Abstract:
A gas-assisted fluid-dispensing device configured to deliver an aerosol onto a surgical site. The fluid-dispensing device includes at least one fluid chamber configured to contain a fluid. The fluid chamber has a distal end and proximal end. A plunger extends at least partially into the fluid chamber from the proximal end. A spray nozzle tip is fluidly coupled to the distal end of the fluid chamber and is coupled to a gas supply. The tip is capable of generating aerosol with a gas from the gas supply and the fluid from the fluid chamber. A housing has an upper portion with a docking port configured to operably receive the fluid chamber. An actuating member is operably coupled to a plunger and is configured to apply a force to the plunger to discharge fluid from the fluid chamber and into the tip.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the priority of U.S. Provisional Patent Application Ser. No. 61/657,004, filed on Jun. 7, 2012 (pending), the disclosure of which is incorporated by reference herein in its entirety. 
         [0002]    The disclosures of International Patent Application No. PCT/US11/29763, filed on Mar. 24, 2011 and entitled GAS-ASSISTED FLUID DISPENSING DEVICE and U.S. application Ser. No. 61/657,008, filed Jun. 7, 2012 and entitled LOW PROFILE HANDLE PNEUMATIC ASSIST DEVICE FOR DISPENSING DUAL MATERIALS WITH OR WITHOUT A GAS ASSIST USED FOR SPRAYING MATERIALS are incorporated herein by reference in their entireties. 
     
    
     FIELD OF THE INVENTION 
       [0003]    The present invention relates generally to fluid-dispensing devices and, more particularly, to a fluid-dispensing device configured to dispense aerosols. 
       BACKGROUND OF THE INVENTION 
       [0004]    In the medical field, a surgeon routinely needs to deliver a drug or another fluid to an anatomical surface within a surgical site in a patient. Conventional manual and non-manual syringes are often used to deliver these fluids to the surgical site. For example, one known conventional syringe design includes two barrels, each containing separate fluids that are simultaneously dispensed and mixed to form a coating adapted to prevent bleeding at the surgical site. In order to spread the coating over a surface area at the surgical site, the double-barreled syringe may be coupled to a known mixing or blending spray tip, such as the FIBRIJET brand of blending tips, such as model SA-3654, that is commercially available from Micromedics of St. Paul, Minn. The blending spray tip receives the fluids from each of the two barrels, along with a pressurized gas from a pressurized gas source, to form a therapeutic aerosol that is sprayed over the surface to be coated. The therapeutic aerosol, including, for example, pain relievers, antibiotics, or coagulants, may be applied to the surgical site before, during, or after a surgical procedure. 
         [0005]    It is widely accepted that a maximum of about 8 pounds of force should be applied to the syringes during use of such gas-assisted dispensers. However, as utility of the dispensers increases to include viscous materials and/or larger fluid containers (barrels, syringes, and so forth) the maximum force is often exceeded. This not only presents concerns for the structural integrity of the dispenser but also increases the discomfort experienced by those users having smaller hands. Thus, there exists a need for ergonomically improved dispensing devices that more efficiently dispense fluids, particularly high viscosity fluids, while increasing user comfort and reducing hand strain. 
       SUMMARY 
       [0006]    Generally, the present invention provides a gas-assisted fluid-dispensing device configured to deliver an aerosol onto a surgical site. In one illustrative embodiment the fluid-dispensing device comprises at least one fluid chamber configured to contain a fluid and including a distal end and proximal end. A plunger extends at least partially into the fluid chamber from the proximal end. A spray nozzle tip is fluidly coupled to the distal end of the fluid chamber and is configured to have a gas supply coupled thereto. The spray nozzle tip is capable of generating aerosol with a gas from the gas supply and the fluid from the fluid chamber. A housing has an upper portion with a docking port configured to operably receive the fluid chamber. An actuating member is operably coupled to the plunger and is configured to apply a force to the plunger to discharge fluid from the fluid chamber and into the spray nozzle tip. In one embodiment, first and second fluid chambers are configured to contain first and second fluids, respectively, and each of the fluid chambers includes a distal end. First and second plungers extend respectively at least partially into the first and second fluid chambers from the proximal ends thereof. The spray nozzle tip is fluidly coupled to the distal end of the first and second fluid chambers. The housing is configured with an upper portion and the docking port receives the first and second fluid chambers. The actuating member is operably coupled to the first and second plungers and is configured to apply a force to the plungers to discharge the fluids from the first and second fluid chambers and into the spray nozzle tip. 
         [0007]    In additional aspects, the actuating member includes a toothed surface and the gas-assisted fluid-dispensing device further comprises a pawl operably configured to engage the toothed surface and to ratchet the actuating member relative to the housing. A torsion spring is provided and biases the pawl toward the toothed surface. The pawl includes a release arm configured to bias the pawl away from the toothed surface and against the bias of the torsion spring. The fluid dispensing device further comprises a holder configured to couple the first and second fluid chambers to the housing. The holder includes first and second channels configured to receive respective ones of the first and second fluid chambers. First and second keyed adaptors are coupled to respective distal ends of the first and second fluid chambers. The first channel includes a projection configured to receive the keyed adaptor of the first fluid chamber. The proximal ends of the first and second fluid chambers have an asymmetrical shape. The holder further comprises a keyed proximal end configured to receive the asymmetric proximal ends of the first and second fluid chambers when the asymmetric proximal ends are in a first orientation and to secure the asymmetric proximal end within the keyed proximal end when the asymmetric proximal ends are in a second orientation. An arm extends distally away from the holder toward the spray nozzle tip and includes a keyed surface. The spray nozzle tip includes a keyed groove configured to receive the keyed surface of the arm. 
         [0008]    In additional aspects, the invention provides methods of operating the gas-assisted fluid-dispensing devices, such as the devices with one or more of the aspects described above. 
         [0009]    Various additional features and advantages of the invention will become more apparent to those of ordinary skill in the art upon review of the following detailed description of the illustrative embodiments taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a perspective view of a gas-assisted fluid-dispensing device constructed in accordance with an illustrative embodiment of the invention. 
           [0011]      FIG. 2  is an exploded perspective view of the device illustrated in  FIG. 1 . 
           [0012]      FIG. 3A  is a cross sectional view taken generally longitudinally along the device as shown in  FIG. 1 . 
           [0013]      FIG. 3B  is a cross sectional view similar to  FIG. 3A , but illustrating actuation of a trigger associated with the device. 
           [0014]      FIG. 3C  is a cross sectional view similar to  FIGS. 3A and 3B , but illustrating the actuation of a release arm associated with the device. 
           [0015]      FIG. 4  is an enlarged perspective view of the distal end of the device. 
           [0016]      FIG. 5  is another exploded perspective view illustrating the device of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    Turning now to the figures, and particularly  FIGS. 1 ,  2 ,  4  and  5 , one embodiment of a gas-assisted fluid dispenser  20  is shown and described in detail. The dispenser  20  includes a fluid-dispensing device  22  having a least one fluid source. The fluid source may include, for example, a dual-syringe having one or more parallel fluid chambers (two fluid chambers  24 ,  26  are shown) for simultaneously dispensing one or more fluids, such as topical or therapeutic medicinal agents. Moreover, it would be readily appreciated that if more than one fluid is administered, equal volume need not be dispensed. Instead, the volume of a first fluid dispensed from the first fluid chamber  24  may be larger than the volume of a second fluid dispensed from the second fluid chamber  26 . Each of the fluid chambers  24 ,  26  includes a tapered distal end  28 ,  30 , a winged proximal end  32 ,  34 , and a cylinder (not shown) extending therebetween. A plunger  36 ,  38  resides, at least partially, within the cylinder of each fluid chamber  24 ,  26  and extends proximally therefrom. Each plunger  36 ,  38  may be constructed in a known, conventional manner and include a distally-positioned stopper  40 ,  42  and a proximally-positioned plunger head  44 ,  46 . 
         [0018]    A spray nozzle tip  50  is coupled to the fluid-dispensing device  22 . And, because the dual-syringe of the illustrative embodiment includes two fluid chambers  24 ,  26 , the spray nozzle tip  50  is illustrated as a Y-connector attached to both fluid chambers  24 ,  26 . The spray nozzle tip  50  further includes a gas inlet  56  configured to receive a gas line (not shown). Thus, the spray nozzle tip  50 , as shown, includes two fluid inlets  52 ,  54 , one gas inlet  56 , and one outlet  58 . One of ordinary skill in the art would readily appreciate that the shape of the outlet  58  may be configured to provide a desired aerosol effect. That is, a desired direction and/or spread of the resultant aerosol, along with the gas pressure, may be determined by incorporating a particular design for the outlet  58 . 
         [0019]    The fluid-dispensing device  22  is supported within a source holder  60 , which may have a molded polymeric material construction that is sized and shaped to accommodate the fluid chambers  24 ,  26 . Accordingly, various sizes, shapes, and configurations of holders  60  are possible for supporting one or more fluid chambers  24 ,  26  of similar or varying sizes. In the illustrative embodiment, the holder  60  includes first and second channels  62 ,  64  that are shaped and sized to receive the two fluid chambers  24 ,  26 . The holder  60  further includes one or more tabs  66  ( FIGS. 3A and 3B ), which are configured to couple the holder  60  to a docking port  72  ( FIG. 3C ) of the dispenser  20 . The docking port  72  may include one or more slots that receive respective ones of the one or more tabs  66  ( FIGS. 3A and 3B ). 
         [0020]    To facilitate consistent assembly of the fluid-dispensing device  22  with the holder  60 , the first fluid chamber  24  containing a first fluid is loaded into the first channel  62  of the holder  60  while the second fluid chamber  26  containing a second fluid is loaded into the second channel  64  of the holder  60 . The distal tapered ends  28 ,  30  of the fluid chambers  24 ,  26  each may include one of two keyed adaptors  68 ,  70 , embodiments of which are shown in  FIG. 4 . The first and second keyed adaptors  68 ,  70  may vary in at least one structural dimension, which, as shown, are different diameters. Each adaptor  68 ,  70  further includes a distally-extending port, such as a luer, configured to be coupled to the inlets  52 ,  54  of the nozzle tip  50 . 
         [0021]    In addition to the keyed adaptors  68 ,  70 , the distal ends of the first and second channels  62 ,  64  of the holder  60  may be particularly configured to receive one of the two keyed adaptors  68 ,  70 . More specifically and in accordance with the exemplary embodiment, the first channel  62  includes a structured surface, such a projection, which is illustrated herein as one or more ribs  76  that reduce the inner diameter of the first channel  62  to approximately the outer diameter of the first keyed adaptor  68 . Meanwhile, the second channel  64 , remaining devoid of diameter-reducing ribs, remains sufficiently large so as to receive the larger outer diameter of the second keyed adaptor  70 . As a result, and when the fluid chambers  24 ,  26  are loaded into the holder  60 , the first fluid within the first fluid chamber  24  is necessarily loaded into the first channel  62  of the holder  60  having the ribs  76  therein to support the smaller outer diameter adaptor  68 . The second chamber  26  containing the second fluid is then necessarily loaded into the second channel  64 . 
         [0022]    If desired, and as shown, the winged proximal ends  32 ,  34  of the fluid chambers  24 ,  26  may be asymmetrically shaped with respect to a keyed proximal end  48  of the holder  60 . As such, the winged proximal ends  32 ,  34  in a first orientation may be directed into the proximal end  48  of the holder  60  and then rotated to a second orientation with respect to the proximal end  48 , which secures the winged proximal ends  32 ,  34  thereto. 
         [0023]    With the fluid chambers  24 ,  26  coupled to the holder  60 , the nozzle tip  50  is coupled to the luers of the keyed adaptors  68 ,  70  such that the first inlet  52  is coupled to the first keyed adaptor  68  and the second inlet  54  is coupled to the second keyed adaptor  70 . 
         [0024]    In some embodiments, the nozzle tip  50  may further include an indicia  78 , such as the imprinted donut of the first arm of the Y-connector, which would be understood to reside on the same side during each use of the nozzle tip  50 . However, use is not prevented by such indicia  78  and a user that is quickly assembling the dispenser  20  or otherwise unaware of the laboratory or surgical suite&#39;s standard operating procedures may inadvertently rotate the nozzle tip  50  such that the indicia  78  is flipped to the opposing side during use. While this switch may be seemingly benign, in those embodiments where the first fluid reacts with the second fluid to form a coagulant or other extremely viscous, gelatinous, or adhesive material, this simple reversal of the Y-connector with respect to the first and second fluids may result in a chemical reaction within the channels of the Y-connector with residual first and second fluids therein. With sufficient residual material and/or reactivity, the channels of the Y-connector may become clogged, rendering the nozzle tip inoperable. 
         [0025]    To prevent such reversal of the nozzle tip  50 , the Y-connector may further be keyed with a groove  80  so as to receive an arm  82  protruding distally from the holder  60 , which prevents reversal of the nozzle tip  50  from its accepted arrangement (with the indicia  58  proper positioned) with respect to the fluid chambers  24 ,  26 . 
         [0026]    A housing  84  of the dispense  20  may be constructed as two halves from a moldable polymeric material, which may be joined by screws to enclose an internal cavity. A trigger  86  is coupled to the housing  84  and operably coupled to the fluid-dispensing device  22 . The housing  84  further includes a first, upper housing portion and a second, lower housing portion that is configured as a handle  88  extending angularly downward from the upper housing portion. The upper housing portion includes a slot  90  through which an actuating member  92  for the fluid-dispensing device  22  extends. That is, the actuating member  92  is operably coupled to the fluid chambers  24 ,  26  for dispensing the fluids therefrom and into the spray nozzle tip  50 . As shown, the actuating member  92  is a T-shaped slide having an elongated base portion  94  that extends through the slot  90  and configured to slide horizontally relative thereto. A top surface of the base portion  94  includes a longitudinal array of indentations  96  extending a substantial portion of the length of the base portion. A spring positioned within the cavity between the top surface of the base portion and an inner surface of the upper housing portion engages one of the indentations  96  and is configured to maintain the relative position of the actuating member  92  during operation and reloading of the fluid-dispensing device  22 . Additional details of the operation of the spring may be found in International Patent Application No. PCT/US11/29763. 
         [0027]    The actuating member  92  further includes an upright portion  98  that extends substantially orthogonally upward from the base portion  94  and is configured to engage the plunger heads  44 ,  46  of the plungers  36 ,  38  and actuate the plungers  36 ,  38  to dispense the fluid to the spray nozzle tip  50 . 
         [0028]    With reference now to FIGS.  2  and  3 A- 3 C, one method of actuating the trigger  86  to dispense fluid from the fluid chambers  24 ,  26  into spray nozzle tip  50  is shown. The trigger  86  is operably coupled to the housing  84  at a first pivot point, represented by a trigger pin  100 , and extends distally therefrom. The length of the trigger  86  may be selected to create a mechanical advantage over direct manipulation of the plungers  36 ,  38 , for example, a 4:1 mechanical advantage. A first torsion spring  102  operably coupled to the trigger  86  at the first pivot point  100  is configured to bias the trigger  86  away from the handle  88 . 
         [0029]    A proximal end  104  of the trigger  86  is positioned within housing  84  and includes a pawl pin  106  defining a second pivot point for operating a pawl  108  and a second torsion spring  110 . The pawl  108  extends angularly upwardly from the pawl pin  106  and engages a linear array of teeth  112  formed in a bottom surface of the base portion  94  of the actuating member  92 . The second torsion spring  110  biases the pawl  108  upwardly and away from the trigger  86  toward the plurality of teeth  112  and with respect to the bottom portion of the housing  84 . 
         [0030]    In use, and by engaging the trigger  86 , i.e., directing the trigger  86  toward the handle  88 , the proximal end  104  of the trigger  86  moves distally within the cavity (e.g., toward the spray nozzle tip  50 ). Because the pawl  108  is coupled to the proximal end  104  of the trigger  86  at the pawl pin  106 , movement of the trigger  86  also causes the pawl  108  to rotate toward the distal direction while the second torsion spring  110  continues to bias the pawl  108  upwardly. The rotational movement of the pawl  108  with continued upward bias creates a forwardly-directed force onto a rear surface of the tooth  112  engaged by the pawl  108  and will direct the slide forward. With sufficient engagement of the trigger  86  and forward movement of the pawl  108 , the actuating member  92  moves forward a sufficient distance so that the pawl  108 , when the trigger  86  is released, ratchets along the linear array of teeth  112  to engage a tooth  112  positioned proximate the now rest position. 
         [0031]    This ratcheting movement of the actuating member  92  causes the upright portion  98  of the actuating member  92  to actuate the plungers  36 ,  38 . Each engagement (or squeezing) of the trigger  86  is thus converted into a horizontal, distally-directed translation of the upright portion  98  and thereby directs the plungers  36 ,  38  into the cylinders of the fluid chambers  24 ,  26 . As the plungers  36 ,  38  move inwardly, the fluid is compressed within each of the respective fluid chambers  24 ,  26  and a volume of the fluid that is proportional to the linear displacement of the plungers  36 ,  38  is dispensed from the tapered distal ends into the spray nozzle tip  50 . Accordingly, metering of the amount of fluid dispensed may be accomplished by the number of trigger compressions, e.g., each complete trigger engagement may cause the pawl  108  to engage every tooth  112  or, alternatively, engage only selected teeth  112 . 
         [0032]    Before, during, and after each trigger squeeze, the dispensing gas is directed into the gas inlet  56  of the nozzle tip  50  from a regulator (not shown) having a foot pedal (not shown) control. In this way, the gas flow may be initiated prior to the release fluids from the fluid chambers  24 ,  26  into the spray nozzle tip  50  such that when the fluids are released, the fluids mixed with the flowing gas, atomizes or disperses, as a treatment aerosol from the outlet of the spray nozzle tip  50 . The surgeon may continue dispensing the treatment aerosol by further compressing the trigger  86 . Without further compression of the trigger  86 , only the dispensing gas is released from the spray nozzle tip  50 . This further dispensing of gas helps in clearing the passages of the nozzle tip  50  in preparation for future use. 
         [0033]    After some use, it may be necessary to reload the dispenser  20  with another fluid dispensing device  22  for use with the same patient or in preparation for another surgery. Accordingly, the fluid-dispensing device  22  may need to be removed and replaced with another fluid-dispensing device  22 . Because the pawl  108  is designed as a one-way ratchet, reverse movement of the actuating member  92  is not possible without first releasing the pawl  108  from the plurality of teeth  112 . A release arm  114 , which is coupled with the pawl  108 , is accessible to the surgeon such that rearward biasing of the release arm  114  (i.e., toward the trigger  86 ), with or without a trigger pull, rotates the pawl  108  against the bias of the second torsion spring  110  and rotates the pawl  108  about the pawl pin  106  to withdraw the pawl  108  from the linear array of teeth  112  ( FIG. 3C ). Accordingly, the actuating member  92  may be retracted rearwardly and the fluid dispensing device  22  with holder  60  removed. 
         [0034]    In accordance with the illustrated configuration, described in some detail herein, the overall movement of the trigger  86  is minimized and reduces the overall operational profile of the dispenser  20  such that users having smaller hands may more easily squeeze the trigger  86  and operate the dispenser  20  as described herein. 
         [0035]    While the invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broadest aspects is not limited to the specific details shown and described. The various features disclosed herein may be used in any combination necessary or desired for a particular application. Consequently, departures may be made from the details described herein without departing from the spirit and scope of the claims which follow.