Barrier Coated Stopper and Method of Forming Same

A system for molding a device comprising:

• a mold assembly having top plate, a sprue/vent plate, a main plate, and a bottom plate, the sprue/vent plate including a core portion extending from a surface thereof, the main plate including a recess defining a mold cavity having a contoured surface, said mold cavity configured for receiving the core portion from the sprue/vent plate to define a space corresponding to the shape of the device to be molded;
• an injection nozzle and runner mated to the top plate, said injection nozzle and runner configured for supplying a polymeric material into the mold cavity to fill said space to form said molded device having a body and molded surface corresponding to said contoured surface;
• at least one cooling member for cooling the polymeric material within the mold cavity;
• a first mechanism for separating the sprue/vent plate from the main plate to withdraw the core portion from within the molded device;
• a second mechanism for separating the sprue/vent plate from the top plate;
• and
• a third mechanism for separating the bottom plate from the main plate to enable removal of the molded device from the main plate.

A stopper adapted for attachment with a plunger rod for use within a syringe barrel, said stopper comprising:

• a main body defining an open rearward end, a closed front end, and a cylindrical sidewall extending between the open rearward end and the closed front end, said open rearward end adapted to receive a front forward end attachment portion of the plunger rod;
• a barrier film positioned adjacent the closed front end;
• at least one rib extending radially outward around a perimeter of said main body, said at least one rib configured for forming an active seal with the syringe barrel;
• a flat portion on a top outer edge surface of the closed front end and adjacent the at least one rib, the flat portion extending inward from the outer edge of the stopper;
• and
• a projection extending from the closed front end, wherein the projection defines a base as it intersects with the closed front end of the stopper and extends from the flat portion to the top of the closed front end, said base having a base diameter less than an outside diameter of the distal end of the stopper and said projection having a profile configured to cooperate with an internal surface of the syringe barrel to reduce dead space during injection.