CROSS-REFERENCE TO RELATED APPLICATIO

|00O1] This application claims priority to United States Provisional Application Serial No. 62/347,91 1 , filed June 9, 2016 and United States Patent Application Serial No. 15/616,183, fifed un 7. 2017, each of which i s hereby incorporated by reference in its en ti rety,

BACKGROUND OF THE INVENTION

Field of the Disclosure

|O0O2] The present disclosure relates generally to an injector device and method for delivering a fluid into the body of a patient by ^' injection.

Description of the Related Art

10003] Various types of automatic injection devices have been developed to allow drug solutions and other liquid therapeutic preparations to be administered by untrained personnel or to b self-injected. Generally, these devices include a reservoir that is pre-filied with the liquid therapeutic preparation, and some type of automatic needle-injection mechanism that ca b triggered by the user. When the volume of fluid or drug to be administered is generally below a certain volume, such as I raL, an auto-injector is typically used, which typically has an injection time of about 10 to 15 seconds. When the volume of fluid or drag to be administered is. above 1 raL, the injection time generally becomes longer resulting in difficulties for the patient to maintain contact between the device and the target area of the patient's skin. Further, as the volume of drug to be administered becomes larger, increasing the time period for injection ^' becomes desirable, The traditional method for a. drug to be injected slowly Into a patient is to initiate an IV and inject the drug into the patient's bod slowly. Such a procedure is typically performed in a hospital or outpatient setting.

0004] Certain devices allow for self-injection in a home setting and are capable of gradually injecting a liquid therapeutic preparation into the skin of a patient. In some cases, these devices re small enough (both in height and in overall ske) to: allow them to be "worn" by a patient while the liquid therapeutic preparation is being infused int the patient. These devices typically include a pump or other type of discharge mechanism to force the liquid therapeutic preparation to flow out of a reservoir and into the injection needle. Such devices also typically include a valve or flow control mechanism to cause the liquid therapeutic preparation to begin to flow at the proper time and a triggering mechanism to initiate the injection. SUMMARY OF THE INVENTION

f 0005 j in one aspect, a drug delivery system for injecting a medicament includes a container, configured to receive a medicament Including a stopper and a closure, where the stopper is configured to move within the container from a pre-use position to a post-use- osition. The system includes a dnve assembly configured to move the stopper between a first position and a second position, and. a spacer assembly engaged with the stopper of the container and configured to be engaged by the drive assembly. The spacer assembly includes a first spacer portion received within the stopper, a second spacer portion spaced from the first spacer portion a predetermined distance, a inner plunger, and a spacer shuttle received by the inner plunger. The inner plunger, the spacer shuttle, and the second portion are configured to move relative to the stopper, where movement of the second spacer portion is restricted by the spacer shuttle, movement of the spacer shuttle is restricted by the inner plunger, and movement of the inner plunger is restricted by the stopper.

The inner plunger may have a first position and a second position spaced axially from, the first position, with the spacer shuttle restricted from axial movement when the inner plunger Is in the first position and moveable relative to the stopper when the inner plunger is i the second position. The second spacer portion may be restricted from axial movement via the spacer shuttle when the inner plunger is in the first position and moveable relative t the stopper when the inne plunger is hi the second position. The stopper may have a closed first end and a second open end, _, with the closed first end of the stopper axially moveable relative to the container between a use posi tion where the closed first end of the stopper Is engaged with the inner plunger and an end-of-dose posi tion where the closed first end of the stopper is spaced from the inner plunger, and where inner plunger Is tree to .move from the first position to the second posiiion when the stopper is in the end-of-dose position. The stopper may he configured to move between the use position and the end-of-dose position based on engagement with a medicament received within the container,

fOOOTj The stopper may have a closed first end and second open end, wit the closed first end of the stopper is axially moveable relative to the container between a use position where the closed first end of the stopper is engaged .with the. inner plunger and an end-of-dose position where the closed first end of the stopper i s s paced from t he inner plunger, and where the in ner plunger is free to move from the first position to the second position whe the stopper is i the end-of-dose position. The stopper may be configured to move between the use position and the eftd-oMose position based on engagement with a medicament received within the container. Movement of the second portion of the spacer assembly the predetermined distance may be configured to cause the drive assembly to trigger retraction of a needle. The spacer shuttle may be- rotatable relative to the inner plunger, and where axial displacement of the second portion of the spacer assembly is configured to cause rotation of the spacer shuttle. The second portion of the spacer assembly may define an access opening configured to allow direct engagement -of the first spacer portion of the spacer assembly.

[0008] in a furthe aspect, a spacer assembl for a drug deliver system for injecting a medicament includes a. first spacer portion configured to be received by a stopper, a second spacer portion spaced from the first spacer portion a predetermined distance, an inner plunger-, and a spacer shuttle received by the inner plunger, where the inner plunger, the spacer shuttle, and the second portion of the spacer are configured to move relative to the first spacer portion. Movement of the second spacer portion is restricted b the spacer shuttle, and movement of the spacer shuttle Is restricted by the inner plunger,

O0O9] The inner plunger may have a first position and a second position spaced axially trom the first position, and the spacer shuttle may be restricted from axial, movement: when the inner plunger is in the. first position and moveable relative to the stopper when the inner plunger is in the second position. The second spacer portion may be restricted from axial movement via the spacer shuttle when the inner plunger is in the firs position and moveable relative to the stopper when the inner -plunger is irr the second position. The second portion of the spacer assembly may be free to move toward the first portion of the spacer assembly when the first plunger is in the second position. The space shuttle may be rotatable relative to the inner plunger, where axial displacement of the second portion of the spacer assembly is configured to cause rotation of the spacer shuttle. The second spacer portio of the spacer assembly may define an access opening configured to allow direct engagement of the first spacer portion of the spacer assembly. The first portion of the spacer assembly and the second portion of the spacer assembly may be secured to each other while allowing relative axial movement for the predetermined distance.

001-0] In a further aspect, a drug -delivery system for injecting a medicament includes a container configured to receive a medicament including a stopper and a closure, with the stopper configured to move within the container from a pre-ose position to a post-use position, The system also includes a spacer assembly comprising fixed spacer and an adjustable spacer, with the fixed spacer received by the stopper. The adjustable spacer is secured to the fixed spacer and moveable relative to the spacer assembly a predetermined axial distance, {(10111 The adjustable spacer may only be moveable in a first axial direction relative to the fixed spacer. The spacer assembly may include, a ratchet arrangement with one of the. fixed spacer and the adjustable spacer including a pluralit of detents and the other of the fixed spacer and the adjustable spacer including a spring detent arm, arid where rotation of the adjustable spacer relative to the fixed spacer in a first rotational -direcfion moves the adjustable spacer the predetermined axial distance. The system may also include a shim configured to be secured to the adjustable spacer.

[ΘΘΪ2] hi a fisriher aspect, a drug deliver} _' system for injecting a medicament includes a container configured to receive a medicament, with the container including a stopper configured to move within the container and a closure, and a drive assembly including: a plunger member configured to move the stopper within the container, with the plunger member having a first position, and a second position axially spaced from the first position, a biasing member configured to move the plunger member irom the first position to the second position, and a plunger actuation member moveable relative to the plunger member. The plunger actuation, member having a first position where the plunger member is axially fixed relative to the plunger actuation .member and a second position, where the plunger member is axially moveable relative to the plunge actuation member. The system also includes a needle actuator assembl including a needle configured to be placed in fluid communication with the container, with the needle moveable from a first position and a second positio spaced from the first position, a restriction member configured to restrict movement of the needle actuator assembly, and a spacer assembl comprising a fixed spacer and an adjustable spacer, with, the fixed spacer received by the stopper. The adjustable space is secured to the fixed spacer and moveable relative to the spacer assembly a predetermined axial distance.

jjOOI 3] The restriction member may be configured to engage rear portion of the container.

BRIEF DESCRIPTION OF THE DRAWINGS.

1001.4] The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will, be better understood by reference to the following descriptions of embodiments of he disclosure taken in conjunction with the _. accompanying drawings, wherein:

{0015) FIG. I is a perspective view of a drug deliver system according to one aspect of the present invention. 10016] FIG. 2 is a perspective, cross-sectional view of the drug delivery system of FIG. 1 according to one .aspect of the ^' present invention.

f Ot?] FIG, 3 is a front, cross-sectional view of the drug deli ery system of FIG. according to one aspect of the present invention.

[OOl j FIG. 4 is a top view of the dmg delivery system of FIG. 1 according to one aspect of the present iiweiition, showing a top po tion of the housing removed and the drag delivery system in a ^■ pre-use position.

[0019] FIG. 5 i s a top, cross-sectional view of die drug delivery system of FIG. I according to one aspect of the present, invention, showing the drug delivery system in a pre-use position.

[0020] FIG. 6 is a trout, cross-sectional view of the drug delivery system of FIG. 1 according to one aspect of the present invention, showing die drug delivery system in a pre-use position.

[0021] FIG - 7 is a top vi ew of the drug del ivery system of FIG. I according to one aspect of the present invention, showing a to portion of the housing removed and the drug delivery system in an initial actuation position,

f 0022] FIG, 8 is a top, cross-sectional view of the drug delivery system of FIG. I according to one aspect of the present in vention, showing the drug delivery system in an initial actuation position,

[0023] FIG. 9 is a front, eross se:ctional view of the drug del ivery sy tem of FIG. 1 according to one aspect of the present invention, showing the drug delivery system in an initial actuation position,

[0024] FIG. 10 is a top view of the drug delivery system of FIG. I according to one aspect of the present invention, showing a top portion of the housing removed and. the drug delivery system In a use position.

[0025] FIG. 11 is a top, cross-sectional view ^* of the drug delivery system of FIG, 1 according to one aspect of the present invention, -showing the drug delivery system in a use position.

[0026] FIG. 1.2- is a front,.- cross-sectional view of die dru delivery system of FIG. 1 according to one aspect, of the present invention, showing the drug deliver system in a use position.

[0027] FIG. 1 is top view of the drug delivery system of FIG, ! according to one aspect of the present invention, showing a top portion of the housing removed and the drug delivery system in a post-use position.

[0028] FIG. 14 is a top, cross-sectional view of the drug delivery system of FIG. 1 according to one aspect of the present invention, showing the drug delivery system i a post-use position. |Θ029] F G. 15 is a front, cross-sectional vie of the drug delivery system of FIG. 1 according to ooe aspect ^" of the present invention, s owing the drug -delivery system in a post- use position.

10030] FIG, ISA is front, cross-sectional view of the drug delivery system of FIG. 1 according to one aspect of the pis-sent invention, showing a pad with the drug deli very system in a pre-ose position,

| 31] FIG. .158 is a perspective, cross-sectional view of. the. drug- delivery system of FIG. 1 according to one aspect of the present invention, showing a. pad with the drug delivery-system in a pre-nse position.

jO032) FIG. 1-5C is a- erspective, cross-sectional view of the drug delivery system of FIG. ! according to one aspect of the present invention, showing a pad with the drag delivery .system, in a pre-nse position.

10033] FIG, 16 is partial cross-sectional view of the; drug deliver system of FIG, 5 according to one aspect, of the present invention, showing a valve assembly,

|0l>34] FIG, 17 is a perspective view of drive assembly for a drug delivery system according to one aspect of the present invention,

10035] FIG, 18 is a cross-sectional view of the drive assembly of FIG. 17 according to one aspect of the present invention, showing a pre _^ use position of the drive assembly.

|0036] FIG. 1 is a cross-sectional view of the dri ve assembly of FIG. 17 according to one aspect of the: present in vention, showing a use. position of the: drive, assembly .

fO037J FIG, 20 is a cross-sectional view of the drive assembly of FIG. 17 according to one aspect of the present invention, showing a post-use positio of the drive assembly.

|0O38| FIG. 21 Is a -perspective view of a plunger actuation -member of the dri ve assembly of FIG, 17 according to one aspect of the present invention.

10039] FIG. 22 is a perspective view of a first plunger member of the drive assembly of IG. 17 according to one aspec t of the present invention ,

10049] FIG. 23 is a perspective view of a plunger actuation member and first plunger member of the drive assembly of FIG. .17 according to one aspect of the present invention, showing the plunger actuation member engaged with the first plunger member.

0041] FIG. 24- is a perspective view of a plunger actuation member and first plunger member of the drive assembly of FIG. 17 according to one aspect of the present invention, showing the plunger actuation member disengaged from the first plunger member,

10042] FIG, 2S is a perspective view of a plunger actuation member and first plunger member of the drive assembly of FIG. 17 according to one aspect of the present invention, showing the plunger actuation member disengaged from and axia!iy displaced relative to the first plunger member.

fO043j FIG, 26 is a .front view of a first plunger member and a second plunger member of the drive assembly of FIG; 17 according to one aspect of the present invention.

|0044] FIG. 27 is a top view of drive assembly fo a drug delivery system according to a ^■ further aspect of the present i nvention .

{0045] FIG. 28 is a perspectiv view of th drive assembly of FIG, 27 according to one aspec t of the present invention.

fOMfitj FIG. 29 i s a cross-sectional view of the drive assembly of FIG. 27 according to one aspect of the present invention, showing, a pre-use position of the drive assembly,

|00 7] FIG, 30 is a perspective view of the drive assembly of FIG, 27 according to one aspect of the present invention, showing the drive assembly received by a bottom portion of a housing.

{0048] FIG. 31 is perspecti ve vi ew of the housing of FIG. 30 according to one aspect of the present Invention.

j0 49j FIG. 32 is a top view of the drive assembly of FIG. 27 according to one aspect of the presen invention, showing engagement of the drive assembly with a portion of a needle actuator in an■initial actuation position, of the drive assembly.

|0β50] FIG. 33 is an enlarged perspective view of the drive assembly of FIG. 27 according to one aspect of the present invention, showing engagement of the drive assembly with a portion of a needle actuator n an initial, actuation position of the drive assembly.

|i§51] FIG. 34 is a. front ^' View of a needle actuator assembly according, to one aspect of the present invention.

|0052] FIG, 35 is a left side perspective ^' view of a needle shuttle of the needle actuator assembly of FIG. 34 according to one aspect of the present invention.

{0053] FIG. 36 is a right side perspective view of a needle shuttle of the needle actuator assembl of FIG. 34 according to one aspect of the present invention.

{ ^' 0054] FIG. 37A is a front view of the needle actuator assembly of FIG. 34 according to one aspect of the present invention, showing the needle actuator assembly in a pre-use position,

10055] FIG. ^" 37B is a front view of the needle . ^■ actuator assembly of FIG. 34 according to one aspect of the present invention, howing the needle actuator assembly in a use position.

{0056] FIG. 37C is a front view of the needle actuator assembly of FIG. 34 according to one aspect of the present invention, showing the needle actuator assembly in an initial post-use position. {0057] F G. 37D is a front view of the needle actuator assembly of FIG, 34 according to one aspect of the present invention, showing the needle actuator assembly in a post-us position. |0058] F IG. 38A is a perspective view of the needle actuator assembly of FIG. 34 according to one aspect of the present invention,, showing the needle actuator asserably in a use position, {0059] FIG.- 3SB is a perspective view of the needle actuator assembly of -FIG. 34 according to one aspect of the present invention, showing the needle actuator asserably in an initial post- use position.

[0060] FIG. 39 is a perspective view of a actuator button and the needle actuator asserably of FIG. 34 according to one aspect of the present invention, showing the needle actuator assembly in an initial post-use position.

{0061] FIG, 40A is a cross-sectional view of an actuator button and the needle actuator assembly of FJG, 34 according to one aspect of the present invention, showing the needle actuator asserabl in an initial post-use position.

[0062] FIG. 40B is a perspective view of an actuator button and the needle actuator assembly of FIG. 34 according to one aspect of the present Invention, showing the needle, actuator assembly i a post-use position.

[0063] FIG. 41 is perspective view of a drive assembly for a drag delivery system according to a further aspect of the present Invention.

[0064] FIG. 42 is a perspective view of the drive assembly of FIG. 41 according to one aspect of the: present in ventioii, showing a lop portion of a housing removed,

|006S] FIG. 43 is a cross-sectional view of the drive assembly of FIG. 1 according to one aspect of the present invention.

[0066] FIG. 44 is a perspective view of the drive assembl of FIG. 41 according to one aspect of the present inve tion.

[0067] FIG. 45 is a cross-sectional view of the drive assembly of FIG. 41 according to one aspect of the present invention _* showing the drive- asserably in a pre~use position.

[0068] FIG. 46 is a cross-sectional, view of the dri e assembly of FIG. 41 according to one aspect of the present invention, showing the drive assembly in a pre-isse position.

[0069] FIG. 47 is a top view of the drive assembly of FIG. 41 according to one aspect of the present invention, showing the drive asserably in a pre-ose position,

]0070] FIG . 48 is a top view of the drive assembly of FIG, 41 according to one aspect of the present invention, showing the drive assembly in -an initial actuation position.

|0071] FIG. 49 i s top view of the dri ve assembly of FIG . 41 according to one aspect of the present invention, showing the drive asserably in an initial actuation position. 10072] F G. 50 is a top view of the dri ve assembly of FIG, 41 according to one aspect of the present invention, showing the- driv assembly an initial actuation position-.

| 073J FIG, 51 is a top view of the drive assembly of FIG, 41 according to one aspect of the present invention, showing the drive assembly in a ^' use- position.

|0ίϊ74] FIG.- 52 is a top view of the drive assembly of -FIG. 41 according to one aspect of the present invention, showing the drive assembly in a use position,

| 075] FIG. 53 is a cross _^ seetional view of the drive assembly of FIG. 4.1 according to one aspect of the present invention, showing the drive assembly in a use position.

[0076] FIG. 54 is a top view of the dri ve assembly of FIG, 41 according to one aspect of the present invention, showing the: drive assembly in -a use position.

|O077] FIG, 55 is a cross-sectional view of the drive assembly of FIG, 41 according to one aspect of the present invention, showing the drive assembly in a use position,

100-78] FIG, 56 is a eross-seettonal view of the drive assembly of FIG. 41 according to one aspect of the present invention, showing the drive assembly in a use position.

f 0079] F IG, 57 is to view of the drive assembly of FIG , 41 according to one aspect of the present invention, showing the drive assembly in a use position.

10080] FIG. 58 is a top view of the drive assembly of FIG. 41 according to one aspect of the present invention, showing the dri e assembly in an initial post-use position.

10081] FIG. 59 is a perspective view of the drive assembly of FIG, 41 according to one aspect of the: present invention, showing the drive assembly in an initial, post-use position.

[0082] FIG, 60 is a top view of the drive assembly of FIG. 41 according to one aspect of the present invention, showing the drive assembly in. a post-use position,

|0083] FIG. 61 top view of the drive assembly of FIG. 1 according to one aspect of the present invention, showing the drive assembly in a post-use position,

[0084] FIG. 62 is a cross-sectional view of the drive assembly of FIG. 4.1 according to one aspect of the present invention, showing the drive assembly in a pre~use position.

10085] FIG. 63 is a cross-sectional view of the dri ve assembly of FIG, 41 according to one aspect of the present invention, showing the drive. assembl -in a use position.

[0086] FIG. 6 is a perspective view of a drive assembly according to a further aspect of the present in vention.

[0087] FIG. 65 A is a front view of a needle actuator assembl according to one aspect of the present invention, showing the: needle actuator assembly in a use position,

[0088] FIG, 65B is a front view of the needle actuator assembly of FIG. 65A according to one aspect of the present invention, showing the needle actuator assembl in a use position. [00 9j FIG. 65C Is a front view of the needle actuator assembl of FIG. 65A according to one aspect of the present invention, showing the needle actuator assembly in -as ini ti al post-use position.

[8890J FIG, 65D is a front view of the needle actuator assembly of FIG. 65A according to one aspect of the present invention, showing the needle actuator assembly in a post-use position,

[0091] FIG. 65E is a front view of the needle actuator assembly of FIG, 65A. according to one aspect of the- present invention, showing the needle actuator assembly in a pre-use position.

[8892] FIG. 65F is a cross-sectional view of the needle actuator assembly of FIG, 65 A according to one aspect of the present invention, showing the needle -actuator assembly in a pre-use position.

[0893! FIG. 650- is a front view of the needle actuator assembly of FIG. 65A accordin to one aspect of the present invention, showing the needle actuator assembly in a pre-use position with a button actuator axialiy displaced.

£0094] FIG, 65M Is a- cross-sectional vie of the needle actuator assembly of FIG, 65A according to on aspect of the present invention, showing the needle actuator assembly in a pre-use position with a button actuator axialiy displaced.

101195] FIG. 66 is a perspective view of a button spring of the needle actuator assembly of FIG. 65 A according to one aspect of the present invention,

10096] FIG, 67 is a perspective view of an actuator button of the needle actuator assembly of FIG. 65A according t one aspect of the present invention..

|i 97] FIG . 68 is a cross-sectional view of a button spring and actuator butto of the needle actuator assembly of FIGS, 65A according to one aspect of the present invention,

|0i)98] FIG, 68A is a perspective view of an actuator button of the needle actuator assembly of FIG. 65 A according to a further aspect of the present Invention.

[88 9! FIG. 68B Is a bottom view of an actuator button of the needle actuator assembly of FIG. 65A according to a further aspect of the present Invention.

[801881 FIG, 68C is a front view of an actuator button of the needle actuator assembly of FIG. 65A according to a. further aspect of the present invention.

[881811 FIG. 68D is top view of an actuator button of the needle actuator assembly of FIG. 65A according t a further aspect of the present invention, showing the actuator button in a pre-use position fOOl §2} FIG. 68B is a front view of an actuator button of the needle actuator assembly of FIG. 65 A according io a further aspect of the present invention, showing -the act uator but ton in a pre~use position.

[00103] FiG. 68P is a top view of an actuator ^' button of the needle actuator ^' assembly of FIG. 65A according; to a further aspect of th present Invention, showing the actuator button m a use position,

[00104! FIX). 6SG is a front view of an actuator button, of the needle actuator assembly of FIG. 65 A according to a further aspect of the present invention,, showing the actuator button in a use position.

j Oft! 05} FIG. 69 is a top view o an actuator button of the needle actuator assembl of FIG. .65 A according to one aspect of the present invention,

FIG. 70 A is a schematic view of a dri ve assembly according to one aspect of the present invention, showing the drive assembly in a ^' pre-u.se position,

[011107} FIG. 70B is a schematic view of the drive assembly of FIG. 70A. according to one aspect of the present invention, showing the drive assembly in use posi tion,

[00108] FIG. 70C is a schematic view of the dri ve assembly of FiG. 70A according to one aspect of the present invention, showing the drive assembly in a use position.

00109! FIG. 70D is a schematic view of the drive assembly of FiG. 70A according to one aspect of the present invention, showin the drive assembly in a use position.

[00110! F.KL70B is a schematic view of the drive assembly of FIG. 70A according to one aspect of the present invention, showing the drive assembly in a use position.

[001 1[ FIG. 70F is a schematic vi ew of ihe dri ve assembly of FIG. 70A according to one aspect of the present invention, showin the drive assembly in a post-use position.

[00112! FIG. 70G is a schematic view of the drive assembly of FIG.. ^' 70 A according to one aspect of the present in vention, showing the drive assembl in a post-use position.

[00113} FIG, 71 is a perspective vie of a spacer assembly for a drug delivery system according to one aspect of the present invention _. , showing an assembled, pre-use position of the spacer assembly,

[00114! FIG. 7 is a perspective view of the spacer assembly of FIG. 71 according to one aspect of th tesentiaveation,. showing a use position of the. spacer assembly.

[00115} FIG. 73 is a perspective view of the spacer assembly of FIG, 71 according to one aspect of the present invention, showing, aa initial post-use position of the spacer assembly,

[00116! FIG. 74 i s a perspecti ve view of a restrictio member according to one aspect of the present invention. fOttJ 17J FIG. 75 is a front view of a spaeer assembly ^' for a drug delivery system according to a. forther aspect of the present invention.

|00H8J FIG. 76 Is a top view of a spacer assembly for a drug delivery system according to one aspect Of the present invention.

10011.9] FIG. 77 is a perspective view of the spaeer assembly of FIG. 76 according to one aspect of the present invention.

jO0l20J FIG. 78 is a cross-sectional view of the spacer assembly of FIG, 76 according to one aspect of the present invention,

0012] J FIG. 79 is a perspective vie of a spacer assembly for a drag delivery system according to a further aspect of the present invention,

100122] FIG, SO is a perspective view of a spacer assembly for a drug deliver system according to another aspect of the present invention.

00123 _. FIG. 81 A is a cross-sectional view of the spacer assembl of FIG . 80 according to one aspect of the present invention, showing a pre-as.sem.bly position of the spaeer assembly. £001241 FIG, 81.B is a cross-sectional view of the spacer assembly of FIG, 80 according to one aspect of the present invention, showin an assembled position of the spacer assembly. 001 51 FIG. 82 is a perspective view of a drive assembly for a drug delivery system according to one aspect of the present invention.

1 01261 FIG. 83 is a perspective view of the drive assembly of FIG. 82 according to one aspect of the: present in ventioij, showing a top portion of a housing removed,

1001.27} FIG. 84 is a cross-sectional view of the drive assembly of FIG. 82 accordin to one aspect of the present invention, showing a pre-use position of the drive assembly.

f 00128} FIG. 85 is an enlarged cross-sectional view of the drive -assembly of FIG. 82 according to one aspect of the present invention, .showing - a pre-use position of the drive assembly.

Ο0Ϊ29| FIG, 86 i a top view of a biasing member of the drive assembly of FIG, 82 according to one aspect of the present invention.

100139} FIG, 87 is a perspective view of the drive assembly of FIG. 82 according to one aspect of the present invention,-showing a restriction, member engaged with the dri ve assembly. O0I31 } FIG. 88 is a perspective view of a drive assembly for a drug delivery system according to one aspect of the present invention.

£00132} FIG. 89 is a perspective view of the drive assembly of FIG. 88 according to one aspect of the present invention, showing a pre-ose position of the dri ve assembly. f 00133 FIG. 90 is a cross-sectional vie of the drive assembl of FIG. 88 according to one aspect of the present invention.

|O0.134J FIG. 91 is a perspective view of the drive assembl of FIG, 8.8 according to one aspect of the present invention _* showing posi-ase position of the drive assembly _*

100135! FIG. -92 is a cross-sectional view .of the drive assembly of FIG. -88 according to one aspect of the present invention, showing a pre-ose position of the drive assembly,

| 0I36| FK). 93 is a front view of the drive assembly of FIG. 88 according to one aspeet of the present invention, showing a use position of the drive- assembly.

00137! FIG. 94 is a perspective view of a spacer assembly for a drag delivery system according to one aspect, of the present invention.

IO0J 38J FIG, 9S is a front view of the spacer assembly of FIG. 94 according to one aspeet of the present inven tion.

00139} FIG. 96 is a cross-sectional view of the spacer assembly of FIG. 94 according to one aspect of the present invention,

|O0J. O| FIG. 97 is a perspective view of the spacer assembly of FIG. 94 according to one aspeet of the present in vention, showing a shi.ni removed.

100141! F G. 98 is a perspective view of a fixed spacer of the spacer assembly of FIG, 94 according to one aspect of the present invention.

0 1 21 FIG. 99 is a perspective view of an adjustable spacer of the spacer -assembly of FIG. 94 accordin to one aspect of the present invention,.

£001431 FIG. 1.00 is a perspective view of a shim of the spacer assembly of FIG. 94 according to one aspect of the present invention.

|0§144} Correspondin reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary aspects of the d sclosure; and such exempKfications. are not to be construed as limiting the scope of the disclosure in any manner.

DETAILED DESCRIPTION

j 001.451 The following description is provided to enable, those skilled in the art t make and use the described embodiments contemplated, for carrying out the invention. Various modifications, equivalents, variations, and aUematives, however, will remain readily apparent to those skilled in the art. Any and all such modifications, variations, equivalents, and aUematives are intended to fall within the spirit and scope of the present invention. |0ftl46J For purposes of the description hereinafter, the terms "upper", "lower", "right", "left", "vertical", "horizontal", "top", "bottom", "lateral", 'longitudinal'', and derivatives thereof shall relate to die invention, as it is oriented in the drawing figures. However, it is to be understood that the invention ma assume various alternativ variations, except where expressly specified to the contrary. If is also to be understood thai the specific devices illustrated in the attached drawings, and described in the following specification,. -are simply exemplar}' .embodiments of the invention. Hence,, specific dimensions and other physical characteristics related to die embodiments disclosed herein are not to be considered as limiting. I00147J Referring to FIGS, 1-16, a drug delivery system 10 according to one aspect of the present invention includes a drive assembl 12, a container 14, a valve assembly 16, and a needle actuator assembly 18, The drive assembly 12, the container 14, the valve assembly 16, and the needle actuator assembly 18 are at least partially positioned within a housing 20. The housing 20 includes a top portion 22 and a bottom portion 24, although othe suitable ^" arrangements for the housing 20 may be utilized, in one aspect, the drug delivery system 10 is an injector device configured to be worn or secured to a user and to deliver a predetermined dose of a medicament provided within the container 14 via injection, into the user. The system. 10 may be utilized to deliver a "bolus injection" where a medicament is delivered within a set time period. The medicament may be delivered over a time period of u to 45 minutes, although other suitable injection amounts and durations may be utilised, A bolus administration or delivery can be carried out with rate controlling or have no specific rate controlling. The system 10 may deliver the medicament at a fixed pressure to the user with the rate being variable. The general operation of the system 10 is described below in reference to PIGS. I- 16 with the specifies of the drive assembly 12, needle actuator assembl 18, and other features of the system 10, discussed below- in. connection -with FIGS. 17-93.

fO0148j Referring again to FIGS. 1-16, the system 10 is configured to operate through the engagement of an actuation button 26 by a user, which results in a needle 2.8 of the needle assembl 18 piercing the ski n of a user, the actuation of the drive assembly 12 to place the needle 28.· in fluid communication with the container 1.4 audio expel fluid or .medicament from the container 1.4, and. the withdrawal of the needle 2S after injection of the medicament Is complete. The genera! operation of a drug delivery system is shown and described in International Publication os. 2013/1551.53 and 2014/179774, which are hereby incorporated by reference in their entirety. The housing 20 of the system 10 ^' includes an indicator window 30 for viewing an indicator arrangement 32 configured to provide an indication to a user on the status of the system 10 and a container window 31 for viewing the coniainer 14. The indicator window 30 may be a magnifying lens for providing a clear view of the indicator arrangement 32. The. indicator -arrangement 32 moves along with the. needle actuator assembly 18 daring use of the system 10 to indicate a pre-use status, use status, and post-use stains of the system 10. The indicator arrangement 32 provides -visual indicia regarding the stains, although other suitable indicia, such an auditory or tactile, may be provided as an .alternative ^' or additional indicia.

| I49| Referring to FIGS- 4-6, during a pre-use position of the system 10, the container 14 is spaced from the drive assembly 12 and the valve assembly 16 and the needle 28 is in a retracted position. During the initial actuation, of the system 10, as shown in FIGS, 7-9, the drive assembly 12 engages the container 14 to move the container 14 toward the valve assembly 16, which is configured to pierce a closure 36 of the container. 14 and place the medicament within the container 1:4 i fluid communication with the needle 28 via a tube (not shown) or other suitable- arrangement. The drive assembly 1.2 is configured to engage a stopper 34 of the container 14, which will initially move the entire container 1 into engagement with the valve assembly 1 due to the incompressibUity of the fluid or medicament within the container 14, T¾e initial, actuation of the system 10 is caused by -engagement of the actuation button 26 by a user, which releases the needl actuator assembly 18 and the drive assembly 12 as discussed below in more detail . During the initial actuation, the needle 28 is still in .the- retracted positio and about to move to the extended posi tion to inject the user of the system 10.

fOOlSOJ During the use position of the _. system 10, as shown in FIGS. 10- 12, the needle 23 is in the extended position at least -partially outside of the housing 20 with the drive assembly 12 moving the stopper 34 -within the container 14 to deliver the medicament from the container 14, through the needle 28, and to the user. In the use position, the valve assembly 16 has already pierced a closure 36 of the containe 14 to place the container 14 in- fluid communication with the needle 28, which also allows the drive assembly 12 to move the stopper 34 relative to the container 14 since fluid is able to be dispensed from the container 1 . At the post-use position of the system 10, shown in FIGS. 13-15, the needle 28 is in the retracted position and engaged wit ^' a pad 38 to seal the needle 28 and prevent an residual flow of fluid or medicament from- the container 14. The container 14 and valve assembly 16 ma be the container 14 and valve assembly 16 shown and described in International Publication No. WO 2015/081337, which is hereby incorporated by reference in Its entirety. fOftl 51 } Referring to FiOS. 15Α-Ί S€, the pad 38 is biased into the pad as the needle actuator body 96 moves from the use position to the post-use position. In particular, the pad 38. is received by a pad arm: 1.22 having a cam surface 124 thai cooperates with a cam track 126 on the bottom portion 24 of the bousing 20. The pad arm 122 is connected to the needle actuator body 96 via. a torsion bar 128, The cam. surface 12 is -configured to engage the cam track 126 to deflect the pad arm 1.22 downwards thereby allowing the pad 38 to pass beneath the needle 28 before being biased upwards into the needle 28. The torsion bar 1.28 allows the pad arm 122 to twist about a pivot of the needle actuator body 96. The pad 38 may be press-fit into an opening of the pad arm 122, although other suitable arrangements for securing the pad 38 may be utilized.

[00152] Referring to FIGS. 1-33, the drive assembl 12 according to one aspect of the present invention is shown. As discussed above, the drive assembl 12 is. configured to move the container 14 to pierce the closure 36 of the container 14 and also t move the stopper 34 within the container 14 to dispense fluid or -medicament from the container 14. The drive assembly 12 shown in FIGS. 1 7-33 is configured to engage and cooperate with a spacer assembly 40 received by the stopper 34 of the container 14. The spacer assembly 40 includes a spacer 42 and a spacer holder 4. The spacer holder 44 is received by the stopper 34 and the spacer 42 is received by the spacer holder 44. The spacer holder 44 includes a. first threaded portion 46 that engages a. correspondin threaded portion, of the stopper 34, although other suitable arrangements may be utilized. The spacer 42 also includes a threaded portion -48 that engages a corresponding second threaded portion 50 of the spacer holder 44 for securing the spacer 42 to the spacer holder 44, although other suitable arrangements may be utilized. The drive assembly 12 is configured to dispense a range of predetermined fill volumes of the container 14 while maintaining the functional features of the system 1.0 described above. Including, but not limited to, retraction of the needle 28 after the end of the dose and providing an indication of the status of the system 10 while also minimising abrupt engagement of the stopper 34 by the drive assembl 12. The drive assembly 12 is configured to dispense a pluralit of discrete fill volume ranges by utilizing a plurality of sizes of the spacers 42. hi one aspect, twelve fill volume ranges and twelve spacer 42 sizes are provided. In one aspect, the length of the spacer 42 is changed to accommodate different fill volumes in the container 1:4. Alternatively, a single size spacer 42 may be utilized with a plurality of fill, volumes in the container 14 accommodated by utilizing a plurality _. -of shims that are received, by the spacer 42.

[00153} Referring to FIGS. 17-26, the drive assembly 12 includes, a first plunger member 52, a second plunger member 54 received by the first plunger member 52, a first biasing member 56, a second biasin member 58, a plunger actuation member 60, and an index member 62. The first plunger member 52 is moveable from a pre-use position (shown in FIG, 18), to a use position (shown in. FIG. 1 ), to a post-use position (shown in FIG. 20) with the first plunger member 52 configured to engage the spacer assembl 40 and .move the stopper 34 within the container .14 to dispense medicament from the container 14. The first phrager member 52 is configured to move axially. The second plunger member 54 and the first plunger member 52 form a telescoping arrangement with the second plunger 54 configured to move axislly after the first plunger member 52 moves a predetermined ask! distance. The movement of the first and second plunger members 52, 54 is provided by the first and second biasing members 56, 58, which are compression springs, although- other suitable arrangements for the biasing members 56, 58 ma e utilized,

|0Θ154| The first biasing member 56 is received by the second plunger member 54 and is constrained between the plunger actuation member 60 (and index member 62) and a first spring seat 64 of the second plunger member 54» The second biasing member 58 is positioned radially inward from the first biasing member 56 and received by the second plunger member 54. The second biasing member 58 is constrained between a second spring seat 6 of the second phmger member 5 and the first plunger member 52. The second biasing member 58 is configure to bias the -first plunger 52 member towards the container 1.4 from the pre-use position, to the use position, and to the post-use position. The first biasing member 56 is configured to bias the second plunger member 5 towards the container 14, which, in turn, biases the first plunger member 52 towards the container 1.4 from the ^■ pre-use position, to the use position, and to the post-use position. More specifically, the second biasing member 58. is configured to drive the first plunger member 52 against the spacer assembly 40 or stopper 34 to move the container 14 into engagement the valve assembly 1.6 thereby piercing the closure 36 of the container 1 and placing the container 1.4 ^' in fluid communication with the needle 28, The first biasing member 56 is configured to move the stopper 34 within the container .14 to dispense the medicament within the container 14, The second biasing member 58 has a different spring constant than the first biasing member 56. In particular, the second biasing 5.8 member is stiller than, the first biasing member 5 to provide a high force for piereing the closure 36 of the container 14 while the first biasing member 56 provides a lower force for dispensing as appropriate for the viscosity of the fluid or medicament within, the container 14,

|O01,55J Referring again to FIGS, 17-26» the plunger actuation member 60 has an annular portion 68 and a spindle portion 70. The plunger actuation member 60 is rotationaSly moveable relative to the first plunger member 52 between a first rotational position and a second rotational position spaced from the first rotational position. The first rotational position may be 15 degrees from the second rotational position, although other suitable positions may be utilized. The annular portion. 68 includes a. drive surface 72 including a pluralit of gears 74, although other suitable arrangements may he utilized for the drive surface 72. The spindle portion 70 includes an actuator locking surface 76 configured for engagement and release from a plunger locking surface 78 of the first plunger member 52, The plunger locking surface 78 includes a plurality of projections 80 configured to he received by a ^■ plurality of slot or cutoius 81 defined bv the actuator locking surface 76,

00156] As shown m FIGS. 18 and 23, in the first rotational position of the plunger actuation member {¾ the plurality of projections 80 and the plurality of slots or cutouts 81 are -out .of alignment- such that the plunger■ actuation member 80 is engaged with the first plunger member 52 to prevent movement of the first and second plunger members 52, 54 with the first and second biasing members 56, 58 biasing the first and second plunger members 52, 54 away from the plunger actuation member 60, As shown in FIGS. 19 and 24, in the second rotational position of the plunger actuation member 60, the plurality of projections 80 and the . plurality of slots or cutouts 81 are aligned with each Other such that the plunger actuation member 60 is disengaged with the first plunger member 52 to allow movement of the first and second plunger members 52, 54 thereby starting the dispensing process from the container 14.

100157] Referring to P IGS. 7 and 33, the drive surface 72 of the plunger actuation member 60 is configured to be engaged by a portion of the needle actuator assembly 18. After engagement of the actuator button 26 and release of the needle actuator assembly 18, whic is discussed in more detail below, the needle actuator assembly 18 moves within the housing 20 from the pre-use position, to the use position,, and to the post-use position. During the initial movement of the needle actuator assembly 18, a portion of the needle actuator assembly 18 engages the drive surface 72 of the plunger actuation member 6 to move the plunger actuation member 60 from the first rotational position to the second rotational position. As shown hi FIG. 33, an angled blade portion 82 of the needle actuator assembly 18 engages the drive surface 72 of the plunger actuation member 60 to cause rotation of the plunger actuation member 60,

|O0158|: Referrin to FIGS. 11, 13, and 26, the second plunger member 52 includes a plurality of coded projections.84 with a preselected one of the plurality of coded projections 84 configured t engage a restriction member 86 of the system. 10, As discussed in more detail below, the restriction member 86 cooperates with the needle actuation assembly 18 and restricts movement of _. the needle actuator assembly 18 from the use position to the post-use position until a predetermined end-of-dose position of the stopper 34 is reached. In one aspect, the restriction member 8.6 is configured to restrict axial movement of the needle actuation assembly 18 from the use position through engagement between the restriction member 86 and a portion of the needle actuation, assembly 18. Such engagement between the restriction member 86 and the needle -actuation assembly 18 is released by rotation -of the restriction member 86 when the stopper 34 reaches the end-ofi-dose position. During the use position of the needle actuator assem l 18, the

the restrictio member 86 being prevented tlMugii engagement between the restriction member 86 and one of the plurality of coded, projections 84 of the second plunger member 54, The plurality of coded projections 84 may be axial ribs of varying length, although other suitable arrangements may be -utilized. Each coded projection 84 defines a point at which the restriction member 86 is able to rotate thereby releasing the needle actuator assembly 18, The smooth portion of the second plunger member 52 may also provide a further "code" for determining when the system 10 transitions to the eiid-oiktose position,

ί 00159 j As discussed above, the indicator arrangement 32 moves with different portions of the indicator ^' arrangement 32 visible through the indicator window 30 as the system 10 moves from the pre-use, use, and post-use or end»of»dose positions. More specifically, the indicator arrangement 32 engages a portion of the restriction member 86 and moves along wit the restriction member 86 through the various stages of the system 1 to provide a indication to the user regarding the state of the system 10.

101116)} Daring assembly of the ^' system 10, the dosage of the container 14 is matched with a specific spacer 42 having a set length and a corresponding one of the plurality of coded projections 84 is aligned with the restriction -member 86. Accordingly, as discussed above, the container 14 may be provided with a .plurality of dosage volumes with each, volume corresponding to a specific spacer 42 and coded projection 84. Thus, even for different dosage volumes, tire system 10 is configured io inject the needle 28 into the user to deliver a dose of medicament from the container 14, retract the needle 28 after the end of the dose, and provide an indication of the status of the system 10 while minimizing abrupt engagement of the stopper 34 by the drive assembly 12. In particular, the size of the stopper 34 may be selected to minimize the distance between the first plunger member 52 and the spacer assembly 40 and does not require the use of damping.

j001.6ij Referring to FIGS. 27-33, a drive assembly 2A accordin -to- a mrther aspect of the present invention is shown. The drive assembly 12A shown in FIGS. 27-33 is similar to .and operates in the same mariner as the drive assembly 12 shown i FIGS. 17-26 and described above. In the drive assembly of FIGS. 27-33, however, -the first plunger member 52 is received by the second plunger member 54 and extends from the second plunger member 54 during axial movement from the pre-use position to the use position. Further, the first plunger member 52 includes an extension portion 88 configured to engage the second plunger member 54 after the first plunger member 52 moves predetermined axial distance such that the first and second, plunger members 52, 54 move together. The first and second biasing members 56, 58 engage and act on. the first and second plunger members 52 _» . 54 in the same manner as the drive assembly 12 of FIGS, 17-26.

001621 Referri g to FIGS, 27-32, the index member 62 is positioned about the first and second plunger members 52, 54 and includes .a plurality of ratchet teeth 90 configured to engage a flexible tab 92 positioned on the bottom portion 24 of the housing 20, When the drive assembly 12 , 12A is installed into the bottom. -portion 24 of the housing 20, the engagement of the ratchet teeth 90 of the inde member 62 with the flexible tab 92: of the housing 20 provide a one-way rota tion of the index member 62, The index member 62 is configured to rotate to align one of the coded projections 84 of the second plunger member 52 with the restriction member 86 based on the dosage volume and spacer 42 size as discussed above. The index member 62 may provide the drive assembl 12, .12 A with 24 rotational positions of which 12 may have unique dose values associated with them.

{00163] Referring to FIGS. 1 -16 and 3 -4GB, the needle actuator assembly 18 according to one aspect of the present invention is shown. The needle actuator assembly 18 includes a needle actuator body 96 having guide surfaces 98, a needle shuttle 1.02 having cam surfaces 104. and the needle 28 received b the needle shuttle 102 and configured to be in fluid communication with the container 14 as discussed above. The needle actuator body 96 is generally rectangular with the guide surfaces 98 protruding radially inward. The needle shuttle 102 is received within the needle actuator body 96. As described above, the needle actuator body 96 is moveable within the housing 20 from a pre-use position (shown In FIGS. 4-6), an initial actuation, position (FIGS, 7-9), a use position (FIGS. 10-12), and a post-use position (FIGS. 13-15). The needle actuator body 96 is biased .from the pre-use position to the post-use position via an extension spring 1 6, although other suitable biasing arrangements may be utilized. The needle actuator body 96 is released and free to move from the pre-use position to the use position upon engagement of the actuator button 26, which Is discussed in more detail below. The needle actuator body 96 moves from the use position to the post-use position after rotation of the restriction member 86 as discussed above in connection with FIG S. 17-33. 100164} Referring to FIGS, 34-40B, the needle shuttle 102 is moveable along vertical axis between a retracted position where the needle 28 is positioned within the housing 20 and a extended position where at least a portion of the needle 28 extends out of the housing 20. The needle shuttle 102 is configured to mov between the retracted position and the extended position through engagement between the guide surfaces 98 of the needle actuator 96 and the cam surfaces 104 of the needle shuttle 102. The cam surfaces- 104 are provided b first and second cam members 108, 11 , with the first cam member 108 spaced from the second cam member 1 0. The housing 20 includes a guide post 112 having recess configured to receive a T-shaped projection 1 14 on the needle shuttle 1.02. although other shape and configurations may be utilized for the guide post 112 and T-shaped projection 1 14, The needle shuttle 102 moves along the guide post 1 12 between the retracted and extended positions. The guide pos 1 12 is linear and extends about perpendicular from the housing 20, although other suitable arrangements may be utilized. The guide surfaces 98 of the needle actuator body 86 are nonlinear and each include a first side 1 1 and a second side 1 18 positioned opposite from the first side 11 .

f OO SJ As discussed below, the guide surfaces 98 of the needle actuator body 96 cooperate with the cam members 108, 110 of the needle shuttle 102 to move the needle shuttle 102 vertically between the retracted and extended positions as the needle actuator body 96 moves axiai!y from the pre-use position to the post-use: position. The needle- shuttle. 102 als -includes a shuttle biasing member 120 configured to engage the housing .20 or the actuator button 26, In particular, the shuttle biasing member 1 0 engages the housing 20 or actuator button 26 and provides a biasing force when the needle actuator bod 96 is transitioning from the use position to the post-use position. When the needle actuator body 96 is folly transitioned to the post-use position, the cam . members 108, 1 10 of the needle shuttle 102 are disengaged from the guide surfaces 98 of the needle actuator body 96 and the shuttle biasing .member 1.20 biase the needle shuttle 102 downward such that the needle 28 engages the pad 38, as discussed above. As discussed above in. connection with FIGS. 1.-16, however, the pad 38 may also be biased into the needle 28 rather than biasing the needle shuttle 102 downwards via the shuttle biasing member 120, Tie needle actuator bod 96 may interact with the actuator button 26 to prevent the ^' actuator button 26 irom popping back up until the post-use position is reached, which is discussed below in more detail

J00166} Referring to FIGS, 37A-40B, in a pre-use position (FIG. 3?A), the needle shuttle 102 is in, the retracted position with, the cam members 1 8, 1 .1 spaced, irom the guide surface 98 of the needle actuator body 96. As the needle actuator body 96 moves to the use posi tion (FIGS. 37B and 38A), the second cam member 1 10 of the needle shuttle 102 engages the second side 1 18 of the guide surfaces 98 to move the needle shuttle 10 from the retracted position to the extended position, During the transition irom the use position to the post-use position of the needle actuator body 96 (FIG, 37C), the first cam member 1.08 of the needle shuttle 102 is engaged with the first side 116 of the guide surfaces 98 to move the needle shuttle 102 from the -second position to the first position. After the needle actuator bod 96 is fully transitioned to the post-use position (FIGS. 37D and 38B), the shuttle biasing member 120 biases the needle shuttle 102 downward as the earn members 1.08, 11 disengage from the gaide surface .98 of the needle actuator body 96 with the needle 28 engaging the pad 38. Th transition of the needle actuator body 96 and the corresponding position of the needle shuttle 102 is also shown in FIGS. 3 -40B. The interaction between the actuator button 26 and the needle actuator bod 96 is discussed in detail in connection with FIGS. 6SA-67. Referring to FIGS. 41-64, a drag delivery system 200 according to a further embodiment is shown. The system 200 includes a housin 202 having an upper housin 20 and -a lower housing 206. The housing has a proximal end 205 and a distal end 207. The upper housing 204 has a status view port 208 so that user can view the operating status of the system 200. The system 200 also includes a valve assembly 212, a tube 214 fluidly connecting the valve assembly -2.14 with a patient needle 215 that is disposed in a proximal end of a needle arm 216. A spring 218 biases a needle actuator 220 distaHy,

|0f>i67J As ^' shown in FfGS. 42-46, the system 200 additionally includes -a container or medicament container 222 with a stopper 224 movabiy disposed therein, although the stopper 224 is omitted from various figures to aid clarity. Preferably, the distal end of the medicament container 222 has a septum assembly 228 that is spaced apart from the valve assembly 212 prior to actuation of the device 222, as best shown in- FIG. 47,

£00168} For manufacturing purposes, using one size for a medicament container is often desirable, even if multiple ^' fill ^' volumes or dosages are contemplated for use ^' with the container. In such cases, when medicament containers are filled, the differing fill volumes result in different positions of the stopper. T accommodate such different stopper positions, as well as accommodate manufacturing differences of the stoppers, aspects of the present invention include a bespoke or custom spacer 226 disposed, in a proximal end of the container 222. proximal to the stopper 224. In other words, the bespoke spacer 226 provides an- option that allows dispensing of a range of manufactures-set pre-defined till volumes by selection of different, spacers 226, and: reduces or eliminates the need for assembly configuration, operations. The size of the spacer 226 can be employed ^' to- account for ^' under-filled volumes of the container 222, and provide a consistent bearin surface at _. the proximal end of the container, 100169J T he spacer 226 is selected from a plurality of different size spacers 226 to occupy space from a proximal end of the stopper 224 to a proximal end of the container 222» Accordin to one embodiment, as shown in FIGS. 45-47, the spacer 226 is selected to be -substantially flush with, the proximal end of the container 222, Additionally, according to one embodimen the spacer 226 has a 'lap hat" shape, which includes a central column 230 and a distal flange 232, as best shown in FIG. 45.

10017 )] Returning to FIGS. 44-47, the system 200 also includes a drive assembl -.234 -for displacing the container 222 distally to establish the fluid connection between the container 222 and the patient needle 215, as well as dispensing the medicament from the container 222. in more detail, the drive assembly 234 includes an inner spring 236 disposed within a central plunger 238;, an outer plunger 240, an outer spring 242 disposed between the central plunger 238 and the outer plunger 240, a telescoping member 244, and a release gate 246,

jOftl 71 J Preferably, the inner spring 236 has a greater spring constant than the outer spring 242, and is therefore, stronger or stiller than the outer spring 242. The inner spring 236 is disposed inside the central plunger 238, and pushes between a spring flange 24 in the lower housing (best shown in FIG. 46) and the centra! plunger 238, which bears directly on the proximal end of the spacer 226 subsequent to device activation. The outer spring 242 is disposed inside outer plunger 240, and pushes between a proximal, external flange 250 of the central plunger 238 and a distal internal flange 252 of the outer plunger 240. Thus, the inner and outer springs 236 and 242 are nested, and can provide a more compact drive assembly (and thus, a more compact system.200) than employing a single spring.

100172J According to one aspect, the inner spring 236 acts only to displace the container 222 to establish the fluid connection with the patient needle 215, and the outer spring 242 acts only to subsequently dispense the .medicament from the container 222, According to another aspect, the inner spring 236 acts to displace the container 222 to establish the fluid connection with the patient needle 215, and also acts to begin dispensing the medicament from the container 222, and the outer spring 242 acts to complete dispensing the medicament, in a further aspect, the inner spring 236 causes the initial piercing of the container 222 with the outer spring 242 completing the piercing and dispensing of the medicament from the container 222.

10 173J As shown in FIGS. 44-47. and as subsequently described in greater detail, the outer plunger 240 includes a pair of proximal flanges or feet 254 that eac h ha ve a slanted surface that interacts with a corresponding slanted surface (or surfaces) on the release gate to retain and subsequently release the power module subsequent to actuation of the device 200,

100174} As best shown in FIGS. 46 and 47, as initially assembled, the container 222 is disposed in clearance from the drive assembly 234 and the valve assembly 212, A lateral flange 256 on the needle actuator 220 axially retains the medicament container 222, and the needle actuator 220 prevents the release gate 246 from displacing laterally. According to one embodiment, a spring (not shown) biases the needle -actuator 220 distally, hut the actuation button 210 (and/or its associated assembly) prevents -distal ^' displacement of the needle actuator 220 prior to actuation of the device 200. A status bar 258 is disposed on the needle actuator 220, and has a top surfac that is visible through the status view port 208, According to one embodiment, the top surface of the status bar has a plurality of colors or patterns, and when the device is in a pre-actuaied state, a first color or pattern, such as yellow, is visible through the status view port 208,

[001751 FIGS , 48-52 are top vie ws of the system 200 illustrating the -operation of events at and subsequent to actuation, of the system 200. In. FIG. 47, a. user slides the actuation button 210 pr ximally and then displaces the button 210 vertically into the housing 202, thereby freeing the needle actuator 220 to displace distally under the influence of the spring, (omitted for clarity). As shown, in FIG. 49, as the needle actuator displaces distally, tracks 260 on the needle actuator 2,2.0 interact with lateral bosses 262 on the needle arm 216 to insert the patient needle 215. Preferably at this stage, the proximal end of the needle actuator 220 has not yet cleared the release gate 246, and thus, the drive assembly 234 has not yet been released. But the lateral flange 256 has displaced distally -and. therefore, the container ^' 222 is unrestrained.,

[00.1761 Subsequently, as shown in FIGS, 50 and 51, with continued distal displacement, the _. proximal end of the needle actuator 220 clears the release gate 246 (thereby releasing the drive assembly 234). The needle actuator 220 comes to. temporarily rest against a feature on a rotatable release flipper 264, driving the release flipper 264 against an outrigger 266 (best ^■ shown in FIGS. 44 and 59) of th telescoping member 244. The .needle actuator 220 remains In this position wriii! the medicament has been dispensed. In this position, preferably, a second color or pattern of the status bar 258, such as green, is visible through the status view port 208. 1001.77} At this stage, the force of the springs 236 and 242 and the interaction of the angle surfaces of the proximal flanges or feet 254 with the corresponding angled surface (or surfaces) on the release gate 246 causes the release gate 246 to displace laterally, ^' thereby freeing the outer plunger 240 from restraining interaction with the release gate 246. Up to this point, the outer plunger 240 has been restraining the central plunger 238.

|00178J Referring to FIGS. 52 and 53 (the inner spring 236 is omitted from FIG, 52 for clarity), the stiff inner spring 236 distally dri ves central plunger 238 to contac the spacer 226, Because the medicament container 222 is filled with a substantiall incompressible fluid, the continued distal displacement of the central plunger 238 distally displaces the spacer 226, the stopper 224, and the container 222 relative to the housing 202, This distal displacement causes the Septum assembly 228 to be pierced b the valve assembly 212, establishing fluid c mmunication between the container 222 and the patient needle 215. The central plunger 23 S travels disially until its proximal external flange -250: (best shown in FIG. 59) contacts a flange on the lower housing 206, thereby limiting the "piercing travel" Preferably, another flange on the. lower housing 206 and/or th lateral flange 256 of the needl actuator 22 limits distal travel of the container 222,

001791 Subsequently, because the inner spring 236 can no longer disially displace the central plunger 238, the lighter outer spring 242 disially displaces the outer plunger 240 relative to the central plunger 238 to contact the distal flange.232 of the spacer 226, as shown in FIGS. 54 and 55, As subsequently described in greater detail, preferably, the contact between the outer plunger 240 and the spacer 226 is damped to minimize the impact force. Further expansion of the outer spring 242 disially displaces the outer plunger 240 to dispense the medicament,

O0180| As shown in FIGS, 56 and 57, as the outer sprin 242 continues, to expand and disially displace the outer plunger 240, upon a predetermined distal displacement of the outer plunger 240 relative to the telescoping member 244, an external, feature or flange 268 of the outer plunger 240 internets ^' with, an internal distal feature or flange 270 of the telescoping member 244 to "pick up" the telescoping member 244. This ensures that further distal displacement of the outer plunger 240 causes ^■ corresponding ^' distal displacement of the telescoping member 244. This paired distal displacement continues until the end of the medicament dispensing.

00:1811 As previously noted, tire outrigger 266 Is disposed on the telescoping member 244, The axial length of the outrigger and the distal travel of the telescoping member 144 controls the timing of the disengagement of the outrigger 266 with the: release flipper 264, As shown In FIGS. 58 and 9, at the end of medicament dispensing, the proximal end of the outrigger 266 bypasses the release flipper 264, This allows the release flipper 264 to rotate out of engagement with the needle actuator 220 (FIG. 60), and allows the needle actuator 220 to continue its distal displacement and withdraw the patient needle 215 (FIG. 1). At this stage, another color or pattern of the status bar 258, such as red, is visible through the status view port 208, signifying that the device 200 has completed, operation.

1821 As previously noted, the contact between the outer plunger 240 and the spacer 226, as illustrated in FIGS. 62 and 63, is preferabl damped to minimise the impact force. The highest level of energy dissipation is desirable for under-filled syringes containing viscous fluid, as the outer spring 242 will be stiffer to provide desired dispense rates. The lowest level of energy dissipation is desirable for maximum-filled syringes containing low-viscosity fluid. as the outer spring can be less stiff to ro ide desired dispense rates. Various methods can be employed to adjust damping. levels, such as air damping, or closed-cell foam damping,

|O0.t83J As another method of damping the impact force, FIG. 64 illustrates an embodiment of a spacer 226 in which one or more axial interface ribs 272 are circumfer^ntiall arrayed ^' about the central column 230 of the spacer 226. In ^' this embodiment, the outer plunger 240 must drive past the interference ribs 272, which provide frictional resistance to the distal displacement of the outer plunger 240 relative to the spacer 226, The frictional force created by the interference between interference ribs 272 and the outer plunger "240 is independent of plunger speed. Preferably, the frictional force does not exceed the minimum dispense spring load, to avoid stalling weaker springs. The interference can be tuned to give the desired level of frictional resistance. For different fluid viscosities, there can be different sizing (axial and/or radial) of th interference ribs 272. This -could mean a bespoke or custom spacer for each viscosity and. fill-level combination, or, depending on the number of springs required for a viscosity range, there can he a number of lined positions, whereb ^' the spacer can be set to a particular position for a- -particular modular spring, (the position have had. the interference/damping tuned for that particular spring load/viscosity scenario).

00t 4 Referring to FIGS. 65A-69, an actuator button arrangement 280 for actuating the system 10 according to one aspect of the present invention is shown. The actuator butto arrangement 280 includes the actuator button 26, a button spring 284, _. and a needle actuator body 286, The needle actuator body 286 ma be similar to the needle actuator bodies 96, 220 discussed above and configured to move within the housing 20 to transition the needle shuttle 102 or needle 28 between retracted and extended positions. As shown in FIG. 69, the actuator button 26 includes a user interface portion 288 for interacting with a user. Preferably, the user interface portion 28S is about 22. mm long and about 10 aim wide, although other suitable dimensions ma be utilized. The actuator button 26 includes two pairs of lockout arms 290, 292 that interact with button contacting surfaces 294, 296 on the needle actuator body 286 prior to device actuation to prevent the needle actuator body 286 from rocking upward. As shown in FIG. 65H, a overlap between the needle .actuator body 286 and, the housing 20 prevents premature actuation. Referring to FIG, 66, the button spring 284 includes a first bearing surface 298 and a second bearing surface 300 spaced from the first bearing surface 298, and a cantilevered central spring arm 302 surrounded by a pair of outer arms 304 that are joined by the first bearing surface 298.

jOOJSSJ The actuation butto arrangement 280 is configured, to provide one or more of the following features, which are discussed in more detail, below: one-way axial displacement or sliding of the actuator button 26; transverse movement (raised and depressed positions) of die ac toator button 26 where the actuator button 26 remains depressed during the use position -of the needle- actuator body 286; and lockout of the actuator button 26 in the post-use position of the needle actuator bod 286 such that the button 26 is in ^' the rais d position and cannot be depressed by a user.

001861 To actuate the system 10 using the actuator button 26, the user first slides the user interface portion 288 in first axial direction, shown as being to the right in FIGS. 65G and 65B, The user may be required to slide the user interface portion 288 about ID ram or about B mm, although other suitable distances may be utilized. Moving the actuator button 26 axially moves the lockout arms 290, 292 to clear the button contact surfaces 294, 296 on the needle actuator bod 286 to allow movement of the actuator button 26 from the raised position to the depressed position.

fO0187| As the user distalS slides the user interface portion 288, the central spring arm 302 of the button sprin 284 rides over a spring arm 306 bearing surface on the housing 2 while the first and second, bearing surfaces 298, 300 engage first and second bearing ramps 308, 310 on the housing 20. The forces on the button spring 284 are balanced through the engagement with the spring arm bearing surface 306 and the ^' first and second bearing ramps 308, 310 to provide a smooth axial displacement or sliding of the. actuator button 26,

1 01881 As the actuator button 26 and the button spring 284 reach the end of their axial sliding travel, the central -spring .arm 302 and ihe first bearing surface 298 pass the end of a respective stops 312, 3 ! 4 to prevent th actuator button 26 from sliding backward to its original position, as shown ^' in FIG. 65H. Further, when the actuator button 26 and the button spring 284 reach the end of their -axial sliding travel, the user engages: the user interface portion 288 to move the actuator button 26 -downward to its depressed position. The actuator button 2 may be depressed about 2 mm and the minimum force required t depress the actuator button 26 is about 3 N, and most prefera ly, about 2.8 N, although other suitable distances and minimum forces may be utilized.

| ^' 00189| As the user depresses the user interface portion 288, shown in FIGS. 65 A and 65B, the actuator button 26 rotates the needle actuator body 286 to release the needle actuator body 286 thereby allowing the needle actuator body 286 to move from the pre-us position to the ^• use position. As shown in FIG. 65B, as the needle actuator body 286 travels to the use position, the lockout arms 290, 292 ran along the underside of the button contact surfaces 294, 296 to prevent the actuato button 26 springing upward. After the medicament has been delivered and as the needle actuator body 286 is transitioning .irons, the use position to the: post-use position, shown in FIG. 65C- the lockout arms 290, 292 are disengaged from -the button contact surfaces

394, 296 allowing the■ actuator button 26 to spring hack up trader th influence of the button spring 284. Once the needle actuator body 286 fully transitions to the post-use position, shown in FIG, 65D, the actuator button 26 has finished movin from, the; depressed position to the raised position due to _: he biasing force of the button spring 284. When the needle actuator body 286 is in the post-use position, a spring arm 316 on the needle actuator body 286 engages the actuator button 26 to prevent the actuator button 26 from moving to the de ressed position while axial movement is still restricted by the engagement of the spring arm 302 with the stops 312, 314, Thus, the actuator button 26 is locked after delivery of the medicament is complete to provide a clear indication between a used system and an ^' unused system.

001 1 Furthermore, if the user holds down the actuator button 26 dining dispensing of the medicament, proper dosing and needle retraction will still complete, but the actuator button 2 will not spring back up to the raised position/until the button 26 is released.

1001 1} in one aspect, the button spring 2S4 is made of plastic. The button spring 284 may also be a pressed metal sprin could be used instead., although, an other suitable material may be utilized.

01 21 Referring to FIGS. 68A-68G, rather than providing a separate actuator button 26 and button spring 2 , the spring ma be provided integrally with the button 26. More specifically, an actuator button 320 according to a further aspect of the present invention includes an integral spring arm 322. The actuator button 320 also includes lockout arms 324, retention arms 3:26, and a rear pivot 328. As shown In FIGS. WD and 6 ^' 8E, the: spring arm 322 engages prongs 330 in the top portion 22 of the housing 20. During transition of the system 10 from the pre~use position to the use position, the spring arm 322 slides past a detent of the prongs 330 providin g an axial spring force. The end of the spri ng arm 322 engages a portio of the top portion 22 of the housing 20 to provide the vertical spring force as the spring arm 322 deflects. The actuator button 320 is configured to a fluid motion between the sliding and depression movements of the button 320 even though two separate motions are occurring, which is similar to the operation of the button 26 discussed above. During transition between the pre-use position and the use position, the button 320 pivots about the rear pivot 32$ _. with, the retention arm 326 engaging a portion of the need le actuator body .286 thereby mai ntaining a depressed position of the button 320 until the end-of-dose position is reached in a simitar manner as actuator button 26. The lockout arms 324 deflect inwards and engages a 'portion of the needle actuator body 286 as the needle actuator body 286 moves to the end-of-dose position thereby preventing further movement of the actuator button 320 in a similar manner as the actuator button 26 discussed above,

|00193J Aspects of the present invention provide improvements over previous button designs. For example, the actuation button ai aagement 280 provides multiple surfaces to hold the needle actuator body 286 in place against a needle actuator spring 106 prior to actuation, thereby reducing the likelihood of premature actuation during a drop impact. The actuation button arrangement 280 physically prevents the needle actuator body 2$6 from moving prior to actuation by holding it in a tilted {locked} state in such a wa that the surfaces have n room to separate and pre-acti vaie.

100194] In addition, button slide forces of the -actuation button arrangement 280 are controlled more precisely by utilizing a flexing arm rather than using a simple bump detent. This .permits, longer sliding strokes of the button 26 with better force control, resulting in a more ergonornieal!y effective design, Further, the actuation button arrangement 280 causes the button 26 to pop back out at the end of injection, giving the user an additional visual, audible, and tactile: indication, that, the medicament delivery is completed.

100195] According to one aspect, the fluid -delivery volume of the system 1.0 is determined by the end position of a plunger relative to a point inside the housing .regardless of actual fill volume, container inner diameter, and stopper starting position, and length . The dosing accuracy variability can be significant because the tolerances of the factors above can he quite large. Aspects of the present invention -allow for the elimination of some or all of these tolerances from the dosing equation, resulting in a more precise and less variable injection volume of medicament.

{00196] Referring, to FIGS. 7 A~?0G, a spacer assembly 400 for use in connection with a drive assembly according to one aspect of the present invention is shown.

00197] Elements ^' in a chain of tolerance in the stopper spacer assembl 400 include a thickness (A) of a flange 402 of an inner plunger 404, an internal length (B) of an outer plunger 406 between an internal ^' proximal end 408 and an internal shoulder 410, and an initial offset distance (Cs) between the. inner plunger flange 402 and the internal proximal end 408 of the outer plunger. This initial effect distance _. (Ci) is preferably greater than a gap di tance (Ci) between outer plunger 406 and the proximal end of the medicament barrel 412. The chain of tolerances in the stopper spacer assembly 400 als includes the internal barrel diameter (D), Once assembled, the stopper spacer 414 and the outer plunger 406 are unique for a given medicament vo lume. f 00198} FIGS. 7QB-70G illustr t operation of the stopper spacer assembly 400, As shown in FIG. 70B, when the system is actuated the both Inner and outer plungers 404 and 406 are released. An outer spring 4 6 pushes the outer plunger 406 ^' .into the barrel 412, compressing damping material 41 , and an inner spring 420, The stopper 422 does not yet mover relative to the barrel 412 due to the fl uid column of medicament.

001991 Next, as shown in FIGS. 70G, the outer spring 416 distaity displaces the outer plunger 406 and the barrel 412 to open a valve (not shown) at the distal end of the barrel 412 that esiablishes fluid communication with the needle (not showa). Due to die ineompressibility of the liquid medicament, the stopper 422 cannot displace relative to the barrel 412 until, the valve is opened and the fluid path to the patient needle is established.

|0020O] Subsequently, as shown in FIGS. 70D and 70E, the inner spring 420 displaces the inner plunge 404, the stopper spacer 414, and the .stopper 422, to dispense the fluid.

100201} FIG.70F illustrates the end of medicament delivery when the proximal flange 402 of the inner plunger 404 contacts the internal shoulder 410 of the outer plunger 406, thereby ceasing displacement of the inner plunger 404 (and the stopper spacer 414 and stopper 422) relati ve to the medicament barrel 212 and stopping the flow of medicament.

100202] According to one aspect, as shown in FIG, 70G, the cessation of displacement of the inner plunger 404 relative to the medicament barrel 412 triggers an end-oiklose indicator for the system.

|00203] Referring to FIGS. 71 and 72, a collapsible spacer assembly 43 includes a forward spacer portion 432 secured to a stopper 434, an inner plunger 436, a rear spacer portion 438., and a rotating shuttle 440, The inner plunger 436 can translate relative to the forward, spacer portion 432, but not rotate relative thereto. Similarly, the rear spacer portion 438 can also move axial Sy relative to the. forward, spacer portion 432, hut not -rotate relative to the forward spacer portion 432. As subsequently described in greater detail, the rotatin shuttle 440 first rotates, and subsequently translates.

1002 41 According to one aspect, .forward spacer portion 432 is fixedly secured to the stopper 434, One skilled in the art will understand that many methods can be employed to secure the forward spacer portio 432 t the stopper 434, lor -example, adhesive, mechanical fasteners, or any other suitable arrangement. Preferably, the forward spacer portion 432 includes threads that engage mating threads in the stopper 434.

100205} When the stopper spacer assembly 430 is screwed into the stopper 434, an axial load is applied through access openings 442 in the mar spacer portion 438. This force can be used to push the stopper 434 forward, applying pressure to the fluid medicament. This pressure causes the front (distal) face of the stopper 434 to deflect and press proxtmaliy, pushing hack on the rear spacer portion 438 and rotating the rotating shuttle into Its "as assembled" condition, in other words, when a medicament barrel is filled with medicament and the system's plunger is applying axial force to the. medicament vi the spacer assembly 430, the distal face; of the stopper 434 is deformed by the pressure of the medicament. During me icame t delivery, pressure is applied by a drive assembly (via the plunger) to the rear spacer portion 438 _» which in turn applies a rotational torque, to the rotating shuttle 440 via helical faces 444 of the rear spacer portion 438. But the stopper deformation from the medicament provides rearward or proximal force on the inner plunger 436, which prevents rotation of the rotating shu ttle 440. 100206] According to one aspect, an axial reaction load on the inner plunge 436 can b increased by increasing the length of the inner plunger 436.

[002071 Once the medicament delivery is complete, as shown in FIG. 73, t e pressure on the stopper 434 decreases, thereby ^■ permitting the distal end of the inner plunger 436 to displace distal!y. This distal displacement permits the rotating shuttle 440 to rotate. The continued axial force applied by the drive assembly rotates and distal ly di splaces the rotating shuttle 440 due to interaction of the helical faces 444 the rear spacer portion 438 with coirespc ding cam faced arras 446 of the rotating shuttle 440. According to one aspect, this final movement of the rotating shuttle 440 cause the drive assembly to trigger needle retraction.

1002081 Referring to FIGS. 74 and 75, a restriction member 452 according to one aspect of the present invention is disposed with the drive assembly, The restriction member 452 governs the timing of the final displacement of the needle actuator bodies 96, 220 subsequent: to the completion of the medicament dose, instead of rotating about a fixed post, the restriction member 452 floats freely. Once a plunger displaces sufficiently d!sta!!y for a gap to align with the restriction member 452 (as shown in FIGS. 74 and 75), the restriction member 452 displaces laterally into the gap because of the force of the spring on the needle actuator 96, 220 and the angled face 454 on the rear of the arm of the restriction member 174 that engages the needle actuator body (best sho wn in FIG, 75). Once the restriction member no longer retains the needle actuator body 96, 220. the needle actuator body 96, 220 is. free to complete the axial movement to the post-use position. Further, as shown in FIG. 75, the restriction member 452 is biased onto the rear of the barrel portion of the containe 14, which minimizes the tolerance chain of the various components and improves dose accuracy.

00209] Referring to FIGS. 76«78, a spacer assembly 460 according to a further aspect of the present invention is shown. The spacer assembly 460 shown in FIGS, 76-78 allows for the removal of the effect of Biaiiufeetoring tolerance build tip through adjustment of the spacer assembly thereby allowing each system to inject the sam amount of medicament

|002l(lj As shown in FIG. 77, the spacer assembly 460 includes a stopper 462 and a stopper spacer 464. The stopper spacer 46 includes a fixed spacer piece or fixed spacer 466 that is fixedly connected wi th the stopper 462, and an adjustable spacer piece or adjustable spacer 468 that is rotationaUy displaceahle in one direction relative to the fixed spacer 466.

jjQOll IJ One skilled in the art will understand that many methods can be employed to secure the fixed spacer 466 to the stopper 462, for- example, adhesive, mechanical fasteners, or any other suitable arrangement. Preferably, the fixed spacer 466 includes one or more external threads that engage one or more mating threads in the stopper 462. According to one aspect, the adjustable spacer 468 has a distal stem with an externa! ihread 470. The distal stem thread. 470 engages an internal ihread 472 in the fixed spacer 466 (best shown in FIG. 78) to rotationally control axial displacement of the adjustable spacer 468 relative to the fixed spacer 466.

|O02I2| As shown in FIGS _* 76 and 77, the fixed spacer 466 includes radially spaced detents 474 and the adjustable spacer 468 includes spring detent arm 476, the free end of which, engages a selected one of the detents 474 to prevent rotation and axial displacement of the adjustable spacer 468 toward the fixed spacer 466. The free.ertd of the spring detent arm 476 is shaped to pass over the detents 474 in one direction, thereby permitting rotation and proximal axial displacement of the adjustable spacer 46$ away from the fixed spacer 466,

100213} Despite variations in the dimensions of stoppers and containers, the adjustable spacer 468 can be adjusted relative to the fixed spacer 466 to provide a consistent axial length of the stopper assembly 460.

j i>2 J 41 As shown in FIG. 78, once the container is filled, an axial load, such as a load that would be encountered when installed in the system 10, 200, can be applied to the adjustable spacer 468 (and thus*, the fixed, spacer 46 and the stopper 462). Once the axial load is applied, the adjustable spacer 468 can be proximail backed out to ensure a consistent gap 478 between the proximal end of a medicament barrel 480 and the proximal face of the adjustable spacer 468, thereby accounting for variations in the medicament barrel glass and the compressibility of any entrapped air. in other words, the spacer assembly ^" 460: allows the adjustable spacer 468 to have a predetermined set position relative to the container 14 independent of the variables of the container 14 and stopper length. Accordingly, the start position of the spacer assembly 460 Is a predetermined distance from the container 14 and the end position of the spacer assembly 460 is also -a .predetermined distance from the container 14 such that the travel of the stopper 462 is defined by the effective length of the plungers 52, 54 of the drive assembly 12. |00215J Referring to FIGS. 79 and 80, a base column 482 and a cap 484 of an automatically, adjusting spacer 486 according to one aspect of the present invention Is shown. The base column 482 includes: a base portion 488 and an axially extending column 490. According to one embodiment, the base column 482 includes a plurality of columnar protrusions 491 that each have plurality of ratchet teeth 492 disposed on a proximal. portion thereof A locking barb 493 is -disposed at the proximal end of each of the plurality of ratchet teeth 492. The cap 484 is hollow, and a distal end of the cap 484 includes one or more axial springs 494. According to one aspect, the axial springs 494 are bent, eantilevered arms formed during molding of the cap 484. According to another aspect, a separate biasing member, such as a compression sprin can be employed in the automaticall adjusting spacer 486.. When assembled with the base column 482, the springs 494 engage, the base portion 488 and maintain an initial spacing between the base column 482 and the cap 484, According to one aspect, the springs 494 are omitted. The cap 484 also includes a plurality of flexible eantilevered arras or tabs 496, which, each have a free proximal portion with a plurality - interna! of ratchet teeth 497. The proximal end of each flexible tab 496 includes a foo 498:.

f0i}216J FIG. 81 B illustrates the cap of the automatically .adjusting spacer deployed within a proximal recess of a stopper 494 at a proximal portion of a medicament barrel . The base column 482 is assembled into the hollow cap 484 with the base portion 482 engaging the stopper 494 and the feet 498 disposed outside the proximal end of the barrel.

100217) in operation, as shown in FIGS. 81 A and 81 B, the cap 484 displaces disia!ly relative to the base column 482 (as well as the stopper 494 and the barrel) until the proximal end of the cap 484 is flush with the end of the medicament barrel. This action, causes the feet 498 to engage the internal surface of the barrel and displace radially inward, thereby forcing the ratchet teeth 492 into locking engagement with the ratchet teeth 497, The locking barb 493, the engagement of the ratchet teeth 492 and 497, and the engagement of the feet 498 with the internal surface of the barrel prevents the displacement of the cap 484 relative to the base column 482. Thus, the automatically adjusting spacer 486 can - accommodate, differences in. stoppers, barrel diameters, and medicament fill volumes, to automatically provide a bearing surface Hush the proximal end of the medicament barrel

002 ^" l 8J One aspect of the present Invention is a spacer assembly 486 that is situated: against the stopper in the container within the system, The spacer design is such that its effective length can be adjusted in order to allow the dispensing of a precise quantity of medicament. The length adjustment is intended to compensate ibr maoufeetnring tolerances within the container, the fill volume, and especially the · stopper length, which can add up to 1/3 of the variability in a delivered dose using a non-adjustable spacer. The spacer length can he adjusted through several techniques, depending on the specific aspect. The spacer length can be self adj usting based on its location to the back of the container, it can be adjusted by assembly equipment at the time of final assembly of the primary container into the subassembly, and it can be made an integral p rt of the stopper and adjusted as a subassembly prior to filling. The adjustable spacer 486 allows a more precise volume of fluid to be injected compared to a non-adjustable stopper. £011219} Referring to FK3S. 82-87, a drive assembly 500 for a drug delivery system according to one aspect of the present invention is shown. The drive assembly 500 includes an actuation button 506, container 508, a needle actuator assembly 510, an actuation release- or Slipper 51.2, a lead screw 514, and -a plunger 516. The lead screw includes a drum portion 518 with external radially-protTodlng va es 520,, and, as best shown in FIGS. 84 and 85 and subsequently described in greater detail, a screw thread portion 52.2. Prior to activation, as best shown in FIGS. 83 and 86 one end 513 of the actuation release 512 engages one of the vanes 520 to prevent rotation of the lead scre 514.

{00220! According to one aspect, as shown in FIGS. 84-86, the screw thread portion 522 of the lead screw 514 engages .internal threads o -a .nut. 524 connected, with- the- plunger 51.6. According to another aspect, the nut and its internal threads are integrally formed with the plunger as a unitary structure. Additionally, a constant force spring 526 is received within the drum portion 518 and biases the lead screw 5.14 in a rotational direction. According to one aspect, the spring 526 is secured to the base cover 04. According to another aspect, as shown In FIGS. 84-86, a drive assembly housing 528 is disposed within the system and the spring 526 is- secured, to. the power pack housing 528.

{00221J Unlike a helical spring, such as a compression spring, which has a force profile proportional to its displacement, the constant force spring 526 and the like maintain a relatively fiat or even force profile over a long working length. The even force profile advantageously provides an injection, force that is proportional to the spring force. This will provide a fiat or even, injection force, and thus, a substantially constant injection, rate for the medicament. Although the spring 526 is illustrated in FIG. 86 as having -only two turns of material,, one skilled in the art will appreciate that fewer or greater numbers of turns can be employed. Preferably, an assembler winds the spring 526 when the drive assembly 500 is assembled, and the spring 526 is stored in the wound position until the time of actuation. {00222] Upon actuation of the system, the needle actuator assembly 510 is released to axiaUy displace (to the ri ht in FIGS. 82-85) from the pre-use position to the post-use position under the influence of a biasing member 530 (best shown in FIG, 83). During this displacement, the needle actuator assembly 510 bears against a second end 532 of the actuation release 512 and rotates the release 512 conn ter-ciock wise, as shown in FIG. 87. This counter-clockwise: rotation of the actuation release 512 frees the first end 513 thereof from engagement with the vane 520. Subsequent to the disengagement of the first end 513 from the vane 520, the spring 526 unwinds and drives rotation of the lead screw 514, which, in combination with the nut 524, advances the plunger 514 to dispense the medicament.

100223] As the lead screw 514 is rotating, the rotation of the drum portion 518 and the vanes 520 is visible through a window 534 in the housing. This window 534 indicates progress of the screw in. a. way that is much more apparent than viewi g the linear movement of the stopper 536 in the container 508* In feet, this rotational movement is many times more sensitive than the linear movement One skilied in the art will appreciate that the exact amount of advantage or increase depends on the pitch of screw thread portion 522 of the lead screw 514, the diameter of the drum portion.518, and number of vanes 520 on. the dram, portion 518.

00 24} Referring to FIGS. 88-93, a drive assembly 600 for a drug delivery system according to a further aspect of the present invention is shown. The drive assembly 600 acts t store a spring's mechanical energy and to activate it when triggered. The drive assembly 600 includes a medicament barrel 601, a stopper 602 slidably disposed in the barrel 601, a first valve plunger 603, a second valve plunger 604, a first revolve nut 605, and a second revolve nut 606, The drive assembly 600 also includes a rotary indicator 607, a locking element 608, a constant force spring 609 disposed within the rotary indicator 607, and an actuation release or flipper 610. The drive assembly 600 is at least partially disposed within a housing 61 1 that can be assembled into a drug deliver system.

00225] The constant force spring 609 is contained ^' between the housing 611 and the rotary indicator 607 within a drum portion 616 of the rotary indicator 607. The drive assembl 's inactive state is such that energy is applied- by uncoiling the spring 609 and harnessing this energy geometrically with the housing 61 1, rotary indicator 607, and actuation release 610, When the drive assembly 600 is deactivated, the spring recoils and translates the mechanical energy into rotational motion of the rotary Indicator.

{00226} The telescoping multi-part plunger is oriented along a force axis between the medicament barrel 601 and the rotary indicator 607. The rotary indicator 607 features a threaded shaft 618. According to one aspect, the threads are dual lead, and are either square or rectangular in nature. The multi-part telescoping plunger includes a two-part threaded nut (first revolve nut 605 and. second revolve nut 606) and a two-part lunger (first valve plunger 603 and second valve plunger 604). The second revolve nut 606 is a threaded shaft that mates with the rotary indicator 60? and first revolve nut 60S and features matching threads on it inner and outer surfaces (internal and external threads, respectively) to mat with. them. The second revolve nut 606 also has a circular collar 620 (best shown in FIG. 92) on its proxiraai end that bottoms down on the second valve plunger 604. The second revolve nut 606 is free to spin, along the force axis. The first revolve nut 605 is also a threaded shall that features threads on its inner diameter corresponding to the external thread of the second revolve mit 606 to mate with the second revolve nut 606.

jO022?J According to one aspect, on one end, the first revolve nut 605 has a hexagonal collar that press fits on the first valve plunger 603 to fixedly connect the first valve plunger 603 with the. first revolve nut 605. In the drive assembly 600, the first revolve nut i not free to rotate and will only translate when the power module subassembly is actuated,

|O0228| The second valve plunger 604 is a -hollow .cylindrical .component with a small collar

622 on Its distal end, a large collar 624 on its proximal end, and an extended L-shaped arm 6.26 (best shown in FIG. 93.) protruding from the large proxiraai collar 624. According to one embodiment the small collar 622 is discontinuous and features four leaf eamiievered amis or leaf springs 62 that allow th collar to bend and mate with the first valve plunger 603. The inner surface of the second valve plunger 604 ha an un ercut through its length ^' terminatin .at its proximal nd a radially inward protruding, shelf 628 of the large collar 624. The shelf 628 engages the second revolve nut 606 within the telescoping assembly.

f0§229ji The first valve plunger 603 attaches to the stopper 602 and is also a hollow cylindrical component that mates. ith the second valve- plunger 604. More specifically, the first valve plunger 603..features, a cylindrical protrusion 630 on its distal end to mate with the stopper 602. According to one aspect, as best shown in FIG. 89, four thru slots 632 are- disposed on the proximal quadrants of the first val ve plunger 603 to mate with the leaf springs or arms

623 and small collar portion 622 of the second valve plunger 604. Both, the first and second, valve plungers 603 and 604 are free to slide.

f 0 2361 Telescoping is achieve when the- constant force, spring 609 recoils and the rotary indicator 607 starts spinning. The threaded attachment between the rotary indicator 607 and the second, revolve nut 606 causes second revolve nut 606 to rotate. But because the second revolve nut 60 I threaded to the first revolve nut 605, which cannot rotate and experiences resistance to distal translation due to the pressure caused by .medicament in. the barrel 603 , the second revolve nut 606 will displace proximally and bottom out on the second valve plunger's radially inward, protruding shelf 628. The second valv plunger 604 is prevented front displacing proximally by the housing 61 L Subsequently, and with continued rotation of the rotary indicator 607, because the second revolve nut 606 is threaded, with the first revolve mi 605 (which cannot rotate) the first revolve nut 605 .translates distaliy to push/the first valve plunger 603 (and the stopper .602) to dispense medicament from the barrel 601.

jO0231J The. first valve plunger 60 displaces distaliy relative to the second valve plunger 604 until the small collar sections 622 {respectively disposed on the distal ends of the leaf springs or am s 623 of the second valve plunger 604) engage the corresponding proximal ends of the slots 632 of the first valve plunger 603. This locks the relative positon of the first and second valve plungers 603 and 604, with continued rotation of the rotary indicator 607, both valve plungers translate distaliy while also pushing the second revolve nut. along (because of its proximal engagement with the shelf 624),

(M)232f The initial and final positions of the telescoping plunger, and thus the medicament dose, are controlled, by the■rectangular thread form of the threaded shafi 618 of the rotary indicator 607, a threaded shaft on the dram portio 616 of the rotary indicator 607, and a stepped pin that acts as the locking element 608. According to on aspect, threaded shaft on the drum portion. 616 of the rotary indicator 607 is single lead, and because the rest of the components in the telescoping chain have dual lead threads, the axial travel of the other threaded components is twice the axial travel of the lock 60S relative t the rotary indicator. 00233] According to one embodiment, the lock 608 is cylindrical and features a domed tip on one end and a cylindrical colla o the other. The thread oft the exterior of the rotary indicator's dram portion 616 along with a slot and undercut 63 at the bottom of the housing 61 1 captures the lock 608 in place, allowing it to slide parallel to the force axis. Thus, as the spring 609 is released and the rotary indicator 607 turns, the lock 608 translates as well and creates a positive stop when the distal end. of the thread on the exterior of the rotary indicator's dmm portion 6.1 is reached.

100234} One benefit, of aspects of the .drive, .assembly 600. include the use of a constant force spring 609, the mechanical energy of which is converted into- substantially constant-linear force to the medicament in the barrel 601. In turn, this creates a uniform medicament delivery rate. Another benefit is that employing the telescoping plunger driven by a thread form,, the drive assembly can create in-line space savings of up to 0.75 inches compared to other plunger designs. Additionally, the drive assembly provides a controlled medicament, dose through an initial and final mechanical constraint within the same component. |0§235J As previously noted, other drug delivery systems utilize a compressed, coil spring, which exerts a maximum force at actuation that eventually decreases as the spring expands.. A decreasing force at the plunger translates into variable medicament delivery time and medicament exit pressure. By using a constant force spring, the force exerted on the plunger is constant from the beginning to the end of the dosage, hi addition, the distance a coil spring has to travel in addition to the length of a static plunger that needs translate inside the drug container can create a long assembly, In. contrast, in embodiments of the present in vention, the constant force spring is contained radially and does not require any additional space befor or after activation. Furthermore, the aspects of the telescoping plunger allow that the plunger length of the can be significantly reduced in comparison to the length of a static plunger.

1002361 Previous drug delivery systems have variable dose accuracy performance because the mechanical components enablin the drug delivery create geometric dependence by bottoming down on the container, which cannot be fabricated, with tight tolerances. Some embodiments of the present invention create a control to the start and end times of the translating plunger via a thread form in th rotary indicator and the use of the constant force spring.

100 37} The drive assembly creates a space saving geometry in addition to well-controlled time, volume and pressure; for the drag delivery device, which: translates t a more attracti vely compact and precise drug delivery device.

j00238J Some aspects of the drive assembly implement thre rotating threaded shafts to create a linear space savings of about 0.75 inch. In other aspects, the same concept can be employed using two rotating threaded shafts ^' and result in a space savings of about 0.5 inch. Some aspects of the present invention con vert the rotational energy of a cons tant force spring to a tenslational force motion of a plunger.

00239} Referring to FIGS. 94-100, a spacer assembly 660 according to a further aspect of the present invention is shown. The spacer assembl 660 is similar to the spacer assembl 460 discussed above and shown in FIGS. 76-78 and operates in a similar manner to achieve similar advantages. The spacer assembly 660 -includes a fixed spacer 666 and an adjustable spacer 668. The fixed spacer 666 is configured to be received, by the stopper 462 with, lugs 670 engaging the stopper 462 to secure the fixed spacer 66 within the stopper 462, although other suitable securing arrangements, such as threads, may be utilized. The fixed spacer 666 includes interior threads 672 that receive exterior threads 678 of the adj sta le space 668, The fixed spacer 666 includes a plurality of detents 674 positioned on a helical portion of the fixed spacer 666, The adjustable spacer 668 includes a spring detent ami 676 that engages one of the detents 674 to prevent rotation and axial displacement of the adjustable spacer 668 relative toward the fixed spacer .666, The spring detent ^" arm 676 is shaped and configured to pass over the detects 674 in one direction to allow rotation and axial, displacement of the adjustable spacer 668 away from th fixed spacer 666. The adjustable spacer 668 may be initially secured to the fixed spacer 666 via the threads 672, 78 by applying a force to the top of the spring; detent arm 676, which biases the spring detent arm 676 away from the detents 674 to allow the spacers 666, 668 to be secured to each other. Accordingly* in. the same manner as discussed above in connection with spacer assembly 460, the adjustable spacer is free to rotate i one axial directio to adjust the length of the spacer assembl 660.

fO0240J Referring again to FIGS, 94-100, -the spacer assembly 660 further includes a shim 680 configured to be received and secured to the adjustable spacer 668, Rather than providin a plurality of .sizes of adjustable spacers 468, 668, a plurality of shim 680 sizes can be provided to accommodate a plurality of different, fill volumes within the container 14. The shim 680 may be secured to the adjustable spacer 668 via a connector 6S2 extending from the shim 680 that is received by the adjustable spacer 668 using a snap-tit, although other suitable securing arrangements may be utilized, A center portion 684 of the fixed spacer 666 is configured to be engaged while the adjustable spacer 668 is rotated relative to the fixed spacer 666 to prevent rotation of the fixed spacer 666 along with ^' the. adjustable spacer 268. The center portion 684 of the fixed spacer 666 is accessible through an opening in the shim 680,

|00241 Elements of one disclosed aspect can be combined with elements of one or more other disclosed aspects to form different combinations, all of which are considered to be within the scope of the present invention .

f0§242ji While this disclosure has been described as having exemplary designs, the present disclosure can- be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any -variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims,