Patent Publication Number: US-11641921-B1

Title: Dermal spray apparatus with disposable cartridge and method

Description:
FIELD OF THE INVENTION 
     This application relates to dermal spray devices that utilize disposable cartridges, the disposable cartridges containing fluid that is dispensed by the spray devices. 
     BACKGROUND OF THE INVENTION 
     Skin care is very important. Many are turning to plant based and natural remedies. Certain plant-derived constituents can protect skin from deleterious effects, carcinogens, and a variety of chemical interactions. This concept has much scientific backing. 
     Human skin includes the epidermis, dermis and subcutis. The epidermis includes the stratum corneum and an underlying pigment layer. The stratum corneum is the outer layer of skin that protects the body. It is composed primarily of layers of dead, flattened keratinocytes surrounded by a phospholipid matrix. This acts in a similar as brick and mortar wall and functions to provide barrier to a microbial parasites as well as environmental toxins. The stratum corneum also presents a significant barrier to the delivery of transdermal drugs, vitamins, minerals, nutraceuticals and cosmeceuticals. 
     There are two major transdermal pathways. One is the intercellular route, which includes the movement of topically applied products around the cells of the stratum corneum via a phospholipid matrix that surrounds the cells. This is a tortuous path, so there are challenges to optimizing the speed of delivery and efficacy of skin-improving substances. 
     The other pathway is the transcellular pathway, which includes skin-improving substances directly passing through the cytoplasm of the dead keratinocytes of the stratum corneum, as well as the phospholipids matrix surrounding the cells. This is a more direct pathway yet there are still many challenges. 
     In either case, spraying a formulated fluid at a controlled pressure, spray pattern, and flow rate way can enhance penetration through the stratum corneum, so that the beneficial substances in the formulated fluid can penetrate and nourish the dermis, and in some cases enter the vasculature directly through the skin. 
     In the case of cosmetics and medical skincare products, the spray pattern, flow rate and other delivery aspects can be adjusted to optimize delivery to a desired region of the skin. For example, certain cosmetics can be delivered to provide a uniform coating on top of the stratum corneum, certain pigmentation products may be designed to reach the pigment layer under the stratum corneum. 
     U.S. Pat. No. 10,252,283 to Gouchtchina and Gallar includes a dermal spray apparatus that allows a system and method for dermal spraying includes a portable, hand-held skin care device with disposable formulation capsules that spray a formulation onto the skin. The device is set to maximize absorption and provide professional and uniform quality of application. The device receives, clamps and identifies the formulation capsules and its contents. Control circuitry regulates the formulation delivery. This assures the quantity, proportion, speed and timing of the application of the cosmetic formulation, including self-cleaning cycle operation and single button control logic. The capsule enables convenience and sterility from use of disposable capsules at home. Preferably the capsules contain a cosmetic formulation. 
     There remains a need to improve cartridge systems for use in dermal spray devices and system. 
     SUMMARY OF THE INVENTION 
     In one aspect, the invention involves a cartridge for dispensing a liquid comprising: a nozzle assembly, a liquid reservoir, and a cap attached to the liquid reservoir, wherein the cap is adapted to engage the nozzle assembly; the nozzle assembly comprising an inner body and an outer body, the inner body and outer body forming a first fluid passage therebetween, the first fluid passage adapted to deliver compressed air, the inner body comprising a second fluid passage in its interior, the second fluid passage adapted to deliver liquid from the liquid reservoir; wherein the nozzle assembly is moveable in a controlled direction relative to the cap; and the inner body of the nozzle assembly is adapted to pierce the liquid reservoir when the nozzle assembly is moved in the direction of the liquid reservoir to allow liquid from the liquid reservoir to flow into the second fluid passage. 
     The nozzle assembly of the cartridge may comprises a guide adapted to translate lateral motion into vertical motion for engaging the nozzle assembly with the liquid reservoir. The fluid reservoir of the cartridge may be a pouch and the cap seals the pouch. The cap may include recesses for capturing air bubbles in the fluid of the reservoir. The nozzle assembly may further comprise at least one guide flange adapted to guide movement of the nozzle assembly in a back and forth direction relative to the liquid reservoir. The guide flange, if used, is designed to guide movement of the nozzle assembly in a rotational direction relative to the liquid reservoir in addition to a back and forth direction relative to the liquid reservoir. The nozzle assembly may have a conical or rectangular shape, among others. In one aspect, the nozzle assembly has a rectangular shape and the first fluid path and second fluid path exit the nozzle assembly at about a 45 degree angle relative to the horizontal. In another aspect, the nozzle assembly comprises a first guide member and a second guide member, wherein the first guide member and second guide member are adapted to engage with the cap in a manner that permits the nozzle assembly to move in a controlled direction relative to the cap. 
     In another aspect, the invention relates to a dermal spray device for dispensing liquid from a cartridge, the dermal spray device comprising: a housing; a source of a compressed air; and a cartridge receiver, wherein the cartridge receiver is adapted to accept a cartridge including both a liquid container and a spray nozzle, wherein the dermal spray device dispenses liquid from the cartridge by supplying the compressed air to the nozzle of the cartridge, the nozzle assembly drawing liquid from the liquid container and mixing it with the compressed air. One or more of the features above related to the cartridge may be present in a cartridge that works with this dermal spray device. 
     The device may further comprise a sliding cover adapted to position the cartridge in the dermal spray device wherein the cartridge so positioned is capable of dispensing liquid through the spray nozzle. The sliding cover, if used, is adapted to engage with spray nozzle of the cartridge and activate the spray nozzle when the sliding cover is moved into an engaged position. The dermal spray device may include a base with an inductive charging element that allows for charging of a battery of the dermal spray device. The device may further comprise a compressor for supplying compressed air to the spray nozzle. The cartridge receiver may comprise a fluid conduit in fluid communication with the compressor, wherein the fluid conduit is adapted to engage with the cartridge. 
     In another aspect, the invention relates to a method of spraying a liquid onto a user&#39;s skin using the dermal spray device comprising inserting the cartridge including both a liquid container and a spray nozzle in the dermal spray device; and directing a spray of the liquid from the liquid container through the spray nozzle toward the user&#39;s skin. The method may also include a step of closing a cover adapted to position the cartridge in the dermal spray device wherein the cartridge so positioned is capable of dispensing liquid through the spray nozzle. In one aspect, closing the cover may engage the spray nozzle by moving it toward the liquid container of the cartridge allowing liquid to flow into the spray nozzle. 
     In another aspect the invention involves a dermal spray system for dispensing liquid from a cartridge, the dermal spray device comprising: a housing; a source of a compressed air; a cartridge receiver, wherein the cartridge receiver is adapted to accept a cartridge; wherein the dermal spray device dispenses liquid from the cartridge by supplying the compressed air to the nozzle of the cartridge, the nozzle drawing liquid from the liquid container and mixing it with the compressed air; and wherein the cartridge comprises: a nozzle assembly, a liquid reservoir, and a cap attached to the liquid reservoir, wherein the cap is adapted to engage the nozzle assembly; the nozzle assembly comprising an inner body and an outer body, the inner body and outer body forming a first fluid passage therebetween, the first fluid passage adapted to deliver compressed air, the inner body comprising a second fluid passage in its interior, the second fluid passage adapted to deliver liquid from the liquid reservoir; wherein the nozzle assembly is moveable in a controlled direction relative to the cap; and the inner body of the nozzle assembly is adapted to pierce the liquid reservoir when the nozzle assembly is moved in the direction of the liquid reservoir to allow liquid from the liquid reservoir to flow into the second fluid passage. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    shows a dermal spray apparatus. 
         FIG.  2 A  shows a dermal spray cartridge according to an embodiment of the invention. 
         FIG.  2 B  shows a first side view of a pouch-type reservoir which forms part of a cartridge according to an embodiment of the invention. 
         FIG.  2 C  shows a second side view of a pouch-type reservoir which forms part of a cartridge according to an embodiment of the invention. 
         FIG.  2 D  shows a bottom view of a pouch-type reservoir which forms part of a cartridge according to an embodiment of the invention. 
         FIG.  2 E  shows a top view of a pouch-type reservoir which forms part of a cartridge according to an embodiment of the invention. 
         FIG.  2 F  shows a side view of a nozzle assembly according to an aspect of the invention. 
         FIG.  2 G  shows a perspective view of a nozzle assembly according to an aspect of the invention. 
         FIG.  3    shows a diagram of an exemplary process for making a pouch-type reservoir to be used with a cartridge according to an aspect of the invention. 
         FIG.  4 A  shows a nozzle having a 45 degree bend according to an aspect of the invention. 
         FIG.  4 B  shows a dermal spray cartridge having the nozzle of  FIG.  4 A  according to an embodiment of the invention. 
         FIG.  4 C  shows a perspective view of an exemplary dermal spray device incorporating the nozzle of  FIG.  4 A . 
         FIG.  4 D  shows a perspective view of an exemplary dermal spray device incorporating the nozzle of  FIG.  4 A . 
         FIG.  4 E  shows a side view of an exemplary dermal spray device incorporating the nozzle of  FIG.  4 A  with a cartridge door in an open position. 
         FIG.  4 F  shows a perspective view of an exemplary dermal spray device incorporating the nozzle of  FIG.  4 A  with a cartridge door in an open position. 
         FIG.  5 A  shows a dermal spray cartridge having the nozzle with a 45 degree exit angle according to an embodiment of the invention. 
         FIG.  5 B  shows a side view of an exemplary dermal spray device incorporating the nozzle of  FIG.  5 A  where the cartridge is closed within the device. 
         FIG.  5 C  shows a close up view of the nozzle body of the dermal spray cartridge of  FIG.  5 A . 
         FIG.  5 D  shows a cross-sectional view of the dermal spray device of  FIG.  5 A . 
         FIG.  6 A  shows a schematic view of a dermal spray device according to an aspect of the invention. 
         FIG.  6 B  shows a perspective view of the dermal spray device shown schematically in  FIG.  6 A . 
         FIG.  7 A  shows a schematic view of a dermal spray device according to an aspect of the invention. 
         FIG.  7 B  shows a perspective view of the dermal spray device shown schematically in  FIG.  7 A . 
         FIG.  8 A  shows a schematic view of a dermal spray device according to an aspect of the invention. 
         FIG.  8 B  shows a perspective view of the dermal spray device shown schematically in  FIG.  8 A . 
         FIG.  9 A  shows a schematic view of a dermal spray device according to an aspect of the invention. 
         FIG.  9 B  shows a perspective view of the dermal spray device shown schematically in  FIG.  9 A . 
         FIG.  10 A  shows a schematic view of a dermal spray device according to an aspect of the invention. 
         FIG.  10 B  shows a perspective view of the dermal spray device shown schematically in  FIG.  10 A . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention involves improvements to dermal spray systems that provide unique advantages for dermal and topical application. 
       FIG.  1    shows a dermal spray device  32  described in U.S. patent application Ser. No. 17/224,824, entitled “DERMAL SPRAY DEVICE AND METHOD”, filed Apr. 7, 2021. Hidden lines are used to reveal the internal components of the device  32 . The device includes a spray head  36 , including a nozzle  38 , and a body  34 . The body  34  includes a pressure source  52  such as an air compressor that can be used to propel a dermal composition supplied in a container  60  when the user presses a button  40  mounted on the body  34 . 
     The device  32  includes a battery  50 , control circuitry  54 , a data storage unit  76 , a data transmission unit  77  that is configured to permit data transmission of device data  79  to and from a mobile device  78 , such as a smartphone. The mobile device  78  can communicate with a server  81  using a secure internet connection  82 , to communicate user device data between the server and mobile device. The mobile device  78  is configured (a) to combine the device data with secure user data into user device data, and (b) to display the user device data to the user. The mobile device may send anonymized user device data to the server, which can be used to build a database that can be utilized in several machine learning processes of aid in the selection of serums. The device also includes an accelerometer  80  and an encoding identification unit  86 . 
     The capsule  60  is inserted into a compartment  46  the dermal spray device  32 . The compartment  60  includes a door  44  and a capsule nest  58  for holding the capsule in place. A needle  62  penetrates the capsule  60  and allows the contents of the capsule to be drawn toward the nozzle  38 . Air from a pressure chamber  64  is routed to the nozzle through a pressurized conduit  56 . Further details regarding the dermal spray device and its use may be found in U.S. patent application Ser. No. 17/224,824, incorporated above. The inventors have perceived a need to improve the spray device  32  in several respects. 
     The present inventors have perceived a need to provide a cartridge system for a dermal spray device that has one or more of the following features. In one aspect, the cartridge is capable of being stored and easily pierced at the time of use. In another aspect, the cartridge may be easily inserted into a spray device and activated after it is positioned within the spray device. In another aspect, the cartridge has a disposable nozzle that eliminates or reduces the need for cleaning of the dermal spray device. In another aspect, the cartridge is capable of being filled and dispensed without air pockets interfering with the consistent dispensing of contents. 
     A cartridge is provided for dispensing a liquid from a dermal spray device, wherein the cartridges includes a nozzle assembly, a fluid reservoir, and a cap attached to the fluid reservoir that is adapted to engage the nozzle assembly. The cartridge includes a disposable nozzle assembly that is attached to the cartridge. When the cartridge is inserted into the device the nozzle assembly is moved into a position that allows an inner body, e.g., a needle, to pierce a reservoir and allow liquid to enter the nozzle assembly. 
     A cartridge  200  according to one aspect of the invention is shown in  FIGS.  2 A-G . The cartridge  200  includes a reservoir body  202 , a reservoir cap  201  and to which a nozzle assembly is attached. The nozzle assembly includes an outer nozzle body  208  and an inner nozzle body  220 . The inner nozzle body  220  is rigidly attached to the outer nozzle body  208 . The inner nozzle body  220  preferably has a tapered outer surface  221 , and the outer nozzle body  208  has a tapered inner surface  225 . The space between the outer surface  221  of the inner nozzle body  220  and the inner surface  225  of the outer nozzle body  208  form a fluid passage of the nozzle assembly for delivering compressed air. Compressed air is provided into the passage through a fluid attachment point  224 . The inner nozzle body  220  has a first end  226  and a second end  223 , the second end being adapted to pierce a seal in the reservoir body  202  and provide liquid material from the reservoir body (e.g., a liquid-containing pouch) to the spray nozzle. 
       FIGS.  2 B-E  show aspects of the reservoir body  202  of the cartridge  200 . This includes a reservoir cap  201  and flat edges  205 . Also provided is guide post  203  adapted to receive the nozzle assembly shown in  FIG.  2 A . The reservoir cap  201  includes a reservoir cap recess  207  as shown in  FIG.  2 F . As shown in  FIGS.  2 C and  2 E , the guide post  203  includes a guide slot  204  that is adapted to define a controlled sliding movement of the inner nozzle body  220  through the opening  206  relative to the reservoir body  202 . This movement is used to allow the second end  223  of the inner nozzle  220  to pierce the reservoir body  202 . If desired, the guide slot may include curvature so that the nozzle assembly rotates by for example 90 degrees while it is being engaged. 
       FIG.  2 F  shows the details of the nozzle assembly when it is slid into the engaged position relative to reservoir body. The fluid attachment point  224  includes a passage  227  linking it to the recess between the outer nozzle body  208  and the inner nozzle body  220 . Portions of the guide post  203  are shown projecting above the guide flanges  222 . The inner nozzle body  220  and outer nozzle body  208  can be made by injection molding of rigid plastic materials. It is important for the materials to be strong enough to maintain precise tolerances of the fluid passage, and allow for movement of the inner nozzle body  220  and outer nozzle body  208  relative to the fluid reservoir  201 . 
       FIG.  2 G  shows a perspective view of the nozzle assembly. It should be noted that the guide flanges  222  may be seated in the outer nozzle body  208  by insertion into the nozzle body recesses  228 . The seal  229  is shown in the reservoir cap  201  in  FIG.  2 G . The seal  229  may be made of a material that can be readily pierced by the second end  223  of the inner nozzle body  220 . While the flange  222  and guide slot  204  are pictured in a form that is adapted for back and forth motion of the nozzle assembly, other configurations are possible. For example the guide flange may be provided in cylindrical form and the notch designed to permit both back and forth movement as well as twisting movement. In one instance, the nozzle assembly may be configured to rotate by a desired amount such as 45 degrees or 90 degrees such that the inner nozzle body pierces the seal  229  at the end of the motion, allowing the liquid contents of the fluid reservoir to move into the fluid passage within the inner nozzle body. 
     In one aspect, fluid reservoirs may be manufactured using a process as shown in  FIG.  3   . A bottom film  320  and top film  321  are fed from respective feeding spindles  310  through a series of rollers  312  into a mold for heat welding  313 . The mold  313  may include a lower mold foundation  314  and an actuator  311  which opens and closes the mold. A cutter including a bottom cutting element  315  and top cutting element  316  can be intermittently engaged to cut away finished pouches  322  of each fluid reservoir. While this method is advantageous for the rapid production of a larger number of reservoirs other techniques may be used to manufacture a fluid reservoir. In addition, it is possible to use different types or reservoirs with the cartridges of the present invention. 
     In one aspect, one or both of the bottom film  320  and top film  321  used to make the reservoir is a flexible plastic film that allows the reservoir to collapse as fluid is withdrawn from the reservoir. For example, the film may be a polyethylene terephthalate (PET) film having a thickness of between 40-50 microns. In one aspect, the film may include two or more layers of film that are adhered together. In this case, a radio frequency identification (RFID) tag or other information containing device may be positioned between separate layers of a multilayer film that makes up the reservoir. The RFID tag may include information about the dermal serum or material contained within the cartridge that may be read by the dermal spray device upon insertion of the cartridge into the device. In another aspect, the cartridge may contain a barcode, NFC, QR code or other information containing mechanism that is read by the dermal spray device. 
       FIGS.  4 A-F  show a cartridge and system according to another aspect of the invention, wherein the nozzle assembly has a 45 degree bend. The angle of the bend may range from 0 degrees to 90 degrees, and can depend on the geometry of the dermal spray device. The cartridge  400  includes a reservoir cap  401 , reservoir body  402 , and nozzle body  408 . The reservoir cap  401  has a guide post  403  that includes guide slots  404  on either side to allow for up and down movement of the nozzle assembly relative to the reservoir body  402 . The reservoir body may have flat edges  405  around its periphery. 
     The nozzle assembly includes an inner nozzle body  420  having a tapered outer surface  421  and a guide flange  422 . The inner nozzle body  420  has a first end  426  and a second end  423 . The outer nozzle body  408  includes a tapered inner surface  425  and the inner nozzle body  420  has a tapered outer surface  421 . These surfaces form an air passage to the nozzle through fluid passage  430 . Fluid moves from the reservoir through the fluid passage  427  through the inner nozzle body  420 . The fluid passage includes a bend  431 . The bend  431  is shown having an angle but may also be smooth.  FIG.  4 B  shows a cartridge including the nozzle shown in  FIG.  4 A . The cartridge includes a nozzle body  408 , which is attached to a fluid reservoir  402  having flat sides  405  by way of a guide post  403  with guide slot  404  being provided on a reservoir cap  401 . 
       FIG.  4 C-F  shows how a the nozzle body  408  assembled on a dermal spray device. The dermal spray device has a handle body  440  and a handle base  442 . The device includes a door  443  for insertion of a cartridge. The spray device includes a recess  446  that provides clearance of the nozzle body  408  when the cartridge is inserted into the spray device. The spray device may include a button  444  for activating the sprayer. 
       FIG.  5 A  shows a cartridge having a nozzle body  508  that includes a nozzle outlet  526  that has a 45 degree angle  5  relative to the fluid reservoir  502 . The fluid reservoir may include a flat edge  505  as described above. The nozzle body  508  includes a sloped guide  591  on both sides of the nozzle body. When the device cap  543  is slid laterally into position as shown in  FIG.  5 B , a cam or wing (not shown) on the underside of the device cap  543  engages with the sloped guide  591  and exerts a downward pressure on the outer nozzle body  508  and nozzle assembly. The downward force of the nozzle assembly allows the second end of the inner nozzle body to pierce the seal of the reservoir body  502  allowing the liquid from the reservoir body to be drawn into the fluid passage within the inner nozzle body. The nozzle body may include a guide post  503  that includes guide flanges  504  on either side to allow for up and down movement of the nozzle assembly. 
     The cartridge including the reservoir  502  and nozzle body  508  is inserted into a slot  562  in the handle body  540  of the dermal spray device. A button  544  is provided for activating the device. A connection  590  allows pressurized gas (e.g., compressed air) to flow into a fluid passage in the bottom of the nozzle body  508  that is directed to the tapered gap between the inner nozzle body and outer nozzle body. The fluid is typically pressurized air that mixes with fluid from the fluid reservoir  502  at or near the nozzle outlet  526 . 
       FIG.  5 D  shows a cross section view that includes many of the elements discussed above. In addition to those elements, a battery  561  is shown in the handle assembly, and an induction coil  566  is shown near the base of the handle body. The induction coil cooperates with electric power transmitted through the base  542  to conveniently charge the device. An air compressor  564  is provided to supply compressed air to the nozzle body  508  through conduit  571 . A PCB  563  is provided within the handle to provide control and other functionality to the dermal spray device. 
       FIG.  6 A-B  show a dermal spray device where a cartridge is inserted and positioned into place by a vertically sliding door  643 . The device includes a nozzle body  608  connected to a reservoir  601 , a compressor  664  and a fluid conduit  671  connecting the compressor  664  to the nozzle body  608 . The device includes a button  644  for activating the spray, a printed circuit board  663  and a battery  661 . A perspective view of the dermal spray device is shown in  FIG.  6 B  showing the motion of the door  643  that encloses the cartridge within the handle body  640  of the dermal spray device. 
       FIG.  7 A-B  show another dermal spray device where a cartridge is inserted and positioned into place by a vertically sliding door  743 . The device includes a nozzle body  708  connected to a reservoir  701 , a compressor  764  and a fluid conduit  771  connecting the compressor  764  to the nozzle body  708 . The device includes a printed circuit board  763  and a battery  761 . A perspective view of the dermal spray device is shown in  FIG.  7 B  showing the motion of the door  743  that encloses the cartridge within the handle body  740  of the dermal spray device. 
       FIG.  8 A-B  show a dermal spray device where a cartridge is inserted and positioned by pushing up into a receiver and then enclosed with a cartridge tray  862 . The device includes a nozzle body  808  connected to a reservoir  801 , and a compressor  864 . The device includes a printed circuit board  863  and a battery  861 . A side view of the dermal spray device is shown in  FIG.  8 B  showing the motion of the cartridge tray  862  that encloses the cartridge within the handle body  840  of the dermal spray device. 
       FIG.  9 A-B  show a dermal spray device where a cartridge is inserted and positioned laterally into the device and closed by a door  943 . The device includes a nozzle body  908  connected to a reservoir  901 , a compressor  964  and a fluid conduit  971  connecting the compressor  964  to the nozzle body  908 . The device includes a printed circuit board  963  and a battery  961 . A perspective view of the dermal spray device is shown in  FIG.  9 B  showing the motion of the door  943  that encloses the cartridge within the handle body  940  of the dermal spray device. The door  943  includes an spray opening  979  that allows spray from the nozzle to pass through. 
       FIG.  10 A-B  show a dermal spray device where a cartridge is inserted and positioned laterally into the device and closed by a vertically sliding door  1043 . The device includes a nozzle body  1008  connected to a reservoir  1001 , a compressor  1064  and a fluid conduit connecting the compressor  1064  to the nozzle body  1008 . The device includes a printed circuit board  1063  and a battery  1061 . A side view of the dermal spray device is shown in  FIG.  10 B  showing the motion of the door  1043  that encloses the cartridge within the handle body  1040  of the dermal spray device. The door  1043  includes an spray opening  1079  that allows spray from the nozzle to pass through. 
     Other embodiments and uses of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. All references cited herein, including all U.S. and foreign patents and patent applications, are specifically and entirely hereby incorporated herein by reference. It is intended that the specification and examples be considered exemplary only, with the true scope and spirit of the invention indicated by the following claims.