Patent Description:
Medical rubber products applied to pharmaceutical preparation containers are required to have a high level of quality characteristics and a high level of physical properties. For example, quality characteristics that are required of medical rubber plugs for sealing or plugging an opening of a vial preserving therein a preparation such as an antibiotic should, in terms of use of the medical rubber plugs, comply with the regulations stipulated in "<NPL>. Further, medical rubber plugs for, for example, sealing an opening of a vial are required to have many characteristics such as resistance to gas permeation, non-oozing characteristics, high cleanability, chemical resistance, resistance to needle piercing, and self-sealability.

<CIT> discloses a medical rubber plug that is applied to a port portion of a medical container and that has a piercing portion capable of being pierced by an injection needle of an injector. The medical rubber plug has an upper surface portion provided with a nylon film layer having a thickness of <NUM> to <NUM>.

<CIT> discloses a plug manufacturing method as a two-stage molding method including: molding a leg portion; and then molding a capping portion while adhering the capping portion to the leg portion. The plug manufacturing method includes sandwiching, between the leg portion and the capping portion, a film made from a polymer alloy composed of at least one selected from the group consisting of olefin-based plastics and synthetic rubbers and at least one selected from among thermoplastic elastomers.

<CIT> discloses a medical rubber plug including: a flange portion having the shape of a disc; and a leg portion formed so as to be contiguous with a lower surface side of the flange portion. A region on the lower surface side of the flange portion, and the leg portion, are each made from a nitrile-based rubber. A region on an upper surface side of the flange portion is made from a butyl-based rubber. The leg portion is laminated with a coating layer made from a fluorine-based resin film.

International Publication No. <CIT> discloses a rubber molded product for a cryogenic storage container, the rubber molded product being obtained by stacking a silicone rubber in which an elastomer has been blended and a butyl-based rubber or a silicone rubber in which an elastomer has been blended, with a polyethylene film having a molecular weight of <NUM> million to <NUM> million being interposed therebetween.

<CIT> discloses a rubber plug for a reduced-pressure blood collecting tube, the rubber plug being used for a reduced-pressure blood collecting tube in which the degree of reduction in the pressure thereof needs to be maintained. The rubber plug includes a film made from a material having gas barrier properties and a rubber plug body made from a thermoplastic elastomer. The rubber plug is configured to substantially prevent air from being diffused through the rubber plug into the reduced-pressure blood collecting tube.

<CIT> discloses a rubber gasket for vacuum blood sampling tube.

A medical rubber plug for a medical container such as a vial is subjected to operations of: piercing the medical rubber plug by an injection needle; and pulling out the injection needle after a medical preparation is suctioned from the medical container into the injector. When the injection needle is pulled out, a problem arises in that a residual liquid in the medical container leaks from a gap formed through the piercing by the injection needle and is scattered to the surroundings.

The present disclosure has been made in view of the above circumstances, and an object of the present disclosure is to provide a medical rubber plug through which little residual liquid in a medical container leaks even when an injection needle is pulled out from the medical rubber plug.

A medical rubber plug of the present disclosure is a medical plug including: a capping portion; and a leg portion extending downward from the capping portion, wherein the medical rubber plug includes a piercing portion consisting of a first portion and a second portion, wherein the first portion is located on the leg portion side and the second portion is located on an upper surface side of the first portion, and the first portion and the second portion are adjacent to each other in an up/down direction, and are not adhered to each other.

If the medical plug of the present disclosure is used, a residual liquid in a medical container does not leak even when an injection needle is pulled out from the medical plug.

The present invention provides a medical rubber plug according to claim <NUM>.

The medical rubber plug of the present disclosure has an up/down direction. The upper surface side is defined as an upper side, and the leg portion side is defined as a lower side. The medical rubber plug of the present disclosure includes: the capping portion; and the leg portion extending downward from the capping portion.

The capping portion preferably has the shape of a disc. The diameter of the capping portion having the shape of a disc can be designed as appropriate according to the size of a medical container to be plugged.

The capping portion includes: the piercing portion capable of being pierced by an injection needle of an injector; and a flange portion which is, when a medical container is plugged with the medical rubber plug, brought into contact with an upper rim surface of a port portion of the medical container.

The piercing portion is preferably present at the center of the capping portion in a plan view of the medical rubber plug. The piercing portion of the capping portion preferably has a circular shape in the plan view. The piercing portion is preferably formed in a shape recessed from an upper surface of the capping portion.

The upper surface of the capping portion is also preferably provided with projections for imparting an effect of, when the medical rubber plug is cleaned, sterilized, and dried, preventing close contact between the rubber plug and another rubber plug and preventing close contact between the rubber plug and a cap rolled and fastened onto the rubber plug.

Each projection is preferably a projection projecting from a part of an upper surface of the flange portion. The planar shape of the projection is not particularly limited and may be not only a circular shape or a nearly circular shape such as an elliptic shape, a semicircular shape, a fan shape, or an oval shape but also a nearly rectangular shape that is a track shape in which sides of a rectangle facing each other have been replaced with semicircles, or the like. These projections preferably have small contact surfaces in consideration of: a case where, at the time of conveyance or cleaning in a parts feeder, the rubber plug comes into close contact with a wall surface thereof; and a case where a large number of rubber plugs are packed in a bag together. These projections are preferably projections that, when the rubber plug is inverted, support a body of the rubber plug over the entire circumference of an upper surface of the body not at surfaces but at points. The number of the projections is not particularly limited but is preferably <NUM> to <NUM>. The arrangement state of the projections is also not particularly limited, but the projections are preferably arranged in a radial pattern or along the circumference of the flange portion.

The medical rubber plug of the present disclosure includes the leg portion extending downward from a lower surface of the capping portion. When the medical container is plugged with the medical rubber plug of the present disclosure, the leg portion is fitted into a port portion of the medical container.

The shape of the leg portion is not particularly limited as long as the shape allows the leg portion to be fitted into the port portion of the medical container. Examples of the leg portion can include: a leg portion with a cylindrical continuous shape; and a plurality of leg portions in the forms of two or more branching portions.

The leg portion with a cylindrical continuous shape or the plurality of leg portions in the forms of two or more branching portions have inner surfaces facing each other that are preferably formed in a tapered shape such that the distance between the inner surfaces of the leg portion(s) gradually decreases from the lower side to the upper side (upper surface side).

In one mode of the present disclosure, the medical rubber plug includes a piercing portion in which: a first portion located on the leg portion side and a second portion located on an upper surface side of the first portion are provided; and the first portion and the second portion are not adhered to each other.

The first portion is a portion of the piercing portion that is located on the leg portion side, and has a portion of the piercing portion that is located on the lower side of the capping portion. The first portion may have the leg portion in addition to the portion of the piercing portion that is located on the lower side of the capping portion.

The second portion is a portion located on the upper surface side of the first portion and has a portion of the piercing portion that is located on the upper side of the capping portion. The second portion may have the flange portion of the capping portion in addition to the portion of the piercing portion that is located on the upper side of the capping portion. The first portion and the second portion of the medical rubber plug of the present disclosure are, in the piercing portion, preferably adjacent to each other in the up/down direction. That is, the boundary in the up/down direction between the first portion and the second portion is preferably present in the capping portion at the piercing portion.

Although the first portion and the second portion are not adhered to each other in the piercing portion, the first portion and the second portion may be adhered to each other in a region other than the piercing portion. In this mode, when the injection needle is pulled out, the second portion is elastically deformed so that a space is generated between the first portion and the second portion. The space serves as a buffer space to accommodate a drug solution having leaked from the medical container. Thus, the medical plug of the present disclosure enables reduction in liquid leakage.

Examples of a method for causing the first portion and the second portion not to be adhered each other can include: a method in which the leg portion and the capping portion are separately obtained through vulcanization molding, and, at the time of adhering the leg portion and the capping portion to each other by an adhesive agent, the adhesive agent is not applied to either of piercing regions of the leg portion and the capping portion, and the adhesive agent is applied to regions outside the piercing regions; and a method in which the leg portion is obtained through vulcanization molding, a mold release agent is applied only to a piercing region of the upper surface of the molded leg portion, an unvulcanized rubber sheet is stacked on the piercing region, and the capping portion is obtained through vulcanization molding.

In another preferable mode of the present disclosure (not claimed), it is preferable that: the medical rubber plug includes one film between the first portion and the second portion; and, in the piercing portion, the film is adhered to one of the first portion and the second portion and not adhered to another one of the first portion and the second portion.

In this mode (not claimed), when the injection needle is pulled out, the second portion is elastically deformed so that a space is generated between the film and either the first portion or the second portion that is not adhered to the film. The space serves as a buffer space to accommodate the drug solution having leaked from the medical container. Thus, the medical plug of the present disclosure enables reduction in liquid leakage.

A mode in which a material having a higher rigidity than a rubber material forming the first portion or the second portion is used for the film, is also preferable. A space is easily generated owing to the difference between the rigidity of the film and the rigidity of the first portion or the second portion (not claimed).

It is preferable that: the medical plug includes at least two films between the first portion and the second portion; and, in the piercing portion, the first portion and a first film, out of the films, that is in contact with the first portion are adhered to each other, the second portion and a second film, out of the films, that is in contact with the second portion are adhered to each other, and the first film and the second film are not adhered to each other (not claimed).

In this mode (not claimed), when the injection needle is pulled out, the second portion is elastically deformed so that a space is generated between the first film and the second film which are not adhered to each other. The space serves as a buffer space to accommodate the drug solution having leaked from the medical container. Thus, the medical plug of the present disclosure enables reduction in liquid leakage.

Although the number of the films to be disposed between the first portion and the second portion is not particularly limited as long as the number is two or more, the number is preferably two (not claimed).

In the piercing portion, the shape of each film disposed between the first portion and the second portion is, in the plan view, preferably identical or similar to the shape of the piercing portion and more preferably a circular shape (not claimed). The proportion of the area of the film to the area of the piercing portion is preferably not lower than <NUM>%, more preferably not lower than <NUM>%, and further preferably not lower than <NUM>%. Meanwhile, the proportion is preferably not higher than <NUM>%, more preferably not higher than <NUM>%, and further preferably not higher than <NUM>%.

The film and the piercing portion are preferably arranged so as to overlap with each other in the plan view (not claimed). In the case where the shapes of the film and the piercing portion are identical to each other, the film and the piercing portion are preferably arranged so as to be superposed on each other. In the case where the shapes of the film and the piercing portion are similar to each other, the film and the piercing portion are preferably arranged such that the centers of the similar shapes are present within the film and the piercing portion.

In the piercing portion, a resin film is preferable as the film to be disposed between the first portion and the second portion (not claimed). As the resin film, at least one resin film selected from the group consisting of fluorine resin, polyamide, and ultrahigh-molecular-weight polyethylene (UHMWPE) is preferable.

Examples of the fluorine resin can include at least one fluorine resin selected from the group consisting of polytetrafluoroethylene (PTFE), tetrafluoroethylene-ethylene copolymer (ETFE), tetrafluoroethylene-peralkyl vinyl ether copolymer (PFA), polychlorotrifluoroethylene (PCTFE), polyvinylidene fluoride (PVDF), and polyvinyl fluoride (PVF).

Tetrafluoroethylene-ethylene copolymer (ETFE) is obtained by copolymerizing ethylene and tetrafluoroethylene in a molar ratio of <NUM>/<NUM> to <NUM>/<NUM>, and examples of the ETFE include a modified ETFE obtained by further copolymerizing another component for the purpose of modification. Examples of the other component include fluorine-containing olefins and hydrocarbon-based olefins. Specific examples of the other component include: α-olefins such as propylene and butene; fluorine-containing olefins such as hexafluoropropylene, vinylidene fluoride, perfluorobutylethylene, and trifluorochloroethylene; vinyl ethers such as ethyl vinyl ether, perfluoromethyl vinyl ether, and perfluoropropyl vinyl ether; fluorine-containing acrylates; and the like. About <NUM> to <NUM>% by mole of the other component is copolymerized to modify the ETFE.

Examples of the polyamide include polyamide <NUM>, polyamide <NUM>, polyamide <NUM>, polyamide <NUM>, polyamide <NUM>, polyamide <NUM>, copolymerized polyamide, monomer casting polyamide, polyamide MXD, polyamide <NUM>, and the like. The polyamide may contain fluorine.

The thickness of the film is preferably small. Specifically, the thickness is preferably not smaller than <NUM>, and meanwhile, preferably not larger than <NUM>, more preferably not larger than <NUM>, and further preferably not larger than <NUM>. The reason for this is because, if the thickness of the film is set to fall within the aforementioned range, a resistance at the time of piercing decreases.

Examples of a method for adhesion between the film and the first portion or the second portion can include: a method involving adhesion by vulcanization; a method involving adhesion with an adhesive agent; a method involving usage of an adhesive film; and the like.

In the case of performing adhesion by vulcanization, it is preferable that: a region, of the film, that is to be adhered is subjected to surface roughening treatment; and a region, of the film, that is not to be adhered is not subjected to surface roughening treatment. The reason for this is because, if the surface of the film is subjected to surface roughening treatment, the film and rubber can be firmly fixed to each other through vulcanization molding without using any adhesive material or the like. This fixation is achieved by the anchor effect in which vulcanized rubber enters the roughened inner surface of the film.

For roughening of the surface of the film, it is possible to employ, for example, a method in which an ion beam is applied to the surface so that the molecular structure of the inside near the surface is destroyed to perform the roughening (see, for example, <CIT>). Examples of the surface roughening treatment for the film include, in addition to the ion beam treatment, glow discharge treatment, plasma treatment (discharge treatment) under atmospheric pressure or under a vacuum, excimer laser treatment (discharge treatment), and the like. Further, examples of the treatment for increasing the adhesiveness between the rubber and the film include, in addition to the surface roughening treatment for the film, chemical treatment in which surface treatment is performed by using an acid, an alkali (for example, sodium hydroxide), or the like. In this case, it is preferable that the region, of the film, that is not to be adhered is not subjected to the chemical treatment.

The adhesive agent for adhesion between the film and the first portion or the second portion is not particularly limited, and, for example, it is possible to use: a thermosetting resin adhesive agent containing, as a component, at least one resin among phenol resins, resorcin resins, furan resins, polyurethane, epoxy resins, or silicone resins; a thermoplastic resin adhesive agent containing, as a component, at least one resin among polyvinyl acetate, polyvinyl chloride, or polyacrylic acid esters; an elastomer adhesive agent containing, as a component, at least one of butadiene acrylonitrile rubber or neoprene; and the like.

Examples of the method for the adhesion can include a method in which an adhesive film having functional groups in surfaces thereof is used as a film. The adhesive film has adhesiveness to rubber owing to an effect of functional groups that are present in the surfaces of the adhesive film. In a method in which an adhesive film, both surfaces of which have adhesiveness to rubber owing to the effect of the functional groups, is used, functional groups on the first portion side (leg portion side) are not deactivated but functional groups on the second portion side (upper surface side) are deactivated at the time of a first stage of vulcanization molding as described later. Therefore, the adhesive film is adhered to the first portion but is not adhered to the second portion (on the upper surface side). As the adhesive film, it is also possible to use an adhesive film, only one surface of which has adhesiveness to rubber owing to the effect of the functional groups.

Examples of the adhesive film having functional groups can include modified ETFE. Examples of the functional groups include a carboxyl group, a carboxylic anhydride group, an epoxy group, a hydroxy group, an isocyanate group, an ester group, an amide group, an aldehyde group, an amino group, a cyano group, a carbon-carbon double bond, a sulfonic acid group, an ether group, and the like. Examples of commercially available modified ETFEs include Fluon AH-<NUM> manufactured by AGC Inc. , and the like.

The leg portion of the medical rubber plug may be laminated with a resin film or coated with a silicone lubricant. The lamination or the coating makes it possible to prevent close contact between rubber plugs and smoothly convey, by a parts feeder, the rubber plugs each having an inverted posture with the upper surface of the capping portion being oriented to a conveyance surface. Not only the leg portion but also the upper surface of the capping portion can be laminated, and the resin film can be used in the same manner as in the case of the leg portion.

The thickness of the resin film used for lamination of the upper surface or the leg portion is preferably <NUM> to <NUM> and more preferably <NUM> to <NUM>. If the thickness is smaller than <NUM>, there is a tendency that the film is torn at many locations during molding. Meanwhile, if the thickness is larger than <NUM>, there is a tendency that: the dimensional stability of a molded product decreases; and cost for the molded product increases so that the molded product becomes uneconomical.

Examples of the resin film include films made from inactive resins such as polytetrafluoroethylene (PTFE), tetrafluoroethylene-ethylene copolymer (ETFE), modified products thereof, and ultrahigh-molecular-weight polyethylene (UHMWPE). Among these resin films, a film made from a fluorine resin is preferable since such a film is inactive, has excellent heat resistance, chemical resistance, and non-adhesiveness, and has a lower friction resistance than rubber.

The resin film only has to be, for example, press-molded in a state of being superposed on a rubber composition having the shape of a sheet such that the resin film is integrated with the medical rubber part formed after the press-molding.

As a type of sterilization for the medical rubber plug, sterilization with vapor, sterilization with ethylene oxide gas, or sterilization with gamma ray is performed, and meanwhile, PTFE has a low resistance to gamma ray. Considering this, ETFE, modified ETFE, and PCTFE each having a high resistance to sterilization with gamma ray are particularly preferable.

The upper side of the capping portion can be covered with a cap that is made from metal (for example, aluminum) or resin and that can cover an opening end of the medical container and the medical rubber plug. The purpose of tightly closing the medical rubber plug together with the opening end of the medical container by using the cap is to prevent bacteria from adhering at a location at which the piercing portion is to be pierced by an injection needle of an injector, and thus prevent the bacteria from entering an injection drug solution from the injection needle. Regarding the type of the cap, a flip-off cap, a pull-top cap, a clean cap, or the like can be used. In the case where a large amount of injection drug solution is used as in a hospital, it is preferable to use a clean cap that can be opened with one hand and that is easy to handle.

A thermoplastic resin or a thermoplastic resin composition having a melting point, obtained according to the measurement method stipulated in ASTM-D2117, of <NUM> to <NUM> can be used as a material for the cap. The reason for this is because such a thermoplastic resin or thermoplastic resin composition can be easily molded through injection molding. Specific examples of the thermoplastic resin and the thermoplastic resin composition include: a synthetic resin composed of one or more selected from among polyacetal (POM), polyamide (PA), polyarylate (PAR), polyether ether ketone, ethylene-propylene copolymer, polypropylene (PP), polyethylene terephthalate (PET), liquid crystal polyester (LCP), polyphenylene ether (PPE), modified polyphenylene ether, polycarbonate (PC), polymethylpentene (PMP), polyurethane (PU), polyethylene (PE), polybutylene phthalate, polysulfone (PS), polyethersulfone (PES), ultrahigh-molecular-weight polyethylene, cyclic olefin-based compounds, copolymers containing a crosslinked polycyclic hydrocarbon as a polymer component, and the like; and a composition of the synthetic resin. If a thermoplastic resin obtained by blending an organic-based reinforcing agent or an inorganic-based reinforcing agent with a thermoplastic elastomer forming the plug is used, a cap having a very high hardness and a very high strength is obtained.

The medical rubber plug of the present disclosure is preferably formed from a medical rubber composition containing a (a) rubber component. As the (a) rubber component, isobutylene-isoprene rubber is preferable and halogenated isobutylene-isoprene rubber is more preferable in terms of chemical resistance and resistance to gas permeation. Examples of the halogenated isobutylene-isoprene rubber include: chlorinated isobutylene-isoprene rubber; brominated isobutylene-isoprene rubber; a bromide of a copolymer of isobutylene and p-methylstyrene; and the like. As the halogenated isobutylene-isoprene rubber, a chlorinated isobutylene-isoprene rubber or a brominated isobutylene-isoprene rubber is preferable. The chlorinated isobutylene-isoprene rubber or the brominated isobutylene-isoprene rubber is obtained by, for example, causing a reaction in which: chlorine or bromine is added to an isoprene structural moiety (specifically, a double bond and/or a carbon atom adjacent to the double bond) in an isobutylene-isoprene rubber; or the isoprene structural moiety is substituted with chlorine or bromine. The isobutylene-isoprene rubber is a copolymer obtained by polymerizing isobutylene and a small amount of isoprene.

The (a) rubber component may contain a rubber component other than isobutylene-isoprene rubber. Examples of the other rubber component include isoprene rubber, butadiene rubber, styrene-butadiene rubber, natural rubber, chloroprene rubber, nitrile-based rubbers such as acrylonitrile butadiene rubber, hydrogenated nitrile-based rubbers, norbornene rubber, ethylene-propylene rubber, ethylene-propylene-diene rubber, acrylic rubber, ethyleneacrylate rubber, fluororubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, silicone rubber, urethane rubber, polysulfide rubber, phosphazene rubber, <NUM>,<NUM>-polybutadiene rubber, and the like. These rubber components may be used singly, or two or more of these rubber components may be used in combination.

In the case of using the other rubber component, the proportion of the isobutylene-isoprene rubber contained in the (a) rubber component is preferably not lower than <NUM>% by mass, more preferably not lower than <NUM>% by mass, and further preferably not lower than <NUM>% by mass. A mode in which the (a) rubber component contains only the halogenated isobutylene-isoprene rubber is also preferable.

The medical rubber composition of the present disclosure preferably further contains a (b) crosslinking agent. The (b) crosslinking agent is blended to cause crosslinking in the (a) rubber component. The (b) crosslinking agent is not particularly limited as long as the crosslinking agent can cause crosslinking in rubber. Examples of the (b) crosslinking agent can include sulfurs, metal oxides, resin crosslinking agents, organic peroxides, triazine derivatives, and the like. These crosslinking agents may be used singly, or two or more of these crosslinking agents may be used in combination.

In the medical rubber composition of the present disclosure, the amount of the (b) crosslinking agent contained per <NUM> parts by mass of the (a) rubber component is preferably not smaller than <NUM> parts by mass, more preferably not smaller than <NUM> parts by mass, and further preferably not smaller than <NUM> parts by mass. Meanwhile, the amount is preferably not larger than <NUM> parts by mass, more preferably not larger than <NUM> parts by mass, and further preferably not larger than <NUM> parts by mass. The reason for this is because, if the amount of the (b) crosslinking agent falls within the aforementioned range, a rubber having favorable rubber physical properties (hardness, tensile properties, Cset) and good processability (less susceptibility to scorching) can be obtained.

The medical rubber composition of the present disclosure preferably contains no vulcanization accelerator. The reason for this is because a vulcanization accelerator could remain in a rubber product obtained as a final product and could ooze into a drug solution inside a vial. Examples of the vulcanization accelerator include guanidine-based accelerators (e.g., diphenylguanidine), thiuram-based accelerators (e.g., tetramethylthiuram disulfide and tetramethylthiuram monosulfide), dithiocarbamate-based accelerators (e.g., zinc dimethyldithiocarbamate), thiazole-based accelerators (e.g., <NUM>-mercaptobenzothiazole and dibenzothiazyl disulfide), and sulfenamide-based accelerators (N-cyclohexyl-<NUM>-benzothiazole sulfenamide and N-t-butyl-<NUM>-benzothiazole sulfenamide).

The medical rubber composition of the present disclosure may contain a (c) hydrotalcite. The (c) hydrotalcite functions as an anti-scorching agent upon crosslinking in the halogenated isobutylene-isoprene rubber and also has a function of preventing increase in permanent strain upon compression in the medical rubber part. Further, the hydrotalcite functions also as an acid acceptor for absorbing chlorine-based gas and bromine-based gas, which have been generated upon crosslinking in the halogenated isobutylene-isoprene rubber, and preventing occurrence of, for example, crosslinking inhibition due to these gases. Magnesium oxide can also function as an acid acceptor.

Examples of the hydrotalcite include one or more of Mg-Al-based hydrotalcites such as Mg<NUM>Al<NUM>(OH)<NUM>CO<NUM>·<NUM><NUM>O, Mg<NUM>Al<NUM>(OH)<NUM>CO<NUM>, Mg<NUM>Al<NUM>(OH)<NUM>CO<NUM>·<NUM><NUM>O, Mg<NUM>Al<NUM>(OH)<NUM>CO<NUM>·<NUM><NUM>O, Mg<NUM>Al<NUM>(OH)<NUM>CO<NUM>·<NUM><NUM>O, and Mg<NUM>Al<NUM>(OH)<NUM>CO<NUM>·<NUM><NUM>O, and the like.

In the medical rubber composition of the present disclosure, a (d) filler may further be blended. Examples of the (d) filler include inorganic fillers such as clay and talc, resin powders of olefin-based resins, resin powders of styrene-based elastomers, and resin powders of ultrahigh-molecular-weight polyethylene (UHMWPE). Among these fillers, an inorganic filler is preferable and clay or talc is further preferable as the filler. The filler has a function of adjusting the rubber hardness of the medical rubber part and functions also as an extender for reducing manufacturing cost for the medical rubber part.

In the medical rubber composition of the present disclosure, the amount of the (d) filler is preferably set as appropriate according to a target rubber hardness of the medical rubber part and the like. In the medical rubber composition of the present disclosure, the amount of the (d) filler contained per <NUM> parts by mass of the (a) rubber component is, for example, preferably not smaller than <NUM> parts by mass, more preferably not smaller than <NUM> parts by mass, and further preferably not smaller than <NUM> parts by mass. Meanwhile, the amount is preferably not larger than <NUM> parts by mass, more preferably not larger than <NUM> parts by mass, and further preferably not larger than <NUM> parts by mass.

In the medical rubber composition of the present disclosure, a colorant such as titanium oxide or carbon black, stearic acid or low-density polyethylene (LDPE) as a lubricant, polyethylene glycol as a processing aid or as a crosslinking activator, a plasticizer (for example, paraffin oil), and the like may further be blended in appropriate proportions.

The medical rubber plug of the present disclosure is preferably manufactured through a two-stage molding method by using the medical rubber composition. Specifically, the manufacturing method for the medical rubber plug of the present disclosure includes: a step of making the first portion on the leg portion side; and a step of making the second portion on the upper surface side.

The medical rubber composition of the present disclosure is obtained by kneading the (a) rubber component and other blending materials to be added as necessary. The kneading can be performed by using, for example, an open roll, a sealed-type kneader, or the like. A kneaded product is preferably molded in the shape of a ribbon, the shape of a sheet, the shape of a pellet, or the like, and is more preferably molded in the shape of a sheet.

If the kneaded product having the shape of a ribbon, the shape of a sheet, or the shape of a pellet is press-molded, a medical rubber plug having a desired shape is obtained. A crosslinking reaction in the medical rubber composition progresses during the pressing. The temperature in the molding is, for example, preferably not lower than <NUM> and more preferably not lower than <NUM>. Meanwhile, the temperature is preferably not higher than <NUM> and more preferably not higher than <NUM>. The time for the molding is preferably not shorter than <NUM> minutes and more preferably not shorter than <NUM> minutes. Meanwhile, the time is preferably not longer than <NUM> minutes and more preferably not longer than <NUM> minutes. The pressure for the molding is preferably not lower than <NUM> MPa and more preferably not lower than <NUM> MPa. Meanwhile, the pressure is preferably not higher than <NUM> MPa and more preferably not higher than <NUM> MPa.

Hereinafter, the present disclosure will be described with reference to the drawings, but the present disclosure is not limited to modes shown in the drawings.

<FIG> (claimed) and <NUM>(b) (claimed) are each a diagram for explaining an example of the medical plug of the present disclosure. <FIG> (claimed) is a plan view, and <FIG> (claimed) is a cross-sectional view taken at a line A-A in <FIG>.

A medical plug <NUM> of the present disclosure includes a cylindrical leg portion <NUM> extending downward from a lower surface of a capping portion <NUM>. When a medical container is plugged with the medical plug of the present disclosure, the leg portion <NUM> is fitted into a port portion of the medical container. In <FIG> (claimed), the cylindrical leg portion <NUM> has inner surfaces facing each other that are formed in a tapered shape such that the distance between the inner surfaces of the leg portion gradually decreases from the lower side to the upper side (upper surface side).

The capping portion <NUM> has a circular shape in the plan view. The capping portion <NUM> includes: a piercing portion 3a capable of being pierced by an injection needle of an injector; and a flange portion 3b which is, when the medical container is plugged with the medical plug, brought into contact with an upper rim surface of the port portion of the medical container.

Projections <NUM> for preventing close contact with another rubber plug are provided on the upper surface side of the flange portion 3b.

The piercing portion 3a is a region, of the capping portion <NUM>, in which the injection needle is inserted in order to suction a drug solution inside the container. The piercing portion 3a has a circular shape in the plan view and is present at the center of the capping portion <NUM>. The piercing portion 3a is formed in a shape recessed from the upper surface.

In the piercing portion 3a in the medical rubber plug <NUM> of the present disclosure, a first portion <NUM> located on the leg portion side and a second portion <NUM> located on the upper surface side of the first portion <NUM> are provided. The first portion <NUM> and the second portion <NUM> are adjacent to each other in the up/down direction. In <FIG> (claimed), a boundary line <NUM> indicates the boundary between the first portion <NUM> and the second portion <NUM>. In the medical plug <NUM> of the present disclosure, the first portion <NUM> and the second portion <NUM> are not adhered to each other in the piercing portion 3a.

With such a configuration, when the injection needle is pulled out, the second portion <NUM> is elastically deformed so that a space is formed between the first portion <NUM> and the second portion <NUM>. The space serves as a buffer space to accommodate the drug solution having leaked from the medical container. Thus, the medical plug <NUM> of the present disclosure enables reduction in liquid leakage.

<FIG> (not claimed) and <NUM>(b) (not claimed) are each a diagram for explaining another mode of the medical rubber plug <NUM> of the present disclosure. <FIG> (not claimed) is a plan view, and <FIG> (not claimed) is a cross-sectional view taken at a line A-A in <FIG>. The medical rubber plug <NUM> in the present mode includes one film <NUM> between the first portion <NUM> and the second portion <NUM>. Descriptions about portions, of the medical rubber plug <NUM> in <FIG> (not claimed) and <NUM>(b) (not claimed), that share the configurations of the corresponding portions in <FIG>, will be omitted.

In the piercing portion 3a, the film <NUM> is adhered to one of the first portion <NUM> and the second portion <NUM> and not adhered to another one of the first portion <NUM> and the second portion <NUM>.

In this configuration as well, when the injection needle is pulled out, the second portion <NUM> is elastically deformed so that a space is formed between the film <NUM> and either of the first portion <NUM> and the second portion <NUM> to which the film is not adhered. The space serves as a buffer space to accommodate the drug solution having leaked from the medical container. Thus, the medical plug <NUM> of the present disclosure enables reduction in liquid leakage.

The film <NUM> is disposed so as to extend over the entirety in the horizontal direction of the piercing portion 3a. The film <NUM> and the piercing portion 3a are arranged so as to overlap with each other in the plan view.

<FIG> (not claimed) are each a diagram for explaining another mode of the medical rubber plug of the present disclosure. <FIG> (not claimed) is a plan view, and <FIG> (not claimed) is a cross-sectional view taken at a line A-A in <FIG>. Descriptions about portions, of the medical rubber plug <NUM> in <FIG> (not claimed) and <NUM>(b) (not claimed), that share the configurations of the corresponding portions in <FIG>, will be omitted.

The medical rubber plug <NUM> in the present mode includes two films 15a and 15b between the first portion <NUM> and the second portion <NUM>, and, in the piercing portion, the first portion <NUM> and a first film 15a, out of the films, that is in contact with the first portion <NUM> are adhered to each other, the second portion <NUM> and a second film 15b, out of the films, that is in contact with the second portion <NUM> are adhered to each other, and the first film 15a and the second film 15b are not adhered to each other.

In this configuration as well, when the injection needle is pulled out, the second portion <NUM> is elastically deformed so that a space is formed between the first portion <NUM> and the second portion <NUM>. The space serves as a buffer space to accommodate the drug solution having leaked from the medical container. Thus, the medical plug <NUM> of the present disclosure enables reduction in liquid leakage.

<FIG> (not claimed) and <NUM>(b) (not claimed) are each a diagram for explaining another mode of the medical rubber plug <NUM> of the present disclosure. <FIG> (not claimed) is a plan view, and <FIG> (not claimed) is a cross-sectional view taken at a line B-B in <FIG>. Descriptions about portions, of the medical rubber plug <NUM> in <FIG> (not claimed) and <NUM>(b) (not claimed), that share the configurations of the corresponding portions in <FIG>, will be omitted.

The medical rubber plug <NUM> in the present mode includes leg portions <NUM> in the forms of two branching portions extending from the lower surface of the capping portion <NUM>. In <FIG> (not claimed), the leg portions <NUM> in the forms of two branching portions have inner surfaces facing each other that are formed in a tapered shape such that the distance between the inner surfaces of the leg portions gradually decreases from the lower side to the upper side (upper surface side).

The medical rubber plug <NUM> in the present mode includes one film <NUM> between the first portion <NUM> and the second portion <NUM>. In the piercing portion, the film <NUM> is adhered to one of the first portion <NUM> and the second portion <NUM> and not adhered to the other one of the first portion <NUM> and the second portion <NUM>.

<FIG> (not claimed) and <FIG> (not claimed) are each a diagram for schematically explaining a manufacturing method for the medical rubber plug of the present disclosure. With reference to <FIG> (not claimed) and <FIG> (not claimed), descriptions will be given regarding a manufacturing example for the medical rubber plug including the one film between the first portion and the second portion, the film being, in the piercing portion, adhered to the first portion and not adhered to the second portion. However, the manufacturing method for the medical rubber plug of the present disclosure is not limited to the mode shown in the drawings.

<FIG> (not claimed) is a diagram for schematically explaining a first step of making the first portion of on the leg portion side of the medical rubber plug. First, an unvulcanized rubber sheet <NUM> for forming the first portion on the leg portion side of the medical rubber plug is prepared. As the unvulcanized rubber sheet <NUM>, it is possible to use a sheet obtained by blending, in arbitrarily-defined proportions, various additives such as crosslinking components for rubber vulcanization (crosslinking) such as a crosslinking agent, an accelerator, and an acceleration aid, fillers for adjusting hardness such as silica, clay, and talc, and furthermore, a processing aid, a softener, and a colorant, kneading the resultant mixture, and molding the kneaded product into the shape of a sheet.

A film <NUM> to be provided between the first portion and the second portion of the medical rubber plug of the present disclosure is prepared. The film <NUM> is stacked on the unvulcanized rubber sheet <NUM>. At this time, surface roughening treatment is performed in advance on a side, of the film <NUM>, that is brought into contact with the rubber sheet <NUM>. Surface roughening treatment is not performed on a side, of the film <NUM>, that is not brought into contact with the rubber sheet <NUM>.

The obtained stack sheet is supplied between a lower mold portion 25a and an upper mold portion 25b of a primary mold <NUM> heated to a rubber vulcanization temperature. The lower mold portion 25a has a plurality of recesses <NUM> each corresponding to the shape of the leg portion <NUM> of the rubber plug.

Then, vulcanization molding is performed on the stack sheet through mold clamping between the lower mold portion 25a and the upper mold portion 25b. This leads to formation of a primary molded product <NUM> in which: a plurality of the leg portions <NUM> corresponding to the above recesses <NUM> are formed so as to be contiguous with each other by burrs <NUM>; and the upper sides, including the entire surfaces, of the leg portions <NUM> formed so as to be contiguous with each other are laminated with the film <NUM>. Since surface roughening treatment has been performed on the surface of the film <NUM> that is in contact with the rubber sheet <NUM>, the film <NUM> is adhered by vulcanization to each first portion formed on the leg portion side.

Then, the individual leg portions <NUM> are stamped out of the primary molded product <NUM> having been subjected to the molding, whereby plug intermediates <NUM> are made. In each plug intermediate <NUM>, in order to cause the film <NUM> to remain only on the upper side of the piercing portion, the rest of the film is removed from the plug intermediate <NUM>.

<FIG> (not claimed) is a diagram for schematically explaining a step of making the second portion on the upper surface side of the medical rubber plug. An unvulcanized rubber sheet <NUM> for forming the second portion of the medical rubber plug is prepared.

As the unvulcanized rubber sheet <NUM>, it is possible to use the same type of rubber sheet as the aforementioned rubber sheet <NUM>.

The plug intermediates <NUM> made in the aforementioned step are supplied between a lower mold portion 39a having a plurality of recesses <NUM> each corresponding to the shape of the leg portion <NUM> and an upper mold portion 39b having a plurality of recesses <NUM> each corresponding to the shape of the flange portion 3b, of a secondary mold <NUM> heated to the rubber vulcanization temperature. Each plug intermediate <NUM> is set in the corresponding recess <NUM> of the lower mold portion 39a.

The rubber sheet <NUM> is stacked on the plug intermediates <NUM>, and vulcanization molding is performed on the sheet <NUM> through mold clamping between the lower mold portion 39a and the upper mold portion 39b. This leads to formation of a secondary molded product <NUM> in which: a plurality of the flange portions 3b corresponding to the above recesses <NUM> are formed so as to be contiguous with each other by burrs <NUM>; and the plug intermediates <NUM> (leg portions <NUM>) are adhered by vulcanization to the lower surfaces of the flange portions 3b formed so as to be contiguous with each other. At this time, since surface roughening treatment has not been performed on the upper surface sides of the films <NUM>, each film <NUM> is in a state of being not adhered to the corresponding second portion formed on the upper surface side.

The individual capping portions are stamped out of the secondary molded product <NUM> having been formed, whereby medical rubber plugs <NUM> are formed. Thereafter, each medical rubber plug <NUM> having been manufactured can be made as a product through, for example, a cleaning step, a sterilization step, a drying step, an outer appearance inspection step, and a packaging step.

The mode shown in <FIG> (not claimed) and <FIG> (not claimed) has been described on the basis of the method involving roughening the film as a method for adhesion between the film and the first portion or the second portion. However, the method for adhesion between the film and the first portion or the second portion can be changed, as appropriate, to a method involving usage of an adhesive agent or a method involving usage of an adhesive film.

<FIG> (not claimed) and <NUM>(b) (not claimed) are each a cross-sectional view for schematically explaining an advantageous effect in a vial plugged with the medical rubber plug in one of the modes of the present disclosure. <FIG> (not claimed) and <NUM>(b) (not claimed) each show a state where an opening of a vial <NUM> filled with a pharmaceutical preparation is closed by the medical rubber plug <NUM>. The medical rubber plug <NUM> includes the capping portion <NUM> and the leg portion <NUM>. The capping portion <NUM> includes: the piercing portion 3a capable of being pierced by an injection needle of an injector; and the flange portion 3b in contact with an upper rim surface of a port of a medical container <NUM>. The leg portion <NUM> projects from the lower surface (the upper surface in <FIG>) of the capping portion <NUM> and is fitted into the port of the medical container.

The medical rubber plug <NUM> in the present mode includes the one film <NUM> between the first portion <NUM> and the second portion <NUM>, and, in the piercing portion 3a, the film <NUM> is adhered to the first portion <NUM> and not adhered to the second portion <NUM>.

<FIG> (not claimed) schematically shows a state where the piercing portion 3a is pierced by an injection needle <NUM> of an injector in order to suction a drug solution <NUM> into the injector. <FIG> (not claimed) schematically shows a state where the injection needle <NUM> is being pulled out after the drug solution <NUM> is suctioned into the injector. When the injection needle <NUM> is pulled out, the second portion <NUM> of the rubber plug <NUM> is elastically deformed by friction force due to the pull-out of the injection needle <NUM> so that a space <NUM> is generated between the second portion <NUM> and the film <NUM> adhered to the first portion <NUM>. A residual liquid in the medical container having leaked from a gap formed through the piercing by the injection needle is accommodated in the space. As a result, the residual liquid is inhibited from leaking to the outside of the medical container.

With reference to <FIG> (not claimed) and <NUM>(b) (not claimed), description has been given on the basis of the mode in which the film <NUM> is adhered to the first portion <NUM> and not adhered to the second portion <NUM>. Meanwhile, in the case where, for example, the film <NUM> is not adhered to the first portion <NUM> and is adhered to the second portion <NUM>, when the injection needle <NUM> is pulled out, a space <NUM> is formed between the first portion <NUM> and the film <NUM> adhered to the second portion <NUM>.

<FIG> (not claimed) and <NUM>(b) (not claimed) are each a cross-sectional view for schematically explaining an advantageous effect in a vial plugged with the medical rubber plug in another one of the modes of the present disclosure. The medical rubber plug <NUM> in the present mode includes the two films 15a and 15b between the first portion <NUM> and the second portion <NUM>, and, in the piercing portion 3a, the first portion <NUM> and the first film 15a in contact with the first portion <NUM> are adhered to each other, the second portion <NUM> and the second film 15b in contact with the second portion <NUM> are adhered to each other, and the first film 15a and the second film 15b are not adhered to each other.

<FIG> (not claimed) schematically shows a state where the piercing portion 3a is pierced by the injection needle <NUM> of the injector in order to suction the drug solution <NUM> into the injector. <FIG> (not claimed) schematically shows a state where the injection needle <NUM> is being pulled out after the drug solution <NUM> is suctioned into the injector. When the injection needle <NUM> is pulled out, the second portion <NUM> of the rubber plug <NUM> is elastically deformed by friction force due to the pull-out of the injection needle <NUM> so that a space <NUM> is generated between the first film 15a adhered to the first portion and the second film 15b adhered to the second portion. A residual liquid in the medical container having leaked from a gap formed through the piercing by the injection needle <NUM> is accommodated in the space. As a result, the residual liquid is inhibited from leaking to the outside of the medical container.

Hereinafter, the present disclosure will be described in detail by means of examples, but the present disclosure is not limited to the following examples, and any of modifications and implementation modes made within the scope of the present disclosure is included in the scope as defined by the appended claims.

Various additives such as a crosslinking agent, a filler, and a processing aid were blended with an isobutylene-isoprene rubber, and the resultant mixture was kneaded, to make an unvulcanized rubber sheet for forming first portions on leg portion sides of medical plugs.

An ETFE film having one surface subjected to surface roughening treatment was prepared as a film to be provided between the first portions and the second portions of the medical plugs. As shown in <FIG>, the ETFE film <NUM> was stacked such that the roughened surface thereof was in contact with the unvulcanized rubber sheet <NUM>. The obtained stack sheet was supplied between the lower mold portion 25a and the upper mold portion 25b of the primary mold heated to the rubber vulcanization temperature. At this time, the stack sheet was disposed such that: the ETFE film <NUM> faced the upper mold portion 25b; and the rubber sheet <NUM> faced the lower mold portion 25a.

Vulcanization molding was performed on the stack sheet through mold clamping between the lower mold portion 25a and the upper mold portion 25b. This led to formation of a primary molded product in which a plurality of the leg portions <NUM> were formed so as to be contiguous with each other by burrs <NUM>. The entire surfaces on the upper sides of the leg portions <NUM>, of the primary molded product, formed so as to be contiguous with each other were laminated with the ETFE film <NUM>.

The individual leg portions <NUM> were stamped out of the primary molded product <NUM> having been formed, whereby plug intermediates <NUM> were made. In each plug intermediate <NUM>, in order to cause the ETFE film <NUM> to remain only on the upper side of the piercing portion, the rest of the film was removed from the plug intermediate <NUM>.

As shown in <FIG>, an unvulcanized rubber sheet <NUM> for forming second portions of the medical rubber plugs was prepared. As the unvulcanized rubber sheet <NUM>, a rubber sheet having the same composition as that of the rubber sheet <NUM> forming the first portions was used.

The plug intermediates <NUM> made in the aforementioned step were supplied between the lower mold portion 39a having the plurality of recesses <NUM> each corresponding to the shape of the leg portion <NUM> and the upper mold portion 39b having the plurality of recesses <NUM> each corresponding to the shape of the flange portion 3b, of the secondary mold <NUM> heated to the rubber vulcanization temperature. Each plug intermediate <NUM> was set in the corresponding recess <NUM> of the lower mold portion 39a.

The rubber sheet <NUM> was stacked on the plug intermediates <NUM>, and vulcanization molding was performed on the sheet <NUM> through mold clamping between the lower mold portion 39a and the upper mold portion 39b. This led to formation of a secondary molded product <NUM> in which: a plurality of the flange portions 3b corresponding to the above recesses <NUM> were formed so as to be contiguous with each other by burrs <NUM>; and the plug intermediates <NUM> (leg portions <NUM>) were adhered by vulcanization to the lower surfaces of the flange portions 3b formed so as to be contiguous with each other.

The individual capping portions were stamped out of the secondary molded product <NUM> having been formed, whereby medical rubber plugs <NUM> were formed. Each medical rubber plug <NUM> was cleaned, sterilized, dried, and used in a test. The medical rubber plug No. <NUM> was such that, in the piercing portion, the film and the first portion were adhered to each other, and the film and the second portion were not adhered to each other.

Medical rubber plugs No. <NUM> were manufactured in the same manner as the medical rubber plugs No. <NUM>, except that a PTFE film was used instead of the ETFE film as the film to be provided between the first portions and the second portions.

The various additives such as the crosslinking agent, the filler, and the processing aid were blended with the isobutylene-isoprene rubber, and the resultant mixture was kneaded, to make an unvulcanized rubber sheet for forming first portions on leg portion sides of medical plugs.

An ETFE film was prepared. The ETFE film was stacked on the unvulcanized rubber sheet. The obtained stack sheet was supplied between the lower mold portion 25a and the upper mold portion 25b of the primary mold heated to the rubber vulcanization temperature. At this time, the stack sheet was disposed such that: the ETFE film faced the lower mold portion 25a; and the rubber sheet faced the upper mold portion 25b.

Vulcanization molding was performed on the stack sheet through mold clamping between the lower mold portion 25a and the upper mold portion 25b. This led to formation of a primary molded product in which a plurality of the leg portions <NUM> were formed so as to be contiguous with each other by burrs <NUM>. The entire surfaces on the lower sides of the leg portions <NUM>, of the primary molded product, formed so as to be contiguous with each other were laminated with the ETFE film.

The individual leg portions <NUM> were stamped out of the primary molded product <NUM> having been formed, whereby plug intermediates <NUM> were made.

An unvulcanized rubber sheet <NUM> for forming second portions of the medical rubber plugs was prepared. As the unvulcanized rubber sheet <NUM>, a rubber sheet having the same composition as that of the rubber sheet <NUM> forming the first portions was used.

The individual capping portions were stamped out of the secondary molded product <NUM> having been formed, whereby medical rubber plugs No. <NUM> were formed. Each medical rubber plug No. <NUM> was cleaned, sterilized, dried, and used in a test.

The various additives such as the crosslinking agent, the filler, and the processing aid were blended with the isobutylene-isoprene rubber, and the resultant mixture was kneaded, to make an unvulcanized rubber sheet for forming medical plugs. The rubber sheet was subjected to mold clamping between the upper mold portion and the lower mold portion, and medical rubber plugs No. <NUM> were manufactured through a one-stage molding method. Each medical rubber plug No. <NUM> was cleaned, sterilized, dried, and used in a test.

The liquid leakage amount in each of the medical rubber plugs No. <NUM> to No. <NUM> was indicated as an index value with the liquid leakage amount in the medical rubber plug No. <NUM> being regarded as <NUM>.

Properties of the medical rubber plugs No. <NUM> to No. <NUM> and the results of evaluating the liquid leakage amounts are indicated in Table <NUM>.

Claim 1:
A medical rubber plug (<NUM>) comprising:
a capping portion (<NUM>); and
a leg portion (<NUM>) extending downward from the capping portion (<NUM>), wherein
the medical rubber plug (<NUM>) includes a piercing portion (3a) consisting of a first portion (<NUM>) and a second portion (<NUM>), the first portion (<NUM>) being located on the leg portion (<NUM>) side, characterized in that the second portion (<NUM>) is located on an upper surface side of the first portion (<NUM>), and
the first portion (<NUM>) and the second portion (<NUM>) being adjacent to each other in an up/down direction, and being not adhered to each other.