US20220280729A1 - Low deadspace syringe including a pivoting needle guard - Google Patents
Low deadspace syringe including a pivoting needle guard Download PDFInfo
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- US20220280729A1 US20220280729A1 US17/540,805 US202117540805A US2022280729A1 US 20220280729 A1 US20220280729 A1 US 20220280729A1 US 202117540805 A US202117540805 A US 202117540805A US 2022280729 A1 US2022280729 A1 US 2022280729A1
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- Prior art keywords
- guard
- hub
- syringe assembly
- safety
- distal end
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M5/00—Devices for bringing media into the body in a subcutaneous, intra-vascular or intramuscular way; Accessories therefor, e.g. filling or cleaning devices, arm-rests
- A61M5/178—Syringes
- A61M5/31—Details
- A61M5/32—Needles; Details of needles pertaining to their connection with syringe or hub; Accessories for bringing the needle into, or holding the needle on, the body; Devices for protection of needles
- A61M5/3205—Apparatus for removing or disposing of used needles or syringes, e.g. containers; Means for protection against accidental injuries from used needles
- A61M5/321—Means for protection against accidental injuries by used needles
- A61M5/3216—Caps placed transversally onto the needle, e.g. pivotally attached to the needle base
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M5/00—Devices for bringing media into the body in a subcutaneous, intra-vascular or intramuscular way; Accessories therefor, e.g. filling or cleaning devices, arm-rests
- A61M5/178—Syringes
- A61M5/31—Details
- A61M5/3129—Syringe barrels
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M5/00—Devices for bringing media into the body in a subcutaneous, intra-vascular or intramuscular way; Accessories therefor, e.g. filling or cleaning devices, arm-rests
- A61M5/178—Syringes
- A61M5/31—Details
- A61M5/32—Needles; Details of needles pertaining to their connection with syringe or hub; Accessories for bringing the needle into, or holding the needle on, the body; Devices for protection of needles
- A61M5/3293—Needles; Details of needles pertaining to their connection with syringe or hub; Accessories for bringing the needle into, or holding the needle on, the body; Devices for protection of needles characterised by features of the needle hub
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M5/00—Devices for bringing media into the body in a subcutaneous, intra-vascular or intramuscular way; Accessories therefor, e.g. filling or cleaning devices, arm-rests
- A61M5/178—Syringes
- A61M5/31—Details
- A61M5/32—Needles; Details of needles pertaining to their connection with syringe or hub; Accessories for bringing the needle into, or holding the needle on, the body; Devices for protection of needles
- A61M5/34—Constructions for connecting the needle, e.g. to syringe nozzle or needle hub
- A61M5/348—Constructions for connecting the needle, e.g. to syringe nozzle or needle hub snap lock, i.e. upon axial displacement of needle assembly
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M5/00—Devices for bringing media into the body in a subcutaneous, intra-vascular or intramuscular way; Accessories therefor, e.g. filling or cleaning devices, arm-rests
- A61M5/50—Devices for bringing media into the body in a subcutaneous, intra-vascular or intramuscular way; Accessories therefor, e.g. filling or cleaning devices, arm-rests having means for preventing re-use, or for indicating if defective, used, tampered with or unsterile
- A61M5/5066—Means for preventing re-use by disconnection of piston and piston-rod
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M2205/00—General characteristics of the apparatus
- A61M2205/58—Means for facilitating use, e.g. by people with impaired vision
- A61M2205/581—Means for facilitating use, e.g. by people with impaired vision by audible feedback
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M2205/00—General characteristics of the apparatus
- A61M2205/58—Means for facilitating use, e.g. by people with impaired vision
- A61M2205/582—Means for facilitating use, e.g. by people with impaired vision by tactile feedback
Definitions
- This invention relates to a low deadspace syringe having a pivoting protective needle guard on a fixed needle assembly that is permanently attached to the syringe, as shown, for example, in FIG. 1 .
- LDS Low deadspace
- FN uni-body fixed needle
- FIGS. 2 a -2 b Another two-piece version of a low deadspace (LDS) syringe with a fixed needle (FN) has a molded syringe barrel that is permanently fitted with a separately molded hub in manufacturing ( FIGS. 3 a -3 b ).
- a major benefit of these FN syringes is the reduction or near elimination of dead-space which results in medication savings.
- Luer 6% taper detachable types as shown by example in FIG. 4 syringe barrels can come with a locking threaded collar to securely hold needle. Due to industry design requirement specifications for Luer 6% taper medical connectors like these, a wide range of dimensions for both the needle and syringe exist. These design specifications intentionally leave space between the mating male (typically the syringe) and female (typically the needle hub) parts to ensure that they mate properly. Other contributing factors are in plastic manufacturing where molding the female Luer hub requires additional space beyond the Luer sealing surface adding to a larger space.
- Another type of syringe used today includes a needle guard 61 pivotably attached to an annual ring 62 that is press-fit onto the distal end 63 of a unibody type syringe 60 .
- the annular ring 62 may have the needle guard 61 integrally molded thereto with a living hinge 64 as described in U.S. Pat. No. 7,648,480 ( FIG. 6 ) or have provisions 65 for attaching the needle guard 61 as shown in U.S. Pat. No. 7,722,572 ( FIGS. 7-8 ). In all these cases the technology is limited due to the plastic materials used in both the annular ring and mating syringe body.
- plastic materials when two mating parts are force fit together the hoop stresses that are created will cause the material in either or both parts to creep until a point of relaxation. When the plastic relaxes (which may take only hours or a couple of months) the parts no longer will have a desired tight fitment and can easily be moved or rotated relative to one another even inadvertently during activation of the needle guard. Adding more interference by making one of the parts smaller or larger only increases the stresses which can accelerate the relaxation hence reducing the desired fit. Other factors that can come into play with press-fit annular ring technology is heat and radiation, these too will have effects on the interference fit and relaxation between the mating parts allows them to creep and move as the designs allow unrestrained movement in some directions (collapsing or expanding).
- Needle pop-off is another serious safety issue that can be caused by interchangeable needles that have not been properly secured (having a connection force between needle hub and syringe tip greater than the activating force) to the syringe barrel tip. Such needles may be inadvertently dislodged when a user attempts to activate a needle guard since the direction of the force to activate the needle guard is in the same direction for removal of the mounted needle from the syringe tip.
- the current invention is directed to a permanently factory attached hub syringe connection that removes this concern.
- the current invention relates to a low deadspace syringe having a pivoting protective needle guard on a fixed needle assembly that is permanently attached to the syringe.
- a low deadspace syringe assembly comprises a syringe barrel having a chamber for retaining fluid and an open distal end having a coupling extending therefrom that is connected to a distal wall opening in the chamber and a needle assembly having a hub, a cannula and a guard rotatably mounted on the hub to rotate from an open position to a locked safety position, wherein the guard covers the distal end of the cannula when in the locked safety position, and the proximal end of the hub having a cork extending therefrom and into the coupling of the syringe barrel to connect a conduit in the hub to the chamber such that the proximal end of the conduit is substantially flush with the distal wall opening in the chamber.
- distal shall refer to a direction towards a patient
- proximal shall refer to a direction away from a patient
- FIG. 1 is a side elevation view of a low deadspace syringe with a pivoting protective needle guard on a permanently attached fixed needle assembly in accordance with the subject invention
- FIGS. 2 a -2 b are a side elevation and cross-sectional views of an existing insulin syringe with a uni-body fixed needle integrally molded hub;
- FIGS. 3 a -3 b are a side elevation and cross-sectional views of an existing insulin syringe with a fixed needle having a molded syringe barrel that is permanently fitted with a separately molded hub;
- FIG. 4 is a side elevation assembly view of a traditional syringe with a Luer detachable type needle hub assembly
- FIG. 5 is an enlarged cross-sectional view of the distal end of the Luer needle hub assembly attached to the syringe shown in FIG. 4 and showing wasted medication contained in deadspace;
- FIG. 6 is an exploded side view of an existing fixed needle syringe receiving an annular ring having a needle guard attached by a living hinge;
- FIG. 7 is a side view of an annular ring with other provisions for attaching a needle guard
- FIG. 8 is an assembled side view of an existing fixed needle syringe with the annular ring and needle guard shown in FIG. 7 attached thereto;
- FIG. 9 is an enlarged exploded cross-sectional assembly view of the distal end of the low deadspace syringe and the needle assembly shown in FIG. 1 in accordance with the subject invention.
- FIG. 10 is an enlarged cross-sectional view of the needle assembly shown in FIGS. 1 and 9 with the needle guard attached thereto in accordance with the subject invention
- FIG. 11 is a perspective view of a needle guard of the current invention.
- FIG. 12 is an enlarged cross-sectional view of the pivot shaft on the needle guard shown in FIG. 11 ;
- FIG. 13 is a perspective view of an alternative embodiment of a needle guard of the current invention.
- FIG. 14 is an enlarged cross-sectional view of the pivot shaft on the needle guard shown in FIG. 13 ;
- FIG. 15 is a perspective view of the distal end of the low deadspace syringe of the current invention shown in FIG. 1 and its permanently attached fixed needle assembly with the pivoting protective needle guard in an open unlocked position and the needle protection cap removed;
- FIG. 16 is a side elevation view of the distal end of the low deadspace syringe of the current invention shown in FIG. 1 ;
- FIG. 17 is a perspective view of the distal end of the low deadspace syringe of the current invention with the pivoting protective needle guard of its fixed needle assembly in a locked safety position;
- FIG. 18 are side elevation views of low deadspace syringes with pivoting protective needle guards on permanently attached fixed needle assemblies having a normal length syringe barrel and an optimal length syringe barrel in accordance with the subject invention
- FIG. 19 is a perspective view of a Luer taper syringe and another embodiment of a safety needle assembly of the current invention.
- FIG. 20 is a side elevational view of the safety needle assembly shown in FIG. 19 attached to the Luer taper syringe;
- FIG. 21 is a cross-sectional view of assembled safety needle assembly and Luer taper syringe shown in FIG. 20 .
- a low dead-space fixed needle syringe 100 includes a permanently attached, separately molded needle assembly 106 having a hub 102 with an attached pivoting protective needle guard 101 .
- Syringe dead-space is the volume of residual fluid that remains within the syringe assembly after the plunger 104 is fully depressed during a medication injection.
- a low dead-space fixed needle syringe can result in a reduction in wasted medication 30 times that of a traditional detachable Luer taper syringe 400 with a mating Luer taper hub 401 . As shown in FIG.
- needle hub 102 of needle assembly 106 is preferably attached to the syringe barrel 103 of the syringe 100 with a press-fit fluid seal interference fit.
- Hub 102 on needle assembly 106 is preferably made of plastic.
- syringe barrel 103 may be made of glass or plastic and still provide the press-fit fluid seal interference fit.
- needle hub 102 is permanently mounted to the syringe barrel 103 in the manufacturing process.
- needle hub 102 includes a needle cannula 911 extending from its distal end and a needle hub cavity 901 within its proximal end that allows for the barrel nozzle tip 902 to engage and permanently connect with needle hub 102 .
- a sealing cork 903 is included within needle hub cavity 901 and due to sealing cork 903 having an outer diameter larger than the internal orifice 904 of barrel nozzle tip 902 an interference fit creates a fluid seal when sealing cork 903 is mated with internal orifice 904 of barrel nozzle tip 902 .
- sealing cork 903 with barrel nozzle tip 902 is provided by a locking ring 913 surrounding barrel nozzle tip 902 engaging with a locking trough 914 on an interior surface within needle hub cavity 901 and locking ring 913 also thereby maintains sealing cork 903 in sealing engagement with internal orifice 904 .
- Sealing cork 903 when connected to barrel nozzle tip 902 may occupy all or nearly all the area of the internal orifice 904 and may stop at a distal wall opening 916 of the syringe fluid chamber 905 or even minimally enter the syringe fluid chamber 905 area to eliminate any and all dead-space when mating to a syringe barrel 103 .
- the sealing cork 903 may include a conduit 906 allowing bidirectional access between the syringe barrel 103 internal fluid chamber 905 and a needle lumen 907 within and extending through needle cannula 911 .
- the needle hub 102 distal end includes a bulkhead 917 and a cavity 908 for permanently affixing needle cannula 911 typically with an adhesive bonding material 909 .
- a needle protection cap 910 is removably mounted to the distal end of needle hub 102 to protect the sharp bevel point 915 at the distal end of cannula needle 911 .
- the invention further includes a needle guard 101 connected and rotatable to the permanently mounted fixed needle hub 102 preferable by the interference gripping fitted C shape clasp 1001 and a clasp opening 912 , shown in FIG. 9 , that cooperates with a pivot shaft 1002 of needle guard 101 .
- This arrangement permits needle guard 101 easy rotation from an unlocked position, shown in FIGS. 1 and 15 , to a final lock position, shown in FIG. 17 , before disposal or an alternative intermediate desired position during use.
- Needle guard 101 can also be connected to fixed needle hub 102 by other known mechanical hinges or an integrally molded living hinge making needle hub 102 and needle guard 101 one molded part.
- the rotatable fit between needle guard pivot shaft 1002 and C clasp 1001 allows for the user to selectively position the needle guard 101 and maintain an intermediate desired position during a procedure.
- pivot shaft 1002 of the needle guard 102 includes one or more brakes 1101 that exceed the circumference of the pivot shaft 1002 to intentionally cause friction between pivot shaft 1002 and C clasp 1001 .
- brakes 1101 may include a raised area at a concentrated location on pivot shaft 1002 or, as shown in FIG. 13 , run the full length of pivot shaft 1002 or something less than the full length. Needle guard 102 is held in its open position when brakes 1101 are positioned in open section 912 of C clasp 1001 and/or in a relief cutout 1003 of the C clasp bearing contact surface 1004 , shown in FIG. 10 , that the pivot shaft 1002 rides along.
- a preferred embodiment of needle guard 101 includes user controlled manual locks activated soon after an injection and before disposal.
- the user activates the needle guard 101 causing rotation of needle guard 101 over the needle cannula 911 with a force typically by a finger or hard surface.
- the needle guard 101 includes a one-way secured lock.
- needle guard 101 includes two shielding sidewalls 1301 with two locking tabs 1302 , at the end nearest pivot shaft 1002 .
- Each locking tab 1302 extends inward into the needle and hub channel 1303 .
- the locking tabs 1302 deflect outward when meeting the needle hub ramp 1304 hub lock members, shown in FIG. 16 , until they bypass the ramps 1304 and flex back into a position creating a locked unit.
- the hub lock 1400 feature is located on opposite side of needle hub 102 than that of the C clasp 1001 . Locking the needle guard 101 to the needle hub 102 may produce an audible sound and tactile feel.
- the lock is single use.
- Other locking mechanisms that lock needle guard 101 to the needle hub 102 may be used, e.g., one-way barbed pin into a mating hole.
- the preferred embodiment also includes at least one needle hook lock 1501 .
- the needle hook lock 1501 is housed within the needle and hub channel 1303 and may be attached to one side wall 1301 or may extend from a supporting post 1502 mounted on a wall connected to the side walls.
- the needle hook lock 1501 is a narrow deflecting resilient cantilever hook that flexes inward (opposite direction of needle approach) when needle cannula 911 is forced against it allowing the needle cannula 911 to bypass and springs back once needle cannula 911 fully passes by needle hook lock 1501 , trapping needle cannula 911 within needle guard 101 which prevents needle cannula 911 from exiting back out.
- the needle locks may be positioned facing one another along the channel. In other embodiments only one (hub or needle) of the two lock systems are included.
- the needle guard cross member wall 1201 that connects the two side walls 1301 includes a finger guiding slanted/curved surface 1202 at the end opposite pivot shaft 1002 .
- finger guiding slanted/curved surface 1202 allows for user fingertip access between needle guard 101 and syringe barrel 103 to facilitate a one hand activation of needle guard 101 with a substantially horizontal finger stroke.
- Syringes normally come in standard volume capacities of 1, 2, 3, 5 and 10 mL for skin injections. For each size the length of the barrel is optimized based on the volume capacity and graduation of unit markings so that a user can accurately set the plunger to a dosage mark. Vaccine immunization typically requires a fraction of the smallest lml version of syringe.
- the optimal syringe assembly of the current invention shown in FIG. 18 has been shortened to remove the unnecessary portion of the barrel and plunger rod that leads to more cost, manufacturing challenges (see barrel bow in the following section) and environmental waste. The smaller footprint of these shorter syringes will lead to additional cost savings including packaging, shipping and disposal. As shown in FIGS.
- a safety needle assembly 206 can alternatively be connected to a syringe barrel 203 using a Luer taper connection having a Female Luer taper in the cavity 205 of the hub 202 and a Male Luer taper on the barrel tip 204 of the syringe barrel 203 .
- the Luer taper connection also provides a liquid tight seal between the internal hub cavity 205 and the external surface of the barrel tip 204 .
- the invention is suitable to self-contained syringes that do not require flexible packaging and instead use plastic caps to maintain sterility; re-use prevention (RUP) syringes with frangible plunger features that prevent re-use after an injection has been completed (as shown and described in EP0925083B1) and fixed dose auto-disable (AD) syringes with plunger locking element features that prevent re-use during and/or after movement of the plunger in the injection phase (as shown and described in U.S. Pat. No. 9,205,205).
- ROP re-use prevention
- AD fixed dose auto-disable
- the current invention also offers a low deadspace syringe with a protective guard design for either a healthcare provider or patient that can be easily and safety activated without the fear of the guard spinning or popping off during activation of the needle guard is beneficial and has been previously disclosed. Preventing unintended rotational movement of the needle guard during activation will remove the risk of a potential needle stick injury from occurring.
- the mounting of the needle guard to the needle hub adapter without allowing a means for rotation solves this potential issue. Having the needle hub permanently fixed to the barrel and the guard mounted directly to the hub also eliminates the hazard of a needle popping off the syringe distal tip if it had not been securely fastened by the user which can occur with Luer slip detachable type needles and syringes.
- Another benefit of the current invention is the low profile of the needle guard which allows for unobstructed visual viewing of the injection site and needle point position prior to injecting the patient.
- the low profile aids in reducing the likelihood the needle guard will snag onto loose clothing or bedding and get damaged or cause a needlestick injury.
- Another beneficial design feature is the distal end of needle guard (proximal to user before activation) having a slanted inverse ramp or curvature area 1202 , as shown in FIGS. 11 and 13 , which allows for guiding a user to place their fingertip between the underside of needle guard 101 and syringe barrel 103 to easily begin a single handed preferred activation method of the needle guard to the activated position. Low or even no waste-space is achieved and maintained with this design compared to a Luer needle hub and Luer syringe assembly.
- the manufacturability of the current invention two pieces syringe barrel is also an improvement when compared to the one piece uni-body syringe barrel since the metal core-pin that creates the fluid chamber of the molded barrel is held in place by a support pin at the distal end that is much greater in diameter and stiffness within the mold which minimizes core shift (bending), the major contributing factor that causes syringe barrel bow in the molding process which is undesirable.
- “Bow” (banana shape) occurs when the proximal and distal ends of the barrel are out of alignment with the horizontal axis of the barrel cylinder, causing alignment issue in the assembly process.
- reducing the overall length of the barrel will also be beneficial towards molding the optimal straight concentric barrel.
- Orienting needle bevel 915 relative to needle guard 101 is desirable in some injection practices like intradermal injections and this is easily achieved by the current invention during the manufacturing process when mounting the needle 911 in needle hub 102 , thereby eliminating the user needing to rotate the needle guard during use.
- the current invention also allows for color coding needle hub 102 by pigmenting the raw material to quickly and easily identifying the gauge of the needle cannula 911 is most desirable; having needle hub 102 molded separately from syringe barrel 103 as describe in this invention allows this improvement over integrally molded needle hub syringes. Integrally molded hub syringes cannot offer coloring options since the barrel is required to be made of a clear material so that the fluid content can easily be viewed.
- Reading the syringe barrel graduation is also important to the medication preparation of the syringe by a healthcare worker.
- needle guard 101 may be positioned to best view the graduation. Another benefit to having the manufacturer position needle hub 102 and needle guard 101 is to align needle guard 101 with the finger flanges 107 of syringe 103 to minimize syringe packaging.
Abstract
A low deadspace syringe having a pivoting protective needle guard on a fixed needle assembly that is permanently attached to the syringe.
Description
- This application is a continuation of U.S. patent application Ser. No. 17/192,481, filed Mar. 4, 2021, now allowed, the entire contents of which are incorporated by reference herein.
- This invention relates to a low deadspace syringe having a pivoting protective needle guard on a fixed needle assembly that is permanently attached to the syringe, as shown, for example, in
FIG. 1 . - Low deadspace (LDS) syringes with uni-body fixed needle (FN) integrally molded hubs (
FIGS. 2a-2b ) are widely utilized within the healthcare community most commonly for insulin or vaccination syringes where dosages are small (<1 ml) and medication is limited and expensive. Another two-piece version of a low deadspace (LDS) syringe with a fixed needle (FN) has a molded syringe barrel that is permanently fitted with a separately molded hub in manufacturing (FIGS. 3a-3b ). A major benefit of these FN syringes is the reduction or near elimination of dead-space which results in medication savings. - Other traditional molded
syringes 400 andneedles 401 include Luer 6% taper detachable types as shown by example inFIG. 4 syringe barrels can come with a locking threaded collar to securely hold needle. Due to industry design requirement specifications for Luer 6% taper medical connectors like these, a wide range of dimensions for both the needle and syringe exist. These design specifications intentionally leave space between the mating male (typically the syringe) and female (typically the needle hub) parts to ensure that they mate properly. Other contributing factors are in plastic manufacturing where molding the female Luer hub requires additional space beyond the Luer sealing surface adding to a larger space. All this cumulated space between the syringe tip and needle lumen along with the internal hole at the tip of the syringe permits medication to be trapped and leftover after an injection, as shown in theshaded area 402 inFIG. 5 which leads to precious wasted medication. - Another type of syringe used today includes a
needle guard 61 pivotably attached to anannual ring 62 that is press-fit onto thedistal end 63 of aunibody type syringe 60. Theannular ring 62 may have theneedle guard 61 integrally molded thereto with aliving hinge 64 as described in U.S. Pat. No. 7,648,480 (FIG. 6 ) or haveprovisions 65 for attaching theneedle guard 61 as shown in U.S. Pat. No. 7,722,572 (FIGS. 7-8 ). In all these cases the technology is limited due to the plastic materials used in both the annular ring and mating syringe body. The nature of plastic materials is that when two mating parts are force fit together the hoop stresses that are created will cause the material in either or both parts to creep until a point of relaxation. When the plastic relaxes (which may take only hours or a couple of months) the parts no longer will have a desired tight fitment and can easily be moved or rotated relative to one another even inadvertently during activation of the needle guard. Adding more interference by making one of the parts smaller or larger only increases the stresses which can accelerate the relaxation hence reducing the desired fit. Other factors that can come into play with press-fit annular ring technology is heat and radiation, these too will have effects on the interference fit and relaxation between the mating parts allows them to creep and move as the designs allow unrestrained movement in some directions (collapsing or expanding). - The above-mentioned patents adapt annular ring technology to uni-body type syringes that have a hub integrally molded at the distal end of the syringe barrel with a needle bonded into the hub prior to attaching the needle guard. An additional shortcoming of this type of design occurs when assembling the needle guard to the completed syringe during manufacturing which may result in the annular ring damaging the sharp needle point when passing over the sharp needle point. In this case, the entire syringe and needle guard would need to be discarded which is costly and adds to the waste cycle negatively impacting the environment.
- As mentioned, force fitting the annular ring technology can also result in the needle guard being loosely attached to the syringe which may result in the needle guard spinning while the user is attempting to activate the needle guard. Such movement can lead to a safety issue with potentially dire consequences if the user is accidentally pricked with the used contaminated needle during the shielding process. Balancing of forces with this type of technology is difficult to control when attempting to have the annular ring tight enough to resist rotation when being activating but loose enough to rotate when the user wants to rotate the guard in order to orientate the guard with the bevel point of the needle for some procedures.
- Needle pop-off is another serious safety issue that can be caused by interchangeable needles that have not been properly secured (having a connection force between needle hub and syringe tip greater than the activating force) to the syringe barrel tip. Such needles may be inadvertently dislodged when a user attempts to activate a needle guard since the direction of the force to activate the needle guard is in the same direction for removal of the mounted needle from the syringe tip. The current invention is directed to a permanently factory attached hub syringe connection that removes this concern.
- Exemplary embodiments of the current invention address at least the above problems and/or disadvantages and provide at least the advantages described below. The current invention relates to a low deadspace syringe having a pivoting protective needle guard on a fixed needle assembly that is permanently attached to the syringe.
- In one exemplary embodiment, a low deadspace syringe assembly comprises a syringe barrel having a chamber for retaining fluid and an open distal end having a coupling extending therefrom that is connected to a distal wall opening in the chamber and a needle assembly having a hub, a cannula and a guard rotatably mounted on the hub to rotate from an open position to a locked safety position, wherein the guard covers the distal end of the cannula when in the locked safety position, and the proximal end of the hub having a cork extending therefrom and into the coupling of the syringe barrel to connect a conduit in the hub to the chamber such that the proximal end of the conduit is substantially flush with the distal wall opening in the chamber. With such a configuration deadspace in the syringe is minimized while still providing a pivoting protective needle guard on the fixed needle assembly permanently attached to the syringe barrel.
- As used herein, the term “distal,” and derivatives thereof, shall refer to a direction towards a patient, while the term “proximal,” and derivatives thereof, shall refer to a direction away from a patient. Also note that other objects, advantages and salient features of the current invention will become apparent to those skilled in the art from the flowing detailed description of exemplary embodiments of the invention taken in conjunction with the referenced drawings.
- The invention will be more fully understood from the following detailed description, in conjunction with the following figures, where:
-
FIG. 1 is a side elevation view of a low deadspace syringe with a pivoting protective needle guard on a permanently attached fixed needle assembly in accordance with the subject invention; -
FIGS. 2a-2b are a side elevation and cross-sectional views of an existing insulin syringe with a uni-body fixed needle integrally molded hub; -
FIGS. 3a-3b are a side elevation and cross-sectional views of an existing insulin syringe with a fixed needle having a molded syringe barrel that is permanently fitted with a separately molded hub; -
FIG. 4 is a side elevation assembly view of a traditional syringe with a Luer detachable type needle hub assembly; -
FIG. 5 is an enlarged cross-sectional view of the distal end of the Luer needle hub assembly attached to the syringe shown inFIG. 4 and showing wasted medication contained in deadspace; -
FIG. 6 is an exploded side view of an existing fixed needle syringe receiving an annular ring having a needle guard attached by a living hinge; -
FIG. 7 is a side view of an annular ring with other provisions for attaching a needle guard; -
FIG. 8 is an assembled side view of an existing fixed needle syringe with the annular ring and needle guard shown inFIG. 7 attached thereto; -
FIG. 9 is an enlarged exploded cross-sectional assembly view of the distal end of the low deadspace syringe and the needle assembly shown inFIG. 1 in accordance with the subject invention; -
FIG. 10 is an enlarged cross-sectional view of the needle assembly shown inFIGS. 1 and 9 with the needle guard attached thereto in accordance with the subject invention; -
FIG. 11 is a perspective view of a needle guard of the current invention; -
FIG. 12 is an enlarged cross-sectional view of the pivot shaft on the needle guard shown inFIG. 11 ; -
FIG. 13 is a perspective view of an alternative embodiment of a needle guard of the current invention; -
FIG. 14 is an enlarged cross-sectional view of the pivot shaft on the needle guard shown inFIG. 13 ; -
FIG. 15 is a perspective view of the distal end of the low deadspace syringe of the current invention shown inFIG. 1 and its permanently attached fixed needle assembly with the pivoting protective needle guard in an open unlocked position and the needle protection cap removed; -
FIG. 16 is a side elevation view of the distal end of the low deadspace syringe of the current invention shown inFIG. 1 ; -
FIG. 17 is a perspective view of the distal end of the low deadspace syringe of the current invention with the pivoting protective needle guard of its fixed needle assembly in a locked safety position; -
FIG. 18 are side elevation views of low deadspace syringes with pivoting protective needle guards on permanently attached fixed needle assemblies having a normal length syringe barrel and an optimal length syringe barrel in accordance with the subject invention; -
FIG. 19 is a perspective view of a Luer taper syringe and another embodiment of a safety needle assembly of the current invention; -
FIG. 20 is a side elevational view of the safety needle assembly shown inFIG. 19 attached to the Luer taper syringe; and -
FIG. 21 is a cross-sectional view of assembled safety needle assembly and Luer taper syringe shown inFIG. 20 . - Referring to
FIG. 1 , a low dead-space fixedneedle syringe 100 includes a permanently attached, separately moldedneedle assembly 106 having ahub 102 with an attached pivotingprotective needle guard 101. Syringe dead-space is the volume of residual fluid that remains within the syringe assembly after theplunger 104 is fully depressed during a medication injection. A low dead-space fixed needle syringe can result in a reduction in wasted medication 30 times that of a traditional detachableLuer taper syringe 400 with a matingLuer taper hub 401. As shown in FIG. 1needle hub 102 ofneedle assembly 106 is preferably attached to thesyringe barrel 103 of thesyringe 100 with a press-fit fluid seal interference fit.Hub 102 onneedle assembly 106 is preferably made of plastic. However,syringe barrel 103 may be made of glass or plastic and still provide the press-fit fluid seal interference fit. - The
needle hub 102 is permanently mounted to thesyringe barrel 103 in the manufacturing process. As shown inFIG. 9 ,needle hub 102 includes aneedle cannula 911 extending from its distal end and aneedle hub cavity 901 within its proximal end that allows for thebarrel nozzle tip 902 to engage and permanently connect withneedle hub 102. A sealingcork 903 is included withinneedle hub cavity 901 and due to sealingcork 903 having an outer diameter larger than theinternal orifice 904 ofbarrel nozzle tip 902 an interference fit creates a fluid seal when sealingcork 903 is mated withinternal orifice 904 ofbarrel nozzle tip 902. The permanent connection of sealingcork 903 withbarrel nozzle tip 902 is provided by alocking ring 913 surroundingbarrel nozzle tip 902 engaging with a lockingtrough 914 on an interior surface withinneedle hub cavity 901 and lockingring 913 also thereby maintains sealingcork 903 in sealing engagement withinternal orifice 904. Sealingcork 903 when connected tobarrel nozzle tip 902 may occupy all or nearly all the area of theinternal orifice 904 and may stop at a distal wall opening 916 of thesyringe fluid chamber 905 or even minimally enter thesyringe fluid chamber 905 area to eliminate any and all dead-space when mating to asyringe barrel 103. The sealingcork 903 may include aconduit 906 allowing bidirectional access between thesyringe barrel 103 internalfluid chamber 905 and aneedle lumen 907 within and extending throughneedle cannula 911. Theneedle hub 102 distal end includes abulkhead 917 and acavity 908 for permanently affixingneedle cannula 911 typically with anadhesive bonding material 909. Aneedle protection cap 910 is removably mounted to the distal end ofneedle hub 102 to protect thesharp bevel point 915 at the distal end ofcannula needle 911. - As shown in
FIG. 10 , the invention further includes aneedle guard 101 connected and rotatable to the permanently mounted fixedneedle hub 102 preferable by the interference gripping fittedC shape clasp 1001 and aclasp opening 912, shown inFIG. 9 , that cooperates with apivot shaft 1002 ofneedle guard 101. This arrangement permitsneedle guard 101 easy rotation from an unlocked position, shown inFIGS. 1 and 15 , to a final lock position, shown inFIG. 17 , before disposal or an alternative intermediate desired position during use.Needle guard 101 can also be connected to fixedneedle hub 102 by other known mechanical hinges or an integrally molded living hinge makingneedle hub 102 andneedle guard 101 one molded part. The rotatable fit between needleguard pivot shaft 1002 andC clasp 1001 allows for the user to selectively position theneedle guard 101 and maintain an intermediate desired position during a procedure. - As shown in
FIGS. 12 and 14 ,pivot shaft 1002 of theneedle guard 102 includes one ormore brakes 1101 that exceed the circumference of thepivot shaft 1002 to intentionally cause friction betweenpivot shaft 1002 andC clasp 1001. As shown inFIG. 11 ,brakes 1101 may include a raised area at a concentrated location onpivot shaft 1002 or, as shown inFIG. 13 , run the full length ofpivot shaft 1002 or something less than the full length.Needle guard 102 is held in its open position whenbrakes 1101 are positioned inopen section 912 ofC clasp 1001 and/or in arelief cutout 1003 of the C clasp bearingcontact surface 1004, shown inFIG. 10 , that thepivot shaft 1002 rides along. Placing thebrakes 1101 in an area that does not expose the feature to a compressive load fromC clasp 1001 after assembly and before use (shelf life) is advantageous to maintain a desired frictional fit during use. The additional frictional fit betweenC clasp 1001 andpivot shaft 1002 can be released with the inclusion of arelief area 1003 at the activated mode orientation if desired. Having the frictional feature positioned in theclasp opening 912 orrelief 1003 to maintain a stable guard in the packaged position also facilitates the automation of the packaging process. - A preferred embodiment of
needle guard 101 includes user controlled manual locks activated soon after an injection and before disposal. The user activates theneedle guard 101 causing rotation ofneedle guard 101 over theneedle cannula 911 with a force typically by a finger or hard surface. In the preferred embodiment theneedle guard 101 includes a one-way secured lock. As shown inFIG. 15 ,needle guard 101 includes two shieldingsidewalls 1301 with two lockingtabs 1302, at the end nearestpivot shaft 1002. Eachlocking tab 1302 extends inward into the needle andhub channel 1303. When theguard 101 is activated thelocking tabs 1302 deflect outward when meeting theneedle hub ramp 1304 hub lock members, shown inFIG. 16 , until they bypass theramps 1304 and flex back into a position creating a locked unit. As shown inFIG. 16 , the hub lock 1400 feature is located on opposite side ofneedle hub 102 than that of theC clasp 1001. Locking theneedle guard 101 to theneedle hub 102 may produce an audible sound and tactile feel. The lock is single use. Other locking mechanisms that lockneedle guard 101 to theneedle hub 102 may be used, e.g., one-way barbed pin into a mating hole. - The preferred embodiment also includes at least one
needle hook lock 1501. Theneedle hook lock 1501 is housed within the needle andhub channel 1303 and may be attached to oneside wall 1301 or may extend from a supportingpost 1502 mounted on a wall connected to the side walls. - In the preferred embodiment (hub & needle lock configuration) dual locks engage nearly simultaneously when
needle guard 101 is rotated into the desired locked position, as shown inFIG. 17 . Theneedle hook lock 1501 is a narrow deflecting resilient cantilever hook that flexes inward (opposite direction of needle approach) whenneedle cannula 911 is forced against it allowing theneedle cannula 911 to bypass and springs back onceneedle cannula 911 fully passes byneedle hook lock 1501, trappingneedle cannula 911 withinneedle guard 101 which preventsneedle cannula 911 from exiting back out. When more than one flexingneedle hook lock 1501 is included, the needle locks may be positioned facing one another along the channel. In other embodiments only one (hub or needle) of the two lock systems are included. - As shown in
FIGS. 11 and 13 , the needle guardcross member wall 1201 that connects the twoside walls 1301 includes a finger guiding slanted/curved surface 1202 at the end oppositepivot shaft 1002. Whenneedle guard 101 is at the initial openposition needle guard 101 is nearly horizontal to thesyringe barrel 103, as shown inFIG. 1 , finger guiding slanted/curved surface 1202 allows for user fingertip access betweenneedle guard 101 andsyringe barrel 103 to facilitate a one hand activation ofneedle guard 101 with a substantially horizontal finger stroke. - Syringes normally come in standard volume capacities of 1, 2, 3, 5 and 10 mL for skin injections. For each size the length of the barrel is optimized based on the volume capacity and graduation of unit markings so that a user can accurately set the plunger to a dosage mark. Vaccine immunization typically requires a fraction of the smallest lml version of syringe. The optimal syringe assembly of the current invention shown in
FIG. 18 has been shortened to remove the unnecessary portion of the barrel and plunger rod that leads to more cost, manufacturing challenges (see barrel bow in the following section) and environmental waste. The smaller footprint of these shorter syringes will lead to additional cost savings including packaging, shipping and disposal. As shown inFIGS. 19, 20 and 21 , asafety needle assembly 206 according to the current invention can alternatively be connected to asyringe barrel 203 using a Luer taper connection having a Female Luer taper in thecavity 205 of thehub 202 and a Male Luer taper on thebarrel tip 204 of thesyringe barrel 203. The Luer taper connection also provides a liquid tight seal between theinternal hub cavity 205 and the external surface of thebarrel tip 204. - Also note that the invention is suitable to self-contained syringes that do not require flexible packaging and instead use plastic caps to maintain sterility; re-use prevention (RUP) syringes with frangible plunger features that prevent re-use after an injection has been completed (as shown and described in EP0925083B1) and fixed dose auto-disable (AD) syringes with plunger locking element features that prevent re-use during and/or after movement of the plunger in the injection phase (as shown and described in U.S. Pat. No. 9,205,205).
- The current invention also offers a low deadspace syringe with a protective guard design for either a healthcare provider or patient that can be easily and safety activated without the fear of the guard spinning or popping off during activation of the needle guard is beneficial and has been previously disclosed. Preventing unintended rotational movement of the needle guard during activation will remove the risk of a potential needle stick injury from occurring. The mounting of the needle guard to the needle hub adapter without allowing a means for rotation solves this potential issue. Having the needle hub permanently fixed to the barrel and the guard mounted directly to the hub also eliminates the hazard of a needle popping off the syringe distal tip if it had not been securely fastened by the user which can occur with Luer slip detachable type needles and syringes. Another benefit of the current invention is the low profile of the needle guard which allows for unobstructed visual viewing of the injection site and needle point position prior to injecting the patient. The low profile aids in reducing the likelihood the needle guard will snag onto loose clothing or bedding and get damaged or cause a needlestick injury. Another beneficial design feature is the distal end of needle guard (proximal to user before activation) having a slanted inverse ramp or
curvature area 1202, as shown inFIGS. 11 and 13 , which allows for guiding a user to place their fingertip between the underside ofneedle guard 101 andsyringe barrel 103 to easily begin a single handed preferred activation method of the needle guard to the activated position. Low or even no waste-space is achieved and maintained with this design compared to a Luer needle hub and Luer syringe assembly. - The manufacturability of the current invention two pieces syringe barrel is also an improvement when compared to the one piece uni-body syringe barrel since the metal core-pin that creates the fluid chamber of the molded barrel is held in place by a support pin at the distal end that is much greater in diameter and stiffness within the mold which minimizes core shift (bending), the major contributing factor that causes syringe barrel bow in the molding process which is undesirable. “Bow” (banana shape) occurs when the proximal and distal ends of the barrel are out of alignment with the horizontal axis of the barrel cylinder, causing alignment issue in the assembly process. Alternatively, reducing the overall length of the barrel will also be beneficial towards molding the optimal straight concentric barrel.
- Orienting
needle bevel 915 relative toneedle guard 101 is desirable in some injection practices like intradermal injections and this is easily achieved by the current invention during the manufacturing process when mounting theneedle 911 inneedle hub 102, thereby eliminating the user needing to rotate the needle guard during use. - The current invention also allows for color
coding needle hub 102 by pigmenting the raw material to quickly and easily identifying the gauge of theneedle cannula 911 is most desirable; havingneedle hub 102 molded separately fromsyringe barrel 103 as describe in this invention allows this improvement over integrally molded needle hub syringes. Integrally molded hub syringes cannot offer coloring options since the barrel is required to be made of a clear material so that the fluid content can easily be viewed. - Reading the syringe barrel graduation is also important to the medication preparation of the syringe by a healthcare worker. When manufacturing the current
invention syringe barrel 103 andneedle hub 102 with theneedle guard 101,needle guard 101 may be positioned to best view the graduation. Another benefit to having the manufacturerposition needle hub 102 andneedle guard 101 is to alignneedle guard 101 with thefinger flanges 107 ofsyringe 103 to minimize syringe packaging. - As will be recognized by those skilled in the art, the subject invention is not limited to these arrangements.
Claims (20)
1. A safety syringe assembly comprising:
a syringe barrel having an open proximal end, an open distal end, and a chamber therebetween for retaining fluid, said open distal end having a coupling extending therefrom and connected to a distal wall opening in said chamber; and
a needle assembly comprising:
a hub having a proximal end, a distal end, and a conduit therethrough, said proximal end of said hub having a cork extending therefrom and into said coupling of said open distal end of said syringe barrel to connect said conduit to said chamber such that said proximal end of said conduit is substantially inserted into said open distal end of said syringe barrel;
a cannula having a proximal end, a distal end, and a lumen therethrough, said proximal end of said cannula mounted within said conduit of said hub; and
a guard rotatably mounted on said hub to rotate from an open position to a locked safety position, wherein said guard covers said distal end of said cannula when in said locked safety position.
2. A safety syringe assembly of claim 1 , wherein said guard is rotatably mounted on said hub using a hinge.
3. A safety syringe assembly of claim 2 , wherein said hinge is a pivot hinge having a pivot shaft on said guard that is received in a pivot mount clasp on said hub.
4. A safety syringe assembly of claim 3 , wherein said guard can be user dependently parked between said open position and said locked safety position.
5. A safety syringe assembly of claim 2 , wherein said hinge is a living hinge connecting said guard to said hub.
6. A safety syringe assembly of claim 1 , wherein said guard has a tapered distal end to provide a gap between said guard and said syringe barrel when said guard is in said open position to facilitate activation by a user.
7. A safety syringe assembly of claim 1 , further comprising a plunger rod having a distal end and a proximal end, said plunger rod being slidably mounted within said chamber of said syringe barrel.
8. A safety syringe assembly of claim 7 , wherein dead-space between said distal end of said cannula and said distal end of said plunger rod is no more than 10 μL when said distal end of said plunger rod abuts said distal wall opening of said chamber.
9. A safety syringe assembly of claim 7 , wherein said distal end of said plunger rod includes a stopper and wherein dead-space between said distal end of said cannula and said stopper is no more than 10 μL when said stopper of said plunger rod abuts said distal wall opening of said chamber.
10. A safety syringe assembly of claim 1 , wherein said guard locks to said hub when in said locked safety position.
11. A safety syringe assembly of claim 1 , wherein said guard traps said cannula within said guard when in said locked safety position.
12. A safety syringe assembly of claim 1 , wherein said guard locks to said hub and traps said cannula within said guard when in said locked safety position.
13. A safety syringe assembly of claim 1 , wherein said guard provides an audible click when entering said locked safety position.
14. A safety syringe assembly of claim 1 , wherein said guard provides tactile feedback when entering said locked safety position.
15. A safety syringe assembly of claim 1 , wherein said hub is permanently fixed to said syringe barrel.
16. A safety syringe assembly of claim 1 , wherein said hub is attached to said syringe barrel using a snap-fit.
17. A safety syringe assembly of claim 1 , wherein said syringe assembly includes a re-use prevention frangible plunger feature to prevent re-use after the injection has been completed.
18. A safety syringe assembly of claim 1 , wherein said syringe assembly includes an auto-disable plunger locking element feature to prevent re-use after the injection has been completed.
19. A safety syringe assembly of claim 1 , wherein said syringe barrel includes gradations on an exterior surface and said hub is attached to said syringe barrel such that said guard does not cover said gradations when in said open position.
20. A safety syringe assembly of claim 1 , wherein said distal end of said cannula includes a bevel and said guard is mounted on said hub such that said bevel is properly aligned with said guard to ensure that said guard does not interfere with injection technique when performing an injection with said safety syringe assembly.
Priority Applications (1)
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US17/540,805 US20220280729A1 (en) | 2021-03-04 | 2021-12-02 | Low deadspace syringe including a pivoting needle guard |
Applications Claiming Priority (2)
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US17/192,481 US11207469B1 (en) | 2021-03-04 | 2021-03-04 | Low deadspace syringe including a pivoting needle guard |
US17/540,805 US20220280729A1 (en) | 2021-03-04 | 2021-12-02 | Low deadspace syringe including a pivoting needle guard |
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US17/192,481 Continuation US11207469B1 (en) | 2021-03-04 | 2021-03-04 | Low deadspace syringe including a pivoting needle guard |
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US20220280729A1 true US20220280729A1 (en) | 2022-09-08 |
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US17/540,805 Pending US20220280729A1 (en) | 2021-03-04 | 2021-12-02 | Low deadspace syringe including a pivoting needle guard |
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US17/192,481 Active US11207469B1 (en) | 2021-03-04 | 2021-03-04 | Low deadspace syringe including a pivoting needle guard |
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US (2) | US11207469B1 (en) |
EP (1) | EP4301439A1 (en) |
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Cited By (1)
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US11612692B1 (en) | 2021-10-29 | 2023-03-28 | Thomas C. Kuracina | Method and apparatus to reduce the deadspace in syringes and small-bore devices |
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USD968591S1 (en) * | 2020-12-14 | 2022-11-01 | Expressions Design Studio, LLC | Safety needle |
USD969314S1 (en) * | 2020-12-14 | 2022-11-08 | Expressions Design Studio, LLC | Blood collection safety needle |
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- 2021-12-02 US US17/540,805 patent/US20220280729A1/en active Pending
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- 2022-02-25 EP EP22763812.9A patent/EP4301439A1/en active Pending
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US11612692B1 (en) | 2021-10-29 | 2023-03-28 | Thomas C. Kuracina | Method and apparatus to reduce the deadspace in syringes and small-bore devices |
US11612693B1 (en) | 2021-10-29 | 2023-03-28 | Thomas C. Kuracina | Method and apparatus to reduce the deadspace in syringes and small-bore devices |
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US11207469B1 (en) | 2021-12-28 |
WO2022187094A1 (en) | 2022-09-09 |
CN116710162A (en) | 2023-09-05 |
EP4301439A1 (en) | 2024-01-10 |
CN218248037U (en) | 2023-01-10 |
BR112023017785A2 (en) | 2023-10-03 |
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