One-Piece Safety Tube Closure with Film Element

Abstract

A closure having enhanced oxygen barrier capabilities includes a cap body formed from a first material, the cap body defining a cavity therethrough, a stopper formed from a second material, the second material being different than the first material and disposed within the cavity, and a barrier layer formed from a third material, the third material being different than at least the second material and associated with at least one of the cap body and the stopper. A container assembly including a closure and a method of forming the closure is also provided.

The invention claimed is: 
     
         1 . A closure, comprising:
 a cap body formed from a first material, the cap body defining a cavity therethrough;   a stopper formed from a second material and disposed within the cavity, the second material being different than the first material; and   a barrier layer formed from a third material, the third material being different from the first material and the second material, and associated with at least one of the cap body and the stopper, and wherein the barrier layer is disposed across at least a portion of the cavity.   
     
     
         2 . The closure of  claim 1 , wherein the barrier layer isolates a portion of the cap body from a portion of the stopper. 
     
     
         3 . The closure of  claim 1 , wherein the barrier layer isolates a first portion of the stopper from a second portion of the stopper. 
     
     
         4 . A closure, comprising:
 a cap body formed from a first material, the cap body including a first leg, a second leg, and a third leg and wherein the cap body defines a cavity therethrough;   a stopper formed from a second material and disposed within the cavity, the second material being different than the first material; and   a barrier layer formed from a third material, the third material being different from at least the second material, and associated with at least one of the cap body and the stopper,   wherein the third leg is positioned adjacent a top surface of the stopper to secure the stopper within the cap body.   
     
     
         5 . The closure of  claim 4 , wherein the stopper is formed in a two-shot molding process and the barrier layer is applied within a body of the stopper. 
     
     
         6 . The closure of  claim 5 , wherein the stopper is formed from a first portion and a second portion and the barrier layer is coined to one of the first portion and the second portion such that, when assembled, the barrier layer is located within the body of the stopper. 
     
     
         7 . The closure of  claim 1 , wherein the cap body, the stopper, and the barrier layer are formed in a multi-shot molding process. 
     
     
         8 . The closure of  claim 7 , wherein the cap body includes an inward rim extending into the cavity and wherein the barrier layer is in contact with at least one of a portion of the inward rim and a portion of the stopper. 
     
     
         9 . The closure of  claim 8 , wherein the barrier layer is heat sealed to at least one of the inward rim and the stopper. 
     
     
         10 . The closure of  claim 8 , wherein the barrier layer includes a bottom surface positioned adjacent a top portion of the inward rim and a portion of the stopper is positioned adjacent a top surface of the barrier layer to mechanically lock the barrier layer within a portion of the closure. 
     
     
         11 . The closure of  claim 8 , wherein a portion of the inward rim includes apertures extending therethrough and a top surface of the barrier layer is coined to a bottom surface of the inward rim. 
     
     
         12 . A closure, comprising:
 a cap body formed from a first material, the cap body defining a cavity therethrough;   a stopper formed from a second material and disposed within the cavity, the second material being different than the first material; and   a barrier layer formed from a third material, the third material being different from at least the second material, and associated with at least one of the cap body and the stopper and a seal ring positioned within an opening defined by a top portion of the cap body and adjacent the barrier layer.   
     
     
         13 . The closure of  claim 12 , wherein the inward rim is a stepped member having a first portion for receiving a portion of the stopper and a second portion for contacting the barrier layer, wherein the barrier layer is sandwiched between the seal ring and the second portion. 
     
     
         14 . A closure, comprising:
 a cap body formed from a first material, the cap body defining a cavity therethrough;   a stopper formed from a second material and disposed within the cavity, the second material being different than the first material; and   a barrier layer formed from a third material, the third material being different from at least the second material, and associated with at least one of the cap body and the stopper, wherein the cap body and the stopper are formed in a two-shot molding process and the barrier layer is applied in a post-molding process, and   wherein the barrier layer is applied to cover at least a portion of an opening defined by a top portion of the cap body and a top portion of the stopper.   
     
     
         15 . The closure of  claim 1 , wherein the stopper is formed in a two-shot molding process and the barrier layer is applied within a body of the stopper. 
     
     
         16 . The closure of  claim 15 , wherein the stopper is formed from a first portion and a second portion and the barrier layer is coined to one of the first portion and the second portion such that, when assembled, the barrier layer is located within the body of the stopper. 
     
     
         17 . The closure of  claim 16 , wherein the barrier layer is supplied during a first shot of the two-shot molding process. 
     
     
         18 . The closure of  claim 16 , wherein the barrier layer is supplied during a second shot of the two-shot molding process. 
     
     
         19 . The closure of  claim 16 , wherein the barrier layer is coined to at least one of the first portion and the second portion of the stopper in an overmolding process. 
     
     
         20 . The closure of  claim 16 , wherein a top portion of the stopper, the barrier layer, and a bottom portion of the stopper are separately assembled and wherein the barrier layer is coined to at least one of the first portion and the second portion of the stopper. 
     
     
         21 . The closure of  claim 1 , wherein the stopper is formed in a molding process and the barrier layer is coined to the stopper simultaneously with the molding process. 
     
     
         22 . The closure of  claim 1 , wherein the barrier layer is substantially oxygen impermeable. 
     
     
         23 . The closure of  claim 1 , wherein the first material comprises at least one of high density polyethylene (HDPE) and low density polyethylene (LDPE). 
     
     
         24 . The closure of  claim 1 , wherein the second material comprises a thermoplastic elastomer. 
     
     
         25 . The closure of  claim 24  wherein the thermoplastic elastomer is free from di(2-ethylhexyl)phthalate (DEHP). 
     
     
         26 . The closure of  claim 25  wherein the third material comprises a multi-layer laminate having a central layer formed from polyethylene terephthalate (PET) or ethylene vinyl alcohol (EVOH) sandwiched between at least two polyethylene layers. 
     
     
         27 . The closure of  claim 1 , wherein the third material is at least one of a polymeric and metal based film or foil structure. 
     
     
         28 . The closure of  claim 27  wherein the third material has a thickness of approximately 0.005 mm. 
     
     
         29 . The closure of  claim 1 , wherein the third material comprises polyethylene terephthalate (PET) or ethylene vinyl alcohol (EVOH). 
     
     
         30 . The closure of  claim 1 , wherein the barrier layer includes at least one of a weak area, a cross-cut, or a slit. 
     
     
         31 . A closure, comprising:
 a cap body formed from a first material, the cap body defining a cavity therethrough;   a stopper formed from a second material and disposed within the cavity, the second material being different than the first material; and   a barrier layer formed from a third material, the third material being different from at least the second material, and associated with at least one of the cap body and the stopper,   wherein the barrier layer is provided on a bottom surface of the stopper.   
     
     
         32 . A container assembly, comprising:
 a collection container having a closed bottom, an open top portion, and a sidewall extending therebetween, the collection container defining an interior adapted to receive a specimen sample therein; and   a closure for closing the open top portion of the collection container, comprising:
 a cap body formed from a first material, the cap body defining a cavity therethrough; 
 a stopper formed from a second material and disposed within the cavity, the second material being different from the first material; and 
 a barrier layer formed from a third material, the third material being different from the first material and the second material, and associated with at least one of the cap body and the stopper, and wherein the barrier layer is disposed across at least a portion of the cavity. 
   
     
     
         33 . The container assembly of  claim 32 , wherein the barrier layer is disposed across at least a portion of the cavity. 
     
     
         34 . The container assembly of  claim 32 , wherein the barrier layer isolates a portion of the cap body from a portion of the stopper. 
     
     
         35 . The container assembly of  claim 32 , wherein the barrier layer isolates a first portion of the stopper from a second portion of the stopper. 
     
     
         36 . The container assembly of  claim 32 , wherein the barrier layer is provided on a bottom surface of the stopper. 
     
     
         37 . The container assembly of  claim 32 , wherein the barrier layer is substantially oxygen impermeable. 
     
     
         38 . A method of forming a closure for closing and sealing a container, said method comprising:
 providing a cap body formed from a first material, the cap body defining a cavity therethrough;   providing a stopper formed from a second material and disposed within the cavity, the second material being different than the first material;   providing a barrier layer formed from a third material, the third material being different from the first material and the second material, and associated with at least one of the cap body and the stopper; and   assembling the cap body, the stopper, and the barrier layer together to form the closure, wherein the barrier layer is disposed across at least a portion of the cavity.   
     
     
         39 . The method of  claim 38 , wherein the cap body, the stopper, and the barrier layer are formed in a multi-shot molding process. 
     
     
         40 . The method of  claim 38 , wherein the cap body and the stopper are formed in a two-shot molding process and the barrier layer is applied in a post-molding process. 
     
     
         41 . The method of  claim 38 , wherein the barrier layer is applied to cover at least a portion of an opening defined by a top portion of the cap body and/or a top portion of the stopper. 
     
     
         42 . The method of  claim 38 , wherein the cap body includes an inward rim extending into the cavity and the barrier layer is in contact with a portion of the inward rim and a portion of the stopper. 
     
     
         43 . The method of  claim 38 , wherein the barrier layer is at least one of heat sealed, secured with a seal ring, mechanically sealed, and coined to at least one of the cap body and stopper. 
     
     
         44 . The method of  claim 38 , wherein the barrier layer is provided on a bottom surface of the stopper. 
     
     
         45 . The method of  claim 38 , wherein the barrier layer is substantially oxygen impermeable. 
     
     
         46 . The method of  claim 38 , wherein the barrier layer is secured within an interior portion of the stopper by a coining process.