Intraocular lens delivery system with a disposable plunger segment and method of use therefor

1. An intraocular lens delivery system, comprising:

a cartridge;

a disposable plunger tip segment comprising,

an elongated body having a proximate end and a distal end;

a fastening mechanism, which is a projection, a cavity or both, at the proximate end of the elongated body; and

a pushing surface at the distal end of the elongated body; wherein:

i. the elongated body and fastening projection or cavity are integrally molded of single polymeric material;

ii. the fastening mechanism is configured to releasably, but securely and rigidly, attach the disposable plunger tip segment to a reusable plunger segment of the intraocular lens delivery system; and

iii. the single polymeric material has a flexural modulus of at least 3500 MPa; and

a disposable tool that is used to attach the disposable plunger tip segment to the reusable plunger segment,

wherein the disposable tool forms a shaped cavity that receives the proximate end of the elongated body.

2. The disposable plunger tip segment of claim 1 wherein the fastening mechanism is a cavity that lockably receives a projection extending from the reusable segment.

3. The disposable plunger tip segment of claim 2 wherein the pushing surface is provided by a soft push tip that is overmolded onto the elongated body at the distal end thereof.

4. The disposable plunger tip segment of claim 3 wherein the soft push tip is formed of a material having an elongation at break of at least 200%.

5. The disposable plunger tip segment of claim 1 wherein the single polymeric material is a thermoplastic material and has a flexural modulus of at least 30,000 MPa.

6. A kit for an intraocular delivery system that includes an elongated housing having a length and a reusable base segment of a plunger disposed within the elongated housing, the kit comprising:

a disposable tip segment of the plunger, wherein:

i. the disposable tip segment includes an elongated body, a fastening mechanism at a proximate end of the elongated body, and a pushing surface at a distal end of the elongated body;

ii. the fastening mechanism of the disposable tip segment is a projection or cavity;

iii. the projection or cavity of the disposable tip segment of the fastening mechanism mates with a projection or cavity of a fastening mechanism of the reusable segment to releasably, but securely and rigidly, fasten the disposable tip segment to the reusable segment;

iv. the elongated body and fastening projection or cavity of the disposable tip segment are integrally molded of a single polymeric material; and

v. a disposable tool that is used to attach the disposable tip segment to the reusable segment, the disposable tool comprising a shaped cavity that is configured to receive the proximate end of the elongated body, wherein upon receiving the proximate end of the elongated body, the disposable tool is operable to attach the disposable tip segment to the reusable segment.

7. The kit of claim 6 further comprising a cartridge configured to fasten to the housing wherein the cartridge comprises an opening at a distal end of the cartridge and the opening has a maximum internal diameter that is less than 4 millimeters.

8. The kit of claim 6 wherein the fastening mechanism of the disposable tip segment is a cavity that lockably receives a projection forming the fastening mechanism of the reusable segment, the projection extending from the reusable segment.

9. The kit of claim 6 wherein the pushing surface is provided by a soft push tip that is overmolded onto the elongated body of the disposable tip segment at the distal end thereof.

10. The kit of claim 9 wherein the soft push tip is formed of a material having an elongation at break of at least 200%.

11. The kit of claim 6 wherein the single polymeric material is a thermoplastic material and has a flexural modulus of at least 30,000 MPa.

12. The kit of claim 6 wherein the single polymeric material has a flexural modulus of at least 3500 MPa.

13. A kit for an intraocular lens delivery system wherein the intraocular lens delivery system includes a housing and a reusable segment, the kit comprising:

a disposable plunger tip segment comprising an elongated body having a proximate end and a distal end;

a fastening mechanism, which is a projection, a cavity or both, at the proximate end of the elongated body, the fastening mechanism is configured to releasably, but rigidly, attach the disposable plunger tip segment to the reusable segment of the intraocular lens delivery system and the fastening portion and the elongated body forming an integral component;

a pushing surface at the distal end of the elongated body; and

a disposable tool that is used to attach the disposable plunger tip segment to the reusable segment, the disposable tool comprising a shaped cavity that is configured to receive the proximate end, wherein upon receiving the proximate end, the disposable tool can twist the disposable plunger tip segment to attach the disposable plunger tip segment to the reusable segment.

14. The kit of claim 13 , further comprising a disposable cartridge that is attachable or detachable from the housing.

15. The kit of claim 13 , wherein the disposable plunger tip segment is formed from a material having a flexural modulus of at least 3500 MPa.

16. The kit of claim 13 , wherein the pushing surface is formed from a material having an elongation at break of at least 200%.