Co-Molded Pierceable Stopper and Method for Making the Same

Abstract

A closure and method of making a closure are disclosed. The closure includes a cap body having a top portion and an opening extending therethrough defining a cavity in communication with said opening. A flow channel is defined within a portion of the cap body having an inlet and an outlet. A stopper is disposed within the cavity adjacent the outlet of the flow channel. The stopper is formed from a material adapted for flowing through the flow channel to form a pierceable portion, with at least one of the cap body and the stopper configured for closing a container.

What is claimed is: 
     
         1 . A method of forming a pierceable cap assembly for a container, comprising the steps of:
 providing a mold having a molding cavity;   injecting a first molding material into the molding cavity to form a cap body having a top portion, an opening extending therethrough, and a cavity in communication with the opening, the cap body having a flow channel extending from the top portion of the cap body to a target location within the cavity; and   injecting a second molding material into the flow channel such that the second molding material flows through the flow channel to the target location, wherein the second molding material forms a pierceable septum within the cavity of the cap body.   
     
     
         2 . The method of  claim 1 , wherein the first molding material forms an external annular skirt and an internal annular skirt, each depending from the top portion, wherein at least a portion of the internal annular skirt defines the target location. 
     
     
         3 . The method of  claim 1 , wherein the second molding material is injected from a location which is offset with respect to a longitudinal centerline extending through the target location. 
     
     
         4 . The method of  claim 2 , wherein the flow channel extends along a vertical height of an interior wall surface of the internal annular skirt. 
     
     
         5 . The method of  claim 2 , wherein the internal annular skirt comprises at least one protrusion adjacent the target location. 
     
     
         6 . The method of  claim 5 , wherein the second molding material flows to the target location to form a bond with the at least one protrusion. 
     
     
         7 . The method of  claim 5 , wherein the second molding material flows to the target location to form a star-shaped septum with the at least one protrusion. 
     
     
         8 . The method of  claim 1 , wherein the first molding material comprises high density polyethylene and the second molding material comprises a thermoplastic elastomer. 
     
     
         9 . The method of  claim 1 , further including a first gate for injection of the first molding material and a second gate for injection of the second molding material, wherein the second gate is positioned adjacent the top portion of the cap body at an inlet of the flow channel. 
     
     
         10 . The method of  claim 9 , wherein the second gate is positioned at approximately 180° with respect to the first gate. 
     
     
         11 . The method of  claim 1 , wherein after injection of the second molding material, at least a portion of the second molding material remains within the flow channel. 
     
     
         12 . A closure made by the method of  claim 1 . 
     
     
         13 . A method of forming a two-shot molded closure, comprising the steps of:
 supplying a first molding material into a mold to form a cap body having an interior wall surface and a flow channel defined therein, the flow channel having an inlet and an outlet; and   supplying a second molding material into the mold at a location adjacent to the inlet of the flow channel such that at least a portion of the second molding material flows through the outlet to a target location to form a septum,   wherein the inlet of said flow channel is remote from the target location.   
     
     
         14 . The method of  claim 13 , wherein the inlet of the flow channel is offset with respect to a longitudinal centerline extending through the target location. 
     
     
         15 . A closure made by the method of  claim 13 . 
     
     
         16 . A method of forming a closure for a container comprising:
 injecting a first molding material into a mold to form a cap body defining a center portion; and   injecting a second molding material into the mold to form a pierceable septum within the center portion of the cap body,   wherein the second molding material is injected from a location that is offset with respect to a longitudinal centerline extending through the center portion.   
     
     
         17 . The method of  claim 16 , wherein the cap body comprises a flow channel extending therethrough and wherein the second molding material flows through the flow channel to form the pierceable septum. 
     
     
         18 . A closure made by the method of  claim 16 . 
     
     
         19 . A specimen collection assembly, comprising:
 an outer cap having a top portion and an annular skirt portion depending from the top portion, the top portion having an opening extending therethrough and defining a cavity;   a stopper disposed within the cavity having a bottom surface, a pierceable closure, and a conical recess defined within the stopper extending from the bottom surface of the stopper to the pierceable closure; and   a collection container having a top opening and an exterior sidewall defining a collection cavity,   wherein the outer cap engages the collection container such that the annular skirt portion engages the exterior sidewall of the collection container with the stopper extending into the collection cavity so as to sealingly engage a sidewall of the collection cavity with the conical recess of the stopper being in communication with the collection cavity.   
     
     
         20 . The specimen collection assembly of  claim 19 , wherein the collection container further comprises a collection funnel adjacent the top opening, and the outer cap defines an opening for receiving the collection funnel therein when the outer cap is engaged with a portion of the collection container. 
     
     
         21 . A specimen collection assembly, comprising:
 an outer cap having a top portion and an annular skirt portion depending from the top portion, the top portion having an opening extending therethrough and defining a cavity;   a stopper disposed within the cavity having a bottom surface, a pierceable closure, and a conical recess defined within the stopper extending from the bottom surface of the stopper to the pierceable closure; and   a collection container having a top opening and an exterior sidewall defining a collection cavity adapted to receive a specimen therein, at least a portion of one of the outer cap and the stopper engageable with the collection container to seal the top opening,   wherein the stopper is molded within the cavity such that a sampling distance extending between a top surface of the top portion of the outer cap and an apex of the conical recess is adapted to position an aspiration hole of a probe assembly at the apex of the conical recess during withdrawal of the specimen from the collection cavity.   
     
     
         22 . The specimen collection assembly of  claim 21 , wherein the sampling distance is from 0.58 to 0.60 inches. 
     
     
         23 . The specimen collection assembly of  claim 21 , wherein the collection container comprises a second portion extending away from the top opening beyond the collection cavity.