TECHNICAL FIELD
[0001] The present invention relates to a medical rubber plug for sealing or stopping a
mouth of a container (or receptacle) for medical use, particularly for sealing or
stopping the mouth of a vial which stores freeze-drying preparation.
BACKGROUND ART
[0002] A conventional medical rubber plug for sealing or stopping a mouth of a vial which
stores preparation such as antibiotics, has a leg 22 that is fitted into the mouth
of the vial 21 and a flange 24 that contacts with a top edge surface 23 of the mouth
of the vial 21, as shown in Fig. 2. In general, projections 26 are provided on the
top surface 25 of the mushroom-cap-like part of the medical rubber plug in order to
prevent rubber plugs from adhering (or sticking) each other during its cleaning, disinfection
and drying, and/or in order to prevent the rubber plug from adhering to an aluminum
cap to be fitted around the rubber plug. The shape and position of the projection
26 on the top surface 25 of the mushroom-cap-like part of the rubber plug are not
limited, for example, as shown in Fig. 3 illustrating T-shaped projections 27, and
as shown in Figs. 4 and 5 illustrating semicylindrical (or semicircular) projections
28 and 29.
[0003] Meanwhile, preparation, such as antibiotics, is frozen, evacuated (or made vacuous)
and dried, by filling up a specified quantity of medicament (or medication liquid)
in a vial, by half-inserting into the opening (or mouth) of the vial a rubber plug
the leg of which has an opening to facilitate a passage of aqueous vapor from the
medicament, by placing the vial in a shelf (or rack) inside a freeze dryer, and by
maintaining a specified temperature and a specified degree of vacuum inside the freeze
dryer. The freeze vacuum drying of the preparation in the freeze dryer includes a
primary drying step and a secondary drying step. In the primary drying step, normally,
the medicament is frozen at temperature of -30 to -45°C, and then it is kept at the
degree of vacuum of 1 to 0.03 Torr and at temperature of -20 to +30°C for 12 to 36
hours. The freeze vacuum drying of the medicament is completed after the medicament
is kept at temperature of +20 to +40°C for 1 to 6 hours in the secondary drying step.
[0004] Next, nitrogen is supplied to the freeze dryer to raise the inside pressure to the
normal level (-300 mmH
2O to 0), and a stainless steel press panel of the shelf inside the freeze dryer is
employed to press (or bias) the rubber plug and to fit it completely in the vial mouth.
The general condition for plugging it therein is: the pressing force (or biasing force)
per vial is 1 to 5 kg; the pressing duration is 1 to 10 minutes; and the frequency
of pressing it is once or twice. Once the insertion of the rubber plug thereto is
completed, the vial is moved out of the freeze dryer, and then it is transferred to
the succeeding process for winding an aluminum cap around the rubber plug tightly,
thus gaining the preparation with the vial being plugged therewith.
[0005] For preparation in the freeze vacuum drying, butyl rubber such as isobutylene-isoprene
copolymer is generally employed as material of the rubber plug, in order to prevent
water, air and the like from stealing in from outside while the preparation is hermetically
kept therein, or in order to maintain air-tightness inside the vial. Butyl rubber,
however, shows a high degree of unsaturation, and shows a low degree of bridge density;
namely, the butyl rubber is inferior in elasticity, and the viscosity of the rubber
surface is greater. Accordingly, when the rubber plug, made of butyl rubber, is pressed
to plug the mouth with the press panel of the freeze dryer after the freeze vacuum
drying is completed, the top surface of the rubber plug may stick to the press panel
due to the stickiness, and the vial may be hung upwards together with the rubber plug
sticking to the press panel when the press panel is lifted. If the vial is dropped
down in a few seconds, it may cause the surrounding vials to overturn, which hinders
a removal of the vials from inside the freeze dryer and which blocks a transfer thereof
to the following step (or process).
[0006] To solve the problem, oil, or reacting type of silicone, is coated on the top surface
of the butyl rubber plug in order to reduce adhesion to the press panel of the freeze
dryer. Also, as rubber plugs with no adhesion to the press panel of the shelf inside
the freeze dryer, there have been proposed rubber plugs such as ones 51 in which the
top surface 52 thereof, or both of the top surface 52 and the leg 53 thereof, is/are
laminated with resin film, as shown in Figs. 6 and 7. Namely, there have been proposed
the rubber plug 51 in which the whole part of the top surface 52 and leg 53 thereof,
or a part thereof, is laminated with fluoroplastic film 54 (Patent Publication No.
2,545,540), and the rubber plug 51 in which the top surface 52, or the leg 53, or
the whole surface thereof, is laminated with a surface, processed by corona discharging,
of ultra high polymer polyethylene film 55 (Japanese Laid-Open Patent Publication
No. 4-22,362 ), and the like.
[0007] However, the shape, number and position of the projections which are provided on
the top surface of the rubber plug for the purpose of preventing the adhesion, are
not specified. Therefore, even if the adhesion between the rubber plugs is prevented
by the silicone coat on the surface of the rubber plug, the actual situation is that
the complete prevention thereof from sticking to the press panel of the shelf inside
the freeze dryer has not been realized. Therefore, generally, silicone is coated on
the surface of the press panel of the shelf inside the freeze dryer to prevent the
adhesion between the top surface of the rubber plug and the press panel. This method,
however, requires an extra work for coating silicone onto the surface of the press
panel of the shelf inside the free dryer, and it may cause contamination inside the
freeze dryer.
[0008] A technique for laminating the resin film onto the top surface of the rubber plug
has an advantage that the top surface of the rubber plug is prevented from sticking
to the press panel of the shelf inside the freeze dryer. However, the top surface
of the rubber plug has a double-layer construction in which the soft rubber thereof
is laminated with a resin film. Therefore, not only the method for molding the rubber
plug is complicated, but also it is difficult to prevent a generation of film fragments
or coring, thus making difficult its quality assurance as a rubber plug for medical
use. Furthermore, the rubber plug in which the resin film is coated on the top surface
thereof has a disadvantage that it is not possible to provide the rubber plug at low
cost, because the resin film is relatively expensive, and because not a few manufacturing
processes (or steps) are required.
[0009] An object of the present invention is to provide a rubber plug for medical use that
solves the problems of the aforementioned prior art, in which it satisfies various
characteristics including a low gas permeability, a low water permeability (or low
moisture permeability), an air tightness (or hermetic property), an easiness of needling
(or pricking) it, a nature (or property) of heat resistance, a nature (or property)
of resistance against aging, a nature (or property) of low coring, and the like, which
complies with the Japan Pharmacopoeia, which satisfies the Rubber Plug Testing Standard
for Infusion, and which prevents the top surface of the rubber plug from sticking
(or adhering) to the press panel when the rubber plug, being kept half-inserted inside
an opening of a vial that is placed inside the freeze dryer, is completely plugged
into the opening of the vial by the press panel of the shelf inside the freeze dryer
after the preparation is frozen, evacuated and dried inside the vial.
DISCLOSURE OF THE INVENTION
[0010] The inventor et al. repeated various tests and discussed on shape, number and quantity,
and mounting position, of projections on the top surface of the mushroom-cap-like
part of the rubber plug, in order to achieve the aforementioned object. As a result,
the inventor et al. found that the adhesion of the top surface of the rubber plug
to the press panel of the shelf inside the freeze dryer can be prevented, by positioning
the projection for preventing the adhesion thereto of the rubber plug which is to
be plugged in the mouth of the vial for medical use, on an upper part of an edge surface
which locates outside the internal diameter of the mouth of the vial, and found that
the rubber plug is easier in manufacturing and less expensive than the conventional
rubber plug having the double-construction which is formed by laminating with the
resin film.
[0011] The medical rubber plug in accordance with claim 1 of the present invention comprises:
a leg part which is inserted into a mouth of a vial; and a flange part which contacts
an upper edge surface of the mouth of the vial, in which a projection which is provided
on a top surface of a mushroom-cap-shaped part of the medical rubber plug and which
prevents an adhesion of the top surface thereof, is arc-shaped, and in which the projection
is provided on an upper part of an edge surface locating outside an inner diameter
of the mouth of the vial. With the construction that the projection which is provided
on the top surface of the mushroom-cap-shaped part of the medical rubber plug and
which prevents the adhesion of the top surface thereof, is arc-shaped, and with the
construction that the projection is provided on the upper part of the edge surface
locating outside the inner diameter of the mouth of the vial, the lower part of the
arc-shaped projection on the top surface of the mushroom-cap-shaped part of the rubber
plug comes to contact the edge surface locating outside the mouth of the vial, and
the compressive deformation of the arc-shaped projection is suppressed by the edge
surface functioning as a base. Namely, the whole top surface of the rubber plug does
not contact the press surface closely, and a space is formed between the press surface
and the top surface of the rubber plug. Therefore, the adhesion therebetween is prevented.
[0012] In the medical rubber plug in accordance with claim 2 of the present invention, there
are provided six to twelve projections each of which is the projection that is provided
on the top surface of the mushroom-cap-shaped part of the medical rubber plug and
that prevents the adhesion of the top surface thereof. With the construction that
there are provided six to twelve projections each of which is the projection that
is provided on the top surface of the mushroom-cap-shaped part of the medical rubber
plug and that prevents the adhesion of the top surface thereof, it is possible to
completely prevent the adhesion between the press surface of the shelf inside a freeze
dryer, and the top surface of the rubber plug; at the same time, it is possible to
keep in good condition the tightness with which the aluminum cap is wound around the
flange of the rubber plug. Therefore, it is possible to prevent the rubber plug from
dropping in the vial.
BRIEF DESCRIPTION OF DRAWINGS
[0013]
Fig. 1 shows a medical rubber plug according to the present invention, where Fig.
1a is a plan view thereof, and Fig. 1b is a vertical cross-sectional view showing
a state in which the rubber plug is fully inserted into a mouth of a vial;
Fig. 2 shows a conventional medical rubber plug, where Fig. 2a is a plan view thereof,
and Fig. 2b is a vertical cross-sectional view showing a state in which the rubber
plug is fully inserted into a mouth of a vial;
Fig. 3 is a plan view of the conventional medical rubber plug on a top surface of
which T-shaped projections are formed;
Fig. 4 is a plan view of the conventional medical rubber plug on a top surface of
which semi-cylindrical projections are formed;
Fig. 5 is a plan view of the conventional medical rubber plug on a top surface of
which other semi-cylindrical projections are formed;
Fig. 6 is a vertical cross-sectional view of the conventional medical rubber plug
on a top surface and a leg part of which a fluoroplastic film is laminated; and
Fig. 7 is a vertical cross-sectional view of the conventional medical rubber plug
on a top surface of which an ultra high polymer polyethylene film is laminated.
BEST MODE FOR CARRYING OUT THE INVENTION
[0014] A medical rubber plug in accordance with the present invention has a leg to be fitted
into a mouth of a vial, and a flange to come to contact with an upper edge surface
of the mouth of the vial, which is similar to the conventional rubber plug, and the
medical rubber plug has a size and a shape, each of which does not change especially.
The medical rubber plug is different from the conventional one in that each of projections
provided on a top surface of a mushroom-cap-shaped part (or mushroom-pileus-shaped
part or lamp-shade-like part) of the rubber plug of the present invention is arc-shaped
(or arcuate in shape), and in that the projections are arranged on an upper part of
an edge surface locating outside an internal diameter of the mouth of the vial. Thus,
even if the arc-shaped projections according to the present invention are added to
the conventional rubber plug so that the arc-shaped projections are positioned on
the upper part of the edge surface outside the internal diameter of the mouth of the
vial, there is no particular difference in function and effect. The material which
the rubber plug of the present invention is made of, is butyl rubber with a low gas
permeability and a low vapor (or moisture) permeability, which has been conventionally
utilized.
[0015] The size of the projection provided on the top surface of the mushroom-cap-shaped
part of the medical rubber plug in accordance with the present invention, is determined
by the size of the medical rubber plug, and is not specifically determined. The desirable
size thereof is 1.0 to 2.0 mm in its base and 0.4 to 0.8 mm in its height. It is preferable
to provide six to twelve arc-shaped projections, and it is preferable that the arc-shaped
projections are provided on the same circumference (or circle) at an equal interval.
If the number of the arc-shaped projections is less than six, the adhesion between
the top surface of the rubber plug and the aluminum cap can be prevented, but the
adhesion between the pressing surface of the shelf inside the freeze dryer and the
top surface of the rubber plug can not be prevented completely. Meanwhile, if the
number of the arc-shaped projections exceeds twelve, the adhesion between the pressing
surface of the shelf inside the freeze dryer and the top surface of the rubber plug
can be prevented completely, but the tightness between the flange of the rubber plug
and the aluminum cap becomes deteriorated, thus easily allowing the rubber plug to
drop in the vial at time of piercing a needle therethrough.
[0016] The usage of the medical rubber plug in accordance with the present invention is
the same as that in accordance with the conventional medical rubber plug. Namely,
a specified quantity of medicament liquid is filled up in the vial; the rubber plug
is half-inserted (or half-engaged) into the mouth of the vial; plural vials are arranged
inside each of the shelves inside the freeze dryer in alignment; they are frozen,
evacuated and dried under a predetermined condition (in respect of temperature, degree
of vacuum, and time); they are dried at a specified temperature for a specified duration
of time; they are pressed down by the press panels of the shelves in the freeze dryer;
and then the rubber plugs are completely fitted and inserted in the mouths of the
vials.
EMBODIMENT 1
[0017] The medical rubber plug of the present invention is explained below in detail based
on Fig. 1, which illustrates an embodiment thereof. Fig. 1a is a plan view of the
medical rubber plug of the present invention, and Fig. 1b is a vertical cross-sectional
view showing a state in which the rubber plug is completely inserted inside the mouth
of the vial.
[0018] In Fig.1, a reference number 1 points to a vial; and 2 to a rubber plug which has
a leg 4 having an opening 3 and being inserted into the mouth of the vial 1 and which
has a flange 6 contacting the upper edge part 5 of the mouth of the vial 1. On the
top surface 7 of the flange 6 of the rubber plug 2, there are provided the arc-shaped
projections 8 which locate above the upper edge part 5 of the mouth of the vial 1.
The distance "D" between centers of the arc-shaped projections 8 is greater than the
internal (or inner) diameter "d" of the mouth of the vial 1. There are provided six
to twelve arc-shaped projections 8 (eight projections 8 in Fig. 1) on a circumference
(or circle) corresponding to a part "a" which is equal to a difference between an
external (or outer) diameter of the rubber plug 2 and the aforementioned internal
diameter "d". With the construction, the rubber plugs 2 are prevented from closely
adhering (or sticking) to each other at time of cleaning, disinfecting (or sterilizing)
and drying the rubber plugs; an unshown aluminum cap tightly wound around the rubber
plug 2 is prevented from closely adhering (or sticking) to the rubber plug 2; and
the adhesion between the press surface (or biasing surface) of the shelf inside the
freeze dryer and the top surface 7 is prevented after the medicament liquid therein
is frozen, evacuated and dried.
[0019] According to the aforementioned structure, when the rubber plug 2 is half-inserted
into the mouth of the vial 1 for the purpose of the freeze vacuum drying of the medicament
liquid therein, and then when the top surface 7 of the rubber plug 2 is pressed by
the press panel of the shelf inside the freeze dryer, not shown in the figure, in
order to completely put the rubber plug 2 inside the mouth of the vial 1, a lower
surface of the flange 6 of the rubber plug 2 comes to contact with the upper edge
part 5 of the mouth of the vial 1. Namely, the arc-shaped projection 8 on the top
surface is securely supported on the upper edge surface 5 which functions as a base.
Therefore, the contact of the entire top surface of the rubber plug 2 with the press
panel is prevented, resulting in no adhesion of the top surface of the rubber plug
2 with respect to the pressing surface. Also, it goes without saying that the adhesion
between the rubber plugs 2 is prevented during their cleaning, disinfecting and drying,
and that the tightness of the unshown aluminum cap being wound on the rubber plug
2 is kept in good condition.
EMBODIMENT 2
[0020] The vial made of glass has a capacity of 10 ml, an internal (or inner) diameter being
12.5 mm of the mouth, an external (or outer) diameter being 20mm of the edge surface
of the mouth, and a height of 50 mm. The rubber plug in accordance with the present
invention has an construction in which 4 to 14 arc-shaped projections are symmetrically
provided on the top surface on the upper part of the edge surface that locates outside
the inner diameter of the mouth of the vial where the arc-shaped projection has a
base of 1.5mm, a height of 0.6mm and where the distance "D" between the centers of
the projections is 15.5mm, and has the construction in which silicone coat of 30 to
50 mg/piece is applied to the top surface thereof. For comparison, there is prepared
a rubber plug that has a construction in which 8 or 12 arc-shaped projections are
symmetrically provided on the top surface on the upper part thereof that locates inside
the inner diameter of the mouth of the vial, or symmetrically provided on the top
surface on the upper part thereof that locates on a boundary with the edge surface,
where the arc-shaped projection has a base of 1.5mm, a height of 0.6mm and where the
distance "D" between the centers of the projections is 10.5mm or 12.5mm, and has the
construction in which silicone coat of 30 to 50 mg/piece is applied to the top surface
thereof. Both of the rubber plugs were half-inserted into the mouths of the vials,
and then each of the rubber plugs was pressed with a pressure of 5 kg for 10 minutes
by a stainless steel press panel. Under the condition, the degrees of adhesion between
the press surfaces and the top surfaces of the rubber plugs, were measured while video-recording
the situation at time of raising the pressure plate. Using 50 specimens of both of
the rubber plugs respectively, measurements were made in order to seek for the time
during which they sticked to the pressure panels. Together with the measurements,
the tightness with which the aluminum caps were wound around the flanges of the rubber
plugs was also tested. Table 1 shows the results. By the way, how to evaluate the
tightness is based upon a procedure in which a plastic needle with its tip being cut
to a diameter of 5 mm was pressed against the part of each of the rubber plugs which
a needle is pierced through, and in which the number of rubber plugs that were dropped
down into the vial with a pressure of 5 kg, or less, was counted.
[Table 1]
|
Present Invention Example |
Example in Contrast |
|
1 |
2 |
3 |
4 |
5 |
1 |
2 |
3 |
Number of Projections (pcs) |
4 |
6 |
8 |
12 |
14 |
8 |
12 |
8 |
Inter-projection distance D (mm) |
15.5 |
15.5 |
15.5 |
15.5 |
15.5 |
12.5 |
12.5 |
10.5 |
Adhesion Duration: 0 sec. |
45 |
50 |
50 |
50 |
50 |
- |
- |
- |
Adhesion Duration< 0.5 sec. |
4 |
- |
- |
- |
- |
- |
- |
- |
Adhesion Duration< 1.0 sec. |
1 |
- |
- |
- |
- |
2 |
6 |
3 |
Adhesion Duration< 2.0 sec. |
- |
- |
- |
- |
- |
6 |
8 |
7 |
Adhesion Duration< 3.0 sec. |
- |
- |
- |
- |
- |
33 |
29 |
19 |
Adhesion Duration< 4.0 sec. |
- |
- |
- |
- |
- |
9 |
7 |
14 |
Adhesion Duration≧ 4.0 sec. |
- |
- |
- |
- |
- |
- |
- |
7 |
Tightness with Aluminum Cap |
0/50 |
0/50 |
0/50 |
0/50 |
15/50 |
0/50 |
0/50 |
0/50 |
[0021] As shown in Table 1, regarding the rubber plug according to the present invention,
no adhesion between the press panel and the top surface of the rubber plug was recorded,
and a favorable result was also gained of the tightness with which the aluminum cap
was wound around the flange of the rubber plug, when there were provided six to twelve
arc-shaped projections. When there were provided four arc-shaped projections, slight
adhesion therebetween was recorded. When there were provided 14 arc-shaped projections,
it was observed that the nature of the tightness between the aluminum cap and the
flange of the rubber plug became deteriorated, and that some rubber plugs were dropped
off by the needle's piercing therethrough. On the other hand, it was observed that
the rubber plugs, employed for comparison, respectively, showed the adhesion between
the press panels and the flanges of the rubber plugs.
EMBODIMENT 3
[0022] Regarding the rubber plug of "Present Invention Example 6" which is the same as the
rubber plug of "Present Invention Example 3" in "EMBODIMENT 2", regarding the rubber
plug of "Prior Example 1" in which the rubber plug has a double-layer structure where
a resin film is laminated, regarding the rubber plug of "Prior Example 2" that has
a construction in which three projections are radially arranged at an equal interval
between adjacent projections on the same circumference (or periphery or circle) where
the projection has a width being 1.2mm of a base, a length of 3.0mm, a height of 0.4mm
and where the distance between the centers of the projections is 11.5mm, and has the
construction in which silicone coat of 30 to 50 mg/piece is applied to the top surface
thereof, regarding the rubber plug of "Prior Example 3" that has a construction in
which four projections are radially arranged at an equal interval between adjacent
projections on the same circumference (or periphery or circle) where the projection
has a width being 1.0mm of a base, a length of 2.5mm, a height of 0.4mm and where
the distance between the centers of the projections is 12.5mm, and has the construction
in which silicone coat of 30 to 50 mg/piece is applied to the top surface thereof,
and regarding the rubber plug of "Prior Example 4" that has a construction in which
four projections, being T-shaped as shown in Fig. 3, are radially arranged at an equal
interval between adjacent projections on the same circumference (or periphery or circle)
where each projection has a width of 1.2mm, a length of 4.0mm, a height of 0.6mm and
where the distance between the centers of the projections is 13.0mm, and has the construction
in which silicone coat of 30 to 50 mg/piece is applied to the top surface thereof,
the degrees of adhesion between the press panels and the top surfaces of the rubber
plugs, were measured while video-recording the situation at time of raising the pressure
plate, under the same condition as the condition of "EMBODIMENT 2." Using 50 specimens
of both of the rubber plugs respectively, measurements were made in order to seek
for the time during which they sticked to the pressure panels. Together with the measurements,
the tightness with which the aluminum caps were wound around the flanges of the rubber
plugs was also tested. Table 2 shows the results. By the way, The method in which
the tightness was evaluated, complied with the method of evaluation which was used
in "EMBODIMENT 2".
[Table 2]
|
Present Invention Example 6 |
Prior Example 1 |
Prior Example 2 |
Prior Example 3 |
Prior Example 4 |
Number of projections (pcs) |
8 |
0 |
3 |
4 |
4 |
Inter-projection Distance (mm) |
15.5 |
- |
11.5 |
12.5 |
13.0 |
Adhesion Duration: 0 sec. |
50 |
50 |
- |
- |
- |
Adhesion Duration< 0.5 sec. |
- |
- |
- |
- |
- |
Adhesion Duration< 1.0 sec. |
- |
- |
- |
2 |
10 |
Adhesion Duration< 2.0 sec. |
- |
- |
3 |
15 |
19 |
Adhesion Duration< 3.0 sec. |
- |
- |
6 |
14 |
13 |
Adhesion Duration< 4.0 sec. |
- |
- |
24 |
13 |
8 |
Adhesion Duration≧ 4.0 sec. |
- |
- |
17 |
6 |
- |
Tightness with Aluminum Cap |
0/50 |
0/50 |
0/50 |
0/50 |
0/50 |
[0023] As shown in Table 2, regarding the rubber plug of "Present Invention Example 6" and
the same of "Prior Example 1", there was no adhesion between the press panels and
the top surfaces of the rubber plugs respectively, and the nature of the tightness
between the aluminum cap and the flange of the rubber plug was in good condition.
Meanwhile, regarding the rubber plugs of "Prior Example 2," "Prior Example 3," and
"Prior Example 4," the nature of the tightness between the aluminum cap and the flange
of the rubber plug was in good condition; however, it was observed that there was
adhesion between the press panel and the top surface of the rubber plug.
[0024] The medical rubber plug according to claim 1 has a construction in which the projection
for preventing the adherence of the top surface of the flange of the rubber plug is
formed arc-shaped (or in arc) and in which the projection is arranged on the upper
part of the edge surface outside the internal diameter of the mouth of the vial. With
the construction, the lower part of the arc-shaped projection on the top surface of
the flange of the rubber plug comes to contact with the edge surface outside of the
mouth of the vial, and the compressive deformation of the arc-shaped projection is
suppressed by the edge surface serving as a base. Namely, the whole top surface of
the flange of the rubber plug does not adhere to the press surface, and a space is
formed between the press surface and the top surface of the flange, thus preventing
the adhesion therebetween.
[0025] The medical rubber plug according to claim 2 has six to twelve pieces of the arc-shaped
projections for preventing the adherence of the top surface of the flange of the rubber
plug. With the construction, it is possible to completely prevent the adhesion between
the press surface of the shelf of the freeze dryer, and the top surface of the rubber
plug; at the same time, it is possible to keep in good condition the property of the
tightness with which the aluminum cap is wound around the flange of the rubber plug.