Telescoping plunger assembly

Abstract

A bone filler mixing and delivery device includes a mixing section adapted to mix components to form bone filler. A syringe barrel is coupled to the mixing section and has an opening through which the bone filler can be dispensed. A controllable portal can be manipulated to open a flow path between the mixing section and the syringe barrel. A plunger assembly is adapted to extend telescopically in an axial direction through the syringe barrel to dispense the bone filler through the opening.

1 . A bone filler mixing and delivery device, comprising: 
 a mixing section adapted to mix components to form bone filler;    a syringe barrel coupled to the mixing section and including an opening through which the bone filler can be dispensed;    a controllable portal to open a flow path between the mixing section and the syringe barrel; and    a plunger assembly that is adapted to extend telescopically in an axial direction through the syringe barrel to dispense the bone filler through the opening.    
     
     
         2 . The bone filler mixing and delivery device of  claim 1  wherein the plunger assembly is adapted to retract telescopically to a position completely contained within the mixing section.  
     
     
         3 . The bone filler mixing and delivery device of  claim 1  wherein the plunger assembly comprises: 
 a drive shaft that can be rotated about an axis;    a lead screw threaded to the drive shaft; and    a plunger shaft threaded to the lead screw.    
     
     
         4 . The bone filler mixing and delivery device of  claim 3  wherein the drive shaft is restricted from moving in an axial direction.  
     
     
         5 . The bone filler mixing and delivery device of  claim 3  wherein the plunger shaft is restricted from moving in a rotational direction.  
     
     
         6 . The bone filler mixing and delivery device of  claim 3  further comprising a cover assembly with a manually actuable crank handle, that is movable to a first position to engage a mixing element in the mixing section and disengage the drive shaft, movable to a second position to engage the drive shaft and disengage the mixing element, and movable to drive the engaged mixing element or the engaged drive shaft.  
     
     
         7 . The bone filler mixing and delivery device of  claim 3  wherein rotation of the drive shaft causes relative rotation between the lead screw and at least one of either the plunger shaft or the drive shaft.  
     
     
         8 . The bone filler mixing and delivery device of  claim 7  wherein the relative rotation causes the plunger shaft to move axially through the bone filler mixing and delivery device.  
     
     
         9 . The bone filler mixing and delivery device of  claim 3  wherein the lead screw comprises: 
 a first portion threaded to the drive shaft; and    a second portion threaded to the plunger shaft.    
     
     
         10 . The bone filler mixing and delivery device of  claim 9  wherein threads on the second portion have multiple leads.  
     
     
         11 . The bone filler mixing and delivery device of  claim 3  further comprising a support sleeve adapted to provide mechanical support to the plunger shaft.  
     
     
         12 . The bone filler mixing and delivery device of  claim 11  wherein the plunger shaft is coupled to the support sleeve to allow relative motion between the plunger shaft and the support sleeve in an axial direction, but to restrict relative motion between the plunger shaft and the support sleeve in a rotational direction.  
     
     
         13 . The bone filler mixing and delivery device of  claim 11  wherein a longitudinal slot is formed in the plunger shaft.  
     
     
         14 . The bone filler mixing and delivery device of  claim 13  further comprising a pin that extends from the support sleeve to engage the longitudinal slot and prevent the plunger shaft from rotating about the axis.  
     
     
         15 . The bone filler mixing and delivery device of  claim 14  wherein the pin is adapted to move longitudinally through the longitudinal slot as the plunger shaft is moved axially through the bone filler mixing and delivery device.  
     
     
         16 . The bone filler mixing and delivery device of  claim 15  wherein the support sleeve is movable in an axial direction and wherein the pin is adapted to drag the sleeve in the axial direction with the plunger shaft as the plunger shaft moves beyond an axial position where the pin reaches an end of the longitudinal slot.  
     
     
         17 . The bone filler mixing and delivery device of  claim 11  further comprising a sliding tube arranged so that the sliding tube can move in an axial direction through the bone filler mixing and delivery device but cannot rotate inside the bone filler mixing and delivery device.  
     
     
         18 . The bone filler mixing and delivery device of  claim 17  wherein the support sleeve is coupled to the sliding tube to permit relative motion between the sliding tube and the support sleeve in an axial direction but to prevent relative motion between the sliding tube and the support sleeve in a rotational direction.  
     
     
         19 . The bone filler mixing and delivery device of  claim 3  further comprising: 
 a retaining ring coupled to a forward end of the drive shaft,    wherein the retaining ring is adapted to engage the lead screw when the lead screw nears an end of its stroke, and    wherein engagement between the retaining ring and the lead screw prevents the lead screw from becoming disengaged from the drive shaft.    
     
     
         20 . The bone filler mixing and delivery device of  claim 3  further comprising a mixing element in the mixing section.  
     
     
         21 . The bone filler mixing and delivery device of  claim 1  wherein the plunger assembly is adapted to extend through substantially the entire length of the syringe barrel.  
     
     
         22 . The bone filler mixing and delivery device of  claim 1  wherein the bone filler comprises a bone cement.  
     
     
         23 . A material delivery device comprising: 
 a syringe barrel including an opening through which the material can be dispensed;    an access portal to load material into the syringe barrel; and    a plunger assembly adapted to extend telescopically in an axial direction through the syringe barrel to dispense the material through the opening.    
     
     
         24 . The material delivery device of  claim 23  wherein the plunger assembly is adapted to retract telescopically to a position completely withdrawn from the syringe barrel.  
     
     
         25 . The material delivery device of  claim 23  wherein the plunger assembly comprises: 
 a drive shaft that can be rotated about an axis;    a lead screw threaded to the drive shaft; and    a plunger shaft threaded to the lead screw.    
     
     
         26 . The material delivery device of  claim 25  wherein the drive shaft is restricted from moving in an axial direction, and 
 wherein the plunger shaft is restricted from moving in a rotational direction.    
     
     
         27 . The material delivery device of  claim 25  wherein rotation of the drive shaft causes relative rotation between the lead screw and at least one of either the plunger shaft or the drive shaft, and 
 wherein the relative rotation causes the plunger shaft to move axially through the material delivery device.    
     
     
         28 . The material delivery device of  claim 25  further comprising a support sleeve adapted to provide mechanical support to the plunger shaft, and 
 wherein the plunger shaft is coupled to the support sleeve in a manner that allows relative motion between the plunger shaft and the support sleeve in an axial direction, but restricts relative motion between the plunger shaft and the support sleeve in a rotational direction.    
     
     
         29 . The material delivery device of  claim 28  wherein a longitudinal slot is formed in the plunger shaft, and 
 wherein the material delivery device further comprises a pin that extends from the support sleeve to engage the longitudinal slot and prevent the plunger shaft from rotating about the axis, and    wherein the pin is adapted to move longitudinally through the longitudinal slot as the plunger shaft is moved axially through the bone filler mixing and delivery device.    
     
     
         30 . The material delivery device of  claim 29  wherein the support sleeve is movable in an axial direction and wherein the pin is adapted to drag the sleeve in the axial direction with the plunger shaft as the plunger shaft moves beyond an axial position where the pin reaches an end of the longitudinal slot.  
     
     
         31 . The material delivery device of  claim 23  further comprising: 
 a first section coupled to the syringe barrel and adapted to store the material,    wherein the plunger assembly is adapted to extend from the first section through the syringe barrel.