Wearable drug delivery device

Abstract

This application discloses aspects drug delivery devices for delivering medicament to patients. The device includes a housing with a cartridge receptacle to receive a cartridge with the medicament; a door attached to the housing to move between an open position, in which the cartridge receptacle is accessible from outside the housing and the cartridge can be introduced into the cartridge receptacle, and a closed position, in which the cartridge receptacle is not accessible from outside the housing; an injection needle through which the medicament can be moved to the patient; an actuator to contact a plunger within the cartridge and to move the plunger to cause the medicament to move to the injection needle; and a button to be pressed to cause the medicament to be moved from the cartridge.

Description

WEARABLE DRUG DELIVERY DEVICECROSS REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to U.S. Provisional Patent Application No. 63 / 760,201, filed on February 19, 2025, the entire disclosure of which is incorporated herein by reference.TECHNICAL FIELD

[0002] This disclosure generally relates to devices and methods of injecting a medicament from a container to a patient.BACKGROUND

[0003] Drug delivery devices that inject liquid medicament into a patient require careful manufacturing and can include many different components and assembly steps. Such devices have many moving parts that need to work together to prevent inadvertent activation of the device, loss of the medicament, and injury to the patient. These devices must also endure physical stresses of manufacturing, storage, filling, transportation, and use without degrading or losing structural integrity to allow consistent use. There is a need for an improved wearable drug delivery device that can be used by a patient to deliver medicament while ensuring safe use.SUMMARY

[0004] The foregoing needs are met by the various aspects of drug delivery devices disclosed. According to some aspects, a drug delivery device for delivering a medicament to a patient includes: a housing defining a cartridge receptacle configured to receive a cartridge containing the medicament therein; a door attached to the housing and configured to move between an open position, in which the cartridge receptacle is accessible from outside the housing and the cartridge can be introduced into the cartridge receptacle, and a closed position, in which the cartridge receptacle is not accessible from outside the housing; an injection needle through which the medicament can be moved to the patient; an actuator configured to contact a plunger within the cartridge and to move the plunger to cause themedicament in the cartridge to move to the injection needle; and a button configured to be pressed to cause the medicament to be moved from the cartridge.

[0005] According to another aspect of this disclosure, a drug delivery kit can include a drug delivery device and a cartridge containing a medicament therein. The drug delivery device can include: a housing defining a cartridge receptacle configured to receive the cartridge therein; a door attached to the housing and configured to move between an open position, in which the cartridge receptacle is accessible from outside the housing and the cartridge can be introduced into the cartridge receptacle, and a closed position, in which the cartridge receptacle is not accessible from outside the housing; an injection needle through which the medicament can be moved to the patient; an actuator configured to contact a plunger within the cartridge and to move the plunger to cause the medicament in the cartridge to move to the injection needle; and a button configured to be pressed to cause the medicament to be moved from the cartridge.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present application is further understood when read in conjunction with the appended drawings. For the purpose of illustrating the subject matter, exemplary aspects of the subject matter are shown in the drawings; however, the presently disclosed subject matter is not limited to the specific methods, devices, and systems disclosed. In the drawings:

[0007] FIG. 1 illustrates an angled perspective view of a drug delivery device according to an aspect of this disclosure;

[0008] FIG. 2 illustrates another angled perspective view of the drug delivery device of FIG. 1;

[0009] FIG. 3 illustrates a cross-sectional internal view of the drug delivery device of FIG. 1;

[0010] FIG. 4 illustrates an exploded view of an actuator according to an aspect of this disclosure;

[0011] FIG. 5 A illustrates an angled perspective view of an actuator according to another aspect of this disclosure;

[0012] FIG. 5B illustrates a cross-sectional view of the actuator of FIG. 5 A;

[0013] FIG. 6 illustrates a side perspective view of the actuator of FIG. 5 A;

[0014] FIG. 7 A illustrates a cross-sectional view of a portion of the actuator of FIG.5A;

[0015] FIG. 7B illustrates an attachment interface of the actuator shown in FIG. 5 A;

[0016] FIG. 8 illustrates a cross-sectional view of a needle safety assembly according to an aspect of this disclosure in a first configuration;

[0017] FIG. 9 illustrates a cross-sectional view of the needle safety assembly of FIG. 8 in a second configuration;

[0018] FIG. 10 illustrates a side perspective view of an electronic contact according to an aspect of this disclosure;

[0019] FIG. 11 illustrates a partial internal view of a drug delivery device according to another aspect of this disclosure;

[0020] FIG. 12 illustrates a side perspective view of an electronic contact according to another aspect of this disclosure;

[0021] FIG. 13 illustrates a partial angled perspective view of a drug delivery device according to yet another aspect of this disclosure;

[0022] FIG. 14A illustrates a cross-sectional view of a latch according to an aspect of this disclosure shown in one position;

[0023] FIG. 14B illustrates a cross-sectional view of the latch of FIG. 14A shown in another position;

[0024] FIG. 14C illustrates a cross-sectional view of the latch of FIG. 14A shown in yet another position;

[0025] FIG. 15 illustrates a cross-sectional view of a cartridge limiter assembly according to an aspect of this disclosure in a first position;

[0026] FIG. 16 illustrates a cross-sectional view of the cartridge limiter assembly of FIG. 15 in a second position;

[0027] FIG. 17 illustrates a cross-sectional view of a portion of a drug delivery device according to another aspect of this disclosure in a first position;

[0028] FIG. 18 illustrates a cross-sectional view of the portion of the drug delivery device of FIG. 17 in a second position;

[0029] FIG. 19 illustrates an angled perspective view of a portion of a drug delivery device according to yet another aspect of this disclosure in a first position; and

[0030] FIG. 20 illustrates an angled perspective view of the drug delivery device of FIG. 19 in a second position.

[0031] Aspects of the disclosure will now be described in detail with reference to the drawings, wherein like reference numbers refer to like elements throughout, unless specified otherwise.DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0032] Embodiments of wearable injector devices are disclosed. Disclosed features are intended to improve the structural rigidity of the device, increase accuracy during use, and improve large-scale manufacturability. Specifically, in some aspects, the disclosed features are designed to improve the device structural integrity during physical impacts of the device, such as if the device is dropped onto a surface. It will be appreciated that some or all features disclosed can be implemented into one or more, or all, of the embodiments disclosed.

[0033] Referring to FIGs. 1-3, a wearable drug delivery injection device 10 and components thereof are shown according to an aspect of this disclosure. The device 10 includes a housing 14 that defines a patient contacting surface 18 configured to be placed adjacent the intended injection site on the patient. A needle shield 20 is configured to movably extend from the housing 14, specifically relative to the contacting surface 18.Before use, the needle shield 20 is in an extended position at a first distance away from the contact surface 18. When the device 10 is placed onto the desired injection surface, the needle shield 20 is moved to a retracted position at a second distance away from the contact surface 18 that is smaller than the first distance. The needle shield 20 is intended to cover a needle tip to prevent inadvertent injury by the patient.

[0034] The device 10 has a cartridge door 22 disposed on the housing 14. The cartridge door 22 defines a cartridge receptacle 26 configured to receive a cartridge containing medicament therein. The cartridge door 22 is configured to pivotally move relative to the housing 14 between an open position, in which the cartridge receptacle 26 is accessible from outside the housing 14 to allow insertion or removal of a cartridge, and a closed position, in which the door blocks access to the cartridge receptacle 26 and prevents the cartridge from being inserted into, or removed from, the device 10.

[0035] The device 10 may include electronic components configured to power one or more features of the injection. Referring to FIG. 3, the device 10 can include, for exampleinside the housing 14, a power source 30 (e.g., a battery), a printed circuit board 34, and a motor 38. An actuator 100 can be disposed in the housing 14 and configured to move medicament from the inserted cartridge to the patient. In some aspects, the actuator 100 can be a telescoping plunger assembly having multiple components configured to extend and / or retract relative to each other during operation of the device 10. The actuator 100 can be moved by the motor 38, which can be controlled by instructions on the printed circuit board 34 and powered by the power source 30.

[0036] An exemplary telescoping actuator 100 is depicted in FIGs. 4-6. The actuator 100 may include a lead screw 104 configured to engage with, and be rotated by, the motor 38. As the lead screw 104 rotates, a sleeve 108 disposed concentrically around the lead screw 104 can be moved along an actuation axis, for example toward the cartridge in the cartridge receptacle 26. The sleeve 108 may be disposed around the lead screw 104 or, alternatively, the lead screw 104 may be disposed around the sleeve 108. In some aspects, the actuator 100 may include a plurality of sleeves 108, with each subsequent sleeve 108 being disposed at least partially around another sleeve 108 or the lead screw 104, and each sleeve 108 being configured to be laterally moved along the actuation axis upon rotation of the lead screw 104.

[0037] The actuator 100 may include a pushing nut 116 disposed on at least one sleeve 108. The pushing nut 116 is configured to contact a plunger within the cartridge in the device 10 and to push the plunger along the actuation axis, thus causing the medicament in the cartridge to be pushed out of the cartridge. In some aspects, the one or more sleeves 108 may be in contact with the pushing nut 116, for example prior to actuation of the actuator 100 when the one or more sleeves are telescopically retracted. Forces applied to the actuator 100 (such as drops or strikes to the device 10) can cause the one or more sleeves 108 to slide towards and contact the pushing nut 116 damaging or displacing the pushing nut 116.Referring to FIGs. 5 A, 5B, and 6, the actuator 100 may include a spacer 132 disposed thereon between the pushing nut 116 and at least one of the sleeves 108. The spacer 132 is configured to block the sleeve 108 from unintentionally contacting and damaging or dislodging the pushing nut 116. In some aspects, the spacer 132 can include one or more protrusions 136 arranged radially thereon. The protrusions 136 are configured to contact a sleeve 108 to prevent the sleeve 108 from passing over the protrusions 136 and thus the spacer 132. In some aspects, the sleeve 108 may define one or more receptacles 140 thereon configured to receive the one or more protrusions 136 therein. The spacer 132 defines a gap 144 betweenthe pushing nut 116 and the sleeve 108 when the sleeve 108 contacts the spacer 132. FIGs.5A and 5B show the sleeve 108 spaced away from the spacer 132, specifically showing the protrusions 136 spaced away from the receptacles 140. FIG. 6 depicts the sleeve 108 contacting the spacer 136, where the protrusions 136 are received into the receptacles 140 and contact the sleeve 108. In this position, the sleeve 108 is still spaced away from the pushing nut 116 by the gap 144.

[0038] The actuator 100 is secured to the device 10, specifically being attached to the housing 14. It will be understood that the actuator 100 can be secured by a variety of mechanisms, such as a fastener, an adhesive, friction fit, snap fit, or the like. As shown in FIG. 3, for example, the actuator 100 can be snap fit to a feature of the housing to prevent translational movement of the actuator 100 relative to the housing. Referring to an exemplary embodiment shown in FIGs. 7A and 7B, the actuator 100 can include an attachment interface 120 at one end thereof configured to attach to a corresponding actuator receptacle 128 of the housing 14. Features of the attachment interface 120 may be configured to deflect radially inward or outward relative to the actuator 100 to allow the actuator 100 to be moved onto or into the housing 14 and then revert to its pre-deflected configuration, thus locking the actuator 100 in position relative to the housing 14. In some specific embodiments, it may be preferable for the attachment interface 120 to define a plurality of arms 124 extending from the actuator 100. The arms 124 can be arranged concentrically around attachment interface 120. Each arm 124 can be configured to deflect radially inward, i.e., towards the center of the actuator 100. During assembly of the device 10, the actuator 100 can be moved laterally along an insertion axis 101 (see FIG. 3) relative to the housing 14 such that the arms 124 contact the actuator receptacle 128 and are received therein. The housing 14 can include a barrier or shelf 130 defining the actuator receptacle 128. As the actuator 100 is further moved along the insertion axis 101 in the same direction, the arms 124 can contact the shelf 130 and deflect radially inward (relative to the insertion axis 101) as they pass by the shelf 130. When the actuator 100 is inserted into the actuator receptacle 128 such that the arms 124 entirely pass by the shelf 130, the arms 124 may deflect radially out and revert to their original position. At this point, the actuator 100 cannot be easily removed from the actuator receptacle 128 because the arms 124 will contact the shelf 130 and prevent further translation of the actuator 100 out of the actuator receptacle 128. Such an arrangement of the arms 124, i.e., radially facing outward relative to the insertion axis 101, may be beneficial in preventing theactuator 100 from inadvertently detaching from the housing 14 upon an impact force, such as if the device 10 is dropped.

[0039] To use the device 10, the user must place the device 10 onto the injection surface (e.g., the skin). Once actuated, a needle stored in the housing 14 moves out of the housing 14 and penetrates the skin. The needle should only be released from the housing 14 when the device is placed on the skin and is ready to be used. As such, it is advantageous to prevent the needle from inadvertently being released prematurely. Referring to FIGs. 8 and 9, a needle safety assembly 200 is depicted. The needle safety assembly 200 can be part of the device 10 according to any embodiment described throughout this application. It will be appreciated that although the needle safety assembly 200 is shown isolated in the figures, it would be part of the device as a whole, specifically being arranged within the housing 14. An injection needle 212 can be disposed along or parallel to an injection axis 202. The injection axis 202 can generally be orthogonal to the intended injection surface, but this disclosure is not limited to such angles. The needle 212 can be configured to move between a first position, where the needle 212 is within the housing 14 such that a user cannot contact the needle 212, and a second position, in which the needle 212 is at least partially extending outside of the housing 14 and can contact the user’s skin. The needle 212 can be actuated by any suitable mechanism, such as spring, motor and gears, levers, etc. In the depicted exemplary embodiment, the needle 212 is configured to be moved along or parallel to the injection axis 202 by a spring 216. With further reference to the exemplary embodiment shown in FIGs. 8 and 9, the needle 212 can be attached to a needle hub 208, which can be moved by the spring 216.

[0040] In some embodiments, the spring 216 can be compressed prior to injection of the needle 212. The spring 216 can be held in its compressed configuration by a retention member 224. As shown in FIG. 8, the retention member 224 can contact the needle hub 208 and block lateral movement of the needle hub 208 along the injection axis 202. When injection occurs, the retention member 224 can be deflected away from the needle hub 208, such that the retention member 224 no longer blocks the needle hub 208 from lateral movement along the injection axis 202, and the spring 216 pushes the needle hub 208, and the attached needle 212, along the injection axis 202 out of the housing 14 and into the user’s skin. In some embodiments, the retention member 224 can be moved away from the needle hub 208 by an actuation assembly activated by the user when the device is ready to be used.The actuation assembly can include a button 204 that the user depresses, for example along or parallel to the injection axis 202. A deflection member 228 can be attached to the button 204 and be configured to also move along or parallel to the injection axis 202 when the button 204 is depressed. As the deflection member 228 is moved laterally along the injection axis 202, it can contact the retention member 224 and move at least part of the retention member 224 away from the needle hub 208, for example by deflecting the retention member 224 in a direction radially away from the injection axis 202 (see FIG. 9). When the deflection member 228 moves the retention member 224 away from the needle hub 208 such that the needle hub 208 is no longer blocked from lateral movement, the needle hub 208 and the needle 212 can be moved along the injection axis 202 by the compressed spring 216.

[0041] In some aspects, it may be beneficial to ensure that the retention member 224 does not inadvertently or prematurely move away from the needle hub 208 and result in premature movement of the needle hub 208 and needle 212. As shown in FIGs. 8 and 9, the actuation assembly can further include a stabilizing member 232 attached to the button 204 and / or the deflection member 228. The stabilizing member 232 can include a contact surface 236 configured to contact the retention member 224 when the retention member 224 is not deflected and is blocking axial movement of the needle hub 208. The stabilizing member 232 thus prevents the retention member 224 from being deflected laterally away from the needle hub 208. This is beneficial in instances when the device 10 receives a sudden force or jolt, e.g., if it is dropped. By blocking lateral movement of the retention member 224, the needle hub 208 and the attached needle 212 cannot be prematurely released. The stabilizing member 232 can be moved away from the retention member 224 such that the retention member 224 is movable laterally away from the hub 208. When the button 204 is depressed and the deflection member 228 is moved axially toward the retention member 224, the stabilizing member 232 can also be moved axially such that the contact surface 236 is moved out of contact with the retention member 224. The stabilizing member 232 can define a notch 240 that can be positioned adjacent the retention member 224 when the stabilizing member 232 is axially moved when the button 204 is depressed. The notch 240 allows the retention member 224 to be deflected or moved laterally away from the needle hub 208 by the deflection member 228, thus releasing the needle hub 208.

[0042] As noted above, the device 10 includes a power source 30. In some aspects, the power source can be a battery 30. The battery 30 can be integrated into the housing 14such that the printed circuit board 34 and the motor 38 are configured to receive power from the battery 30 (see, generally, FIG. 3). The battery 30 can be in contact with one or more electronic contacts 300 configured to transmit electricity from the battery 30 to the intended destination. In some aspects, the device 10 can include two contacts 300, one at each of the positive and negative terminals of the battery 30. The two contacts 300 may be arranged such that the battery 30 is situated between them. To allow the battery 30 to be inserted snugly between the contacts 300 and to retain the battery 30 from shifting or moving out of contact with the contacts 300, the contacts 300 may be deformable such that each contact 300 is pushed away from the battery 30 as the battery 30 is inserted into the device 10 (see, for example, FIG. 11). The contacts 300 can be biased toward the battery 30, such that each contact 300 applies a pushing force onto the battery 30 when the battery 30 is situated between the two contacts 300. Such deformation of the contacts 300 is helpful to allow insertion of the battery 30 into the housing 14 and to maintain the battery 30 in the desired position. However, if the contacts 300 deform too much, the connection between one or both contacts 300 and the battery 30 can be interrupted. In such instances, the battery 30 can also be dislodged from the desired orientation within the housing 14. In some embodiments, each contact 300 may include a spacer 304 configured to prevent deformation of the contact 300 beyond a predetermined distance. As shown in the diagram of FIG. 10, when the contact 300 deforms, a portion thereof can move a deformation distance 308. If the deformation distance 308 is greater than the elasticity of the contact 300, the contact 300 may not revert to its undeformed position, thus decreasing the pushing force onto the battery 30. As such, it is preferable that the deformation distance 308 is less than the elastic limit of the contact 300. As shown in FIGs. 11 and 12, the spacer 304 can be positioned onto or into the contact 300 to prevent excess deformation of the contact 300. The spacer 304 can physically block portions of the contact 300 from being pushed and deformed beyond the desired deformation distance 308, while permitting some deformation below or at the desired deformation distance 308 to allow the battery 30 to be inserted into the housing 14 and be secured by the pushing spring forces acting on the battery 30 by the two contacts 300.

[0043] As described above, the device 10 is configured to receive a cartridge containing a medicament into a cartridge receptacle 26. The cartridge receptacle 26 may be defined by the housing 14 and / or by the cartridge door 22. In some embodiments, the cartridge door 22 is configured to pivotally move relative to the housing 14 between an openposition, in which the cartridge can be inserted into the cartridge receptacle 26, and a close position, in which the cartridge receptacle 26 is not accessible from outside of the housing 14 (see, generally, FIG. 13). When the cartridge door 22 is moved to the closed position, it may be advantageous to secure the cartridge door 22 relative to the housing 14 such that the cartridge door 22 cannot be moved to the open position again. This prevents inadvertent removal of the cartridge in the cartridge receptacle 26 and decreases risk of needle stick injury to the user.

[0044] In some embodiments, the device 10 may include a latch 400 configured to retain the cartridge door 22 in the closed position after the cartridge has been inserted into the cartridge receptacle 26. The latch 400 can be configured to contact a latch engagement protrusion 420 on the cartridge door 22. As shown in FIGs. 14A-14C, the latch 400 can include a latch body 404 configured to attach to the housing 14. The body 404 can be pivotally movable relative to the housing 14. A latch head 408 extends from the body 404 and is configured to contact the engagement protrusion 420 on the cartridge door 22. The latch 400 may be attached to the housing 14 at a pivot 412 and configured to be pivoted or deflected relative to the housing 14 by the cartridge door 22 as the cartridge door 22 moves into the closed position. The latch 400 can have a first position and a second position pivotally displaced from the first position. In some aspects, the latch 400 may be biased toward the first position by a spring 416 acting thereon. When the cartridge door 22 is not in the closed position, the latch 400 can be in its first position as shown in FIG. 14 A. As the cartridge door 22 is moved toward its closed position, the engagement protrusion 420 contacts the latch 400 and pivots the latch 400 towards its second position as shown in FIG.14B. It will be appreciated that the force acting on the cartridge door 22 to move it to the closed position should be greater than the spring force of the spring 416 biasing the latch 400 to its first position. In some embodiments, the engagement protrusion 420 can define a sloped portion 424 configured to contact the head 408 of the latch 400. The sloped portion 424 can help the latch 400 slide along the engagement protrusion 420 as it pivotally rotates toward its second position. When the cartridge door 22 moves into its closed position, the engagement protrusion 420 passes by the head 408 of the latch 400 and is no longer applying force against the latch 400. At this point the biasing force of the spring 416 pushes the latch 400 back to its first position. The engagement protrusion 420 can further include a retention surface 428 configured to contact the head 408 when the latch 400 is moved back into the first positionafter the cartridge door 22 is in the closed position as shown in FIG. 14C. The engagement between the retention surface 428 and the head 408 of the latch 400 prevents the cartridge door 22 from being moved out of the closed position toward the open position.

[0045] The cartridge containing the medicament can be inserted into the drug delivery device prior to use. As described in embodiments throughout this application, the cartridge can be inserted into the cartridge receptacle by being placed into the open cartridge door and then closing the cartridge door. After the cartridge is in the cartridge receptacle and the cartridge door is closed, the drug delivery device can be used to administer the medicament from the cartridge to the patient. In some embodiments, a transfer needle is configured to pierce a septum on the cartridge to access the medicament in the cartridge. The medicament can travel through this needle to the injection needle that delivers the medicament to the patient. To maintain sterility and prevent leakage and loss of medicament, it is advantageous to prevent the cartridge to be pierced with the transfer needle until the user is ready for the medicament to be delivered. In some embodiments, the drug delivery device may include a mechanism configured to prevent premature connection of the cartridge with the transfer needle.

[0046] Referring to FIGS. 15-18, the drug delivery device 10 can include a cartridge limiter assembly 500 configured to selectively prevent or permit the cartridge 50 from being pierced by the transfer needle (not shown). When the cartridge 50 is inserted into the cartridge receptacle on the cartridge door 22 and the door 22 is closed, the cartridge 50 can be axially aligned with the transfer needle along an axis 501. The cartridge 50 can be axially moved along the axis 501 between a first position, where the cartridge is spaced away from the needle (see FIG. 15), and a second position, where the cartridge 50 contacts the needle and its septum is pierced by the needle (see FIG. 16). Movement of the cartridge 50 from the first position to the second position is selectively prevented or permitted by the cartridge limiter assembly 500. A sliding engagement member 504 is configured to contact the cartridge 50, for example by contacting a flange 54 on the cartridge 50. The sliding engagement member 504 blocks movement of the cartridge 50 along the axis 501 toward its second position. The sliding engagement member 504 can be configured to also axially move along the axis 501 in a channel 508 defined in or on the cartridge door 22. Movement of the sliding engagement member 504 can be blocked by a deflectable member 512 within the channel 508. When the deflectable member 512 is in the channel 508, the sliding engagementmember 504 is prevented from moving axially within the channel 508. When the deflectable member 512 is moved out of the channel 508, the sliding engagement member 504 is no longer blocked by the deflectable member 512 and can move within the channel 508. When the sliding engagement member 504 moves in the channel 508, the cartridge 50 is also no longer prevented from movement along the axis 501 towards its second position.

[0047] The deflectable member 512 can be moved out of the channel 508 when the drug delivery device 10 is ready to deliver the medicament to the patient. In some aspects, when the patient activates the actuation button (e.g., the button 204 described above), the deflectable member 512 can be moved out of the channel 508. As shown in the exemplary embodiment of FIGS. 15-18, the deflectable member 512 can include a protrusion 520 thereon configured to contact the button 204. The button 204 can include an arm 524 configured to contact the protrusion 520 on the cartridge limiter assembly 500 when the button 204 is pressed. It will be appreciated that the protrusion 520 and the arm 524 can include any suitable engagement shapes, for example hooks, ramps, and the like. When the button 204 is not pressed, the arm 524 is spaced from the protrusion 520 (see, e.g., FIG. 17). When the button 204 is pressed, the arm 524 moves towards and contacts the protrusion 520 (see, e.g., FIG. 18). When the arm 524 contacts the protrusion 520, deflectable member 512 is moved out of the channel 508. This allows the sliding engagement member 504 to axially move within the channel 508, which in turn no longer blocks the cartridge 50 from being moved axially along the axis 501 from its first position to its second position and contacting the transfer needle to create a fluid path between the medicament inside the cartridge 50 and the injection needle of the drug delivery device 10.

[0048] It will be appreciated that various embodiments of the drug delivery devices described throughout this application can be manufactured in multiple steps. As components are assembled, it is important to ensure that the device has structural integrity and retains the structural integrity during the rest of assembly, packaging, storage, transportation, and use. For example, in some aspects, the housing 14 can include multiple pieces that are assembled together to form the housing 14. In some aspects, as shown in FIGS. 19 and 20, the housing 14 can include a first half 14a and a second half 14b. Because the cartridge door 22 is designed to pivot between an open and closed position relative to the housing 14, movement of the cartridge door 22 can, in time, deform the material of the housing 14 or loosen the connection between the first half 14a and the second half 14b. To enhance structural integrityand decrease risk of separation of the housing parts, one or more structural ribs 600 can be disposed on the housing 14. The cartridge door 22 can define complementary notches 604 configured to receive the ribs 600 when the cartridge door 22 is in the closed position. When the cartridge door 22 is closed, the engagement of the ribs 600 and the notches 604 decreases or prevents lateral movement of the cartridge door 22 relative to the housing 14 (see FIG. 20). It will be appreciated that the described arrangement can be reversed, where the ribs 600 are disposed on the cartridge door 22 while the notches 604 are on the housing 14. Alternatively, in some aspects, one or more ribs 600 and one or more notches 604 can be disposed on the housing 14 while one or more other ribs 600 and one or more other notches 604 can be disposed on the cartridge door 22.

[0049] While systems and methods have been described in connection with the various embodiments of the various figures, it will be appreciated by those skilled in the art that changes could be made to the embodiments without departing from the broad inventive concept thereof. It is understood, therefore, that this disclosure is not limited to the particular embodiments disclosed, and it is intended to cover modifications within the spirit and scope of the present disclosure as defined by the claims.

Claims

What is claimed:

1. A drug delivery device for delivering a medicament to a patient, the device comprising:a housing defining a cartridge receptacle configured to receive a cartridge containing the medicament therein;a door attached to the housing and configured to move between an open position, in which the cartridge receptacle is accessible from outside the housing and the cartridge can be introduced into the cartridge receptacle, and a closed position, in which the cartridge receptacle is not accessible from outside the housing;an injection needle through which the medicament can be moved to the patient; an actuator configured to contact a plunger within the cartridge and to move the plunger to cause the medicament in the cartridge to move to the injection needle; anda button configured to be pressed to cause the medicament to be moved from the cartridge.

3. The drug delivery device of claim 2, further comprising a needle retention assembly, the needle retention assembly having:a needle hub containing the injection needle;a spring configured to move the needle hub and the injection needle;wherein the needle hub is movable from a first position, in which the needle is within the housing, to a second position, in which the needle extends out of the housing, and wherein the needle hub is permitted to be moved by the spring when the button is pressed.

4. The drug delivery device of claim 3, further comprising a needle retention assembly configured to selectively prevent and permit movement of the needle hub from the first position to the second position, the needle retention assembly having:a retention member configured to contact the needle hub when the needle hub is in the first position to prevent movement of the needle hub to the second position;a deflection member configured to cause the retention member to be moved away from the needle hub; anda stabilizing member configured to prevent the retention member from being moved away from the needle hub until the deflection member contacts the retention member and moves the retention member away from the needle hub;wherein when the retention member is moved away from the needle hub by the deflection member, the retention member does not prevent movement of the needle hub to the second position.

5. The drug delivery device of claim 4, wherein movement of the button when the button is pressed causes the deflection member to move toward the retention member and move the retention member away from the needle hub and causes movement of the stabilizing member to move away from the retention member to permit the retention member to be moved away from the needle hub by the deflection member.

6. The drug delivery device of claim 1, wherein the actuator includes:a plurality of sleeves, at least some of the plurality of sleeves telescopically arranged relative to each other;a pushing nut at one end thereof configured to contact the plunger in the cartridge; anda spacer arranged between the pushing nut and at least one of the plurality of sleeves, wherein the at least one of the plurality of sleeves is configured to contact the spacer and prevented from contacting the pushing nut.

7. The drug delivery device of claim 6, wherein the spacer includes a protrusion configured to contact a receptacle on the at least one of the plurality of sleeves.

8. The drug delivery device of claim 1, wherein the actuator includes an attachment interface via which the actuator is configured to attach to the housing, the attachment interface having a plurality of arms extending radially away from the actuator, each arm configured to deflect radially inward toward the actuator during assembly of the drug delivery device during attachment of the actuator to the housing.

9. The drug delivery device of claim 1, wherein the housing includes a battery contact configured to receive a battery thereon, such that electricity from the battery flows through the battery contact to at least one component within the housing, the battery contact having a non-deflected position and a deflected position, wherein the battery contact is moved a predetermined distance when the battery contact is moved from the non-deflected position to the deflected position,the battery contact including a contact spacer configured to prevent the battery contact from moving greater than the predetermined distance when the battery contact is moved from the non-deflected position to the deflected position.

10. The drug delivery device of claim 1, wherein when the door is moved to its closed position, the door is prevented from moving to the open position by a latch disposed on one of the housing and the door, the latch having:a body pivotally attached to the one of the housing and the door; anda head extending from the body, the head being configured to engage with a latch engagement protrusion on the other of the housing and the door when the door is in its closed position,wherein when the head is engaged with the latch engagement protrusion, the door cannot be moved to its open position.

11. The drug delivery device of claim 10, wherein the body of the latch is movable between a latched position and an unlatched position, and the latch is biased to the latched position by a spring acting on the body of the latch.

12. The drug delivery device of claim 1, further comprising a transfer needle configured to be placed in fluid communication with the medicament in the cartridge, wherein the cartridge receptacle is configured to receive the cartridge in a first configuration, in which the cartridge is spaced away from the transfer needle and the transfer needle is not in fluid communication with the medicament in the cartridge, and a second configuration, in which the cartridge contacts the transfer needle and the transfer needle is in fluid communication with the medicament in the cartridge, andwherein the cartridge is moved from the first configuration to the second configuration when the button is pressed.

13. The drug delivery device of claim 12, further comprising a cartridge limiter assembly configured to prevent movement of the cartridge from the first configuration to the second configuration before the button is pressed, the cartridge limiter assembly including:a sliding engagement member movable within a channel of the door, the sliding engagement member configured to contact the cartridge and block the cartridge from moving to the second configuration; anda deflectable member configured to selectively block and unblock the channel to prevent or allow, respectively, movement of the sliding engagement member within the channel,wherein, when the button is pressed, the deflectable member is moved relative to the channel to unblock the channel and allow movement of the sliding engagement member to allow the cartridge to be moved to the second configuration.

14. The drug delivery device of claim 13, wherein the deflectable member includes a protrusion and the button includes an arm, the arm being configured to contact the protrusion when the button is pressed, wherein contact of the arm to the protrusion moves the deflectable member such that the sliding engagement member is allowed to move within the channel.

15. The drug delivery device of claim 1, further comprising:a structural rib extending from one of the housing and the door toward the other of the housing and the door; anda notch on the other of the housing and the door configured to receive the rib therein when the door is in the closed configuration.

16. A drug delivery kit comprising:a cartridge containing a medicament therein; anda drug delivery device for delivering the medicament to a patient, the device including:a housing defining a cartridge receptacle configured to receive the cartridge therein;a door attached to the housing and configured to move between an open position, in which the cartridge receptacle is accessible from outside the housing and the cartridge can be introduced into the cartridge receptacle, and a closed position, in which the cartridge receptacle is not accessible from outside the housing;an injection needle through which the medicament can be moved to the patient;an actuator configured to contact a plunger within the cartridge and to move the plunger to cause the medicament in the cartridge to move to the injection needle; anda button configured to be pressed to cause the medicament to be moved from the cartridge.

17. The drug delivery kit of claim 16, wherein the cartridge is provided separate from the drug delivery device to the patient, and the cartridge is configured to be inserted into the drug delivery device prior to use.

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