Injector device, and method for its operation, for containers of syringe type, comprising a barrel of axially roughly constant cross-section, a front opening and at least one movable wall inserted in the barrel for displacement of a container content, the injector comprising a) a housing or housing part arranged to receive the container at least axially stationary, b) an integral or composite piston rod arrangement operable to displace the container movable wall at least in the forward direction and c) a track system for controlling or sequencing the piston rod movements, the track system comprising at least one cooperating track and follower, the cooperating track and follower being arranged stationary with respect to the housing and the piston rod respectively, or vice versa, and in cooperation allowing at least one forward for the piston rod. The track system comprises arrangements initiation, dose setting and expulsion of container content.

The present invention relates to an injector device for containers of syringe type, comprising a barrel of axially roughly constant cross-section, a front opening and at least one movable wall inserted in the barrel for displacement of a container content, the injector comprising a) a housing or housing part arranged to receive the container at least axially stationary, b) an integral or composite piston rod arrangement operable to displace the container movable wall at least in the forward direction and c) a track system for controlling or sequencing the piston rod movements, the track system comprising at least one cooperating track and follower, the cooperating track and follower being arranged stationary with respect to the housing and the piston rod respectively, or vice versa, and in cooperation allowing at least one forward for the piston rod. The invention also relates to a method for operating such a device.
Although simple in principle injection procedures based on syringe type devices with injection needles require mastering of several discrete steps. Before the mere injection procedure some initiation actions may be required. Filling the syringe with medication withdrawn from a reservoir such as a vial may be needed, taking into account the proper dose to be administered. In order to avoid this step in the actual treatment situation it is common to provide pre-filled syringes, in which case, however, a dose setting or selecting step may be needed. In its first movement the syringe piston may need an extraordinary break-loose force after storage to overcome both internal reshaping resistance and an increased wall friction due to adherence or depletion of lubricant in contact points. For storage and shelf life reasons pre-filled syringes sometimes are delivered in dual or multiple-chamber form, requiring an additional mixing step immediately before treatment. De-aeration and pre-ejection are generally needed to remove gas in the vessel compartment and fill out spaces for example at the front sealing, outlet attachments and the interior of the outlet devices or needles. Syringes containing multiple doses further requires repeated ejection of predetermined volumes under avoidance of both over and under dosing, overdosing generally being irreversible and under-dosing often being undetected or unavoidable when ejecting an insufficient last dose from the syringe. Proper sequencing of all these steps are crucial to a safe and non-traumatic treatment.
These demands can be met also when using the simplest injection devices, such as the common hypodermic syringe, when in the hands of a skilled operator who also may initiate medically relevant corrective measures in case of accidents and malfunction. However, a general treatment trend is to place administration responsibility on the patients themselves, also in the case of child, elderly and disabled persons. In long-term treatment the patient often develop a certain skill but less frequent administration schemes also exist, often including situations of emergency or patient imbalance. Other unique problems in patient selfadministration, as compared to assistant operated administration, is that less suitable and often strained body positions are required and that apprehended or experienced pain or discomfort may interfere with the medically desirable action pattern. In summary, especially the selfadministration requires more sophisticated devices to facilitate the injection procedure and avoid or reduce risks for mistakes. Patients dependent on daily or occasional administrations also have a legitimate need for convenience and devices discrete enough to be brought around in daily life. Yet it is desirable that such sophistication and convenience is kept simple and inexpensive to allow for widespread distribution and inclusion also in disposable devices.
Various proposals have been put forward for injector devices assisting the user in many of the steps outlined. While meritorious in some respects none seem to deal with more than part of the total sequence. The U.S. Pat. No. 5,244,465 describes limiting arrangements for securing a single ejection of one of several selectable dose volumes. The U.S. Pat. No. 4,050,459, GB 1230522 and DE G8509572 specifications describe various trail for securing repeated multiple equal doses of predetermined volume. The U.S. Pat. Nos. 3,517,668 and 5,807,346 and the PCT/CH96/00115 application describe arrangements for multiple ejections of selectable dose volumes. The U.S. Pat. No. 4,832,694 describes a trail arrangement for a single aspiration and ejection cycle under prevention of any reverse movement. The specifications referred to do not give any solutions to the earlier phases in injection sequence or how to integrate such phases. The U.S. Pat. Nos. 4,968,299, 4,874,381, 5,080,649 and 5,728,075 and WO 93/14799 all relates to arrangements for securing mixing of contents in two chamber syringes followed by injection, utilizing a screw-threaded mechanism for the mixing phase. Again these suggestions only relate to a part of the overall operation.
Accordingly there is a continuing need for simple and inexpensive injection devices able to assist the user in the various handling steps involved, preventing or ameliorating mistakes and offering an ergonomic, convenient and non-traumatic product, especially useful for patients under self-administration. Although the present invention may have a more general utility, it will mainly be described against this background.
A main object of the present invention is to avoid the disadvantages of known injection devices as described. A more specific object is to provide an injection device able to assist the user in proper performance of all or most operation steps up to and including injection, such as, when applicable, chamber mixing, de-aeration, dose selection and ejection of single or repeated pre-determined doses. Another object is to provide a device assisting the user in securing a proper sequencing of such steps. Still another object is to provide a device being mechanically programmed for proper sequencing. A further object is to provide a device with improved dose setting properties and suitable for delivery of varying doses. Yet another object is to provide a device usable for single or multiple controlled ejections from a container. Another object is to provide a device compatible with pre-filled syringes of various natures. Still another object is to provide a device suitable for self-administration. A further object is to provide a device convenient to handle. Yet another object is to provide a device having few and simple parts, yet giving high operation safety and precision. Still another object is to provide a device easy to manufacture and assemble. Another object is to provide a simple device of low cost, usable as a disposable device. A further object is to provide methods for operating the devices as described.
These objects are reached with the device and method having the characteristics set forth in the appended claims.
By use of a program arrangement based on a system of cooperating tracks and track followers several objects are met. An overall simple design is possible, which can be implemented in low cost parts. It also allows high flexibility in part selection for the cooperating parts and few components are needed if placed on the standard syringe parts, such as housing and piston rod construction, and even so a track can be arranged either on one or the either part, with the follower on the opposite, or a combination thereof for highest program flexibility and for allowing secondary considerations, e.g. in respect of strength and manufacture. The system can be used to positively urge the user into one action sequence only and can even be made irreversible by use of one-way structures. Yet the system is also compatible with reversible action at selected points in the sequence, e.g. when setting the dose, by simply allowing two-directional relative track and follower movements or such movement in an endless loop, e.g. around the device circumference. It is compatible with both axial and rotational movements, and combinations thereof, and can serve to give force or speed transformation, such as in a screw-threaded track, e.g. high force for piston break-loose and low speed for cautious mixing. Use of several track parts branching off from a common track part makes it possible to select one of several programmed paths, e.g. for setting variable doses. Guided multiple dosing systems are offered, e.g. by extending track parts into consecutive axial and transversal parts, optionally with repeated branching to create multiplied alternatives. This with maintained option of combining with a common program part, e.g. for initiation steps with compulsory change therebetween, including de-aeration and unification movements for multiple chamber containers, the latter with option of combining with screw-threaded track parts, as known per se. The system can be divided into more than one track and follower parts, if arranged so that the parts do not counteract, for further program flexibility or design freedom, e.g. with consideration to device size, strength, manufacture etc., or to allow for different characteristics in the various program phases, e.g. several followers for mechanical rigidity in phases not requiring many alternatives, such as initiation, whereas a single follower can be used for phases requiring several alternatives, notably dose setting, for full utilization of available surface for program structures or indicia. It should be noted that in spite of the multitude of functions possible the device can be extremely simple and in its most extreme form the entire track system can be molded or pressed into one surface, e.g. the piston rod outer surface or the hosing inner surface with the follower point structures on the opposing surface, requiring no more than minimum parts. This in strong contrast to prior art devices, which typically require multiple parts already for dose setting, offers multiple ejections only of one dose or requires additional reciprocating parts, use different mechanisms for multiple chamber mixing and often neglect or and leaves to the user the problem of de-aeration and pre-ejection. The simplicity provided meets the objects of device low cost, small size and suitability for disposable design. It also meets the objects of easy manufacture, assembly and compatibility with various container designs. The complete programming and few movements required meet the objects of safety, convenience and suitability for use in patient self-administration.
Further objects and advantages will be evident from the detailed description of the invention hereinbelow.
In the absence of explicit statements to the contrary, as used herein expressions like xe2x80x9ccomprisingxe2x80x9d, xe2x80x9cincludingxe2x80x9d, xe2x80x9chavingxe2x80x9d, xe2x80x9cwithxe2x80x9d and similar terminology shall not be understood to be exclusively restricted to recited element but shall be understood to allow for the presence of further elements as well and shall be understood to cover any element in integral, subdivided or aggregate forms. Similarly, expressions like xe2x80x9cconnectedxe2x80x9d, xe2x80x9cattachedxe2x80x9d, xe2x80x9carrangedxe2x80x9d, xe2x80x9cappliedxe2x80x9d, xe2x80x9cbetweenxe2x80x9d and similar terminology shall not be understood to cover exclusively direct contact between the recited elements but shall be understood to allow for the presence of one or several intervening elements or structures. The same applies for similar expressions when used for description actions.
The injector described herein may be used for a variety of purposes within and beyond the medical area and for any type of preparations, such as chemicals, compositions or mixtures, in any container and delivered for any purpose. For reasons outlined the system have certain special values in connection with medical delivery devices where also the design constraints are more severe than in most other applications. For convenience the invention will be described in terms of this application.
Normally the material to be delivered is a fluid and preferably a liquid, including materials behaving as liquids such as emulsions or suspensions. These observations relate to the final preparation whereas other components, notably solids, may be present before final preparation. The nature of container content shall also be understood to include medical in broad terms and to embrace for example natural components and body fluids pre-filled or drawn into the container although most commonly the medical is factory prepared. Although the principles of the invention are mainly described with respect to ejection they are equally applicable for aspiration steps.
The containers usable in the present injectors generally comprises a container for the preparation and an opening through which the preparation can be delivered and a broad range of container types are useful. Syringe type containers are preferred for use in the present injector and shall be understood in broad terms and can generally be said to include a barrel having a front part and a rear part defining a general axis, an outlet for the preparation, typically comprising a liquid in broad sense, arranged at the front part and at least one movable wall arranged at the rear part, a displacement of which wall causes the preparation to be moved towards or expelled through the outlet. Barrel shape and movable wall have to be mutually adapted. The barrel of for example glass or plastic may have a substantially constant internal cross-section, with a similarly constant barrel axis, between front and rear parts giving a generally tube-shaped barrel, and most preferably the cross-section is of the common circular type giving a substantially cylindrical barrel. The movable wall is then preferably a substantially shape-permanent, although possibly elastic, body sealingly adapted to the internal barrel surface and preferably of the piston type. Depending on the use purpose for the injector, at the outlet a needle, a cannula, an infusion tube or a similar delivery may be in fluid connection with the opening, e.g. by being arranged on, at or with a conduit to the opening. Within these limits and preferences a broad range of syringe type containers can be used with the present injector device, such as ampoules, cartridges, carpoules and syringes. It is also within the spirit of the invention that the container is not a separate part from the housing but that the housing integrally comprises the container although in most instances it is preferred that the container is a separate part. The container need not have a separate plunger but it is preferred that the piston rod to be described can act more or less directly on the container movable wall, although it is fully possible that the container has a plunger, in the sense of a part protruding from barrel rear end, on which the injector piston rod can act for movement of the piston, since many standardized devices are so designed. The injector can with preference be used with standard container types, e.g. as defined in DIN and ISO standards. Also usable are dual or multi chamber container types, known e.g. for preparations demanding a mixing of two or more components or precursors before administration. The components are kept separated by one or more intermediate walls of different known designs, which walls divide the barrel into several chambers, sometimes placed parallel along cartridge axis but most commonly in stacked relationship along the axis. Unification of the components may take place by breaking, penetrating or opening a valve construction in the intermediate walls. In another known design the intermediate wall or walls are of the piston type and flow communication between the chambers is accomplished by moving the piston to a by-pass section where the interior wall has one or several enlarged sections or repeated circumferential grooves and lands or piston deforming structures in a manner allowing by-flow of rear chamber content into front chamber at displacement of the rear movable wall. For the present purposes it is preferred to use multiple chamber designs where mixing can be achieved by an axial movement of the piston rod, either a straight axial movement or a screw movement as known per se. The chambers may contain gas, liquid or solids. Generally at least one liquid is present. Most commonly in pharmaceutical applications only two chambers are present and typically contains one liquid and one solid, the latter being dissolved and reconstituted during the mixing operation. For these types of containers it is possible both that the mixing or reconstitution step has already taken place when the container is placed in the injector or that means are provided within the device for unifying the chamber contents before the actual injection process is started.
As used herein positional and directional statements shall be understood with reference to the container. The xe2x80x9caxisxe2x80x9d or xe2x80x9caxialxe2x80x9d direction refers to the axis along which the container barrel has substantially constant cross-section. The xe2x80x9cfrontxe2x80x9d refers to the barrel end having the opening for content flow and xe2x80x9cforwardxe2x80x9d to directions from the barrel side towards the opening and xe2x80x9crearxe2x80x9d and xe2x80x9crearwardsxe2x80x9d to the opposite end and direction. xe2x80x9cTransversalxe2x80x9d refers to a direction perpendicular to the axial direction and includes xe2x80x9crotationalxe2x80x9d movements around a line parallel or concentric with the axis. Unless otherwise indicated use of the directional statements, such as xe2x80x9caxialxe2x80x9d or xe2x80x9crotationalxe2x80x9d shall not be understood to be restricted to purely the indicated direction but shall be understood to incorporate everything having a component in the indicated direction.
The injector device comprises a housing, which shall be understood in broad sense as long as it performs its basic functions of supporting the container and having, or providing support for, the track or follower structures to be described. The container may be movably arranged with respect to the housing, e.g. to allow initiation steps under movement relative the housing such as under mixing of mixing of multiple chamber containers as known per se, although for the present purposes it is preferred to perform even such steps with the container stationary with respect to the housing. Unless otherwise indicated the container shall be assumed to be stationary, at least in the axial direction, with respect to the housing. The container can be attached to the housing in such a manner that it remains exposed, although it is preferred that the housing also confines the container. The housing should leave exposed parts operated by the user, notably the piston rod when manually operated and for example needle attachments. As indicated it is often preferred to use the device as a disposable in which case it is preferred to factory load it with the container and a simple closure arrangement is of value for rational assembly in manufacture. In broad terms the housing shape is not critical for the basic function of the device but may influence its ergonomic and convenience properties and as common in the art the housing may have a design facilitating it manipulation, such as finergrips and other grip surfaces. Otherwise the overall shape of the housing can take a variety of shapes depending on among others the internal component layout. The housing may be a single or multiple piece part although it is preferred to design it with as few parts as possible. Preferably housing parts are made from plastic material by for example moulding.
The injector comprises a piston rod, which shall also be understood in a broad sense as long as it performs its basic functions of being able to displace the movable wall and having, or providing support for, the track or follower structures to be described. The piston rod need to be movably arranged in relation to the container and is preferably also movably arranged with respect to the housing. It should at least be movable in the axial direction but in order to increase the program design freedom it is preferably also movable in the transversal direction, preferably by being rotatable, preferably around the container axis. Generally the piston rod comprises a penetrating part designed to penetrate into the container barrel and preferably also have an accessible part remaining outside, e.g. providing access for manipulation. The piston rod can be moved by an actuator system incorporating stored energy, e.g. by springs, compressed or generated gas or electric motor means, but when simplicity is important it is preferred to design the piston rod for manual actuation for which the principles of the invention are also well suited. The track and follower structures can be arranged on different parts of the piston rod, a track even on the penetrating part whereas a follower preferably is arranged on an accessible part. When essential parts of the track are arranged on the piston rod it has been found beneficial to provide for a large surface on the piston rod, e.g. by making the penetrating part as large as the barrel size allows. A preferred way to increase the available surface is to enlarge the accessible part of the piston rod, which part in principle can be made as large as required in length and width, which has the additional advantage of allowing small containers, and to locate track parts to these enlarged surfaces of the piston rod. The enlarged surface can be arranged axially rearwards of the penetrating part but it is preferred that it extends axially forwards to at least partially extend over the container barrel outside when the penetrating part moves into the barrel. Preferably the penetrating part and the extended part run at least partly in parallel to accommodate the barrel therebetween. Most preferably the extended part of the accessible part has the overall shape of a tube or sleeve concentric with the penetrating part. The general layout described gives manufacturing and rigidity advantages in addition to the track structure benefits. Also the piston rod can be designed as a multipart piece although it is preferred an possibel to make it as a single piece. Preferably the piston rod is molded in plastic.
Tracks can be provided on either a housing part, a piston rod part or on both. The followers shall be arranged on the opposite housing or piston rod part, having the track with which it arranged to cooperate. For purpose of track system description, any other injector part, such as an intermediate part, shall be regarded as part of the housing or the piston rod respectively depending on its functional relationship thereto, mainly with which part it moves. Tracks can be arranged on the housing, for example on the housing interior surface or as slits in the housing wall, with one or more followers on the piston rod, which for example allows for a slim device. It is preferred to place tracks on the piston rod with one or more followers on the housing part, which among others allows for rigidity, ease of manufacture and flexibility in track layout. It is possible to place tracks on both the housing and the piston rod although it is generally more advantageous to have tracks only on one of the parts.
The physical implementation of the tracks can take a variety of forms. The track may be a raised rail gripped by a correspondingly shaped follower. Especially in thin materials the track may be a slit. Tracks in the form of grooves are generally preferred among others for rigidity and ease of manufacture. Such a groove may have cross-section for example being concave, rectangular or with undercut, e.g. for catching a correspondingly shaped follower. The tracks in general preferably having constant cross-section over a certain extension corresponding to at least several times their width and may be so in their entire length but it is also possible that the cross-section changes, for example at a knee or bend, e.g. to accommodate an asymmetrical follower, which may be used to meet different space or strength limitations in different directions. Mostly it is preferred that the track guides the follower line movement only, which need not and most often is not straight, so that movements away from the line are prevented. The track may, however, also widen or disappear at certain locations, e.g. to release a follower for example when another follower is engaged, to allow several movements or where a guided movement is not necessary. In such situations the line guidance of the follower can be said to widen into an area. Another similar situation is when it is only necessary or suitable to guide the follower movement against dislocations towards one of the lateral sides of the track, e.g. when dislocations to the other side is prevented by other means for example a second track or follower, when a pumping action is allowed or to allow entrance of a follower into the track from more than one or numerous positions. The track may then be reduced to a one-sided track, e.g. an edge.
Also the followers can take a variety of shapes. The follower can basically be regarded as a xe2x80x9cpointxe2x80x9d structure able to pass along the line or area provided by the track and should have physical dimensions slightly less than the track parts to be passed, except where friction controlled elements are arranged to be described. It can with preference be symmetrical, e.g. have a round or square cross-section when seen perpendicular to the track plane. The follower may, however, also be asymmetrical, e.g. longer than wide, when only unidirectional movements are needed or even in multi-directional tracks if the track changes cross-section when it changes direction to accommodate the new width of the follower or if the follower is movably, e.g. rotationally attached to its substrate, which also can be used to allow adaptation to threads of varying pitch. The follower cross-section when seen along the track may be adapted to the corresponding track cross-section although it is not necessary and sometimes a non-congruent shape is preferred, e.g. giving point rather than surface contact between track and follower for reduced friction. The follower may also be movable in a direction substantially perpendicular to the track carrying surface, e.g. to allow engagement or disengagement with the track, preferably biased in one direction by spring or material resilience, for automatic or manually assisted control. In the later case, the follower is preferably arranged on the housing.
Any track can have additional control elements as known per se, such as one-way structures, facilitating follower movement in one direction in the track but preventing movement in the opposite direction, e.g. in the form of a hinged stop surface yielding only in one direction or a structure having a ramp surface in the forward direction and a steeper stop surface in the other. Alternatively a follower movable towards the track surface as described can be arranged to require an operator action before further movement is possible. Also any track can have tactile structures where a change in resistance takes place, for example to alert the user at critical points in the process or to bias the follower into predetermined positions such as when aligned with a continuing track part. Optionally the tactile structure also provides an audible click confirmation. Grooves or ridges in the over the track or the abovesaid one way structures can be used for this purpose.
As used herein xe2x80x9ctrack systemxe2x80x9d refers to the total arrangement of tracks and followers in the device. For purposes of description the track system will often be described as comprising different tracks, in turn being divided in sections and parts. Such categorization shall not be regarded as binding as a different terminology or categorization gives the same functional result. The track system may comprise a single xe2x80x9ccontinuousxe2x80x9d track, in the sense that it can be traversed by a single follower, where cooperation with the follower assists in various operational phases. Preferably the track system incorporates more than one continuous tracks cooperating with at least one follower each. The two or more tracks may then be arranged in xe2x80x9cparallelxe2x80x9d, meaning that over at least part of their operational range they are arranged to allow the same movement of the piston rod, which may be used to increase guiding rigidity and precision or to allow a smaller or slimmer device with maintained rigidity and precision. A threaded track for example may have two or more parallel threads with followers. Preferably the track system incorporates at least two xe2x80x9cserialxe2x80x9d or xe2x80x9cseriallyxe2x80x9d arranged tracks, meaning that the tracks are arranged for guidance of the piston rod into different movements, either in true series or enabled by engagement/disengagement of follower, which may be uses for larger design freedom or to adapt the track and follower characteristics different for different operational phases, e.g. parallel tracks followed by a single additional serial track allowing utilization of the full circumference of the device. Another advantage is that serial tracks normally allows a more compact track system layout, e.g. less axial extension. Normally serial tracks requires the first follower to go out of engagement when the second follower goes into engagement with its track. The disengagement can be made by letting the first follower leaving its track entirely, i.e. by having an xe2x80x9copenxe2x80x9d termination, by going from a line to an area guidance as described, by allowing multiple line guidance alternatives for the first follower corresponding to all movement options for the second follower or by use of movable followers as described.
General control features of the tracks are to provide either a stop for a piston rod movement or a change of its allowed movement direction. A permanent stop at a predetermined location or distance can be provided by giving a track a xe2x80x9cclosedxe2x80x9d termination, i.e. the follower has no further movement alternative than possibly to go back. Such a permanent stop may be used at the end of the operation cycle, for example when the ejections programmed for are completed. The follower may then be allowed to move in the opposite direction in the same track, for example to permit re-filling of the container or it may be prevented therefrom, e.g. by a one-way structure behind, for example to block a disposable device from further use. In most other situations a stop for a running piston movement is preferably not permanent but combined with new movement options for the piston rod. The stop is then preferably provided by a track wall where the track changes direction, preferably at a sharp change and most often at a substantially right angle to the current track part, e.g. at xe2x80x9ckneexe2x80x9d, giving the follower only one new movement alternative, or at a xe2x80x9cbranchxe2x80x9d, giving the follower at least two new movement alternatives, preferably so that a change in piston rod movement is needed before a new movement alternative can be reached.
Track directional changes may be combined and repeated. If for example multiple knees are combined a xe2x80x9cstaircasexe2x80x9d track shape can be provided if each second movement is made in the same direction and a xe2x80x9cmeanderingxe2x80x9d track shape can be obtained if each second movement change is made in opposite directions. If some or all of the knees are replaced with branches a xe2x80x9cgridxe2x80x9d track shape is possible, allowing more than one movement option in each grid intersection, creating multiple combined alternatives. The multiple directional changes described can with preference be used in multiple dose systems, preferably so that the track provides several axial sections combined with intermediate transversal and preferably rotational movement sections, whereby the user experiences a definite stop at the end of each dosing with the requirement for an active directional change. The axial sections can be of different lengths but it is preferred in most instances that the axial sections are of about equal lengths in each track to provide repeated equal doses, possibly with exception for the first axial part, which may be used to force the user making a de-aeration step of pre-determined volume and/or to initially discard content volume not to be used, and normally these volumes are different from the dosing volumes. Most preferably the equal axial parts represent an integer division of the whole container content and when several tracks are arranged for they may provide different integer divisions of the total volume. The transversal section can also be given varying length, e.g. larger than one track width, shorter than two track widths if the stop surface is sufficient, normally at least two widths but can be longer but preferably less than the available circumference. Space considerations may be determining but also e.g. positioning of readable scales or indicia, for which purpose small transversal movements may serve to keep axially arranged characters within trail of window limits and large transversal movements may serve to bring large characters out of a windows and new in. These considerations also apply for transversal movements in single dose applications.
While axial piston rod movements generally performs an active function on the container content, rotational movements may be used for other purposes. One such purpose have been indicated above in multidose arrangements where rotational movements are used to assist in stopping one dose operation and requiring an active step before a new dose can be delivered. A further preferred purpose of a rotation track is to allow for selection between several axial tracks branching off from the rotational track, which then preferably may be designed in ring form, either at least partial ring form with closed termination to permit only reciprocating movements or preferably as a complete ring allowing full rotation of the follower therein. A third preferred use of a rotational track is to allow for a screw-threaded movement of the piston rod, performing both an axial and a rotational movement, which may be used for known purposes, e.g. change of speed or force ratio to eject small controlled volumes, high viscosity products or perform controlled reconstitution of multiple chamber containers, as known per se. The thread may extend only partially over a complete revolution, e.g. for ejection of small volumes, up to several turns, e.g. in reconstitution. It is fully possible to use threads of varying or pitch if the follower is designed accordingly, as indicated above. Generally rotation is made around a line concentric with the container axis.
A preferred use of ring track is as a joining track for several tracks branching of from the ring track and running at least partially in the axial direction. This layout can be used to provide for different track programs for differences in container type, container content type or patient requirements. Especially the layout is useful as a dose setting arrangement for a given container. The ring track should preferably provide for a line guidance of the follower, either by itself or in combination with a second track, as any uncontrolled axial movement of the piston rod may result in a dosing or initiation error or create uncertainty with the user. Dosing, or expelling, tracks branching off from the joining track and running at least partially in the axial direction, preferably for forward movement of the piston rod when moving from the joining track to the dosing tracks, may be of the general types outlined above, i.e. being arranged for single or multiple ejections. It is preferred that at least two, and preferably all, of the tracks are different, preferably by providing for different stroke lengths.
It is also preferred to arrange for readable dose indications in connection with dose selection arrangements. Generally the program provided forces the user into a single chain of sequential actions without alternatives but in connection with dose selection several alternatives are necessarily present and, although indications can be used in any phase, preferably indications are used for guidance in the dose selection phase. This can preferably be done so that indications or characters on one of the piston rod or housing parts are shown in a window, or pointed to by a pointer, on the other part. The characters may be positioned in a ring parallel to the joining track, e.g. on surfaces between the dosing tracks to conserve axial space or on a ring area free of dosing tracks, preferably to the rear of the dosing tracks, to enable use of larger characters.
It is also preferred to arrange for guided initiation steps in connection with this layout and in particular to provide for a controlled de-aeration step. As used herein de-aeration shall be regarded as including the possibility of pre-ejection of liquid, which in turn shall be understood to include discarding of liquid not to be used, which is an alternative known way of performing partial single dose ejections. De-aeration can be arranged for by providing each of the dosing tracks with an initial part, adapted in axial length for the de-aeration step, followed by a transversal part before the actual axial dosing part. Preferably the initial part for the different dosing tracks have about the same axial length, unless used for discarding, whereas the dosing part of the tracks preferably are different and preferably longer than the initial part. Another preferred layout, especially when discarding is not included in the de-aeration step, is to arrange an initiation track in the process before the joining track, so that the de-aeration takes place before the dose is selected, which gives a proper action sequence, necessitates only one initiation track for all dosing tracks and automatically gives the same initiation length for all the dosing tracks. The initiation track should run an axial distance suited for de-aeration and preferably land on a stop surface to require an active directional change for dose track selection. Preferably the stop is a wall of the joining track not allowing entrance to any dosing track, e.g. between such entrances. The initiation may include other process steps than the deaeration and preferably then is preceded still earlier by a mixing track for multiple chamber containers. Such a track can be substantially axial, e.g. straight and terminated with a knee or branch, but is preferably screw-threaded as known per se, and may contain several parallel thread tracks with several followers as generally described above.
As indicated above a screw-threaded track, with constant or varying pitch, may be used for several purposes of which not all need any additional actions after the screw movement, for example when the movement is used for final ejection of small or high viscosity doses. In contrast, when used for multiple chamber reconstitution most process steps comes later in the cycle and it is desirable to provide a track system integrating these demands and in particular such a track system incorporating multiple dosing since multiple chamber systems frequently are designed to result in multiple doses after mixing, which hitherto has required complicated injector mechanisms. Hence a preferred track system layout incorporating screw-threaded tracks is to incorporate also a track for multiple dosing, e.g. any of the general types outlined above such as of staircase, meandeing or grid type with only one or several selectable tracks. In order to enable this it is preferred to provide a joining track of the general ring type described above and let the threaded track continue directly into the joining track, which is possible with only a small directional change, the magnitude of which depends on the thread pitch. With the follower in the joining track all the optional alternatives described in relation the branching layout described above are available, especially for selection of several continuing tracks. Another preferred alternative is to let the thread track continue substantially in the axial direction, whereby the user will experience a stop for the threaded movement indicating that an axial movement is now necessary. The axial track part may be the entrance of a dosing track for single or preferably multiple doses as described. Preferably, however, the first part of the axial part is a de-aeration track, running a length adapted for this purpose, which may then continue in a knee or branch for single or multiple selection dosing tracks respectively, which dosing tracks in turn may be designed for single or multiple sequential dosing. The axial length of the de-aeration track is preferably different from the axial length of the dosing tracks, which in turn may be individually different but when of multiple dose type preferably each has repeater dosing sections of equal axial length. The arrangements described are fully compatible with two or more parallel tracks, having at least one follower each, e.g. by parallel threads continuing into parallel de-aeration tracks and parallel dosing tracks.
The above layouts have been described as if composed of continuous tracks in the sense that they can be traversed by a single follower. It is fully possible to modify the layouts to instead use two or more serial tracks as with corresponding advantages as generally described earlier. A preferred use of serial tracks is to use a first track with first follower, or preferably two or more parallel first tracks with first followers, for initial steps in the cycle, preferably mixing step and/or de-aeration step and most preferably both whereas a second track with a second follower for dose setting and actual ejection or ejections, the first and second tracks with respective followers being arranged as serial. The initial steps may not require selection among several track alternatives but instead may require parallel tracks and several followers of high rigidity and precision for the extended piston rod extended in the early phases. The dose selecting step instead may require substantial surface and full utilization of available circumference for the several tracks and possible information display to the user. Use of serial tracks solves this problem and in addition permits a compact track system layout. The followers may be arranged on the same part for both of the serial tracks, i.e. on either the housing or the piston rod, e.g. for simplest layout, or the first tracks may be arranged on one of the parts and the second track on the other part, e.g. to increase available surface for the track system and allowing for example tracks on axially overlapping parts. It is possible to perform disengagement of the first followers and engagement of the second follower or followers by a rotational movement, e.g. with exits and entrance respectively for example arranged in a bayonet type arrangement, but it is preferred that follower disengagement and engagement takes place by an axial relative movement between track and follower, especially so that the disengagement and engagement take place at rear and front parts respectively of the part having the track system. In other respects the first and second tracks can be of the general types earlier outlined, e.g. a straight or preferably threaded track for mixing, a straight axial track for de-aeration and a ring shaped joining track for dose selection, branching into several single or multiple ejection dosing tracks.
The above description has been made with reference both to structural and operational features, directly or indirectly, or follows from the descriptions made of structures, functions and objects. The invention shall be regarded to incorporate and embrace both the device and method aspects and characteristics described. The methodological aspects are not separately repeated. It should be pointed out, however, that all layouts described are compatible with the crucial step of securing de-aeration of the container before ejections are made, a step often neglected although important to positively guide during operation, especially at self-administration. A method for securing this operational phase may include the steps of a) displacing the piston rod forwards in a movement having at least a component in the axial direction, performing hereunder de-aeration and/or pre-ejection of the container content, b) rotating the piston rod in a direction different from that of step a), and c) advancing the piston rod forwards in a movement having at least a component in the axial direction, performing hereunder ejection of container content. During the de-aeration step the user should preferably hold the device so as to secure flow of container content from below and upwards, preferably by pointing the container opening at least partly upwards. Any other method step as described may be added.
In other aspects the injector of the invention may be used conventionally or as described in prior art. Below a summary of preferred actions. If the container is not preassembled in the device housing the operator inserts the container and possibly connects it to attachments provided and assemble parts involved. If the container is a dual or multiple chamber device mixing operation may be undertaken before attachment to the device but is preferably made when attached as described. Unless a needle, infusion tube or other delivery unit is already in place the operator may mounts such a device on the container opening and possibly removes any needle shield present. The opening is pointed roughly upwards and the movable wall is moved forward to expel air and possibly eject a small preparation amount to assure proper function. Preferably the wall is moved forward by disclosed herein. If applicable a dose setting operation may take place by any of the methods described. If applicable the device is moved so as to perform a penetration movement to bring the needle into a target object, e.g. human or animal tissue or any other material or device. One or more ejections may now be performed by any of the means and methods outlined. Finally any penetrating device may be withdrawn from its target site.

Injector device and method for its operation


Described is a method of treating or coating homogeneously at least a portion of the surface of a material selected from metallic materials having a thickness of less than 100 xcexcm and/or polymeric materials. The method of the present invention comprises exposing at least a portion of the surface of the material to an atmospheric plasma generated by an indirect plasmatron. In the method of the present invention, the surface of the material may undergo at least one of an increase in surface tension, a surface grafting, a surface cleaning and a surface sterilization.

The present invention relates to method of finishing films of plastic and/or metal with an atmospheric plasma.
Many finishing steps, such as, for example, printing, coating, lacquering, gluing etc., are possible on films of plastic or metal only if an adequate wettability with solvent- or water-based printing inks, lacquers, primers, adhesives etc. exists. A corona treatment is therefore in general carried out in- or offline with the film processing.
As described e.g. in the publications DE-A-42 12 549, DE-A-36 31 584, DE-A-44 38 533, EP-A-497 996 and DE-A-32 19 538, in this process the materials in web form are exposed to a uniformly distributed electrical discharge. Two working electrodes are a prerequisite, one of which is sheathed with a dielectric material (silicone, ceramic). A high alternating voltage with a frequency typically of between 10 and 100 kHz is applied between the two electrodes, so that a uniform spark discharge takes place. The material to be treated is passed between the electrodes and exposed to the discharge. A xe2x80x9cbombardmentxe2x80x9d of the polymer surface with electrons occurs here, the energy of which is sufficient to break open bonds between carbon-hydrogen and carbonxe2x80x94carbon. The radicals formed react with the corona gas and form new functional groups here. Cleaning of the polymer or metal surface furthermore takes place, since film additives and rolling oils are oxidized and distilled off.
In spite of the broad spectrum of use and the constant further development, corona treatment has significant disadvantages. Thus, a parasitic corona discharge on the reverse occurs, especially at higher web speeds, if the materials in web form do not lie on the cylindrical electrode. The corona treatment furthermore causes a significant electrostatic charging of the materials in web form, which makes winding up of the materials difficult, obstructs the subsequent processing steps, such as lacquering, printing or gluing, and in the production of packaging films in particular is responsible for particulate materials, such as coffee or spices, adhering to the film and in the worst case contributing towards leaking weld seams. Finally, corona treatment is always a filament discharge which does not generate a homogeneously closed surface effect. Moreover, it is found in time that a loss in the surface properties occurs, because of migration of film additives, and that molecular rearrangement based on minimisation of surface energy takes place.
Corona treatment is limited here to thin substrates, such as films of plastic and papers. In the case of thicker materials the overall resistance between the electrodes is too high to ignite the discharge. However, individual flashovers can then also occur. Corona discharge is not to be used on electrically conductive plastics. Dielectric electrodes moreover often show only a limited action on metallic or metal-containing webs. The dielectrics can easily burn through because of the permanent exposure. This occurs in particular on silicone-coated electrodes. Ceramic electrodes are very sensitive towards mechanical stresses.
In addition to corona discharge, surface treatments can also be carried out by flames or light. Flame treatment is conventionally carried out at temperatures of about 1,700xc2x0 C. and distances of between 5 and 150 mm. Since the films heat up briefly here to high temperatures of about 140xc2x0 C., effective cooling must be undertaken. To further improve the treatment results, which are in any case good, the torch can be brought to an electrical potential with respect to the cooling roll, which accelerates the ions of the flame on the web to be treated (polarised flame). The process parameters which have to be adhered to exactly are to be regarded as a disadvantage in particular for surface treatment of films. Too low a treatment intensity leads to minor effects which are inadequate. Too high intensities lead to melting of the surfaces, and the functional groups dip away inwards and are thus inaccessible. The high temperatures and the necessary safety precautions are also to be evaluated as disadvantages. For example, the safety regulations in force do not allow pulsed operation of a flame pretreatment unit. It is known that the choice of torch gas allows only certain reactive species (ions and radicals) and that the costs of flame treatment are significantly higher than in the case of corona treatment.
The main disadvantage of corona treatment, the localised microdischarges (filaments), can be bypassed by using a low-pressure plasma. These usually xe2x80x9ccoldxe2x80x9d plasmas are generated by means of a direct, alternating or high-frequency current or by microwaves. With only a low exposure to heat of thexe2x80x94usually sensitivexe2x80x94material to be treated, high-energy and chemically active particles are provided. These cause a targeted chemical reaction with the material surface, since the processes in the gas phase under a low pressure proceed in a particularly effective manner and the discharge is a homogeneous volume discharge cloud. With microwave excitation in the giga-Hz region, entire reactor vessels can be filled with plasma discharge. Extremely small amounts of process means are needed compared with wet chemistry processes.
In addition to targeted activation (modification) of surfaces, polymerizations (coating) and graftings can also be carried out in such processes. As a result of the action of the plasma, conventional polymerization monomers, such as ethylene, acetylene, styrenes, acrylates or vinyl compounds, and also those starting substances which cannot polymerise in conventional chemical reactions can be excited to undergo crosslinking and therefore formation of a polymer or layer. These starting substances are, for example, saturated hydrocarbons, such as methane, silicon compounds, such as tetramethylsilane, or amines. Excited molecules, radicals and molecular fragments which polymerise from the gas phase on to the materials to be coated are formed here. The reaction usually takes place in an inert carrier gas, such as argon. Reactive gases, such as hydrogen, nitrogen, oxygen etc., can advantageously be added in a targeted manner for various purposes.
Established physical and chemical plasma coating processes, such as cathodic evaporation (sputtering) or plasma-activated chemical deposition from the gas phase (PACVD), as a rule take place in vacuum under pressures of between 1 and 10xe2x88x925 mbar. The coating processes are therefore associated with high investment costs for the vacuum chamber required and the associated pump system. Furthermore, the processes are as a rule carried out as batch processes because of the geometric limitations due to the vacuum chamber and the pump times needed, which are sometimes very long, so that long process times and associated high piece costs arise.
Coating processes by means of corona discharge advantageously require no vacuum at all, and proceed under atmospheric pressure. Such a process (ALDYNE(trademark)) is described in DE 694 07 335 T 2. In contrast to the conventional corona, which operates with the ambient air as the process gas, a defined process gas atmosphere is present in the discharge region in corona coating. By selected precursors, layer systems of the following structure can be obtained: e.g. layers based on SiOx from organosilicon compounds, such as tetramethylsilane (TMS), tetraethoxysilane (TEOS) or hexamethyidisiloxane (HMDSO), polymer-like hydrocarbon layers from hydrocarbons, such as methane, acetylene or propargyl alcohol, and fluorinated carbon layers from fluorinated hydrocarbons, such as, for example, tetrafluoroethene.
A serious disadvantage of the existing processes is, however, the non-closed surface deposition caused by the filament-like discharge characteristics of the corona. The process is accordingly unsuitable for application of barrier coatings. For surface polarisation by introduction of functional groups, in contrast to simple corona discharge, the process is too expensive.
To avoid pin holed coatings over a part area, such as occur in corona coating, atmospheric plasmas can also be generated by arc discharges in a plasma torch. With conventional torch types only virtually circular contact areas of the emerging plasma jet on the surface to be processed can be achieved because of the electrode geometry with a pencil-like cathode and concentric hollow anode. For uses over large areas the process requires an enormous amount of time and produces very inhomogeneous surface structures because of the relatively small contact point.
DE-A-195 32 412 describes a device for pretreatment of surfaces with the aid of a plasma jet. By a particular shape of the plasma nozzle, a highly reactive plasma jet is achieved which has approximately the shape and dimensions of a spark plug flame and thus also allows treatment of profile parts with a relatively deep relief. Because of the high reactivity of the plasma jet a very brief pretreatment is sufficient, so that the workpiece can be passed by the plasma jet with a correspondingly high speed. For treatment of larger surface areas, a battery of several staggered plasma nozzles is proposed in the publication mentioned. In this case, however, a very high expenditure on apparatus is required. Since the nozzles partly overlap, striped treatment patterns can moreover occur in the treatment of materials in web form.
DE-A-298 05 999 describes a device for plasma treatment of surfaces which is characterised by a rotating head which carries at least one eccentrically arranged plasma nozzle for generation of a plasma jet directed parallel to the axis of rotation. When the workpiece is moved relative to the rotating head rotating at a high speed, the plasma jet brushes over a strip-like surface zone of the workpiece, the width of which corresponds to the diameter of the circle described by the rotation of the plasma nozzle. A relatively high surface area can indeed be pretreated rationally in this manner with a comparatively low expenditure on apparatus. Nevertheless, the surface dimensions do not correspond to those such as are conventionally present in the processing of film materials on an industrial scale.
DE-A-195 46 930 and DE-A-43 25 939 describe so-called corona nozzles for indirect treatment of workpiece surfaces. In such corona nozzles an oscillating or circumferentially led stream of air emerges between the electrodes, so that a flat discharge zone in which the surface to be treated on the workpiece can be brushed over with the corona discharge brush results. It has been found to be a disadvantage of this process that a mechanically moved component must be provided to even out the electrical discharge, which requires a high expenditure on construction. The specifications mentioned moreover do not describe the maximum widths in which such corona nozzles can be produced and used.
For the present invention there was the object of treating or coating surfaces of films of plastic and/or metal such that subsequent finishing steps, such as, for example, printing, coating, lacquering, gluing etc., can be carried out without wetting problems and with good adhesion properties.
The aim was pursued here of providing a process which bypasses the disadvantages given by low-pressure plasmas (batch operation, costs), corona (filament-like discharge, treatment on the reverse, electrostatic charging etc.) and plasma nozzles (striped surface treatment).
In accordance with the present invention, there is provided a method of treating or coating homogeneously at least a portion of the surface of a material comprising,
exposing at least a portion of the surface of said material to an atmospheric plasma generated by an indirect plasmatron, wherein said material is selected from metallic materials having a thickness of less than 100 xcexcm, polymeric materials and combinations thereof.
Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients, reaction conditions, etc. used in the specification and claims are to be under stood as modified in all instance by the term xe2x80x9cabout.xe2x80x9d
In an embodiment of the present invention, the material that is treated or coated is a material in web form. As used herein the term xe2x80x9cmaterial in web formxe2x80x9d means a material, preferably a substantially flat material or film, that is collected on and/or taken off of a roll, cylinder or spool. Preferably, the material that is surface treated or coated in the present invention is in the form of a film.
An indirect plasmatron which is suitable for generating the atmospheric plasma in the method of the present invention is described, for example, in EP-A-851 720, the disclosure of which is incorporated herein by reference in its entirety. As used herein and in the claims, by xe2x80x9catmospheric plasmaxe2x80x9d is meant a plasma that is exposed to the surface of the material under conditions of ambient atmospheric pressure, e.g., at a pressure of 760 torr.
The torch is distinguished by two electrodes arranged coaxially at a relatively large distance. A direct current arc which is stabilised at the wall by a cascaded arrangement of freely adjustable length burns between these. By blowing transversally to the axis of the arc, a plasma jet in band form flowing out laterally can emerge. This torch, also called a plasma broad jet torch, is also characterised in that a magnetic field exerts a force on the arc which counteracts the force exerted on the arc by the flow of the plasma gas. Furthermore, various types of plasma gases can be fed to the torch.
The atmospheric plasma of the method of the present invention is generated by an indirect plasmatron having an elongated plasma chamber therein. In an embodiment of the present invention, the indirect plasmatron comprises, a neutrode arrangement comprising a plurality of plate-shaped neutrodes which are electrically insulated from one another, and which define the elongated plasma chamber of the plasmatron. Preferably, the plurality of neutrodes are present and arranged in cascaded construction. The elongated plasma chamber has a long axis. The neutrode arrangement also has an elongated plasma jet discharge opening that is substantially parallel to the long axis of the elongated plasma chamber, and which is in gaseous communication with the plasma chamber. At least one pair of substantially opposing plasma arc generating electrodes are also present in the indirect plasmatron, and are aligned coaxially with the long axis of the elongated plasma chamber. Typically, the pair of plasma arc generating electrodes are positioned opposingly at both ends of the elongated plasma chamber.
In an embodiment of the present invention, at least one neutrode is provided with a pair of permanent magnets here to influence the shape and position of the plasma arc. Operating parameters, such as, for example, the amount of gas and gas speed, can be taken into consideration by the number, placing and field strength of the magnets employed.
At least individual neutrodes can furthermore be provided with a possibility, e.g. a channel, for feeding a process gas into the plasma chamber. As a result, this process gas can be fed to the arc in a particularly targeted and homogeneous manner. By blowing transversally to the arc axis, a band-like plasma free jet flowing out laterally can emerge. By applying a magnetic field, deflection and the resulting breaking of the arc is prevented.
The method described according to the present invention for surface treatment can be carried out both after a film production and before further processing, i.e. before printing, laminating, coating etc., of films. The thickness of the polymeric film materials may vary, but is typically is in the range of from 0.5 xcexcm to 2 cm, and preferably in the range of from 10 and 200 xcexcm.
The method described according to the invention for surface treatment can be used on polymeric materials, but also for the treatment of metallic substrates, but in particular on films of plastic and metal. In particular, the process according to the invention can also be used on polymeric materials in web form which are optionally vapour-deposited with metal, metal oxides or SiOx.
In the context of the present invention, films of plastic are understood in particular as those which comprise a thermoplastic material, in particular polyolefins, such as polyethylene (PE) or polypropylene (PP), polyesters, such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT) or liquid crystal polyesters (LCP), polyamides, such as nylon 6,6; 4,6; 6; 6,10; 11 or 12, polyvinyl chloride (PVC), polyvinyl dichloride (PVDC), polycarbonate (PC), polyvinyl alcohol (PVOH), polyethylvinyl alcohol (EVOH), polyacrylonitrile (PAN), polyacrylic/butadiene/styrene (ABS), polystyrene/acrylonitrile (SAN), polyacrylate/styrene/acrylonitrile (ASA), polystyrene (PS), polyacrylates, such as polymethyl methacrylate (PMMA), cellophane or high-performance thermoplastics, such as fluorine polymers, such as polytetrafluoroethylene (PTFE) and polyvinyl difluoride (PVDF), polysulfones (PSU), polyether-sulfones (PES), polyphenyl sulfides (PPS), polyimides (PAI, PEI) or polyaryl ether ketones (PAE), and in particular also those materials which are prepared from mixtures or from co- or terpolymers and those which are prepared by coextrusion of homo-, co- or terpolymers.
Films of plastic are also understood as those which comprise a thermoplastic material and are vapour-deposited with a metal of main group 3 or sub-group 1 or 2 or with SiOx or a metal oxide of main group 2 or 3 or sub-group 1 or 2.
Films of metal are understood as films which comprise aluminium, copper, gold, silver, iron (steel) or alloys of the metals mentioned.
Surface treatment by an atmospheric plasma is understood in the context of the present invention as meaning that an increase in the surface tension of the polymer surface takes place by the interaction with the plasma gas. Plasma grafting or plasma coating (plasma polymerization) at or on the surface can furthermore be carried out by means of certain types of plasma gas. The extremely reactive species of the plasma gas can moreover have a cleaning and even sterilising effect on the surface, so that according to the invention surface treatment is also understood as surface cleaning or surface sterilisation.
The polarisation of the polymeric surface leads to an increase in the surface tension. Complete wetting with polar liquids, such as, for example, alcohols or water, becomes possible as a result. While not intending to be bound by any theory, it is believed, based on the evidence at hand, that the polarisation occurs when atoms or molecular fragments (excited by the plasma) react with surface molecules and are consequently incorporated into the surface. Since these are usually oxygen- or nitrogen-containing fragments, surface oxidation is also referred to.
Surface grafting occurs when a targeted incorporation of molecules, preferably at the polymer surface, takes place due to a reaction. Thus, for example, carbon dioxide reacts with hydrocarbon compounds to form carboxyl groups.
A plasma coating is characterised in that a reactive plasma gas is deposited on the surface by a type of polymerization. As a result, it is possible, inter alia, to produce release, barrier, antifogging or quite generally protective layers on the films of plastic and metal.
Surface cleaning is characterised in that impurities, additives or low molecular weight constituents deposited on the surface are oxidized and evaporated off. Sterilisation occurs if the number of germs is reduced such that it lies below the critical germ concentration.
The process gas employed in the method according to the present invention is characterised here in that it comprises mixtures of reactive and inert gases and/or aerosols. Due to the high energy in the arc, excitation, ionisation, fragmentation or radical formation of the process gas and/or aerosol occurs. Because of the direction of flow of the process gas, the active species are carried out of the torch chamber and can be caused to interact in a targeted manner with the surface of films of plastic and/or metal.
The process gas and/or process aerosol with an oxidizing action can be present in concentrations of 0 to 100%, preferably between 5 and 95% by volume based on total volume of the process gas and/or process aerosol. Oxidizing process gases and/or process aerosols which are employed are, preferably, oxygen-containing gases and/or aerosols, such as oxygen (O2), carbon dioxide (CO2), carbon monoxide (CO), ozone (O3), hydrogen peroxide gas (H2O2), water vapour (H2O) or vaporised methanol (CH3OH), nitrogen-containing gases and/or aerosols, such as nitrous gases (NOx), dinitrogen oxide (N2O), nitrogen (N2), ammonia (NH3) or hydrazine (H2N4), sulfur-containing gases and/or aerosols, such as sulfur dioxide (SO2) or sulfur trioxide (SO3), fluorine-containing gases and/or aerosols, such as carbon tetrafluoride (CF4), sulfur hexafluoride (SF6), xenon difluoride (XeF2), nitrogen trifluoride (NF3), boron trifluoride (BF3) or silicon tetrafluoride (SiF4), or hydrogen (H2) or mixtures of these. Inert process gases are preferably noble gases, and argon (Ar) is particularly preferred.
Crosslinkable process gases and/or process aerosols which may be used in the method of the present invention include, preferably, unsaturated hydrocarbons, such as ethylene, propylene, butene or acetylene; saturated hydrocarbons with the general composition CnH2n+2, such as methane, ethane, propane, butane, pentane, iso-propane or iso-butane; vinyl compounds, such as vinyl acetate or methyl vinyl ether; acrylates, such as acrylic acid, methacrylic acid or methyl methacrylate; silanes of the general composition SinH2n+2, halogenated silicon hydrides, such as SiCl4, SiCl3H, SiCl2H2 or SiClH3, or alkoxysilanes, such as tetraethoxysilane; hexamethyldisilazane; or hexamethyldisiloxane.
Maleic anhydride, acrylic acid compounds, vinyl compounds and carbon dioxide (CO2) are preferably employed as process gases and/or process aerosols which can be grafted, in the method of the present invention.
Preferably, the active and the inert process gas and/or process aerosol are mixed in a preliminary stage and are then introduced into the arc discharge zone. For safety reasons, certain process gas and/or process aerosol mixtures, such as, for example, oxygen and silanes, are mixed directly before introduction into the arc discharge zone.
Plasmas formed in the method according to the present invention are characterised in that their temperatures in the region of the arc are several 10,000 Kelvin. Since the emerging plasma still has temperatures in the range from 1,000 to 2,000 Kelvin, adequate cooling of the temperature-sensitive polymeric materials is necessary. This can in general take place by means of an effectively operating cooling roll.
The contact time of the plasma and film material is of great importance. This should preferably be reduced to a minimum so that no thermal damage to the materials occurs. A minimum contact time with the plasma may be achieved by increasing the speed at which the material is passed before the indirect plasmatron. In an embodiment of the present invention, the material or film is moved over at least one pair of rolls during the exposure step. The speed at which the material or film is moved over the rolls is typically greater than 1 meter (m) per minute, and is preferably from 1 to 600 m per minute, and more preferably from 20 and 600 m per minute.
Since the life of the active species (radicals and ions) under conditions of atmospheric pressure is limited, it is advantageous to pass the films of plastic and/or metal past the torch opening or plasma jet discharge opening (nozzle) at a very short distance. This is typically effected at a distance of 0 to 40 mm, preferably at a distance of 1 to 40 mm, and more preferably at a distance of 1 to 15 mm.
The present invention is more particularly described in the following examples, which are intended to be illustrative only, since numerous modifications and variations therein will be apparent to those skilled in the art. Unless otherwise specified, all parts and percentages are by weight.

Method of surface treating or coating of materials


A card-shaped flashlight device includes a holder, a lamp module mounted on the holder, one or both of a flasher light module and a buzzer module mounted on the holder, and a planar battery attached to the holder for powering the lamp module, buzzer module and flasher module. Lamp, flasher and buzzer circuits which respectively include the lamp module, buzzer module and flasher module are connected to the battery in parallel with one another such that the lamp module, buzzer module and flasher module are actuatable by corresponding lamp switch, buzzer switch and flasher switch independently of one another.

1. Field of the Invention
The present invention generally relates to portable lighting devices and, more particularly, is concerned with a card-shaped flashlight device with lamp, flasher and/or buzzer features and powered by a common power source.
2. Description of the Prior Art
Miniature portable flashlight devices which can be stored in a pocket or attached to a key chain are known in the prior art. An example of a miniature pocket flashlight is the one disclosed in U.S. Pat. No. 4,644,451 to Chabria. The Chabria miniature pocket flashlight has a hollow flexible outer case open at opposite ends, a pair of end caps closing the opposite ends of the outer case, a battery receptacle, an electric switch unit disposed in the case which is activated by squeezing the flexible case, and a lamp electrically connected and mounted to the unit and protruding through a hole in one of the end caps on the case (or alternatively the lamp is mounted to a socket in the end cap itself). At least the one end cap is removable in order to replace the lamp and batteries.
The design of the Chabria flashlight embodies at least three major drawbacks. First, the design permits light generated by the lamp to disperse in all possible radial directions from the lamp thus reducing the amount of light projected by the lamp on any one desired location. Second, the design requires that the lamp extend through a hole or from a socket in the end cap of the case. This design requirement leaves the lamp unprotected, exposing it to frequent impacts with extraneous objects while the flashlight is being handled and carried by the user. Such impacts are likely to soon cause breakage of the lamp filament and result in malfunction and premature shortening of the useful life of the lamp. Third, the design requires that one or both of the end caps of the case be frictionally fitted to the ends of the case so as to be readily removable to replace the lamp and batteries. Over time such frictional fit tends to loosen up and allow the parts of the flashlight to come apart. This increases the risk of losing an end cap which would then require the replacement of the flashlight itself.
A thin card-like flashlight device disclosed in U.S. Pat. No. 5,457,613 owned by Lumatec Industries, Inc. of Austin, Tex., and marketed under the trademark FLASHCARD, provides a functional and reliable design which overcomes the aforementioned drawbacks of the pocket flashlight design of the Chabria patent. The Lumatec flashlight device provides a package which is relative thin and flat, has a card-like appearance and handles and feels similar to a credit card with which users are familiar. The Lumatec flashlight device provides a highly fashionable appearance as well as providing the lighting function in a highly reliable way in terms of projecting a beam of light toward a desired location and protecting all parts in a peripherally sealed outer protective cover.
In order for the advantages and benefits of the highly commercially successful Lumatec flashlight device to be enjoyed by an even wider range of users, the inventor(s) herein have perceived a need for incorporation of other functional features in this flashlight device which will provide users with other useful and desirable benefits.
The present invention provides a card-shaped flashlight device with lamp, flasher and/or buzzer features and powered by a common power source, which flashlight device is thus designed to satisfy the aforementioned need.
Accordingly, the present invention is directed to a card-shaped flashlight device which comprises: (a) a battery of a generally planar configuration and having a pair of opposite faces and a pair of electrical terminals of opposite polarities mounted on one of the opposite faces; (b) a holder having a generally planar configuration, a front edge, a rear edge spaced from the front edge, a pair of opposite surfaces, means for receiving and holding the battery along one of the opposite surfaces of the holder and an interior edge defining a slot recessed into the holder from the front edge thereof; (c) a reflector at least partly disposed in the slot of the holder and interfitted on the interior edge of the holder and having top and bottom portions which protrude in opposite directions outwardly beyond the opposite surfaces of the holder; (d) a lamp mounted within the reflector; (e) a lamp switch mounted on the holder and actuatable between on and off conditions; and (f) means for forming a lamp circuit which includes the lamp, the terminals of the battery and the lamp switch such that the lamp projects a generally spotlight beam shaped by the reflector in response to actuation of the lamp switch.
The flashlight device of the present invention also comprises means for enclosing the holder, the battery, the lamp switch and the reflector in a sealed pouch which permits actuation of the lamp switch from, and projection of the spotlight beam to, the exterior of the device.
The flashlight device of the present invention further comprises: a flasher module mounted on the holder between the slot and the rear edge of the holder; a flasher switch actuatable between on and off conditions; and means for forming a flasher circuit which includes the flasher module, the terminals of the battery and the flasher switch such that the flasher module generates a blinking light beam in response to actuation of the flasher switch.
The flashlight device of the present invention still further comprises: a buzzer module mounted on the holder between the flasher module and the rear edge of the holder; a buzzer switch actuatable between on and off conditions; and means for forming a buzzer circuit which includes the buzzer module, the terminals of the battery and the buzzer switch such that the buzzer module generates a sound in response to actuation of the buzzer switch. The buzzer circuit is connected to the battery in parallel with the flasher circuit and the lamp circuit such that the buzzer module, the lamp and the flasher module are operable independently of one another by actuation of the corresponding buzzer switch, lamp switch and flasher switch independently of one another.
The present invention also is directed to a card-shaped flashlight device which comprises: (a) a holder; (b) a lamp module mounted on the holder; (c) a flasher light module mounted on the holder; (d) a buzzer module mounted on the holder; (e) a planar battery attached to the holder for powering the lamp module, buzzer module and flasher module; and (f) lamp, flasher and buzzer circuits which respectively include a lamp switch and the lamp module, a buzzer switch and the buzzer module and a flasher switch and the flasher module being connected to the battery in parallel relationships with one another such that the lamp module, buzzer module and flasher module are operable independently of one another by the actuation of the corresponding lamp switch, buzzer switch and flasher switch independently of one another.
These and other features and advantages of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description when taken in conjunction with the drawings wherein there is shown and described an illustrative embodiment of the invention.

Card-shaped flashlight device with lamp, flasher and/or buzzer features


An apparatus for applying force to a multi-chip module, a printed wiring board and an interposer to facilitate electrical contact there-between, includes a plurality of load posts, a load transfer plate, a spring member, a backside stiffener plate and a spring actuator. The load posts are affixed to the multi-chip module and pass through the printed wiring board. The load transfer plate has a first stiffness. The spring member is disposed adjacent the load transfer plate and has a second stiffness that is less than the first stiffness. The a backside stiffener plate is disposed between the spring member and the printed wiring board and has a third stiffness that is greater than the second stiffness. The spring actuator engages the spring member to apply force to the backside stiffener plate, causing the substrate, the interposer and the printed wiring board to be held in contact.

1. Field of the Invention
The present invention relates to electrical connectors and more specifically to a device for connecting a multi-chip module to a printed wiring board.
2. Description of the Prior Art
Land grid array socket assemblies are common in the electronics industry for mounting single chip modules to printed wiring boards. The interconnection of a land grid array (LGA) module to a printed wiring board (PWB) requires the accommodation of a high area density of electronic contacts and must result in a highly reliable electronic connection over a range of operating environments. One method of interconnecting an LGA module to a PWB is by using a conductive interposer. The interposer has an array of electrical contacts on one surface which mirrors those of the LGA module and, on the opposing surface, an array of electrical contacts which mirrors those of the PWB. The mounting of the LGA module is then accomplished by aligning the electrical contacts of the LGA module, interposer and PWB and mechanically compressing the interposer.
A land grid array socket assembly using an interposer has several advantages over other more traditional methods of component mounting. The modules may be changed or easily upgraded in the field. Also, system assembly and rework costs may be reduced during production. The interposer reduces the effects of thermal expansion mismatch between the chip modules and the PWB by acting as a compliant member between the chip module substrate and the PWB surface. This compliant property of the interposer ensures electrical connectivity of the assembly over a range of thermal and dynamic operating environments.
The demand for higher performance in electronic equipment has led to the development of LGA socket and interposer assemblies for multi-chip module applications. However, the mounting of a multi-chip module presents challenges due to the greater number of electrical contacts and larger substrate size inherent with this type of electronic component.
A key challenge in using LGA sockets with interposers for multi-chip modules is the creation of a consistent mechanical clamping force to compress the interposer between the multi-chip module and the PWB. A consistent clamping force is required to ensure positive electrical connections between the components and to maintain the alignment of the assembly over various operating environments. A multi-chip module requires a high density of electrical contacts over the surface of the module substrate. This high density of contacts necessitates an initial accurate alignment of the assembly and a controlled and predictable compression force to maintain the multi-chip module, interposer and PWB in electrical contact.
Various hardware configurations have been employed to achieve the compression of the LGA socket, interposer and multi-chip module assembly. Typical existing systems use a spring member to compress the components together. The components are assembled upon the PWB and a spring member is deflected by spring actuation hardware thus clamping the components in place. One problem inherent in this approach is the range of spring deflections achieved, and hence the range of clamping forces generated, due to the mechanical tolerances presented by the assembly. The mechanical tolerances of the actuation hardware, multi-chip module, interposer and printed wiring board all directly effect the spring deflections generated in the complete assembly.
One example of an existing system for securing a multi-chip module in an LGA socket connection upon a printed wiring board is shown in FIG. 1. In such a system, a multi-chip module body 110 includes a substrate portion 112, upon which a plurality of integrated circuit chips are mounted, and a housing, which typically includes a heat sink. The substrate portion 112 is mounted upon a printed wiring board (PWB) 116 using an interposer 114. An interposer 114 is a thin sheet with a plurality of electrical contacts, arranged to mirror the electrical contacts of the substrate 112 and the printed wiring board 116, passing therethrough that facilitates electrically coupling the substrate 112 to the printed wiring board 116. The multi-chip module 110 is clamped into position by load posts 120, spring elements 122, and actuation nuts 124. The spring elements act upon a load plate 118 positioned on the underside of the PWB 116. As the actuation nuts 124 are tightened, the spring elements 122 are compressed between the load plate 118 and the actuation nuts 124. The actuation nuts 124 create a tensile load on the load posts 120 and the load plate 118 is compressed up against the PWB 116. The tensile load in the load posts results in a downward force on the multi-chip module body 110 which compresses the substrate 112, interposer 114 and PWB 116 together.
The spring actuation hardware typically includes a threaded actuation member which is used to compress the spring member. To compress the spring, the clearances in the assembly are first removed by advancing the actuation member. The actuation member is then further advanced a given number of turns to create a known deflection of the spring member. One source of uncertainty in this approach is that the determination of when the tolerances have been removed from the assembly is a subjective judgment. A second source of uncertainty is associated with monitoring the turn count of the actuation member. The end result is an imprecise displacement of the spring element and a resulting uncertainty in the compressive force applied to the multi-chip module, interposer and PWB assembly.
As further demonstrated in FIG. 1, existing systems apply the compressive force about the periphery of the assembly only. This non-uniform application of force results in an uneven deflection of the multi-chip module substrate 112, PWB 116 and interposer 114. This deflection of the components allows a corresponding variance in the compressive force seen by the individual electrical contacts across the surface of each component. The result is that the electrical contacts at the center of each mating component face are not as tightly compressed as the electrical contacts about the edges of the assembly, demonstrated by arrows 126. This variance in contact pressure reduces the integrity of the electrical connection when exposed to a range of operating environments.
Therefore, there is a need for a device that predictably applies even force to a multi-chip module and a printed wiring board.
The disadvantages of the prior art are overcome by the present invention which, in one aspect, is an apparatus for applying force to a multi-chip module having a substrate, a printed wiring board having a first side and an opposite second side and an interposer. The interposer facilitates electrical contact between the substrate and the printed wiring board through the interposer. The multi-chip module and the interposer are disposed on the first side of the printed wiring board.
The apparatus includes a plurality of elongated spaced-apart load posts, a load transfer plate, a spring member, a backside stiffener plate, and a spring actuator. The load posts are affixed to the multi-chip module and pass through a plurality of post holes defined by the printed wiring board from the first side to the second side of the board. Each load post has a proximal end affixed to the multi-chip module and an opposite distal end that defines an engagement surface. The load transfer plate is disposed opposite the multi-chip module and spaced apart from the second side of the printed wiring board. The load transfer plate defines a plurality of openings through which the distal ends of each of the plurality of load posts pass. Each of the plurality of openings is shaped so as to engage the engagement surface of the distal end of a corresponding load post.
The spring member is disposed adjacent the load transfer plate between the load transfer plate and the printed wiring board. The backside stiffener plate is disposed between the spring member and the printed wiring board. The spring actuator is engageable with the spring member so that the spring actuator applies force to the backside stiffener plate, thereby causing the substrate, the interposer and the printed wiring board to be held in contact. The spring member has a stiffness which is substantially less than the stiffness of either the load transfer plate or the backside stiffener plate.
In another aspect, the spring member includes a plurality of similarly shaped spring plates placed in vertical alignment. Each spring plate defines a bushing hole passing through the body of the plate having a size sufficient to receive a portion of the spring actuator within the opening. The bushing hole is chamfered where the hole intersects the upper and lower surface of the spring plate. The spring plates include a center portion and a plurality of spaced-apart cantilevered beams extending radially from the center portion. Each beam ends in a beam end. Moreover, the shape of the cantilevered beams is chosen such that the load verses deflection curve for the spring plate is substantially linear.
Each spring plate further includes an alignment hole passing through each beam end. The load transfer plate has an inward surface and a plurality of truncated corners with an alignment pin positioned inwardly from the inward surface at each of the truncated corners. Each alignment pin is disposed so as to be in alignment with a different alignment hole of a beam end. The spring member is positioned over the alignment pins, upon the load transfer plate. A plurality of clips are affixed to a different one of the truncated corners and are shaped to hold a different beam end adjacent to a corresponding truncated corner.
The spring element defines a bushing hole passing therethrough and disposed substantially central to the spring member. The spring actuator includes an elongated actuation screw having a first end with a tool engagement portion extending therefrom. The actuation screw has a second end with a threaded portion extending therefrom and a screw collar disposed between the tool engagement portion and the threaded portion. The spring actuator also includes a bushing with an outer surface and defines a threaded passage passing longitudinally therethrough that is complimentary to the threaded portion of the actuation screw. The bushing also has a bushing collar extending outwardly from the outer surface. The bushing is positioned within the bushing hole of the spring element and the threaded actuator positioned within the bushing.
In yet another aspect, the substrate has a substrate thickness tolerance. The printed wiring board has a first side and an opposite second side and has a printed wiring board thickness tolerance. The interposer also has an interposer thickness tolerance. The deflection of the spring member is of a magnitude of at least eight times a total stacked tolerance. The total stacked tolerance includes the sum of the substrate thickness tolerance, the interposer thickness tolerance, the printed wiring board thickness tolerance, the load post length tolerance, and the actuator length tolerance.
In yet another aspect, the apparatus also includes a backside stiffener plate, or a load transfer plate, or both a backside stiffener plate and a load transfer plate. The backside stiffener plate is disposed between the spring member and the printed wiring board and has a backside stiffener plate thickness tolerance. The load transfer plate is disposed opposite the multi-chip module and is spaced apart from the second side of the printed wiring board. The load transfer plate is coupled to the distal ends of the load posts and has a load transfer plate thickness tolerance.
These and other aspects of the invention will become apparent from the following description of the preferred embodiments taken in conjunction with the following drawings. As would be obvious to one skilled in the art, many variations and modifications of the invention may be effected without departing from the spirit and scope of the novel concepts of the disclosure.

Land grid array socket actuation hardware for MCM applications

International Business Machines Corporation


A slim cooker hood casing, comprising a casing and a frame. The casing has a front sheet, two lateral sheets, a top sheet and a back sheet. The frame is fastened to the lower edge of the casing and further comprises a front bar and two side bars. The front bar has a rear side with a vertical strip, which is connected with a connecting strip at the front edge of the front sheet. The two side bars have inner sides with downward bent vertical strips, which are connected with connecting strips at the lower edges of the two lateral sheets. Thereby the frame reinforces the casing, reducing vibrations of the casing during operation.

1. Field of the Invention
The present invention relates to a slim cooker hood casing, particularly to a slim cooker hood casing having a reinforcement for greater strength and being easily mountable and dismountable.
2. Description of Related Art
A conventional cooker hood casing is formed of a single metal sheet and punched. Being made of a metal sheet, a casing is structurally weak. A lower plate is needed as a reinforcement, but strength thereof is insufficient. Thus, when the cooker hood is running, vibrations develop, resulting in a high level of noise.
Furthermore, todayxe2x80x94s cooker hoods are usually integrated into kitchen furniture. Often an opening in a cupboard is prepared to accommodate a cooker hood, two sides of which are then fastened to the cupboard. The cooker hood has a front side of the same color as of the kitchen furniture to provide for a uniform look. Thus space is saved and a beautiful appearance is achieved.
However, when the cooker hood is installed, hanging elements have to be provided on a back side thereof close to a wall. Then hanging elements protrude from the cooker hood casing outward or upward. Since the cooker hood is combined with the cupboard, holes have to be dug into side walls thereof that contact the cooker hood, damaging the cupboard and making installation of the cooker hood awkward.
It is the main object of the present invention to provide a slim cooker hood casing of high structural strength for low noise during operation.
Another object of the present invention is to provide a slim cooker hood casing having openings for accommodating hanging elements, avoiding damaging of adjacent kitchen furniture during installation.
The present invention can be more fully understood by reference to the following description and accompanying drawings.


A system for a facility including a server coupled to a database, a plurality of tags coupled to a plurality of assets, each tag being configured to transmit a tag ID that is uniquely associated in the database with data describing the asset, a plurality of first transceivers for receiving tag IDs and transmitting the tag IDs and a transceiver ID to the server, which is configured to update the database with location information for the asset to indicate that the asset is adjacent the transceiver, and a plurality of portable client devices configured to wirelessly transmit to the server a client device ID that is uniquely associated in the database with a user of the client device, whereby, in response to receipt of the client device ID, the server is configured to update the database with location information for the user to indicate a location of the user.

Caregivers such as physicians, nurses and other staff in a hospital ward, hospital wing, or other healthcare facility generally work under high pressure, high stress and long hours. These caregivers should be highly responsive to patient needs, in non-emergency as well as emergency situations. Due to ever-increasing costs of healthcare and other economic practicalities, efficient deployment of the caregivers in a healthcare facility is desired, particularly at night when the number of caregivers is typically maintained at a minimum. Nevertheless, optimizing efficiency is of secondary importance relative to the primary objective of providing a high level of healthcare. Accordingly, it is desirable to increase the efficiency of caregivers and improve the healthcare provided to patients.
The present invention provides a wholly integrated, universal communications, tracking, monitoring and control system for a healthcare facility. The system permits direct wireless communication among personnel, wireless access to continuously updated, stored information relating to patients, personnel and other assets, covert or automatic collection of information relating to the movement and status of such patients, personnel and other assets, and control (either manually or automatically) of equipment and environmental features of the facility based on activities and/or the movement or status of patients, personnel or other assets.
Additional features and advantages of the present invention will be evident from the following description of the drawings and exemplary embodiments.

Universal communications, monitoring, tracking, and control system for a healthcare facility