U.S. patent application number 09/985466 was filed with the patent office on 2009-07-30 for automatic injector with anti-coring needle.
This patent application is currently assigned to Meridian Medical Technologies ,INC. Invention is credited to Seth P. Cain, Robert L. Hill, C. Michael Mesa, John Whittier, John G. Wilmot.
Application Number | 20090192486 09/985466 |
Document ID | / |
Family ID | 25531514 |
Filed Date | 2009-07-30 |
United States Patent
Application |
20090192486 |
Kind Code |
A1 |
Wilmot; John G. ; et
al. |
July 30, 2009 |
AUTOMATIC INJECTOR WITH ANTI-CORING NEEDLE
Abstract
In one embodiment, an automatic injector comprises a cartridge
adapted to contain a charge of medicament, a seal structure
disposed toward a forward end of the cartridge, a plunger normally
disposed in a generally rearward end of the cartridge and movable
through the cartridge toward a generally forward end thereof in
response to an actuating procedure. The movable plunger rearwardly
confines the medicament within the cartridge. A needle normally
disposed in communication with the medicament container provides a
passage in which the medicament is released into an individual's
flesh in response to an actuating procedure projecting the needle
into the flesh of the individual. The cartridge having an increased
friction region so as to slow the motion of the plunger when the
forward end of the needle travels through the seal in order to
eliminate coring.
Inventors: |
Wilmot; John G.; (Mount
Airy, MD) ; Whittier; John; (Columbia, MD) ;
Hill; Robert L.; (Abington, MD) ; Cain; Seth P.;
(Baltimore, MD) ; Mesa; C. Michael; (Boyds,
MD) |
Correspondence
Address: |
JONES DAY
222 EAST 41ST ST
NEW YORK
NY
10017
US
|
Assignee: |
Meridian Medical Technologies
,INC
|
Family ID: |
25531514 |
Appl. No.: |
09/985466 |
Filed: |
November 2, 2001 |
Current U.S.
Class: |
604/506 ;
604/135 |
Current CPC
Class: |
A61M 2005/3151 20130101;
A61M 5/3291 20130101; A61M 2005/2086 20130101; A61M 5/2033
20130101; A61M 5/3202 20130101; A61M 5/3129 20130101; A61M 5/286
20130101; A61M 2205/195 20130101; A61M 2005/206 20130101; A61M 5/24
20130101; A61M 2005/2013 20130101; A61M 5/3286 20130101; A61M
2205/192 20130101; A61M 2005/2073 20130101 |
Class at
Publication: |
604/506 ;
604/135 |
International
Class: |
A61M 5/20 20060101
A61M005/20 |
Claims
1. An automatic injector comprising: a housing having a rearward
end and a forward end; a seal structure disposed toward the forward
end of said housing; a cartridge contained within said housing; a
charge of medicament contained in said cartridge; a plunger
normally disposed in a generally rearward end of said cartridge and
movable through said cartridge toward a generally forward end
thereof in response to an actuating procedure, said movable plunger
rearwardly confining said medicament within said cartridge; a
needle normally disposed within said housing, said needle being
projectable from the forward end of said housing through said seal
structure, said needle being communicable with said medicament so
that movement of said plunger through said cartridge forces said
medicament through said needle and into the flesh of an individual
in response to said predetermined actuating procedure, said needle
comprising: a hollow rigid tubing having a cylindrical wall, the
cylindrical wall having an inner surface and outer surface; a lumen
opening having a front pointed portion comprising a lancet shaped
tip having a facet grinding at an angle, said tip bent in a curve
directed toward a longitudinal axis of said cylindrical wall so as
to shield the entire cross section of said lumen opening, said
cross section of said lumen opening perpendicular to a longitudinal
axis of said hollow rigid tubing, said tip comprising primary and
secondary facets, said secondary facets ground at an angle at the
inner surface of the needle; and a releasable energy source
releasable in response to said predetermined actuating procedure to
project said needle from the forward end of the housing and
slidingly drive said plunger through said cartridge in sealed
relation to expel said medicament through said needle and into the
flesh of an individual.
2. The automatic injector as claimed in claim 1, wherein said seal
structure seals a forward end of said cartridge.
3. The automatic injector as claimed in claim 1, wherein said
friction area comprises a narrowed diameter portion in a wall of
said cartridge.
4. The automatic injector as claimed in claim 1, wherein said
friction area is a corrugated portion in a wall of said
cartridge.
5. The automatic injector as claimed in claim 1, wherein a tip of
said needle is coated with polyparaxylylene.
6. The automatic injector as claimed in claim 5, wherein said
polyparaxylylene coating has a thickness between about 0.0001 to
0.001 inches.
7. The automatic injector as claimed in claim 1, wherein said
needle is normally stored within said cartridge, in contact with
said medicament.
8. (canceled)
9. (canceled)
10. The automatic injector as claimed in claim 1, wherein said
secondary facets are also ground at an angle at the outside surface
of the needle.
11. The automatic injector as claimed in claim 1, wherein said
plunger comprises a material selected from the group of plastics
and rubbers.
12. The automatic injector as claimed in claim 3, wherein said
plunger comprises ribs arranged to reduce the rate of acceleration
of said needle when in contact with said friction region.
13. The automatic injector as claimed in claim 4, wherein said
plunger comprises ribs arranged to reduce the rate of acceleration
of said needle when in contact with said friction region.
14. The automatic injector as claimed in claim 11, wherein said
plunger comprises a plurality of materials having different
ductilities, said materials are selected to interact differently
with said friction area to reduce the rate of acceleration of said
needle.
15. The automatic injector as claimed in claim 1, wherein said
releasable energy source comprises a normally compressed spring
which is released in response to said predetermined actuating
procedure.
16. The automatic injector as claimed in claim 1, wherein said
spring having a spring constant between 1.5 lb/in and 6.5
lb/in.
17. The automatic injector as claimed in claim 1, wherein said seal
structure comprises a material selected from the group of plastics
and rubber.
18. An automatic injector comprising: a housing having a rearward
end and a forward end; a seal structure disposed toward the forward
end of said housing; a cartridge contained within said housing; a
charge of medicament contained in said cartridge; a plunger
normally disposed in a generally rearward end of said cartridge and
movable through said cartridge toward a generally forward end
thereof in response to an actuating procedure, said movable plunger
rearwardly confining said medicament within said cartridge; a
needle normally disposed within said housing, said needle being
projectable from the forward end of said housing through said seal
structure, said needle being communicable with said medicament so
that movement of said plunger through said cartridge forces said
medicament through said needle and into the flesh of an individual
in response to said predetermined actuating procedure; wherein said
needle comprises a damping structure for reducing the rate of
acceleration of said needle by the viscous resistance created when
said damping structure moves within said medicament; and a
releasable energy source releasable in response to said
predetermined actuating procedure to project said needle from the
forward end of the housing and slidingly drive said plunger through
said cartridge in sealed relation to expel said medicament through
said needle and into the flesh of an individual.
19. The automatic injector as claimed in claim 18, wherein said
damping structure comprises a damping disk attached to said needle
and arranged to reduce the rate of acceleration of said needle by
the flow resistance created when said disk moves through said
medicament.
20. An automatic injector comprising: a housing having a rearward
end and a forward end; a seal structure disposed toward the forward
end of said housing; a cartridge contained within said housing; a
charge of medicament contained in said cartridge; a plunger
normally disposed in a generally rearward end of said cartridge and
movable through said cartridge toward a generally forward end
thereof in response to an actuating procedure, said movable plunger
rearwardly confining said medicament with said cartridge; a needle
normally disposed within said housing, said needle being
projectable from the forward end of said housing through said seal
structure, said needle being communicable with said medicament so
that movement of said plunger through said cartridge forces said
medicament through said needle and into the flesh of an individual
in response to said predetermined actuating procedure; said needle
comprising: a hollow rigid tubing having a cylindrical wall
defining a longitudinal passage therethrough, said cylindrical wall
including opposing first and second wall portions, said first wall
portion having a forward tip portion terminating in a forward end
tip, said second wall portion terminating at a position rearwardly
spaced from said end tip, said forward tip portion being bent in a
manner to shield the entire cross-section of said longitudinal
passage, said cross section of said longitudinal passage
perpendicular to a longitudinal axis of said hollow rigid tubing;
and a releasable energy source releasable in response to said
predetermined actuating procedure to project said needle from the
forward end of the housing and slidingly drive said plunger through
said cartridge in sealed relation to expel said medicament through
said needle and into the flesh of an individual.
21. The automatic injector as claimed in claim 20, wherein said
seal structure seals a forward end of said cartridge.
22. The automatic injector as claimed in claim 20, wherein the tip
of said needle is coated with polyparaxylylene.
23. The automatic injector as claimed in claim 22, wherein said
polyparaxylylene coating has a thickness between about 0.0001 to
0.001 inches.
24. An automatic injector comprising: a housing having a rearward
end and a forward end; a seal structure disposed toward the forward
end of said housing; a cartridge contained within said housing; a
charge of medicament contained in said cartridge; a plunger
normally disposed in a generally rearward end of said cartridge and
movable through said cartridge toward a generally forward end
thereof in response to an actuating procedure, said movable plunger
rearwardly confining said medicament within said cartridge; a
needle normally disposed within said housing, said needle being
projectable from the forward end of said housing through said seal
structure, said needle being communicable with said medicament so
that movement of said plunger through said cartridge forces said
medicament through said needle and into the flesh of an individual
in response to said predetermined actuating procedure; said needle
comprising: a hollow rigid tubing having a cylindrical wall
defining a longitudinal passage therethrough, said cylindrical wall
including opposing first and second wall portions, said first wall
portion having a forward tip portion terminating in a forward end
tip, said second wall portion terminating at a position rearwardly
spaced from said end tip, said forward tip portion being bent in a
manner to shield the entire cross-section of said longitudinal
passage, said cross section of said longitudinal passage
perpendicular to a longitudinal axis of said needle; wherein said
forward tip portion is bent at an angle approximately between 51
degrees and 100 degrees; said angle being defined as the angle
between a tangent to a curvature of an outer surface at said end
tip and the longitudinal axis of said needle; and a releasable
energy source releasable in response to said predetermined
actuating procedure to project said needle from the forward end of
the housing and slidingly drive said plunger through said cartridge
in sealed relation to expel said medicament through said needle and
into the flesh of an individual.
25. The automatic injector as claimed in claim 24, wherein said
seal structure seals a forward end of said cartridge.
26. An automatic injector comprising: a housing having a rearward
end and a forward end; a seal structure disposed toward the forward
end of said housing; a cartridge contained within said housing; a
charge of medicament contained in said cartridge; a plunger
normally disposed in a generally rearward end of said cartridge and
movable through said cartridge toward a generally forward end
thereof in response to an actuating procedure, said movable plunger
rearwardly confining said medicament within said cartridge; a
needle normally disposed within said housing, said needle being
projectable from the forward end of said housing through said seal
structure, said needle being communicable with said medicament so
that movement of said plunger through said cartridge forces said
medicament through said needle and into the flesh of an individual
in response to said predetermined actuating procedure; said needle
comprising: a hollow rigid tubing having a cylindrical wall
defining a longitudinal passage therethrough, said cylindrical wall
including opposing first and second wall portions, said first wall
portion having a forward tip portion terminating in a forward end
tip, said second wall portion terminating at a position rearwardly
spaced from said end tip, said forward tip portion having a back
ground lancet wherein back grinds of said lancet are ground at an
angle of about 120 degrees measured in relation to a base line
extending transversely across the forward tip portion, the forward
tip portion being bent at an angle approximately between 51 degrees
and 100 degrees; said angle being defined as the angle between a
tangent to a curvature of an outer surface at said end tip and a
longitudinal axis of said needle; a releasable energy source
releasable in response to said predetermined actuating procedure to
project said needle from the forward end of the housing and
slidingly drive said plunger through said cartridge in sealed
relation to expel said medicament through said needle and into the
flesh of an individual.
27. The automatic injector as claimed in claim 26, wherein said
seal structure seals a forward end of said cartridge.
28. An automatic injector comprising: a housing having a rearward
end and a forward end; a seal structure disposed toward the forward
end of said housing; a cartridge contained within said housing; a
charge of medicament contained in said cartridge; a plunger
normally disposed in a generally rearward end of said cartridge and
movable through said cartridge toward a generally forward end
thereof in response to an actuating procedure, said movable plunger
rearwardly confining said medicament within said cartridge; a
needle normally disposed within said housing, said needle being
projectable from the forward end of said housing through said seal
structure, said needle being communicable with said medicament so
that movement of said plunger through said cartridge forces said
medicament through said needle and into the flesh of an individual
in response to said predetermined actuating procedure; said needle
comprising: a hollow rigid tubing having a cylindrical wall
defining a linear longitudinal passage entirely there through, said
cylindrical wall including opposing first and second wall portions,
said first wall portion having a forward tip portion terminating in
a forward end tip, said second wall portion terminating at a
position rearwardly spaced from said end tip, said forward tip
portion being bent in a manner to shield the entire cross-section
of said longitudinal passage, said cross section of said
longitudinal passage perpendicular to a longitudinal axis of said
hollow rigid tubing; said needle comprising an enlarged rearward
portion constructed and arranged for engagement with said plunger;
and a releasable energy source releasable in response to said
predetermined actuating procedure to project said needle from the
forward end of the housing and slidingly drive said plunger through
said cartridge in sealed relation to expel said medicament through
said needle and into the flesh of an individual.
29. The automatic injector as claimed in claim 28, wherein said
seal structure seals a forward end of said cartridge.
30. An automatic injector comprising: a housing having a rearward
end and a forward end; a seal structure disposed toward the forward
end of said housing; a cartridge contained within said housing; a
charge of medicament contained in said cartridge; a plunger
normally disposed in a generally rearward end of said cartridge and
movable through said cartridge toward a generally forward end
thereof in response to an actuating procedure, said movable plunger
rearwardly confining said medicament within said carriage; a needle
normally disposed within said housing, said needle being
projectable from the forward end of said housing through said seal
structure, said needle being communicable with said medicament so
that movement of said plunger through said cartridge forces said
medicament through said needle and into the flesh of an individual
in response to said predetermined actuating procedure; said needle
comprising: a hollow rigid tubing having a cylindrical wall
defining a linear longitudinal passage entirely there through, said
cylindrical wall forming the boundary of the linear longitudinal
passage, said cylindrical wall including opposing first and second
wall portions, said first wall portion having a forward tip portion
terminating in a forward end tip, said second wall portion
terminating at a position rearwardly spaced from said end tip; said
forward tip portion is bent at an angle approximately between 51
degrees and 100 degrees; said angle being defined as the angle
between a tangent to a curvature of an outer surface at said end
tip and a longitudinal axis of said needle; wherein said needle
comprises an enlarged rearward portion constructed and arranged for
engagement with said plunger; a releasable energy source releasable
in response to said predetermined actuating procedure to project
said needle from the forward end of the housing and slidingly drive
said plunger through said cartridge in sealed relation to expel
said medicament through said needle and into the flesh of an
individual.
31. The automatic injector as claimed in claim 30, wherein said
seal structure seals a forward end of said cartridge.
32. An automatic injector comprising: a housing having a rearward
end and a forward end; a seal structure disposed toward the forward
end of said housing; a cartridge contained within said housing; a
charge of medicament contained in said cartridge; a plunger
normally disposed in a generally rearward end of said cartridge and
movable through said cartridge toward a generally forward end
thereof in response to an actuating procedure, said movable plunger
rearwardly confining said medicament within said cartridge; a
needle normally disposed within said housing, said needle being
projectable from the forward end of said housing through said seal
structure, said needle being communicable with said medicament so
that movement of said plunger through said cartridge forces said
medicament through said needle and into the flesh of an individual
in response to said predetermined actuating procedure; said needle
comprising: a hollow rigid tubing having a cylindrical wall
defining a longitudinal passage extending there through, said
cylindrical wall having an inner surface and including opposing
first and second wall portions, said first wall portion having a
forward tip portion terminating in a forward end tip, said second
wall portion terminating at a position rearwardly spaced from said
end tip, said forward tip portion being bent; an enlarged rearward
portion constructed and arranged for engagement with said plunger,
and a lumen opening having a front pointed portion comprising a
lancet shaped tip having a facet grinding at an angle, said forward
tip bent in a curve directed toward a longitudinal axis of said
cylindrical wall so as to constitute a shield to said lumen
opening, said tip comprising primary and symmetrical secondary and
tertiary facets, said secondary and tertiary facets each ground at
the outside surface of the needle at an angle ranging from 120
degrees to 130 degrees measured in relation to a base line
extending transversely across the forward tip portion; and a
releasable energy source releasable in response to said
predetermined actuating procedure to project said needle from the
forward end of the housing and slidingly drive said plunger through
said cartridge in sealed relation to expel said medicament through
said needle and into the flesh of an individual.
33. The automatic injector as claimed in claim 32, wherein said
seal structure seals a forward end of said cartridge.
34. An automatic injector comprising: a housing having a rearward
end and a forward end; a seal structure disposed toward the forward
end of said housing; a cartridge contained within said housing; a
charge of medicament contained in said cartridge; a plunger
normally disposed in a generally rearward end of said cartridge and
movable through said cartridge toward a generally forward end
thereof in response to an actuating procedure; a needle normally
disposed within said housing, and projectable from the forward end
of said housing through said seal structure, said needle being
communicable with said medicament so that movement of said plunger
through said cartridge forces said medicament through said needle
in response to said predetermined actuating procedure, said needle
comprising: a hollow rigid tubing having a cylindrical wall that
includes opposing first and second wall portions, said first wall
portion having a forward tip portion terminating in a forward end
tip, said second wall portion terminating at a position rearwardly
spaced from said end tip, said forward end tip portion having a
back ground lancet wherein back grinds of said forward end tip
portion are at an angle ranging from 120 degrees to 130 degrees in
relation to a base line extending transversely across the forward
tip portion; and a releasable energy source releasable in response
to said predetermined actuating procedure to project said needle
from the forward end of the housing and slidingly drive said
plunger through said cartridge to expel said medicament through
said needle and into the flesh of an individual.
35. A method for injecting a medicament with an automatic injector,
which injector comprises a housing, a seal structure disposed
toward a forward end of said housing, a cartridge contained within
said housing, a charge of medicament contained in said cartridge, a
plunger movable through said cartridge toward a generally forward
end thereof in response to an actuating procedure, said movable
plunger rearwardly confining said medicament within said cartridge,
a needle normally disposed within said housing, said needle being
projectable from the forward end of said housing through said seal
structure, said needle being communicable with said medicament so
that movement of said plunger through said cartridge forces said
medicament through said needle and into the flesh of an individual
in response to said predetermined actuating procedure, a releasable
energy source releasable in response to said predetermined
actuating procedure to project said needle from the forward end of
the housing and slidingly drive said plunger through said cartridge
in sealed relation to expel said medicament through said needle and
into the flesh of an individual; said method comprising: releasing
said energy source; accelerating said needle forwardly within said
housing; reducing the rate of acceleration of said needle prior to
said needle penetrating said seal; and expelling said medicament
through said needle.
36. The method for injecting a medicament with an automatic
injector as recited in claim 35, wherein said penetrating said seal
is performed at a speed between 250 inches/s and 680 inches/s.
37. The method for injecting a medicament with an automatic
injector as recited in claim 35, further comprising: speeding up
said needle after said needle has fully penetrated said seal.
38. A method of injecting a medicament with an automatic injector,
the injector comprising a housing, a seal structure disposed toward
a forward end of said housing, a cartridge contained within said
housing, a charge of medicament contained in said cartridge, a
plunger movable through said cartridge toward a generally forward
end thereof in response to an actuating procedure, a needle
disposed within said housing and having a linear longitudinal
passage entirely through the needle, said needle projectable from
the forward end of said housing through said seal structure, said
needle communicable with said medicament so that movement of said
plunger through said cartridge forces said medicament through the
longitudinal passage of said needle in response to said actuating
procedure, a releasable energy source responsive to said actuating
procedure to project said needle from the forward end of the
housing and slidingly drive said plunger through said cartridge to
expel said medicament through said needle; said method comprising:
releasing said energy source; forcing said medicament through said
linear longitudinal passage of said needle; moving said needle
forwardly within said housing at a speed of less than 680 inches/s
as said needle penetrates said seal structure; penetrating said
seal structure with said needle having a forward tip portion bent
so as to shield the entire cross-section of the longitudinal
passage, said cross section of the longitudinal passage
perpendicular to a longitudinal axis of said needle; and expelling
said medicament through said needle.
39. The method as recited in claim 38, wherein said moving said
needle forwardly within said housing comprises moving said needle
at a speed of more than 150 inches/s as said needle penetrates said
seal structure.
Description
BACKGROUND
[0001] 1. Field of Invention
[0002] The present invention relates to automatic injectors, and
more particularly, to automatic injectors that reduce the
likelihood of coring a sealing member.
[0003] 2. Discussion of Related Art
[0004] Automatic injectors are well known. Basically an automatic
injector is a device for enabling an individual to self-administer,
or administer to another, a dosage of a liquid medicament. An
advantage of automatic injectors is that they contain a measured
dosage of a liquid medicament in a sealed sterile condition capable
of storage in such condition for an extensive period of non-use,
during which period immediate injection of the stored dosage may be
accomplished at any time under severe emergency conditions. Another
advantage of automatic injectors is the administration of the
self-contained dosage of liquid medicament is accomplished without
the necessity of the user initially seeing the hypodermic needle
through which the liquid medicament is injected or of manually
penetrating such visible needle into the user's or another person's
tissue.
[0005] As stated above, automatic injectors are particularly suited
for use under emergency conditions. For example many tens of
millions of such automatic injectors have been manufactured and
sold containing nerve gas antidotes for use under emergency
chemical warfare conditions. Typical units which have been utilized
for this purpose are disclosed in U.S. Pat. Nos. 2,832,339,
3,882,863, and 4,031,893. In addition units of this type have been
manufactured and used in administering anti-arrhythmic medicaments
under emergency conditions relating to hart attack medical
situations. The use of an auto injector has also been proposed to
provide other medicaments useful in treating heart attack symptoms
such as clot selective thrombolic agents (for example, tPA) and
related medicaments. See for example, U.S. Pat. Nos. 4,689,042,
4,755,169, and 4,795,433. In addition, automatic injectors have
been widely marketed containing a dosage of epinephrine as an
antidote for counteracting severe allergic reactions, as for
example, to bee stings, and the like.
[0006] In all of these instances, the auto-injector is specifically
structured so that in its normal operation the needle extends into
the tissue of the individual and a specified amount of liquid
medicament stored in a cartridge within the injector is injected
into the tissue of the individual.
[0007] The hypodermic needle of an autoinjector has a forward end
adapted to penetrate the clothing and flesh of an individual and a
rearward end adapted to communicate with a liquid medicament source
so that the medicament is permitted to flow from the source,
through the central longitudinal bore or lumen in the needle, and
into the flesh of the individual. In some embodiments, the needle
is contained inside the cartridge containing the liquid medicament.
For example one application exists in the field of automatic
injection devices, wherein the liquid medicament is sealed within a
tubular container or cartridge, generally made of glass, plastic or
metal, having a rubber seal closing off at the forward end and a
rubber plunger at the rearward end. For example see U.S. Pat. No.
5,354,286. During an injection operation, a stressed spring
assembly is released moving a push rod against the plunger. The
plunger pushes against the hub-end of the needle causing the needle
to puncture the forward end seal of the cartridge and penetrates
into the flesh of an individual. The liquid medicament is pushed at
the same time through the needle, thus releasing the medicament
into the individual's flesh.
[0008] In another type of automatic injector, the needle is
connected to the forward end of the cartridge. See U.S. Pat. No.
5,102,393. During an injection operation, the needle is forced
through a resilient seal at the forward end of the outer housing or
through an elongated rubber sheath surrounding the needle. In
either case the needle is kept sterile by a seal disposed toward a
forward end of the housing while the injector is stored. After the
needle punctures the seal or sheath, it then is forced into the
flesh of the individual.
[0009] An issue that must be dealt with in each of the mentioned
arrangements is that the forward end of the needle must perforate a
rubber or other type of seal, and it is possible for the forward
end of the needle to core out or dislodge a small particle of
material from the seal and potentially block the needle
orifice/lumen or be forced into the individual's flesh.
SUMMARY OF INVENTION
[0010] To overcome these problems and others, it is proposed to
provide an automatic injector in which the amount of coring by the
needle is substantially reduced or eliminated.
[0011] Therefore, in one embodiment of the present invention is to
provide an automatic injector that comprises: a housing; a seal
structure disposed toward a forward end of the housing; a cartridge
contained within the housing; a charge of medicament contained in
the cartridge; a plunger normally disposed in a generally rearward
end of the cartridge and movable through the cartridge toward a
generally forward end thereof in response to an actuating
procedure. The movable plunger rearwardly confines said medicament
within said cartridge. A needle is normally disposed within the
housing, the needle being projectable from a forward end of said
housing through said seal structure. The needle is communicable
with the medicament so that movement of the plunger through the
cartridge forces the medicament through the needle and into the
flesh of an individual, in response to the predetermined actuating
procedure. A releasable energy source is releasable in response to
the predetermined actuating procedure to project the needle from
the forward end of the housing and slidingly drive the plunger
through the cartridge in sealed relation to expel the medicament
through the needle and into the flesh of an individual. The
cartridge has an increased friction region so as to slow the motion
of the plunger as the forward end of the needle travels through the
seal.
[0012] In another embodiment, the needle carries a damping
structure for reducing the rate of acceleration of the needle by
the resistance created when said damping structure moves within
said medicament.
[0013] In addition, the present invention is directed to several
automatic injection devices comprising novel needle structures that
reduce coring of an elastic, plastic or rubber based structure at
the forward end of the injector.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] These and other objects and advantages of the invention will
become more apparent and more readily appreciated from the
following detailed description of the presently preferred exemplary
embodiments of the invention, taken in conjunction with the
accompanying drawings, of which:
[0015] FIG. 1 is a longitudinal sectional view of an automatic
injector according to an embodiment of the present invention;
[0016] FIG. 2 is a longitudinal sectional view of a cartridge
showing the friction region according to an embodiment of the
present invention;
[0017] FIG. 3 is a longitudinal sectional view of the cartridge
showing the friction region according to an alternative embodiment
of the present invention;
[0018] FIG. 4 is a graph showing the force versus distance of
travel of plunger in a configuration without an increased friction
region, as will be described hereinafter;
[0019] FIG. 5 is a graph showing the force versus distance of
travel of plunger in a configuration when using embodiment
illustrated in FIG. 3;
[0020] FIG. 6 is a graph showing the force versus distance of
travel of plunger in a configuration when using embodiment
illustrated in FIG. 2;
[0021] FIG. 7 is a graph showing the percentage of coring versus
the inside diameter measured at an increased friction region, as
will be described hereinafter;
[0022] FIG. 8 is a graph showing the core length versus the inside
diameter measured at an increased friction region, as will be
described hereinafter;
[0023] FIG. 9 is an enlarged view of a straight tip showing the
point and the heel of the needle.
[0024] FIG. 10 is a longitudinal sectional view of the hypodermic
needle as installed in a cartridge according to another embodiment
of the present invention; the hypodermic needle is shown having a
curved tip;
[0025] FIG. 11A is an enlargement of the tip of the needle
according to embodiment illustrated in FIG. 10 having curved "C"
tip;
[0026] FIG. 11B is an enlargement frontal view of the pointed tip
of the needle;
[0027] FIG. 12 is a longitudinal expanded sectional view of the
forward end of the needle showing the interaction of the seal
material with a curved tip needle having a regular/thinner wall
thickness;
[0028] FIG. 13 is a longitudinal expanded sectional view of the
forward end of the needle show the interaction of the seal material
with a needle having a heavy/thicker wall thickness;
[0029] FIG. 14 is a longitudinal expanded sectional view of the
forward end of the needle showing the curvature tolerance
limits;
[0030] FIG. 15 is a longitudinal expanded sectional view of the
forward end of the needle showing the front-ground geometry;
[0031] FIG. 16 is a sectional transversal view of the forward end
of the needle showing the front-ground geometry;
[0032] FIG. 17 is a longitudinal expanded sectional view of the
forward end of the needle showing the back-ground geometry;
[0033] FIG. 18 is a sectional transversal view of the forward end
of the needle showing the back-ground geometry;
[0034] FIG. 19 shows the consecutive transversal sectional views of
the forward end of the needle illustrating the back-ground
geometry;
[0035] FIG. 20 shows consecutive transversal sectional views of the
forward end of the needle illustrating the front-ground
geometry;
[0036] FIG. 21 is a longitudinal view of the forward end of the
needle according to an alternative embodiment of the present
invention where Parylene coating is applied to the needle;
[0037] FIG. 22 is a longitudinal expanded view of the heel of
needle according to embodiment illustrated in FIG. 21. The heel is
shown uniformly coated with a conformal coating;
[0038] FIG. 23 is a graph showing the percentage of coring and the
coring mean length versus the coating thickness as applied in
embodiment illustrated in FIG. 22; and
[0039] FIG. 24 is a longitudinal sectional view of an automatic
injector according to another embodiment of the present
invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
[0040] In the following description, for purposes of explanation
and not limitation, specific details are set forth such as
particular shapes and materials, mechanical components, techniques,
etc. in order to facilitate a thorough understanding of the present
invention. However, the invention may be practiced in other
embodiments that depart from these specific details. The terms
"damping structure", "friction area", "speed bump" and "narrowed
diameter portion" are used interchangeably in this description to
illustrate a feature that is used as a way to reduce the rate of
acceleration thus decrease the speed at which the hypodermic needle
punctures or pierces the forward seal in comparison with prior art
auto-injectors. Also, for the purpose of this disclosure, the
portions of the injector on the right side of FIG. 1 (on the needle
extension end) will be considered the front end, while the left
side or activation end will be considered the rear end.
[0041] Referring, more particularly, to the drawings in detail,
there is shown in FIG. 1 an automatic injector 100. The automatic
injector 100 includes a tubular housing 102, a medicament cartridge
assembly 104, within the forward end portion of the housing
assembly 102, and a releasable energy source 106 which is
releasable in response to a predetermined actuating procedure as
will be described in detail in the following paragraphs. While the
releasable energy source can be any type of assembly which
effectuates an injection operation, such as a compressed gas
assembly as disclosed in U.S. Pat. No. 4,518,384, it is preferred
that the releasable energy source be a stressed spring assembly, as
generally indicated at 106. The stressed spring assembly is
disposed within the rearward end portion of the housing assembly
102 in operative relation with the medicament cartridge assembly
104. A releasable end safety cap 108 positioned at the rear of the
housing assembly 102 is in operative relation with the stressed
spring assembly 106.
[0042] The housing assembly 102, medicament cartridge assembly 104,
and stress spring assembly 106 are generally constructed in
accordance with the teaching of U.S. Pat. No. 2,832,339, hereby
incorporated by reference. As shown in FIG. 1, the housing assembly
102 includes a cylindrical outer housing member 110 having a
centrally apertured cylindrical rear wall portion 112 of reduced
diameter on which the safety end cap 108 is mounted. The housing
assembly 102 also includes an inner cylindrical housing member 114
within the housing member 110 within which is mounted the
medicament cartridge assembly 104 and the stressed spring assembly
106. The forward portion of the inner housing member 114 is formed
with a counterbore for receiving therein a cylindrical dosage
container or cartridge 116 of the medicament cartridge assembly
104. The cartridge of the present invention is preferably made of
metallic materials such as, but not limited to, stainless steel and
aluminum. Other materials, such as plastic materials (eg.,
polypropylene) or glass are also within the scope of the present
invention.
[0043] The forward end of the container or cartridge 116 is closed
by a stopper or seal 118, preferably, of suitable rubber or
compliant plastic material. The cartridge assembly 104 is retained
in closing relation with the forward end of the inner housing
member 114 by a housing end cap member 120 of molded plastic
material. The cap 120 is preferably retained on the inner housing
member 114 by inter-engagement of a pair of ridges 122 formed on
the exterior periphery of the tubular member 114 with an annular
groove 124 formed on the interior periphery of the cap member 120.
The rearward end of the cartridge 116 is closed by a rubber or
plastic plunger 126 which is slidably, sealingly engaged with the
inner surface of cartridge 116 so as to enclose within the
cartridge a dosage 128 of a liquid medicament.
[0044] A hypodermic needle 130 is disposed within the cartridge
116. It thus can be appreciated that the cartridge assembly 104
includes cartridge 116, seal 118, needle 130 and disc 132. As can
be discerned from FIG. 1, needle 130 is normally stored in contact
with the medicament 128. However, in the broadest aspects of the
present invention, it can be appreciated that needle 130 can be
disposed in a separate chamber (either evacuated or filled with a
preferably inert gas) forwardly of the medicament 128 (for example,
see our U.S. Pat. Nos. 5,085,642 and 5,102,393), so long as the
needle is somehow communicable with the medicament in a manner
which permits the medicament to travel through the needle and into
the flesh of an individual. The needle can also be disposed in
contact with one of two medicaments, which are normally stored
separately within the injector and then either mixed within the
injector prior to an injection (e.g. see U.S. Pat. No. 5,041,088)
or injected separately one after the other (see U.S. Pat. No.
5,092,843). The hypodermic needle 130 is preferably made from
stainless steel.
[0045] In the present embodiment, the needle 130 has its pointed
end disposed within a recess formed in the seal 118. A disc 132 of
plastic is disposed within the forward end of the cartridge 116 in
surrounding, securing and guiding relation with the hypodermic
needle 130 and in abutting engagement with the seal 118. The disc
132 serves to releasably hold the needle in its storage position to
provide peripheral centering therefore during the dosage injecting
stroke of the plunger 126. The rearward end of the hypodermic
needle 130 is enlarged for engagement by the plunger and has a slot
134 formed in its side wall adjacent the enlarged end for
communicating the dosage 128 with the hollow interior of the
hypodermic needle 130 when the plunger 126 is in engagement
therewith. The inner housing member 114 is mounted within the outer
housing member 110 for limited reciprocating movement as determined
by a pair of ridges 136 formed on the exterior periphery of the
tubular inner housing member 114 at a position spaced rearwardly
from the pair of ridges 122. The pair of ridges 136 is adapted to
engage with an elongated annular groove 138 formed on the interior
periphery of the outer housing member 110.
[0046] The stressed spring assembly 106 includes a normally
compressed but releasable coil spring 142 and an elongated collet
member 140. The collet member is disposed within the rearward
portion of the housing member 114 and has its forward end disposed
adjacent to the plunger 126. The forward end of the collet member
140 has a flange 141 configured to engage the forward end of the
stressed coil spring 142, which surrounds the central portion of
the elongated collet member 140. The collet 140 has its rearward
end engaged with a locking ring 152 sitting on an annular end
flange 144 formed integrally on the rearward end of the inner
housing member 114.
[0047] The rearward end of the elongated collet member 140 are
split to provide a plurality (e.g., four) flexible spring fingers
146, the rearward extremities of which are formed with rearwardly
and outwardly facing cam releasing surfaces 148. Extending inwardly
from the rearward end of each cam surface 148 is locking shoulder
150 adapted to engage a locking ring 152 seated on the rear surface
of flange 144. The forward portion of the apertured cylindrical
wall portion 112 is formed with a complementary cam surface 154,
which is disposed in engagement with the cam surfaces 148 so as to
effect a laterally inward movement of the spring fingers 146 toward
one another to disengage locking shoulders 150 from locking ring
152 in response to a relative forward actuating movement of the
outer housing member 110 with respect to the inner housing member
114. This inward action of the spring fingers 146 is permitted only
after the safety cap 108 is removed, as will be described.
[0048] The operation of the injector will now be described. In the
first step of operation, releasable end cap 108 is removed from the
injector 100. This removal is accomplished simply by gripping the
exterior periphery of the end cap 108 and moving it rearwardly
while gripping and holding the outer housing member 110. The cap
member 108 carries with it a safety pin portion 160. With the
safety pin portion 160 removed from its safety position, which
normally prevents the laterally inward movement of the spring
fingers 146, the user can now complete the operation by moving the
forward cap member 120 into contact with the tissue of a person to
be injected. By applying a continued forward force on the exterior
periphery of the outer housing member 110, cam surfaces 154 thereof
are moved forwardly. This forward movement in cooperation with the
cam surfaces 148 on the spring fingers 146 causes the locking
surfaces 150 of the latter to move inwardly off of the locking ring
152, thus releasing the stressed spring 142. The spring 142 acts
through the collet member 140 to move the same forwardly which has
the effect of moving the plunger 126 with it. As the plunger moves
forwardly, it carries with it the needle 130. The pointed forward
end of the needle pierces through the seal 118 and into the tissue
of the patient. At the same time, the dosage 128 of liquid
medicament within the cartridge 116 is caused to move inwardly into
the slot 134 of the needle and outwardly of the pointed forward end
thereof as the same moves into the tissue of the user.
[0049] Referring more particularly to FIG. 2A, describing in more
detail the cartridge assembly 104. The hypodermic needle 202
comprises an elongated tube, generally cylindrical terminated at
the rearward end by hub 206. The forward end of the needle has a
pointed shape 208, shown in more detail in enlarged FIG. 2B. The
needle 202 is maintained along a longitudinal axis X with holder
210. Needle 202 is shown housed inside cartridge 212, containing a
liquid medicament. However as stated previously needle 202 need not
be inside cartridge 212 but can be arranged to be outside the
medicament cartridge. The forward end of cartridge 212 is
terminated by seal 214 to keep the liquid medicament from leaking,
shown in more detail on FIG. 2B. The pointed end 208 of needle 202
is oriented toward seal 214. Therefore, initially the needle 202 is
disposed between plunger 204 and seal 214. The plunger is shown in
this figure as a one piece material, however it is understood that
the plunger can be made of a plurality of pieces with various
ductile constants such as a harder piece and a softer piece of
rubber.
[0050] Seal 214 is made of a flexible material, such as but not
limited to, rubber. It is known that polymers behave in a ductile
manner when strained at low speed and behave in a brittle manner
when strained at high speed.
[0051] In order to substantially reduce or eliminate coring, the
needle 202 is arranged to penetrate in a "gentle" manner into the
rubber seal 214 by reducing the thrust of the needle. Cartridge 104
has a friction region 215 for slowing the motion of plunger 204
thus reducing the rate of acceleration of needle 202 when
perforating seal 214. The acceleration rate is reduced so that the
speed of the needle is less than 680 inches/s when the needle
pierces the seal. The reduction in acceleration rate is intended
specifically to reduce the speed to a level at which coring will
not occur. Preferably, the speed at which the seal is pierced is
also greater than 150 inches/s so that the injection operation is
not delayed more than what is desirable. The friction region in
this embodiment is a narrowed diameter portion or localized
narrowed diameter portion 222 in the wall 224 of cartridge 212. The
narrowed diameter portion 222 also referred to as speed bump is
arranged between seal 214 and plunger 204. The narrowed diameter
portion 222 is arranged and configured to reduce acceleration of
plunger 204, thus reducing the speed at which the needle 202 would
otherwise travel when the needle tip 208 travels through seal 214.
The narrowed diameter portion 222 is created on the wall of the
cartridge 212 with a pressure forming method, for example with a
clamshell die. The die or a rolling process can be used to imprint
a selected shape to the stainless wall of cartridge 212. For
example cylindrical rounded narrowed diameter portion around the
cylindrical wall of the cartridge can be imprinted.
[0052] The localized narrowed diameter portion 222 in the wall 224
of cartridge 212 acts as a "speed bump" by slowing down the motion
of plunger 204. Indeed, the narrowed diameter portion 222 increases
the normal force between the plunger periphery and the wall 224 of
cartridge 212, thus creating a frictional force counter to the
plunger's movement. The narrowed diameter portion 222 increases the
diametrical interference thereby increasing the friction and
retarding plunger 204 movement. This slowed movement causes the
needle 202 to strain the seal 214 in a more ductile mode, thus
leading to a substantial reduction in coring.
[0053] The speed bump is arranged to be only effective along a
partial length of the cartridge 212. This allows the plunger to
receive the full spring force at the beginning of operation helping
to overcome static friction between the plunger 204 and the
cartridge 212. The speed bump then takes effect immediately prior
to the front end of the needle contacts the seal 214. After the
needle tip 208 completes its penetration of the seal 214, the speed
bump disengages making the full spring force available to ensure
completeness of the injection process.
[0054] The plunger 204 meets increased resistance when the plunger
204 reaches the narrowed diameter portion 222. Plunger 204 has a
plurality of ribs 230 as shown in FIG. 2C. Each time a rib 230 of
the plunger 204 encounters an edge of narrowed diameter portion 222
the friction force is increased thus leading to a net decrease in
injection acceleration rate.
[0055] In another embodiment, illustrated in FIG. 3A, the friction
region 300 comprises a corrugated configuration comprising a
plurality of projections 302, shown enlarged in FIG. 3B, in order
to multiply the interference with the plunger 304.
[0056] It is to be understood however, that friction region 300 can
be any structure of the cartridge that slows plunger 304. While in
the embodiments shown it is the wall of the cartridge itself that
performs this function, it should be appreciated that the cartridge
may employ a separate structure inserted therein. The plunger 304
meets increased resistance when the plunger's leading rib crosses
the friction region leading edge. The rippled shape of friction
region 300 illustrated in FIG. 3 exchanges some of the
aforementioned diameter decrease in the previous embodiment in
exchange for a multitude of leading edges.
[0057] To demonstrate the effectiveness of the present invention in
substantially reducing formation of cores, a series of tests are
implemented and data is acquired.
[0058] FIG. 4 shows the force-distance data profile of a standard
cartridge-plunger. The curve 400 exhibits a high static friction
spike 402 followed by a constant kinetic friction stage 404.
Numerous tests are run to collect statistical data. The mean
kinetic friction from the statistical data is determined to be 0.54
lb. The nearly vertical spike 406 at the terminus represents
bottoming of the plunger against the seal.
[0059] FIG. 5 shows the force-distance data profile of a cartridge
having corrugated portion and a plunger, as illustrated in FIG. 3.
The portion of travel in which the ripples are in effect is clearly
visible on curve 500. The "spikiness" of data at the friction phase
502 is caused by the individual matings and separations of the
individual ripples with plunger ribs. Similarly statistical data is
acquired to allow calculation of the mean kinetic friction during
the speed bump phase. The mean kinetic friction is determined to be
1.47 lb. The mean kinetic friction of the post speed bump phase,
shown on FIG. 5 as phase 504, is 0.52 lb.
[0060] FIG. 6 shows the force-distance data profile 600 of a smooth
speed bump and a plunger having three ribs, as illustrated in FIG.
2. The three large consecutive spikes 602 are caused by the three
ribs of the plunger entering the speed bump. The smaller spikes 604
occur as the plunger's ribs exit the speed bump. Similarly
statistical data is acquired to allow calculation of the mean
kinetic friction during the speed bump phase. The mean kinetic
friction during the speed bump phase is determined to be 1.71 lb.
The mean kinetic friction of the post-speed bump phase, shown on
FIG. 6 as phase 606, is similar to the data described
previously.
[0061] Data is also acquired to demonstrate that the introduction
of the speed bump reduces coring. FIG. 7 shows the coring frequency
versus the inside diameter of the cartridge at the speed bump. The
highest point on the curve corresponds to the inside diameter
0.298'' of the cartridge without a speed bump. At this size
(without a speed bump) approximately 70% of units tested produced
cores. The lowest point on the curve corresponds to the smooth
(without ridges) speed bump in its intended diameter of 0.278''.
Statistical data showed a population of less than 1% revealed
coring.
[0062] In the case of a cartridge with a speed bump, a softer
spring for pushing the plunger, may be used if desired to allow a
smoother transition from the diameter of cartridge without the bump
to the diameter of the cartridge at the bump.
[0063] In addition to coring frequency, the diameter of the
particles generated by coring are also measured and reported in
FIG. 8. As seen in FIG. 8, the dimension of the core (particle)
decreases when the inside diameter of the cartridge at the speed
bump decreases. Therefore, the speed bump has also an advantage in
decreasing the size of the coring particles.
[0064] These tests are carried out for a straight tip needle such
as shown in FIG. 9 (which is a simplified view of the needle of
FIG. 3A). Needle tip 900 has generally a point 902 and a heel 904.
As can be seen in the following embodiments the needle tip can have
a curved shape instead of a straight shape as in FIG. 9.
[0065] FIG. 10 shows a longitudinal sectional view of the automatic
injector with hypodermic needle according to another embodiment of
the present invention. The hypodermic needle 1000 is shown having a
curved tip 1002. As mentioned previously, and now illustrated in
FIG. 11A, the curved leading edge 1002 of needle 1000 having a
C-tip configuration pushes the material of the seal 1004 far enough
away from the heel 1100 to prevent intimate contact. The curved
arrow 1102 indicates the direction of flow of seal material
relative to the movement of the needle 1000. The arrow indicates in
particular that the seal material flows around the curved tip 1002.
In other words, the curved tip 1002 acts as a shield for the
orifice or lumen 1104 of needle 1000, by blocking the seal material
1004 from penetrating through the orifice 1104. The extent to which
the needle tip is curved over the orifice influences seal coring
frequency.
[0066] FIG. 11B shows an enlargement frontal view of the pointed
tip 1110 of the needle. The curved forward tip 1114 is shown
completely shielding lumen 1112 thus protecting lumen 1112 of being
in direct contact with the seal material as previously discussed.
In other words, the bent tip 1114 shields the entire cross-section
of the longitudinal passage in the needle.
[0067] FIG. 12 shows the interaction of seal material 1200 with
needle 1202 having a regular wall thickness, preferably between
0.0055 inch and 0.0065 inch. FIG. 13 show the interaction of seal
material 1300 with needle 1302 having a thicker wall (heavy wall)
preferably between 0.0083 inch and 0.0090 inch. In particular, FIG.
13 illustrates that in the case of needle with heavy wall thickness
1302, the heel 1304 is further away from the seal material 1300,
thus further reducing coring potential compared to needle with
regular wall thickness 1202. Testing shows that in the eventuality
cores are produced, cores are generally smaller when using
heavy-wall needles versus regular wall needles of similar
geometry.
[0068] FIG. 14 shows the geometry of the C-tip needle 1400 with
manufacturing limits for the hard C-tip geometry. The needle
comprises a hollow rigid tubing 1401 having a cylindrical wall
defining a longitudinal passage. The cylindrical wall includes
first and second opposing wall portions. First wall portion is
illustrated in this figure by longitudinal cross-section 1404 and
second wall portion is illustrated in this figure by longitudinal
cross-section 1406. The first wall portion 1404 has a forward tip
portion 1408 terminating in a forward end tip 1410. The second wall
portion 1406 terminating at a position 1412 rearwardly spaced from
the end tip 1408. The forward tip portion 1408 is bent at angle
1414. Angle 1414 is defined as the angle between tangent 1416 to
curvature of the outer surface at the end tip 1410 and the
longitudinal axis 1418 of needle 1400. In one embodiment, the
forward end tip 1410 terminates in a region defined by an imaginary
forward extrapolation of the thickness of second wall 1406 defined
by limits 1422 and 1424 which are intended to insure that the end
tip 1410 is always deflected far enough to always shield the lumen
or opening 1420, but not deflected so far to hinder the penetration
or withdrawal of the needle (this applies equally to the embodiment
of FIG. 17). Other C-tip geometry is the soft C-tip needle where
the tip is deflected such that it is aligned with the cannula
centerline or longitudinal axis 1418. The soft C-tip geometry does
not reduce coring as well as the hard C-tip geometry of needle 1400
of the present invention.
[0069] The hard C-tip needle is manufactured according to the
following process: Two-meter length of tubes are bundled and are
cut to the cannula blank length. The ends of the tubes are
de-burred and the tubes cleaned. The tubes are then automatically
fed and automatically taped onto 18 inch grinding fixtures. The
tubes on the grinding fixtures are placed on a grinding machine
where a primary grind facet is applied. The tubes are then inclined
and rotated to grind a second facet and inclined and rotated again
to grind a third facet. The second and third facets are preferably
symmetrical to one another. The cannula needle tip are rolled over
to produce the curved hard "C" tip. The cannula are de-burred again
and an anti-coring micro-blast is applied to the heel. The
micro-blast may alternately be applied before bending. The cannula
are electro or chemically polished then cleaned, dried, passivated
and inspected before packaging. The cannula are packaged with the
points/tips oriented in the same direction and wrapped in
non-shedding paper to be placed in a polyethylene bag and into a
foam line carton for distribution.
[0070] All hypodermic needles have primary and secondary facets.
The secondary facets are called lancets. FIG. 15 shows a sectional
longitudinal view of a C-tip needle 1500. Lancets 1502 are shown in
relation to the primary bevel 1504. A sectional transversal cut 16
of the tip 1508 is shown in FIG. 16 with a front ground where the
tip 1508 is ground from the inside as shown on transversal cut
1600. FIG. 17 shows a sectional longitudinal view of a C-tip needle
1700. Lancets 1702 are shown in relation to the primary bevel 1704.
A sectional transversal cut 18 of the tip 1708 is shown in FIG. 18
with a back ground where the tip 1708 is ground from the outside as
shown on transversal cut 1800. Back-ground lancets bring advantages
to a C-tip needle. An advantage is that the angled lancets may
serve to further direct seal material away from the lumen. Another
advantage is that the effectively narrower thus sharper leading
edge may cut through clothing and skin or tissue more easily. The
use of heavy-wall cannulas provides more wall thickness allowing a
better optimization of the geometry of the back-ground lancets.
[0071] FIG. 19 shows the consecutive transversal cross sectional
views of the needle tip 1900 in a case of a Hard-C tip needle with
a back ground geometry. In one embodiment, the length of the needle
is 1.343'', the inside diameter 1906 is between 0.0138 inch and
0.0154 inch and the outside diameter 1908 is between 0.0280 and
0.0285. The tip 1900 is shown with consecutive transversal cross
sectional views AA, BB, CC, DD, EE, FF, GG, MM displayed in FIGS.
19A, 19B, 19C, 19D, 19E, 19F, 19G and 19M. FIG. 19A shows the
transversal cut AA having the shape of a disc corresponding to the
tube/cylindrical form of the needle. Further along approaching the
tip of the needle, FIG. 19D shows the cross-section DD with the
back grinds 1910 at an angle of 120.degree. in relation to the base
line 1912. Other embodiments with a back grind with an angle of
130.degree. are also within the scope of the present invention.
[0072] FIG. 20 shows the consecutive transversal cross sectional
views of the needle tip 2000 in a case of a Hard-C tip needle with
a front ground geometry. In one embodiment, the length of the
needle is 1.343'', the inside diameter 2002 is between 0.0155 inch
and 0.0170 inch and the outside diameter 2004 is between 0.0280 and
0.0285. The tip 2000 is shown with consecutive transversal cross
sectional views AA, BB, CC, DD, EE, FF, MM displayed in FIGS. 20A,
20B, 20C, 20D, 20E, 20F, 20M. FIG. 20A shows the transversal cut AA
having the shape of a disc corresponding to the tube/cylindrical
form of the needle, notice the cylindrical wall of the needle is
thinner than in the previous embodiment. Further along approaching
the tip of the needle, FIG. 20D shows cross-section DD with the
front grinds 2010 at an angle of between about 25.degree. and
35.degree. and preferably 30.degree. in relation to the base line
2015.
[0073] Tests show that the hard C-tip needle configuration can
substantially eliminate coring when used in conjunction with softer
springs that allow the tip of the needle to "flow" more easily
inside the seal material. Combination of geometry elements for the
C-tip such as back-ground geometry and hard C-tip configuration in
conjunction with the use of softer springs, having a K spring
constant between 1.5 lb/in and 6.5 lb/in, more preferably between 3
lb/in and 5 lb/in, provides enhanced performance of the needle in
reducing coring.
[0074] FIG. 21 shows a longitudinal sectional view of the needle
tip 2100 coated with a conformal coating 2200 (shown in FIG. 22). A
conformal coating is coating that conforms to the shape of the
substrate while allowing blunting of sharp edges. In one
embodiment, conformal coating 2200 consists of a Parylene coating
(shown in FIG. 22). Parylene is a registered trademark of
polyparaxylylene coating, manufactured by Specialty Coating
Systems, Inc. of Indianapolis, Ind. The application of Parylene in
coating an injection device and needle is described in U.S. Pat.
No. 5,354,286 which is incorporated herein by reference. FIG. 22
shows a close up view of needle heel 2102. Membrane coring occurs
when the needle heel 2102 cuts the outer surface of the seal. A
rounded, or blunted, edge on the heel alleviates coring. Standard
needles receive an abrasive blast during manufacturing however this
blast is not sufficient since standard needles still create cores.
Tests show that Parylene coating 2200 conforms well to the
substrate geometry, including edges, for example edge 2202, as
shown in FIG. 22.
[0075] Parylene coating is applied at various thicknesses ranging
from 0.0001 to 0.001 inch. Data collected in the study of effect of
Parylene coating thickness on coring is summarized in graph shown
in FIG. 23. The graph particularly shows that Parylene coating
overall decreases the likelihood of coring as well as decreases the
size of the core. However, as seen on the graph, increasing the
coating thickness beyond around 0.0005'' does not help in
decreasing coring but acts in the opposite manner by increasing
coring. Indeed, the graph in FIG. 23 clearly shows a curve minimum
indicating that the optimum thickness of the coat accomplishing the
desired results is a Parylene coating thickness around 0.0005''. In
addition, tests have shown that the use of a spring having a spring
constant between 1.5 lb/inch and 6.5 lb/inch in conjunction with
the use of a needle coated with Parylene is particularly beneficial
in reducing coring.
[0076] FIG. 24 shows a longitudinal sectional view of a cartridge
assembly 2400 used in an automatic injector according to another
embodiment of the present invention. Automatic injector uses an
alternative mechanism for reducing the rate of acceleration of the
needle thus slowing down the speed of the needle in comparison with
prior art devices. The acceleration rate is reduced so that the
speed of the needle is less than 680 inches/s when the needle
pierces the seal. The reduction in acceleration rate is intended
specifically to reduce the speed to a level at which coring will
not occur. Preferably, the speed at which the seal is pierced is
also greater than 150 inches/s so that the injection operation is
not delayed more than what is desirable. Indeed, damping disk 2402
attached to needle 2404 is used to reduce the rate of acceleration
of needle 2404 by the friction generated when disk 2402 flows
inside liquid medicament 2406. In other words, the flow resistance
generated by the viscosity of the fluid liquid medicament against
the movement of damping disk 2402 acts to reduce the rate of
acceleration of needle 2404. Therefore, similarly to the previous
embodiments, the damping disk plays the role of friction for
slowing the tip of the needle, hence ultimately to substantially
eliminating coring.
[0077] The Table below shows examples of geometries for various
embodiments of the tip of the needle. The primary angle is selected
between 13 to 18 degrees. The bend angle, that is the angle between
a tangent to a curvature of the outer surface of the end tip of the
needle and a longitudinal axis of the needle, is selected to be
between 51.degree. and 100.degree., preferably between 85.degree.
and 95.degree., most preferably 90.degree. (FIG. 14 shows a bend
angle of approximately 63.degree. and FIG. 17 shows a bend angle of
approximately 90.degree.). The tip offset in relation to the wall
of the needle is between 0.024 and 0.026 inches. The opening length
is selected between 0.033 and 0.055 inches. The inside diameter is
selected between 0.011 and 0.016 inches. The ratio length of
opening to outside diameter of passage is between 1.7 to 2.2.
TABLE-US-00001 Primary Bend Angle Opening Inside Angle (tangent @
tip) Length Diameter Ratio, Tip Offset (deg) (deg) (in) (in) L/OD
(in) 10010 (Hard-C) 14 63, 81 .061 .016 2.2 .026 10014 (HC, Heavy
Wall) 13 51, 81 .049 .015 1.7 .024 10017 (HC, HW, Back Ground) 16.5
90, 90 .063 .015 1.9 .024 10018 (HC, HW, BG, B-tip) 13 90 .053 .011
1.9 .024
[0078] While the invention has been described in connection with
particular embodiments, it is to be understood that the invention
is not limited to the disclosed embodiments, but on the contrary it
is intended to cover various modifications and equivalent
arrangements included within the spirit and scope of the invention
as defined by the claims, which follow.
* * * * *