(12) United States Patent
`Thibault et al.
`
`USOO6382442B1
`(10) Patent No.:
`US 6,382,442 B1
`(45) Date of Patent:
`May 7, 2002
`
`(54) PLASTIC CLOSURE FOR VIALS AND
`OTHER MEDICAL CONTAINERS
`(75) I
`Jean-Claude Thibault, Saint E
`nVentOS: ean-Claude
`ibault, Saint Egreve;
`Hubert Jansen, Poisat, both of (FR);
`Volker Niermann, Little Falls, NJ (US)
`(73) Assignee: Becton Dickinson and Company,
`Franklin Lakes, NJ (US)
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`- - -
`c:
`(*) Notice:
`
`(21) Appl. No.: 09/168,502
`(22) Filed:
`Oct. 8, 1998
`Related U.S. Application Data
`(60) Provisional application No. 60/082,382, filed on Apr. 20,
`1998.
`7
`(51) Int. Cl. ......................... B65D 39/00; B65D 41/10;
`B65D 41/28
`(52) U.S. Cl. ....................... 215/249; 215/247; 215/251;
`215/274; 215/324; 215/325; 215/DIG. 3;
`604/411; 604/415
`(58) Field of Search ................................. 215/247, 249,
`215/251, 274, 317,321, 320, 324, 325,
`327, DIG. 3, 248, 253,297, 250, 252, 295,
`296; 222/81, 83, 83.5; 141/2, 25, 26, 27,
`28, 329, 330, 18, 21; 604/403, 406, 411-416;
`220/265-268, 278
`
`(56)
`
`EP
`E.
`EP
`
`References Cited
`U.S. PATENT DOCUMENTS
`37,221. A 12/1862 Dunton
`(List continued on next page.)
`FOREIGN PATENT DOCUMENTS
`
`3/1987
`O 236 127 A2
`s i 3. R g
`O 769 456 A2 10/1996
`
`
`
`CCC.
`
`EP
`WO
`
`0 747 293 A1 12/1996
`WO 84/04673
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`(List continued on next page.)
`OTHER PUBLICATIONS
`EPatent No. 2.738.550, Sep. 9, 1995–translation
`(List continued on next page.)
`Primary Examiner Stephen P. Garbe
`Assistant Examiner Niki M. Eloshway
`(74) Attorney, Agent, or Firm-Allen W. Mark, Esq.
`(57)
`ABSTRACT
`The plastic closure of this invention is particularly, but not
`exclusively adapted for Sealing medicament Vials and other
`medical containers or as a collar for retaining a fluid
`transferSet on a medical container. The plastic re of this
`invention includes a generally tubular portion which Sur
`rounds the rim of the container and a free end portion which
`is permanently radially deformed or crimped into the neck of
`the container. The plastic closure of this invention is formed
`of a polymer, preferably polymeric alloy or melt blend,
`which is sufficiently malleable to permit radial deformation,
`yet Sufficiently rigid to retain its shape following deforma
`tion and Sufficiently resistant to creep to maintain the Seal
`between the plastic closure and the container following
`deformation. A preferred polymer for the plastic closure of
`this invention is an alloy or melt blend comprising a rela
`tively rigid polymer Such as polycarbonate and a Soft
`malleable co-polymer Such as a polyester. Where the plastic
`closure of this invention is used to Seal a Vial, for example,
`the closure includes a radial portion overlying the rim
`portion of the Stopper having a central opening and a
`cup-shaped cap is received over the collar having retainer
`portions received within the central opening of the cap
`which may be removed by finger pressure. When the collar
`of this invention is used to Secure a fluid transferSet on a vial,
`the collar includes a proximate tubular portion integral with
`the radial portion which Surrounds at least a portion of the
`transferSet. In one embodiment, the Second tubular portion
`Surrounds the entire transferSet and the open end is Sealed
`with a peel-off Seal and in another embodiment a Separate
`cap Surrounds the distal end of the transferSet.
`21 Claims, 5 Drawing Sheets
`
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`US 6,382,442 B1
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`
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`
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`US 6,382,442 B1
`Page 3
`
`5,598.939 A 2/1997 Watson et al.
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`
`FOREIGN PATENT DOCUMENTS
`
`WO
`WO
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`WO
`WO
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`WO
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`WO
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`WO
`WO
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`
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`WO95/14176
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`WO95/35.125
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`WO 97/00702
`WO 97/10156
`WO 97/397.20
`97.3972O
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`
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`* 10/1997
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`
`OTHER PUBLICATIONS
`French Patent No. 2.395.198, Jan. 19, 1979.
`French Patent No. 950.625, Jul. 28, 1947.
`French Patent No. 1.071.487, Feb. 26, 1953.
`French Patent No. 1.328.635, Jul. 4, 1962.
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`UK Patent Application No. 2 121016 A, Jun. 1, 1983.
`* cited by examiner
`
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`

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`U.S. Patent
`
`May 7, 2002
`
`Sheet 1 of 5
`
`US 6,382,442 B1
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`
`
`46
`
`24
`
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`
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`
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`
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`
`Eton Ex. 1067
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`U.S. Patent
`
`May 7, 2002
`
`Sheet 2 of 5
`
`US 6,382,442 B1
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`
`
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`
`Eton Ex. 1067
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`U.S. Patent
`U.S. Patent
`
`May7, 2002
`
`Sheet 3 of 5
`
`US 6,382,442 B1
`US 6,382,442 BI
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`Eton Ex. 1067
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`Eton Ex. 1067
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`U.S. Patent
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`May 7, 2002
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`Sheet 4 of 5
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`US 6,382,442 B1
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`Eton Ex. 1067
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`U.S. Patent
`
`May 7, 2002
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`Sheet 5 of 5
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`US 6,382,442 B1
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`1
`PLASTIC CLOSURE FOR VIALS AND
`OTHER MEDICAL CONTAINERS
`
`This application claims benefit of U.S. application Ser.
`No. 60/082,382, filed Apr. 20, 1998.
`FIELD OF THE INVENTION
`This invention relates to an improved plastic closure Such
`as a cap or collar for closing or Sealing containerS Such as
`Vials containing a medicament which eliminates the prob
`lems associated with a malleable metal cap or collar Such as
`aluminum. The plastic closure of this invention may be used
`as a cap to Seal a conventional vial having an elastomeric
`Stopper or as a collar for retaining a fluid transferSet Separate
`from or integral with the collar.
`BACKGROUND OF THE INVENTION
`It is conventional to Store medicament Such as drugs in a
`Sealed vial or other container for later use. Such medica
`ments may be in a dry or powdered form to increase the shelf
`life of the drugs and reduce inventory Space. Such dry or
`powdered drugs are generally Stored in a Sealed Vial and
`reconstituted in liquid form for administration to a patient by
`adding a diluent or Solvent. Alternatively, the drug may be
`in liquid or even gaseous form. A conventional vial for
`Storing medicament generally includes an open end, a radial
`rim portion Surrounding the open end and a reduced diam
`eter neck portion adjacent the rim portion. The Vial is
`conventionally Sealed with an elastomeric Stopper which
`generally includes a tubular portion inserted into the neck of
`the Vial and a planar rim portion which Overlies the Vial rim.
`The stopper is normally secured to the vial with a thin
`malleable metal cap, Such as aluminum. The aluminum cap
`includes a tubular portion which Surrounds the rim portions
`of the Stopper and Vial, an inwardly projecting annular
`portion which overlies the rim portion of the Stopper and a
`distal end portion which is crimped or deformed radially into
`the vial neck beneath the Vial rim portion. Because alumi
`num is malleable, the collar accommodates the buildup of
`tolerances of the dimensions of the Stopper and vial rim. The
`dimensions and tolerances of Standard Vials and StopperS are
`set by the International Standards Organization (ISO).
`The radial portion of the aluminum cap which overlies the
`Stopper rim portion may be closed, in which case the
`aluminum cap is removed by "peeling the aluminum cap
`from the vial. A pre-slit tab located in the middle area is
`provided which overlies the Vial rim, permitting the cap to
`be torn from the top and peeled from the Vial prior to use.
`This closed embodiment of an aluminum cap has Several
`disadvantages. First, the tearing of the metal cap creates
`Sharp edges which may cut or damage Sterile gloves and cut
`the perSon administering the drug, thereby exposing both the
`healthcare worker and the patient to disease and contami
`nation of the drug. Second, the tearing of the aluminum cap
`generates metal particles which may also contaminate the
`drug. The dangers associated with the tearing of an alumi
`num cap has been Solved in part by adding a “flip-off plastic
`cap. In one Such embodiment, the aluminum collar includes
`a central opening and a shallow plastic cup-shaped cap is
`received over the aluminum collar having a central project
`ing riveting portion which is received and Secured in the
`central opening of the aluminum collar. The plastic cap is
`then removed by forcing the flip-off cap away from the
`aluminum collar, which tears an annular Serrated portion
`Surrounding the central opening and exposes an opening in
`the collar for receipt of a hypodermic needle or the like. This
`
`5
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`15
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`25
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`35
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`45
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`50
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`55
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`US 6,382,442 B1
`
`2
`embodiment reduces but does not eliminate the possibility of
`tearing the Sterile gloves of the healthcare worker. More
`importantly, however, aluminum dust is still created which
`may contaminate the medicament. It is also important to
`note that metallic dust is also created Simply by forming and
`affixing the aluminum collar to the vial because aluminum
`dust is created in forming the aluminum collar, crimping of
`the collar and removal of the flip-off plastic cap.
`Aluminum collars have also been used to Secure a fluid
`transferSet on medicament vials. TransferSets may be
`utilized, for example, to transfer fluid from a Syringe to a
`Vial, Such as to reconstitute a dry or powdered drug in a vial
`by adding a diluent or Solvent. The reconstituted drug may
`then be withdrawn from the vial by the syringe. The inner
`Surface of the transferSet may be part of the drug fluid path
`and the aluminum collar or ring may bring aluminum
`particles in the Sterile room where the drug is added to the
`Vial or into the drug fluid path contaminating the drug. There
`have been attempts to reduce this problem by applying a
`coating to the aluminum cap or collar. Finally, the prior art
`also includes Snap-on cup-shaped plastic caps or collars
`having a radially inwardly projecting end portion which is
`Snapped over the rim portion of the Vial. Snap-on plastic
`collars, however, do not assure adequate Sealing of the Vial
`or fully accommodate the tolerances of Standard Vials and
`StopperS as required.
`The need therefore remains for a closure for vials and
`other medical containers which may be utilized with con
`ventional containers, Such as medicament Vials or cartridges,
`which assures Sealing of the container and which achieves a
`good level of cleanliness, without metal particles or dust
`which may contaminate the medicament, the transferSet or
`the clean room and which does not expose the healthcare
`worker to Sharp metal edgeS. The plastic closure of this
`invention Solves these problems and permits the use of the
`plastic closure of this invention for attaching and Sealing
`containers and fluid transferSets as described below.
`
`SUMMARY OF THE INVENTION
`AS Set forth above, the plastic closure for Sealing a vial or
`other medical container of this invention eliminates the
`problems associated with a malleable metal or aluminum
`cap or collar, but which accommodates the buildup of
`tolerances of the rim portion of the container and the
`elastomeric Stopper, when used. The plastic closure of this
`invention is relatively inexpensive to manufacture and use.
`The plastic closure of this invention may be utilized as a cap
`to Seal a conventional medicament Vial, as a collar in
`combination with a flip-off cap or as a collar used to Secure
`and Seal a transferSet on a vial for transferring fluid between
`a vial or other container and a Second container. AS used
`herein, the term closure is generic to either a cap or collar.
`AS Stated, the plastic closure for Sealing a container of this
`invention may be utilized with a conventional vial having an
`open end and a reduced diameter neck portion adjacent the
`open end. The plastic closure of this invention includes a
`generally tubular portion and a portion which is deformed
`radially or crimped into the reduced diameter portion of the
`container to retain the closure on the container and as a cap
`to Seal the open end of the container. The plastic closure of
`this invention may also be used as a cap or collar with a
`conventional vial and elastomeric Stopper In the preferred
`embodiment, the plastic closure of this invention is formed
`of a polymer which is sufficiently malleable to permit radial
`deformation, yet Sufficiently rigid to retain its shape follow
`ing deformation and Sufficiently resistant to creep to main
`
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`15
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`35
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`3
`tain the Seal between the plastic cap and the container
`following radial deformation.
`The preferred embodiment of the plastic closure of this
`invention is formed of a polymer alloy or melt blend which
`includes a relatively tough Soft malleable copolymer and a
`relatively rigid polymer. In the most preferred embodiment
`of the plastic closure of this invention, the composite poly
`mer is a polymer alloy of a relatively Soft malleable
`co-polymer and a relatively rigid polymer. The preferred
`relatively rigid polymer is a polyamid or a polycarbonate
`and the preferred relatively Soft co-polymer may be Selected
`from polyesters or polyolefins. The resultant polymer alloy
`or composite preferably has an elongation at yield between
`5% and 10% and an elongation at break greater than 100%
`with a flectural modulus of greater than 1900 MPa.
`Where the container includes a radial rim portion adjacent
`the open end, the plastic closure of this invention includes a
`generally cylindrical tubular portion preferably having an
`internal diameter generally equal to or slightly greater than
`the external diameter of the rim portion of the container
`adapted to be received over the rim portion of the container
`having a free distal end adapted to be deformed radially
`inwardly or crimped beneath the rim portion of the container
`and Sealed relation. The plastic cap or collar of this invention
`may also include a radially inwardly projecting proximate
`portion which overlies the rim portion of the container
`and/or the Stopper. This radial portion may be closed or more
`preferably includes a central opening which may be closed
`with a flip-off or peel-off type plastic closure or Seal. In the
`preferred embodiment, the peel-off Seal includes a looped
`end portion which is welded or glued to the tubular portion
`Surrounding the transferSet providing indication of tamper
`ing and a free end which may be gripped to remove the Seal.
`Where the plastic collar of this invention is utilized to
`Secure a transferSet for transferring fluid from the container
`to a Second container, the preferred embodiment of the collar
`includes a Second tubular portion which at least partially
`Surrounds the internal components of the transferSet. In one
`preferred embodiment, the Second tubular portion com
`pletely Surrounds the internal components of the transferSet,
`40
`which may have a closed end integral with the Second
`tubular portion or closed with a Sealing member. In the most
`preferred embodiment, the collar portion is integral with the
`tubular portion Surrounding the transferSet and the tubular
`fluid transfer portion Such that the major components of the
`transferSet may be molded in one piece. In another
`embodiment, the transferSet includes a cup-shaped cap
`which is received over the second tubular portion of the
`collar. In the preferred embodiments of the plastic collar of
`this invention which Secures or is integral with a transferSet
`attached to the container, the internal Surface of the tubular
`portion which Surrounds the rim of the container includes an
`annular resilient ring which is biased against the rim portion
`of the container to prevent rotation of the collar and trans
`ferset on the vial. In one preferred embodiment, the internal
`Surface of this tubular portion includes an annular groove
`adjacent the free end of the tubular portion and the annular
`resilient ring is received and retained in the annular groove.
`The preferred embodiment of the plastic closure of this
`invention may also be formed of a relatively clear polymer
`or polymer alloy which maintains its clarity under the StreSS
`of deformation which is particularly advantageous where the
`plastic closure of this invention is utilized as a collar to
`Secure and Seal a transferSet on the container.
`The method of this invention then includes forming a
`plastic closure having a generally cylindrical tubular portion
`having an internal diameter generally equal to or slightly
`
`50
`
`55
`
`60
`
`65
`
`4
`greater than an outside diameter of the rim portion of the
`container and an integral radial rim portion, disposing the
`closure over the rim of the container with the radial rim
`portion overlying the rim portion of the vial and the tubular
`portion Surrounding the container rim, and then radially
`permanently deforming or crimping the free end of the
`tubular portion of the collar into the neck portion of the
`container, beneath the rim portion, permanently Securing the
`closure on the container and Sealing the container open end.
`In the most preferred embodiment of the method of this
`invention, the plastic closure of this invention is formed by
`injection molding the plastic closure from a polymeric alloy
`or composite having a relatively Soft malleable polymer or
`co-polymer and a relatively rigid polymer, wherein a poly
`meric alloy or composite is formed during the injection
`molding. Where a resilient or polymeric ring is utilized to
`prevent rotation of the closure on the container, the ring may
`be co-injected with the polymer forming the closure or an
`annular groove may be formed in the tubular portion of the
`closure, adjacent the free end. The method then includes
`inserting the annular resilient ring in the groove prior to
`radial permanent deformation of the free end of the closure
`as described, Such that the resilient ring is biased against the
`rim portion of the container. A thermoplastic elastomer may
`also be co-injected with the polymer forming the closure to
`form a coating or film on the inside Surface of the closure
`which is integrally bonded to the polymer of the cap.
`The plastic closure of this invention may be utilized with
`a vial or other medical container having a conventional
`elastomeric Stopper or as a collar in combination with a
`transferSet having a Sealing member as disclosed in the prior
`art or more preferably the collar portion may be formed
`integral with components of the transferSet. Where the
`plastic closure of this invention is used to Seal a container
`having an elastomeric Stopper, the proximate radial lip of the
`closure is received over and preferably biased against the
`resilient radial lip of the Stopper during radial deformation or
`crimping of the free of the tubular portion of the closure
`beneath the rim of the container. The plastic closure of this
`invention thus eliminates the problems associated with mal
`leable metal collars or caps, Such as aluminum, and is
`relatively inexpensive, and Simple to manufacture, particu
`larly when compared with aluminum caps having a protec
`tive coating. The plastic closure of this invention assures an
`excellent Seal of the container and can be injection molded
`in a clean environment or washed, if necessary. Finally, the
`plastic closure of this invention accommodates the toler
`ances of the Vial and particularly the buildup of tolerance
`variations in the combination of a conventional vial and
`elastomeric Stopper. Other advantages and meritorious fea
`tures of the present invention will be more fully understood
`from the following description of the preferred
`embodiments, the appended claims and the drawings, a brief
`description of which follows.
`BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. 1 is a side cross-sectional view of one preferred
`embodiment of the plastic closure of this invention Secured
`to and Sealing a conventional vial having an elastomeric
`Stopper,
`FIG. 2 is an exploded side cross-sectional view of the
`open end of a conventional Vial, elastomeric Stopper and the
`plastic closure shown in FIG. 1 prior to radial deformation
`of the free end of the closure;
`FIG. 3 is a side partially cross-sectioned view of the
`assembly shown in FIG. 1 illustrating radial deformation or
`crimping of the closure,
`
`Eton Ex. 1067
`10 of 16
`
`

`

`US 6,382,442 B1
`
`S
`FIG. 4 is a partial side view of an alternative embodiment
`of the plastic closure of this invention assembled on a vial
`or other container;
`FIG. 5 is a top cross-sectional view of FIG. 4 in the
`direction of view-arrows 5-5,
`FIG. 6 is a side view of a vial and transferset assembly
`having the plastic collar of this invention;
`FIG. 7 is a partial side cross-sectional view of an alter
`native embodiment of the vial and transferset assembly;
`FIG. 8 is a partial side cross-sectional view of the vial,
`collar and transferset assembly similar to FIG. 7 of an
`alternative embodiment of this invention;
`FIG. 9 is a partial side cross-sectional view of a vial,
`Stopper and transferSet assembly of this invention;
`FIG. 10 is a partial side cross-sectional view illustrating
`a further alternative embodiment of the vial and transferset
`assembly of this invention;
`FIG. 11 is a side cross-sectional view of an embodiment
`of a collar and transferset assembly similar to FIG. 9 which
`has been Simplified to reduce costs, and
`FIG. 12 is top perspective view of the transferset shown
`in FIG. 11 illustrating a preferred embodiment of the peel-off
`Seal.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENTS
`FIGS. 1 to 3 illustrate one preferred embodiment of the
`Vial, Stopper and cap assembly 20 of this invention. AS Set
`forth above, the closure of this invention may be utilized to
`Seal various containers and is particularly useful for Sealing
`medicament containerS Such as the conventional vial 22
`illustrated in FIGS. 1 to 3. The vial includes an open end 24,
`an annular radially extending rim portion 26 and a neck
`portion 28 adjacent the rim portion. As best shown in FIGS.
`9 and 10, the neck portion 28 of the vial has a reduced
`diameter when compared to the rim portion 26 and the
`container portion 30. The internal surface 31 of the vial
`adjacent the open end 24 is generally cylindrical. Medica
`ment vials of this type are generally formed of glass or a
`sterilizable plastic. The open end 24 of the vial is typically
`closed with an elastomeric Stopper 32 having a tubular body
`portion 34 which is received in the open end 24 of the vial
`and a planar rim portion 36 which overlies the rim portion
`26 of the vial as shown in FIG. 1. The stopper is generally
`formed of a resilient elastomeric material Such as Synthetic
`or natural rubber. The central portion 38 of the planar rim
`portion 36 may be pierced with a hypodermic needle, for
`example, to either withdraw fluid from the vial or add a
`Solvent or diluent to the vial where the medicament in the
`vial is a dry or powder drug. The tubular portion 34 of the
`Stopper has an external diameter generally greater than the
`internal diameter of the internal cylindrical Surface 31 of the
`Vial to provide a tight or interference fit.
`One preferred embodiment of the closure 40 is shown in
`FIG. 1 attached to a vial 22 and stopper 32 assembly, prior
`to assembly in FIG. 2 and during assembly in FIG. 3. This
`embodiment of the collar 40 includes a tubular portion 42
`which surrounds the rim portion 26 of the vial and the planar
`rim portion 36 of the stopper. Where the external surface of
`the rim portion 26 of the vial is cylindrical, the tubular
`portion 42 of the collar will generally also be cylindrical. As
`shown in FIG. 1, the free end 44 of the tubular portion 42 is
`deformed inwardly or crimped beneath the adjacent Surface
`of the rim portion 26 of the Vial, permanently Securing the
`collar 40 on the vial and sealing the vial. This embodiment
`
`6
`of the collar 40 also includes an integral radial proximate
`portion 46 which overlies the rim portions 26 and 36 of the
`Vial and stopper, respectively. The radial portion 46 is
`preferably integral with the tubular portion 42 of the collar.
`This embodiment of die collar 40 also includes a central
`opening 48 which overlies the central portion 38 of the
`Stopper, preferably coaxially aligned with the central portion
`of the stopper AS described below, however, the central
`opening 48 may be eliminated in certain applications of this
`invention. AS used herein, the terms proximate and distal are
`used Solely for ease of description, wherein the term proxi
`mate refers to elements or portions of elements closest to the
`rim portion 36 of the stopper and distal refers to elements or
`portions of elements more remote from the rim portion of the
`Stopper. Further, the terms cap and collar are Sometimes used
`herein interchangeably. The term cap, however, generally
`refers to a closure having a radial portion which overlies the
`container opening and collar is used to refer to a closure used
`to Secure an element, Such as a transferSet, to the container.
`In this disclosed embodiment, the collar 40 includes a
`shallow cup-shaped cap 50. In the disclosed embodiment,
`the cap 50 includes a tubular portion 52 which surrounds the
`proximate portion of the tubular portion 42 of the collar, an
`integral central radial bridging portion 54 and a plurality of
`U-shaped tabs which, in the disclosed embodiment, are
`integral with the central bridging portion 54. The U-shaped
`tabs 56 are received through the central opening 48 of the
`collar and Snap in place to Securely retain the cap 50 on the
`collar 40. As shown in FIG. 2, the cap 50 may be preas
`sembled on the collar 40 prior to assembly of the collar on
`the vial. The tabs 56 may also be separate members or the
`central portion of the cap 50 including the tabs 56 may be a
`Separate member.
`The collar 40 is then assembled on the vial 22 as shown
`in FIG. 2. In a typical application, the tubular portion 34 of
`the Stopper is first inserted into the opening 24 of the vial 22
`generally after the vial is filled. As set forth above, the
`plastic collar 40 of this invention may be used with various
`containers including conventional medicament Vials as
`shown. Thus, in a typical application, the Vial 22 will first be
`filled with a medicament. The tubular portion 42 of the collar
`40 is then received over the rim portion 36 of the stopper and
`the rim portio