to a disengaged position where the ram (58) can move relative to the shell (52). The syringe of claim 1.

7. the engaging member (68) is in the engaging position when the shell (52) is in the initial position, the engaging member (68) is in the disengaged position when the shell (52) is in the injection position; 7. The syringe of claim 6.

8. Further comprising a second member (40) fixed to the housing; the second member includes a catch (46) engageable with the shell (52) to prevent movement of the shell (52) relative to the housing (32); the second member (40) blocks movement of the engaging member from the engaged position to the disengaged position when the shell (52) is in the initial position; 7. The syringe of claim 6.

9. a syringe (72); a syringe holder (98) having a first end (99), a second end (101), a longitudinal axis extending from the first end (99) to the second end (101), and a sidewall (103) extending from the first end (99) toward the second end (101); Furthermore, The sidewall (103) defines a receiving area for the syringe (72); The sidewall (103) includes a sidewall opening so that the syringe can be loaded into the syringe holder (98) from the side of the syringe holder (98). The syringe of claim 1.

10. The syringe (72) is loaded into the syringe holder (98) without axial movement through a rear opening of the syringe holder.

10. The syringe of claim 9.

11. a needle shield (108) coupled to said syringe (72); The syringe (72) is loaded into the syringe holder (98) without passing the needle shield (108) through the syringe holder (98).

10. The syringe of claim 9.

12. the sidewall opening extends from the first end to the second end; 10. The syringe of claim 9.

13. The syringe (72) includes a body (100) defining a medicament chamber, a needle (74) fluidly coupled to the medicament chamber, and a needle shield (108) housing the needle (74); The needle shield (108) has a needle shield diameter; The syringe holder (98) includes an end wall (104) having an end wall opening (107) with an end wall opening diameter smaller than the needle shield diameter.

10. The syringe of claim 9.

14. the syringe (72) includes a syringe flange (106) at a proximal end of the syringe (72); When the syringe (72) is coupled to the syringe holder (98), the distal end of the syringe engages the end wall (104) and the syringe flange (106) is spaced from the second end of the side wall.

14. The syringe of claim 13.

15. Movement of the plunger (70) forces medication from the medication chamber through the needle (74).

14. The syringe of claim 13.

16. The syringe (72) includes a body (100) defining a medicament chamber, a needle (74) fluidly coupled to the medicament chamber, and a needle shield (108) receiving the needle (74); The needle shield (108) has a needle shield diameter; The syringe holder (98) includes an end wall (104) having an end wall opening (107) with an end wall opening diameter smaller than the needle shield diameter. The syringe comprises: a needle shield remover (110) having a protrusion disposed between the proximal end of the needle shield (108) and the distal end of the syringe (72); Further provided with 10. The syringe of claim 9.

17. a cap (34) coupled to the housing (32); the needle shield remover (110) is coupled to the cap (34) such that the needle shield (108) is removed when the cap (34) is uncoupled from the housing (32); The cap (34) at least temporarily maintains the needle guard (78) in the extended position.

17. The syringe of claim 16.

18. The needle guard (78) is movable to a locked-out position; the needle guard (78) includes a needle guard lock that engages a lockout surface to prevent proximal movement of the needle guard (78) when the needle guard is in the locked out position; The syringe of claim 1.

19. the needle guard lock includes lockout arms (94) that flex radially outward to engage the lockout surface when the needle guard is in the locked position; 19. The syringe of claim 18.

20. further comprising a collar (38) coupled to the housing (32); the collar includes the lockout surface; 19. The syringe of claim 18.

21. further comprising a biasing element (122) coupled to said collar and said needle guard; the biasing element biases the needle guard toward the extended position; 21. The syringe of claim 20.

22. The actuation assembly includes: moving the shell from the initial position to the injection position when the first member moves relative to the housing; moving the plunger relative to the shell when the shell is in the injection position; The syringe of claim 1.

23. Proximal movement of the needle guard (78) moves the first member (48) proximally relative to the housing (32). The syringe of claim 1.

24. The shell (52) moves distally relative to the housing (32) when the first member (48) moves proximally relative to the housing (32).

24. The syringe of claim 23.

25. The shell (52) moves relative to the housing (32) in response to movement of the needle guard (78). The syringe of claim 1.

Images