Housing and Drug Delivery Device herewith and Method for Producing a Housing

Abstract

The present disclosure is generally directed to a drug delivery device for selecting and dispensing a number of user variable doses of a medicament and to a housing for such a device. The housing comprises a twin-shot injection moulded casing with at least one window and at least one interface for engaging a further component part of the drug delivery device. The casing comprises a first shell injection-moulded in a translucent material and a second shell injection-moulded in an opaque material. Further, the disclosure is directed to a method for producing such a housing.

Claims

1. A housing for a drug delivery device, the housing comprising: a twin-shot injection-molded casing with at least one window and at least one interface for engaging a further component part of the drug delivery device, wherein the casing comprises a first shell injection-molded translucent material and a second shell injection-molded in an opaque material.

2. The housing according to claim 1, wherein the first shell and the second shell are permanently joined with each other.

3. The housing according to claim 1, wherein the second shell at least partly surrounds the first shell.

4. The housing according to claim 1, wherein the first shell comprises the at least one window and the at least one interface for engaging a further component part of the drug delivery device.

5. The housing according to claim 1, wherein the second shell comprises the at least one interface for engaging a further component part of the drug delivery device.

6. The housing according to claim 5, wherein the at least one interface for engaging a further component part of the drug delivery device comprises a thread, a rib, a groove, a bead, a tooth, a ramp and/or an arm.

7. The housing according to a claim 1, wherein the first shell comprises a tubular portion with an axially extending protrusion at a distal end of the tubular portion and a series of crown teeth at an opposite, proximal end of the tubular portion.

8. The housing according to claim 7, wherein the tubular portion comprises an oblong elevation extending in an axial direction, and the oblong elevation forms the at least one window.

9. The housing according to claim 7, wherein the first shell further comprises an insert located at or near the distal end of the tubular portion.

10. The housing according to claim 1, wherein the second shell comprises ramps and at least one guiding rib or groove.

11. A drug delivery device for selecting and dispensing a number of user variable doses of a medicament, the device comprising: a housing comprising a twin-shot injection-molded casing with at least one window and at least one interface for engaging a further component part of the drug delivery device, wherein the casing comprises a first shell injection-molded in a translucent material and a second shell injection-molded in an opaque material; and a cartridge holder and a cartridge containing a medicament disposed in the housing.

12. The drug delivery device according to claim 11, wherein the housing is coupled via the at least one interface to at least one of: the cartridge holder, a piston rod, a drive member, a nut, a dose setting element, a button, a dose setting grip, a drive spring, a gauge element, a clutch, and a clutch spring.

13. The drug delivery device according to claim 12, wherein the piston rod is in threaded engagement with the housing, the drive member is axially displaceable relative to the housing and comprises teeth engaging with corresponding teeth of the housing depending on the relative axial position of the drive member to the housing, the dose setting element is clipped to the housing to allow relative rotational movement and to prevent relative axial movement, the button is axially displaceable relative to the housing and comprises teeth engaging with corresponding teeth of the housing depending on the relative axial position of the button to the housing, the dose setting grip is clipped to the housing to allow relative rotational movement and to prevent relative axial movement, one end of the drive spring is axially and/or rotationally constrained to the housing, the gauge element is rotationally constrained to the housing and axially displaceably guided in the housing, and/or one end of the clutch spring is axially and/or rotationally constrained to the housing.

14. A method for producing a housing for a drug delivery device, the method comprising: injection molding a first shell during a first shot with a translucent material; and injection molding a second shell during a second shot with an opaque material, wherein the first and second shells form at least one window and at least one interface for engaging a further component part of the drug delivery device.

15. The method according to claim 14, wherein the at least one window is formed in an area in which the opaque material does not cover the translucent material.

16. The drug delivery device of claim 11, wherein the medicament comprises a pharmaceutically active compound.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0095] Non-limiting, exemplary embodiments of the disclosure will now be described with reference to the accompanying drawings, in which:

[0096] FIG. 1 shows a top view of a drug delivery device according to a first embodiment of the present disclosure;

[0097] FIG. 2 shows an exploded view of the components of the device of FIG. 1;

[0098] FIG. 3 shows a top view of a first shell of the housing of the device of FIG. 1;

[0099] FIG. 4 shows a top view of a second shell of the housing of the device of FIG. 1;

[0100] FIG. 5 shows a sectional view of the housing of the device of FIG. 1;

[0101] FIG. 6 shows a detail of FIG. 5;

[0102] FIG. 7 shows a detail of the housing of FIG. 1 with a button; and

[0103] FIG. 8 shows an alternative to the detail of FIG. 7.

DETAILED DESCRIPTION

[0104] FIG. 1 shows a drug delivery device in the form of an injection pen. The device has a distal end (left end in FIG. 1) and a proximal end (right end in FIG. 1). The component parts of the drug delivery device are shown in FIG. 2. The drug delivery device comprises a body or housing 10, a cartridge holder 20, a lead screw (piston rod) 30, a drive sleeve 40, a nut 50, a dose indicator (number sleeve) 60, a button 70, a dial grip or dose selector 80, a torsion spring 90, a cartridge 100, a gauge element 110, a clutch plate 120, a clutch spring 130 and a bearing 140. A needle arrangement (not shown) with a needle hub and a needle cover may be provided as additional components, which can be exchanged as explained above. All components are located concentrically about a common principal axis of the mechanism.

[0105] The housing 10 or body is a generally tubular casing element having a proximal end with an enlarged diameter. The housing 10 provides location for the liquid medication cartridge 100 and cartridge holder 20. As shown in FIGS. 3 and 4, the housing comprises a casing consisting of a first shell 10a and a second shell 10b which are injection moulded using a twin-shot injection technique. In this embodiment, a first window 11a, a second window (or lens) 11b and a third window 11c (FIG. 6) are incorporated into the housing body by twin-shot molding. The windows 11a, 11b, 11c are molded during a first shot in a translucent (and preferably transparent) material, and the outer cover or second shell 10b of the housing is molded during a second shot in an opaque material.

[0106] Openings in the second shell 10b allow the user to view internal parts of the injector through the first shell 10a. For examples a part that may be viewed through at least one of these windows 11a, 11b, 11c is the number sleeve 60 which may be printed with dose numbers, allowing the user to determine the size of the selected dose. Further, at least one of these windows 11a, 11b, 11c may be used to view the gauge element 110. The gauge element 110 is used to create a sliding scale or progress bar. As a dose is set by the user, the gauge element 110 translates axially, the distance moved proportional to the magnitude of the dose set. This feature gives clear feedback to the user regarding the approximate size of the dose set. The gauge element 110 also provides feedback to the user during dispense regarding dispense progress without the need to read the dose number itself. These windows 11a, 11b, 11c reduce dust ingress and prevent the user from touching moving parts may be separate components. A first shot of translucent material forms the internal features and the windows (FIG. 3), and then a second shot of opaque material forms the outer cover of the housing 10 (FIG. 4). In this way, a window is formed in any areas where the second shot (second shell 10b) does not cover the first shot (first shell 10a).

[0107] An e.g. flange-like insert (interface) 12 is shown in FIG. 6 as a part of the first shell 10a. This insert is moulded together with the first shell 10a in the translucent material. As an alternative, the insert or parts thereof may be formed with the second shell 10b in the opaque material.

[0108] Internal features (interfaces) may be molded as part of the first shell 10a, or as part of the second shell 10b in any areas where the first shell 10a extends through to the inside surfaces of the housing 10. In the exemplary embodiment shown in the Figures, the distal end of the first shell 10a is provided with an axially extending strip 13 partly overlapping cartridge holder 20. This strip forms the first window 11a. The housing 10 further comprises a fixture for engaging number sleeve 60. This fixture has the form of an inner bead 14 (FIG. 6) which is located at a distal region of housing 10 on its inner surface. Further, angled crown teeth 15 are molded at the proximal end of the first shell 10a. The first shell 10a has a feature on its external surface, e.g. a circumferential groove 16, to axially retain the dose selector 80.

[0109] The insert 12 of the first shell 10a may have various interfaces. For example, the tubular inner body of insert 12 comprises an inner thread 17 engaging the piston rod 30. In addition the radial space between the tubular inner body and the outer portion of the first shell 10a may provide a bearing area receiving the drive spring 90 and/or clutch spring 130. Further, teeth 18 are provided on the insert 12 of the first shell 10a. Teeth 18 interact with drive member 40 to rotationally couple and de-couple the drive member and the housing 10.

[0110] The first shell 10a and/or the second shell 10b has at least one internal, axially orientated slot (hidden in FIG. 4) or the like for axially guiding the gauge element 110. Further, ramps 19 are provided on the second shell 10b for snap attachment of a cap (not shown).

[0111] The Figures depict the housing 10 as a single housing component. However, the housing 10 could comprise two or more housing components which may be permanently attached to each other during assembly of the device.

[0112] The cartridge holder 20 is located at the distal side of housing 10 and permanently attached thereto. The cartridge holder may be a transparent or translucent component which is tubular to receive cartridge 100. The distal end of cartridge holder 20 may be provided with means for attaching a needle arrangement. A removable cap (not shown) may be provided to fit over the cartridge holder 20 and may be retained via clip features on the housing 10.

[0113] The piston rod 30 is rotationally constrained to the drive sleeve 40 via a splined interface. When rotated, the piston rod 30 is forced to move axially relative to the drive sleeve 40, through its threaded interface with the insert 12 of housing 10. The lead screw 30 is an elongate member with an outer thread engaging the corresponding thread of the insert 12 of housing 10. The interface comprises at least one longitudinal groove or track and a corresponding protrusion or spline of the driver 40. At its distal end, the lead screw 30 is provided with an interface for clip attachment of the bearing 140.

[0114] The drive sleeve 40 is a hollow member surrounding the lead screw 30 and arranged within number sleeve 60. It extends from an interface with the clutch plate 120 to the contact with the clutch spring 130. The drive sleeve 40 is axially movable relative to the housing 10, the piston rod 30 and the number sleeve 60 in the distal direction against the bias of clutch spring 130 and in the opposite proximal direction under the bias of clutch spring 130.

[0115] A splined tooth interface 18 with the housing 10 prevents rotation of the drive sleeve 40 during dose setting. This interface comprises a ring of radially extending outer teeth at the distal end of drive sleeve 40 and corresponding radially extending inner teeth of the housing component 10. When the button 70 is pressed, these drive sleeve 40 to housing 10 spline teeth are disengaged allowing the drive sleeve 40 to rotate relative to housing 10. A further splined tooth interface with the number sleeve 60 is not engaged during dialling, but engages when the button 70 is pressed, preventing relative rotation between the drive sleeve 40 and number sleeve 60 during dispense. In a preferred embodiment this interface comprises inwardly directed splines on a flange on the inner surface of the number sleeve 60 and a ring of radially extending outer splines of drive sleeve 40. These corresponding splines are located on the number sleeve 60 and the drive sleeve 40, respectively, such that axial movement of the drive sleeve 40 relative to the (axially fixed) number sleeve 60 engages or disengages the splines to rotationally couple or decouple the drive sleeve 40 and the number sleeve 60.

[0116] A further interface of the drive sleeve 40 comprises a ring of ratchet teeth located at the proximal end face of drive sleeve 40 and a ring of corresponding ratchet teeth on the clutch plate 120.

[0117] The driver 40 has a threaded section providing a helical track for the nut 50. In addition, a last dose abutment or stop is provided which may be the end of the thread track or preferably a rotational hard stop for interaction with a corresponding last dose stop of nut 50, thus limiting movement of the nut 50 on the driver thread. At least one longitudinal spline of the driver 40 engages a corresponding track of the lead screw 30.

[0118] The last dose nut 50 is located between the number sleeve 60 and the drive sleeve 40. It is rotationally constrained to the number sleeve 60, via a splined interface. It moves along a helical path relative to the drive sleeve 40, via a threaded interface, when relative rotation occurs between the number sleeve 60 and drive sleeve 40 which is during dialling only. As an alternative, the nut 50 may be splined to the driver 40 and threaded to the number sleeve 60. A last dose stop is provided on nut 50 engaging a stop of drive sleeve 40 when a dose is set corresponding to the remaining dispensable amount of medicament in the cartridge 100.

[0119] The dose indicator or number sleeve 60 is a tubular element. The number sleeve 60 is rotated during dose setting (via dose selector 80) and dose correction and during dose dispensing by torsion spring 90. Together with gauge element 110 the number sleeve 60 defines a zero position (at rest) and a maximum dose position. Thus, the number sleeve 60 may be seen as a dose setting member.

[0120] For manufacturing reasons, the number sleeve 60 of the embodiment shown in the Figures comprises a number sleeve lower 60a which is rigidly fixed to a number sleeve upper 60b during assembly to form the number sleeve 60. Number sleeve lower 60a and number sleeve upper 60b are separate components only to simplify number sleeve 60 mould tooling and assembly. As an alternative, the number sleeve 60 may be a unitary component. The number sleeve 60 is constrained to the housing 10 by snap engagement to allow rotation but not translation. The number sleeve 60 comprises an annular recess or groove near its distal end which engages a corresponding bead 14 on an inner surface of the housing 10. The number sleeve lower 60a is marked with a sequence of numbers, which are visible through the gauge element 110 and the openings 11a, 11b in the housing 10, to denote the dialled dose of medicament.

[0121] Further, the number sleeve lower 60a has a portion with an outer thread engaging the gauge element 110. End stops are provided at the opposite ends of thread to limit relative movement with respect to the gauge element 110.

[0122] Clutch features which have the form of a ring of splines are provided inwardly directed on number sleeve upper 60b for engagement with splines of the button 70 during dose setting and dose correction. A clicker arm is provided on the outer surface of number sleeve 60 which interacts with the drive sleeve 40 and the gauge member 110 for generating a feedback signal. In addition, the number sleeve lower 60a is rotationally constrained to the nut 50 and to the clutch plate 120 via a splined interface comprising at least one longitudinal spline. Further, number sleeve lower 60a comprises an interface for attachment of the torsion spring 90.

[0123] The button 70 which forms the proximal end of the device is permanently splined to the dose selector 80. A central stem extends distally from the proximal actuation face of the button 70. The stem is provided with a flange carrying the splines for engagement with splines of the number sleeve upper 60b. Thus, it is also splined via splines to the number sleeve upper 60b when the button 70 is not pressed, but this spline interface is disconnected when the button 70 is pressed. The button 70 has a discontinuous annular skirt with splines. When the button 70 is pressed, splines on the button 70 engage with splines on the housing 10, preventing rotation of the button 70 (and hence the dose selector 80) during dispense. These splines disengage when the button 70 is released, allowing a dose to be dialled. Further, a ring of ratchet teeth is provided on the inner side of button flange for interaction with clutch plate 120.

[0124] The dose selector 80 is axially constrained to the housing 10. It is rotationally constrained, via the splined interface, to the button 70. This splined interface which includes grooves interacting with spline features formed by the annular skirt of button 70 remains engaged irrespective of the dose button 70 axial positions. The dose selector 80 or dose dial grip is a sleeve-like component with a serrated outer skirt.

[0125] The torsion spring 90 is attached at its distal end to the housing 10 and at the other end to the number sleeve 60. The torsion spring 90 is located inside the number sleeve 60 and surrounds a distal portion of the drive sleeve 40. The torsion spring 90 is pre-wound upon assembly, such that it applies a torque to the number sleeve 60 when the mechanism is at zero units dialled.

[0126] The action of rotating the dose selector 80, to set a dose, rotates the number sleeve 60 relative to the housing 10, and charges the torsion spring 90 further.

[0127] The cartridge 100 is received in cartridge holder 20. The cartridge 100 may be a glass ampoule having a moveable rubber bung at its proximal end. The distal end of cartridge 100 is provided with a pierceable rubber seal which is held in place by a crimped annular metal band. In the embodiment depicted in the Figures, the cartridge 100 is a standard 1.5 ml cartridge. The device is designed to be disposable in that the cartridge 100 cannot be replaced by the user or health care professional. However, a reusable variant of the device could be provided by making the cartridge holder 20 removable and allowing backwinding of the lead screw 30 and the resetting of nut 50.

[0128] The gauge element 110 is constrained to prevent rotation but allow translation relative to the housing 10 via a splined interface. The gauge element 110 has a helical feature on its inner surface which engages with the helical thread cut in the number sleeve 60 such that rotation of the number sleeve 60 causes axial translation of the gauge element 110. This helical feature on the gauge element 110 also creates stop abutments against the end of the helical cut in the number sleeve 60 to limit the minimum and maximum dose that can be set.

[0129] The gauge element 110 has a generally plate or band like component having a central aperture or window and two flanges extending on either side of the aperture. The flanges are preferably not transparent and thus shield or cover the number sleeve 60, whereas the aperture or window allows viewing a portion of the number sleeve lower 60a. Further, gauge element 110 has a cam and a recess interacting with the clicker arm of the number sleeve 60 at the end of dose dispensing.

[0130] The clutch plate 120 is a ring-like component. The clutch plate 120 is splined to the number sleeve 60 via splines. It is also coupled to the drive sleeve 40 via a ratchet interface. The ratchet provides a detented position between the number sleeve 60 and drive sleeve 40 corresponding to each dose unit, and engages different ramped tooth angles during clockwise and anti-clockwise relative rotation. A clicker arm is provided on the clutch plate 120 for interaction with ratchet features of the button 70.

[0131] The clutch spring 130 is a compression spring. The axial position of the drive sleeve 40, clutch plate 120 and button 70 is defined by the action of the clutch spring 130, which applies a force on the drive sleeve 40 in the proximal direction. This spring force is reacted via the drive sleeve 40, clutch plate 120, and button 70, and when at rest it is further reacted through the dose selector 80 to the housing 10. The spring force ensures that the ratchet interface between drive sleeve 40 and clutch plate 120 is always engaged. In the at rest position, it also ensures that the button splines are engaged with the number sleeve splines, and the drive sleeve teeth are engaged with teeth of the housing 10.

[0132] The bearing 140 is axially constrained to the piston rod 30 and acts on the bung within the liquid medicament cartridge. It is axially clipped to the lead screw 30, but free to rotate.

[0133] With the device in the at rest condition as shown in FIG. 1, the number sleeve 60 is positioned against its zero dose abutment with the gauge element 110 and the button 70 is not depressed. Dose marking 0 on the number sleeve 60 is visible through the window 11b of the housing 10 and gauge element 110, respectively.

[0134] The torsion spring 90, which has a number of pre-wound turns applied to it during assembly of the device, applies a torque to the number sleeve 60 and is prevented from rotating by the zero dose abutment.

[0135] The user selects a variable dose of liquid medicament by rotating the dose selector 80 clockwise, which generates an identical rotation in the number sleeve 60. Rotation of the number sleeve 60 causes charging of the torsion spring 90, increasing the energy stored within it. As the number sleeve 60 rotates, the gauge element 110 translates axially due to its threaded engagement thereby showing the value of the dialled dose. The gauge element 110 has flanges either side of the window area which cover the numbers printed on the number sleeve 60 adjacent to the dialled dose to ensure only the set dose number is made visible to the user.

[0136] A specific feature of this disclosure is the inclusion of a visual feedback feature in addition to the discrete dose number display typical on devices of this type. The distal end of the gauge element 110 creates a sliding scale through the small window 11a in the housing 10. As an alternative, the sliding scale could be formed using a separate component engaged with the number sleeve 60 on a different helical track.

[0137] As a dose is set by the user, the gauge element 110 translates axially, the distance moved proportional to the magnitude of the dose set. This feature gives clear feedback to the user regarding the approximate size of the dose set. The dispense speed of an auto-injector mechanism may be higher than for a manual injector device, so it may not be possible to read the numerical dose display during dispense. The gauge feature provides feedback to the user during dispense regarding dispense progress without the need to read the dose number itself. For example, the gauge display may be formed by an opaque element on the gauge element 110 revealing a contrasting coloured component underneath. Alternatively, the revealable element may be printed with coarse dose numbers or other indices to provide more precise resolution. In addition, the gauge display simulates a syringe action during dose set and dispense.

[0138] The drive sleeve 40 is prevented from rotating as the dose is set and the number sleeve 60 rotated, due to the engagement of its splined teeth with teeth of the housing 10. Relative rotation must therefore occur between the clutch plate 120 and drive sleeve 40 via the ratchet interface.

[0139] The user torque required to rotate the dose selector 80 is a sum of the torque required to wind up the torsion spring 90, and the torque required to overhaul the ratchet interface. The clutch spring 130 is designed to provide an axial force to the ratchet interface and to bias the clutch plate 120 onto the drive sleeve 40. This axial load acts to maintain the ratchet teeth engagement of the clutch plate 120 and drive sleeve 40. The torque required to overhaul the ratchet in the dose set direction is a function of the axial load applied by the clutch spring 130, the clockwise ramp angle of the ratchet teeth, the friction coefficient between the mating surfaces and the mean radius of the ratchet interface.

[0140] As the user rotates the dose selector 80 sufficiently to increment the mechanism by one increment, the number sleeve 60 rotates relative to the drive sleeve 40 by one ratchet tooth. At this point the ratchet teeth re-engage into the next detented position. An audible click is generated by the ratchet re-engagement, and tactile feedback is given by the change in torque input required.

[0141] Relative rotation of the number sleeve 60 and the drive sleeve 40 is allowed. This relative rotation also causes the last dose nut 50 to travel along its threaded path, towards its last dose abutment on the drive sleeve 40.

[0142] With no user torque applied to the dose selector 80, the number sleeve 60 is now prevented from rotating back under the torque applied by the torsion spring 90, solely by the ratchet interface between the clutch plate 120 and the drive sleeve 40. The torque necessary to overhaul the ratchet in the anti-clockwise direction is a function of the axial load applied by the clutch spring 130, the anti-clockwise ramp angle of the ratchet, the friction coefficient between the mating surfaces and the mean radius of the ratchet features. The torque necessary to overhaul the ratchet must be greater than the torque applied to the number sleeve 60 (and hence clutch plate 120) by the torsion spring 90. The ratchet ramp angle is therefore increased in the anti-clockwise direction to ensure this is the case whilst ensuring the dial-up torque is as low as possible.

[0143] The user may now choose to increase the selected dose by continuing to rotate the dose selector 80 in the clockwise direction. The process of overhauling the ratchet interface between the number sleeve 60 and drive sleeve 40 is repeated for each dose increment. Additional energy is stored within the torsion spring 90 for each dose increment and audible and tactile feedback is provided for each increment dialled by the re-engagement of the ratchet teeth. The torque required to rotate the dose selector 80 increases as the torque required to wind up the torsion spring 90 increases. The torque required to overhaul the ratchet in the anti-clockwise direction must therefore be greater than the torque applied to the number sleeve 60 by the torsion spring 90 when the maximum dose has been reached.

[0144] If the user continues to increase the selected dose until the maximum dose limit is reached, the number sleeve 60 engages with its maximum dose abutment on the maximum dose abutment of gauge element 110. This prevents further rotation of the number sleeve 60, clutch plate 120 and dose selector 80.

[0145] Depending on how many increments have already been delivered by the mechanism, during selection of a dose, the last dose nut 50 may contact its last dose abutment with stop face of the drive sleeve 40. The abutment prevents further relative rotation between the number sleeve 60 and the drive sleeve 40, and therefore limits the dose that can be selected. The position of the last dose nut 50 is determined by the total number of relative rotations between the number sleeve 60 and drive sleeve 40, which have occurred each time the user sets a dose.

[0146] With the mechanism in a state in which a dose has been selected, the user is able to deselect any number of increments from this dose. Deselecting a dose is achieved by the user rotating the dose selector 80 anti-clockwise. The torque applied to the dose selector 80 by the user is sufficient, when combined with the torque applied by the torsion spring 90, to overhaul the ratchet interface between the clutch plate 120 and drive sleeve 40 in the anti-clockwise direction. When the ratchet is overhauled, anti-clockwise rotation occurs in the number sleeve 60 (via the clutch plate 120), which returns the number sleeve 60 towards the zero dose position, and unwinds the torsion spring 90. The relative rotation between the number sleeve 60 and drive sleeve 40 causes the last dose nut 50 to return along its helical path, away from the last dose abutment.

[0147] With the mechanism in a state in which a dose has been selected, the user is able to activate the mechanism to commence delivery of a dose. Delivery of a dose is initiated by the user depressing the button 70 axially in the distal direction.

[0148] When the button 70 is depressed, splines between the button 70 and number sleeve 60 are disengaged, rotationally disconnecting the button 70 and dose selector 80 from the delivery mechanism, i.e. from number sleeve 60, gauge element 110 and torsion spring 90. Splines on the button 70 engage with splines on the housing 10, preventing rotation of the button 70 (and hence the dose selector 80) during dispense. As the button 70 is stationary during dispense, it can be used in the dispense clicker mechanism. A stop feature in the housing 10 limits axial travel of the button 70 and reacts any axial abuse loads applied by the user, reducing the risk of damaging internal components.

[0149] The clutch plate 120 and drive sleeve 40 travel axially with the button 70. This engages the splined tooth interface between the drive sleeve 40 and number sleeve 60, preventing relative rotation between the drive sleeve 40 and number sleeve 60 during dispense. The splined tooth interface between the drive sleeve 40 and the housing 10 disengages, so the drive sleeve 40 can now rotate and is driven by the torsion spring 90 via the number sleeve 60, and clutch plate 120.

[0150] Rotation of the drive sleeve 40 causes the piston rod 30 to rotate due to their splined engagement, and the piston rod 30 then advances due to its threaded engagement to the housing 10. The number sleeve 60 rotation also causes the gauge element 110 to traverse axially back to its zero position whereby the zero dose abutment stops the mechanism.

[0151] Tactile feedback during dose dispense is provided via the compliant cantilever clicker arm integrated into the clutch plate 120. This arm interfaces radially with ratchet features on the inner surface of the button 70, whereby the ratchet tooth spacing corresponds to the number sleeve 60 rotation required for a single increment dispense. During dispense, as the number sleeve 60 rotates and the button 70 is rotationally coupled to the housing 10, the ratchet features engage with the clicker arm to produce an audible click with each dose increment delivered.

[0152] Delivery of a dose continues via the mechanical interactions described above while the user continues to depress the button 70. If the user releases the button 70, the clutch spring 130 returns the drive sleeve 40 to its at rest position (together with the clutch plate 120 and button 70), engaging the splines between the drive sleeve 40 and housing 10, preventing further rotation and stopping dose delivery.

[0153] During delivery of a dose, the drive sleeve 40 and number sleeve 60 rotate together, so that no relative motion in the last dose nut 50 occurs. The last dose nut 50 therefore travels axially relative to the drive sleeve 40 during dialling only.

[0154] Once the delivery of a dose is stopped, by the number sleeve 60 returning to the zero dose abutment, the user may release the button 70, which will re-engage the spline teeth between the drive sleeve 40 and housing 10. The mechanism is now returned to the at rest condition.

[0155] At the end of dose dispensing, additional audible feedback is provided in the form of a click, distinct from the clicks provided during dispense, to inform the user that the device has returned to its zero position via the interaction of the clicker arm on the number sleeve 60 with the ramp on the drive sleeve 40 and the cam and the recess on the gauge element 110. This embodiment allows feedback to only be created at the end of dose delivery and not created if the device is dialled back to, or away from, the zero position.

[0156] FIGS. 7 and 8 show two alternatives of an interface between the housing 10, namely the first shell 10a of the housing, and the button 70 or trigger used to initiate dose dispensing. For example, angled crown teeth 15 are molded at the proximal end of the first shell 10a. When the button 70 is depressed, spline teeth on the button 70 engage with spline teeth 15 on the housing, preventing rotation of the button during dispense, and also preventing rotation of the dial grip 80, as this is splined to the button. The form of these teeth makes them easy to mold, as they extend through the thickness of the housing 10. It also pushes the button 70 out of engagement if dial grip 80 is turned when the button 70 is pressed.

[0157] During selection and deselection of a dose, a clutch interface between the drive sleeve 40 and clutch plate 120 is able to slip, allowing relative rotation between the two parts. The clutch plate 120 is rotationally constrained to the number sleeve 60, so the clutch allows the number sleeve and drive sleeve to rotate relative to one another. When the button 70 is fully pressed, the clutch spring 130 becomes more compressed, reducing the axial movement that is possible between the drive sleeve 40 and clutch plate 120, and so preventing slipping of the clutch interface. When the button 70 is only partially pressed, there is a risk that the clutch may slip. The number sleeve 60 would then rotate relative to the drive sleeve 40, driven by the torsion spring 90, and the user would not receive the whole of the selected dose. As mentioned above, this problem may be solved by splines between the number sleeve 60 and drive sleeve 40 that engage before dispense can start.

[0158] FIG. 8 shows an alternative solution in which each crown tooth 15 between the housing 10 and button 70 has one angled face and one flat face. When the button is partially pressed, the teeth 15 engage between the housing 10 and button 70. The flat sides of the teeth 15, in addition to splines between the button 60 and number sleeve 60, prevent rotation of the number sleeve 60 in the dispense direction. The splined tooth interface 18 between the drive sleeve 40 and the housing 10 remains engaged, so the drive sleeve 40 cannot rotate and there is no relative rotation between the drive sleeve 40 and the clutch plate 120. When the button 70 is pressed further, the splined tooth interface 18 between the drive sleeve 40 and the housing 10 disengages. As there is no torque on the drive sleeve 40, it does not rotate. The splines between the button 70 and number sleeve 60 then disengage, rotationally disconnecting the number sleeve 60 from the housing 10, so the drive sleeve 40 can rotate to deliver the dose. The number sleeve 60, clutch plate 120 and drive sleeve 40 rotate together, driven by the torsion spring 90.

REFERENCE NUMERALS

[0159] 10 housing (casing)

[0160] 10a first shell

[0161] 10b second shell

[0162] 11a-c window

[0163] 12 insert (interface)

[0164] 13 strip

[0165] 14 bead

[0166] 15 crown teeth

[0167] 16 groove

[0168] 17 thread

[0169] 18 teeth

[0170] 19 ramp

[0171] 20 cartridge holder

[0172] 30 piston rod (lead screw)

[0173] 40 drive sleeve

[0174] 50 nut

[0175] 60 dose setting element

[0176] 60a number sleeve lower

[0177] 60b number sleeve upper

[0178] 70 button

[0179] 80 dose selector

[0180] 90 torsion spring

[0181] 100 cartridge

[0182] 110 gauge element

[0183] 120 clutch spring

[0184] 130 clutch spring

[0185] 140 bearing