Packing nests with stacking pins and plunger stoppers to ensure reliable alignment of nest piles (PILE)

Abstract

A nest (10) for storing medical device components including a top surface (12), a bottom surface (14), and a plurality of receptacles (20) for storing a plurality of medical device components therein, each of the plurality of receptacles (20) including a sidewall portion (22) extending downwardly from the bottom surface (14) of the nest (10). The nest (10) further includes a plurality of openings (26) formed in the top surface (12) and a plurality of stacking pins (28) extending from the bottom surface (14). Each of the plurality of openings (26) is substantially aligned with each of the plurality of stacking pins (28) to allow two or more nests (10) to be stacked vertically relative to one another via association between the openings (26) and the stacking pins (28).

Description

Technical Field

[0001] The present disclosure generally relates to a nesting configuration for the packaging of plunger stoppers used in medical devices such as syringes. More specifically, the present disclosure relates to a nesting arrangement that utilizes stacking pins to ensure reliable alignment of nests (or stacks) of nests arranged vertically on top of each other.

[0002] This application claims priority to European priority application No. 21305101.4, filed on January 26, 2021, entitled "A Nest for the Packaging of Plunger Stoppers with Stacking Pins Ensuring A Reliable Alignment of a Pile of Nests", the entire disclosure of which is hereby incorporated by reference in its entirety.

Background Art

[0003] As is known in the art, transfer or storage devices (such as syringes) for the delivery or storage of drugs, medications, or vaccines generally utilize a plunger stopper that contacts the inner surface of a tubular syringe barrel to draw substances into (or expel substances from) the device via a plunger rod.

[0004] Currently, many such devices are filled and assembled using automated filling machines. Such machines not only improve productivity and accuracy but also provide a substantially sterilized and aseptic filling environment. The various components of the device (such as plunger stoppers, syringe barrels, etc.) are provided separately within the filling machine to enable at least some level of automated assembly.

[0005] Typically, multiple plunger stoppers are provided in bags or nests (supplied inside bags) that are accessed by the filling machine during assembly. Conversely, syringe barrels are generally packaged in nests that have a number of "chimneys" formed within them to hold the barrel, and each nest is configured to be held in a tab when introduced into the filling machine.

[0006] Current nests for syringe barrels are specifically designed for use with tabs, but current nests designed to hold plunger stoppers are not configured for use with specific tab profiles and do not fit snugly into the tabs used for syringe barrels. Some automated filling machines do not have a tab for holding plunger stopper nests, so this is not a problem. However, other, more recently designed filling machines (e.g., Vanrx SA25 robotic sterile filling work cell from Vanrx Pharmasystems Inc.) are capable of handling only components packaged in both nests and tabs.

[0007] Furthermore, as mentioned above, the currently available nests for plunger stoppers are not designed to be held within existing tab designs, and their nests are not configured for consistently stackable plunger stoppers. Therefore, attempting to utilize existing nests and tabs together in relation to plunger stoppers would result in combinations that, when stacked, lead to unreliable positioning and undesirable nest movement within and / or above or below the tab, which would be problematic for robotic handling of nests in filling equipment. References EP3450349A1, EP3834943A1, EP3524293A1 and EP2017624A1 relate to packaging for containers. [Overview of the project]

[0008] Considering the above, a nest specifically designed for plunger stoppers is required, as well as a nest designed to ensure consistent and secure alignment when stacked vertically either inside or outside the tabs.

[0009] Embodiments of the present disclosure relate to a nest for storing medical device components. The nest includes a top surface, a bottom surface, and a plurality of receptacles for housing a plurality of medical device components, each of the plurality of receptacles including a side wall portion extending downward from the bottom surface of the nest. The nest further includes a plurality of openings formed in the top surface and a plurality of stacking pins extending from the bottom surface, each of the plurality of openings substantially aligned with each of the plurality of stacking pins, allowing two or more nests to be stacked perpendicular to one another via associations between the openings and the stacking pins.

[0010] In some embodiments, each stacking pin includes an upper and a lower section, the lower section being smaller in size than the upper section.

[0011] In some embodiments, the lower part of each stacking pin and each of the multiple openings are substantially cylindrical.

[0012] In some embodiments, the outer diameter of the bottom of each stacking pin is smaller than the inner diameter of each of the multiple openings.

[0013] In some embodiments, the lower part of each stacking pin of the first nest is configured to fit into the respective openings of the second nest when the first and second nests are stacked perpendicularly to each other.

[0014] In some embodiments, the lower part of each stacking pin is formed from a different material than the upper part of each stacking pin.

[0015] In some embodiments, each stacking pin includes a pin base, each of the multiple receptacles includes a receptacle base, and the pin base extends further below the nest base than the receptacle base.

[0016] In some embodiments, when at least two nests are stacked perpendicular to each other, the side wall portions of the multiple receptacles of the upper nest do not come into contact with the lower nest.

[0017] In some embodiments, the nest is substantially quadrilateral in shape.

[0018] In some embodiments, multiple openings and multiple stacking pins are positioned close to each corner of the nest.

[0019] In some embodiments, the multiple openings include at least three openings, and the multiple stacking pins include at least three stacking pins.

[0020] In some embodiments, each of the multiple openings has a depth less than the total thickness of the nest between the top and bottom surfaces.

[0021] In some embodiments, at least one finger opening is formed within the nest.

[0022] In some embodiments, the nest further includes a flange that extends at least partially around each finger opening and extends from the bottom surface of the nest.

[0023] In some embodiments, the nest is formed of polypropylene.

[0024] Further details and benefits of this disclosure will be understood from the following detailed description, which should be read in conjunction with the attached drawings. [Brief explanation of the drawing]

[0025] [Figure 1] Figure 1 is an isometric view of the upper surface of a nest for storing a plunger stopper according to an aspect of the present disclosure. [Figure 2] Figure 2 is an isometric view of the bottom surface of the nest of Figure 1. [Figure 3] Figure 3 is a top view of the nest of Figure 1. [Figure 4] Figure 4 is a partial cross-sectional side view of a pair of stacked nests according to an aspect of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The following description is provided to enable one of ordinary skill in the art to make and use the described embodiments contemplated for carrying out the invention. However, various modifications, equivalents, variations, and alternatives will be readily apparent to one of ordinary skill in the art. Any and all such modifications, variations, equivalents, and alternatives are intended to fall within the spirit and scope of the invention.

[0027] For the purposes of the following description, the terms "upper", "lower", "right", "left", "vertical", "horizontal", "uppermost", "lowermost", "lateral", "longitudinal", and their derivatives shall relate to the invention as oriented in the drawings. However, it will be understood that the invention may assume various alternative variations unless explicitly specified to the contrary. It should also be understood that the specific devices shown in the accompanying drawings and described in the following specification are merely exemplary embodiments of the invention. Therefore, specific dimensions and other physical characteristics related to the aspects disclosed herein should not be considered limiting.

[0028] Referring to Figures 1-3, a nest 10 according to one aspect of the present disclosure is shown. Each nest 10 is configured to house a plurality of plunger stoppers (not shown) in a manner that provides desired positioning and alignment of both the plunger stoppers and the nest to enable precise handling by robotic components of an automated filling machine. Although not shown, the plurality of nests 10 can be removably held within a tab or other retaining configuration configured such that the nests 10 can be stacked vertically on top of each other, as will be described in more detail below. Typically, between 2 and 10 nests can be stacked vertically relative to each other. For example, in some embodiments, at least two nests are stacked on top of each other. In one embodiment, the tab is configured such that seven nests can be stacked on top of each other. Furthermore, it should be understood that the nests described herein are not limited to use with plunger stoppers and can be used with other elements and / or devices such as needle covers, tip caps, or any other medical components.

[0029] Each nest 10 includes a plurality of stopper receptacles 20 formed therein. The stopper receptacles 20 may be formed as substantially frustoconical “chimneys,” each capable of holding a plunger stopper for access and removal by, for example, components of an autonomous filling machine. Referring to Figures 1 and 2, each stopper receptacle 20 includes an upper opening formed in the top surface 12 of the nest 10, and the “chimney” of the stopper receptacle 20 is formed by a substantially frustoconical wall portion 22 extending below the bottom surface 14 of the nest 10. The diameter and size of each stopper receptacle 20 may vary based on the type of stopper to be used during a particular filling operation. In one embodiment, the nest 10 may be configured to hold, for example, 160 stoppers of a size for use with a 1 mL syringe. However, it should be understood that the nest 10 may be configured to hold more or fewer stoppers, as well as stoppers of different sizes. For example, in another embodiment, the nest 10 may be configured to hold 100 stoppers sized for use with a 2.25 mL syringe. Thus, in some embodiments, the total number and position of the stopper receptacles 20 may vary compared to those shown in Figures 1 and 2.

[0030] Nest 10 includes a pair of long sides 16 and a pair of short sides 18. However, it should be understood that in alternative embodiments, the sides of nest 10 do not need to be of the same length and / or parallel, and instead may be, for example, equal, non-parallel, etc. The general dimensions (i.e., length, width, and height) of each nest 10 may be adapted based on the specific holding tab or automatic filling machine being used.

[0031] As shown in Figures 1 and 2, each long side 16 may include a finger opening 24 formed thereon, each finger opening 24 designed to allow simplified manual loading (and / or removal) of the nest 10 to (or from) a tab or other retaining arrangement, for example. In some embodiments, a flange 25 may at least partially surround each finger opening 24 and extend from the bottom surface 14 of the nest 10, thereby providing the user with a larger surface area for gripping the nest 10. Although two finger openings 24 are shown on opposing long sides 16 in Figures 1 and 2, it should be understood that the nest 10 may include more or fewer finger openings on either the long side 16 or the short side 18. Furthermore, in some embodiments, the finger openings 24 may be omitted entirely.

[0032] Referring to Figures 1-4, the nest 10 according to this disclosure includes a plurality of openings 26 formed within the top surface 12 adjacent to each corner of the nest 10. In some embodiments, each opening 26 may be substantially cylindrical and have a depth less than the overall thickness of the nest 10 between the top surface 12 and the bottom surface 14. However, in other embodiments, each opening 26 may extend all the way through the nest 10.

[0033] Furthermore, the nest 10 according to this disclosure includes a plurality of stacking pins 28. The stacking pins 28 extend from the bottom surface 14 of the nest 10 and are positioned substantially in line with the opening 26. In one embodiment, each stacking pin 28 is at least partially cylindrical and includes an upper part 30 and a lower part 32, the lower part 32 having a smaller diameter than the upper part 30. However, in some embodiments, each stacking pin 28 may have a consistent diameter along its entire length. Furthermore, in some embodiments, at least a portion of the stacking pin 28 may be non-cylindrical. For example, in some embodiments, at least the lower part 32 may be frustoconical, thereby tapering slightly toward the distal end of the stacking pin 28.

[0034] As will be described in more detail below, the positional relationship between the opening 26 and the stacking pins 28 is configured to assist in the relative alignment of multiple nests 10 when stacked vertically on top of each other. The stacking pins 28 are sized and configured to resist movement of the stacked nests 10 due to slight lateral and / or vertical forces applied to the nests 10, but to allow for vertical separation of the nests 10 if necessary.

[0035] Referring to Figures 2 and 4, the lower part 32 of each stacking pin 28 includes a pin base 33, and the frustoconical wall portion 22 of each stopper receptacle 20 includes a receptacle base 23. As shown in Figure 4, the pin base 33 of each stacking pin 28 is configured to extend a longer distance below the base 14 of the nest 10 than the receptacle base 23. For example, the receptacle base 23 may extend between 7 and 12 mm below the base 14 of the nest 10, while the pin base 33 may extend, for example, 1 to 3 mm further below the base 14 than the receptacle base 23.

[0036] Therefore, as shown in Figure 4, when two (or more) nests 10 are stacked on top of each other, the bottom 32 of each stacking pin 28 extending from the upper nest 10 is configured to fit into the respective openings 26 of the lower nest 10, while the frustoconical wall portions 22 of each stopper receptacle 20 of the upper nest 10 remain in contact with the frustoconical wall portions 22 of the stopper receptacle 20 of the lower nest 10. In this way, the association between the openings 26 and the stacking pins 28 is configured to ensure proper alignment and retention of the stacked nests 10 relative to each other.

[0037] Referring further to Figure 4, in one embodiment, the bottom 32 of each stacking pin 28 may be sized and configured to fit substantially into the corresponding opening 26 of the nest 10 located beneath it. The outer diameter of the bottom 32 of each stacking pin 28 may be configured to be slightly smaller than the inner diameter of the opening 26, while the height of each bottom 32 may be slightly greater than the depth of the opening 26. In this way, the bottom 32 of each stacking pin 28 can be fitted into the respective opening 26 such that a minimum amount of "play" (i.e., lateral movement) is allowed between the bottom 32 and the respective opening 26, thereby preventing the stacking pin 28 from becoming fixed within the opening 26. In such a configuration, two or more stacked nests 10 can resist movement by minimal horizontal or vertical movement, but can be separated by the filling machine and / or user as needed.

[0038] In the embodiments shown in Figures 1-4, each nest 10 is shown to include four openings 26 and four stacking pins 28, each positioned close to each corner of the nest 10. However, it should be understood that more or fewer openings 26 and / or stacking pins 28 may be available in accordance with this disclosure. For example, in an alternative embodiment, each nest 10 may include only three openings 26 and three stacking pins 28. Furthermore, the arrangement of the openings 26 and / or stacking pins 28 is not limited to the corner regions of the nest 10, but may be arranged, for example, along the sides of the nest 10, in the central region of the nest 10, etc. Furthermore, although the nest 10 is shown as a quadrilateral in Figures 1-3, it should be understood that the nest 10 is not limited in this way and may be formed in any suitable shape and / or size.

[0039] Each nest 10 can be formed from any suitable material and by any suitable method. For example, nest 10 can be formed from, for example, plastic, polymer (e.g., polypropylene), metal, etc., and can be formed by, for example, molding, stamping, thermoforming, extrusion, welding, etc. Furthermore, nest 10 can be formed as a single part or as multiple parts joined together. If it is formed from multiple parts, the materials forming each part may be the same or different.

[0040] Additionally and / or alternatively, each stacking pin 28 may be formed integrally with the nest 10 by methods such as molding, stamping, or thermoforming. However, in another embodiment, each stacking pin 28 may be formed separately so that the stacking pin 28 is subsequently fixed to the nest 10 by any suitable method such as adhesive, welding, or one or more fasteners.

[0041] Additionally and / or alternatively, the upper 30 and lower 32 of each stacking pin 28 may be formed of the same or different materials. For example, in some embodiments, the bottom 32 may be formed of a material having increased hardness and / or wear resistance compared to the upper 30. Since the bottom 32 is the portion of the stacking pin 28 that contacts and / or fits into the opening 26 of another nest 10, having such increased hardness and / or wear resistance may be beneficial, for example, to extend the life of the nest 10 and to ensure a consistent and smooth relationship between the stacking pin 28 and the opening 26.

[0042] Furthermore, the openings 26 may be formed by any suitable method, such as molding, stamping, machining, or drilling. In addition, in some embodiments, the openings 26 may be reinforced with material and / or coatings to increase the hardness and / or wear resistance of the internal contact surfaces of each opening 26. Similar to the stacking pins 28 described above, such increased hardness and / or wear resistance of the openings 26 may be beneficial, for example, to extend the life of the nest 10 and to ensure a consistent and smooth relationship between the stacking pins 28 and the openings 26.

[0043] While several embodiments of nesting and nesting arrangements are shown in the accompanying figures and described in detail herein, other embodiments will be apparent and easily constructed to those skilled in the art without departing from the scope and spirit of the invention. For example, it should be understood that this disclosure intends, to the extent possible, to combine one or more features of any embodiment with one or more features of any other embodiment. Accordingly, the foregoing description is intended to be illustrative rather than restrictive.

Claims

1. A nest (10) for storing medical device parts, Top surface (12) and Bottom surface (14) and A plurality of receptacles (20) for housing a plurality of medical device components formed within the nest (10), wherein each of the plurality of receptacles (20) includes a side wall portion (22) extending downward from the bottom surface (14) of the nest (10), The nest (10) further includes a plurality of openings (26) formed in the top surface (12) and a plurality of stacking pins (28) extending from the bottom surface (14), wherein each of the plurality of openings (26) is substantially aligned with one of the plurality of stacking pins (28), and each of the stacking pins (28) extending from the nest (10) is configured to fit into the respective opening of another nest (10), so that two or more nests (10) can be stacked vertically on top of each other, wherein the lower part (32) of each of the stacking pins (28) is formed of a different material from the upper part (30) of each of the stacking pins (28), and the material of the lower part (32) is harder than the material of the upper part (30).

2. The nest (10) according to claim 1, wherein each stacking pin (28) includes an upper part (30) and a lower part (32), the lower part (32) being smaller in size than the upper part (30).

3. The nest (10) according to claim 2, wherein each of the lower parts (32) of the stacking pins (28) and each of the plurality of openings (26) are substantially cylindrical.

4. The nest (10) according to claim 3, wherein the outer diameter of the lower part (32) of each of the stacking pins (28) is smaller than the inner diameter of each of the plurality of openings (26).

5. The nest (10) according to any one of claims 2 to 4, wherein the lower part (32) of each stacking pin (28) of the first nest (10) is configured to fit into the respective openings (26) of the second nest (10) when the first nest (10) and the second nest (10) are stacked perpendicularly to each other.

6. The nest (10) according to any one of claims 1 to 5, wherein each stacking pin (28) includes a pin base (33), and each of the plurality of receptacles (20) includes a receptacle base (23), and the pin base (33) extends further below the base (14) of the nest (10) than the receptacle base (23).

7. The nest (10) according to any one of claims 1 to 6, wherein when at least two nests (10) are stacked perpendicular to each other, the side wall portion (22) of each of the plurality of receptacles (20) of the upper nest (10) does not come into contact with the lower nest (10).

8. The nest (10) according to any one of claims 1 to 7, wherein the nest (10) is substantially quadrilateral in shape.

9. The nest (10) according to any one of claims 1 to 8, wherein the plurality of openings (26) and the plurality of stacking pins (28) are arranged in close proximity to each corner of the nest (10).

10. The nest (10) according to any one of claims 1 to 9, wherein the plurality of openings (26) includes at least three openings (26), and the plurality of stacking pins (28) includes at least three stacking pins (28).

11. The nest (10) according to any one of claims 1 to 10, wherein each of the plurality of openings (26) has a depth less than the overall thickness of the nest (10) between the top surface (12) and the bottom surface (14).

12. The nest (10) according to any one of claims 1 to 11, further comprising at least one finger opening (24) formed along the side surface of the nest (10).

13. The nest (10) according to claim 12, further comprising a flange (25) that extends at least partially around each finger opening (24) and extends from the bottom surface (14) of the nest (10).

14. The nest (10) according to any one of claims 1 to 13, wherein the nest (10) is made of polypropylene.

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