U.S. patent application number 14/633127 was filed with the patent office on 2015-06-18 for perforable container cap.
This patent application is currently assigned to INTEGRITY PRODUCTS, INC.. The applicant listed for this patent is Integrity Products, Inc.. Invention is credited to Jeffrey Bailey, Dale Sass.
Application Number | 20150166219 14/633127 |
Document ID | / |
Family ID | 53367514 |
Filed Date | 2015-06-18 |
United States Patent
Application |
20150166219 |
Kind Code |
A1 |
Bailey; Jeffrey ; et
al. |
June 18, 2015 |
PERFORABLE CONTAINER CAP
Abstract
A perforable container cap that reseals after puncture by a
sampling tube or needle. Embodiments of the container cap may
include a container cap locking mechanism having a barb and
adjacent stop both projecting downward from a cap edge to mesh with
a V-shaped block projecting outward from a container sidewall.
Inventors: |
Bailey; Jeffrey; (Grandview,
MO) ; Sass; Dale; (Gardner, KS) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Integrity Products, Inc. |
Grandview |
MO |
US |
|
|
Assignee: |
INTEGRITY PRODUCTS, INC.
Grandview
MO
|
Family ID: |
53367514 |
Appl. No.: |
14/633127 |
Filed: |
February 26, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12697094 |
Jan 29, 2010 |
8998012 |
|
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14633127 |
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Current U.S.
Class: |
215/253 |
Current CPC
Class: |
B01L 2300/044 20130101;
B01L 2300/123 20130101; B65D 41/0471 20130101; B01L 2300/041
20130101; B01L 2300/0672 20130101; B01L 3/50825 20130101; B01L
2200/0689 20130101; B01L 2200/141 20130101; B65D 41/0414 20130101;
B65D 51/246 20130101; B65D 51/002 20130101 |
International
Class: |
B65D 17/50 20060101
B65D017/50; B65D 41/34 20060101 B65D041/34 |
Claims
1. A perforable container cap comprising: a cap having a top,
perforable wall, and an internally threaded annular flange formed
integrally with said perforable wall and extending downwardly from
said perforable wall to enclose a cavity open at a bottom end of
said cap.
2. A perforable container cap comprising: an annular side wall
surrounding a cavity closed at a top end by an integral top wall,
said top wall perforable by a relatively thin diameter, elongated,
tubular sampling element; said side wall and said top wall
substantially formed from a single molded piece.
3. The perforable container cap of claim 2, wherein said top wall
is of substantially uniform thickness.
4. The perforable container cap of claim 2, wherein said top wall
includes a perforation area of reduced thickness.
5. The perforable container cap of claim 2, wherein said top wall
includes a perforation area comprising material optimized to reseal
after perforation.
6. The perforable container cap of claim 2, wherein said top wall
comprises a relatively soft and resilient plastic material.
7. The perforable container cap of claim 2, wherein said top wall
comprises a material selected from the group consisting of
polyethylene, polypropylene, high density polyethylene, linear low
density polyethylene, butyl rubber, silicon rubber, urethane and
thermoplastic elastomer.
8. The perforable container cap of claim 2, wherein said top wall
comprises a primary layer of polyethylene and also a secondary
layer comprising material selected from the group consisting of
thermoplastic elastomer, urethane, silicon or butyl rubber, with
one of said layers disposed over the other of said layers so that
the layers are pierced concurrently or consecutively by a sampling
element.
9. A perforable container cap comprising: a cap having a top wall,
and an annular flange formed integrally with said top wall and
extending downwardly from said top wall to enclose a cavity open at
a bottom end of said cap, said top wall and said annular flange
molded to form a single piece, said top wall including a central
aperture covered by a thin, pierceable membrane.
10. The perforable container cap of claim 9 wherein said membrane
is integrated into said top wall by in-mold labeling.
11. A method for producing an integral, perforable container cap
comprising the steps of: positioning a thin membrane within a mold
so that the membrane extends across the margins of an aperture to
be molded in the top wall of a container cap; injecting
thermoplastic material into the mold to form the cap and to adhere
or fuse to the membrane.
12. The method of claim 11 wherein said membrane comprises a
thermoplastic material selected to melt sufficiently during molding
to fuse with the thermoplastic material of the cap body.
13. The method of claim 11 wherein said membrane comprises a metal
foil.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of, and is a
continuation-in-part of, the prior filed, co-pending application
Ser. No. 12/697,094, filed Jan. 29, 2010.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a perforable container cap
that may be pierced and perforated by a needle or other sampling
element and that will reseal after the needle is withdrawn. The cap
may include a distinctive color to alert users that the cap is
perforable. Certain embodiments of a container cap according to the
present invention include a container cap locking mechanism having
features on a container cap and on an associated container body
that interlock with one another when the cap is fully tightened to
provide physical and visual indication that the cap is fully closed
and optimally sealed to the container.
[0004] 2. Description of the Related Art
[0005] Features and devices for locking container caps onto
container bodies typically are hidden between the wall of the cap
and/or the container neck and often comprise multiple pieces that
must be assembled prior to use. Hidden cap locking features
typically are used to secure the cap to the container and to
prevent the container from inadvertently opening. They do not
typically provide a visual indicator to alert a user when the cap
has been properly secured to the container body. In particular, a
threaded cap must be appropriated threaded onto an associated
container body in order for the inner surface of the cap to
completely seal against the top surface of the container body neck.
Over-tightening can result in deformation of cap and body threads
and can also cause the cap or body itself to deform, thereby
breaking the seal therebetween.
[0006] It is often advantageous for container caps to be paired
with a pierceable element such as a septum so that the contents of
the container may be withdrawn and sampled via syringe or
autosampler needle or other similar, rigid, tubular, sampling
element. Container caps in the prior art typically comprise a rigid
plastic cap having a large central aperture. A rubber septum is
fitted into the bottom of the cap to cover the aperture so that
when the cap is attached (typically threaded) onto the top of a
container, the top edge of the container seals against the septum
around the circumference of the container top edge. Because the cap
and septum are manufactured from different materials using
different processes, and sometimes by different manufacturers,
there is a cost for laboratories to source and purchase caps and
septa, and for laboratory personnel to assemble caps and septa
prior to use.
[0007] What is needed, therefore, is a container cap locking
mechanism that not only locks the cap onto the container when in
sufficient sealed engagement, but also provides visual indication
of the lock to the user. In addition, there is a need for a cap
manufactured with a perforable area integral to the body of the cap
rather than manufactured separately for later assembly.
SUMMARY OF THE INVENTION
[0008] An embodiment of a container cap locking mechanism and
sealing alignment indicator may include the following features. A
threaded cap includes an annular flange or wall having a downward
pointing barb and adjacent downward pointing stop, both at the
lower edge of the flange. The container body sidewall includes an
outwardly extending block having a V-notch sized to receive the
barb. Upon sufficient rotation of the threaded cap onto the
threaded container neck, the barb is received into the notch and
rotation is halted by the stop abutting a side of the block, thus
indicating that the closure has achieved maximum desired rotation
and is sealed. The interlocked barb and notch also prevent the cap
from loosening inadvertently, as may occur due to air pressure
changes and/or vibration during shipping. The stop prevents the cap
from being over-tightened as the cap is threaded upon the container
body.
[0009] The locking mechanism disclosed herein aids a specimen
collector by providing a physical as well as visual indication that
the container lid or cap has been tightened to an optimal position
for sealing the cap to the container, while avoiding and even
preventing excessive torque from being applied to the cap through
over tightening, thereby ensuring that the container is properly
closed, sealed and ready for transport without leakage.
[0010] A further embodiment may include a container cap or closure
having an integral sampling member (probe, spoon, spork, spatula,
etc.). Preferably, the spoon has tines on the distal end to form a
structure similar to one commonly known as a spork (combination
spoon and fork). The threaded cap includes an integral stem
extending from its inner surface and the spoon is on the distal end
of the stem.
[0011] Certain embodiments of a container cap according to the
present invention comprise a relatively soft and resilient plastic
material so that the upper, perforable wall (top surface) of the
cap may be readily pierced by a sampling element such as a sampling
needle. Due to the resilience of the plastic material, the puncture
hole or perforation substantially reseals after the sampling
element is withdrawn.
[0012] An embodiment of a perforable container cap may include a
cap having a top, perforable wall and an internally threaded
annular flange formed integrally with the perforable wall. The
annular flange extends downward from the perforable wall to enclose
a cavity open at a bottom end of the cap.
[0013] Another embodiment of a perforable container cap may include
an annular side wall surrounding a cavity closed at a top end by an
integral top wall, the top wall being perforable by a relatively
thin diameter, elongated, tubular sampling element. In this
embodiment, the side wall and top wall are substantially formed
from a single molded piece of resilient material, such as a
thermoplastic. In some embodiments of the cap, the top wall is of
substantially uniform thickness. In some embodiments of the cap,
the top wall includes a perforation area of reduced thickness. In
some embodiments of the cap, the top wall includes a perforation
area comprising material optimized to reseal after perforation. In
some embodiments of the cap, the top wall comprises a relatively
soft and resilient plastic material. More specifically, in some
embodiments of the cap, the top wall comprises a material selected
from the group consisting of polyethylene, polypropylene, high
density polyethylene, linear low density polyethylene, butyl
rubber, silicon rubber, urethane and thermoplastic elastomer. In
some embodiments of the cap, the top wall comprises a primary layer
of polyethylene and also a secondary layer comprising material
selected from the group consisting of thermoplastic elastomer,
urethane, silicon or butyl rubber, with one of the layers disposed
over the other of the layers so that the layers are pierced
concurrently or consecutively by a sampling element.
[0014] Some embodiments of a perforable container cap include a top
wall with an annular flange formed integrally with the top wall and
extending downwardly from the top wall to enclose a cavity open at
a bottom end of the cap. The top wall and annular flange are molded
to form a single piece, and the top wall includes a central
aperture covered by a thin, pierceable membrane. In some
embodiments of this cap, the membrane is integrated into said top
wall by in-mold labeling.
[0015] A method for producing an integral, perforable container cap
may include the steps of (a) positioning a thin membrane within a
mold so that the membrane extends across the margins of an aperture
to be molded in the top wall of a container cap, and (b) injecting
thermoplastic material into the mold to form the cap and to adhere
or fuse to the membrane. In some embodiments of the method and of
the cap, the membrane comprises a thermoplastic material selected
to melt sufficiently during molding to fuse with the thermoplastic
material of the cap body. In some embodiments of the method and of
the cap, the membrane comprises a metal foil.
[0016] Other advantages of the invention will become apparent from
the following description taken in connection with the accompanying
drawings, wherein is set forth by way of illustration and example
several embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a front elevation of a container cap threadably
attached to a container body and showing the locking features of
the cap intermeshed with the locking features of the body.
[0018] FIG. 2 is a partial, enlarged view of a portion of a
container, including a view of a locking mechanism of the present
invention.
[0019] FIG. 3 is a perspective view of a container body.
[0020] FIG. 4 is a front elevation of a container body.
[0021] FIG. 5 is a side elevation of a container body.
[0022] FIG. 6 is a sectional view of a container body taken along
line 6-6 in FIG. 4.
[0023] FIG. 7 is a front perspective view of a container body.
[0024] FIG. 8 is a bottom perspective view of a container body.
[0025] FIG. 9 is a top perspective view of a container body.
[0026] FIG. 10 is a top plan view of a container body showing the
interior of the container.
[0027] FIG. 11 is a top plan view of a container cap.
[0028] FIG. 12 is a perspective view of an alternative embodiment
of a container cap including a tined spoon projecting from the
bottom surface of the cap.
[0029] FIG. 13 is a side elevation of the cap of FIG. 12.
[0030] FIG. 14 is an enlarged view of the locking mechanism shown
in FIG. 13.
[0031] FIG. 15 is a side elevation of the cap with the spoon
pointing upward and the top of the cap pointing downward.
[0032] FIG. 16 is a section of the cap of FIG. 15 taken in the
plane of line 16-16.
[0033] FIG. 17 is a perspective view of a cap with two barb and
stop assemblies located on the annular flange in diametrical
opposition to each other.
[0034] FIG. 18 is a diagram not drawn to scale illustrating the
function of the locking mechanism relative to the rotation and
sealing of the inner surface of a cap to the upper end of a
container body.
[0035] FIG. 19 is a diagram not drawn to scale illustrating the
function of the locking mechanism relative to the rotation and
sealing of the inner surface of a cap to the upper end of a
container body.
[0036] FIG. 20 is a diagram not drawn to scale illustrating the
effect of the locking mechanism of the present invention on
achieving and retaining an optimal cap and container seal.
[0037] FIG. 21 is a cross sectional cut-away view of a perforable
cap according to alternative embodiments of the invention.
[0038] FIG. 22 is a cross sectional cut-away view of a perforable
cap according to alternative embodiments of the invention including
a perforable area of decreased thickness.
[0039] FIG. 23 is a cross sectional diagram of a perforable cap
according to alternative embodiments of the invention showing a
sampling element about to pierce and perforate the perforable
wall.
[0040] FIG. 24 is a cross sectional diagram of the perforable cap
of FIG. 23 showing the perforable wall completely perforated by the
sampling element.
[0041] FIG. 25 is a cross sectional diagram of the perforable cap
of FIG. 23 showing the perforable wall substantially resealed after
withdrawal of the sampling element from the perforable wall.
[0042] FIG. 26 is a top perspective view of a perforable cap
according to alternative embodiments of the invention showing a
perforable area in phantom lines.
[0043] FIG. 27 is a top perspective view of an alternative
embodiment of a cap.
[0044] FIG. 28 is a bottom perspective view of an alternative
embodiment of a cap.
[0045] FIG. 29 is a cross sectional diagram of a cap showing a
perforable membrane disposed across the top surface of the cap to
seal a central aperture.
[0046] FIG. 30 is a cross sectional diagram of a cap showing a
perforable membrane disposed across a portion of the top surface of
the cap to seal a central aperture.
[0047] FIG. 31 is a cross sectional diagram of a cap showing a
perforable membrane disposed across a portion of the bottom surface
of the cap to seal a central aperture.
DETAILED DESCRIPTION
[0048] As required, a detailed embodiment of the present invention
is disclosed herein; however, it is to be understood that the
disclosed embodiment is merely exemplary of the invention, which
may be embodied in various forms. Therefore, specific structural
and functional details disclosed herein are not to be interpreted
as limiting, but merely as a basis for the claims and as a
representative basis for teaching one skilled in the art to
variously employ the present invention in virtually any
appropriately detailed structure.
[0049] Referring now to the drawings, FIGS. 1 and 2 illustrate a
container 100 including an embodiment of the container cap locking
mechanism 105. A container cap 110 is threadably attached to a vial
or other container body 115 by tightening the cap 110 onto the body
115 until the cooperating elements of the locking mechanism on the
cap 110 and on the body 115 align and lock together. The container
cap locking mechanism 105 also serves as a sealing alignment
indicator and may include the following features. The cap 110 is
threaded and includes an annular flange 120 having a downward
pointing barb 125 and adjacent downward pointing stop 130 both at
the lower edge of the flange 120. The container body 115 sidewall
includes an outwardly extending block 135 having a V-shaped notch
140 sized to receive the barb 125. As shown in FIGS. 1, 2, and
18-20, the barb 125 and notch 140 are substantially coplanar when
engaged with one another and both exhibit a V-shape when viewed at
a front elevation. Upon sufficient rotation of the threaded cap 110
onto the threads 142 of the container threaded neck 145, the barb
125 is received in the notch 140 and rotation is halted by the stop
130 abutting a side of the block 135, thus indicating that the cap
110 has achieved maximum desired rotation and is sealed against the
body 115.
[0050] FIG. 1 is a perspective view of a container cap 110 fully
screwed or threaded upon a container body 115 and showing the barb
125 and stop 130 of the cap 110 intermeshed or interlocked with the
block 135 projecting from the body 115. FIG. 2 is a partial,
enlarged view of a container 100 and associated container cap
locking mechanism 105. The barb 125 is more clearly shown held
within the V-notch 140 of the block 135 and the stop 130 is shown
abutting the right side of the block 135 as will occur when the
locking mechanism is configured for a cap 110 that is threaded
clockwise (as viewed looking down upon the top of the cap 110) onto
a container body 115. As shown in FIGS. 1, 2, 19 and 20, the barb
125 and notch 140 are shaped to have cooperating, complimentary,
mating surfaces so that when the barb 125 is seated within the
notch 140 such surfaces abut to hold the barb 125 at a fixed
position within the notch 140 indicating full and optimal closure
of the cap 110. As shown mostly clearly in FIGS. 2, 14 and 18-20,
the barb 125 includes forward and rear sides that taper and
converge to a point, thereby defining the substantial V-shape of
the barb 125. More particularly, barb forward side 125a tapers
downward and rearward to terminate at the lower margin thereof (and
of the barb 125 itself) at the point 125b. Barb rear side 125c
tapers downward and forward to also terminate at a lower margin
thereof at the point 125b. The notch 140 includes a notch forward
side 140a and a notch rear side 140c that are substantially
parallel to complimentary, adjacent sides of the barb 125 when the
barb is seated within the notch 140. The notch forward side 140a
tapers downward and rearward to the nadir 140b or lowest portion of
the notch 140. Notch rear side 140c tapers downward and forward to
meet notch forward side 140a at nadir 140b, which is defined by the
vertex of sides 140a and 140c. In use, as the cap 110 is tightened
upon the container body 115, the point 125b rides or slides across
the top margin 140d of the notch rear side 140c and then descends
into the notch 140 until the point 125b rests at the nadir 140b
(see FIGS. 18-20). When the point 125b is at the nadir 140b, the
barb forward side 125a lies against the notch forward side 14a, the
barb rear side 125c lies against the notch rear side 140c, and the
barb 125 is fully engaged with the notch 140. Concomitantly, the
stop 130 abuts the right rear edge 135a of the block 135 thereby
halting the barb 125 from further forward movement out of the notch
140.
[0051] FIGS. 3, 4 and 5 show perspective, front elevation, and side
elevation views of a container body 115, respectively. FIG. 6 shows
a cross sectional view of a container body 115 or vial having a
conical bottom surface 155. FIGS. 7 through 10 show various
additional views of a container body 115. FIG. 11 provides a view
of the top surface of a container cap 110. As shown most clearly in
FIGS. 5 and 9, a container body 115 may include two or more thread
starts 150A and 150B, typically no more than four. If preferred, a
block 135 may be provided at each thread start to allow for more
than one closure site.
[0052] A further embodiment of a container 100 may include an
alternative container cap 160 or closure having an integral
sampling member (probe, spoon, spork, spatula, etc.) 165.
Preferably, the spoon 165 has a plurality of tines 170 projecting
from the distal end of the spoon 165 to form a structure similar to
one commonly known as a spork (combination spoon and fork). The
threaded cap 160 includes an integral stem 175 extending from its
inner surface 180 and the spoon 165 is on the distal end of the
stem 175.
[0053] FIGS. 12, 13, 15 and 16 provide various views of the cap 160
including cap threads 185. FIG. 14 is an enlargement of a region
defined by circle A in FIG. 13. The embodiment shown in FIG. 14
includes an operable angle of approximately 69.degree. between the
surface 190 of the stop 130 that abuts the block 135 and the
proximate surface 195 of the barb 125. The surface 190 of the stop
130 is generally parallel to the longitudinal axis (see phantom
line B in FIG. 15) of the container and cap 160.
[0054] FIGS. 18 and 19 are diagrams not drawn to scale illustrating
the function of the locking mechanism 105 relative to the rotation
and sealing of the inner surface of a cap 110 to the upper end of a
container body 115. Phantom lines in FIGS. 18 and 19 represent
structures associated with a cap 110, and solid lines represent
structures associated with a container body 115. Phantom line 200
represents the inner surface of a cap 110 adapted to seal against
the upper end of a container 115. Solid line 205 represents the
surface of the upper end of a container body 115 adapted to seal
against the inner surface of a cap 110. Phantom line 210 represents
the inclined plane of a cap thread adapted to cooperatively and
threadably engage a container body thread. Solid line 215
represents the inclined plane of a container body thread adapted to
cooperatively and threadably engage a cap thread. Phantom line 220
represents the barb 125 and stop 130 of a cap 110 and moves in
conjunction with lines 200 and 210. Solid shape 225 represents a
block 135 attached to a container body 115 and moves in conjunction
with lines 205 and 215. As elements 200, 210 and 220 move leftward
in accord with cap rotation to tighten upon a container, elements
205, 215 and 225 may be moved rightward or may remain stationary,
the effect being that such elements move relative to each other in
the directions shown by arrows 230 and 235.
[0055] As illustrated through the comparison of FIGS. 18 and 19, as
the cap elements move leftward and thread 210 slides downward along
thread 215, the cap sealing surface 200 is drawn downward (in the
direction of arrow 237) against the container sealing surface 205.
Elements 200-225 are calibrated and constructed so that when
sealing surfaces 200 and 205 are drawn together optimally to form a
seal, barb 125 has moved leftward and downward sufficiently to
fully engage with notch 140 and stop 130 abuts the right, rear edge
of block 225. Block 225 therefore presents an impediment via its
engagement with barb 125 and stop 130 to further leftward movement
and tightening of the cap relative to the container body 115, and
optimal sealed engagement of the cap 110 to the container is
achieved and indicated visually via the disposition of barb 125
within notch 140.
[0056] FIG. 20 is a diagram not drawn to scale illustrating the
effect of the novel locking mechanism of the present invention on
achieving and retaining an optimal cap and container seal. Solid
line 250 represents the interface between cap and container sealing
surfaces when an optimal seal is achieved therebetween. Solid line
255 represents the relative degree of tightening between the cap
110 and container 115 with the space between lines 250 and 255
indicating the magnitude of the gap therebetween. Phantom line 260
intersects the point on line 255 where line 255 intersects line 250
indicating that optimal tightening of the cap 110 to the container
115 has been achieved and that this is concomitant with full
engagement of the barb 125 within the notch 140. Phantom line 265
indicates that if overtightening were to occur, as might be the
situation without the present locking mechanism 105 to prevent
overtightening, further tightening of the cap 110 upon the
container 115 may cause flexion of the cap 110 and/or container 115
structures thereby reducing the quality of the seal by creating or
increasing gaps between the cap and container sealing surfaces.
[0057] A method of using a locking mechanism 105 of the present
invention may include the steps of providing a threaded container
body 115 with an open upper end, and providing a cooperatively
threaded container cap 110 having a closed upper end and an open
bottom end. The cap 110 may have a forward rotative direction of
travel when rotated to tighten upon the container body 115 and a
rearward rotative direction of travel when rotated to loosen and
disengage from the container body 115.
[0058] The cap 110 further includes a pointed barb 125 projecting
downward from the bottom end and a stop 130 positioned proximate
to, and rearward of, the barb 125 and also projecting downward from
the bottom end. The container body 115 includes a block 135
projecting outward from the body 115. The block 135 includes a
notch 140 in an upper surface thereof, the notch 140 sized to
accept and retain the barb 125. Further steps include rotatively
engaging the cap 110 with the body 115 by turning the cap 110 in a
forward direction to engage cooperative threads on the cap 110 and
body 115 with one another, and continuing to turn the cap 110 in a
forward direction until the barb 125 is positioned within the notch
140 and the stop 130 is positioned against a rearward side of the
block 135, thereby halting rotation of the cap 110 relative to said
body 115. Turning the cap 110 until the barb 125 is positioned
within the notch 140 assures that the body 115 and the cap 110 are
in sealed engagement. Turning the cap 110 until the barb 125 is
positioned within the notch 140 also visually indicates that the
body 115 and the cap 110 are in sealed engagement.
[0059] Alternative embodiments of the invention include a
perforable container cap 300 which may include an annular, side
flange or wall 305 surrounding a cavity 310 closed at a top end by
a top, transverse, perforable wall 315 pierceable or perforable by
a relatively thin diameter elongated element such as a hollow
needle or other tubular sampling element 320 adapted for
transferring liquid from a container body 115 enclosed by the cap
300 to the sampling element 320. In preferred embodiments of the
invention, a sampling element 320 may be inserted through the
perforable wall 315 without the need to previously pierce the
perforable wall 315.
[0060] The perforable wall 315 may be of substantially uniform
thickness and composition or may include a needle receiving or
perforation area 325 (indicated by phantom lines in FIG. 26) that
is of reduced thickness (see e.g. cap 301 illustrated in FIG. 22)
relative to the remaining area of the wall 315 or is of a
composition particularly optimized for resealing after being
pierced or perforated. In preferred embodiments, no slits are
required in the perforable wall 315 to ease or accommodate
insertion of the sampling element 320. In such embodiments, the
perforable wall 315 comprises a relatively soft and resilient
plastic material, such as polyethylene or polypropylene, that may
be readily punctured by a sharp object if sufficient force is
applied to the object to drive it through the perforable wall 315,
and will yet substantially reseal around the puncture site or hole
330 once the object (e.g. sampling element 320) is withdrawn.
[0061] Appropriate cap materials include plastics such as high
density polyethylene (HDPE) and linear low density polyethylene
(LLDPE), including mixtures thereof. A perforable wall 315
comprising such materials tends to stretch around a sampling
element 320 when pierced by same and then substantially or
generally relaxes or returns to its original configuration or
disposition after the sampling element 320 is withdrawn so that the
puncture hole 330 substantially or generally reseals. In some
embodiments, the perforable wall 315 may comprise an elastomer
membrane comprising silicon, butyl rubber and/or a thermoplastic
elastomer (TPE). In some embodiments, the perforable wall 315 may
include two or more layers of perforable material comprising two or
more of the following materials: TPE, polyethylene, urethane,
silicon or butyl rubber. In some embodiments, the perforable wall
315 comprises a primary layer of polyethylene and also a secondary
layer of TPE, urethane, silicon or butyl rubber, one layer disposed
over the other so that the layers are pierced concurrently or
consecutively by a sampling element 320.
[0062] When creating an embodiment of the perforable wall 315 of
the cap 300, factors that may be considered or optimized, as they
may affect resistance of the cap 300 to perforation which may,
therefore, affect the selection of material used to form the cap
300 or perforation area 325, include:
[0063] a. the diameter of the needle or other sampling element 320
to be used to pierce or perforate the cap 300;
[0064] b. whether the sampling element 320 is provided with a
sharpened tip 335 to facilitate piercing the cap 300;
[0065] c. the softness, elasticity or malleability of the material
(e.g. plastic) used to form the cap 300 or perforation area
325;
[0066] d. the thickness of the perforation wall 315 (increased
thickness may to tend to increase resistance of the wall 315 to
puncture or perforation but may also enhance the ability of the
wall 315 to reseal around the puncture hole 330); and e. the
perforation wall 315 diameter.
[0067] It should be appreciated that other factors may be
considered both when selecting sampling elements 320 and cap 300
dimensions, construction and materials. It may be advantageous for
certain embodiments of a cap 300 to be optimized for suitable use
with sampling elements 320 such as autosampler needles.
[0068] Certain embodiments of a perforable container cap 301
comprise a main cap body 340 manufactured to include a central
aperture 345 (see FIGS. 27-31) in the top wall or surface 181 of
the cap 301. The central aperture 345 is created either during
molding of the cap, as a feature of the cap 301 incorporated into
the mold, or is die cut or otherwise created after molding of the
cap 301 as a secondary operation. The central aperture 345 is
covered and sealed using a thin, piercable membrane 350.
[0069] The membrane 350 may be integrated into the structure of the
cap 301 via a process generally referred to in the art as in-mold
labeling. The process includes inserting a label, or other thin,
relatively planar item, into an empty mold prior to injection of
the molding resin so that the label is adhered to the molded item
as it is formed. In correspondence with the present invention, a
thermoplastic resin (see examples above) is selected to comprise
the cap 301. Prior to injection of the resin into a cap mold (not
shown), a membrane 350 is inserted into the mold and appropriately
positioned to cover the aperture 345. The cap 301 with integral
membrane 350 is then created by injecting melted resin into the
mold so that the membrane 350 is integrated into the cap 301
structure and disposed across the aperture 345. If the selected
membrane 350 material and cap 301 material comprise similar
materials, i.e. both are substantially thermoplastics, the membrane
350 and cap 301 typically melt into one another (plastic weld),
where adjoined, thereby substantially forming a single integrated
cap 301 structure.
[0070] In certain other embodiments of a cap 301, after the main
body 340 (including aperture 345) is formed a thin membrane 350 is
disposed across and to seal the aperture 345 and then is heated and
melted to adhere, fuse or weld to the main body 340. As shown in
FIGS. 27, 28 and 31, the membrane 350 may be positioned across the
inner, lower surface 180 of the cap 301 proximate the aperture 345
or may be positioned across the outer, top surface 181 of the cap
301 (either partially or completely) as shown in FIGS. 29 and
30.
[0071] In order for users to readily distinguish between perforable
and non-perforable caps, the perforable caps 300 of an embodiment
of the present invention may typically comprise a plastic material
provided with a distinctive and distinguishing color. Colorant or
colored material selected for this purpose should be chemically
stable under anticipated operating conditions to avoid leaching and
contamination of samples and to avoid degradation of the cap 300
itself. In general, material used to construct a cap 300 should be
selected for resistance to common laboratory solvents and sample
reagents.
[0072] Materials used to form a cap (300 or 301) may include
formulations comprising HDPE, LLDPE, a colorant and slip. Slip
comprises a material known in the art to reduce friction in
threaded caps. An exemplary formulation for the cap body 340
includes 95% HDPE, 3% slip and 2% colorant. LLDPE can be
substituted for a portion of the HDPE at a 1:1 ratio. Exemplary
formulations for cap 300 having a perforable wall 315 (i.e. without
separate membrane) include:
Example 1
[0073] HDPE 47.5%-85%
[0074] LLDPE 47.5%-10%
[0075] Slip 3%-3%
[0076] Color 2%-2%
Example 2
[0077] HDPE 65%-85%
[0078] LLDPE 30%-10%
[0079] Slip 3%
[0080] Color 2%
[0081] Color may be provided by selecting from various plastic
colorants used in the art to color thermoplastics, including
various oxides. Slip agents known in the art may be used, such as
amides. If colorant or slip are not used, they should be made up
with or replaced by corresponding amounts of HDPE or LLDPE.
[0082] It is to be understood that while certain forms of this
invention have been illustrated and described, it is not limited
thereto except insofar as such limitations are included in the
following claims and allowable equivalents thereof.
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