Drug delivery device having minimized risk of component fracture upon impact events

1. A drug delivery device comprising:

a housing having a distal end and a proximal end;

a reservoir disposed in the housing and having a distal end and a proximal end;

a carrier encasing the reservoir;

a drug delivery member in fluid communication with the distal end of the reservoir;

a plunger disposed in and moveable relative to the reservoir;

a plunger rod having a mass M P , a distal end and a proximal end, the plunger rod being movable from (i) a first position, where the distal end of the plunger rod is spaced apart from the plunger to (ii) a second position, where the distal end of the plunger rod contacts the plunger; and

a drive mechanism coupled to the proximal end of the plunger rod, the drive mechanism being configured to deliver a drive force F D to move the plunger rod from the first position to the second position,

wherein a ratio of the mass of the plunger rod to the drive force of the drive mechanism (M P /F D ) is in a range of approximately a value greater than 0 kg/kgf to approximately 0.05 kg/kgf;

wherein the plunger rod, plunger, carrier, and reservoir have a total combined mass M T ; and

wherein a ratio of the total combined mass M T of the plunger rod, plunger, carrier, and reservoir to the drive force F D of the drive mechanism (M T /F D ) is in a range of approximately a value greater than 0 kg/kgf to approximately 0.15 kg/kgf.

2. The drug delivery device of claim 1 , wherein the plunger rod, plunger, carrier, and reservoir are movable from (i) the second position to (ii) a third position, where the carrier contacts the distal end of the housing,

the drive mechanism being configured to move the plunger rod, plunger, carrier, and reservoir from the second position to the third position.

3. The drug delivery device of claim 1 , wherein the mass of the plunger rod is in a range of approximately 1.5 g to approximately 3 g and/or a mass of the carrier is in a range of approximately 5 g to approximately 10 g.

4. The drug delivery device of claim 1 , wherein the drive force is in a range of approximately 4.0 kgf to approximately 4.5 kgf and the mass of the plunger rod is in a range of approximately 0.02 kg to approximately 0.2 kg.

5. The drug delivery device of claim 1 , wherein the drive force is in a range of approximately 2.0 kgf to approximately 2.5 kgf and the mass of the plunger rod is in a range of approximately 0.02 kg to 0.1 kg.

6. The drug delivery device of claim 1 , wherein the drive force is in a range of approximately 4.0 kgf to approximately 4.5 kgf and the total combined mass of the plunger rod, plunger, carrier, and reservoir is in a range of approximately 0.06 kg to approximately 0.6 kg.

7. The drug delivery device of claim 1 , wherein the drive force is in a range of approximately 2.0 kgf to approximately 2.5 kgf and the total combined mass of the plunger rod, plunger, carrier, and reservoir is in a range of 0.06 kg to approximately 0.3 kg.

8. The drug delivery device of claim 1 , wherein the reservoir is a prefilled syringe.

9. A method of manufacturing a drug delivery device, the method comprising:

providing a reservoir, a plunger disposed in and moveable relative to the reservoir, a drive mechanism, and a drug delivery member in fluid communication with a distal end of the reservoir, wherein the drive mechanism is configured to move a plunger rod by a drive force F D ;

providing a housing having a distal end and a proximal end, the reservoir disposed in the housing;

enclosing the reservoir with a carrier;

selecting the plunger rod having a distal end, a proximal end, and a mass M P based on a ratio of mass of the plunger rod to drive force (M P /F D ) in a range of approximately a value greater than 0 kg/kgf to approximately 0.05 kg/kgf;

providing the plunger rod having the mass based on the plunger rod mass to drive force ratio, wherein a ratio of total mass of the plunger rod, plunger, carrier, and reservoir to drive force (M T /F D ) is in a range of approximately a value greater than 0 kg/kgf to approximately 0.15 kg/kgf; and;

coupling the proximal end of the plunger rod to the drive mechanism, the drive mechanism arranged to deliver the drive force F D to move the plunger rod from (i) a first position, where the distal end of the plunger rod is spaced apart from the plunger to (ii) a second position, where the distal end of the plunger rod contacts the plunger.

10. The method of manufacturing the drug delivery device of claim 9 , the method further comprising:

selecting the carrier having a mass based on the ratio of total mass of the plunger rod, plunger, carrier, and reservoir to drive force (M T /F D ); and

providing the carrier having the mass based on the ratio of total mass of the plunger rod, plunger, carrier, and reservoir to drive force.

11. The method of manufacturing the drug delivery device of claim 9 , wherein providing the drive mechanism includes providing a spring configured to move the plunger rod at a drive force that is in a range of approximately 4.0 kgf to approximately 4.5 kgf and providing the plunger rod having the mass M P in a range of approximately 0.02 kg to approximately 0.2 kg.

12. The method of manufacturing the drug delivery device of claim 9 , wherein providing the drive mechanism includes providing a spring configured to move the plunger rod at a drive force that is in a range of approximately 2.0 kgf to approximately 2.5 kgf and providing the plunger rod having the mass M P in a range of approximately 0.02 kg to approximately 0.1 kg.

13. The method of manufacturing the drug delivery device of claim 9 , wherein providing the drive mechanism includes providing a spring configured to move the plunger rod at a drive force that is in a range of approximately 4.0 kgf to approximately 4.5 kgf and providing the plunger rod, plunger, carrier, and reservoir having a total mass in a range of approximately 0.06 kg to approximately 0.6 kg.

14. The method of manufacturing the drug delivery device of claim 9 , wherein providing the drive mechanism includes providing a spring configured to move the plunger rod at a drive force that is in a range of approximately 2.0 kgf to approximately 2.5 kgf and providing the plunger rod, plunger, carrier, and reservoir having a total mass in a range of approximately 0.06 kg to approximately 0.3 kg.