WO2023102008A1

WO2023102008A1 - Blow molded transfer tube and methods of making the same

Info

Publication number: WO2023102008A1
Application number: PCT/US2022/051338
Authority: WO
Inventors: Zachary MCMASTER; Michael WINNETT; David Graham
Original assignee: Silgan Unicep Packaging Llc
Priority date: 2021-12-02
Filing date: 2022-11-30
Publication date: 2023-06-08

Abstract

A unit dose dispenser including a blow-molded container created in a blow-fill-seal process wherein the blow-molded container includes a cap portion and a sample portion that may be easily separated by snapping the cap portion from the sample portion and including test kits utilizing blow-molded containers according to embodiments of the invention. A blow-molded container of various embodiments of the invention may be produced in a blow-fill-seal process. In addition, a blow-molded container may be connected to, or produced as a part of, a plurality of blow-molded containers. For example, a package of at least two blow-molded containers may include two blow-molded containers connected along a container parting line which is configured to allow a user to separate the blowmolded containers along the container parting line for individual use.

Description

TITLE OF THE INVENTION

BLOW MOLDED TRANSFER TUBE AND METHODS OF MAKING THE SAME

BACKGROUND OF THE INVENTION

[0001] Field of the Invention: Embodiments of the present invention relate to blow-molded transfer tubes or containers, and in some instances, blow-molded transfer tubes having ribs above, below, or both above and below a twist or snap-off opening feature in the transfer tube. The blow-molded transfer tubes of embodiments of the invention are formed and filled in blow-fill-seal processes.

[0002] State of the Art: Blow-molded containers are known and are commonly used in blow-fill-seal processes to package a dose or quantity of liquid or flowable material for one-time use and/or application. For example, blow-fill-seal processes are used to blowmold a container, fill it with a product - such as eye wetting drops - and then seal the container. The sealing process creates a tab which a user may use to twist off a portion of the blow-molded container to reveal an opening through which the liquid or product in the blow- molded container may be accessed or dispensed.

[0003] Typically, blow-fill-seal - or BFS - processes are used to package small quantities of a fluid or product in a plastic, blow-molded container, for individual or singledose use. After use, the container may be discarded or recycled depending on the materials used in the blow-molding process and the product contained in the container.

[0004] BFS processes are well known and are used for many different products. However, the containers created in BFS processes typically have a very small opening and the size of the blow-molded containers are relatively small. The small opening is also a function of the strength of the packaging and the need to provide an easy tear-off cap or removeable tip for the BFS products.

[0005] The use of glass ampules or plastic ampule-like vials are also common, especially in testing kits used in the medical and pharmaceutical fields of use. Such kits usually contain an ampule with a testing liquid that is sealed and which can be opened, allowing a user to insert a sample to be tested. For example, a testing kit may include a cotton swab and an ampule with a testing liquid into which the cotton swab will be inserted once a specimen has been collected on the cotton swab. A user may obtain a specimen on the cotton swab, open the ampule, and insert the swab into the ampule where it will contact the liquid or testing solution in the ampule and a test will be performed. [0006] While such kits are common, there is a push to reduce the overall cost of such testing kits, especially as more tests are being performed worldwide with the spread of viruses and other diseases.

BRIEF SUMMARY OF THE INVENTION

[0007] According to certain embodiments of the invention, a unit dose dispenser includes a blow-molded container created in a blow-fill-seal process having a unitary body with a sample portion and a cap portion. The blow-molded container may be at least partially filled with a product and sealed at the cap portion. The cap portion may be removed from the sample portion by twisting of the cap portion relative to the sample portion or twisting of the sample portion relative to the cap portion. The cap portion, the sample portion, or both the cap portion and sample portion may include ribs configured to add structural support to the container. In various embodiments of the invention, the blow-molded container also includes an opening into the sample portion of the container once the cap portion is removed. The opening may have a diameter of not less than 0.270 inches. In other embodiments, the opening diameter may be between about 0.270 inches and about 0.373 inches.

[0008] A blow-molded container of various embodiments of the invention may be produced in a blow-fill-seal process. In addition, a blow-molded container may be connected to, or produced as a part of, a plurality of blow-molded containers. For example, a package of at least two blow-molded containers may include two blow-molded containers connected along a container parting line which is configured to allow a user to separate the blow- molded containers along the container parting line for individual use.

[0009] A blow-molded container according to certain embodiments of the invention may include a connection feature on an exterior surface thereof such that the blow-molded container may be connected to another container, component, or device. For example, a blow-molded container may include external threads, snap beads or features, or bayonet connection to facilitate connection of the blow-molded container to a test strip or stick or other closure device.

[0010] Various embodiments of the invention may also include blow-molded containers shaped and formed to facilitate snap separation of a cap portion from a sample portion of the blow-molded container. In such embodiments, a cap portion of the blow- molded container may be snapped off of, or separated from, the sample portion without using a twisting motion and instead applying a force to snap or separate the cap portion from the sample portion. In such embodiments, a cap portion may be snapped off the sample portion by applying a force to the cap portion, the sample portion, or both.

[0011] According to various embodiments of the invention, a blow-molded container may be formed from a mixture of a low density polyethylene resin with a high density polyethylene resin. In certain embodiments of the invention, a mixture may include 50% low density polyethylene resin and 50% high density polyethylene resin. In other embodiments, a mixture may include 45% low density polyethylene resin and 55% high density polyethylene resin. In other embodiments, a mixture may include 55% low density polyethylene resin and 45% high density polyethylene resin. In other embodiments, a mixture may include 40% low density polyethylene resin and 60% high density polyethylene resin. In other embodiments, a mixture may include 60% low density polyethylene resin and 40% high density polyethylene resin. Other mixture ratios may also be used.

[0012] A blow-molded container according to various embodiments of the invention is produced in a blow-fill-seal process wherein the blow-molded container is blow- molded, filled, and sealed, creating a product or blow-molded container at least partially filled with a product.

[0013] In other embodiments of the invention, a testing kit is provided. A testing kit may include a package or container configured to hold the components of a test kit. For instance, a kit may include a package, at least one blow-molded container according to embodiments of the invention in which a testing fluid is retained, and at least one swab for collecting a sample to be inserted into the blow-molded container to contact the testing fluid. Instructions on how to use the test kit may also be included in the kit. In other embodiments, a test kit having a blow-molded container having a connection feature on an external surface thereof may include a cap, a cap with a swab, or other component that may be connected to the blow-molded container by a corresponding connection feature after a cap portion of the blow-molded container is separated from the sample portion.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] While the specification concludes with claims particularly pointing out and distinctly claiming particular embodiments of the present invention, various embodiments of the invention can be more readily understood and appreciated by one of ordinary skill in the art from the following descriptions of various embodiments of the invention when read in conjunction with the accompanying drawings in which:

[0015] FIG. 1 illustrates a blow-molded container according to various embodiments of the invention;

[0016] FIG. 2 illustrates a set of blow-molded containers according to various embodiments of the invention;

[0017] FIG. 3 illustrates a blow-molded container separated into a cap portion and a sample portion according to various embodiments of the invention;

[0018] FIG. 4 illustrates a blow-molded container according to various embodiments of the invention;

[0019] FIG. 5 illustrates a blow molded container according to various embodiments of the invention;

[0020] FIG. 6 illustrates a testing kit according to various embodiments of the invention;

[0021] FIG. 7 illustrates a perspective view of blow-molded container according to various embodiments of the invention;

[0022] FIG. 8 illustrates a front view of a blow-molded container according to various embodiments of the invention;

[0023] FIG. 9 illustrates a side view of a blow-molded container according to various embodiments of the invention;

[0024] FIG. 10 illustrates a perspective view of a blow-molded container according to various embodiments of the invention;

[0025] FIG. 11 illustrates a front view of a blow-molded container according to various embodiments of the invention;

[0026] FIG. 12 illustrates a side view of a blow-molded container according to various embodiments of the invention;

[0027] FIG. 13 illustrates a front view of a blow-molded container according to various embodiments of the invention;

[0028] FIG. 14 illustrates a front view of the blow-molded container of FIG. 11 in a sealed state; and

[0029] FIG. 15 illustrates a front view of the blow-molded container of FIG. 8 in a sealed state. DETAILED DESCRIPTION OF THE INVENTION

[0030] According to embodiments of the invention, a blow-molded container 100 includes a cap portion 110 and a sample portion 120 as illustrated in FIG. 1. The cap portion 110 may be separated from the sample portion 120 along a line defined by the twist feature 190 between the cap portion 110 and the sample portion 120.

[0031] The cap portion 110 of the blow-molded container 100 may include a cavity through which product may be introduced into the sample portion 120 during a filling processes, such as during a blow-fill-seal process. A filling opening 115 in the cap portion 110 may be open following a blow-molding process to allow product to be filled through the opening 115 and then sealed as part of a sealing process, preventing product in the blow- molded container 100 from escaping.

[0032] The sample portion 120 may include or define a hollow space into which a product is filled and contained. The hollow space may be a generally tubular form 130 defined by the walls of the sample portion 120. According to various embodiments of the invention, the inner diameter of the tubular form 130 may be about 0.373 inches or less. In some embodiments, the inner diameter of the tubular form 130 is at least 0.270 inches and no more than 0.373 inches.

[0033] The twist feature 190 may be formed in the blow-molding process or the sealing process or both. According to embodiments of the invention, the twist feature 190 provides a weakened point in the blow-molded container 100 that allows the cap portion 110 and the sample portion 120 to be separated along the twist feature 190 by rotating the cap portion 110 and the sample portion 120 in opposite directions or about one another. When the cap portion 110 is removed from the sample portion 120 as illustrated in FIG. 3, an opening 128 is exposed in the sample portion 120 which allows access to an interior of the tubular form 130 where a liquid or product may be stored.

[0034] Blow-molded containers 200 according to other embodiments of the invention are illustrated in FIGs. 4 and 5. As illustrated, the blow-molded containers 200 shown in FIGs. 4 and 5 include a cap portion 210, a sample portion 220 having a tubular form 230, and a twist feature 290. They do not include ribs, however, as in other embodiments of the invention. [0035] While the blow-molded containers 200 illustrated in FIGs. 4 and 5 work and provide larger openings and larger blow-molded containers 200, it has been found that the larger size can be detrimental to the structure of the blow-molded container 200. This is especially true when the cap portion 210 is removed from the sample portion 220. For example, when removing a cap portion 210 from the blow-molded containers 200 illustrated in FIGs. 4 and 5, twisting and deformation of the sample portion 220 occurs in some products. This deformation can result in spillage of a fluid or product contained in the sample portion 220 or deformation of an opening 228 in the sample portion 220 which may prevent the insertion of a swab 800 or testing strip into the tubular form 230 of the sample portion 220.

[0036] To overcome such deformation, and to provide a more ridged form for the blow-molded containers 100, at least one rib is included on the blow-molded container 100. As illustrated in FIGs. 1-3, a blow-molded container 100 may include three ribs, a cap rib 112 and two sample ribs 122, 124. While three ribs are illustrated in certain embodiments of the invention, it is understood that a fewer or greater number of ribs could be used with various embodiments of the invention. For example, a blow-molded container 100 may include just a single sample rib 124. In other embodiments there may be a single sample rib 124 and a single cap rib 112. Furthermore, a sample rib may be located at a lower end of the sample portion 120 such that the sample rib creates a base upon which the sample portion 120 rests on a surface in an upright position such that the sample portion 120 - or the complete blow- molded container 100 - can stand on a surface using such sample rib.

[0037] Blow-molded containers 100, 200, 400 according to embodiments of the invention may also be provided in a connected package as illustrated in FIG. 2. As shown, three blow-molded containers 100 may be connected along container separation lines 180 such that a package of blow-molded containers 100 may be formed, filled, and sealed during a blow-fill-seal process. The individual blow-molded containers 100 may then be separated along the container separation lines 180 and used as desired. While a package of three blow- molded containers 100 is illustrated, it is understood that such package may include two or more blow-molded containers 100.

[0038] A blow-molded container 400 according to other embodiments of the invention is illustrated in FIGs. 7 through 9 and the blow-molded container 400 at least partially filled with a product 900 and sealed is illustrated in FIG. 15. As illustrated, a blow- molded container 400 may include a cap portion 410 and a sample portion 420. A snap line 492 may be positioned between the cap portion 410 and the sample portion 420 as illustrated. According to certain embodiments of the invention, the cap portion 410 may be separated from the sample portion 420 along the snap line 492. In some embodiments, the cap portion 410 and sample portion 420 may be separated by twisting the two portions in opposite directions to create separation along the snap line 492. In other embodiments, the cap portion 410 may be snapped off of the sample portion 420 by pushing on the cap portion 410 and creating enough force to snap the portions apart. For example, pushing on the front side of a cap portion 410 as illustrated in FIG. 8 will cause the cap portion 410 to snap off of the sample portion 420. Similarly, pushing on the side of the cap portion 410 as illustrated in FIG. 9 will cause the cap portion 410 to snap off of the sample portion 420. According to embodiments of the invention, blow-molded container 400 is formed from a mixture of low density polymer and high density polymer which provides the desired characteristics to allow the cap portion 410 to be snapped off of the sample portion 420 instead of requiring a user to twist the cap portion 410 off of the sample portion 420.

[0039] As with other embodiments of the invention, one or more ribs may be formed with the blow-molded container 400 such as sample ribs 422 and 424 illustrated in FIGs. 7 through 9 and 15. In some embodiments, a cap rib 412 may include a bulbous protrusion in the cap portion 410 as illustrated in FIG. 9. In other embodiments, a cap rib 412 may be formed in a shape similar to that of the sample ribs 422, 424. The ribs may be positioned to provide additional structural support to the blow-molded container 400 and to allow the cap portion 410, sample portion 420, or both to absorb forces encountered during the removal of the cap portion 410 from the sample portion 420 without damaging the structural integrity of the blow-molded container 400. While the number and location of the ribs 422 and 424 are illustrated in FIGs. 7 through 9, it is understood that fewer or more ribs may be included and that the positioning of the ribs may be different in various configurations of blow-molded containers 400 according to embodiments of the invention.

[0040] A blow-molded container 400 may also include a filling opening 415 through which a product 900 may be filled into the sample portion 420 of the container during the blow-molding process or a blow-fill-seal process as described with respect to other embodiments of the invention. For example, the blow-molded container 400 may be blow- molded, filled, and sealed in a conventional blow-fill-seal process such that a product as illustrated in FIGs. 14 or 15 having a sealed tip 490 comes off the production line ready for use or shipping to a customer.

[0041] A blow-molded container 400 according to still other embodiments of the invention is illustrated in FIGs. 10 through 12 and 14. As illustrated, the blow-molded container 400 includes a cap portion 410 and a sample portion 420 which are initially joined together but which may be separated along the snap line 492 in the same manner as with other embodiments of the invention. The blow-molded container 400 illustrated in FIGs. 10 through 12 and 14 also includes a connection feature 450 on an exterior surface of the blow- molded container 400. The connection feature 450 may be configured to allow a device or component to be fitted with the sample portion 420 after the sample portion 420 is separated from the cap portion 410 of the blow-molded container 400. For example a cap may be attached to the connection feature 450 to again seal the sample portion 420 after being separated from the cap portion 410.

[0042] While the connection feature 450 is illustrated on the exterior surface of the blow-molded container 400, it is possible to include such a feature on an interior surface such as on an interior surface of the sample portions 420. However, such positioning may be more difficult and not as desirable as a feature on the exterior surface of the blow-molded container 400.

[0043] As illustrated, a connection feature may include a thread system capable of mating with or being connected to a similar threaded device or component. For example, a cap having threads on an internal surface could be screwed onto the threaded connection feature 450 illustrated to close or seal the sample portion 420 after being separated from the cap portion 410.

[0044] An alternative connection feature 450 is illustrated in FIG. 13. A bayonet or snap connection feature 450 is shown and will be able to connect to a cap or other device or component having corresponding features on an interior surface. The use of threaded, bayonet, and snap features to connect two components or to seal the opening of a container are known and any such connection feature 450 may be incorporated with and included on the blow-molded containers 400 according to embodiments of the invention.

[0045] Blow-molded containers 400 according to various embodiments of the invention may be provided in connected packages with individual blow-molded containers 400 being connected along container connection lines and which may be removed or separated from one another. The connected packages may be formed in a blow-fill-seal process where the connected package is blown and filled virtually simultaneously or blown and indexed on a blow-fill-seal line to the filling station and then sealed in the filling station or in an index thereafter. The resulting product coming off of the blow-fill-seal line includes packages of multiple blow-molded containers 400 at least partially filled with a product and sealed at the filling opening.

[0046] Blow-molded containers 100, 200, 400 according to various embodiments of the invention may be made of any material commonly used in blow-molding processes or in blow-fill-seal processes. In some embodiments of the invention, the blow-molded container 100, 200, 400 may be made of polypropylene, low density polyethylene, or medium density polyethylene.

[0047] Furthermore, in some instances it may be advantageous to form a blow- molded container 100, 200, 400 from a mixture of resins or materials. This may be even more desirable in situations where a snap-off feature or separation of the cap portion of the blow-molded container 100, 200, 400 from a sample portion is desired. For example, a blow- molded container 400 may be molded or formed from a mixture of a low density polyethylene and a high density polyethylene. In some embodiments of the invention, a mixture of 50% by weight of a low density polyethylene resin with 50% by weight of a high density polyethylene resin may be used as the material from which the blow-molded container 400 is formed. For example, a blow-molded container 400 may be made from a mixture of the low density polymer TRUCOAT® EC808 from Westlake Chemical and the high density polymer T60-800-119 polyethylene homopolymer from INEOS® Olefins & Polymers. In one embodiment, the mixture includes 50% by weight of the low density polymer and 50% by weight of the high density polymer. Other mixtures that work well and facilitate the desired snap-off features of the blow-molded containers 100, 200, 400 according to embodiments of the invention include mixtures of 45% to 50% by weight low density polymer with 50% to 55% by wight high density polymer. In other embodiments a mixture of 55% to 50% by weight low density polymer with 50% to 45% by weight high density polymer is used to make blow-molded containers 100, 200, 400 according to embodiments of the invention.

[0048] Other mixture ratios have also been found to be capable of providing the necessary properties to allow the desired snap separation of cap portions from sample portions of the blow-molded containers 100, 200, 400 of the present invention. For instance, the following mixtures (by weight) have been found to provide the desired properties: 45% low density polymer with 55% high density polymer; 40% low density polymer with 60% high density polymer; 55% low density polymer with 45% high density polymer; 60% low density polymer with 40% high density polymer; and mixtures containing between 40% and 60% low density polymer with a corresponding 60% to 40% high density polymer.

[0049] According to other embodiments of the invention, a kit 300 is provided as illustrated in FIG. 6. A kit 300 may include a box or other container 310 configured to hold or contain at least one blow-molded container containing a test fluid or product and at least one testing swab 800 or testing strip. The blow-molded container may include a blow- molded container 100 as illustrated or any other blow-molded container according to embodiments of the invention. A kit 300 may also include instructions 360 on how to use the kit 300. In some embodiments, the kit 300 may be a testing kit used to test for viruses, illnesses, or other medical issues. A kit 300 may also include a cap or other feature on the testing swab 800 or separate therefrom configured to mate with or connect to a blow-molded container according to various embodiments of the invention.

[0050] While certain dimensions for blow-molded containers 100, 200, 400 are given herein, it is understood that various embodiments of the invention may also include different dimensions. In some embodiments of the invention, a blow-molded container 100, 200 may include the following dimensions: minimum inner diameter of the tubular form of at least 0.270 inches; maximum inner diameter of the tubular form of about 0.373 inches; maximum height of the blow-molded container of about 2 inches; maximum fin diameter of material outside the tubular form 130 of about 0.520 inches; nominal wall thickness of between about 0.015 inches and about 0.025 inches; rib diameters of about 0.1375 inches; and angel of twist feature between about 43 degrees to about 33 degrees, and preferably about 35 degrees. In some embodiments of the invention, the diameter of the opening 128 may be about 0.255 inches +/- 10%. In other embodiments, the diameter may be as large as about 0.3825 inches.

[0051] Having thus described certain particular embodiments of the invention, it is understood that the invention defined by the appended claims is not to be limited by particular details set forth in the above description, as many apparent variations thereof are contemplated. Rather, the invention is limited only be the appended claims, which include within their scope all equivalent devices or methods which operate according to the principles of the invention as described.

Claims

CLAIMS What is claimed is:

1. A blow-molded container, comprising: a sealed cap portion; a sample portion at least partially filled with a product; at least one rib associated with the sample portion; a snap line between the cap portion and the sample portion; and wherein removal of the cap portion from the sample portion forms an opening in the sample portion.

2. The blow-molded container of claim 1, wherein the at least one rib associated with the sample portion comprises one rib.

3. The blow-molded container of claim 1, wherein the at least one rib associated with the sample portion comprises two ribs.

4. The blow-molded container of claim 1, further comprising a cap rib associated with the cap portion.

5. The blow-molded container of claim 1, wherein the opening has a diameter between about 0.270 inches and about 0.373 inches.

6. The blow-molded container of claim 1, wherein the opening has a diameter of at least 0.270 inches.

7. The blow-molded container of claim 1, wherein the opening has a diameter of a size sufficient to allow passage of a test swab.

8. A kit for use in testing for a virus, comprising: a package; at least one blow-molded container contained in the package, the blow-molded container comprising: a cap portion; a sample portion; a snap line between the cap portion and the sample portion; and a testing fluid at least partially contained in the sample portion; at least one swab contained in the package.

9. The kit of claim 8, further comprising a set of instructions for using the at least one swab and the at least one blow-molded container.

10. The kit of claim 8, wherein the at least one blow-molded container further comprises a set of at least two blow-molded containers co-molded and separable along a container parting line.

11. The kit of claim 8, wherein the at least one blow-molded container further comprises an opening in the sample portion when the cap portion is removed of between about 0.270 inches and about 0.373 inches.

12. A blow-molded container, comprising: a cap portion; a sample portion; at least one rib associated with the sample portion; a snap line between the cap portion and the sample portion, wherein the cap portion may be removed from the sample portion along the snap line; and wherein the blow-molded container is formed from a polymer mixture comprising a low density polymer and a high density polymer.

13. The blow-molded container of claim 12, wherein the polymer mixture comprises 50% by weight low density polymer and 50% by weight high density polymer.

14. The blow-molded container of claim 12, wherein the polymer mixture comprises between 40% and 50% by weight low density polymer and between 50% and 60% by weight high density polymer.

15. The blow-molded container of claim 12, wherein the polymer mixture comprises between 60% and 50% by weight low density polymer and between 50% and 40% by weight high density polymer.

16. The blow-molded container of claim 12, wherein the polymer mixture comprises between 45% and 50% by weight low density polymer and 50% and 55% by weight high density polymer.

17. The blow-molded container of claim 12, wherein the polymer mixture comprises between 55% and 50% by weight low density polymer and 50% and 55% high density polymer.

18. The blow-molded container of claim 12, further comprising a connection feature on an exterior surface of the sample portion.

19 The blow-molded container of claim 18, wherein the connection feature comprises a threaded connection feature.

20. The blow-molded container of claim 18, wherein the connection feature comprises a bayonet connection feature.

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