Device for collecting samples and method of use

The present invention comprises a sampling device for collecting samples having a detachable handle with a threaded portion. The device for collecting samples is further provided having a connecting head with a receiving member whereby the receiving member detachably engages the threaded portion of the handle. An absorbent material is placed about the connecting head wherein the absorbent material is a single piece of generally rectangular material folded at a distal edge of the connecting head and adhered through at least one aperture of the connecting head. The detachable handle with the threaded portion is releasably attached to a connecting head with an absorbent material by rotating the detachable handle into the connecting head in a clockwise direction. The user can rotate the handle in a counter-clockwise direction and easily release the handle from the connecting head with the absorbent material into the collection bag.

FIELD OF THE INVENTION

The present invention relates to sampling devices, and more particularly to a device for collecting samples that is ideally suited for use in sterile collection in preventing and monitoring contamination of certain areas.

BACKGROUND OF INVENTION

For sterile collection, it is necessary to collect samples for testing and monitor for any microbial contamination. Microorganisms, such asListeria monocytogenes, can reside in biofilms, or have strong attachments to industrial surfaces that afford protection to these types of pathogenic or disease-causing microorganisms from sanitizing agents, competition from other microorganisms, mechanical removal, and environmental stressors, such as drying or UV exposure.

Food manufacturers have a need to continuously monitor and collect samples, particularly in production areas, in order to avoid outbreaks or to produce food products with little to no microbial contamination. It is commonly known that pathogenic microorganisms in the production environment may contribute to contamination of the food products being produced. Consequently, surfaces in the production areas where samples are routinely collected include ceilings, floors, walls, drains, and equipment. Improper or incomplete sampling of a surface may lead to inaccurate and false results for microbial safety in the production environment and potentially result in contamination of the food products during production.

It is crucial that the device for collecting samples be robust and durable to avoid any mishap that could stop or delay production. A mishap can easily occur if the device for collecting samples, or a portion of the collection device, breaks in hard-to-reach areas or is inadvertently dropped into a cooking vessel or a storage tank. Similarly, if the collection device breaks or fragments during sample collection, pieces of the collection device can easily enter the food during production. Furthermore, an improperly designed collection device could become wedged or caught in hard-to-reach areas of production equipment, and removal could require disassembling the production equipment.

Typically, the device for collecting samples has a swab of absorbent material attached on the distal portion of the device that is rubbed onto or scrubbed against a sampling surface for collecting the sample. Such swabs of cotton, dacron, alginate, or foam on a swab stick handle made of wood or plastic are commonly used to collect the sample. After collecting the sample, the swab is placed into a sterile test tube or a collection bag for later testing and processing. The swabs are normally suited for small clinical sampling surface areas such as the throat, while industrial sampling surfaces require stronger and bigger collection devices. The swab may be effective in accessing hard-to-reach areas because of its thin profile, however, it is inefficient when sampling a larger industrial area such as a conveyor belt or floor. Further, the user collecting the sample is required to press down firmly and to scrub the surfaces of a food production area to disrupt biofilms that are formed by microorganisms. A failure to disrupt and collect a biofilm during sampling can result in a false negative determination. The swabs may easily break when rubbing and lifting the biofilm to obtain a good sample from an industrial surface.

Sometimes a sponge is held directly by the user in collecting a sample. Direct handling of pre-moistened sponges is described in the U.S. Department of Agriculture (USDA) methods for sampling and testing cattle carcasses forSalmonellaandEscherichia coli.However, these sponges are susceptible to mishandling by the user, resulting in contamination of the sample and inaccurate results. The user may easily contaminate the sample by touching the sponge.

Alternative swab devices have been developed for collection of samples, such as the device described in U.S. Pat. No. 6,383,804, wherein a sampling device with a snap-off head includes an elongate handle, a paddle head, and an absorbent material that wraps around the paddle head. A score line is included between the paddle head and the elongate handle that allows the user to snap off the paddle head from the elongate handle. The disadvantage of this design is that while the sampling device with a thicker wall of plastic at the score line can withstand greater force when the user presses on the sampling device, the greater wall thickness at the score line makes it difficult to break away the head away from the handle after the sample is collected. On the other hand, a thinner wall at the score line makes the paddle head susceptible to breaking away the paddle head from the handle while the sample is being collected if the user presses hard on the surface to disrupt the biofilm. Consequently, the design is not desirable since it is imperative that the score line thickness be precisely accurate to avoid inadvertent breakage during sampling while maintaining sufficient durability to remain intact when the user presses and scrubs against the surface for sampling.

The other disadvantage of the sampling device with a snap-off head is that the absorbent material is affixed to the paddle head using an adhesive or sonic welding between the absorbent material to the plastic portion of the paddle head. Bonds between absorbent materials and the plastic used for the paddle head are typically weak. Therefore, the sponge may easily detach from the plastic paddle head during sampling or rubbing against rough surfaces.

Therefore, the ideal device for collecting and sampling should be durable and strong enough to withstand the pressure applied by the user pressing on the collection device without breaking or snapping off from the handle. The ideal collection device would be designed in a way that the device can be easily inserted into a hard-to-reach area with minimal concern that it will be caught or that portions of the device will be left behind after the sample is collected. The ideal collection device would be designed and constructed in a manner that resists breakage, yet affords sufficient flexibility to collect samples around a bend or corner in production equipment. Moreover, the collection device would be easy to use and present minimal opportunity for the collection device to get caught in equipment when collecting samples. The ideal collection device further would be effective in collecting from rough and/or wide surfaces such as concrete floors or evaporation coil fins in refrigeration units without the absorbent material abrading and tearing away from the handle. The ideal collection device would be capable of easily detaching from the handle without the need for the user to touch the sample, in order to prevent contamination. The ideal collection device would be modular to accommodate different sizes of paddle heads for providing flexibility in use.

The present invention incorporates a design in which the absorbent material used for collection is directly bonded to itself. The strongest bonds and the greatest flexibility in the choice of adhesives are obtained when the adhesive can be applied to two areas of the same material. Bonding of the absorbent material to itself strongly affixes the absorbent to the sampling device to withstand the pressure applied by the user during sampling. The present invention is directed to fulfilling all of these needs and others as described below.

SUMMARY OF THE INVENTION

In accordance with the present invention, a device for collecting samples is provided having a detachable handle with a threaded portion and a tip protruding adjacently from the threaded portion. The device for collecting samples is further provided having a connecting head with a receiving member whereby the receiving member detachably engages the threaded portion of the handle. The connecting head further comprises a hollow pocket through which the tip of the detachable handle fits before locking the detachable handle to the connecting head. The detachable handle further comprises a pair of wings extending laterally at a distal portion of the handle with a perpendicular edge that is substantially similar in width as the connecting head to prevent the connecting head from catching at hard-to-reach areas or detaching from the handle. The absorbent material is placed about the connecting head wherein the absorbent material is a single piece of generally rectangular material folded at a distal edge of the connecting head and adhered through a first and second aperture of the connecting head. The detachable handle further comprises a locking member adjacent to the threaded portion of the detachable handle for locking the detachable handle to the connecting head by internally clicking the locking member into a protruding member of the connecting head.

The detachable handle with the threaded portion is releasably attached to a connecting head with an absorbent material by rotating the detachable handle into the connecting head by 180 degrees in a clockwise direction. By holding the detachable handle, the connecting head with the absorbent material is rubbed against a surface with the absorbent material on the connecting head of the device for collecting samples. After collecting the sample, the connecting head and absorbent material containing the sample is placed into a sterile, collection bag. A user can hold the connecting head with the absorbent material from the outside of the collection bag without directly touching the absorbent material. The user can grasp the detachable handle, rotate the handle in a counter-clockwise direction while holding the connecting head still, detach the handle from the connecting head, and leave the connecting head with the absorbent material in the collection bag.

DETAILED DESCRIPTION OF THE INVENTION

The detailed description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed and/or utilized. The description sets forth the functions of and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. However, it is to be understood that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.

The present invention is directed to sampling devices, and more particularly to a device for collecting samples that is ideally suited for use in sterile collection in preventing and monitoring contamination of certain areas. The device for collecting samples50may be used for collecting any samples including microorganisms and other types of samples on larger surfaces.

Referring toFIG. 1A, a top view of the detachable handle10of the device for collecting samples50is shown. The detachable handle10is comprised of a proximal portion12, a distal portion14, a notch30located between the proximal portion12and the distal portion14, a pair of wings15a,15blocated on the distal end of the distal portion14with a perpendicular edge17, and a tip40with a threaded portion20connected to the distal portion14extending from the perpendicular edge17. The detachable handle10is generally flat with rounded corners on the proximal portion12and has a straight, perpendicular edge at the distal portion14with gradual widening of the wings15a,15bat the lateral sides of the distal portion14.

In one embodiment, the detachable handle10is formed of a rigid material such as polystyrene, polycarbonate, polyethylene, polypropylene, or ABS (Acrylonitrile-Butadiene-Styrene). The notch30is located approximately midway between the proximal portion12and the distal portion of the handle10to provide a reference point for a user to insert the device14in hard-to-reach areas and also to hold the handle10while collecting samples. As shown inFIGS. 1B-1C, the notch30a,30bon an upper side and lower side of the detachable handle10is slightly elevated from the flat handle10for an easy grip of the detachable handle10and for point of reference during use.

Continuing down to the distal portion14of the detachable handle10, the first and second wings15a,15bon each side of the distal portion14span the width of the connecting head100(shown in later FIGS.) to prevent the connecting head100from detaching from the handle10or catching on protruding areas of the manufacturing equipment while sampling from difficult-to-access areas. More specifically, the perpendicular edge17of the distal portion14of the handle10is substantially similar in width to the distal edge145and proximal edge155of the connecting head100to prevent the connecting head100from catching at difficult-to-reach areas and/or detaching from the detachable handle10. The tip40with the threaded portion20is integrally connected to the distal portion14extending from the perpendicular edge17that fits with the connecting head100.

The tip40is substantially cylindrical in shape with a locking member35on an intermediate portion37centrally located adjacently inbetween the tip40and the threaded portion20. The intermediate portion37is slightly thicker in diameter than the tip40with a locking member35on one side or both top and bottom sides of the intermediate portion37. The threaded portion20is slightly thicker in diameter than the intermediate portion37to engage the matching threaded surface125(as shown in later FIGS.) of the receiving member120of the connecting head100. The threaded portion20continues as a smooth portion25that is integrally connected to the perpendicular edge17of the distal portion14of the detachable handle10. The diameter of the intermediate portion37and the smooth portion25are substantially similar.

Referring toFIGS. 1A to 1D, in one embodiment of the present invention, the detachable handle10is approximately 6.3 inches long, 0.15 inches thick, and 0.625 inches wide. The length of the tip40is approximately 0.55 inches and the diameter of the tip40is approximately 0.12 inches. The length of the tip40, threaded portion20, and intermediate portion37is approximately 0.98 inches. The dimensions of this handle10are not meant to be limiting and the size of the detachable handle10may be changed accordingly to accommodate different areas and to use with varying shapes and sizes of the connecting head100.

Referring toFIGS. 2A to 2C, the connecting head100is generally rectangular and flat in shape with rounded edges comprising a cylindrically hollow pocket110to receive the tip40, first and second apertures105a,105b, and a receiving member120with a matching threaded surface125to receive the threaded portion20. Around the apertures105a,105b, the connecting head100includes distal sides140a,140b, outer sides130a,130b, and proximal sides150a,150bspanning the width of the perpendicular edge17of the detachable handle10.

The connecting head100has a hollow cylindrical pocket110that is centrally and axially located along the middle portion of the connecting head100to receive the tip40. The distal end of the receiving member120of the head100also receives the intermediate portion37with a locking member35and the immediately adjacent threaded portion20. The user may insert the tip40into the channel115of the cylindrically hollow pocket110and rotate the handle10by 180 degrees in a clockwise direction to removably engage the threaded portion20against the matching threaded surface125of the receiving member120. When the handle10is rotated in the receiving member120by 180 degrees in a clockwise direction, the locking member35with an indentation located on the intermediate portion37of the handle10also securely engages and clicks into place with an internally protruding member (not shown in these FIGS.) to removably hold the connecting head100with the handle10. Similarly, the handle10may be held and rotated by 180 degrees in a counter-clockwise direction to release the connecting head100from the handle10after collecting samples. The release action of the connecting head100after collecting the sample will be more readily understood as shown inFIGS. 5A-5C. The degrees of rotation between the handle10and the receiving member120are not meant to be limiting and the degrees of rotation for engaging the handle10to the connecting head100may be changed accordingly to accommodate different degrees for engagement. In one embodiment, the connecting head100is approximately 0.26 inches long, 1.26 inches wide, and 0.065 inches thick. The diameter of the channel115is similar to that of the tip40so that the channel115can accommodate the tip40. The first and second apertures105a,105bare approximately 0.9 inches long and 0.3 inches wide. The outer sides130a,130bare approximately 0.11 inches wide. The first and second wings15a,15bspan the same width of the connecting head100, and the perpendicular edge17is approximately 1.26 inches long to substantially match the width of the connecting head100from the first outer edge135ato the second edge135bof the connecting head100. The dimensions of the connecting head100are not meant to be limiting and the size of the connecting head100may be easily adjusted to accommodate different areas and to use with varying sizes and shapes of the detachable handle10.

In the embodiment ofFIG. 3, the assembled device for collecting samples50is shown without the absorbent material200. The detachable handle10is assembled and removably attached to the connecting head100after the detachable handle10is rotated by 180 degrees in a clockwise direction in connection with the connecting head100. The channel115of the hollow pocket110retains the tip40of the detachable handle10, and the threadable portion20engages the receiving member120. The tip40is first inserted into the channel115and the handle10is rotated in a clockwise direction to engage the threadable portion20with the matching threadable surface125of the receiving member120. The detachable handle10is securely and removably locked or clicked into the connecting head100by the locking member35gently clicking into place with an internal protruding member (not shown in FIGS.) of the receiving member120of the connecting head100. Gentle pressure applied in a counter-clockwise direction and rotating of the handle10in a counter-clockwise direction are required to release the connecting head100from the handle10when the connecting head100is ready to be released after collecting a sample on the absorbent material200.

In the embodiment ofFIG. 4, the assembled device for collecting samples50is shown with the absorbent material200. The absorbent material200is a single piece of generally rectangular absorbent material folded and placed about the connecting head100at the distal edge145. The absorbent material200is formed of an absorbent material, such as cellulose, polyurethane, polyester, gauze, or other similar material. The absorbent material200sufficiently covers the connecting head100. More specifically, the absorbent material200folds over the distal edge145and comes up to the proximal edge155to sufficiently cover the connecting head100. The space between the proximal edge155of the connecting head100and the perpendicular edge17of the distal portion14of the handle10is not covered by the absorbent material200.

The absorbent material200adheres to the connecting head100by using a non-toxic adhesive on the inner side of the absorbent material200through the first and second apertures105a,105b. A short strip of adhesive may be applied on the first inner side of the absorbent material200through the apertures105a,105bso that when the absorbent material200is folded over at the distal edge145, and the second inner side of the absorbent material200can easily adhere to the first inner side with the strips of adhesive through the apertures105a,105b.Therefore, the absorbent material200bonds directly to itself through the apertures105a,105bwith adhesive inbetween and does not rely upon adhesion to the connecting head100. If desired, adhesive can also be placed on the connecting head100to provide additional bonding between the absorbent material200and the connecting head100.

With the current design of the present invention, there is usually no need to attach the absorbent material200to the connecting head100. Typically, the bond between two different materials, the absorbent material200and the connecting head100, is weaker than a bond between two layers of absorbent material. Additionally, an absorbent material-to-connecting head bond typically requires special manufacturing processes such as sonic welding, whereby the plastic of the connecting head100is melted using ultrasonic energy so that the melted plastic migrates a small distance into the absorbent material200. Use of this two-material bond alone (i.e., without bonding the absorbent material to itself) is not recommended because the two-material bond is generally weaker and makes the absorbent material susceptible to tearing away or fragmenting during use in collecting a sample. In addition, sonic welding or other cumbersome two-material bonding processes are generally less convenient and more expensive than the process of bonding the absorbent material200to itself. Therefore, the single-piece of generally rectangular material of the absorbent material200is folded at a distal edge145of the connecting head100and is directly bonded to itself through the apertures105a,105busing a non-toxic adhesive prior to attaching the connecting head200to the detachable handle10. Alternatively, two, separate pieces of the absorbent material200are directly bonded to itself through the apertures105a,105busing a non-toxic adhesive prior to attaching the connecting head200to the detachable handle10.

Referring toFIG. 5A, a user collects a sample onto the absorbent material200and inserts the connecting head100of the device50into a sterile, sample collection bag. Prior to collecting a sample, the method of collecting samples using the present invention comprises the step of attaching the detachable handle10with the threadable portion20to the connecting head100to have the fully assembled device50. The assembled device50with the connecting head200attached to the detachable handle10is then placed into a collection bag. Optionally, the absorbent material200placed about the connecting head100is hydrated with a culture broth for sampling dry surfaces. For all other surfaces of sampling, hydrating the absorbent material200is not necessarily required. The collection bag is then sealed and sterilized with the assembled device50in the collection bag prior to use. After sterilization of the assembled device50in the sealed collection bag, a user takes the assembled device50out of the collection bag and holds the detachable handle10to rub against a surface with the absorbent material200touching the surface for collecting samples.

After rubbing against the surface, the connecting head100and absorbent material200portion of the device is placed into a collection bag. Any flexible, sterile plastic bag may be used so that the device for collecting samples50can be inserted to prevent direct contact with the collected sample on the absorbent material200of the connecting head100for avoiding any contamination of the sample. After the connecting head100with the absorbent material200containing the sample is inserted into the sterile, sample collection bag, the user holds the connecting head100with one hand from the outside of the collection bag while the other hand is used to directly grasp the detachable handle10. The user may rotate or twist the detachable handle10from the connecting head100by 180 degrees in a counter-clockwise direction. Rotating of the handle10in a counter-clockwise direction releases the detachable handle10from the connecting head100and leaves the connecting head100and absorbent material200containing the sample in the collection bag. Therefore, the user collects samples and deposits the sample in a sterile, collection bag without touching the absorbent material200containing the sample, preventing contamination during transportation for later examination and analysis.

The terms and expressions that have been employed in the foregoing specification are used as terms of description and not of limitation, and are not intended to exclude equivalents of the features shown and described or portions of them. The scope of the invention is defined and limited only by the claims that follow.