Auto-injector

• US 10,258,740 B2
• Filed: 06/04/2012
• Issued: 04/16/2019
• Est. Priority Date: 06/02/2011
• Status: Active Grant

• Current Assignee: Ucb Biopharma Sprl (UCB SA)
• Original Assignee: Ucb Biopharma Sprl (UCB SA)
• Inventors: McLoughlin, Martin John, Morgan, Darrell P., Lozeau, Kevin Richard, Enga, Agnete, Freitag, Eric, Formosa, Daniel, Schumann, Michael, Lipford, Brian, Cowperthwaite, Jake, Flamm, Alex, Melzi, Ilario, Bodnar, Jonathan
• Primary Examiner(s): Farrar, Lauren P
• Application Number:
  US14/123,081
• Publication Number:
  US 20140330203A1
• Time in Patent Office: 2,507 Days
• CPC Class Codes: A61M 2005/206 With automatic needle insertion
• CPC Class Codes: A61M 2005/3139 Finger grips not integrally formed with the syringe barrel, e.g. using adapter with finger grips
• CPC Class Codes: A61M 2005/3152 including gearings to multiply or attenuate the piston displacing force
• CPC Class Codes: A61M 2005/3215 Tools enabling the cap placement
• CPC Class Codes: A61M 2202/04 Liquids
• CPC Class Codes: A61M 2205/27 preventing use
• CPC Class Codes: A61M 2205/276 preventing unwanted use
• CPC Class Codes: A61M 2205/33 Controlling, regulating or measuring
• CPC Class Codes: A61M 2205/50 with microprocessors or computers
• CPC Class Codes: A61M 2205/502 User interfaces, e.g. screens or keyboards
• CPC Class Codes: A61M 2205/505 Touch-screens; Virtual keyboard or keypads; Virtual buttons; Soft keys; Mouse touches
• CPC Class Codes: A61M 2205/583 by visual feedback
• CPC Class Codes: A61M 2205/584 having a color code
• CPC Class Codes: A61M 2205/586 Ergonomic details therefor, e.g. specific ergonomics for left or right-handed users
• CPC Class Codes: A61M 2205/8206 battery-operated
• CPC Class Codes: A61M 5/1452 pressurised by means of pistons
• CPC Class Codes: A61M 5/14546 Front-loading type injectors
• CPC Class Codes: A61M 5/158 Needles for infusions; Accessories therefor, e.g. for inserting infusion needles, or for holding them on the body
• CPC Class Codes: A61M 5/172 electrical or electronic A61M5/16804, A61M5/16831 take precedence
• CPC Class Codes: A61M 5/20 Automatic syringes, e.g. with automatically actuated piston rod, with automatic needle injection, filling automatically A61M5/142 , A61M5/46 take precedence; hypodermic projectiles F42B12/54
• CPC Class Codes: A61M 5/3129 : Syringe barrels A61M5/3205 and A61M5/50 take precedence
• CPC Class Codes: A61M 5/3134 : characterised by constructional features of the distal end, i.e. end closest to the tip of the needle cannula
• CPC Class Codes: A61M 5/3137 : Specially designed finger grip means, e.g. for easy manipulation of the syringe rod
• CPC Class Codes: A61M 5/31511 : Piston or piston-rod constructions, e.g. connection of piston with piston-rod A61M5/5066 takes precedence
• CPC Class Codes: A61M 5/3202 : Devices for protection of the needle before use, e.g. caps A61M5/50 takes precedence; for infusion spikes A61M5/1626; protectors for sharps A61B50/3001
• CPC Class Codes: A61M 5/3204 : Needle cap remover, i.e. devices to dislodge protection cover from needle or needle hub, e.g. deshielding devices
• CPC Class Codes: A61M 5/3213 : Caps placed axially onto the needle, e.g. equipped with finger protection guards axially-extensible protective sleeves A61M5/3243
• CPC Class Codes: A61M 5/326 : Fully automatic sleeve extension, i.e. in which triggering of the sleeve does not require a deliberate action by the user
• CPC Class Codes: A61M 5/5086 : for indicating if defective, used, tampered with or unsterile
• CPC Class Codes: F04C 2270/0421 : Controlled or regulated

Abstract

Provided is a cassette unit suitable for use with an auto-injector having an electrically powered drive unit. The cassette unit has a housing defining a cassette unit housing cavity and a needle projection aperture. The cassette unit housing cavity is arranged for receipt of a syringe. The syringe has a barrel for containing a volume of a liquid drug formulation, the barrel defining a flange at the rear end thereof and a forward shoulder at the forward end thereof; a hollow needle at a front end of the barrel, the hollow needle defining a needle tip; and a plunger that is axially movable within the barrel. The cassette unit includes, in contact with the plunger and axially movable within the barrel, a plunger slaving part arranged such that when a drive load is applied to a rear drive-receiving face thereof the drive load is evenly transmitted to the plunger.

Claims

1. An auto-injector comprising:

a cassette unit for use with an auto-injector having an electrically powered drive unit, said cassette unit comprising;

a cassette unit housing defining a cassette unit housing cavity and a needle projection aperture, said cassette unit housing cavity in receipt of a syringe comprising;

a barrel for containing a volume of a liquid drug formulation, said barrel defining a flange at the rear end thereof and a forward shoulder at the forward end thereof;

a hollow needle at a front end of said barrel, said hollow needle defining a needle tip for dispensing of said liquid drug formulation; and

a plunger that is axially movable within the barrel; and

in contact with said plunger and axially movable within the barrel, a plunger slaving part defining a rear drive-receiving face and a forward drive-transferring face, and arranged such that when a drive load is applied to a rear drive-receiving face thereof the drive load is evenly transmitted to a rear end of the plunger by contact with said forward drive-transferring face thereof,

wherein a drive end of a drive transfer element for transferring axial drive to the plunger slaving part and subsequently to the plunger is arranged for receipt in a central recess of the plunger slaving part and configured to apply a point load to the rear-drive receiving face of the plunger slaving part,

wherein the plunger defines a hollow well therein and has a rear end wall that defines both the perimeter of said hollow well and the rear end of the plunger, and

wherein said hollow well has a well floor that tapers to a central point; and

a drive unit comprising;

a drive unit housing defining a docking cavity and a needle delivery aperture, wherein said docking cavity is arranged for docking receipt of the cassette unit at a docking position, whereupon said cassette unit and/or said syringe is movable from a rest position, in which the needle tip of the syringe is within the drive unit housing to a use position, in which the needle tip protrudes from said needle delivery aperture; and

a drive arrangement, said drive arrangement comprising;

one or more electrically powered sources of axial drive;

a first drive transfer element for transferring said axial drive to the cassette unit and /or to the syringe for advancing the syringe to said use position; and

a second drive transfer element for subsequently transferring the axial drive to the plunder slaving part and hence, to the plunger of the syringe for moving the plunger into the barrel of the syringe to eject at least part of said volume of liquid drug formulation,

wherein the second drive transfer element defines said drive end for transferring axial drive to the plunger slaving part and subsequently to the plunger and arranged for receipt in the central recess of the plunger slaving part and configured to apply a point load to the rear-drive receiving face of the plunger slaving part, and

wherein the second drive transfer element is in the form of a rotating screw or worm drive.

2. An auto-injector according to claim 1, wherein said plunger slaving part engages with the plunger.

3. An auto-injector according to claim 2, wherein the plunger slaving part is in threaded engagement with the plunger.

4. An auto-injector according to claim 1, wherein the diameter of the plunger slaving part corresponds to the diameter of the plunger.

5. An auto-injector according to claim 1, wherein the plunger is made of a material that is resiliently compressible and the plunger slaving part is made of a less compressible material.

6. An auto-injector according to claim 5, wherein the plunger slaving part is made of a rigid material.

7. An auto-injector according to claim 1, wherein said central recess is of conical form.

8. An auto-injector according to claim 1, wherein the plunger slaving part is comprised of brightly colored material to provide a clear visual indicator of the position of the plunger within the barrel of the syringe.

9. An auto-injector according to claim 1, additionally comprising one or more shoulder support features for supporting said forward shoulder of the syringe.

10. An auto-injector according to claim 9, further comprising a needle cover defining a needle sheath for sheathing of said needle tip, wherein said one or more shoulder support features locate between the needle cover and the forward shoulder of the syringe.

11. An auto-injector according to claim 10, wherein said needle cover is provided with a needle sheath cover for covering the needle sheath thereof and the one or more shoulder support features locate between said needle sheath cover and the forward shoulder of the syringe.

12. An auto-injector according to claim 11, wherein the needle sheath cover is comprised of a rigid material.

13. An auto-injector according to claim 10, wherein the one or more shoulder support features are in snap-fit arrangement between the needle cover and the forward shoulder of the syringe.

14. An auto-injector according to claim 9, wherein a ring of material is arranged for receipt over the one or more shoulder support features.

15. An auto-injector according to claim 14, wherein the ring of material acts such as to secure the one or more shoulder support features in place.

16. An auto-injector according to claim 9, wherein the one or more shoulder support features are integral with the cassette unit housing.

17. An auto-injector according to claim 9, wherein the one or more shoulder support features are defined by one or more separate shoulder support parts provided to the cassette unit.

18. An auto-injector according to claim 1, additionally comprising a removable cap that fits over and thereby, acts such as to close off, the needle projection aperture, wherein the needle cover connects to said removable cap.

19. An auto-injector according to claim 18, wherein the removable cap is provided with a finger-grip feature that is sized and shaped for gripping by the finger of a user to allow for removal of the removable cap and needle cover from the cassette unit housing.

20. An auto-injector according to claim 1, wherein the drive end defines a conical tip and the central recess is of conical form to guide and centre said conical tip therein.

21. An auto-injector according to claim 20, wherein the angle of the conical recess is greater than the angle of the conical tip.

22. An auto-injector according to claim 1, wherein the housing receives a syringe containing a liquid drug formulation.

23. An auto-injector according to claim 22, wherein the liquid drug formulation comprises an aqueous formulation of a therapeutic biologic type drug.

24. An auto-injector according to claim 1, wherein the plunger slaving part is received as an insert to the rear end of the plunger.

25. An auto-injector comprising:

a cassette unit comprising;

a housing defining a cavity, said cavity arranged to receive a syringe comprising;

a barrel;

a needle at a front end of said barrel; and

a plunger that is axially movable within the barrel; and

a plunger slaving part axially movable within said barrel, the plunger slaving part defining a rear drive-receiving face and a forward drive-transferring face, and arranged such that when a drive load is applied to a rear drive-receiving face thereof the drive load is evenly transmitted to a rear end of the plunger by contact with said forward drive-transferring face thereof,

wherein a drive end of a drive transfer element for transferring axial drive to the plunger slaving part and subsequently to the plunger is arranged for receipt in a central recess of the plunger slaving part and configured to apply a point load to the rear-drive receiving face of the plunger slaving part,

wherein the plunger defines a hollow well therein and has a rear end wall that defines both the perimeter of said hollow well and the rear end of the plunger, and

wherein said hollow well has a well floor that tapers to a central point; and

a drive unit comprising;

a drive unit housing defining a clocking cavity and a needle delivery aperture, wherein said docking cavity is arranged for docking receipt of the cassette unit at a docking position, whereupon said cassette unit and/or said syringe is movable from a rest position, in which the needle tip of the syringe is within the drive unit housing to a use position, in which the needle tip protrudes from said needle delivery aperture; and

a drive arrangement, said drive arrangement comprising;

one or more electrically powered sources of axial drive;

a first drive transfer element for transferring said axial drive to the cassette unit and /or to the syringe for advancing the syringe to said use position; and

a second drive transfer element for subsequently transferring the axial drive to the plunger slaving part and hence, to the plunger of the syringe for moving the plunger into the barrel of the syringe to eject at least part of said volume of liquid drug formulation,

wherein the second drive transfer element defines said drive end for transferring axial drive to the plunger slaving part and subsequently to the plunger and arranged for receipt in the central recess of the plunger slaving part and configured to apply a point load to the rear-drive receiving face of the plunger slaving part, and

wherein the second drive transfer element is in the form of a rotating screw or worm drive.

26. An auto-injector according to claim 25, wherein the plunger slaving part is received as an insert to the rear end of the plunger.