Abstract:
The present invention relates to packaging for storing and/or transporting and/or holding, in a suspended vertical position, articles equipped with flanges, said packaging comprising a plate, said plate comprising a plurality of rails positioned next to one another. Supporting lips are arranged along rails, a lip and a rail thus forming with a lip of an adjacent rail and this rail a groove. A pair of adjacent lips are capable of supporting and sorting said articles. The plate also comprises an upper wall parallel to the plurality of openings for preventing said articles from coming out of said plate when the latter pivots about a horizontal axis. The rails and the lips are free of bumps, thus enabling the articles to slide along the rails. The packaging of the invention may also comprise a box for holding the plate and a collar for surrounding the plate.

Description:
SUBJECT OF THE INVENTION 
       [0001]    The present invention relates to a device for storing, transporting and protecting medical product containers. The invention relates, more particularly, to a device connected with the storage, protection and transport of syringes or any other product provided with flanges or collars which are stored suspended in a vertical position. 
       TECHNOLOGICAL BACKGROUND 
       [0002]    Currently, medical product containers, such as glass syringes, are packed by manufacturers in a nest form and delivered in sterile conditions. Delivering syringes in a nest format means delivering syringes which have been packed on a plastic plate principally comprising a support plate, called “nest plate” hereinafter, which is formed from a matrix of openings, each of these openings holding a syringe. This nest plate is typically supported in a plastic box, called “nest box” hereinafter, which protects the syringes (see for example the product HYPAK® SCF®, Becton, Dickinson and Company of Franklin Lakes, N.J., USA). This packaging is, moreover, covered with a plastic film and is then ready for sterilization. 
         [0003]    When the syringes are delivered to a pharmaceutical company in the nest format, they must be handled in order to be filled individually. After removing the plastic film from each packaging using automated equipment, each nest plate is withdrawn from its corresponding nest box and the syringes are then filled individually. After the filling step, it is necessary on the one hand to label each syringe with the aim of defining the medical product contained, and on the other hand to inspect the syringes in order to detect any contamination of the product and any cracks or scratches in the syringes. Further operations may be required, for example the addition of needle protectors or stoppers. Inspection is conventionally carried out by means of a system of optical sensors (or a camera) which inspect the syringes individually. However, in line with usual practice and due to technical limitations (number of syringes, difficulties with labeling and/or with inspecting the syringes placed in the central part of the nest plate, etc.), the syringes are first removed from the nest plate before being labeled and/or checked. Thus, when the syringes are finally labeled and/or checked, they are then handled again and stored either directly in the nest box without being stored on the nest plate, or in a different support, called a comb plate hereinafter (see the document U.S. Pat. No. 6,012,595 described hereinafter), the latter having a large number of elongate fingers to keep the syringes suspended by their collars. It should be noted that after labeling and/or inspection, the syringes are no longer reinserted into the nest plate because it is more efficient and easier to store them in the comb plate which is bought separately. Packaging of the nest type, such as the product HYPAK® SCF®, is thus not suitable for automated handling since it requires complex machines. In addition, in the context of semi-automatic handling (with human assistance), it is difficult to exceed speeds of more than 6000 syringes per hour. However, while comb plates are preferred to nest plates for storing the syringes more rapidly and more easily, they are not suitable for transporting and storing syringes. This is because, when the comb plates are stored one on the other in vertical columns, some parts of the syringes risk being damaged or broken due to their direct contact with the bottom of the packaging put over them. In order to prevent this problem, the comb plates must be placed in specific additional boxes and provided with lids having an inner blocking rim. 
         [0004]    It is clear that there is a need for a plate capable of overcoming the limitations and drawbacks of current supports and of enabling storage, transport and delivery of the medical containers to be carried out more easily and rapidly. In particular, there is a need for a plate which enables syringes suspended in a vertical position to be supported more easily and safely, which makes the handling of large numbers of syringes during the sterilization, filling, labeling and inspection processes, which are carried out by highly automated machines, more efficient and simple. 
       PRIOR ART 
       [0005]    The document US 2001/0052476 A1 discloses a device for transporting medical containers comprising a rigid plastic plate having a large number of openings for taking and supporting containers such as syringes or ampoules. However, this device has the following drawbacks. This plate is not compatible with an automated machine because the introduction of the containers into or the withdrawal thereof from such a support requires time. In addition, when a container, such as a syringe, is stored in one of the openings in this plate, the friction between this opening and the needle-protecting stopper of the syringe may cause damage to the needle of the syringe or compromise the sterility of the containers or of the medical products they contain. 
         [0006]    A system for storing syringes is also known from the document U.S. Pat. No. 6,012,595. This storage system comprises a box and a plate made of an assembly of elongate fingers connected to a common spine. These fingers frame a number of parallel channels which support the syringes by their collars. However, this storage system is not capable of supporting the syringes when the plate is withdrawn from the box and turned vertically upside down. Moreover, this plate requires a specific box having a lid provided with an inner blocking rim in order to fasten said plate, since the channels are not rigid enough and can easily be deformed, this possibly leading to the syringes falling and being damaged. Moreover, the plate mentioned in the document U.S. Pat. No. 6,012,595 is manufactured by a molding process, which is a long and expensive process. Also, this storage system is not suitable for high-speed automatic handling because it requires the use of a complex automatic machine capable of handling this specific box and this particular plate. Finally, this storage system needs a particular type of plate for a given type of syringe (i.e. a syringe having a given diameter or a syringe having a given type of collar), with the aim of protecting the syringes from falling and being damaged. The consequence of this is that, in order to be compatible with the four types of syringe most commonly used, it is necessary to manufacture four different types of storage system. 
         [0007]    A device for handling identical articles (syringes, inter alia) in a suspended position is also known from the document EP 1088566 B1. This device is an improvement of the device described in the document U.S. Pat. No. 6,012,595. The improvement consists in the addition of a lid hinged to the body of the box, which can easily be closed or opened and which is provided with openings for enabling the medical containers to be moved around easily. However, owing to the complexity of the hinged lid, automatic handling of such a device with the aim of removing the syringes from their packaging takes time and is difficult to carry out. It should finally be noted that this device is manufactured by means of long and complex manufacturing process. 
         [0008]    The aim of the present invention is to provide a device for storing, protecting and transporting sterilized articles or articles to be sterilized, which does not have any of the disadvantages of the prior art. In particular, the aim of the invention is to provide a device for storing, protecting and transporting a large number of medical containers securely, and enabling them to be arranged one above the other. Another aim of the present invention is to provide a device for supporting the containers in a vertical suspended and inverted position. Yet another aim of the present invention is to provide a device which can be easily handled by automated means with the aim of removing the containers from said devices rapidly and securely. Finally, another aim of the present invention is to provide a device which is compatible with syringes independently of their length, type of collar and diameter, for example accepting both syringes having a diameter of 6.85 mm and those having a diameter of 8.15 mm or syringes having flanges of different forms. 
         [0009]    Nowadays, packagings for liquid medical product containers are typically provided in the form of a block of 1200×1000 mm, forming a pallet (EuroPallet format), in accordance with the standard UIC 435-2. This means that several container packagings are arranged next to one another and one above the other. Thus, another aim of the present invention is to provide a device for storing, protecting and transporting medical containers, which enables them to be arranged next to one another and one above the other, protecting said containers from harm or contamination. 
       SUMMARY OF THE INVENTION 
       [0010]    According to a first aspect of the invention, a packaging for storing and/or transporting and/or treating and/or supporting, in a suspended vertical position, articles having flanges is provided. This packaging comprises a plate, on one face of which a plurality of rails is arranged in parallel with one another. Support lips are arranged along the rails, one lip and one rail thereby forming a groove with a lip of an adjacent rail and this rail. A pair of adjacent lips is able to support and store the articles by their flanges. According to the invention, the plate comprises an upper wall parallel to the plurality of grooves. This prevents the articles escaping from the plate when the latter is in a position in which the suspended articles are on top. Also according to the invention, said rails and said lips are substantially free of irregularities. The articles can thus be inserted and slid without effort through either end of the groove. The treatments of the articles may relate to bottles or syringes and comprise the checking, filling, stoppering, or sterilization thereof. 
         [0011]    Preferably, this plurality of rails is fastened rigidly to said upper wall such that the plurality of grooves does not deform. The articles are thereby prevented from falling, in particular while being handled by machines. 
         [0012]    Advantageously, this upper wall of the plate has a plurality of passages made opposite said grooves in order to enable access to an upper face of said articles. These passages are preferably equidistant, with a distance between each other equal to that separating the articles inserted into the groove. These passages also have the advantage of aiding sterilization of said packaging by means of a vapor, ethylene oxide or ionization sterilization process. 
         [0013]    The packaging according to the invention may also comprise a holding tongue, said holding tongue being able to take a plurality of articles by snap-fastening and to position said articles opposite said passages. The articles are thus positioned precisely opposite the passages and access to the articles (such as bottles or syringes) is enabled in order to fill or stopper them. 
         [0014]    According to a second aspect of the invention, a packaging comprising a plate according to the first aspect of the invention and a box is provided. This box has an upper opening, a base, side walls and a step formed between said upper opening and said side walls in order to support said plate, thereby spacing the ends of the articles from the base. This packaging is characterized in that said box comprises concave peripheral walls extending toward the outside such that when said packaging is arranged side by side with another packaging of the same type and their respective concave peripheral walls extending toward the outside are pressed together, said concave peripheral walls extending toward the outside prevent said packagings from overlapping. 
         [0015]    Preferably, said plate comprises, in the upper part of said upper wall, secondary ribs for keeping stable the base of the box of a packaging which is placed on the upper wall of the plate of a second packaging of the same type, when these packagings are arranged one above the other. 
         [0016]    Advantageously, said box comprises at least one recess in its side walls for easily taking hold of and withdrawing said plate from said box. 
         [0017]    More advantageously, said recess is located in a corner of said box. 
         [0018]    More advantageously, said box has a parallelepipedal form. 
         [0019]    Preferably, said box has perforations in said peripheral walls in order to aid the sterilization of said packaging by means of a vapor, ethylene oxide or irradiation sterilization process. 
         [0020]    According to a third aspect of the invention, a packaging comprising a plate according to the first aspect of the invention and a collar is provided. This collar is suitable for enclosing said plate and said articles that it contains. 
         [0021]    Preferably, said collar has supports in order for several plates containing articles to be stacked in an inverted position. 
         [0022]    According to a fourth aspect of the invention, a method for storing and/or transporting and/or supporting, in a suspended vertical position, articles having flanges is also provided. This method comprises the steps of:
       supplying a plate, a plurality of rails being arranged in parallel with one another on one face of said plate, support lips being arranged along said rails, one lip and one rail thereby forming a groove with a lip of an adjacent rail and this rail, a pair of adjacent lips being able to support and store said articles by their flanges, said plate being suitable for inserting or withdrawing said articles through each end of said grooves and having an upper wall; and   handling said plate with automated means.
 
By using this method, it is possible to use one and the same packaging from the start to the finish of the container production process.
       
 
         [0025]    The method may advantageously comprise the filling and/or stoppering of said articles through passages made in the plate. 
         [0026]    More advantageously, said handling step also comprises the steps of:
       taking hold of said plate;   turning said plate upside down; and   keeping said articles in a fixed position during a sterilization process.       
 
         [0030]    Further aspects and advantages of embodiments of the invention will be discussed with reference to the figures and to the detailed description of the preferred embodiments. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0031]      FIG. 1  and FIG.  1 ′ are, respectively, a perspective top view and a perspective bottom view of a support plate according to the invention. 
           [0032]      FIG. 2  is a side view in cross section of the plate in  FIG. 1 . 
           [0033]    FIG.  2 ′ is a side view in cross section of the plate in  FIG. 1  supporting syringes. 
           [0034]      FIG. 3  is a partial perspective view of a tongue supporting syringes. 
           [0035]    FIG.  3 ′ is a partial perspective view of a plate into which tongues supporting syringes have been inserted. 
           [0036]      FIG. 4  is a perspective top view of a box according to the invention. 
           [0037]      FIG. 5  is a perspective top view of the plate in  FIG. 1  in use with the box in  FIG. 4 , forming a packaging according to a second aspect of the invention. 
           [0038]      FIG. 6  is a side view in cross section of the packaging in  FIG. 5  in use with syringes inside. 
           [0039]    FIG.  6 ′ is a side view in cross section of the same packaging as in  FIG. 5 . 
           [0040]      FIG. 7  is a perspective view in cross section of the packaging in  FIG. 5 . 
           [0041]      FIG. 8  is another perspective view in cross section of the packaging in  FIG. 5  supporting syringes. 
           [0042]      FIG. 9  is a view in cross section of the packaging in  FIG. 6  in use with syringes inside. 
           [0043]      FIG. 10 ,  FIG. 11  and  FIG. 12  are respectively a side view, a top view and a perspective view of several packagings of the same type as the packaging in  FIG. 6 , which are arranged side by side according to the second aspect of the invention. 
           [0044]      FIG. 13  is a perspective view of several packagings of the same type as the packaging in  FIG. 6 , which are arranged side by side and one above the other in accordance with the second aspect of the invention. 
           [0045]      FIG. 14  and  FIG. 15  are respectively a perspective view and a side view of several packagings of the same type as that in  FIG. 6 , arranged one above the other in accordance with the second aspect of the invention. 
           [0046]      FIG. 16  is a perspective view of several packagings of the same type as the packaging in  FIG. 6 , which are arranged on a pallet (EuroPallet format) side by side and one above the other. 
           [0047]      FIG. 17  is a perspective top view of a support plate supported by a particular type of box, according to a third aspect of the invention.  FIG. 18  is a perspective top view of the same plate turned upside down. 
           [0048]      FIG. 19  is a perspective view of several packagings in use in an inverted position and in which each support plate is supported by a particular type of collar, according to another variant of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0049]      FIG. 1  and FIG.  1 ′ are, respectively, a perspective top view and a perspective bottom view of a support plate  30  according to a first aspect of the invention. This plate  30  makes it possible to transport and keep, in a suspended vertical position, articles provided with flanges, wings, collars or other protuberances, etc. (hereinafter generally described as flanges). These articles may be, for example, glass or plastic medical syringes  20 , or bottles. 
         [0050]    As shown in  FIG. 2 , said plate  30  is composed of a series of rails  31  arranged one beside another with the aim of forming a plurality of grooves  32  in order to support and store a series of syringes  20 . In use, as shown clearly in FIG.  2 ′, the syringes  20  slide in the rails  31  and are supported by their flanges  21  in a suspended vertical position. Said plate  30  also comprises secondary rails  33  at the end of the rails  31  which have a intransverse cross section in the form of a V in order to prevent the syringes  20  moving laterally with respect to these grooves  32 . This particular form of the secondary rails  33  provides a stable point of reference for automatic or manual handling operations which require precise positioning of the plate  30 . The width of the openings in the grooves  32  may be chosen so as to accommodate several types of syringe. For example, the applicant found that by giving the opening a width of 8.8 mm, with a tolerance of +0.1 mm, −0.3 mm, both syringes having a diameter of 6.85 mm and those having a diameter of 8.15 mm can be supported with good stability during transporting, storing and transferring operations. 
         [0051]    As shown in FIG.  2 ′, the syringes may be inserted individually into a groove  32 . Alternatively, the packaging according to the invention may also have holding tongues  38 , one example of which is shown in  FIG. 3 . The tongue  38  has a plurality of snap-fastening positions  39  in which the syringes  20  can be kept. Numerous mechanisms for snap-fastening an article having a collar are known in the prior art, for example by the backstop  10  shown in  FIG. 1  of the document EP 0738517 or in  FIG. 2  of the document EP 0764450. The tongue  38  has a slightly smaller cross section than that of the groove  32 , making it possible to insert it easily into this groove. The width of the tongue is also approximately the same as the outside diameter of the flanges  21 , such that the same plate  30  can be used both with and without tongues  38 . 
         [0052]    FIG.  3 ′ is a partial perspective view of a plate  30  in which tongues  38  assembled with syringes  20  have been inserted in the grooves  32 . The tongues  38  are supported by the same lips  29  as those used when the syringes  20  are supported individually. Alternatively, the tongues may snap-fasten the syringes in a cylindrical part located under the flange  21 . The syringes are then supported on the lips  29  by their flanges  21  and the tongue  38  is inserted into a space between the rails  31 , under the lips  29 . Fastening bottles  20  by means of tongues  38  has numerous advantages. Thanks to the tongues  38 , two syringes  20  inserted successively into a groove  32  are prevented from knocking together and risking being scratched. Adjacent syringes also have predetermined distances between each other. Passages  37  are thus formed in the plate  30  at positions opposite each of the syringes  20 . The syringes or bottles loaded on a plate may then be filled and stoppered by an automatic device which accesses the bottles through the passages  37 . The passages  37  are advantageously distributed in a network in the two directions, thereby aiding the work of a filling machine. The diameter of the passages is chosen to be sufficiently small for there to be no risk of the syringes provided with their flange passing into them, but sufficiently large to enable easy access to the filling and stoppering devices. Finally, the tongue  38  further improves the holding of the syringes when a needle protector is plugged onto the needle of a syringe. 
         [0053]    According to an important aspect of the invention, the plate  30  is manufactured by an extrusion process, as a result of which said plate  30  is open at its two ends and has an upper wall  34  which prevents the syringes  20  from escaping from said plate  30  when the latter is in a position in which the syringes are located at the top as shown in  FIG. 18 . The plates may be turned by means of grippers, which close the ends of the grooves  32 , or may be surrounded by collars  60  as shown in  FIG. 18 . In addition, the upper wall  34  holds the syringes when a needle protector is plugged onto the needle of a syringe. 
         [0054]    In its lower part inside the grooves  32 , this upper wall  34  comprises ribs  35  in the form of a V, in order to optimize the processes of sterilizing syringes  20  in the following manner. As the plate  30  can be turned without dropping the syringes  20 , it is possible to perform a sterilization process, such as vapor sterilization, while keeping the syringes  20  in an inverted vertical position. The advantage of sterilizing syringes in an inverted vertical position is that water is prevented from accumulating in the syringes. Said ribs  35  separate the flanges  21  of the inverted syringes  20  from the upper wall  34  of said plate  30 , as a result of which the sterilization is more effective since the vapor can easily reach the internal parts of the syringe  20 . In addition, at the end of the vapor sterilization, residual water can easily be removed. Furthermore, in its upper part, this upper wall  34  comprises secondary ribs  36  in the form of a V in order to keep the packagings arranged one above the other stable, as shown in  FIG. 14  and  FIG. 15 . 
         [0055]    The plate  30  is made, for example, from extruded polycarbonate. The structure of the plate  30  in fact enables it to be produced by extrusion. 
         [0056]    Preferably, said plate  30  is made from a transparent extruded polycarbonate so as to enable visual checking of the syringes  20  stored in said plate  30 . It should be noted that it is easier, cheaper and quicker to produce this plate  30  by extrusion processes than by the molding processes required by the devices of the prior art. 
         [0057]    According to a particular form of the present invention, the dimensions of the plate  30  are 20×23 cm so as to be dimensionally compatible, for example, with the current support boxes described hereinabove. 
         [0058]    As shown in  FIG. 4  and  FIG. 5 , according to a second aspect of the invention, the plate  30  is suitable to be used with and supported by a box  40 , forming a packaging  10 . Said box  40  comprises concave peripheral walls extending toward the outside  41 . These concave peripheral walls extending toward the outside each have at least one and preferably two vertically extending portions  47 , such that a box  40  can be arranged side by side with another box of the same type such that the vertically extending portions  47  of these boxes are pressed together, leaving spaces  50  between each other, as clearly shown in  FIG. 11 ,  FIG. 12  or  FIG. 13 . The vertical extent of these portions  47  prevents overlapping even when two neighboring boxes  40  are not at exactly the same level. The boxes known from the prior art, for example from  FIG. 6  of U.S. Pat. No. 6,012,595, by contrast, present narrow edges to an adjacent box of the same type, and this may lead to overlapping if the narrow edges of two adjacent boxes do not coincide at the same height. 
         [0059]    Said box  40  also comprises an upper opening  42 , a base  43 , side walls  44  and a portion  45  formed between said upper opening  42  and said side walls  44  for supporting the plate  30  and for separating the syringes  20  contained in said plate  30  from the base  43  of said box  40 , as illustrated in  FIG. 9 . This is because it is important to protect the accessories fitted on the syringes, such as needles or needle protectors, from any contact with the box. 
         [0060]    As illustrated in  FIG. 6  and FIG.  6 ′, when the plate  30  is inserted into a box  40  so as to form a closed packaging  10 , the upper part of said packaging is wider than its lower part such that when a first packaging  10  covers a second of the same type, the base  43  of the box  40  of the first packaging rests stably on the upper wall  34  of the plate  30  of the second packaging. 
         [0061]    Referring again to  FIG. 4  and  FIG. 5 , said box  40  also comprises recesses  46 , in its side walls  44 , at its four corners, for taking hold of and withdrawing the plate  30  easily, if necessary, as is shown more clearly in  FIG. 6 , FIG.  6 ′,  FIG. 7  and  FIG. 8 . 
         [0062]    According to this second aspect of the invention, the vertical portions  47  have a form as shown in  FIG. 10 , such that, when the plate  30  is inserted into the box  40  so as to form a closed packaging  10 , when such a packaging is arranged side by side with another packaging of the same type, the respective portions  47  of each box are pressed together, leaving a space  51  between the corners of said packagings. 
         [0063]    The presence of the spaces  50  and  51  prevents the packagings  10  overlapping, as a result of which the risk of damaging or breaking the stored syringes  20  is substantially reduced, even when several packagings are arranged together side by side and/or one above the other as shown in  FIG. 11 ,  FIG. 12  and  FIG. 13 . 
         [0064]    It should be noted that the plate  30  according to the invention is entirely compatible with the boxes of the prior art, and likewise the box  40  according to the invention is entirely compatible with the plates of the prior art (such as nest plates or comb plates). Furthermore, as the plate  30  is produced by an extrusion process, other plates having different dimensions can easily and quickly be obtained. 
         [0065]    Several support plates  30  may easily be superposed one above the other after use, since the secondary ribs  36  in the form of a V of one plate interlock with the secondary rails  33  of the corresponding lower plate. Several support boxes may easily be interlocked with one another after use. 
         [0066]      FIG. 16  is a perspective view showing an arrangement of several packagings  10  of the same type on a pallet (EuroPallet format) side by side and one above the other. This type of arrangement is advantageous for storing, transporting within an industrial plant, or transporting (by road, inter alia) between two distant industrial plants. 
         [0067]    According to a third aspect of the invention and as shown in  FIG. 17  and  FIG. 18 , the plate  30  is suitable for use with a collar  60  and is supported thereby in order to enclose said plate  30  and the syringes  20  that it contains. In use, this collar  60  supports said plate  30  and makes it easier to handle the plate  30  while holding firmly onto said syringes  20 , even when said plate  30  is upside down. 
         [0068]    According to a variant of the first and second aspects of the invention and as shown in  FIG. 20 , said upper wall  34  of the plate  30  and the side walls  44  of the box  40  have perforations  81  and  82  in order to aid the sterilization of the packaging  10  (for example sterilization by means of water vapor, ethylene oxide or irradiation). 
         [0069]    According to a variant of the third aspect of the invention and as shown in  FIG. 19 , said collar  60  has supports, such as boards  83  for superposing several inverted plates  30  containing syringes  20 , in order to sterilize them. 
         [0070]    One advantage of the present invention is that the plate can pivot about a horizontal axis parallel to the grooves  32  without dropping the syringes and without any additional element such as a lid being added. 
         [0071]    Another advantage of the present invention is that the syringes can be transported more easily and more safely since the lateral movements of the syringes are limited. 
         [0072]    Another advantage of the present invention is that it is particularly suitable for cooperating with entirely automated machines and thus enables the time and costs in all the steps of the transporting and storing process to be reduced. In addition, the plate, according to the invention, is suitable for high-speed and long-distance handling by anthropomorphic robots due to its low mechanical inertia. Finally, the plate according to the invention has front/rear symmetry which has numerous advantages, both for their production, which can be carried out by extrusion, and for their handling, which enables filling and discharging through one side or the other. The plates of the invention enable greater storage density than known supports. An industrial process may use the packaging according to the invention during all the successive phases of the treatment: checking, sterilization, intermediate storage, filling, stoppering, final checking, storage, and transport.