Auto-injector with needle cover

1 . A drug delivery device comprising:

a housing;

a syringe assembly comprising a barrel, a stopper, and a cannula,

at least a portion of the syringe assembly positioned within the housing;

a drive assembly associated with a motor body receiving at least a portion of the drive assembly, the drive assembly configured to move the stopper within the barrel upon actuation of the drive assembly, at least a portion of the drive assembly positioned within the housing;

a lever actuation member moveable between a locked position where the actuation of the drive assembly is prevented and a released position where the actuation of the drive assembly is allowed; and

a needle cover having a pre-use position where the cannula is positioned within the needle cover, an actuation position where the drive assembly is actuated, and a post-use position where the cannula is positioned within the needle cover, the needle cover configured to contact and engage the lever actuation member and move the lever actuation member to the released position when the needle cover is moved into the actuation position,

wherein the needle cover contacts the lever actuation member and prevents the movement of the lever actuation member from the locked position to the released position when the needle cover is in the pre-use position,

wherein the lever actuation member is rotatable about a rotation axis of the lever actuation member extending perpendicular to a longitudinal axis of the device, between the locked position and the released position,

wherein the lever actuation member comprises a restriction surface configured to engage the needle cover and restrict the rotation of the lever actuation member in a direction of the released position when the needle cover is in the pre-use position, and an assembly surface, distal to the rotation axis of the lever actuation member, configured to engage a locking pin that extends through a pin opening in the motor body in a perpendicular direction with respect to the longitudinal axis of the device and parallel to the rotation axis of the lever actuation member to prevent rotation of the lever actuation member and unintentional actuation of the drive assembly during assembly of the device, and

wherein the drive assembly is actuated by the movement of the needle cover to the actuation position.

2 . The drug delivery device of claim 1 , further comprising a syringe holder moveable relative to the housing between a first position and a second position, the syringe assembly received by the syringe holder.

3 . The drug delivery device of claim 2 , wherein the syringe holder is configured to move from the first position to the second position when the needle cover is in the actuation position, a portion of the cannula of the syringe assembly extending outside of the needle cover when the syringe holder is in the second position and when the needle cover is in the actuation position.

4 . The drug delivery device of claim 3 , wherein a portion of the needle cover engages a cover stop of the syringe holder to restrict axial movement of the needle cover in at least one direction when the needle cover is in the pre-use position.

5 . The drug delivery device of claim 1 , wherein the drive assembly comprises a plunger body having a plunger rod portion and a drive member, the drive member is configured to move the plunger body within the housing.

6 . The drug delivery device of claim 5 , wherein a longitudinal axis of the plunger rod portion is spaced from and parallel to a longitudinal axis of the drive member.

7 . The drug delivery device of claim 5 , wherein the drive member comprises a compression spring.

8 . The drug delivery device of claim 1 , wherein the restriction surface of the lever actuation member is spaced from the needle cover to form a gap when the needle cover is in the pre-use position.

9 . The drug delivery device of claim 1 , wherein the needle cover comprises a lever contact portion and the lever actuation member comprises a needle cover contact surface, the lever contact portion of the needle cover is configured to engage the needle cover contact surface of the lever actuation member and rotate the lever actuation member about the rotation axis from the locked position to the released position when the needle cover is in the actuation position.

10 . The drug delivery device of claim 9 , wherein the lever actuation member defines a recessed area configured to receive a portion of the lever contact portion of the needle cover when the needle cover is in the actuation position.

11 . The drug delivery device of claim 9 , wherein the lever contact portion of the needle cover defines a cylindrical surface and the needle cover contact surface of the lever actuation member defines a planar surface.

12 . The drug delivery device of claim 1 , wherein the motor body comprises a stop surface and the lever actuation member comprises a motor body contact surface, wherein the motor body contact surface of the lever actuation member is engaged with the stop surface of the motor body when the lever actuation member is in the locked position and is disengaged from the stop surface of the motor body when the lever actuation member is in the released position.

13 . The drug delivery device of claim 12 , wherein the stop surface of the motor body defines a planar surface and the motor body contact surface of the lever actuation member defines a cylindrical surface.