US20050021005A1 - Laminated patient infusion device - Google Patents

Abstract

A device for delivering fluid to a patient including an exit port assembly adapted to connect to a transcutaneous patient access tool, and a dispenser including at least two laminated layers of material defining a passageway connected to the exit port assembly, and an expandable accumulator in fluid communication with the passageway for controlling fluid flow from a reservoir to the exit port assembly. The laminated construction provides many benefits including simplifying the design and manufacturing of the device, in order to further reduce the size, complexity and costs of the device so that the device lends itself to being small and disposable in nature.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• The present application is related to U.S. patent application Ser. No. 09/943,992, filed on Aug. 31, 2001, which is assigned to the assignee of the present application and incorporated herein by reference.
FIELD OF THE INVENTION
• The present invention relates generally to medical devices, systems and methods, and more particularly to small, low cost, portable infusion devices and methods that are useable to achieve precise, sophisticated, and programmable flow patterns for the delivery of therapeutic liquids to a mammalian patient.
BACKGROUND OF THE INVENTION
• Today, there are numerous diseases and other physical ailments that are treated by various medicines including pharmaceuticals, nutritional formulas, biologically derived or active agents, hormonal and gene based material and other substances in both solid or liquid form. In the delivery of these medicines, it is often desirable to bypass the digestive system of a mammalian patient to avoid degradation of the active ingredients caused by the catalytic enzymes in the digestive tract and liver. Delivery of a medicine other than by way of the intestines is known as parenteral delivery. Parenteral delivery of various drugs in liquid form is often desired to enhance the effect of the substance being delivered, insuring that the unaltered medicine reaches its intended site at a significant concentration. Also, undesired side effects associated with other routes of delivery, such as systemic toxicity, can potentially be avoided.
• Often, a medicine may only be available in a liquid form, or the liquid version may have desirable characteristics that cannot be achieved with solid or pill form. Delivery of liquid medicines may best be accomplished by infusing directly into the cardiovascular system via veins or arteries, into the subcutaneous tissue or directly into organs, tumors, cavities, bones or other site specific locations within the body.
• Parenteral delivery of liquid medicines into the body is often accomplished by administering bolus injections using a needle and reservoir, or continuously by gravity driven dispensers or transdermal patch technologies. Bolus injections often imperfectly match the clinical needs of the patient, and usually require larger individual doses than are desired at the specific time they are given. Continuous delivery of medicine through gravity feed systems compromise the patient's mobility and lifestyle, and limit the therapy to simplistic flow rates and profiles. Transdermal patches have special requirements of the medicine being delivered, particularly as it relates to the molecular structure, and similar to gravity feed systems, the control of the drug administration is severely limited.
• Ambulatory infusion pumps have been developed for delivering liquid medicaments to a patient. These infusion devices have the ability to offer sophisticated fluid delivery profiles accomplishing bolus requirements, continuous infusion and variable flow rate delivery. These infusion capabilities usually result in better efficacy of the drug and therapy and less toxicity to the patient's system. An example of a use of an ambulatory infusion pump is for the delivery of insulin for the treatment of diabetes mellitus. These pumps can deliver insulin on a continuous basal basis as well as a bolus basis as is disclosed in U.S. Pat. No. 4,498,843 to Schneider et al.
• The ambulatory pumps often work with a reservoir to contain the liquid medicine, such as a cartridge or reservoir, and use electro-mechanical pumping or metering technology to deliver the medication to the patient via tubing from the infusion device to a needle that is inserted transcutaneously, or through the skin of the patient. The devices allow control and programming via electromechanical buttons or switches located on the housing of the device, and accessed by the patient or clinician. The devices include visual feedback via text or graphic screens, such as liquid crystal displays known as LCD's, and may include alert or warning lights and audio or vibration signals and alarms. The device can be worn in a harness or pocket or strapped to the body of the patient.
• Currently available ambulatory infusion devices are expensive, difficult to program and prepare for infusion, and tend to be bulky, heavy and very fragile. Filling these devices can be difficult and require the patient to carry both the intended medication as well as filling accessories. The devices require specialized care, maintenance, and cleaning to assure proper functionality and safety for their intended long term use. Due to the high cost of existing devices, healthcare providers limit the patient populations approved to use the devices and therapies for which the devices can be used.
• Clearly, therefore, there was a need for a programmable and adjustable infusion system that is precise and reliable and can offer clinicians and patients a small, low cost, light weight, simple to use alternative for parenteral delivery of liquid medicines.
• In response, the applicant of the present application provided a small, low cost, light weight, easy to use device for delivering liquid medicines to a patient. The device, which is described in detail in co-pending U.S. application Ser. No. 09/943,992, filed on Aug. 31, 2001, includes an exit port, a dispenser for causing fluid from a reservoir to flow to the exit port, a local processor programmed to cause a flow of fluid to the exit port based on flow instructions from a separate, remote control device, and a wireless receiver connected to the local processor for receiving the flow instructions. To reduce the size, complexity and costs of the device, the device is provided with a housing that is free of user input components, such as a keypad, for providing flow instructions to the local processor.
• What is still desired are new and improved devices for delivering fluid to a patient. Preferably, the fluid delivery devices will be simple in design, and inexpensive and easy to manufacture, in order to further reduce the size, complexity and costs of the devices, such that the devices lend themselves to being small and disposable in nature.
SUMMARY OF THE INVENTION
• In response, the present invention provides a device for delivering fluid to a patient, including an exit port assembly adapted to connect to a transcutaneous patient access tool, and a dispenser including at least two laminated layers of material defining a passageway connected to the exit port assembly, and an expandable accumulator in fluid communication with the passageway for controlling fluid flow from a reservoir to the exit port assembly. The laminated construction provides many benefits including, but not limited to, simplifying the design and manufacturing of the device, and further reducing the size, complexity and costs of the device. The device of the present invention, therefore, lends itself to being small and disposable in nature.
• According to one aspect of the present invention, at least one layer of the dispenser comprises a resilient diaphragm. According to another aspect, the at least two laminated layers of the dispenser further include a first layer and a second layer received against the first layer. The second and the first layers define the passageway connected to the exit port assembly, and the second layer includes an opening in fluid communication with the passageway. The resilient diaphragm is received on the second layer covering the opening, and a third layer is received over the diaphragm on the second layer. The third layer has an pulse chamber over the diaphragm and in alignment with the opening of the second layer, and a port in fluid communication with the pulse chamber.
• According to another aspect, one of the second and the third layers defines a recess receiving the diaphragm, and wherein the recess has a depth about equal to a thickness of the diaphragm such that the diaphragm is secured in a substantially fluid-tight manner between the second and the third layers. Preferably, a length and a width of the recess are greater than a length and a width of the diaphragm in order to decrease required manufacturing tolerances of the dispenser.
• According to an additional embodiment of the present invention, the at least two laminated layers include a first layer, and a second layer received against the first layer. The second and the first layers define the passageway connected to the exit port assembly. The second layer includes a surface facing away from the first layer and having a recess, and an opening providing fluid communication between the recess and the passageway defined by the first and the second layers. The resilient diaphragm is received on the second layer covering the recess to form the expandable accumulator.
• According to one aspect, the device includes an actuator for pushing the diaphragm into the recess to reduce the volume of the accumulator. According to another aspect, the actuator comprises a rotatable cam.
• According to another embodiment, a third layer is received against the diaphragm and has a bore aligned with the recess of the second layer, and the actuator comprises a piston slidingly received in the bore. According to one aspect, a magnetic coil is received in the third layer coaxial with the piston for biasing the piston against the diaphragm upon being electrified. According to another aspect, the dispenser includes multiple accumulators arranged sequentially with respect to the passageway, and magnetic coils and pistons associated with each accumulator.
• According to another embodiment, a third layer is received against the diaphragm and has a bore aligned with the recess of the second layer, and a fourth layer is received against the third layer and has a bore aligned with the bore of the third layer, and a gas generator is received in the bore of the fourth layer for pressurizing the bore and biasing the piston against the diaphragm upon being actuated. According to one aspect, the dispenser includes multiple accumulators arranged sequentially with respect to the passageway, and gas generators and pistons associated with each accumulator.
• According to a further embodiment, the dispenser includes a first layer having a surface defining a groove, with the diaphragm positioned against the surface of the first layer such that the diaphragm and the groove define the passageway connected to the exit port assembly. A second layer is received against the diaphragm and includes a recess separated from the passageway by the diaphragm, and the portion of the passageway opposite the recess comprises the expandable accumulator. An actuator is received in the recess of the second layer for pushing the diaphragm towards the first layer upon being actuated to reduce the volume of the accumulator. According to one aspect, the actuator comprises a piece of piezoelectric material arranged to push the diaphragm upon contracting. According to another aspect, the actuator comprises multiple pieces of piezoelectric material arranged sequentially with respect to the passageway within the recess.
• Another embodiment includes a first layer received against a second layer, with the layers defining the passageway connected to the exit port assembly, and the second layer including a recess facing the first layer. The dispenser further includes a piston slidingly received in the recess of the second layer, such that the piston and the recess define the expandable accumulator. According to one aspect, a spring biases the piston towards the first layer. According to another aspect, a magnetic coil is received in the second layer coaxial with the piston for biasing the piston towards the first layer upon being electrified.
• These aspects of the invention together with additional features and advantages thereof may best be understood by reference to the following detailed descriptions and examples taken in connection with the accompanying illustrated drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a perspective view of a first exemplary embodiment of a fluid delivery device in accordance with this invention shown secured on a patient, and a remote control device for use with the fluid delivery device (the remote control device being enlarged with respect to the patient and the fluid delivery device for purposes of illustration);
• FIG. 2 is a sectional side view of the fluid delivery device ofFIG. 1;
• FIGS. 3aand3bare sectional side views of a dispenser of the fluid delivery device ofFIG. 1, illustrating operation of the dispenser;
• FIGS. 4aand4bare sectional views of another dispenser constructed in accordance with the present invention, illustrating operation of the dispenser;
• FIGS. 5aand5bare sectional views of an additional dispenser constructed in accordance with the present invention, illustrating operation of the dispenser;
• FIG. 6 is a sectional view of an additional embodiment of a dispenser constructed in accordance with the present invention;
• FIG. 7 is a top plan view of a portion of fluid delivery device constructed in accordance with the present invention;
• FIG. 8 is a sectional view of the portion of the fluid delivery device taken along line8-8 ofFIG. 7;
• FIG. 9 is a sectional view of the portion of the fluid delivery device taken along line9-9 ofFIG. 7;
• FIG. 10 is a sectional view of the portion of the fluid delivery device taken along line10-10 ofFIG. 7;
• FIGS. 11aand11bare sectional views of the entire fluid delivery device ofFIG. 7, illustrating operation of the device;
• FIGS. 12aand12bare sectional views of an embodiment of a valve constructed in accordance with the present disclosure, illustrating operation of the valve;
• FIGS. 13aand13bare sectional views of another embodiment of a valve constructed in accordance with the present disclosure, illustrating operation of the valve;
• FIG. 14 is a sectional view of a further embodiment of a valve constructed in accordance with the present disclosure;
• FIG. 15 is a sectional view of another embodiment of a valve constructed in accordance with the present disclosure;
• FIG. 16 is a sectional view of another embodiment of a dispenser constructed in accordance with the present invention;
• FIGS. 17aand17bare sectional views of another embodiment of a dispenser constructed in accordance with the present disclosure, illustrating operation of the dispenser;
• FIGS. 18aand18bare sectional views of another embodiment of a dispenser constructed in accordance with the present disclosure, illustrating operation of the dispenser;
• FIGS. 19aand19bare sectional views of another embodiment of a dispenser constructed in accordance with the present disclosure, illustrating operation of the dispenser;
• FIGS. 20aand20bare sectional views of a further embodiment of a dispenser constructed in accordance with the present disclosure, illustrating operation of the dispenser;
• FIGS. 21a,21band21care sectional views of another embodiment of a dispenser constructed in accordance with the present disclosure, illustrating operation of the dispenser;
• FIGS. 22aand22bare sectional views of a portion of another embodiment of a fluid delivery device including a priming mechanism constructed in accordance with the present disclosure, and illustrating operation of the priming mechanism;
• FIGS. 23aand23bare sectional views of a portion of an additional embodiment of a fluid delivery device including a priming mechanism constructed in accordance with the present disclosure, and illustrating operation of the priming mechanism;
• FIG. 24 is a schematic illustration of a further embodiment of a fluid delivery device constructed in accordance with the present disclosure;
• FIG. 25 is a schematic illustration of another embodiment of a fluid delivery device and a remote control device constructed in accordance with the present disclosure;
• FIG. 26 is a schematic illustration of an additional embodiment of a fluid delivery device constructed in accordance with the present disclosure;
• FIG. 27 is a schematic illustration of a further embodiment of a fluid delivery device constructed in accordance with the present disclosure;
• FIG. 28 is a schematic illustration of a further embodiment of a fluid delivery device constructed in accordance with the present disclosure;
• FIGS. 29athrough29dare sectional views of an embodiment of a fill port constructed in accordance with the present disclosure, and illustrating operation of the fill port;
• FIGS. 30aand30bare sectional views of another embodiment of a fill port constructed in accordance with the present disclosure, and illustrating operation of the fill port;
• FIG. 31 is a top sectional view of another device constructed in accordance with the present invention; and
• FIG. 32 is a side elevation view, partially cut away, of the device ofFIG. 31.
• Like reference characters designate identical or corresponding components and units throughout the several views.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
• Referring first toFIGS. 1 and 2, there is illustrated afluid delivery device10 constructed in accordance with the present invention. The types of liquids that can be delivered by the fluid delivery device of the present invention include, but are not limited to, insulin, antibiotics, nutritional fluids, total parenteral nutrition or TPN, analgesics, morphine, hormones or hormonal drugs, gene therapy drugs, anticoagulants, analgesics, cardiovascular medications, AZT or chemotherapeutics. The types of medical conditions that the fluid delivery device of the present invention might be used to treat include, but are not limited to, diabetes, cardiovascular disease, pain, chronic pain, cancer, AIDS, neurological diseases, Alzheimer's Disease, ALS, Hepatitis, Parkinson's Disease or spasticity.
• Referring toFIG. 2, thedevice10 generally includes anexit port assembly70 adapted to connect to a transcutaneous patient access tool such as a needle, adispenser40 for causing fluid from areservoir30 to flow to theexit port assembly70, and a processor or electronic microcontroller (hereinafter referred to as the “local” processor)50 connected to thedispenser40.
• Thelocal processor50 is programmed to cause a flow of fluid to theexit port assembly70 based on flow instructions from a separate,remote control device100, an example of which is shown inFIG. 1. Referring also toFIG. 2, thefluid delivery device10 further includes awireless receiver60 connected to thelocal processor50 for receiving the flow instructions from the separate,remote control device100 and delivering the flow instructions to the local processor. Thedevice10 also includes ahousing20 containing theexit port assembly70, thereservoir30, thedispenser40, thelocal processor50, and thewireless receiver60.
• As shown, thehousing20 is free of user input components for providing flow instructions to thelocal processor50, such as electromechanical switches or buttons on anouter surface21 of the housing, or interfaces otherwise accessible to a user to adjust the programmed flow rate through thelocal processor50. The lack of user input components allows the size, complexity and costs of thedevice10 to be substantially reduced so that thedevice10 lends itself to being small and disposable in nature.
• In order to program, adjust the programming of, or otherwise communicate user inputs to thelocal processor50, thefluid delivery device10 includes the wireless communication element, orreceiver60 for receiving the user inputs from the separate,remote control device100 ofFIG. 1. Signals can be sent via a communication element (not shown) of theremote control device100, which can include or be connected to anantenna130, shown inFIG. 1 as being external to thedevice100.
• Theremote control device100 has user input components, including an array of electromechanical switches, such as themembrane keypad120 shown. Thecontrol device100 also includes user output components, including a visual display, such as a liquid crystal display (LCD)110. Alternatively, the control device can be provided with a touch screen for both user input and output. Although not shown inFIG. 1, theremote control device100 has its own processor (hereinafter referred to as the “remote” processor) connected to themembrane keypad120 and theLCD110. The remote processor receives the user inputs from themembrane keypad120 and provides “flow” instructions for transmission to thefluid delivery device10, and provides information to theLCD110. Since theremote control device100 also includes avisual display110, thefluid delivery device10 can be void of an information screen, further reducing the size, complexity and costs of thedevice10.
• Thecommunication element60 of thedevice10 preferably receives electronic communication from theremote control device100 using radio frequency or other wireless communication standards and protocols. In a preferred embodiment, thecommunication element60 is a two-way communication element, including a receiver and a transmitter, for allowing thefluid delivery device10 to send information back to theremote control device100. In such an embodiment, theremote control device100 also includes anintegral communication element60 comprising a receiver and a transmitter, for allowing theremote control device100 to receive the information sent by thefluid delivery device10.
• Thelocal processor50 of thedevice10 contains all the computer programs and electronic circuitry needed to allow a user to program the desired flow patterns and adjust the program as necessary. Such circuitry can include one or more microprocessors, digital and analog integrated circuits, resistors, capacitors, transistors and other semiconductors and other electronic components known to those skilled in the art. Thelocal processor50 also includes programming, electronic circuitry and memory to properly activate thedispenser40 at the needed time intervals.
• In the exemplary embodiment ofFIG. 2, thedevice10 includes apower supply80, such as a battery or capacitor, for supplying power to thelocal processor50. Thepower supply80 is preferably integrated into thefluid delivery device10, but can be provided as replaceable, e.g., a replaceable battery.
• Although not shown, the device can include sensors or transducers such as a reservoir volume transducer or a reservoir pressure transducer, for transmitting information to thelocal processor50 to indicate how and when to activate thedispenser40, or to indicate other parameters determining flow, pump flowpath prime condition, blockage in flowpath, contact sensors, rotary motion or other motion indicators, as well as conditions such as thereservoir30 being empty or leaking, or the dispensing of too much or too little fluid from the reservoir, etc.
• The volume of thereservoir30 is chosen to best suit the therapeutic application of thefluid delivery device10 impacted by such factors as available concentrations of medicinal fluids to be delivered, acceptable times between refills or disposal of thefluid delivery device10, size constraints and other factors. Thereservoir30 may be prefilled by the device manufacturer or a cooperating drug manufacturer, or may include external filling means, such as a fill port having needle insertion septum or a Luer connector, for example. In addition, thedevice10 can be provided with a removable reservoir.
• Theexit port assembly70 can include elements to penetrate the skin of the patient, or can be adapted to connect to a standard infusion device that includes transcutaneous delivery means. A needle connection tubing terminating in a skin penetrating cannula (not shown) can be provided as an integral part of theexit port assembly70, for example, with the skin penetrating cannula comprising a rigid member, such as a needle. Alternatively, theexit port assembly70 can be provided with a Luer connector for connecting to a standard infusion device including a skin penetrating cannula, such as a rigid needle. In the preferred embodiment, theexit port assembly70 includes injection means, such as a spring driven mechanism, to assist in penetrating the skin with the skin penetrating cannula. If the cannula is a flexible tube, a rigid penetrator within the lumen of the tube is driven through the skin by the injection means, and withdrawn leaving the soft cannula in place, such as in the subcutaneous tissue of the patient or other internal site. The injection means may be integral to thedevice10, or removable soon after transcutaneous penetration. In any event, theexit port assembly70 can also be provided with a removable plug (not shown) for preventing leakage during storage and shipment if pre-filled, and during priming if filled by user, and prior to use.
• Thedevice10 can also be provided with an adhesive layer on the outer surface of thehousing20 for securing thedevice10 directly to the skin of a patient, as shown inFIG. 1. Although not shown, the adhesive layer is preferably provided in a continuous ring encircling theexit port assembly70 in order to provide a protective seal around the penetrated skin. Thehousing20 can be made from flexible material, or can be provided with flexible hinged sections that allow thefluid delivery device10 to flex during patient movement to prevent detachment and aid in patient comfort.
• Thedispenser40 is connected in fluid communication with thereservoir30, as shown inFIG. 2. When thedevice10 is provided with a pressurized reservoir30 (i.e., fluid maintained within the reservoir at a pressure above atmospheric), thedispenser40 can include aninlet valve41 connected to the reservoir, anoutlet valve42 connected to theexit port assembly70, and anaccumulator43 connected between the inlet valve and the outlet valve, as shown in the exemplary embodiment ofFIGS. 3aand3b. Since the fluid in thereservoir30 is maintained at a pressure above atmospheric pressure, opening of theinlet valve41 allows theaccumulator43 to fill to the reservoir pressure, after which the inlet valve is41 is closed. At the proper time, as determined by thelocal processor50 programming and instructions received from theremote control device100, theoutlet valve42 can be opened to dispense fluid to theexit port assembly70, which is at the pressure of the patient, or atmospheric pressure. Theaccumulator43 will then be at atmospheric pressure, and theoutlet valve42 can be closed, ready for another repeat cycle.
• Thedispenser40 of the exemplary embodiment ofFIGS. 3aand3bdoes not create a driving or pumping force on the fluid passing therethrough, but rather acts as a metering device, allowing pulses of fluid to pass from thepressurized reservoir30, through thedispenser40, to theexit port assembly70 at atmospheric pressure. Theinlet valve41 and theoutlet valve42 of thedispenser40 are controlled by thelocal processor50, which includes electronic programming, controls and circuitry to allow sophisticated fluid delivery programming and control of thedispenser40.
• FIG. 3ashows thedispenser40 with theaccumulator43 at atmospheric pressure. Anaccumulator membrane44 is shown in a non-distended state, caused by atmospheric pressure only.Inlet valve41 is closed, andoutlet valve42 may be open or closed, but must have been opened since the lasttime inlet valve41 was opened.FIG. 3bshows the condition whereoutlet valve42 is closed, andinlet valve41 has been opened. Because of the elevated pressure of the fluid from thereservoir30, theaccumulator membrane44 is distended, thus increasing the volume ofaccumulator43 by anaccumulator volume45. After theinlet valve41 is closed, theoutlet valve42 can be opened, to dispense theaccumulator volume45 and allow theaccumulator membrane44 to retract to the position shown inFIG. 3a.
• Theinlet valve41 and theoutlet valve42 of thedispenser40 and thelocal processor50 are designed to prevent both valves from being opened at the same time, precluding thereservoir30 to ever flow directly to theexit port assembly70. The prevention of both valves opening at the same time is critical and can be accomplished via mechanical means, electrical means, or both. The prevention can be accomplished in thedispenser40 design, thelocal processor50 design, or both.
• Thedispenser40 shown inFIGS. 3aand3bdispenses finite pulses of fluid volume, called pulse volume (PV), with each activation. The PV is determined by the properties, materials and construction of theaccumulator43 and theaccumulator membrane44. PV's delivered by infusion devices are typically chosen to be small relative to what would be considered a clinically significant volume. For insulin applications at a concentration of 100 units per ml, a PV of less than 2 microliter, and typically 0.5 microliter, is appropriate. If thefluid delivery device10 is programmed via theremote control device100 to deliver2 units an hour, the dispenser will deliver40 pulses an hour, or a pulse every 1.5 minutes. Such pulsitile flow is considered continuous if the PV is small enough. Other drugs or concentrations may permit a much larger PV. Various flow rates are achieved by adjusting the time between pulses. To give a fixed volume or bolus, multiple pulses are given in rapid succession until the bolus volume is reached.
• The PV may not always be constant enough to be within the accuracy requirements of thefluid delivery device10. One factor impacting the PV is the pressure of thereservoir30. Thefluid delivery device10 may include means for monitoringreservoir30 pressure and adjust the timing between pulses to achieve the desire flow pattern. An example of such compensation would be to decrease time between pulses as thereservoir30 pressure decreases to maintain the programmed flow rate. An alternative to monitoringreservoir30 pressure is monitoring the volume of thereservoir30. Each time a pulse or series of pulses are delivered, a measurement ofreservoir30 volume can indicate whether a proper amount of fluid has been delivered, both for individual pulses and cumulative pulses. The system could also be designed to compensate fluid flow as errors are detected.
• Referring now toFIGS. 4aand4b, the present invention provides animproved dispenser240 for use with thefluid delivery device10 ofFIGS. 1 and 2. Operation of thedispenser240 ofFIGS. 4aand4bis similar to operation of thedispenser40 ofFIGS. 3aand3b. In addition, some elements of thedispenser240 ofFIGS. 4aand4bare similar to thedispenser40 ofFIGS. 3aand3bsuch that similar elements have the same reference numeral preceded by a “2”.
• Thedispenser240 ofFIGS. 4aand4b, however, includes at least twolaminated layers252,254 of material defining apassageway250 for connection to theexit port assembly70, and anexpandable accumulator243 in fluid communication with thepassageway250 for controlling fluid flow from thereservoir30 to theexit port assembly70. The laminated construction provides many benefits including, but not limited to, simplifying the design and manufacturing of thedispenser240, and further reducing the size, complexity and costs of thedispenser240. Thedispenser240 of the present invention, therefore, lends itself to being small and disposable in nature.
• In the embodiment ofFIGS. 4aand4b, the layers of thedispenser240 include afirst layer252 and asecond layer254 received against the first layer. At least one of the second and thefirst layers252,254 includes a surface groove between the layers which defines thepassageway250 connected to theexit port assembly70. Thesecond layer254 includes anopening246 in fluid communication with thepassageway250. Thelayers252,254 also include aresilient diaphragm244 received on thesecond layer254 covering the opening, and athird layer256 received over thediaphragm244 on thesecond layer254. Thethird layer256 has apulse chamber245 over thediaphragm244 and in alignment with theopening246 of thesecond layer254, and arelief port247 in fluid communication with thepulse chamber245.
• FIG. 4ashows thedispenser240 with theaccumulator243 at atmospheric pressure with theresilient diaphragm244 in a non-distended state.Inlet valve241 is closed, andoutlet valve242 may be open or closed, but must have been opened since the last time theinlet valve241 was opened.FIG. 4bshows the condition wherein theoutlet valve242 is closed, and theinlet valve241 has been opened. Because of the elevated pressure of the fluid from thereservoir30, the fluid expands theresilient diaphragm244 into the pulse chamber245 (with therelief port247 allowing evacuation of the pulse chamber245), thus increasing the volume of theaccumulator243 by about a volume of thepulse chamber245. After theinlet valve241 is closed, theoutlet valve242 can be opened, to dispense theaccumulator volume245 and allow theresilient diaphragm244 to return to the position shown inFIG. 4a.
• The laminated construction of thedispenser240 allows most manufacturing tolerances of thedispenser240 to be lowered, and the manufacturing process to be simplified, without effecting the performance and reliability of thedispenser240. High tolerances are required for only the volume of thepulse chamber245 and the resilience of thediaphragm244, since those dimensions affect the resulting PV produced by thedispenser240. Other dimensions and properties of thedispenser240 can be relatively relaxed to reduce the costs of the dispenser. For example, in the embodiment shown, at least one of the second and thethird layers254,256 defines arecess260 receiving thediaphragm244. Therecess260 has a depth about equal to a thickness of thediaphragm244 such that the diaphragm is secured in a substantially fluid-tight manner between the second and thethird layers254,256. However, a length and a width of therecess260 are greater than a length and a width of thediaphragm244 in order to decrease the required manufacturing tolerances of thedispenser240.
• Manufacturing thedispenser240 is preferably a “drop down” process. First thelayers252,254,256 are individually formed with the necessary openings, groove, and recesses. Thefirst layer252 is then laid down and thevalves241,242 are dropped into recesses (not shown) in the first layer and correctly positioned within thegroove250. Then thesecond layer254 is placed on thefirst layer252, and thediaphragm244 is placed in therecess260 of the second layer. Finally, thethird layer256 is positioned over thediaphragm244 and thesecond layer254. Thelayers252,254,256 can be made from a suitably strong and rigid material such as plastic or stainless steel, and can be secured together in a suitable manner, such as with adhesives or by welding. Thediaphragm244 can be made from a suitably expandable yet resilient material, such as rubber or a synthetic rubber.
• Referring toFIGS. 5aand5b, anotherdispenser270 according to the present invention is shown. Thedispenser270 is similar to thedispenser240 ofFIGS. 4aand4bsuch that similar elements have the same reference numerals. Afirst layer252 defines thepassageway250 connected to theexit port assembly70 and anopening246 in fluid communication with the passageway. Theresilient diaphragm244 is received on thefirst layer252 covering theopening246, and asecond layer254 is received over thediaphragm244 on the first layer. Thesecond layer254 has apulse chamber245 over thediaphragm244 and in alignment with theopening246 of thefirst layer252, and arelief port247 in fluid communication with thepulse chamber245. Athird layer256 is received on thesecond layer254 and defines arelief chamber248 in fluid communication with therelief port247 of thesecond layer252. Therelief chamber248 allows thepulse chamber245 to be evacuated upon expansion of thediaphragm244, yet keeps the pulse chamber sealed and the relief port protected. Therelief chamber248 can also be pressurized to further regulate the PV produced by thedispenser270.
• FIG. 6 shows anotherdispenser280 according to the present invention. Thedispenser280 is similar to thedispenser240 ofFIGS. 4aand4bsuch that similar elements have the same reference numerals. Thedispenser280, however, further includes acompression spring282 biasing thediaphragm244 away from thepulse chamber245. The strength of the spring is set along with the volume of thepulse chamber245 and the resilience of thediaphragm244, to provide a predetermined PV.
• FIGS. 7 through 11aand11bshow an entirefluid delivery device290 incorporating the laminated construction provided by the present invention. Thedevice290 is similar to the device ofFIGS. 1 and 2, but includes afirst layer252 and aresilient diaphragm288 received on a surface of the first layer. The surface of thelayer252 has a recess and a groove extending from the recess to theexit port assembly70, such that the recess of thelayer252 and aportion244 of thediaphragm288 define theexpandable accumulator243, and the groove of thelayer252 and thediaphragm288 define thepassageway250 connected to theexit port assembly70.
• As shown best onFIG. 7, the surface of thefirst layer252 also has avalve seat292 in the groove and anocclusion sensor recess294 in the groove, between thevalve seat292 and theexit port assembly70. The surface of thefirst layer252 further includes areservoir recess296, agroove298 extending between the reservoir and theaccumulator243, and avalve seat291 in thegroove298. In addition, the surface of thefirst layer252 includes abubble removal bay300, agroove302 extending between thebubble removal bay300 and thereservoir recess296, afill port recess304, and agroove298 extending between thefill port recess304 and thebubble removal bay300.
• As also shown inFIGS. 8 through 11aand11b, thediaphragm288 and thefirst layer252, therefore, define anocclusion sensor chamber294, thereservoir296, abubble removal chamber300, and connectingpassageways298,302,306. In between the recesses and grooves, thediaphragm288 is secured to the surface of thelayer252 in a fluid-tight manner, such as with an adhesive. As best shown inFIGS. 8 through 10, theportion244 of thediaphragm288 expands when thereservoir296 is filled in order to pressurize the fluid within the reservoir. In addition, upon the incidence of an occlusion, fluid backs up in theocclusion sensor chamber294 and causes the portion of thediaphragm288 over thechamber294 to expand and increase pressure within the chamber. Aswitch308 is positioned in thechamber294 to monitor for an occlusion, as shown inFIG. 9. Theswitch308 is arranged such that when that portion of thediaphragm288 over thechamber294 expands, the switch closes to indicate an occlusion. Alternatively, a strain gage can be attached to that portion of thediaphragm288 over thechamber294, or a pressure sensor can be positioned in thechamber294 to monitor for an occlusion.
• Thediaphragm288 can be provided with consistent properties, such as resilience, throughout, or can include inconsistent properties. For example, theportion244 of thediaphragm288 over thereservoir recess296 can be provided with a greater thickness to increase the resilience of that portion, while the thickness of thediaphragm288 over the valve seats291,292 may be made thinner to decrease the resilience of those portions. In addition, thediaphragm288 can be made from a material that allows gas to pass through yet prevents liquid from passing through, such that thediaphragm288 also acts as a bubble removal filter. Furthermore, thediaphragm288 can be provided with coatings. For example, surfaces of thediaphragm288 in contact with flow paths can be coated with material that promotes flow and avoids precipitation (such as insulin crystallization). Thediaphragm288 can also be coated with lines of conductive material, for example, to support transmission of electrical signals between the local processor and other components of the device.
• As shown inFIG. 7, thefirst layer252 also definesrecesses310,312,314, which are not covered by thediaphragm288, for other components of the device including thelocal processor50, thewireless communication unit60 and thebattery80.FIGS. 11aand11bshow acover316 attached to thefirst layer252 to complete thehousing20 of the fluid deliverdevice290. Thecover316 contains thepower source80, thewireless communication unit60 and thelocal processor50 of thedevice290. Thecover316 also includes the inlet and theoutlet valves241,242 aligned over the valve seats291,292 of thefirst layer252. Thevalves241,242 and theaccumulator243 comprise thedispenser320 for use with thepressurized reservoir296. As shown, thecover316 also provides an enclosed space that allows for expansion of thediaphragm portion244 over thereservoir296.
• FIGS. 12aand12bshow avalve330 constructed in accordance with the present invention for use as part of a laminated dispenser or part of a laminated fluid delivery device. Thevalve330, for example, can comprise the inlet valve of the dispenser controlling flow from a reservoir into the accumulator. Thevalve330 is part of apassageway250 formed from first andsecond layers252,254, wherein thesecond layer254 includes anopening332 communicating with the passageway. Thevalve330 includes a layer of resilient fluid-tight material334 covering the opening, and a layer ofpiezoelectric material336 covering the layer of resilient fluid-tight material.
• The layers of resilient fluid-tight material334 andpiezoelectric material336 are arranged such that upon contracting, the layer ofpiezoelectric material336 forces the layer of resilient fluid-tight material334 into theopening332 of thepassageway250 and substantially closes the passageway, as shown inFIG. 12a. As shown, thepiezoelectric material336 includes awire338 for connection to a power source (not shown). When power is applied to thepiezoelectric material336, the piezoelectric material straightens out, thereby opening thepassageway250, as shown inFIG. 12b. The resilient fluid-tight material334 can be provided as part of the resilient diaphragm forming the accumulator of the dispenser. In the preferred embodiment, thepiezoelectric material336 is normally curved when de-energized, and deforms to a straight geometry when energized, such that thepassageway250 is normally closed.
• FIGS. 13aand13bshow anothervalve340 constructed in accordance with the present invention. Thevalve340 is similar to thevalve330 ofFIGS. 12aand12bsuch that similar elements have the same reference numerals. Thevalve340 ofFIGS. 13aand13b, however, further includes anopening332 in thefirst layer252, and a layer of resilient fluid-tight material334 covering the opening in the first layer, and a layer ofpiezoelectric material336 covering the layer of resilient fluid-tight material. As shown, the layers ofpiezoelectric material336 react together to close thepassageway250 when de-energized (FIG. 13a), and to open the passageway when energized (FIG. 13b). An alternative embodiment can include a tubular layer of resilient fluid-tight material and a tubular layer of piezoelectric material positioned over an annular opening in the passageway.
• Avalve assembly350 constructed in accordance with the present invention is shown inFIG. 14. Thevalve assembly350 is shown as part of a laminated dispenser having first, second andthird layers252,254,256. Thefirst layer252 defines thepulse chamber245, theevacuation port247, and theenlarged recess260 receiving thediaphragm244 over the pulse chamber to form theaccumulator243. Thesecond layer254 defines the groove for thepassageway250, anopening246 communicating with the groove in alignment with thepulse chamber245, and arecess351 on the surface of thesecond layer254 in alignment with the opening. Thethird layer256 defines avalve assembly chamber352 facing thesecond layer254 in alignment with therecess351 of the second layer.
• Thevalve assembly350 includes avalve member354, springs356 and a fluidresistant cover358. Thevalve member354 is received in thevalve assembly chamber352 of thethird layer256 and includes abar360 extending parallel with thepassageway250 and pivotally mounted on the third layer about apivot point364 aligned with theaccumulator243. Aninlet valve361 and anoutlet valve362 extend from thebar360 into thepassageway250 on opposite sides of the pivot point364 (and on opposite sides of the accumulator243). Thesprings356 are positioned between the ends of thebar360 and thethird layer256 to bias each end towards thesecond layer254. The fluidresistant cover358 is received in therecess351 of the second layer254 (the recess preferably being oversized with respect to the cover to reduce manufacturing tolerances), and provides a water-tight seal between thepassageway250 and thevalve assembly350.
• Although not shown, thevalve assembly350 also includes an actuator for causing thevalve member354 to pivot. The actuator can comprise a rotary motor, a linear motor, a clock spring, and piezoelectric material, for example. Many different types of actuators can be used for causing thevalve member354 to pivot when desired. The pivotingvalve assembly354 provides the benefit of thevalves361,362 alternatively blocking thepassageway250 at all times, such that unregulated flow to the exit port assembly is not permitted. As shown inFIG. 14, thevalve assembly350 also utilizes “drop down” construction, wherein all elements of the valve assembly are assembled from above thesecond layer254, to simplify manufacturing.
• Anothervalve assembly370 constructed in accordance with the present invention is shown inFIG. 15. Thevalve assembly370 is shown as part of a laminated dispenser having first andsecond layers252,254, with thepassageway250 defined between the layers. Thelaminated layers252,254 also define abore372 bisecting thepassageway250 and receiving thevalve assembly370.
• Thevalve assembly370 includes avalve member374 movably received in thebore372 and including anopening376, and aspring378 biasing the valve member such that theopening376 of the valve member is normally offset from thepassageway250 and the passageway is blocked by thevalve member374. Theassembly370 also includes anactuator380 for moving thevalve member374 upon being actuated such that theopening376 of thevalve member374 aligns with thepassageway250 to thereby allow flow through the passageway. In the embodiment shown, the actuator comprises agas generator380 for pressurizing thebore372 upon being actuated. Thegas generator380 is mounted in aplug382 fitted in thesecond layer254 and having agas release port384 communicating with thebore372. As shown inFIG. 15, thevalve assembly370 also utilizes “drop down” construction, wherein all elements of the valve assembly can be assembled from above thesecond layer254, to simplify manufacturing.
• During operation, the actuatedgas generator380 pressurizes thebore372 above thevalve member374 and forces the valve member to move against thespring378, so that theopening376 aligns with thepassageway250 and opens the passageway. Thegas release port384 allows a predetermined rate of gas to exit thebore372 in order to limit the total pressure in the bore and allow a controlled decay of pressure. In one embodiment, thevalve assembly370 is positioned near the exit port assembly of a fluid delivery device to limit the useable life of the fluid delivery device. For example, the fluid delivery device can include automatic or manual means for actuating thegas generator380 upon the device being secured to a patient's skin, and the gas generator can be provided with enough fuel to maintain thevalve member374 open for three days. When the fuel in thegas generator380 is depleted, thevalve member374 closes and the fluid delivery device must be replaced with a new device. Thevalve370 can also be used to pulse fluid as long as the gas generation rate of thegas generator380 and the gas release rate of thegas release port384 have time constants slightly smaller than the maximum pulse rate.
• Referring now toFIG. 16, anotherlaminated dispenser390 constructed in accordance with the present invention is shown. Thedispenser390 is for use with a pressurized reservoir and includes aninlet valve241, anaccumulator243 and anoutlet valve242. The dispenser includes threelayers252,254,256. The second and thefirst layers252,254 define thepassageway250 connected to the exit port assembly, and thesecond layer254 defines thepulse chamber245 communicating with the passageway.
• Apiston392 is slidingly received in thepulse chamber245, and a substantially fluid tight seal is provided between the piston and the wall of the pulse chamber. Thepiston392 in effect comprises the expandable membrane of theaccumulator243. Thethird layer256 is received on thesecond layer254 and closes thepulse chamber245, and springs394 are positioned between the third layer and thepiston392 and bias the piston away from the third layer. During operation, theoutlet valve242 is closed and theinlet valve241 is opened to allow pressurized fluid from the reservoir to move thepiston392 against thesprings392 and into thepulse chamber245 to expand theaccumulator243 by the predetermined pulse volume. Then theinlet valve241 is closed and theoutlet valve242 is opened such that thebiased piston392 can force the pulse volume of liquid to the exit port assembly.
• Referring toFIGS. 17aand17b, an additionallaminated dispenser400 constructed in accordance with the present invention is shown. Thedispenser400 is for use with a non-pressurized reservoir (not shown) and, therefore, is designed to act as a pump instead of simply a regulator. Thedispenser400 includes aninlet valve402, anaccumulator404, and anoutlet valve406. Thevalves402,406 comprise one-way valves, such as duckbill valves, and theaccumulator404 is an “active” accumulator, as opposed to the “passive” accumulators used in the previously described dispensers.
• The second and thefirst layers252,254 of thedispenser400 define thepassageway250 connected between the reservoir and the exit port assembly, and thesecond layer254 defines abore408 communicating with thepassageway250. Apiston410 is slidingly received in thebore408 and acts as the expandable membrane of theaccumulator404. Thedispenser400 also includes anactuator412 for moving thepiston410 in thebore408 to draw fluid from the reservoir through the inlet valve402 (the one-way outlet valve406 prevents fluid from being draw though the outlet valve406) and expel liquid through theoutlet valve406 to the exit port assembly (the one-way inlet valve402 prevents fluid from being expelled though the inlet valve402).
• In the embodiment show, the actuator comprises amagnetic coil412 received in an annular groove provided in thesecond layer254, coaxial with thepiston410, which is made from magnetic material. Aplug414 seals thepiston410 and thecoil412 in thesecond layer254, such that the portion of thebore408 between thepiston410 and theplug414 comprises the pulse chamber of theaccumulator404. Thedispenser400 includes a coiledcompression spring416 positioned between theplug414 and thepiston410 biasing the piston towards thepassageway250. Thecoil412 is arranged to bias thepiston410 against thespring416 upon being energized.
• During operation of thedispenser400, thecoil412 is energized such that movement of thepiston410 expands theaccumulator404, and draws fluid from the reservoir, through the one-way inlet valve402 and into thebore408, as shown inFIG. 17a. The one-way inlet valve402 closes when theaccumulator404 is fully expanded. Then thecoil412 is de-energized, so that thespring416 is allowed to push thepiston410 back towards thepassageway250, compress theaccumulator404, and expel the liquid through the one-way outlet valve406 to the exit port assembly, as shown inFIG. 17b.
• FIGS. 18aand18b, show anotherlaminated dispenser420 constructed in accordance with the present invention, and which operates in a manner similar to thedispenser400 ofFIGS. 17aand17b. Thedispenser420 includes a one-way inlet valve402, an “active”accumulator424, and a one-way outlet valve406. The second and thefirst layers252,254 of thedispenser420 define thepassageway250 connected between the reservoir (not shown) and the exit port assembly (not shown).
• Theaccumulator424 includes apulse chamber426 formed in a surface of thesecond layer254 facing away from thefirst layer252, and anopening428 providing fluid communication between thepulse chamber426 and thepassageway250. Aresilient diaphragm430 is received on thesecond layer254 and covering thepulse chamber426 in a fluid-tight manner.
• Thedispenser420 also includes anactuator432 for pushing thediaphragm430 into thepulse chamber426 to reduce the volume of theaccumulator424 and produce a pulse volume. In the embodiment shown, the actuator comprises arotatable cam432 and a motor (not shown) or other rotational device for rotating the cam. During operation, thecam432 is rotated away from thediaphragm430 such that the diaphragm expands theaccumulator424, and draws fluid from the reservoir, through theinlet valve402 and into thepulse chamber426, as shown inFIG. 18a. Theinlet valve402 closes when theaccumulator424 is fully expanded. Then thecam432 is rotated back into thediaphragm430, so that the diaphragm compresses thepulse chamber426 and expels the liquid through theoutlet valve406 to the exit port assembly, as shown inFIG. 18b.
• Referring toFIGS. 19aand19b, an additionallaminated dispenser440 constructed in accordance with the present invention is shown. Thedispenser440 is for use with a non-pressurized reservoir (not shown) and, therefore, is designed to act as a pump instead of simply a regulator. Thedispenser440 includes a plurality of “active”accumulators442 and no inlet valve or outlet valve. Theaccumulators442 are arranged successively with respect to thepassageway250 and operate one after another such that thedispenser440 operates as a linear peristaltic pump.
• The second and thefirst layers252,254 of thedispenser440 define thepassageway250 connected between the reservoir and the exit port assembly. Theresilient diaphragm444 is positioned between thesecond layer254 and thethird layer256 in a liquid-tight manner. For eachaccumulator442, thesecond layer254 defines apulse chamber446 communicating with thepassageway250, and thethird layer256 defines abore448 aligned with the pulse chamber.
• Thedispenser440 also includes actuators for compressing thepulse chambers446 and expelling pulse volumes of liquid towards the exit port assembly. In the embodiment shown, the actuators comprisepistons450 made from magnetic material and slidingly received in thebores448, andmagnetic coils452 received in annular grooves provided in thethird layer256, coaxial with thepistons450. Eachcoil452 is arranged such that, upon being energized, thecoil452 forces thepiston450 against thediaphragm444 to collapse thepulse chamber446 and expel a pulse volume of fluid from theaccumulator442 into thepassageway250. Upon being de-energized, thecoil452 releases thepiston450 and allows thediaphragm444 to push the piston back, and draw a pulse volume of fluid into thepulse chamber446. During operation of thedispenser440, thecoils452 are successively energized and de-energized so that fluid is drawn from the reservoir, expelled and drawn successively into theaccumulators442, and expelled to the exit port assembly. Preferably, at least one of thepistons450 is always in a closed position to occlude the fluid path and prevent the free flow of fluid through the passageway to the exit port assembly. In an alternative embodiment, thepistons450 can be biased closed, with a spring, and thecoils452 arranged to pull the pistons away from the passageway when energized.
• FIGS. 20aand20bshow anotherlaminated dispenser460 according to the present invention. Thedispenser460 is similar to thedispenser440 ofFIGS. 19aand19b, but includes afourth layer258 definingbores462 aligned with thebores448 of thethird layer256. In addition, the actuators comprise thepistons450, andgas generators464 received in thebores462 of thefourth layer258. Thegas generators464 pressurize thebores448,462 and biasing thepiston450 against thediaphragm444 upon being actuated. Thefourth layer258 also includesgas release ports466 communicating with thebores462.
• Referring toFIGS. 21a,21b, and21c, a further embodiment of alaminated dispenser470 constructed in accordance with the present invention is shown. Thedispenser470 is also for use with a non-pressurized reservoir and acts as a pump instead of simply a regulator. Thedispenser470 includes a plurality of “active”accumulators472 and no inlet valve or outlet valve. Theaccumulators472 are arranged successively with respect to thepassageway250 and operate one after another such that thedispenser470 operates as a linear peristaltic pump.
• Thedispenser470 includes afirst layer252 having arecess476, with adiaphragm474 positioned against the surface of thefirst layer252. Thesecond layer254 is received against thediaphragm474 and includes a surface defining a groove, such that the diaphragm and the groove define thepassageway250 connecting the reservoir to the exit port assembly.
• Eachaccumulator472 includes anactuator478. Theactuators478 are successively positioned with respect to thepassageway250 within therecess476 of thefirst layer252. Theactuators478 are arranged to push thediaphragm474 towards thesecond layer254 upon being actuated. The portion of therecess476 above thediaphragm474 comprises the pulse chambers of theaccumulators472.
• In the embodiment shown, the actuators comprise segments ofpiezoelectric material478. Eachsegment478 is mounted and arranged such that, when de-energized, thesegment478 normally assumes a curved geometry to push thediaphragm474 towards the second layer, and when energized, deforms to a straight geometry to allow the diaphragm to return to its original position. In the preferred embodiment all of thepiezoelectric elements478 are normally in a curved state when de-energized, to occlude thepassageway250 and prevent the free flow of fluid through the passageway to the exit port assembly.
• Referring now toFIGS. 22aand22b, the present invention also provides apriming mechanism500 for simultaneously maintaining aninlet valve502 and anoutlet valve504 of adispenser506 open, such that fluid can flow through the dispenser (also having an accumulator507) to theexit port assembly70 during filling of thereservoir30. Priming ensures that the entire volume of the fluid delivery passages of the fluid delivery device are filled with fluid prior to operation, so that an accurate volume of fluid can be delivered by the device.
• In the specific embodiment shown, thepriming mechanism500 includes a pivotally movablefirst link508 operatively connected to theinlet valve502 such that the inlet valve is opened upon pivoting movement of thefirst link508. A pivotally movablesecond link510 is operatively connected to theoutlet valve504 such that the outlet valve is opened upon pivoting movement of the second link. Thepriming mechanism500 also includes amovable priming rod516 operatively connected to the first and thesecond links508,510 for pivoting the links upon movement of therod516.
• As shown, the inlet and theoutlet valves502,504 each include avalve member512,514 movable between open and closed positions. Thefirst link508 extends between thefirst valve member512 and thepriming rod516 and is pivotally movable about apivot point518 of the first link located between thevalve member512 and the priming rod. Thesecond link510 extends between thesecond valve member514 and thepriming rod516 and is pivotally movable about apivot point520 of the second link located between thevalve member514 and the priming rod. The primingrod516 is linearly movable to pivot thelinks508,510 and open thevalve members512,514. The primingrod516 extends out of thehousing20 of the fluid delivery device, and is depressed into thehousing20 by a user to open thevalves502,504 prior to filling thereservoir30 throughfill port522. One-way valves, such asduckbill valves524, are positioned within thefill port522 and apassageway526 of thedispenser506.FIG. 22bshows thepriming rod516 depressed into thehousing20 and thevalves502,504 opened, whileFIG. 22ashows thepriming rod516 extending out of thehousing20 and thevalves502,504 closed.
• FIGS. 23aand23bshown anotherpriming mechanism530 according to the present invention. Themechanism530 is similar to themechanism500 ofFIGS. 22aand22bsuch that similar elements have the same reference numerals. Themechanism530, however, further includes acollar532 connected to thepriming rod516 and received in thefill port522 of the device. Thefill port522 is connected to thereservoir30 and adapted for receiving aneedle534 for filling the reservoir. Thecollar532 is adapted to frictionally receive theneedle534 inserted into thefill port522 so that the inserted needle causes movement of thecollar532 and thepriming rod516 and pivoting movement of thelinks508,510. Thedispenser valves502,504 are therefore opened and the device is primed automatically upon filling of thereservoir30, shown inFIG. 23b.
• Referring to FIGS.24 to26, the present invention also providesfluid delivery devices10 havingautomatic priming systems600,610,620. Eachdevice10 is provided with an exit port assembly comprising an integrated transcutaneouspatient access tool670 having a known internal volume. In the particular embodiments shown, the patient access tool is aneedle670. Because the volume to the tip of theneedle670 is known, thelocal processor50 of thedevice10 can be programmed to prime theneedle670 automatically.
• In the preferred embodiment ofFIG. 24, thelocal processor50 is programmed to instruct thedispenser40 to deliver a volume of fluid to theneedle670 equal to the known internal volume of theneedle670. Preferably, theremote controller100 is provided with a “PRIME” command for a user to select. In the embodiment of thecontroller100 illustrated inFIG. 24, aprime command button111 is shown provided on atouch screen110 after an “INITIALIZE”command112. When theprime command111 is selected, theremote controller100 communicates with thefluid delivery device10 and instructs thelocal processor50 to prime theneedle670.
• Thefluid delivery device610 ofFIG. 25 further includes aflow sensor612 arranged to provide a signal to thelocal processor50 indicative of the volume of fluid passing from thedispenser40 to theneedle670. Thelocal processor50 is programmed to prime theneedle670 by instructing thedispenser40 to deliver fluid until theflow sensor612 indicates to the local processor that a volume of fluid equal to the known internal volume of theneedle670 has been delivered to the needle. Thelocal processor50 is also programmed to utilize the signals from theflow sensor612 to monitor theneedle670 for occlusions once the needle has been primed.
• Thedevice620 ofFIG. 26 is similar to thedevice600 ofFIG. 24, but further includes afluid detector622 positioned between thedispenser40 and theneedle670 for providing a signal to thelocal processor50 indicative of fluid passing into theneedle670. Thelocal processor50 is programmed to prime theneedle670 by instructing thedispenser40 to deliver fluid for a predetermined period and at a predetermined flow rate after receiving an initial indication from thefluid detector622 that fluid has reached thefluid detector622. In addition, thelocal processor50 can be programmed to provide a signal that air has been detected in the fluid path when thefluid detector622 stops indicating the presence of fluid upon operation of thedispenser40 and after theneedle670 has been primed.
• Referring now toFIGS. 27 and 28, the invention also providesembodiments700,710 of the fluid delivery device including gas removal filters702 for removing gas (e.g., air) bubbles from fluid injected into the devices from a patient. In general the gas removal filters702 are constructed of material that allows the passage of gas therethrough, yet prevents fluid from passing therethrough. Gas removal filters are available, for example, from Pall Corporation of East Hills, N.Y. (www.pall.com). In theembodiment700 ofFIG. 27, thegas removal filter702 is positioned between thereservoir30 and thedispenser40. In the embodiment720 ofFIG. 28, however, thegas removal filter702 is positioned between afill port31 and thereservoir30. Other embodiments are possible. For example, the device can be provided with a reservoir made from gas removal material instead of having a separate gas removal filter.
• Due to issues of infection and contamination, it may be desirable to limit the fluid delivery device of the present invention to a single use. Referring toFIGS. 29athrough29d, the present invention, therefore, also provides a “single-use”fill port800 for allowing thereservoir30 of the fluid device to be filled only once. Thefill port800 includes apassageway802 in fluid communication with thereservoir30, avalve804 positioned within the passageway and allowing one-way flow into thereservoir30, and a removableneedle insertion septum806 sealing thepassageway802. Theneedle insertion septum806 may be constructed of a resealing elastomer such as silicone that allows aneedle150 to puncture theseptum806 to add fluid to thereservoir30, yet provides a seal around theneedle150.
• In the embodiment ofFIGS. 29athrough29b, thefill port800 includes afunnel808 having a smallopen end810 removably received in thepassageway802 and a largeopen end812 receiving theseptum806. Thefill port800 also includes afirst wall814 having anopening816 removably receiving the largeopen end812 of the funnel when the smallopen end810 of thefunnel808 is removably received in thepassageway802, as shown inFIGS. 29aand29b. Asecond wall818 is spaced from thefirst wall814 more than a thickness of theseptum806 and has anopening820 sized to allow passage of aneedle150, but prevent passage of theseptum806, as shown inFIGS. 29cand29d. As shown inFIGS. 29cand29d, removal of theneedle150 from thefill port800 pulls thefunnel808 out of thepassageway802, and thus prevents further refills of thereservoir30 through thefill port800.
• FIGS. 30aand30bshow anotherfill port850 constructed in accordance with the present invention. Thefill port850 includes afirst wall852 having anopening854 preventing passage of theseptum806, as shown inFIG. 30a, and asecond wall856 spaced from thefirst wall852 at least about a thickness of the septum and having anopening858 allowing passage of aneedle150. Thesecond wall856 and the opening of thesecond wall858 are adapted to allow passage of theseptum806 upon at least a predetermined force applied to the septum. Preferably, the predetermined force is less than a force required to pull aneedle150 out of theseptum806, such that a withdrawnneedle150 pulls theseptum806 out of thefill port850, as shown inFIG. 30b.
• Referring toFIG. 31, the present invention also provides afluid delivery device900 having multiplesubcutaneous access tools970. Eachaccess tool970 is independently connected to thedispenser40 through apassageway972, and is initially retracted such that thepassageway972 is occluded. Eachaccess tool970 is also independently deployable. Upon deployment of eachaccess tool970, thepassageway972 of the deployed tool is released to allow fluid flow through the deployed tool. Preferably each access tool includes arigid needle974, as shown inFIG. 32.
• The multiple, independentlydeployable needles974 beneficially extend the useful life of thefluid delivery device900. According to standards set by the Center for Disease Control (CDC), a single needle, such as an infusion needle or intravenous needle, should not remain deployed in a patient for more than three days, to minimize the chances for infection at the injection site through the skin of the patient. The present invention, therefore, increases the useable life of a singlefluid delivery device900 by providing the device with multiple, independently deployable needles974. If the device is provided with threeretractable needles974, and each needle is used for the maximum allowable period of three days in accordance to CDC standards, for example, the life of thedevice900 can be extended to nine days. Theembodiment900 ofFIG. 31 is provided with threeneedles974, but can be provided with two needles or more than three needles, as desired and appropriate.
• Referring to thespecific embodiment900 as shown inFIG. 32, eachneedle974 is manually deployable and includes aslidable lever976 secured to the needle and extending out of thehousing20 of the device for patient access. Theneedle974 is shown retracted inFIG. 32, with thepassageway972 occluded by anocclusion member978 extending from thelever976 and pinching thepassageway972 against aboss980 extending from thehousing wall20. When thedevice900 is attached to a skin surface of a patient, the patient simply slides thelever976 towards the skin to release thepassageway972 and inject theneedle974 into the skin. After three days, the patient slides thelever976 away from the skin to withdraw theneedle974 from the skin and occlude thepassageway972. The next needle can then be deployed. The device can also be provided with means for maintaining each of theneedles974 in an independent sterile condition prior to deployment, such as separate sealed membranes covering the needle opening in thehousing20 and that the needles puncture through during deployment.
• Although exemplary embodiments of the invention have been shown and described, many changes, modifications and substitutions may be made by those having ordinary skill in the art without necessarily departing from the spirit and scope of this invention.

Claims (89)

1. A device for delivering fluid to a patient, comprising:

A) a reservoir;

B) an exit port assembly adapted to connect to a transcutaneous patient access tool; and

C) a dispenser including at least two laminated layers of material defining a passageway connecting the reservoir to the exit port assembly, and an expandable accumulator in fluid communication with the passageway.

2. A device according toclaim 1, wherein at least one layer of the dispenser comprises a resilient diaphragm.

3. A device according toclaim 2, wherein the at least two laminated layers of the dispenser further comprise:

a first layer;

a second layer received against the first layer, the second and the first layers including at least one groove defining the passageway connected to the exit port assembly, the second layer including an opening in fluid communication with the passageway, and wherein the resilient diaphragm is received on the second layer covering the opening; and

a third layer received over the diaphragm on the second layer, the third layer having an pulse chamber over the diaphragm and in alignment with the opening of the second layer, and a port in fluid communication with the pulse chamber.

4. A device according toclaim 3, wherein the pulse chamber has a predetermined volume.

5. A device according toclaim 3, wherein one of the second and the third layers defines a recess receiving the diaphragm, and wherein the recess has a depth about equal to a thickness of the diaphragm such that the diaphragm is secured in a substantially fluid-tight manner between the second and the third layers.

6. A device according toclaim 5, wherein a length and a width of the recess are greater than a length and a width of the diaphragm.

7. A device according toclaim 2, wherein the at least two laminated layers of the dispenser further comprise:

a first layer defining the passageway connected to the exit port assembly and an opening in fluid communication with the passageway, and wherein the resilient diaphragm is received on the first layer covering the opening;

a second layer received over the diaphragm on the first layer, the second layer having an pulse chamber over the diaphragm and in alignment with the opening of the first layer, and a port in fluid communication with the pulse chamber; and

a third layer received on the second layer and defining a secondary chamber in fluid communication with the port of the second layer.

8. A device according toclaim 3, further comprising a spring biasing the diaphragm away from the pulse chamber.

9. A device according toclaim 2, wherein the at least two laminated layers of the dispenser further comprise:

a first layer having a surface defining a recess and a groove extending from the recess;

wherein the resilient diaphragm is received on the surface of the first layer such that the recess and the diaphragm define the expandable accumulator and the groove and the diaphragm defines the passageway connected to the exit port assembly.

10. A device according toclaim 7, wherein the surface of the first layer further defines a valve seat in the groove.

11. (Canceled)

12. (Canceled)

13. (Canceled)

14. A device according toclaim 2, wherein the at least two laminated layers of the dispenser further comprise:

a first layer; and

a second layer received against the first layer, at least one the second and the first layers having a groove defining the passageway connected to the exit port assembly, the second layer including a surface facing away from the first layer and having a recess, and an opening providing fluid communication between the recess and the passageway;

wherein the resilient diaphragm is received on the second layer covering the recess to form the expandable accumulator.

15. A device according toclaim 14, further comprising an actuator for pushing the diaphragm into the recess to reduce the volume of the accumulator.

16. A device according toclaim 15, wherein the actuator comprises a rotatable cam.

17. A device according toclaim 14, further comprising:

a third layer received against the diaphragm and on the second layer and having a bore aligned with the recess of the second layer; and

wherein the actuator comprises a piston slidingly received in the bore.

18. A device according toclaim 17, further comprising a magnetic coil received in the third layer coaxial with the piston for biasing the piston against the diaphragm upon being energized.

19. A device according toclaim 17, further comprising:

a fourth layer received against the third layer and having a bore aligned with the bore of the third layer; and

wherein the dispenser includes a gas generator received in the bore of the fourth layer for pressurizing the bore and biasing the piston against the diaphragm upon being actuated.

20. A device according toclaim 17, comprising multiple accumulators arranged sequentially with respect to the passageway.

21. A device according toclaim 2, wherein the at least two laminated layers of the dispenser further comprise:

first and second layers wherein the diaphragm is positioned between the layers, and one of the layers has a groove defining the passageway connected to the exit port assembly, and the other of the layers has a recess separated from the passageway by the diaphragm; and

the dispenser further includes an actuator received in the recess for pushing the diaphragm into the passageway upon being actuated.

22. A device according toclaim 21, wherein the actuator comprises a piece of piezoelectric material arranged to push the diaphragm upon the piezoelectric material assuming one of a deformed state and an undeformed state.

23. A device according toclaim 22, comprising multiple pieces of piezoelectric material arranged sequentially with respect to the passageway.

24. A device according toclaim 1, wherein the at least two laminated layers of the dispenser comprise:

a first layer;

a second layer received against the first layer, the second and the first layers defining the passageway connected to the exit port assembly, and one of the layers including a bore communicating with the passageway; and

the dispenser further includes a piston slidingly received in the bore.

25. A device according toclaim 24, wherein the dispenser further comprises a spring biasing the piston towards the passageway.

26. A device according toclaim 24, wherein the dispenser further comprises a magnetic coil received in one of the layers coaxial with the piston for biasing the piston one of towards and away from the passageway upon being energized.

27. A device according toclaim 1, further comprising an inlet valve controlling flow from the reservoir into the accumulator, and an outlet valve controlling flow between the accumulator and the exit port assembly.

28. A device according toclaim 27, wherein the passageway includes openings for the valves and the valves each include a layer of resilient fluid-tight material covering the opening and a layer of piezoelectric material covering the layer of resilient fluid-tight material and arranged such that upon the piezoelectric material assuming one of a deformed state and an undeformed state, the layer of piezoelectric material forces the layer of resilient fluid-tight material into the opening of the passageway and substantially closes the passageway.

29. A device according toclaim 27, wherein the dispenser further includes a bar extending parallel with the passageway and pivotally mounted about a pivot point, and wherein the valves comprise gates extending from the bar into the passageway on opposite sides of the pivot point.

30. A device according toclaim 27, wherein the valves comprise one-way valves.

31. A device according toclaim 30, wherein the valves comprise duck bill valves.

32. A device according toclaim 1, wherein the laminated layers further define a bore bisecting the passageway and the dispenser further comprises a valve assembly including:

a valve member movably received in the bore and including an opening;

a spring biasing the valve member such that the opening of the valve member is normally offset from the passageway and the passageway is blocked by the valve member; and

an actuator for moving the valve member upon being actuated such that the opening of the valve member aligns with the passageway.

33. A device according toclaim 32, wherein the actuator comprises a gas generator for pressurizing the bore upon being actuated.

34. (Canceled)

35. A device according toclaim 1, wherein the reservoir contains a therapeutic fluid.

36. A device according toclaim 1, further comprising a fill port connected to the reservoir.

37. A device according toclaim 1, wherein the reservoir is pressurized.

38. A device according toclaim 1, further comprising a transcutaneous patient access tool connected to the exit port assembly.

39. (Canceled)

40. (Canceled)

41. (Canceled)

42. (Canceled)

43. A device according toclaim 1, further comprising:

an inlet valve connected to an inlet of the accumulator;

a outlet valve connecting an outlet of the accumulator to the exit port assembly; and

a priming mechanism for maintaining the inlet valve and the outlet valve simultaneously open.

44. A device according toclaim 43, wherein the priming mechanism comprises:

a pivotally movable first link operatively connected to the inlet valve such that the inlet valve is opened upon pivoting movement of the first link;

a pivotally movable second link operatively connected to the outlet valve such that the outlet valve is opened upon pivoting movement of the second link; and

a movable priming rod operatively connected to the first and the second links for pivoting the links upon movement of the rod.

45. A device according toclaim 44, wherein:

the inlet and the outlet valves each include a valve member movable between open and closed positions;

the first link extends between the valve member of the inlet valve and the priming rod and is pivotally movable about a pivot point of the first link located between the valve member of the inlet valve and the priming rod;

the second link extends between the valve member of the outlet valve and the priming rod and is pivotally movable about a pivot point of the second link located between the valve member of the outlet valve and the priming rod; and

the priming rod is linearly movable.

46. A device according toclaim 44, further comprising:

a fill port adapted to receive a needle; and

a collar connected to the priming rod and received in the fill port, the collar adapted to receive a needle inserted into the fill port so that the inserted needle causes movement of the collar and the priming rod and pivoting movement of the links.

47. A device according toclaim 1, wherein the exit port assembly comprises a transcutaneous access tool having a known internal fluid volume.

48. A device according toclaim 47, further comprising a processor controlling the dispenser, and wherein the processor is programmed to cause the dispenser to deliver a volume of fluid equal to the known internal fluid volume of the access tool upon receiving a command.

49. A device according toclaim 47, further comprising a flow detector positioned between the dispenser and the access tool.

50. A device according toclaim 49, further comprising a processor controlling the dispenser and receiving signals from the flow detector, and wherein the processor is programmed to cause the dispenser to deliver a predetermined flow of fluid for a predetermined period upon receiving a command and upon receiving a signal from the flow detector indicative of an initial flow of fluid to the access tool, the predetermined flow of fluid for the predetermined period producing a volume of fluid substantially equal to the known internal fluid volume of the access tool.

51. A device according toclaim 47, further comprising a fluid detector positioned between the dispenser and the access tool.

52. A device according toclaim 51, further comprising a processor controlling the dispenser and receiving signals from the fluid detector, and wherein the processor is programmed to cause the dispenser to deliver a predetermined volume of fluid upon receiving a command and upon receiving a signal from the fluid detector indicative of fluid initially entering the fluid detector, the predetermined volume of fluid substantially equal to the known internal fluid volume of the access tool.

53. A device according toclaim 47, wherein the access tool comprises a needle.

54. A device according toclaim 1, further comprising a gas removal filter connected to the dispenser for removing gas bubbles from fluid entering the dispenser.

55. (Canceled)

56. A device according toclaim 1, wherein the reservoir is gas permeable.

57. A device according toclaim 1, further comprising:

a fill port including,

a passageway in fluid communication with the reservoir,

a valve positioned within the passageway and allowing one-way flow into the reservoir, and

a removable septum sealing the passageway.

58. A device according toclaim 57, wherein the fill port further comprises a funnel having a small open end removably received in the passageway and a large open end receiving the septum.

59. A device according toclaim 58, wherein the fill port further comprises a first wall having an opening removably receiving the large open end of the funnel when the small open end of the funnel is removably received in the passageway.

60. A device according toclaim 59, wherein the fill port further comprises a second wall spaced from the first wall more than a thickness of the septum and having an opening allowing passage of a needle and preventing passage of the septum.

61. A device according toclaim 57, wherein the fill port further comprises a first wall having an opening preventing passage of the septum, and a second wall spaced from the first wall at least about a thickness of the septum and having an opening allowing passage of a needle, and wherein the second wall and the opening of the second wall are adapted to allow passage of the septum upon at least a predetermined force applied to the septum.

62. A device according toclaim 61, wherein the predetermined force is less than a force required to pull a needle out of the septum.

63. A device according toclaim 1, wherein the exit port assembly comprises a plurality of exit port assemblies and each assembly comprises an independently deployable transcutaneous access tool adapted to provide fluid communication with the dispenser upon deployment.

64. A device according toclaim 63, wherein each access tool comprises a needle.

65. A device according toclaim 63, where each access tool is maintained in a sterile state prior to deployment.

66. (Canceled)

67. (Canceled)

68. (Canceled)

69. (Canceled)

70. (Canceled)

71. (Canceled)

72. (Canceled)

73. (Canceled)

74. (Canceled)

75. (Canceled)

76. (Canceled)

77. (Canceled)

78. (Canceled)

79. (Canceled)

80. (Canceled)

81. (Canceled)

82. (Canceled)

83. (Canceled)

84. (Canceled)

85. (Canceled)

86. (Canceled)

87. (Canceled)

88. (Canceled)

89. (Canceled)

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