Abstract:
A plug insertion device for inserting a plug into a container. The device includes sides defining an opening therebetween. The opening receives a plurality of containers having openings at the upper end thereof. A platen having a plurality of insertion pins is pivoted over the sides. A sheet of plugs is positioned over the openings in the containers. The insertion pins engage the plugs and insert them into the containers upon application of a force to the platen. A return spring returns the insertion pins to their retracted position allowing for the removal of the plugged containers.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The instant application claims priority to and benefit of U.S. Provisional Patent Applications Ser. Nos. 60/905,726 filed Mar. 8, 2007, and 61/013,346 filed Dec. 13, 2007, the entire specifications of which are expressly incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to a plug insertion device for containers such as vials. Further, the present invention relates to a method for inserting plugs into a container as well as a plug for insertion into a container. 
       BACKGROUND OF THE INVENTION 
       [0003]    Presently, scientists generally use in excess of fifty million containers or glass vials worldwide for genetic or other research using subjects such as fruit flies. Frequently, several vials, for example, one hundred vials, come in a corrugated tray pack arranged in a 10 vial×10 vial array. Each vial has a fruit fly or other research subject placed in the vial and then each vial is plugged or closed off by manually inserting a plug into each vial. That is, individual stopper devices or plugs are placed by an individual into each container or vial. 
       SUMMARY OF THE INVENTION 
       [0004]    According to one embodiment of the present invention, there is provided a plug insertion device. The device comprises a base for positioning a container. The device further comprises a platen moveably secured to the base. The device further comprises at least one insertion pin extending out from the platen and adapted to insert a plug into the container when the platen is moved relatively to the base. 
         [0005]    According to an alternate embodiment of the present invention, there is provided a method of inserting a plug into a container. The method comprises providing a device having a base defining an opening therein. The device further has a platen moveable relative to the base and having at least one insertion pin. At least one container is positioned in the opening. The upper platen is moved relative to the base such that the insertion pin engages a plug and urges the plug into the container. 
         [0006]    According to another alternate embodiment of the present invention, there is provided a plug for a container. The plug comprises a base and an annular side wall extending from the base. The side wall defines an opening therein. The plug compresses upon application of a force when being inserted into the container and expands when the force is removed to engage the container. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
           [0008]      FIG. 1  is a perspective view showing a plug insertion device in an open position; 
           [0009]      FIG. 2  is a perspective view showing the plug insertion device with the top platen in position for use; 
           [0010]      FIG. 3  is a cross-sectional view showing the plug insertion device prior to insertion of the plugs; 
           [0011]      FIG. 4  is a cross-sectional view showing the plugs inserted into the vials; 
           [0012]      FIG. 5  is a cross-sectional view showing the platen in an open position and removing the plugged containers; 
           [0013]      FIG. 6A  is a perspective view of an embodiment of a plug; 
           [0014]      FIG. 6B  is a cross-sectional view of an embodiment of a plug in a vial; 
           [0015]      FIG. 7A  is a perspective view of an embodiment of a plug; 
           [0016]      FIG. 7B  is a cross-sectional view of an embodiment of a plug in a vial; 
           [0017]      FIG. 8A  is a perspective view of an embodiment of a plug; 
           [0018]      FIG. 8B  is a cross-sectional view of an embodiment of a plug in a vial; 
           [0019]      FIG. 9  is a perspective view of a plug in an alternate container; and 
           [0020]      FIG. 10  is a perspective view of one embodiment of a sheet of plugs. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0021]    The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
         [0022]    Referring to the Figures, a plug insertion device is generally shown at  10 . The plug insertion device  10  includes a base generally indicated at  12 . The base  12  includes at least a pair of side walls  14 . Front  16  and rear  18  walls interconnect the side walls  14 . The front wall  16  defines an opening  20 . The opening  20  is for receiving at least one and preferably a plurality of containers  22 , such as vials. It should be appreciated by those skilled in the art that the plug insertion device  10  may be designed to receive any number of containers as well as containers other than vials. In one embodiment, the opening  20  extends to the side walls  14  and is rectangular in shape. 
         [0023]    The front wall  16  includes an upper wall portion  30  that may be fixed to the side walls  14 . The upper side wall portion  30  may also include a portion of a vial spacer  24  thereon for positioning and supporting the plurality of vials  22 . In such an instance, the vial spacer  24  is framed by the side walls  14 , front wall  16  and rear wall  18 . The vial spacer  24  may be used to align the vial tray  26 . Alternatively, the vials are positioned by the tray engaging the back and/or side walls. 
         [0024]    The vial spacer  24  also defines a vial plug rest thereon. The vial plug rest may comprise a lip  19  extending inwardly from the walls toward an interior space  37  as described below. The vial plug rest may be located on each of the side walls  14  and rear wall  18  as well as the upper side wall and portion  30  discussed below. The lip  19  may be used to support a sheet of plugs as will be described below. The front wall  16  further includes a lower movable wall portion  32  that is hinged via hinges  34  to an upper wall portion  30 . A handle  36  is connected to the lower movable wall portion  32  so that a user may grasp it and move the lower movable wall portion  32  between closed ( FIG. 1 ) and open ( FIG. 2 ) positions. The lower movable wall portion  32  acts as a door to an interior space  37  of the plug insertion device  10 . In the open position, the lower movable wall portion  32  exposes the interior space  37  and the opening  20  and allows a user to insert a tray  26  of containers  22  through the opening  20  and into the interior space  37 . It should be appreciated by those skilled in the art that the lower movable wall portion  32  can pivot from either side of the base  12  instead of being hinged from its top edge  38 . 
         [0025]    The containers or vials  22  are typically contained in the tray  26  as a tray pack that holds the vials  22  in an upright position. Tray packs of this type are well known in the art. Typically, the tray pack  26  holds an array of vials  22 , such as a 10×10 array having 100 vials  22 . The tray pack  26  holds the vials  22  in an upright orientation. Each vial  22  includes a vial opening  40  at an upper end  42  thereof. Otherwise, the vials  22  are preferably closed. The vials can have any shape. The vial opening  40  of each vial  22  allows items to be placed therein. Once items are placed into the vial  22 , it is often desirable to close off or plug the vial opening  40  to prevent egress of the item placed in the vial  22  or ingress of contaminants into the vial  22 . 
         [0026]    The plug insertion device  10  further includes a platen, generally indicated at  44 . The platen  44  has an upper fixed platen member  46  and a lower movable platen member  48 . The upper fixed platen member  46  is hinged, via hinges  50  to the rear wall  18 . The hinges  50  allow the platen  44  to move between an open position ( FIG. 1 ) and a closed position ( FIG. 2 ). In a descriptive sense, the platen  44  is a top that covers a top access opening  51  that leads to the interior space  37  from above; defined between the side walls  14 , the front wall  16  and rear wall  18 . When in the open position ( FIG. 1 ), a sheet  86  of plugs  28  can be placed on the lip  19  over the top of the vials  22 . A stop  53  prevents the platen  44  from rotating past its open position. 
         [0027]    The upper fixed platen member  46  further includes support flanges  52 . The support flanges  52  are for supporting a handle  54 . The handle  54  extends through a curved path to facilitate the operator to apply a necessary force to the lower movable platen member  48 , as will be discussed in greater detail subsequently. The handle  54  includes a bellcrank  55  at its end disposed adjacent the support flanges  52 . Pins  56  extend out of each of the support flanges  52 . A pair of springs  58  is operatively connected to the pins  56  in the support flanges  52 . Each spring  58  is connected between the pins  56  and the lower movable platen member  48 . The springs  58  help bias the lower movable platen member  48  toward the upper platen member  46 . When the lower movable platen member  48  is disposed adjacent to the upper fixed platen member  46  (when the springs  58  are compressed), it is in its retracted position. 
         [0028]    Linkage members  60  are pivotally connected to the handle  54  on each side thereof. Each linkage member  60  is, in turn, rotatably connected to a biasing member  62 . The biasing members  62  exert a force on the lower movable platen member  48  to move it away from the upper fixed platen member  46  and downwardly toward the opening  20  in response to a downward force being applied to the handle  54 . 
         [0029]    A pair of locking members  64  ( FIG. 1 ) extends from the upper fixed platen member  46  downwardly to a position adjacent each side wall  14 . A lock pin  66  ( FIG. 2 ) extends through each locking member  64  and is adapted to engage the side wall  14  and in some instances a depression or aperture (not shown) in the side wall  14  to secure the upper fixed platen member  46  with the side wall  14 . When the lock pin  66  is in locking engagement with the side wall  14 , the upper fixed platen member  46  cannot pivot between the open and closed positions. 
         [0030]    Guide rods  68  are secured to the lower movable platen member  48 . The guide rods  68  pass through apertures, represented by bushings  70  in the upper fixed platen member  46 . The guide rods  68  guide movement of the lower movable platen member  48  as it moves with respect to the upper fixed platen member  46 , toward and away from the top access opening  51 . As shown, the insertion device may include four guide rods  68 . 
         [0031]    The platen  44  is described in connection with one embodiment as being pivotally connected with respect to the rear wall  18 . It will be appreciated, however, that the upper platen  44  can be connected in any suitable manner to the base  12 . 
         [0032]    The lower movable platen member  48  may include a plurality of insertion pins  76  thereon. The insertion pins  76  are used to engage a plug opening  78  in a plug  28  to insert each plug  28  into each of the vials  22 . The insertion pins  76  further include a plug engaging portion  80 . The plug engaging portion  80  comprises a rounded end  82 . The rounded end  82  acts on the portion of the plug  28  to be pushed into the vial  22  during insertion, as will be described in more detail below. It will be appreciated that the plug engaging portion  80  can have any suitable configuration. In one embodiment, the plug engaging portion  80  tapers from a base  84  of the insertion pin  76 . Further, the length of the insertion pin  76  may be selected to optimize the insertion of the plug  28  into the vial. 
         [0033]    The plug engaging portion  80  may have a diameter less than the diameter of the vial opening  40 . Further, the insertion pins  76  are secured to the platen  44  in such a manner so as to be generally coaxial with the longitudinal axis of the vials  22  inserted into the opening  20 . This allows the insertion pins  76  to extend into the vials  22  to insert the plug  28 . 
         [0034]    As shown in  FIG. 1 , one hundred insertion pins  76  are shown. It will be appreciated, however, that any number of insertion pins  76  may be used within the context of the invention and may be placed in any suitable configuration. 
         [0035]    A sheet  86  of plugs  28  (best seen in  FIG. 10 ) is adapted to be supported on the vials  22  within the vial spacer  24 . Preferably, the sheet  86  of plugs  28  includes a frame  88  of foam that surrounds the plurality of plugs  28  on four sides. The frame  88  is designed to properly position the plugs  28  when inserted into the plug insertion device  10 . The frame  88  may rest on the lip  19  when the sheet  86  is inserted into the device  10 . The sheet  86  of plugs  28  is made out of a suitable material than can easily be inserted into the vial opening  40 . In one preferred embodiment, the sheet  86  of plugs  28  is made of a suitable foam. The sheet  86  of plugs  28  may includes a plurality of individual cuts  88  to produce score lines that are used to separate the individual plugs  28  from one another. Any suitable procedure can be used to make the score lines. Alternatively, the sheet  86  of plugs  28  may be molded to the desired configuration. 
         [0036]    Referring to  FIGS. 6A through 8B , wherein like primed reference characters represent similar elements, three alternate embodiments of the plug  28 ,  28 ′,  28 ″ are shown. Each plug  28  is preferably generally cylindrical. Each plug  28  also includes a generally cylindrical aperture therein, the plug opening  78  discussed above. The aperture  78  does not extend the entire length of the plug  28 . That is, each plug  28  has a bottom portion  90  with an annular side wall  92  extending from the bottom portion  90 . As shown in  FIGS. 1-5  and  10 , the bottom portion  90  has a generally flat bottom. In the alternative embodiments shown in  FIGS. 6-8 , the bottom portion  90  is non-linear. 
         [0037]    The aperture  78  is defined between the annular side wall  92 . It will be appreciated that the annular side wall  92  may taper, such as shown at  92 ′ in  FIG. 7A . The aperture  78  can take any suitable configuration and need not be cylindrical. The aperture  78  can, for example, have a wider diameter toward the top of the plug  28  and a narrower diameter adjacent the bottom portion  90 . The bottom portion  90  in each of the plug embodiments varies. It has been determined that when the contents of the vials  22  includes fruit flies  99 , it is advantageous to increase the surface area of the portion of the plug  28  exposed to the fruit flies  99 . Therefore, the various embodiments shown are designed with the non-linear bottom portion  90  to increase the surface area of the bottom portion  90 . 
         [0038]    The aperture  78  allows the rounded end  82  of the insertion pin  76  to be inserted therein and to engage the bottom portion  90  of the plug  28 . In this manner, the insertion pin  76  pushes on the bottom portion  90  of the plug  28  and causes the remainder of the annular side wall  92  to be pulled into the vial  22  through its vial opening  40 . The force of the insertion pin  76  causes each individual plug  28  to separate from the sheet  86 . That is, the force of the insertion pin  76  detaches each individual plug  28  from the next adjacent plug  28  and from the frame  88  along the individual cuts  88 . 
         [0039]    Further, it will be appreciated that each individual plug  28  may have an initial diameter larger than the diameter of the vial  22  and/or vial opening  40 . More specifically, the diameter of the bottom portion  90  may be greater than the diameter of the vial  22 . Once the plug  28  is disposed in the vial  22 , the periphery of the bottom portion  90  and the annular side wall  92  engage the vial  22  to close or plug the vial opening  40  in one embodiment. As the insertion pin  76  pushes the plug  28  into the vial  22  through the vial opening  40 , it compresses the plug  28 . Once the insertion pin  76  is removed, the plug  28  expands to engage the inner surface of the vial  22 . The plugs  28  may have an upper portion  93  at a top surface  95  thereof. In some instances, the upper portion  93  may include an annular flange, such as at  93 ″ in  FIG. 8A   
         [0040]    A portion  94  of the annular side wall  92  of the plug  28  may remain outside of the vial  22  after insertion. This portion  94 , along with the vial opening  40 , provides a convenient way to remove the plug  28  from the vial  22 , if necessary. Often, it is necessary to access the vial  22  once the plug  28  has been inserted, for example, to collect data. To remove the plug  28 , a user would insert their finger into the aperture  78 , while also grasping the portion  94  of the annular side wall  92  that extends outward from the vial. The plug  28  can then be easily removed by pulling the plug  28  from the vial  22 . 
         [0041]    Use of the insertion device  10  is as follows. The platen  44  is moved to the open position by lifting the handle  36  and pivoting the platen  44  about the hinges  34  ( FIG. 1 ). The lower movable wall portion  32  is pivoted about the hinges  34  to expose opening  20 . When in this position, a vial tray  26  is placed in the opening  20  between the side walls  14  and the rear wall  13 . Once the vial tray  26  is inserted (positioning of the vial tray  26  may be made via vial spacer  24 ), the lower movable wall portion  32  is pivoted to the closed position. The vials  22  may be loaded with specimens. 
         [0042]    The sheet  86  of plugs  28  is positioned over the tops  40  of the vials  22 . More specifically, the sheet  86  of plugs  28  is positioned such that the frame  88  of the sheets  86  rests on lip  19 . The platen  44  is then pivoted to the closed position ( FIG. 3 ). The lock pins  66  engage the side wall  14  and perhaps a detent or aperture therein to prevent movement of the upper fixed platen member  46  relative to the side walls  14 . A downward force is applied to the handle  36 , moving the linkage members  60  and causing the lower movable platen member  48  to move downwardly away from the upper fixed platen member  46 . This movement of the lower movable platen member  48  is generally linear. The downward movement causes the insertion pins  76  to move into the plug opening  78 , engage each plug  28  and push each individual plug  28  through the vial opening  40  of the vial  22  and into the a vial  22 , separating it from the next adjacent plug  28  ( FIG. 4 ). The handle  36  is pushed down until the linkage member  60  reaches the end of its stroke. In this position, the lower movable platen member  48  is moved a sufficient distance to insert the plug  28  into the vial  22 . 
         [0043]    In one embodiment, the upper portion of each plug extends outwardly from the vial after insertion ( FIG. 5 ). This allows for easier removal of the plug from the vial. 
         [0044]    Once the plugs  28  are inserted through the vial opening  40  into the vial  22 , the handle  36  is moved upwardly. The springs  58  aid in moving the lower movable platen member  48  upwardly out of the opening  20  and toward the upper fixed platen member  46 . 
         [0045]    The lock pins  66  can then be removed from engagement with the side walls  14 . The platen  44  can then be pivoted to the open position (arrow  98  in  FIG. 5 ). The lower movable wall portion  32  can be pivoted to the open position and the vials  22  containing the plugs  28  can be removed from the opening  20 . Any remains of the foam sheet  86  can be removed through the top access opening  51 . Each vial  22  now contains a plug  28 . A new tray containing unplugged vials can then be positioned in the opening  16  and the process repeated. 
         [0046]    While the insertion device  10  is described in connection with vials  22 , it will be appreciated that any suitable container or vessel may be used within the context of the present invention. Specifically, flasks, test tubes, bottles or any device that has at least one open end can be used within the context of the present invention. In some instances, it may be necessary to include another member (not shown) for aligning the tops of some types of containers. This may be particularly applicable when the base of the container is wider or has a larger diameter than its opening. 
         [0047]    It will also be appreciated that while the sheet is preferably foam and each individual plug is made of a foam material, any suitable material may be used for the plug. However, the material should preferably have the ability to be compressed so that it can fit through the opening into the vial and expand so as to form a seal with the interior of the vial  22 . Additionally, it is preferred that the foam have a cell structure that minimizes the risk of contamination. For example, when fruit flies are used in a study, it is desirable to eliminate infestation from insects, such as mites. Thus, foam with a micro-cellular structure is desirable. Such a foam and plug may also allow air to pass into the vial while preventing the ingress of undesirable material or the egress of the subject contained in the vial. One such suitable foam is sold under the trade name NOLAPHIL™ which is commercially available from Lendell Manufacturing, Inc. of St. Charles, Mich. The foam plugs can be made by any suitable method. By way of non-limiting example, the plugs, and particularly the sheets of plugs, may be formed from a blank and die cast. Alternatively, the sheets of plugs may be molded. 
         [0048]    Further, the plug shown is generally cylindrical having a circular base and annular side wall. It will be appreciated, however and as set forth above, that the plug can have any configuration. For example, the plug can have an octagonal base and a corresponding high side annular wall defining an opening therebetween. The different shaped plugs can provide different sealing characterizations. Any suitable shaped plug is within the context of the present invention. Similarly, the opening in the plug may take any suitable configuration. 
         [0049]    While the plug insertion device described herein is used, many plugs can be simultaneously inserted. This saves a user considerable time, particularly when several containers need to be plugged. 
         [0050]    Referring to  FIG. 9 , a fourth embodiment of the plug  28 ′″ is shown. This embodiment of the plug  28 ′″ is larger than the plugs  28 ,  28 ′,  28 ″ of the first three embodiments and is designed to be inserted into a container larger than a vial  22 . In the Figure, the container is a beaker styled container. The user of the plug  28 ′″ may force the plug  28 ′″ into the container  22 ′″ by pressing down on the top  95 ′″ thereof. The user may remove the plug  28 ′″ by pinching the top between the aperture  78 ′″ and the outer surface  92 ′″ so that the operator may grab onto the plug  28 ′″ and pull it away from the top  42 ′″ of the container  22 ′″. 
         [0051]    The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. 
         [0052]    Presently, the preferred embodiments of the invention have been described in an illustrative manner. It is to be understood that the terminology used is intended to be in the nature of words of description. Obviously many modifications and variations are possible in light of the above teachings. 
         [0053]    It is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described.