U.S. patent application number 14/117791 was filed with the patent office on 2014-07-24 for skived film for covering surface of plug for medical purposes, plug for medical purposes using said film, pre-filled syringe using said plug and method for producing said film.
This patent application is currently assigned to COKI ENGINEERING INC.. The applicant listed for this patent is Akira Yotsutsuji. Invention is credited to Akira Yotsutsuji.
Application Number | 20140207075 14/117791 |
Document ID | / |
Family ID | 45475309 |
Filed Date | 2014-07-24 |
United States Patent
Application |
20140207075 |
Kind Code |
A1 |
Yotsutsuji; Akira |
July 24, 2014 |
SKIVED FILM FOR COVERING SURFACE OF PLUG FOR MEDICAL PURPOSES, PLUG
FOR MEDICAL PURPOSES USING SAID FILM, PRE-FILLED SYRINGE USING SAID
PLUG AND METHOD FOR PRODUCING SAID FILM
Abstract
Provided is a PTFE skived film capable of exhibiting, with a
single layer, sliding properties, barrier properties with regard to
a liquid contact surface, and excellent tear resistance during
injection molding. This skived film is characterized by being
obtained by cutting a polytetrafluoroethylene block or a modified
polytetrafluoroethylene block subjected to a thermal fusion
treatment under reduced pressure or subjected to a pressurized
thermal fusion treatment after being subjected to fusion under
reduced pressure.
Inventors: |
Yotsutsuji; Akira;
(Osaka-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Yotsutsuji; Akira |
Osaka-shi |
|
JP |
|
|
Assignee: |
COKI ENGINEERING INC.
Osaka-shi, Osaka
JP
|
Family ID: |
45475309 |
Appl. No.: |
14/117791 |
Filed: |
May 20, 2011 |
PCT Filed: |
May 20, 2011 |
PCT NO: |
PCT/JP2011/002836 |
371 Date: |
January 29, 2014 |
Current U.S.
Class: |
604/192 ; 264/41;
526/255; 604/187 |
Current CPC
Class: |
A61M 5/3129 20130101;
A61M 5/31513 20130101; B29D 7/01 20130101; A61L 31/06 20130101;
A61M 2005/3131 20130101; A61M 5/32 20130101; A61M 5/31 20130101;
B29K 2027/18 20130101; A61L 31/048 20130101; B29K 2105/251
20130101 |
Class at
Publication: |
604/192 ;
526/255; 264/41; 604/187 |
International
Class: |
A61L 31/06 20060101
A61L031/06; A61M 5/31 20060101 A61M005/31; A61M 5/32 20060101
A61M005/32 |
Claims
1. A skived film for covering a surface of a plug for medical
purposes obtained by cutting a polytetrafluoroethylene block or a
modified polytetrafluoroethylene block subjected to a thermal
fusion treatment under reduced pressure or subjected to a
pressurized thermal fusion treatment after being subjected to
fusion under reduced pressure.
2. The skived film for covering a surface of a plug for medical
purposes according to claim 1, wherein tensile elongation in a
machine direction which is a longitudinal direction of the film is
greater than or equal to 500%.
3. A plug for medical purposes having a plug body made of
elastomer, wherein the skived film according to claim 1 is overlaid
at least on a sliding part or a liquid contact part of a surface of
the plug body.
4. The plug for medical purposes according to claim 3, wherein the
plug is a gasket for syringe, an intermediate gasket for syringe, a
top cap for syringe, or a laminate plug for vial.
5. A pre-filled syringe produced by hermetically sealing a syringe
barrel charged with a drug liquid with the gasket for syringe or
the top cap for syringe according to claim 4.
6. A method for producing a polytetrafluoroethylene film for
covering a surface of a plug for medical purposes, comprising the
steps of: pressure-molding powder material of
polytetrafluoroethylene or modified polytetrafluoroethylene charged
in a mold to obtain a pressure-molded product having interconnected
cells inside; subjecting the pressure-molded product obtained by
the pressure molding to a thermal fusion treatment under reduced
pressure; and cutting the product subjected to the thermal fusion
treatment obtained by the thermal fusion treatment to obtain a
film.
7. A method for producing a polytetrafluoroethylene film for
covering a surface of a plug for medical purposes, comprising the
steps of: pressure-molding powder material of
polytetrafluoroethylene or modified polytetrafluoroethylene charged
in a mold to obtain a pressure-molded product having interconnected
cells inside; subjecting the pressure-molded product to a primary
thermal fusion treatment under reduced pressure to block outlets of
communication holes of the pressure-molded product to obtain a
product subjected to the primary thermal fusion treatment including
only closed cells remaining inside; subjecting the product
subjected to the primary thermal fusion treatment to a secondary
thermal fusion treatment under increased pressure to obtain a
product subjected to the secondary thermal fusion treatment from
which the closed cells have disappeared; and cutting the product
subjected to the secondary thermal fusion treatment to obtain a
film.
8. The method for producing a polytetrafluoroethylene film for
covering a surface of a plug for medical purposes according to
claim 6, wherein the powder material of polytetrafluoroethylene or
modified polytetrafluoroethylene charged in the mold is pressure
molded under reduced pressure to obtain a pressure-molded
product.
9. The method for producing a polytetrafluoroethylene film for
covering a surface of a plug for medical purposes according to
claim 6, wherein pressure reduction is conducted within a pressure
range of 0.013 to 133 Pa.
10. The method for producing a polytetrafluoroethylene film for
covering a surface of a plug for medical purposes according to
claim 6, wherein a thermal fusion treatment temperature is 320 to
400.degree. C.
11. The method for producing a polytetrafluoroethylene film for
covering a surface of a plug for medical purposes according to
claim 7, wherein a range of pressurization pressure in the
secondary thermal fusion treatment is higher than or equal to 0.2
Ma.
12. The method for producing a polytetrafluoroethylene film for
covering a surface of a plug for medical purposes according to
claim 6, wherein the product subjected to the thermal fusion
treatment has a shape which is a rectangular parallelepiped, a
cube, a circular column, or a cylinder.
13. The method for producing a polytetrafluoroethylene film for
covering a surface of a plug for medical purposes according to
claim 6, wherein the film produced by cutting the product subjected
to the thermal fusion treatment has a thickness ranging from 20 to
150 .mu.m.
Description
TECHNICAL FIELD
[0001] The present invention relates to a method for producing a
polytetrafluoroethylene film suited as a covering film to be
attached on a gasket of a syringe barrel that is used for
administering a drug liquid to a human body or an animal in
pharmaceutical and medical fields, or on an inner surface of an
insertion bore formed in a top cap into which a tip end part of the
syringe barrel for attachment of a needle is to be inserted, and
further to a film produced by the method, and a plug for medical
purposes and a pre-filled syringe using the film.
BACKGROUND ART
[0002] In pharmaceutical and medical fields, various plugs for
medical purposes are used. Hereinafter, the technology concerning
such plugs for medical purposes will be described with a pre-filled
syringe in which such a plug for medical purposes takes a
particularly important functional role, as an example.
[0003] Recently, a so-called pre-filled syringe has become
frequently used. In the pre-filled syringe, a syringe barrel
serving both as an injection cylinder and a drug liquid container
is preliminarily filled with a drug liquid, and the syringe barrel
is transported and stored in the condition that a tip end part to
which a needle is to be attached is hermetically sealed with a top
cap, and before administration of the drug liquid, a needle is
attached to the tip end part of the syringe barrel from which the
top cap has been removed, and then a piston rod (pushing rod) is
pushed-in to slide the gasket toward the tip end of the syringe
barrel, and thus the drug liquid in the syringe barrel is
administered.
[0004] The pre-filled syringe is featured by the ability to
administer a correct dose of a drug liquid without erroneous use of
the drug liquid, non-necessity of a drug liquid transferring
operation, and the ability to prevent microbial contamination of a
drug liquid caused by the transferring operation.
[0005] In conventional pre-filled syringes made of resin, the
gasket is made of vulcanized rubber or the like. For ameliorating
the "poor sliding properties" when the rubber gasket slides on the
inner surface of the syringe barrel, it is necessary to apply
silicon grease on the surface of the gasket or on the inner surface
of the syringe barrel, and decrease in titer due to adsorption of
an active ingredient in the drug liquid by the silicon grease, and
contamination of the drug liquid by silicon microparticles in the
silicon grease and adverse effect thereof on a human body have been
seen as problems. Also, there is a "problem with regard to a liquid
contact surface" because a soluble ingredient in the rubber can
elute into the drug liquid.
[0006] For solving these problems, a gasket in which a covering
film formed of a polytetrafluoroethylene (hereinafter, also
referred to as "PTFE") film is overlaid on the surface of a rubber
gasket body has been developed. In such a gasket, the covering film
formed of a PTFE film allows improvement in sliding properties of
the gasket relative to the syringe barrel, and the like without use
of silicon grease.
[0007] Here, as a method for producing a PTFE film which is to be a
covering film, the following two methods are known: (1) following
thermal pressure bonding of a laminate of at least two skived films
obtained by cutting (skiving) a PTFE pressure-molded product, a
thermal fusion treatment is conducted at a temperature higher than
or equal to the melting point of PTFE to form a film (e.g., see
Patent Literature 1), and (2) using a suspension containing PTFE
resin powder, a dispersing agent, and a solvent as a material, a
PTFE cast film having a center line mean roughness Ra of surface of
0.05 .mu.m or less and a coefficient of kinetic friction of 0.2 or
less is produced by a casting method (e.g., see Patent Literature
2).
[0008] By covering the surface of a gasket body with a covering
film formed of a PTFE film produced by the foregoing methods, it is
possible to improve the sliding properties of the gasket relative
to the syringe barrel as described above, and to eliminate the need
of applying silicon grease on the inner surface of the syringe
barrel, thereby avoiding the aforementioned problems caused by the
silicon grease.
[0009] Further, since the covering film is configured to be
substantially water vapor impermeable by eliminating almost all of
fine pinholes and fusion defective parts, it is possible to prevent
a rubber ingredient (soluble ingredient) of the gasket body from
leaching into the drug to contaminate the drug liquid. Therefore,
the covering film can exert the aforementioned effect by being
overlaid not only on the gasket for syringe where sliding
properties are regarded as the most important properties, but also
on a liquid contact inner surface of an insertion bore of a top cap
for syringe into which a tip end part of the syringe barrel is to
be inserted, or on a liquid contact surface of an insertion portion
of a laminate rubber plug for vial, for its water vapor
impermeability and barrier properties against a leached ingredient
as described above.
CITATION LIST
Patent Literature
[0010] [PTL 1] Japanese Laid-Open Patent Publication No. 6-287540
[0011] [PTL 2] Japanese Laid-Open Patent Publication No.
10-314305
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
[0012] The conventional methods for producing a PTFE film has a
problem of difficulty in efficiently and economically producing a
PTFE film suited as a covering film. To be more specific, although
a skived film obtained by cutting a block-shaped PTFE
pressure-molded product allows efficient mass production of PTFE
film at relatively low cost, the pressure-molded product formed by
pressure molding of PTFE powder is a cluster of porous aggregates,
and interspaces (interconnected cells) communicating with each
other between PTFE powder particles forming the aggregates or along
contact interfaces of neighboring aggregates in a weaving manner
run all over the pressure-molded product in the form of a network.
When such a porous pressure-molded product including interconnected
cells is subjected to a thermal fusion treatment under normal
pressure, the temperature of the block-shaped PTFE product
subjected to the thermal fusion treatment rises from the
superficial side, and contact interfaces of aggregates on the
superficial side start fusing in first, and the fused area spreads,
and eventually the entire surface of the superficial part is fused
and the outlets of the interconnected cells are blocked and the gas
is confined inside. This also applies to an aggregate wherein
fusion starts on the superficial side previous to the inside, and
the ambient gas is confined inside in the same manner. As a result,
no matter if the temperature or the duration of the thermal fusion
treatment is elevated or extended later, the confined gas will not
be dissolved into the product subjected to the thermal fusion
treatment, and will remain as closed cells. Hence, a skived film
obtained by cutting such a product subjected to the thermal fusion
treatment includes an infinite number of fine pinholes and fusion
defective parts.
[0013] For making such a skived film into a covering film that is
impermeable to water vapor, it is necessary to stack and integrate
at least two skived films so that these fine pinholes and fusion
defective parts are out of alignment as is in the forgoing former
method. However, this method has a problem that process management
and quality control are complicated because entirely new steps
"stacking of films", "thermal pressure bonding", and "re-thermal
fusion treatment" are added in order, compared to the case where a
PTFE film is produced just by skiving.
[0014] Even if continuity of fine pinholes or fusion defective
parts is broken by sticking a plurality of porous skived films
together, an infinite number of pinholes still remain in the
superficial skived film although the pinholes do not penetrate to
the surface of the opposite side. When resin which is to become a
plug body is injection molded for sticking the skived films on a
sliding surface or a liquid contact surface of the plug body, the
skived film may tear from one of the infinite number of pinholes as
an origin due to impact elongation exerted on the skived films.
This deteriorates the yield of molding.
[0015] On the other hand, in the latter method, the thickness of a
PTFE film obtained by a single application is very small, and a
film having a uniform thickness cannot be obtained unless the
thickness of the film is gradually increased by repeating a series
of steps of "application of PITFE suspension", "drying", and
"thermal fusion treatment" for obtaining a film having a thickness
of about 20 .mu.m to 150 .mu.m which is particularly suited as a
covering film. Therefore, the production efficiency is very poor,
and there is a problem of difficulty in economically producing a
PTFE cast film suited as a covering film.
[0016] Additionally, since a PTFE suspension is used for
application, an infinite number of pinholes occur in the dry film
as the suspension gradually gets dry, and the pinholes remain even
after the dry film is subjected to a thermal fusion treatment.
Then, films are piled up by repeated application, drying, and a
thermal fusion treatment, and pinholes occurring in the respective
films are out of alignment and do not communicate with each other.
Therefore, a PTFE cast film having excellent water impermeability
and barrier properties comparable with those described above is
formed. However, since pinholes appear in films of front and back
superficial layers, tear can be caused from one of these pinholes
as an origin, during injection as described above.
[0017] Therefore, it is a primary object of the present invention
to provide a PTFE skived film capable of exhibiting, with a single
layer, sliding properties, barrier properties relative to a liquid
contact surface, and excellent tear resistance during injection
molding which are the aforementioned problems, and a method for
producing the film. It is a secondary object of the present
invention to provide a plug for medical purposes and a pre-filled
syringe produced efficiently and economically by using the PTFE
film produced by said method.
Solution to the Problems
[0018] A first aspect is characterized by "a skived film for
covering a surface of a plug for medical purposes obtained by
cutting a polytetrafluoroethylene block or a modified
polytetrafluoroethylene block subjected to a thermal fusion
treatment under reduced pressure or subjected to a pressurized
thermal fusion treatment after being subjected to fusion under
reduced pressure", and a second aspect is characterized in that
"tensile elongation in a machine direction which is a longitudinal
direction of the film is greater than or equal to 500%".
[0019] A conventional skived film can hardly be used for covering a
surface of a plug for medical purposes because it includes an
infinite number of pinholes and fusion defective parts as described
above, and has "water vapor impermeability" much lower than that
required for medical purposes. In contrast, as will be described
later, the film obtained by cutting a product subjected to a
"thermal fusion treatment under reduced pressure", or "pressurized
thermal fusion treatment after being subjected to fusion under
reduced pressure" includes no fine pinholes and fusion defective
parts, and satisfies the water vapor impermeability (amount of
water vapor transmission is measured for determination) required
for covering surface of a plug for medical purposes, so that it
first finds application as a film for covering a surface of a plug
for medical purposes. Also when "tensile elongation in a machine
direction which is a longitudinal direction of the film is greater
than or equal to 500%", impact elongation in covering an elastomer
for a plug body during the injection molding step is overcome and
the film will not tear, so that it is possible to realize such high
yield in injection molding that cannot be achieved by a cast film
or by a conventional skived film. Since the skived film is
stretched in the longitudinal direction when it is passed through
rollers under tension for removing the undesired curling,
elongation is smaller in the longitudinal direction than that in
the width direction. Therefore, elongation occurs in the machine
direction which is a longitudinal direction.
[0020] In a plug for medical purposes described in a third aspect,
for example, a gasket for syringe, an intermediate gasket for
syringe, a top cap for syringe, or a laminate plug for vial as
described in a fourth aspect, or a pre-filled syringe described in
a fifth aspect, since the skived film according to the first or
second aspect is overlaid on the superficial surface, or at least
on the sliding surface or the liquid surface of the plug body made
of elastomer, it is possible to realize smooth movement of a
piston, and to block elution of an inhibitor from the elastomer on
the body side to the drug liquid side in the liquid contact part,
and to block water diffusion from the charged drug liquid by
exertion of "sliding properties", "barrier properties", and "water
vapor impermeability".
[0021] According to a sixth aspect, a method for producing a
polytetrafluoroethylene film for covering a surface of a plug for
medical purposes (first method) is characterized by the steps of
"pressure-molding powder material of polytetrafluoroethylene or
modified polytetrafluoroethylene charged in a mold to obtain a
pressure-molded product having interconnected cells inside;
subjecting the pressure-molded product obtained by the pressure
molding to a thermal fusion treatment under reduced pressure; and
cutting the product subjected to the thermal fusion treatment
obtained by the thermal fusion treatment to obtain a film".
[0022] Here, "subjecting the pressure-molded product obtained by
the pressure molding to a thermal fusion treatment under reduced
pressure" means that the ambient pressure has reached (or almost
reached) a reduced pressure condition before "heating" the
pressure-molded product for "fusion treatment" as will be described
in detail later. And this "reduced pressure condition" is kept
until at least the entire superficial surface of the
pressure-molded product is baked into the state including
practically no pinhole (the entirety is covered with a skin). By
keeping the reduced pressure until the superficial surface is baked
to the state including practically no pinhole, the pressure-molded
product is baked to the state where no pinholes are included up to
the core by preventing the external air from entering the
pressure-molded product undergoing thermal fusion even if the
ambient pressure is returned to normal pressure later. Of course,
pressure reduction may be continued until thermal fusion completes
or cooling completes.
[0023] Next, the "fusion treatment" will be described. PTFE powder
charged in a mold is pressure-molded to form a pressure-molded
product, and the pressure-molded product is a block of a
predetermined shape formed by assembly of aggregates which are
clusters of fine powder particles.
[0024] As is described in the section of PROBLEM, an aggregate is
made up of fine powder particles which are in contact with each
other, and is a porous aggregate in which networks of fine
communication holes run. Also in a pressure-molded product which is
a cluster of the aggregates, the parts that cannot properly come
into contact with each other in the vicinity of contact interfaces
between aggregates form coarse interspaces (interconnected cells),
and networks of these coarse interconnected cells run throughout
the interior of the pressure-molded product as is the same with the
above. Therefore, it is doubly porous.
[0025] By reducing the pressure to a predetermined pressure before
starting heating of the "fusion treatment", not only the coarse
interspaces (interconnected cells) remaining between aggregates as
described above are drawn outside, but also the gas having entered
inside the interconnected cells during the compression molding is
drawn outside from the fine interconnected cells remaining in the
aggregates (degassed), so that the interior has the same (almost
the same) reduced pressure condition as that of the ambient
environment.
[0026] When "heating" for the "fusion treatment" is started in this
condition, contact interface between neighboring aggregates softens
by the heat and fusion gradually progresses from the superficial
side of the pressure-molded product toward the interior. At the
same time, also in the aggregates residing in the superficial part
of the pressure-molded product, softening and fusion gradually
progress from the superficial side. As a result, softening and
fusion progress even in the aggregates residing on the superficial
side of the pressure-molded product, prior to the interior.
Therefore, bubbles that have turned into closed cells from the
interconnected cells because of closure of the outlets are left
inside.
[0027] In association with progression of thermal fusion (or
temperature elevation or keeping of fusion temperature), the fused
area gradually extends due to reduction in surface tension at
contact interface, and the closed cells are reduced. At this time,
since the internal pressure of the closed cells is reduced and
there is little gas in the interior, and there is no resistance
that interferes extension of fusion, the closed cells can be
reduced to the minimum, and occurrence of fine pinholes and fusion
defective parts inevitably accompanying a powder thermal fusion
treatment is greatly controlled. Such fusion also occurs inside
aggregates as well, and substantially complete fusion is achieved
in the entire product subjected to the thermal fusion treatment.
And at the time when fusion has progressed to the core, the "fusion
treatment" completes and cooling follows.
[0028] By producing a film by cutting a product subjected to the
thermal fusion treatment obtained by such a thermal fusion
treatment method, it is possible to obtain a PTFE film including
least fine pinholes and fusion defective parts, that is
substantially water vapor impermeable and suited as a covering
film.
[0029] A seventh aspect is further improvement of the sixth aspect
(second method), and characterized by the steps of
"pressure-molding powder material of polytetrafluoroethylene or
modified polytetrafluoroethylene charged in a mold to obtain a
pressure-molded product having interconnected cells inside;
subjecting the pressure-molded product to a primary thermal fusion
treatment under reduced pressure to block outlets of communication
holes of the pressure-molded product to obtain a product subjected
to the primary thermal fusion treatment including only closed cells
remaining inside; subjecting the product subjected to the primary
thermal fusion treatment to a secondary thermal fusion treatment
under increased pressure to obtain a product subjected to the
secondary thermal fusion treatment from which the closed cells have
disappeared; and cutting the product subjected to the secondary
thermal fusion treatment to obtain a film".
[0030] Also in this case, the "primary thermal fusion treatment" is
started in the condition that the pressure is reduced to an
approximately predetermined pressure. And, the product subjected to
the primary thermal fusion treatment in which apertures of fine
communication holes in aggregates located in the superficial part
of the pressure-molded product or coarse communication holes
between aggregates are closed and only closed cells having reduced
internal pressure remain as a result of the primary thermal fusion
treatment, is subjected to the secondary thermal fusion treatment
under increased pressure. Since the entire superficial surface of
the product subjected to the primary thermal fusion treatment is
covered with a skin, the pressure is applied on the entire
superficial surface of the product subjected to the primary thermal
fusion treatment, and the entirety is pressed toward the center,
and the closed cells gradually disappear by this pressurization
force without any resistance.
[0031] In the first method not employing "pressurization", fusion
progresses only by reduction in surface tension at contact
interface "during fusion". When the closed cells gradually contract
to become very fine pinholes, such fine pinholes are physically
crushed by "pressurization" although they are difficult to be
eliminated only by reduction in surface tension. Hence, the product
subjected to the secondary thermal fusion treatment is much denser
than the product subjected to the thermal fusion treatment produced
by the first method. By preparing a film by cutting the product
subjected to the secondary thermal fusion treatment obtained in
such a manner, it is possible to obtain a PTFE film that includes
lesser fine pinholes and fusion defective parts, and is more
impermeable to water vapor and more desirable as a covering film
than the film formed in the invention described in the sixth
aspect. Shifting from the primary thermal fusion treatment to the
secondary thermal fusion treatment may be conducted continuously
using the same thermal fusion treatment furnace, or the treatments
may be conducted in a batch manner using different thermal fusion
treatment furnaces.
[0032] Powder material of PTFE used herein is powder of solely
PTFE, and modified PTFE is PTFE that is modified for adaptation to
the use. In the present invention, elongation is an important
factor as will be described later, and hence, modified PTFE in
which priority is given to elongation, for example, a polymer of
tetraftluoroethylene obtained by copolymerizing 0.01 to 1 part by
weight of alkylvinylether having one to four carbon atoms in a
perfluoroalkyl chain with 100 parts by weight of PTFE is recited as
an example.
[0033] Here, the pressure in reducing the pressure during the
thermal fusion treatment (or the primary thermal fusion treatment)
preferably falls within the range of 0.013 to 133 Pa. When the
pressure (reduced pressure) during the thermal fusion treatment is
higher than 133 Pa (or the degree of vacuum is lower than the
predetermined range), degassing of the gas having entered
interspaces between neighboring PTFE aggregates as well as in fine
pinholes in PTFE aggregates is insufficient, and the gas is
confined inside during the thermal fusion treatment, so that fine
pinholes and fusion defective parts remain. On the contrary, when
the pressure is lower than 0.013 Pa (or the degree of vacuum is
higher than the predetermined range), gas does not remain not only
in interspaces between neighboring PTFE aggregates but also in fine
pinholes in PTFE aggregates, however, massive equipment is required
for generating vacuum and it is no longer possible to efficiently
and economically obtain the product subjected to the thermal fusion
treatment (or product subjected to the primary thermal fusion
treatment). In short, the reduced pressure is selected so that fine
pinholes and fusion defective parts will not remain in the product
subjected to the thermal fusion treatment (or the product subjected
to the primary thermal fusion treatment).
[0034] An eighth aspect is characterized in that "the powder
material of polytetrafluoroethylene or modified
polytetrafluoroethylene charged in the mold is pressure-molded
under reduced pressure to obtain a pressure-molded product" in the
sixth and seventh aspects, and according to this, it is possible to
obtain a pressure-molded product having a much higher density than
that obtained by pressure-molding at normal temperature.
[0035] In the method for producing a polytetrafluoroethylene film,
it is preferred that "a thermal fusion treatment temperature (or
primary, secondary thermal fusion treatment temperature) is 320 to
400.degree. C.". Since the melting point of PTFE is approximately
327.degree. C. (gelation occurs and mechanical properties rapidly
change at temperatures higher than this), a longer time is required
for the thermal fusion treatment when the temperature during the
thermal fusion treatment is less than 320.degree. C. On the
contrary, since the temperature at which PTFE starts decomposing is
approximately 390.degree. C., decomposition starts and gas bubbles
occur inside the fused product when the temperature during the
thermal fusion treatment exceeds 400.degree. C. In view of the
melting point of PTFE, the temperature is more preferably 350 to
370.degree. C. at which fusion easily progresses, and within this
temperature range, the shape will not be lost upon heating at a
temperature exceeding the melting point, and the shape will be
restored without deterioration upon returning to normal
temperature.
[0036] The pressurization pressure during the secondary thermal
fusion treatment is higher than or equal to 0.2 MPa. Generally,
when the thermal fusion treatment temperature is low, the
pressurization pressure is set high, and when the thermal fusion
treatment temperature is high, the pressurization pressure is set
low. Of course, when both of these are set high, the thermal fusion
treatment is accelerated. When the pressure is lower than 0.2 MPa,
the method does not differ from the first method. The higher the
pressurization force, the more the tensile elongation (%) and the
amount of water vapor transmission are improved, however,
pressurization at 5 MPa or higher is not economical because an
extra cost is required for the pressure resistant structure of the
pressurized heating furnace. Therefore, the upper limit is
practically 5 MPa.
[0037] While the shape of the product subjected to the thermal
fusion treatment (or the product subjected to the secondary thermal
fusion treatment) is not specified, it is preferably "a rectangular
parallelepiped or a cube" or "a circular column or a cylinder". In
the case of a cylinder, in particular, fusion progresses both from
the superficial side and the inner side, and fusion progresses
rapidly and completely to the core. In the case of "a rectangular
parallelepiped or a cube", a film of a required size can be
obtained by planing, and in the case of "a circular column or a
cylinder", a long PTFE film can be produced efficiently and
economically by passing a mandrel in the center, and cutting the
product subjected to the thermal fusion treatment (or the product
subjected to the secondary thermal fusion treatment) while it is
rotated circumferentially about the mandrel.
[0038] It is preferred that "the film obtained by cutting the
product subjected to the thermal fusion treatment (or the product
subjected to the secondary thermal fusion treatment) has a
thickness ranging from 20 to 150 .mu.m". A film having large
thickness is used for deep drawing.
[0039] Here, "elastomer" is a generic name for materials having
rubber-like elasticity, and includes both "thermosetting elastomer"
generally called "rubber" having relatively high heat resistance
that will not soften upon application of heat such as vulcanized
rubber and thermosetting resin elastomer, and "thermoplastic
elastomer" that will soften to exhibit fluidity upon application of
heat, and return to a rubber-like elastic body upon cooling, and
can be rapidly formed by injection molding.
[0040] Examples of the "drug container" include "syringe" and
"vial". Specific examples of the "plug for medical purposes"
include a gasket for syringe, an intermediate gasket for syringe, a
top cap for syringe, and a laminate plug for vial (the fourth
aspect).
[0041] The invention described in the fifth aspect of the present
invention is a pre-filled syringe featured in that "the syringe
barrel 4 charged with the drug liquid 7 is hermetically sealed with
the gasket for syringe 1 and the top cap for syringe 6 as
exemplified in the fourth aspect".
Advantageous Effects of the Invention
[0042] According to the present invention, by developing a novel
skived method and employing the same, application of a skived film
as a covering film for a plug for medical purposes, that has been
conventionally considered to be impossible, is enabled. As a
result, it becomes possible to efficiently and economically provide
a plug for medical purposes such as a gasket for syringe and a
pre-filled syringe by using the PTFE film produced by this
method.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] FIG. 1 is a cross-sectional view showing one example of a
pre-filled syringe to which the present invention is applied.
[0044] FIG. 2 is a cross-sectional view showing another example of
the pre-filled syringe to which the present invention is
applied.
[0045] FIG. 3 is a graph for comparing results of a water vapor
transmission test for skived films prepared by a normal pressure
fusion method and the first and second methods of the present
invention.
[0046] FIG. 4 is a cross-sectional view of major part showing one
example of a method for attaching a film to a gasket body in a
stretched manner.
DESCRIPTION OF EMBODIMENTS
[0047] Hereinafter, for example, a pre-filled syringe (of course
the one to which the PTFE skived film of the present invention is
applied, but not limited to a pre-filled syringe) to which the
present invention is applied, and a PTFE skived film used in the
pre-filled syringe will be described with reference to the
drawings. FIG. 1 is a cross-sectional view showing one example of a
pre-filled syringe A (of the present invention) to which a gasket
for syringe 1 and a top cap for syringe 6 which are plugs for
medical purposes of the present invention are applied.
[0048] As shown in FIG. 1, the pre-filled syringe A of the present
invention generally includes the gasket for syringe 1 (hereinafter,
also referred to simply as "gasket 1"), a syringe barrel 4, a
piston rod 5, and the top cap for syringe 6 (hereinafter, also
referred to simply as "top cap 6"). Reference numeral 7 in FIG. 1
denotes a drug liquid (injection liquid) charged in the syringe
barrel 4.
[0049] As shown in the enlarged view of FIG. 1, the gasket 1
includes a gasket body 2, and a skived film 3 for covering formed
of a polytetrafluoroethylene (PTFE) film overlaid to entirely cover
a sliding surface relative to the inner surface of the syringe
barrel 4, and a liquid contact surface in the gasket body 2.
[0050] The gasket body 2 is an approximately circular columnar
member (namely, plug body) formed of elastomer, having a diameter
of the center part slightly smaller than diameters of the lateral
sides, and is provided in its bottom surface (surface on the side
to which the piston rod 5 is attached) with a female screw portion
8 for connecting the piston rod 5.
[0051] The "elastomer" forming the gasket body 2 includes both
"thermosetting elastomer", such as vulcanized rubber and
thermosetting resin elastomer, and "thermoplastic elastomer" as
described above.
[0052] Examples of the vulcanized rubber include butyl rubber, SUR
(styrene-butadiene rubber), EPR (ethylene-propylene rubber), EPDM
(ethylene-propylene-diene rubber), NBR (acrylonitrile butadiene
rubber), NR (natural rubber), IR (isoprene rubber), CR (chloroprene
rubber), IIR (butyl rubber), chlorinated butyl rubber, and
brominated butyl rubber, and examples of the thermosetting resin
elastomer include fluorine rubber and silicone rubber.
[0053] Examples of the thermoplastic elastomer include SBS
(styrene-butadiene-styrene block copolymer), SEBS
(styrene-ethylene-butadiene-styrene block copolymer), EP
(ethylene-propylene copolymer), PA (polyamide), and
polyurethane.
[0054] The covering film 3 is formed of the PTFE film obtained by
the skived method according to the present invention, and contains
in the entire film, almost no fine pinholes which are residues of
interspaces between aggregates and fine pinholes included in the
aggregates, as well as porous aggregates that are observed in the
state of the pressure-molded product (see the result of the water
vapor transmission test in Table 1 and FIG. 3). Although tensile
elongation (%) differs in the longitudinal direction (machine
direction) and in the width direction (cross direction) of the film
as described above, the film has enough resistance to
later-described impact elongation to endure impact elongation
during injection of the gasket body 2 even in the longitudinal
direction of the film in which tensile elongation (%) is smaller
(see results of elongation test in Table 1), and tear of the film
during injection is hardly observed. The surface of the PTFE film
obtained by the skived method according to the present invention
has an infinite number of very shallow parallel knife cuts that are
formed during cutting in the longitudinal direction of the film,
however, since the infinite number of very shallow knife cuts run
in the longitudinal direction of the film having smaller tensile
elongation (%), the knife cuts will not become an origin of tear
during injection molding, and there is no pit (hole) in the surface
that is to become an origin of tear inevitable for a cast film.
[0055] The skived film as described above is overlaid to entirely
cover the sliding surface relative to the inner surface of the
syringe barrel 4 (in other words, outer circumferential face of the
gasket body 2) and the tip end surface which is a liquid contact
surface in the gasket body 2, to impart high sliding properties to
the sliding surface of the gasket body 2, and barriers properties
of inhibiting transfer of a water-soluble impurity into the drug
liquid from the gasket body 2 and water vapor impermeability of
preventing evaporation of water from the charged drug.
[0056] Preferably, the thickness of the PTFE film forming the
covering film 3, before being overlaid on the gasket body 2, ranges
from 20 .mu.m to 150 .mu.m, inclusive. The film thickness is
selected depending on the shape of the material to be laminated, in
particular, depending on the deep drawing amount. A thicker film is
used for a deeper drawing amount.
[0057] Since the syringe barrel 4 has many variations from a
small-sized one having a small inner diameter (for example, an
inner diameter of 4.65 mm) to a large-sized one having a large
diameter (for example, an inner diameter of 50 mm) for imaging, the
gasket 1 itself also has corresponding variations from one having a
small diameter to one having a large diameter, and also the film
thickness of the covering film 3 used herein is selected depending
on the shape and the depth of drawing.
[0058] Lamination of the covering film 3 onto the gasket body 2 is
achieved by injection molding carried out in the following manner.
The covering film 3 is stretched on a female mold in which the
shape of the gasket is engraved, then a male mold having a male
screw portion 9 formed in a protruding manner for screw attachment
of a piston rod is set to push the covering film 3 into the bore
for forming a gasket in the female mold, and an elastomer which is
to become the gasket body 2 is charged at high speed by being
injected at high pressure between the pushed-in covering film 3 and
the male screw portion 9 (see FIG. 4).
[0059] In such injection molding, the covering film 3 is rapidly
stretched in the machine direction and the cross direction of the
film by injection of the elastomer at high pressure, and elongation
is a very important factor in mass production because poor
elongation may cause tear. A thick film is used for deep drawing
because it allows large elongation. At the same time, it is also
important to improve the elongation of the covering film 3 for
enduring injection at high pressure as is already described, and
for this, it is more preferred to produce and use, in place of the
PTFE film, a modified PTFE film by using modified PTFE (for
example, a polymer of tetrafluoroethylene obtained by
copolymerizing 0.01 to 1 part by weight of alkylvinyl ether having
1 to 4 carbon atoms in a perfluoroalkyl chain with 100 parts by
weight of PTFE) as powder material.
[0060] Regarding the elongations of these films (in particular,
modified PTFE film), these films preferably exhibit tensile
elongation (more strictly, fracture elongation) of at least 500% or
greater in the machine direction in which the film is weak (As
described above, since the skived film is passed between
multi-stage rollers under tension in the longitudinal direction for
eliminating waving of the film after being formed into a film by
cutting, the film is stretched in the longitudinal direction of the
film and thus has higher tensile strength in the longitudinal
direction than in the width direction, but elongation in the
longitudinal direction is deteriorated in comparison with that in
the width direction.). The tensile elongation in the longitudinal
direction of the sample shown in Table 1 that is likely to cause
tear of film during injection molding (Unmodified/Comparative 1
(Comparative example: Film fused at atmospheric pressure without
pressure reduction and pressurization, using unmodified material))
is 450%.
[0061] With the elongation in the machine direction of less than or
equal to 500%, the PTFE film may tear depending on the shape of the
gasket 1 during stretching in injection molding of the gasket 1.
While an upper limit of elongation is not limited, excessive
elongation makes the film too soft to impair not only sliding
properties but also shape retention of the gasket 1, although large
elongation will not inhibit resilience of the gasket body 2. From
this point of view, preferably, an upper limit of elongation is
practically 650% or 700%. Thus, the thickness of the PTFE film or
the modified PTFE film overlaid on the gasket body 2 by injection
is 10 .mu.m to 20 .mu.m. And knife cuts in the shapes of fine
projecting and recessed lines generated by cutting are
significantly lessened to such a degree that they will disappear by
the great elongation during injection molding as described above.
An adhesion surface of the covering film 3 with regard to the
gasket body 2 is subjected to an adhesiveness improving treatment
as will be described later for enhancing adhesiveness.
[0062] The method for producing a PTFE skived film that forms the
covering film 3 described hereinafter is an improved method based
on a conventional skived method. Specifically, first, powder
material (so-called molding powder) of polytetrafluoroethylene
(PTFE) or modified PTFE is charged in a mold, and compressed at
room temperature, under a pressure of 10 to 50 MPa to form a
circular columnar or cylindrical product. The pressure at the time
of compression is limited in the above range because when the
pressure is lower than 10 MPa, mechanical strength of the obtained
pressure-molded product is poor, and the handling such as transfer
to the subsequent step becomes difficult, and a lot of air remain
inside the pressure-molded product, so that fine pinholes and
fusion defective parts frequently occur in the obtained film when
the pressure-molded product is finally processed into a film. When
the pressure is higher than 50 MPa, the mechanical strength of the
pressure-molded product is improved, but the problem of fine
pinholes or fusion defective parts in the obtained film remains
unsolved, and the properties of the film are not so improved
although the massive equipment for pressurization is used. (Here,
the pressure-molded product can be further densitfied by employing
pressure reduction together with compression under pressurization.
The pressure reduction may be employed after compression molding
under pressurization. When the reduced pressure condition can be
maintained continuously to the subsequent fusion treatment, it is
convenient to shift to the fusion treatment while keeping the
reduced pressure condition to avoid the need of reducing the
pressure again in the fusion treatment.) This point also applies to
the second method. The degree of pressure reduction is preferably
0.013 to 133 Pa for adaptation to the subsequent step.
[0063] The shape of the pressure-molded product is not particularly
limited, and an optimum shape such as a circular column, a
cylinder, a rectangular parallelepiped or a cube is selected
depending on the method for forming a film from the product
subjected to the thermal fusion treatment and on the thermal fusion
treatment condition. The pressure-molded product is a cluster of
aggregates of PTFE powder material or modified PTFE powder material
because it is formed just by compression under pressurization.
Therefore, there are an infinite number of interspaces of various
sizes between neighboring powder particles or between neighboring
aggregates although powder particles inside each aggregate adhere
tightly to each other, and the aggregates adhere tightly to each
other at their contact interface. The interspaces communicate with
each other to give a network of fine communication holes throughout
the pressure-molded product, so that the pressure-molded product is
porous. When the pressure-molded product is put in a reduced
pressure condition, and this condition is not maintained, these
communication holes are filled with gas in the ambient environment
(normally air).
[0064] Then, the pressure-molded product formed in an atmospheric
pressure is put into a heating furnace, and the internal pressure
of the heating furnace is reduced to a degree of vacuum of 0.013 to
133 Pa, and the interior of the pressure-molded product
accommodated in the furnace is also made to have the same degree of
vacuum to remove the gas from the interspaces (communication
holes). Typically used degree of vacuum ranges from 0.13 Pa to 13.3
Pa. After conducting the thermal fusion treatment as described
above, normally at 320 to 400.degree. C. (more preferably 350 to
370.degree. C.) for several to several ten hours, depending on the
size and the shape of the pressure-molded product while keeping
this reduced pressure condition, the pressure-molded product is
cooled to obtain a product subjected to the thermal fusion
treatment.
[0065] In the pressure-molded product undergoing the thermal fusion
treatment, since the temperature rises from the superficial side,
and the heat is conducted toward the center part, fusion of PTFE
aggregate itself and fusion at contact interfaces between
aggregates progress from the superficial side in an early stage of
the thermal fusion treatment in the porous pressure-molded product,
and the aforementioned interspaces gradually disappear. On the
other hand, inside the aggregates themselves and inside the
pressure-molded product which is a cluster of the aggregates,
fusion at contact interface is delayed, and interspaces are
confined inside because temperature rise is delayed. In other
words, outlets of interconnected cells are blocked to give closed
cells.
[0066] However, fusion at contact interface is not interfered
because there is little gas inside the interspaces (closed cells),
and disappearance of interspaces (closed cells) up to the core of
the pressure-molded product is eventually achieved. By securing a
sufficient thermal fusion treatment time, fusion at contact
interface completely progresses, and elimination of fusion
defective parts due to defective fusion is also achieved.
Therefore, an estimated duration and heating temperature of the
thermal fusion treatment is the time required for fine pinholes and
fusion defective parts inside the product subjected to the thermal
fusion treatment to disappear, from the purpose of producing a PTFE
film with no fine pinholes, which is an object of the present
invention.
[0067] Here, the pressure reduction range in reducing the internal
pressure of the heating furnace during the thermal fusion treatment
is preferably 0.013 to 133 Pa as described above. Further, the
temperature during the thermal fusion treatment is preferably in
the range from 320 to 400.degree. C. (more preferably 350 to
370.degree. C.) as described above. Technical significances of the
pressure range and the temperature during the thermal fusion
treatment are as described above. As an indication for the thermal
fusion treatment, although fusion is expected to progresses to the
core typically in about five hours after the temperature has
reached a predetermined temperature (360.degree. C.) for a circular
columnar product having an outer diameter of 100 mm, an inner
diameter of 20 mm, and a thickness of 40 mm, heating is conducted
for about ten hours for safety and then cooling by allowing to cool
follows.
[0068] As another method for obtaining a product subjected to the
thermal fusion treatment (second method), the following method may
be employed. Specifically, similarly to the first method, powder
material of polytetrafluoroethylene or modified
polytetrafluoroethylene is charged in a mold, and pressure-molded
under normal pressure or reduced pressure to obtain a
pressure-molded product. The pressure molding and the formed shape
are as same as those in the first method.
[0069] Then, the pressure-molded product is subjected to a primary
thermal fusion treatment under reduced pressure. The condition of
the thermal fusion treatment is as described above, and interspaces
(interconnected cells) are blocked from the superficial side of the
pressure-molded product. In this case, an estimated duration of the
primary thermal fusion treatment is the time required for
communication holes in the entire surface on the superficial side
of the product subjected to the primary thermal fusion treatment to
disappear to give the condition that only closed cells remain
inside. The thermal fusion treatment temperature is as same as that
in the first method.
[0070] After conducting the primary thermal fusion treatment, the
product subjected to the primary thermal fusion treatment is
subjected to a secondary thermal fusion treatment unwder increased
pressure by pressurizing the interior of the same heating furnace
to a predetermined pressure, or by taking out the product subjected
to the primary thermal fusion treatment and transferring it to
another heating furnace, and pressurizing the interior of the
heating furnace to a predetermined pressure.
[0071] The secondary thermal fusion treatment is conducted under
increased pressure because the entire surface of the superficial
part of the product subjected to the primary thermal fusion
treatment is fused, and the pressurization force in the thermal
fusion treatment furnace is exerted toward the center from the
entire superficial surface of the product subjected to the primary
thermal fusion treatment, to crush the closed cells remaining
inside under reduced pressure. At the same time, contact interface
of powder particles forming PTFE aggregates themselves that are
physically in contact with each other, and contact interface of the
aggregates are fused by the heat transferred from the superficial
side, and almost all of the remaining fine pinholes and fusion
defective parts are eliminated. In the second method, since the
secondary thermal fusion treatment is conducted under increased
pressure, elimination of fine pinholes and fusion defective parts
is achieved more completely up to the core. The thermal fusion
treatment temperature is as same as that in the primary thermal
fusion treatment.
[0072] The pressurization pressure in the secondary thermal fusion
treatment is higher than or equal to 0.2 MPa (practically, the
upper limit is 5 MPa as described above). Normally, the
pressurization pressure is raised when the thermal fusion treatment
temperature is low, and the pressurization pressure is lowered when
the thermal fusion treatment temperature is high. For shortening
the fusion time, the temperature and the pressure are raised. The
technical significance of the pressurization range is as already
described. A practical pressurization range is 0.7 to 0.9 MPa.
[0073] Then, the product subjected to the thermal fusion treatment
obtained by the first method or the product subjected to the
secondary thermal fusion treatment obtained by the second method is
set, for example, on a lathe machine while a mandrel is passed
through the center hole thereof when the product is of a
cylindrical shape, and rotated circumferentially, and in this
condition, a cutting tool such as metallic knife is pushed at a
specific angle at a specific pressure to cut the product to obtain
a PTFE film of 20 to 150 .mu.m thick. When the product subjected to
the thermal fusion treatment or the product subjected to the
secondary thermal fusion treatment is a cylindrical solid, after
cutting out the center part of the product, a mandrel is passed
therethrough as described above, or press-fitted therein, and then
the product is subjected to cutting. When the product is a
rectangular parallelepiped or a cube, a PTFE film is obtained by a
method like planing. The obtained film is passed through rollers
under heating to remove the undesired curling occurring by cutting
(rotary cutting). As a result, the film is stretched and has
slightly higher tensile strength in the rolling direction (or the
longitudinal direction of the film or the machine direction) than
in the width direction (cross direction), while on the other hand,
it has smaller elongation in the machine direction than in the
cross direction.
[0074] In the film obtained in this manner, PTFE powder particles
in aggregates themselves and neighboring aggregates are fused and
integrated in a seamless manner as if rice cakes were fused, and
very little fine pinholes and fusion defective parts that may cause
tear of the film during injection molding are included in the
superficial surface, although the superior surface includes
microscopic knife cuts in the longitudinal direction of the film.
Therefore, it becomes possible to efficiently and economically
produce a PTFE film that is substantially impermeable to water
vapor and is desirable as a covering film. As described above,
microscopic knife cuts are not disadvantageous in injection
molding.
[0075] The PTFE film produced in the manner as described above has
essentially poor adhesiveness, and is disadvantageous in that the
joining strength with the gasket body 2 is very weak. For this
reason, it is necessary to apply an "adhesiveness improving
treatment" on the joint surface between the PTFE film and the
gasket body 2. In the present embodiment, the "adhesiveness
improving treatment" is conducted by providing the joint surface
between the PTFE film and the gasket body 2 with a silica
microparticle layer made up of a binder and silica (SiO.sub.2)
microparticles (not shown), to allow secure joining between the
PTFE film having poor adhesiveness and the gasket body 2 mainly by
the anchoring effect. Of course, as the "adhesiveness improving
treatment", other methods such as a chemical treatment with
metallic sodium or a plasma treatment in an argon atmosphere may be
conducted in place of the above method. In FIG. 4(a), the surface
subjected to the adhesiveness improving treatment of the PTFE
skived film 3 is denoted by 22, and the surface not subjected to
the treatment is denoted by 20.
[0076] The syringe barrel 4 is formed with a needle attachment part
4a in its tip end, a finger hook part 4b in its rear end, and a
cylindrical drug liquid packing part 4c therebetween, and is made
of cyclic polyolefin in this embodiment. Of course, the shape of
the syringe barrel 4 is not limited to the depicted one, and the
syringe barrel 4 may be made of polypropylene, glass, or the
like.
[0077] The piston rod 5 is a rod-like member having a gasket
attachment part 5a in its tip end part, and a finger rest part 5b
in its rear end. The outer circumference of the gasket attachment
part 5a of the piston rod 5 is engraved with a male screw to be
screwed with the female screw portion 8 formed by digging the
gasket body 2 of the gasket 1 as described above. Also, the piston
rod 5 is formed of a resin such as cyclic polyolefin,
polycarbonate, or polypropylene, similarly to the aforementioned
cylinder 4.
[0078] The top cap 6 is a sealing member that is attached to the
needle attachment part 4a of the syringe barrel 4 to prevent the
drug liquid 7 charged in the syringe barrel 4 from leaking, and to
prevent the drug liquid 7 from being contaminated by bacteria and
so on suspended in the air. The top cap 6 is made up of an
approximately circular columnar cap body (or plug body) 6a, and the
covering film 3 overlaid in the same manner for the gasket 1, on
the surface of a recess part 6b which is formed concavely on the
top face of the cap body 6a and in which the needle attachment part
4a is to be fit. The cap body 6a is formed of elastomer similarly
to the gasket body 2 described above, and the covering film 3 is
formed of a PTFE film that is formed in the above method similarly
to the one covering the gasket body 2.
[0079] By overlaying the covering film 3 on the superficial surface
of the recess part 6b of the cap body 6a in the manner as described
above, it is possible to make the needle attachment part 4a of the
syringe barrel 4 fit in the recess part 6b of the top cap 6
smoothly, and to improve the liquid tightness and air tightness of
the top cap 6 formed of elastomer.
[0080] FIG. 2 shows the case where an intermediate gasket 10 for
syringe is used, and the intermediate gasket 10 is slidably
accommodated in the syringe barrel 4. In a space 4d between the
needle attachment part 4a of the syringe barrel 4 and the
intermediate gasket 10, a solid agent 7a of, for example, powder of
drug is stored, and a space 4e between the intermediate gasket 10
and the gasket 1 for piston is filled with pure water 7b. The outer
wall of the space 4d for storage of solid agent is provided with a
bypass canal 4f formed in the longitudinal direction of the syringe
barrel 4. As the piston rod 5 is pushed in, the pure water 7b flows
into the space 4d for storage of solid agent through the bypass
canal 4f when the intermediate gasket 10 moves past an inlet 4f1 of
the bypass canal 4f, and rapidly dissolves the solid agent 7a in
the space 4d for storage of solid agent to give an injection
liquid. In this case, as shown in the enlarged view of FIG. 2, the
PTFE film 13 is attached to the intermediate gasket 10 to cover one
end surface 12a and most of the circumferential face of the
cylindrical gasket body 12, and the circumferential part is in
slidable contact with the inner surface of the syringe barrel 4.
The intermediate gasket 10 is disposed inside the syringe barrel 4
so that the end surface 12a on which the film is attached faces the
pure water 7b. Although not shown in the drawing, a groove may be
formed in the longitudinal direction in the inner wall in place of
the external bypass canal 4f to function as a bypass, or although
not shown in the drawing, both end surfaces of the intermediate
gasket 10 and the circumferential face continuing to the both end
surfaces may be covered with the PTFE film 13.
[0081] Focusing on the high barrier properties in a liquid contact
surface with a drug liquid, the invention can be applied to plugs
for medical purposes such as plugs of vials typically the gasket
for syringe 1 and the top cap for syringe 6 configured as described
above.
[0082] (Comparison in time-dependent change between results of a
water vapor transmission measurement test for skived films
according to the first and second methods of the present invention
and a skived film subjected to a fusion treatment in atmospheric
pressure without pressure reduction according to the conventional
method: FIG. 3)
[0083] The transmission amount and its change of each PTFE film
were determined in conformity with JIS Z-0208 (Testing Methods for
Determination of the Water Vapor Transmission Rate of
Moisture-proof Packaging Materials (Dish method)). According to
FIG. 3, the inclination of the skived film (Sample A) obtained by
the first method is smaller than that of the skived film formed by
the conventional method (Comparative example), and the inclination
of the skived film obtained by the second method becomes gentler as
the pressurization force in the secondary thermal fusion treatment
under increased pressure increases and approximates to that of a
sample (Modified C4). Of course, when the pressuring force exceeds
5.0 MPa, the inclination becomes less than that of the sample
(Modified C4), and the amount gradually decreases and converges to
a certain value in the vicinity of the amount of the sample. Water
vapor transmission rate (mg/m.sup.2) per unit area after 24 hours
is calculated from this graph and shown as water vapor transmission
amount in FIG. 3 (the value obtained by dividing measurement of the
moisture having passing through the skived film and absorbed in
calcium chloride (anhydrous) by water vapor transmission area). The
first and second skived films of the present invention are
significantly improved in comparison with the comparative example
(Unmodified/Comparative 1). As will be described later, the degree
of pressure reduction during the primary thermal fusion is low, and
the degree of pressurization during the secondary thermal fusion is
high.
[0084] Table 1 shows comparison of treatment conditions, tensile
elongation and tensile strength, water vapor transmission amount,
and tear of film during injection in these films.
TABLE-US-00001 TABLE 1 Water vapor Pressure Fusion Fusion Tensile
elongation % Tensile strength N/mm.sup.2 transmission Tear of
Sample reduction temperature heating Pressurization Machine Cross
Machine Cross amount mg/m.sup.2 film during No. (Pa) (.degree. C.)
time (MPa) direction direction direction direction 24 hours
injection Unmodified/ 1 * 10.sup.5 360 10 -- 450 850 36.0 30.3 1500
50% x Comparative 1 Unmodified A1 13.30 360 10 -- 507 920 41.7 36.1
372 .smallcircle. Unmodified A2 0.13 360 10 -- 526 963 40.1 36.9
353 .smallcircle. Unmodified A3 13.30 360 10 0.2 531 973 41.2 35.7
359 .smallcircle. Unmodified A4 13.30 360 10 5 554 970 41.1 34.6
248 .smallcircle. Unmodified A5 0.13 360 10 0.2 547 950 41.8 36.1
349 .smallcircle. Unmodified A6 0.13 360 10 5 551 958 41.4 35.9 238
.smallcircle. Modified B1 13.30 360 10 -- 630 915 45.0 37.2 370
.smallcircle. Modified B2 0.13 360 10 -- 641 955 46.9 38.8 340
.smallcircle. Modified B3 13.30 360 10 0.2 645 954 46.0 38.4 358
.smallcircle. Modified B4 13.30 360 10 0.6 649 955 46.0 38.3 235
.smallcircle. Modified B5 13.30 360 10 5 652 956 45.9 38.0 237
.smallcircle. Modified C1 0.13 360 10 0.2 619 932 44.8 37.1 243
.smallcircle. Modified C2 0.13 360 10 0.6 596 947 43.8 36.7 221
.smallcircle. Modified C3 0.13 360 10 5 628 954 43.5 36.4 219
.smallcircle. "Unmodified/Comparative 1" is a comparative example
of an unmodified PTFE skived film without pressure reduction and
pressurization. "Unmodified A1" and "Unmodified A2" are examples of
unmodified PTFE skived films with pressure reduction and without
pressurization (first method). "Unmodified A3" to "Unmodified A6"
are examples of unmodified PTFE skived films with pressure
reduction and pressurization (second method). "Modified B1" and
"Modified B2" are examples of modified PTFE skived films with
pressure reduction and without pressurization (first method).
"Modified B3" to "Modified B5" and "Modified C1" to "Modified C3"
are examples of modified PTFE skived films with pressure reduction
and pressurization (second method). "Pressure reduction" represents
degree of pressure reduction in the furnace during thermal fusion.
"1 .times. 10.sup.5" represents atmospheric pressure.
"Pressurization" represents pressure in the furnace during
secondary thermal fusion in the second method. "Water vapor
transmission amount" represents the amount of water vapor
transmission per unit area after a lapse of 24 hours from starting
of the experiment.
[0085] The gasket body subjected to injection has a diameter of 5
mm and a length of 5 mm, and the skived film used in the experiment
has a thickness of 100 .mu.m. "x" indicates that film tear was
observed, and ".smallcircle." indicates that film tear was not
observed.
[0086] According to Table 1, "Unmodified/Comparative 1" in which
unmodified PTFE was used and thermal fusion was conducted at normal
pressure (1.times.10.sup.5 Pa) exhibits a large water vapor
transmission amount and causes film tear during injection
molding.
[0087] On the other hand, in "Unmodified A1" and "Unmodified A2" in
which unmodified PTFE was used and thermal fusion was conducted
under reduced pressure of 0.013 Pa or 133 Pa according to the first
method, the water vapor transmission amount was dramatically
reduced by virtue of the thermal fusion treatment under reduced
pressure, and film tear was not observed during injection molding
owing to improved elongation. In the second method in which
pressurization is added, further improvement was observed. When
modified PTFE is used, these points are further improved. In other
words, these seem to be gradually converged and improved as the
pressure reduction degree (or pressure reduction degree during
primary fusion) is decreased, and the pressurization degree during
the secondary fusion is increased. FIG. 3 shows data shown in Table
1 selectively.
DESCRIPTION OF THE REFERENCE CHARACTERS
[0088] A pre-filled syringe [0089] 1 gasket for syringe [0090] 2
gasket body [0091] 3 gasket covering film [0092] 4 syringe barrel
[0093] 5 piston rod [0094] 6 top cap for syringe [0095] 7 drug
liquid
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