A needle shield for a prefillable syringe

Abstract: A syringe assembly (20) includes a needle sheath (24) that has a cavity that receives a needle cannula (30). The needle sheath can be formed of materials such as thermoplastic elastomers or plastics yet still be utilized with conventional gas sterilizing processes. The needle sheath includes a passage that permits the sterilizing gases to enter the cavity (40) while preventing entry of microorganisms into the cavity. Thus, a syringe assembly is provided that facilitates sterilizing a needle after the needle sheath has been placed over the needle.

Description: BACKGROUND OF THE INVENTION This invention generally relates to a syringe assembly having a needle sheath. Increasingly, medicaments are supplied from manufacturers in prefilled syringe assemblies. Such assemblies include a syringe that has a needle cannula and is filled with the medicament. Typically, a needle sheath covers the needle cannula to prevent accidental contact with the needle. Manufacturers supply such syringe assemblies as prepackaged, sterile, single use units. Thus, it is necessary to create a syringe assembly than can be sterilized after the needle sheath is placed over the needle cannula. In the past, needle sheaths were primarily composed of rubber. With the advent of modem thermoplastic elastomers, many manufacturers have switched to thermoplastic elastomers as the material of choice for needle sheaths. Thermoplastic elastomers offer the advantages of being: cleaner than natural rubber products; providing better dimensional control of parts; available in a wider variety of synthetic materials to insure compatibility with a particular medicament; lower cost than natural rubber; and reduced leeching of materials from the needle sheath into the medicament. Thermoplastic elastomers also permit a wider choice of sterilization methods between gases like ethylene oxide, irradiation, or autoclaving. One problem with some synthetic thermoplastic elastomers is that the particular composition which is most compatible with a particular medicament has a low permeability to a sterilizing gas. The first part of claim 1 refers to a needle sheath for a syringe as disclosed in US-3,381,813. The needle sheath has a tubular body portion with circumferential ribs on the inner surface thereof. The ribs are spaced from each other in both, circumferential and longitudinal direction of the body portion. Thereby, the ribs define passages permitting gas from the external atmosphere to flow into the cavity of the needle sheath. Thus, sterilization fluid can flow through the passage. The invention concerns a needle sheath that can be sterilized using any sterilizing gas while permitting the needle sheath to be composed of any thermoplastic elastomer, including one having a low permeability to the particular sterilizing gas. In addition, it is sometimes desirable to produce a needle sheath formed of plastic. Plastics generally have low gas permeability. Thus, it is desirable to provide a needle sheath that can be formed of materials with low gas permeability and still be sterilized by a sterilizing gas. The needle shield of the present invention is defined by claim 1. Accordingly, the passage in communication with the first end of the cavity of the body portion comprises a non-linear groove in the inner surface of the needle shield. The invention further relates to a syringe assembly comprising the features of claim 5. These and other features and advantages of this invention will become more apparent to those skilled in the art from the following detailed description of the presently preferred embodiment. The drawings that accompany the detailed description can be described as follows. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a cross-sectional view of a syringe assembly designed according to the present invention; Figure 2 is a cross-sectional view of another embodiment of a syringe assembly designed according to the present invention; Figure 3 is a cross-sectional side view of a needle sheath designed not belonging to the present invention; Figure 4 is a cross-sectional view along line 4-4 of Figure 3; Figure 5 is a cross-sectional side view of an embodiment of a needle sheath designed according to the present invention; Figure 6 is a cross-sectional view along line 6-6 of Figure 5; Figure 7 is a cross-sectional side view of another embodiment of a needle sheath designed according to the present invention; Figure 8 is a cross-sectional view along line 8-8 of Figure 7; Figure 9 is a cross-sectional side view of another embodiment of a needle sheath not designed according to the present invention; Figure 10 is a cross-sectional view along line 10-10 of Figure 9; Figure 11 is a cross-sectional side view of another example of a needle sheath not designed according to the present invention; and Figure 12 is a cross-sectional view along line 12-12 of Figure 11. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT A syringe assembly is generally indicated at 20 in Figure 1. The syringe assembly 20 includes a syringe body 22 and a needle sheath 24. The syringe body 22 has an interior chamber 26 that receives a medicament 32 and is in communication with a passage in a neck portion 28. An integral needle cannula 30 is supported on the neck portion 28 and in communication with the interior chamber 26 through the passage in the neck portion 28. A conventional stopper 34 and plunger rod 36 are used to eject the medicament 32 from the needle cannula 30 while administering an injection in a conventional manner. The needle sheath 24 includes a body portion 38 with a cavity 40. The needle sheath 24 has a first end 42 and a second end 44. The first end 42 defines the cavity opening and is received over the neck portion 28. In Figure 1, the syringe assembly 20 is shown as prefilled syringe containing the medicament 32 loaded in the interior chamber 26. Of course, the syringe assembly 20 could be packaged without any medicament 32 in the interior chamber 26. Figure 2 illustrates another syringe assembly 20 designed according to the present invention. The syringe assembly in Figure 2 does not include an integral needle cannula 30, but includes a needle cannula 46 extending from a hub 48. The hub 48 and needle cannula 46 are supported on the neck portion 28 of the syringe body 22. A cross-sectional side view of a needle sheath 24 not designed according to the present invention is shown in Figures 3 and 4. The cavity 40 has an inner surface 52. Ridges 54 are located on the inner surface 52 of the cavity 40. Each ridge 54 includes a gap 56. Preferably, the gap 56 has a cross-sectional size that is between about 0.0065 and 0.0516 mm 2 (.00001 and .00008 square inches). The gap 56 of adjacent ridges 54 are circumferentially offset from each other. The amount of offset between gaps 56 may be varied as needed in a particular situation. In one example, only a single ridge 54 is used. When the needle sheath 24 is fit over the neck portion 28, the ridges 54 sealingly engage the outer surface of the neck portion 28, for example. The gap 56 provides a passage between the first end 42 and the cavity 40. The size of the gap 56 permits sterilizing gas from outside of the cavity 40 to flow into the cavity 40 while simultaneously preventing undesirable microorganisms from entering the cavity 40. The design of this invention permits a syringe assembly 20 to be assembled under non-sterile conditions and to subsequently be sterilized by a sterilizing gas such as ethylene oxide while using thermoplastic elastomers to form the needle sheath 24. The gaps 56 permit the sterilizing gas to flow into the cavity 40 and to sterilize the interior of the cavity 40 and either the integral needle cannula 30 or the needle cannula 46. Figures 5 and 6 illustrate an embodiment of a needle sheath 24 designed according to the present invention. The needle sheath 24 includes a groove 58 formed on the inner surface 52 of the cavity 40. The groove 58 has a shape that provides a non-linear pathway from the first end 42 into the cavity 40. The non-linear pathway provided by the groove 58 permits a sterilizing gas to enter the cavity 40 while simultaneously preventing undesirable microorganisms from entering the cavity 40. The groove 58 must extend into the cavity 40 sufficient to allow the sterilizing gas to contact the needle. As shown in Figures 7 and 8, a groove 58' provides a pathway that spirals around the inner surface 52 of the cavity 40. In the embodiments shown in Figures 5-8 the inner surface 52 of the needle sheath 24 will be in sealing engagement with either the neck portion 28 or the hub 48 when the syringe assembly 20 is complete. The groove 58 and 58', however, allows for the sterilizing gas to enter the cavity 40 during a sterilizing process. An embodiment not designed according to the present invention of the needle sheath 24 is shown in Figures 9 through 12. In Figure 9, a plurality of ridges 60 are formed on the inner surface 52 of the cavity 40. A gap 62 is located between the plurality of ridges 60. The gap 62 provides a passage from the first end 42 into the cavity 40. The gap 62 permits sterilizing gases to enter the cavity 40 while preventing undesirable microorganisms in the external atmosphere from entering the cavity 40. In the embodiment shown in Figures 9 and 10, the ridges 60 and the majority of the inner surface 52 will be in sealing engagement with either the neck portion 28 or the hub 48 when the syringe assembly 20 is fully assembled. As shown in Figures 11 and 12, the ridges 60 have a shape that provides a spiralling gap 62 around the inner surface 52 of the cavity 40. The shape of the passage permitting sterilizing gas to enter the cavity 40 may take a variety of forms. It is imperative that the passage have some contour or nonlinearity so that microorganisms cannot find their way into the cavity 40. Otherwise, sterility would not be preserved. The example passages disclosed in this description provide the necessary two-fold function of allowing gas flow while simultaneously preventing microorganism entry. The needle sheath 24 can be formed from rubber, thermoplastic elastomers, or plastics. The particular material used to form the needle sheath 24 is selected based on compatibility with the medicament 32 that is eventually loaded into the syringe assembly 20 and other design considerations. The foregoing description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and do come within the scope of this invention. Accordingly, the scope of legal protection afforded this invention can only be determined by studying the following claims.

Claims: A needle sheath for a syringe comprising: a body portion (38) formed of a material having a low gas permeability to a sterilizing gas, said body portion defining a cavity (40) with an opening at a first end (42) and being closed at a second end (44) opposite said first end; and a passage (58) in communication with said first end (42) of said cavity, said passage having a shape that permits gas from the external atmosphere to flow into said cavity (40) and simultaneously prevents entry of microorganisms from the external atmosphere into said cavity, characterized in that said passage (58) comprises a non-linear groove in the inner surface (52) of the needle shield. A needle sheath for a syringe as recited in claim 2, wherein said groove has a cross-sectional size that is between about 0,0065 and 0,0516 mm 2 (.00001 and .00008 square inches). A needle sheath for a syringe as recited in claim 1 or 2, wherein said cavity includes an inner surface and said passage comprises a spiral formed in said inner surface. A needle sheath for a syringe as recited in claim 1, wherein said needle sheath (24) comprises one of a rubber material, a thermoplastic elastomer or plastic material. A syringe assembly comprising a syringe body (22); a needle cannula (30, 46) supported by said syringe body; a needle sheath (24) according to one of claims 1-5.

Inventors: GYURE SANDOR, ODELL ROBERT B, GYURE, SANDOR, ODELL, ROBERT B.
Applicants: BECTON DICKINSON CO, BECTON DICKINSON AND COMPANY
Application year: 1999
Main classification: A61M5
IPC codes: A61M5