Reloadable Automatic or Manual Emergency Injection System

This invention relates to automatic injection apparatuses for injecting liquid medications into bodily tissue.

An automatic injection apparatus is a device which enables an individual to self-administer fluid medication by simply triggering the apparatus. The apparatus contains a measured dose of medication in a sealed sterile condition and is capable of storing the medication for an extensive period of non-use. The apparatus administers the self-contained dose automatically, so that the user does not need to visually insert the needle into his/her own tissue or depress a plunger, such as in a common syringe.

Automatic injectors are particularly advantageous in emergency conditions. Such injectors can carry: antidotes for nerve gas for use during emergency chemical warfare conditions; insulin for diabetes; epinephrine for allergic reactions; or analgesics.

An automatic injector apparatus commonly includes an elongated tubular casing and a medicine "container". The medicine container contains a dose of fluid medication. Also included is a needle for injecting the medication into the user. The injector further has a trigger mechanism which causes the needle to penetrate the user's tissue and inject the medication from the container.

Typical automatic injection apparatuses have a drawback in that they administer a single, one-time dose of medication and are not reusable. After this single use, the entire apparatus is discarded. This results in high cost and waste.

Another drawback is the relatively short storage life of some of medications. The storage life of a medication is generally less than the useful life of the automatic injection apparatus. Automatic injectors are expected to be stored for long periods of time, often 1-2 years or more. Unfortunately, many medications do not have a comparable storage life. For example, some medications have storage lives of only approximately six months or less. The medicine could thus become ineffective before the injector is used, resulting in the wasteful disposal of unused injection apparatuses. This also contributes to high costs.

The inability of automatic injection apparatus to be reloaded causes substantial addition costs in other ways. Storage of integrated one use automatic injections is made more complicated and stock must be carefully inventoried and tracked for dates of use. Medicines needing or best stored under particular conditions (refrigeration) are typically unavailable due to the bulk of the injection apparatus. Medicines used in automatic emergency injectors are also inventoried in addition to inventories of medications used in hospitals. These factors become particularly troublesome and costly for the military because of the logistical problems, storage considerations, and tremendous quantities involved.

Another very serious limitation is that prior automatic injectors are not capable of manual injection in instances where they fail. Prior injectors are manufactured as a single, integrated system that provides one application of medicine, and is then discarded. However, if the trigger, firing or other mechanism fails and the injection is not administered, the user cannot get to the medication contained within the sealed unitary casing. The internal components are also not capable of being used manually. Thus the injectors pose a risk that due to mechanical failure medication will not be capable of administration.

This invention provides an automatic injection apparatus in which the injection apparatus can be loaded just prior to use. The injection apparatus can be loaded with a variety of medications as needed for the particular situation, and can later be reloaded to refreshen the medication or change medications. The apparatus can be reloaded numerous times with cartridges commonly used in hospital inventories so that duplicate inventories are not required and better storage conditions are possible. As individual cartridges are used or the medicine contained therein becomes ineffective, the user simply replaces the cartridge with a new one without disposing of the injector. In this manner, only the inexpensive cartridges are replaced, and not the entire apparatus. This reduces the costs significantly. Furthermore, the injector allows access and removal of a syringe subassembly by the user. The syringe subassembly can be used to provide a manual injection in the event that the injector or cartridge fails, or in the event that the user simply desires to apply the injection manually. The described system also includes embodiments which have dual dose capability for second dose administration either automatically injected or manually injected.

One or more preferred forms of the invention are described herein with reference to the accompanying drawings. The drawings are briefly described below.

FIG. 1 is a side view of a reloadable, automatic injection apparatus according to this invention.

FIG. 2 is a longitudinal sectional view of the FIG. 1 apparatus and shows a syringe subassembly loaded in a barrel of the apparatus. FIG. 2 illustrates the apparatus in a cocked position with the syringe subassembly completely within the barrel.

FIG. 3 is a sectional view of the apparatus similar to that of FIG. 2 and illustrates the apparatus in an extended position with the syringe subassembly partially protruding from the barrel.

FIG. 4 is an enlarged partial sectional view of an end of the FIG. 2 apparatus and illustrates a safety mechanism of this invention.

FIG. 5 is an enlarged partial sectional view similar to FIG. 4 with a safety piece removed and the trigger mechanism depressed.

FIG. 6 is a longitudinal sectional view of an apparatus according to another preferred embodiment of this invention. FIG. 6 illustrates the apparatus in a cocked position with the syringe subassembly completely within the barrel.

FIG. 7 is a longitudinal sectional view of the apparatus similar to that of FIG. 6 and illustrates the apparatus in an extended position with the syringe subassembly partially protruding from the barrel.

FIG. 8 is a cross-sectional view of a stop collar employed in the FIG. 6 apparatus.

FIG. 9 is a longitudinal sectional view of a carrying case for storing and carrying a reloadable inject/on apparatus according to this invention.

This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws "to promote the progress of science and useful arts" (Article 1, Section 8).

FIG. 1 shows a reloadable, automatic injection apparatus 10 according to this invention. The injection apparatus or "injector" has an elongated body or barrel 12 which extends between a first, distal or end cap 14 and a second, proximate or trigger end cap 16. Barrel 12 is a substantially cylindrical, hollow tube and is preferably formed of a hard, durable material, such as metal or plastic. End caps 14 and 16 are likewise formed of a hard, durable material. Barrel 12 has an elongated, longitudinally aligned window 18 formed therein to permit visible access to the interior of the tube. Window 18 may be open, with no material, or preferably consists of a clear material, such as transparent plastic.

FIGS. 2 and 3 show apparatus 10 in more detail. Apparatus 10 is designed to house a replaceable, disposable syringe subassembly 20. A principal component of subassembly 20 is a medicament cartridge 21. Cartridge 21 includes an ampule or medicament container 22 for housing and containing a fluid medication 24. Ampule 22 is preferably a small glass or plastic vial that contains a measured amount of medication. The amount of medication (such as antidotal medicant, antibiotics, epinephrine, insulin, etc.), varies depending upon the medication and anticipated usage conditions. Cartridge 21 also has a hypodermic needle 26 mounted to the distal end of ampule 22 using a needle mounting cap 27. Cartridge 21 further has a fluid tight plunger which includes a stopper 28 which fittingly engages and slides within ampule 22. Stopper 28 is preferably formed of a rubber or elastomer material and has a plunger connector in the form of a mounted peg or threaded extension 29. The plunger connector faces outwardly and as shown extends outwardly from stopper 28. The structure of cartridge 21 is well-known and commercially available. Examples of preferred cartridges of this construction are manufactured under the trademark TUBEX by Wyeth Laboratories, Inc. and under the trademark DOSETTE by Elkins-Sinn.

The plunger of the syringe subassembly also includes a detachable plunger shaft 30. Plunger shaft 30 is detachably connected to stopper 28 using a suitable plunger shaft detachable coupling. While a threaded coupling is preferred, other common techniques for providing a detachable connection between plunger 30 and stopper 28 can be employed. As shown, the coupling includes a threaded extension 29 received within a threaded receptacle formed in the inner end of the plunger shaft. Plunger shaft 30 includes a stem 32 and a shaft head formed as a shoulder or flange 34. Plunger shaft 30 is preferably formed of a rigid material, such as plastic or metal.

Syringe subassembly 20 also preferably includes a protective sheath 76 disposed within barrel 12 around needle 26 of cartridge 21. The tip of needle 26 is slightly embedded in the head of the sheath to protect the sharp point and to seal the needle opening from contaminants. The head of the sheath has a flange 78 received in a receptacle 79 of cap 14. The sheath has a tubular portion which extends from the head and is received upon a needle sleeve portion 130 of the needle cap 27. Sheath 76 thereby provides a protective isolating cap that maintains the sterility of the needle until use occurs. Syringe subassembly 20 is inexpensive to manufacture and is designed to be disposed of once the medication 24 has been injected into the 20 user.

According to this invention, reloadable injection apparatus 10 is designed to automatically deploy and discharge cartridge 21. However, in the event that the apparatus fails, the user can still administer the injection manually using the demountable syringe subassembly 20. Syringe subassembly 20 can be easily unloaded from injection apparatus 10 and can operate as a self-contained manually operated syringe in the event that the injector is damaged and will not fire. This aspect of the invention is advantageous over prior art injectors which are completely encased and do not permit access to or removal of the inner medicant capsule.

Barrel 12 of reloadable injection apparatus 10 is tubular and defines an internal cavity 36 with a first or cartridge chamber 37, sized to receive syringe subassembly 20, and an adjacent second or driver chamber 39. In the preferred form, chamber 37 has a circular cross-section with a diameter that is slightly larger than the diameter of ampule 22 so that the syringe subassembly can easily slide within cavity 36 from a first or storage position shown in FIG. 2 into a second or deployed position shown in FIG. 3. Cartridge chamber 37 is slightly larger in cross-section than second chamber 39. Preferably, chamber 37 tapers into chamber 39, thereby defining a tapered shoulder 41.

Automatic injection apparatus 10 also includes a driver 40 for injecting the needle 26 and discharging :medication from the cartridge. Driver 40 is constrained in a cocked position and controllably released by a driver release mechanism 50. Apparatus 10 also includes a secondary or biasing spring 38 which biases the syringe subassembly 20 away from the muzzle end. The syringe subassembly is preferably biased against shoulder 41 so that needle 26 is better protected against inadvertent deployment. Shoulder 41 also prevents the subassembly from shifting toward the driver, relative to the plunger, and causing premature discharge of the fluid within the barrel during a situation, for example, when the apparatus is accidently dropped. Biasing spring 38 also acts as a suspension and shock absorber with sheath 76 for safely maintaining the subassembly within the tubular casing during transportation and conditions which may cause the subassembly to move or bounce.

Driver 40 includes a longitudinal bar 42 that is slidable within cavity 36 of barrel 12 between a cocked position (FIG. 2) and one or more extended positions (FIG. 3). Driver 40 also has a primary or drive spring 44 for biasing and forcing bar 42 toward an extended position. Driver bar 42 is preferably a rigid piece made of plastic or metal that extends axially within barrel 12. Bar 42 has a ramming or contact head 46 that abuts against plunger shoulder 34 in the cocked position and a tail portion 48. Head 46 also forms a drive spring engagement shoulder against which the drive spring bears. Drive spring 44 is axially aligned with the syringe subassembly and is coiled about bar 42. Driver 40 is positioned within driver chamber 39 of barrel cavity 38 when the driver is in a cocked position.

Driver release 50 holds driver 40 in the cocked position until the user is ready to administer the injection. Driver release 50 includes a catch 52, a trigger 54 for releasing the catch when the trigger is activated or depressed. The driver release also includes a safety 56 for preventing activation of the trigger and release of the catch. Trigger 54 is embodied as end cap 16 and is displaceable relative to barrel 12 from a rest or extended position into a depressed position where it abuts an annular flange 55 on the exterior of barrel 12. Trigger 54 fires the apparatus during its travel between the rest and depressed positions.

FIGS. 4 and 5 illustrate the driver release 50 in more detail. Catch 52 consists of a detent mechanism for releasibly coupling the driver to the driver release. The detent mechanism of catch 52 consists arrow-shaped or barbed tips 62 on multiple prongs 64 (provided on the tail portion 48 of bar 42). The prongs extend through a catch aperture 58 and latch to an end wall 60 of barrel 12. End wall 60 is preferably a metal annular disk molded into the plastic barrel 12, but can be a plastic end piece integrally molded with barrel 12. Prongs 64 are constructed to deflect from a normal, radially expanded position shown in FIG. 4 to a radially constricted position shown in FIG. 5 to enable the tips 62 to pass through aperture 58. The prongs are controllably deflected into the constricted position by the trigger piece 54 as explained below.

A safety pin 56 is inserted centrally of the multiple prongs 64 and through aperture 58 to retain the prongs in the expanded position so that the tips remain caught behind end wall 60. Safety pin 56 is removable from the apparatus 10 in the direction illustrated by arrow 66 (FIG. 4). Safety pin 56 is connected to trigger 54 using a suitable connection to prevent the safety from prematurely popping off the end but allowing manual detachment.

Trigger 54 is depressed or activated by an external force (such as depression by the user's thumb) in the direction illustrated by arrows 68 in FIG. 5. Trigger 54 has pushing member 70 which moves toward and engages external sloped surfaces on tips 62 as the trigger is depressed. The pushing member preferably has a beveled internal surface which is complementary to the sloped surfaces of tips 62. The pushing members 70 force the tips together until they clear end wall 60 and escape through aperture 58. At this point, driver 40 is released and drive spring 44 powers the driver through barrel 12 to sequentially deploy and inject the needle and then discharge the medication through the injected needle.

Returning to FIGS. 2 and 3, left end cap 14 is detachably connected to barrel 12 to permit loading and unloading of syringe subassembly 20. In the preferred form, removable cap 14 and muzzle end 72 of barrel 12 are provided with complementary threads so that removable cap 14 can be screwed onto barrel 12, although other coupling arrangements can be employed. Cap 14 can be twisted onto barrel 12 until it reaches annular flange 73 formed on the exterior of barrel 12. Cap 14 substantially closes cavity 36 when connected to barrel 12 and alternately, opens the cavity when detached from the barrel to allow removal of the syringe subassembly. Removable cap 14 has an aperture or needle passageway 74 formed therein through which needle 26 of cartridge 21 can extend when the user operates the injection apparatus 10 and the syringe subassembly is deployed (FIG. 3).

Sheath 76 covers aperture 74 to prevent contamination of the needle 26. Sheath 76 is preferably formed of a deformable material, such as rubber, which can buckle under the force of drive spring 44 of driver 40 as illustrated in FIG. 3. A flange portion of sheath 76 abuts the inner surface of cap 14 and the head of the sheath is pierced by needle 26 when the syringe subassembly is moved through the barrel by the driver. Cap 14 has a stepped interior surface for accommodating the biasing spring 38 and the flange portion of sheath 76.

The general operation of this invention will now be described with reference to FIGS. 2 and 3. After construction, an empty injection apparatus 10 is suitable for storage for an extended length of time. Individual syringe subassemblies containing different types of medication are manufactured and stored separately according to their prescribed shelf lives. If the medication in the syringe subassemblies exceeds the potency expiration date, the individual subassembly can be discarded. One technique for manufacturing the subassemblies is to simply modify existing cartridges, such as TUBEX and DOSETTE cartridges, with a sheath and detachable plunger such as described herein. In this state, a user can manually administer an injection using the subassembly. This is done by removing the sheath, injecting the needle, and manually depressing the plunger in the typical fashion.

For automatic injection, a desired subassembly of a selected medicine is loaded into the automatic injection apparatus before the time of foreseeable potential use. Cap 14 is first removed from muzzle end 72 of barrel 12. If not already cocked, then a suitable rod can be extended up the cavity to force the driver into the cocked position of FIG. 2. The safety 56 can then be inserted. Then the syringe subassembly 20 is loaded into barrel 12 through the muzzle end and oriented therein so that the sheathed needle points outward toward the muzzle end. Biasing spring 38 is slid over sheath 76 and the cap 14 is screwed back onto the barrel. In this condition, apparatus 10 is in its cocked state with the subassembly safely retracted within the barrel casing as illustrated in FIG. 2. Apparatus 10 is now loaded and ready for use.

Window 18 in barrel 12 enables the user to view the cartridge and medication. From this visual inspection, a user can quickly determine the relative positioning of the plunger, the dosage level, and whether the medicine has become defective (for example, as ascertainable by clouding or a color change).

To fire apparatus 10, safety 56 is removed and trigger 54 is depressed to release catch 52. The energy stored in drive spring 44 of driver 40 is released, forcing subassembly 20 through barrel 12. Needle 26 pierces the head of sheath 76 and is driven out through passageway 74 in cap 14. Simultaneously, the tubular portion of sheath 76 buckles and secondary spring 38 contracts under the force of drive spring 44. Syringe subassembly 20 halts when it reaches the end of the barrel after it has traveled an effective distance to properly insert the exposed needle into the tissue of the user. The fully contracted secondary spring 38 acts as a stop deployment against the ampule 22 or needle cap 27.

After the syringe assembly is deployed into an injection position, the thrusting force of driver 40 continues and depresses plunger 30. This causes cartridge plunger 28 to move and displace fluid medication out through hypodermic needle 26. The plunger depresses until shoulder 34 abuts an end of ampule 22 or is otherwise stopped. The apparatus and cartridges are designed such that the distance of plunger travel is precise for an injection of a prescribed dosage of medication.

After the injection is complete, the user can withdraw the apparatus and needle. The fired apparatus can then be reloaded. To accomplish this, cap 14 is simply detached and the exhausted syringe subassembly is removed and discarded. Driver 40 is recocked by inserting a thin instrument (such as a screw driver, pen, or pencil) down the barrel and pushing bar 42 against the force of spring 44 until the barbed tips constrict and pass through aperture 58 and then spread to lock behind wall 62 (FIG. 4). Safety 56 can be reinserted at this point to prevent undesired firing. A new syringe subassembly containing the same or different medicine can then be inserted into the barrel and the cap reattached.

FIGS. 6-8 show a reloadable injection apparatus 100 according to another preferred embodiment of this invention. Apparatus 100 is designed to administer multiple (typically, two) injections using the same syringe subassembly. Apparatus 100 is very similar to apparatus 10 of FIGS. 2-5, and the same reference numerals are used to identify like components. Only the different features of this apparatus will be described in detail.

Apparatus 100 includes a removable stop 102 for halting movement of driver 40 at an extended position after it has been released. Stop 102 is provided within barrel 12 and positioned at least partially around plunger stem 32 of syringe subassembly 20. Stop 102 is radially sized to abut against the end of ampule 22. Stop 102 has a predetermined length to provide approximately equal dosages for each injection with the same syringe subassembly. In its preferred form, removable stop 102 comprises first and second semi-cylindrical collar portions 104 and 106 positioned around plunger stem 32 (FIG. 8).

In operation, apparatus 100 is loaded with a syringe subassembly and dislodged or fired substantially as described above. In this embodiment, however, stop 102 halts movement of plunger 30 prior to full discharge of the medication from ampule 22 at an intermediate position of the plunger stopper within the ampule. The plunger stopper halts the driver at an intermediate extended position. More particularly, shoulder 34 of plunger 30 is depressed until it engages collar portions 104 and 106. This partial travel of plunger 30 is suitable to inject a first dose of the medication. If the user wishes to administer a second injection with the remaining medication, the user simply removes cap 14, withdraws the syringe subassembly from the barrel. This allows removal of the split collar which easily falls off due to the split design. The injector is then recocked by depressing the driver 40. The partially discharged syringe subassembly is reloaded into the barrel and the end cap 14 reinstalled. With stop 102 removed, apparatus 100 is now essentially identical to apparatus 10 and is ready for its second firing. When driver 50 is actuated, the plunger is forced further into ampule 22 to displace the remaining fluid medication out through needle 26.

Due to the construction of reloadable injector apparatus 100, the user can alternatively administer the second dose manually and without recocking and reloading the apparatus. The user can simply remove the syringe subassembly from the apparatus, take off the stop collars, and manually inject the medication using only the syringe subassembly. This is very useful in dire emergency situations where time is critical and cannot be wasted recocking and reloading the apparatus. In a similar fashion either embodiment 10 or 100 can be opened and the syringe subassembly removed to allow manual injection. This may be needed due to mechanical difficulties or for other reasons.

It should also be appreciated that the novel apparatus according to this invention can be employed to reduce or eliminate the loss of valuable medicines. Such medicines have previously been lost when used in emergency injectors. This occurs because of time deterioration and the fact that the medicine is sealed within the injector. The current invention can be employed in either of two ways to prevent such waste. Firstly, medicines can be installed only when needed and can be taken from regular inventories of the cartridges. Secondly, medicines used in the novel :injectors can be installed and then removed in adequate time to allow the hospital or other medical service to use them in the normal course of providing services, thus preventing waste of the cartridge due to time deterioration. The injector is not lost merely because of medicine aging and can continue to serve standby or be reloaded.

FIG. 9 shows a preferred carrying case 110 which can be used in injector systems according to this invention. Case 110 is sized to house apparatuses 10 or 100. Case 110 has first and second halves 112 and 114 that frictionally mate to form a hollow, tubular enclosure. First half 112 has a foam pad positioned at an end thereof to provide a buffering cushion to help prevent the apparatus from rattling or shifting within the case. A clip 118 that is mounted to the exterior of case 110. Clip 118 is similar to ball point pen clips and likewise, is suited for attaching case 110 to a shirt pocket or the like. Case 110 also includes a pocket area 12() for storing tablets 122, such as oral antihistamines.

The reloadable injection apparatus of this invention is advantageous because it affords maximum flexibility in that manual or automatic injection of a single or multiple dose of medication can be easily and conveniently administered. The invention also improves reliability because, in the event of mechanical failure with the injector, the user can easily access the syringe subassembly and manually inject the medication. These and other advantages and benefits of the invention are described or apparent from the description given herein.

In compliance with the statute, the invention has been described in language necessarily limited in its ability to properly convey the conceptual nature of the invention. Because of this inherent limitation of language, it must be understood that the invention is not necessarily limited to the specific features shown and described, since the means herein disclosed comprise merely preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.