Abstract:
A vial pack cover, a vial pack kit, and a method for forming the vial pack cover is provided. The vial pack cover can simultaneously cover a plurality of containers while preventing the contents of the containers from degrading or permeating through the cover. In addition, the vial pack cover allows a user to access individual containers without having to remove the cover from the un-accessed containers. The vial pack cover generally includes: (1) a plurality of plug portions joined together and formed from a heat curable rubber; and (2) a barrier layer covering each of the plug portions.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Technical Field  
           [0002]    The present invention generally relates to a vial pack cover, a vial pack kit, and a method for forming the same. More particularly, the present invention relates to a vial pack cover and method for forming the same for engaging a vial pack having a plurality of containers therein.  
           [0003]    2. Background Art  
           [0004]    In the medical, analytical chemistry, and biotechnology field, vial packs are often used for simultaneously testing multiple reactions. Such vial packs often include a plurality of compartments into which vials or other similar vessels are placed. Materials or samples are inserted into the removable vials, or in some instances, directly into the compartments of the vial pack. Accordingly, a cover or microplate is required for the vial pack so that the samples contained therein will not be spilled or otherwise released to the surrounding environment, contiguous containers, or become contaminated with outside agents. Heretofore, many have attempted to solve this problem by employing inferior variations. Examples include the following, all of which are herein incorporated by reference:  
           [0005]    U.S. Pat. No. 2,698,272 to Clapp et al.;  
           [0006]    U.S. Pat. No. 2,884,150 to Weichselbaum et al.;  
           [0007]    U.S. Pat. No. 3,302,854 to Midgley et al.;  
           [0008]    U.S. Pat. No. 3,744,661 to Fischer, Jr.;  
           [0009]    U.S. Pat. No. 5,112,574 to Horton;  
           [0010]    U.S. Pat. No. 5,282,543 to Picozza et al.; and  
           [0011]    U.S. Pat. No. 5,324,482 to Scaramella et al.  
           [0012]    All of these related art devices are inadequate because they fail to provide, inter alia, a barrier layer on a cover. The failure to provide a barrier layer can result in the degredation of the cover from solvents or other material placed within the containers. Moreover, a barrier layer prevents gasses accumulated within the containers from permeating through the cover and into the surrounding environment.  
           [0013]    In addition, none of the related art references disclose a cover that allows a user to simultaneously cover a plurality of containers while still allowing the user to access an individual container without having to remove the cover from the entire vial pack. Accordingly, with these related devices, a user must remove the cover from all of the containers to access one individual container. Such a requirement may lead to spillage of the samples contained therein or contamination by outside agents. Therefore, there exists the need for a vial pack cover and method for forming the same that will allow a user to simultaneously cover a plurality containers without concern for the cover being degraded or permeated therethrough by the contents of the containers. In addition, there exists a need for the cover to be such that a user may access individual containers without having to remove the cover from the un-accessed containers.  
         SUMMARY OF THE INVENTION  
         [0014]    The present invention overcomes the deficiencies of the related art by including a vial pack cover and method for forming the same that will allow a user to simultaneously cover a plurality of containers while preventing the contents held therein from degrading the cover, permeating through the cover, or contaminating other containers. In addition, the vial pack cover of the present invention is such that a user may access individual containers while allowing the cover to remain on the un-accessed containers.  
           [0015]    According to one aspect of the present invention, a method for forming a coated vial pack cover is provided, which includes: (1) providing a barrier layer on a mold having a plurality of cavities therein; (2) providing an amount of heat curable rubber to the mold; (3) forming a vial pack cover, including a plurality of plug portions coated with the barrier layer; and 4) removing the vial pack cover from the mold.  
           [0016]    According to a second aspect of the present invention, a method of using a coated heat curable rubber as a cover for a vial pack is provided. The method includes: (1) providing a heat curable rubber cover including a plurality of plug portions, wherein the plug portions are coated with a barrier layer; and (2) engaging the cover with a vial pack having a plurality of containers therein, wherein each plug portion releasably engages one of the containers  
           [0017]    According to a third aspect of the present invention, a vial pack cover is provided. The vial pack cover includes: (1) a plurality of plug portions joined together, wherein the plug portions are formed from a heat curable rubber; and (2) a barrier layer covering each of the plug portions.  
           [0018]    According to a fourth aspect of the present invention, a vial pack cover is provided and includes: (1) a support sheet; (2) a plurality of plug portions fixed to the support sheet, wherein both the support sheet and the plug portions are formed from heat curable rubber; and (3) a barrier layer, wherein the barrier layer coats each of the plug portions.  
           [0019]    According to a fifth aspect of the present invention, a vial pack kit is provided. The vial pack kit includes: (1) a pack, wherein the pack includes a plurality of containers; and (2) a cover for covering the pack, wherein the cover includes: (a) a support sheet; (b) a plurality of plug portions integrally formed as a part of the support sheet, wherein both the support sheet and the plug portions are formed from a heat curable rubber; and (c) a barrier layer coating each of the plug portions, wherein each plug portion releasably engages one of the containers of the pack.  
           [0020]    According to a sixth aspect of the present invention, a vial pack kit is provided. The vial pack kit includes: (1) a device for covering a vial pack including a plurality of plug portions formed from a heat curable rubber, wherein the plug portions are joined together; and (2) an apparatus for removing one of the plug portions from the device.  
           [0021]    It is therefore an advantage of the present invention to provide a vial pack cover for simultaneously covering a plurality of containers while preventing the contents of the containers from degrading or permeating through the cover. In addition, it is also an advantage of the present invention to provide a cover that will allow a user to access individual containers without having to remove the cover from the un-accessed containers.  
           [0022]    The invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. Further, the abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0023]    These and other features and advantages of this invention will be more readily understood from the following detailed description of the various aspects of the preferred embodiments of the invention taken in conjunction with the accompanying drawings in which:  
         [0024]    [0024]FIG. 1 is a flow chart of a method for forming a coated vial pack cover in accordance with an embodiment of the present invention;  
         [0025]    [0025]FIG. 2 is a flow chart of a method of using a coated heat curable rubber as a cover for a vial pack in accordance with an embodiment of the present invention;  
         [0026]    [0026]FIG. 3 is a front sectional view of a heat curable rubber and a mold in accordance with an embodiment of the present invention;  
         [0027]    [0027]FIG. 4 is a top view of a vial pack in accordance with an embodiment of the present invention;  
         [0028]    [0028]FIG. 5 is a top view of a vial pack cover in accordance with an embodiment of the present invention;  
         [0029]    [0029]FIG. 6 is a partial side view of the vial pack cover prior to engaging the vial pack in accordance with an embodiment of the present invention; and  
         [0030]    [0030]FIG. 7 is a front view of a cutter from one embodiment of the present invention for removing one portion of the vial pack cover.  
         [0031]    It is noted that the drawings of the invention are not to scale. The drawings are merely schematic representations, not intended to portray specific parameters of the invention. The drawings are intended to depict only typical embodiments of the invention, and therefore should not be considered as limiting the scope of the invention. In the drawings, like numbering represents like elements between the drawings.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0032]    Referring now to the drawings, FIGS. 1-7 show the vial pack cover and method for forming the same in accordance with the present invention. FIG. 1, depicts a flowchart of a method  10  for forming a vial pack cover  36 . The first step  12  of the method  10  is to provide a barrier layer  50  on a mold having a plurality of cavities  27  therein. The mold is shown in FIG. 3 and includes body portion  26 , depressions  27 , and cap  22  having finger-like projections  23  thereon. Although a precise number of depressions is not necessary, many vial packs  28  are formed with specific number compartments. Thus, the mold used to form the vial pack cover  36  should include an equal quantity of depressions. In addition, although, the barrier layer  50  is shown as being applied only to the body portion  26  of the mold, it should be understood that the barrier layer  50  may be applied to additional components of the mold depending on the needs of the user and the product that is desired.  
         [0033]    Barrier layer  50  is preferably polytetrafluoroethylene (PTFE), however it should be understood that many equivalents exist. For example, any material that will protect an elastomer from solvents, such as toluene, acetone, or the like and that will slow down or prevent the permeation of gasses will suffice, such as aluminum. In addition, barrier layer  50  is preferably applied to the base portion  26  of the mold by spraying. However, it should be understood that other application techniques can be used. For example, barrier layer  50  could be applied as a solid, dry pre-formed sheet that takes the form of the base portion  26 , including the depressions  27 .  
         [0034]    The next step  14  in the method  10  is to provide an amount of heat curable rubber  24  to the mold. The heat curable rubber is the material that will form the vial pack cover  36  after the method  10  is complete. Preferably the heat curable rubber is silicone rubber, however it should be appreciated that many equivalents may be used. For example, the heat curable rubber  24  can be any silicone elastomer, organic elastomer, viton, sanoprene, or EPDM. In addition, the heat curable rubber  24  is preferably provided to the mold in a 2″×4″ segment weighing approximately 24 grams. However, it should be understood that the quantity of the heat curable rubber  24  that is provided to the mold will vary with the size and dimensions of the mold.  
         [0035]    It should also be appreciated that the barrier layer  50  can be applied or sprayed directly onto the heat curable rubber  24  prior to its insertion into the mold. This can be in addition to in or lieu of the application of the barrier layer  50  to the mold.  
         [0036]    The next step  16  of the method  10  is to form a vial pack cover  36  that includes a plurality of plug portions  48 . This is generally accomplished by a compression molding. Specifically heat and pressure are applied to the mold to cure the heat curable rubber into a vial pack cover  36  having a plurality of plug portions  48 , each of which are coated with the barrier layer  50 . The heat and pressure applied to the mold are preferably about 340 F and about 500 PSI, respectively. However, it should be understood that the operating conditions may vary. In addition, although compression molding is preferred, it should be appreciated that other processes may be used. For example, a liquid injection molding (LIM) process or a room temperature vulcanizing (RTV) process could be implemented.  
         [0037]    Finally, the last step  17  of the method  10  is to remove the completed vial pack cover  36  from the mold. FIGS. 5 and 6 show the vial pack cover  36  constructed in accordance this method  10 . Referring to these FIGS., the vial pack cover  36  generally includes a support sheet  42 , a top surface  44  of plug portion  48 , needle aperture  40 , optional ribbing  38  and  46 , and a barrier layer  50  covering the plug portions  48 . The ribbing  38  is optional and can be used to join the plug portions  48  together and to increase the overall durability and strength of the vial pack cover  36 . In addition, as indicated above, the barrier layer is preferably applied only to the base portion  26  of the mold. Accordingly, only the bottom surface of the support sheet  42  and the plug portions  48  are shown as having been covered with the barrier layer  50 . However, if the user had applied the barrier layer to additional components of the mold, it should be understood that additional locations of the vial pack cover  36  would also be covered by the barrier layer  50  in additional locations.  
         [0038]    The vial pack cover  36  is used to engage a vial pack  28  or other similar container. As shown in FIGS. 4 and 6 the vial pack  28  includes a body portion  52 , an upper surface  30 , and compartments  34 . As indicated above, a precise quantity of compartments  34  is not necessary, however, it should also be understood that the quantity of compartments  34  should be matched by the quantity of plug portions  48 . In addition, the vial pack  28  should be constructed of a material that will not be degraded by the contents placed therein, as known by those of ordinary skill in the art.  
         [0039]    Inside of the compartments  34 , vials  32  or other similar storage vessels may optionally be placed. A user can insert the materials to be tested inside of the vials  32  or into the compartments  34  directly. It should be understood that the term containers as set forth herein refers to either the compartments or the vials.  
         [0040]    Once the materials have been inserted into the compartments, the user will then engage the vial pack cover  36  with the vial pack  28 , and in the event vials  32  are used, with the vials  32  as well. Optionally, the vial pack  28  may include a ridge or groove  54 . In such an embodiment, the ribbing  46 , optionally disposed along the periphery of the support sheet  42  of the vial pack cover  36 , will engage the ridge  54  to aid in retaining the vial pack cover  36  to the vial pack  28 . It should be understood, however, that many equivalent variations exist for further securing the vial pack cover  36  to the vial pack  28 . For example, a clamp(s) (not shown), complementary male and female connectors (not shown), snap connectors (not shown), or various adhesives (not shown) could be used.  
         [0041]    Once the vial pack cover  36  is secured over the vial pack  28 , the plug portions  48  will protrude into the openings of compartments  34  and, if used, the openings of the vials  32  as well. The plug portions  48  are formed to releasably engage the compartments  34  or, if used, the vials  32 . In particular, the frictional force between the plug portions  48  and the compartments  34  or the vials  32  will ensure that the vial pack cover  36  remains secured thereto such that material contained within the compartments  34  or vials  32  will remain therein.  
         [0042]    The purpose of the barrier layer  50  is to ensure that the vial pack cover  36 , and more specifically the plug portions  48 , do not become degraded or damaged by the materials placed within the compartments  34  or the vials  32 . In addition, barrier layer  50  will slow down or prevent the permeation of gasses from inside of the compartments  34  or vials  32  to the outside environment. In related devices that lack the barrier layer  50 , not only are increased instances of cover degradation observed but also increased permeation of gasses through the cover  36 . Gas permeation through the vial pack cover  36  leads to contamination of the surrounding environment as well as the degraded accuracy of the medical, chemical, or biotechnological test(s) being performed due to loss of the sample.  
         [0043]    As indicated above, silicone rubber is preferred as the material from which the vial pack cover  36  is formed because of its various characteristics. Specifically, silicone rubber is able to maintain its consistency and characteristics from temperatures as low as about −165 F to as high as about 600 F In addition, silicone rubber is clean when punctured inasmuch as a needle or syringe can penetrate the silicone without becoming contaminated with fragments of silicone. Moreover, once punctured by a needle or the like, silicone rubber is compliant and will re-seal.  
         [0044]    Once the vial pack cover  36  is secured over the vial pack  38 , a user may perform testing or other operation on the contents of the compartments  34  or vials  32  by injected materials through the needle apertures  40  positioned on the top surface  44  of the plug portions  48 . The needle apertures  40  do not extend completely through the plug portion  48 . In contrast, they extend only partially therethrough to ensure that the material contained within the compartments  34  or the vials  32  does not spill through the needle apertures  40 . The needle apertures are preferably formed during the molding of the vial pack cover  36  and are formed by the finger-like projections  23  disposed along the cap  22  of the mold. However, it should be appreciated that many variations exist for forming the needle apertures  40 . For example, the needle apertures  40  can be formed after the molding has been completed.  
         [0045]    By injecting the desired material through the vial pack cover  36 , a user is not forced to remove the cover from the vial pack  28 . Thus, spillage of the materials contained within the compartments  34  or the vials  32  is not risked. In addition, because the vial pack cover  36  is formed from a silicone or organic elastomer, it is easily and cleanly penetrable by a needle or syringe and will re-seal upon the withdrawal of the needle. This will ensure that fragments of the vial pack cover  36  do not contact and/or contaminate the materials contained within the compartments  34  or the vials  32 . Moreover, by using an elastomer that is re-sealable, the hole made in the plug portion  48  by the needle will close once the needle is withdrawn. Thus, reducing the risk of material spillage.  
         [0046]    Referring to FIG. 7, a cutter  56  is shown and generally includes a handle portion  58 , a cutting portion  60 , and a cutting edge  64 . As shown the cutter  56  can be used to remove individual plug portions  48  and/or vials  32  from the vial pack  28 . This need arises when a user desires to access one of the compartments  34  or vials  32 . Without a cutter, a user must completely remove the entire vial pack cover  36  from the vial pack  28  in order to access individual compartments  34  or vials  32 . Such as requisite often leads to spillage or contamination of the materials contained therein. However, with the cutter  56  of the present a user can access individual compartments  34  or vials  32 .  
         [0047]    To be used, the cutter  56  is centered over the plug portion  48  of the compartment  34  or vial  32  in which access is desired. The cutter  56  is then moved in the direction indicated by directional arrow  62  while being rotated about the plug portion  48 . The cutting edge  64  will cut through the support sheet  42  and the ribbing  38 , thus, freeing an individual plug portion  48  from the vial pack cover  36 . The user is then left with either an individual vial  32  that is plugged and free from the vial pack  28  or an individually uncovered compartment  34 . However, the vial pack cover  36  remains firmly secured over the unaccessed compartments  34  or vials  32 . Although a specific design for the cutter  56  has been described, it should be appreciated that many equivalent devices could be implemented. Moreover, it is envisioned that other apparatuses may be used for removing the plug portions  48 . For example, the upper surface  44  of the plug portions  48  could be constructed with perforations or serrated edges allowing the user to manually remove individual plug portions  48  from the cover  36 .  
         [0048]    [0048]FIG. 2 shows another method  18  in accordance with the present invention. Specifically, the method  18  is a method of using a coated heat curable rubber as a cover for a vial pack. The first step  20  of the method is to provide a heat curable rubber including a plurality of plug portions coated with a barrier layer. This structure represents the vial pack cover  36  formed from the method  10  and is described above. The second step  21  is to engage the cover  36  with a vial pack  28  having a plurality of containers therein. This indicates that each plug portion  48  of the vial pack cover  36  will releasably engage either a compartment  34  or, if used, a vial  32 , as described in detail above.  
         [0049]    With respect to the first method  10 , the following experiment run was recorded:  
         [0050]    (1) the mold was preheated to 340 F;  
         [0051]    (2) preforms of silicone rubber of approximately 0.200″ in thickness were provided;  
         [0052]    (3) the preforms were cut to 1½″ in width and 3″ in length and weighed 24 grams;  
         [0053]    (4) the bottom of the mold was sprayed with CAMIE 2000 TEFLON;  
         [0054]    (5) the part were molded using 20 tons on the lab press and 3000 psi on the lab extension press;  
         [0055]    (6) the molding was performed using a 5 minute cycle time;  
         [0056]    (7) the molded parts were removed from the mold and another preform(s) was inserted into the mold for the next cycle; and  
         [0057]    (8) the cycle was repeated.  
         [0058]    The foregoing description of the preferred embodiments of this invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously, many modifications and variations are possible. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims.