BLISTER PACKAGES CONTAINING ACTIVE MATERIAL AND METHODS OF MAKING AND USING SAME

A blister pack having a backing having a first side and an opposing second side. Each of the first and second side is flat or planar. The blister pack can also include a cover having a first side and an opposing second side. At least a portion of the second side of the cover is adhered to the first side of the backing to form a sealed package for containing product. The cover can include at least one blister. Each blister can have a dome portion and a base portion. The base portion can surround the dome portion. The base portion can extend outwardly beyond the first side of the cover. The blister pack can also include an active member positioned within the base portion of each blister.

FIELD

The presently disclosed technology relates to blister packages for product, such as pills, tablets, capsules and the like. Each package has a cover, which can be optionally formed of a thermoformed material, bonded to backing, which can optionally include an aluminum foil component.

BACKGROUND AND DESCRIPTION OF RELATED ART

Blister packaging is commonly used to package oral solid dose medications, vitamins, probiotics, pills, tablets, capsules, and the like. Prior art packaging includes a thermoformed material, which holds the product, and a foil attached to an open side thereof to enclose the product. Blister packaging or “blister packs” are typically used both by pharmaceutical companies and smaller health care facilities. Blister packs are also manufactured by companies in the business of providing unfilled blister packs for filling by third parties.

It is known to place a desiccant or scavenger extruded film in a blister pack. The size and shape of the desiccant or scavenger extruded film may be called the footprint of the film, and in the prior art is at least slightly less than the opening of the blister containing the product. One such blister package with desiccant film is disclosed in U.S. Pat. No. 6,279,736 (Hekel), which is hereby incorporated by reference.FIG. 1shows another prior art blister pack10having four blisters18.FIG. 2shows a cross-sectional view through line2-2ofFIG. 1, and shows a thermoplastic member14, forming one of the blisters18, adhered to foil backing12. Extruded desiccant film16having a width WPA(seeFIG. 2) less than that of a single blister18is adhered to the foil backing12.

In conventional blister packaging, the desiccant or scavenger capacity of the film is limited by the opening of the blister.

BRIEF SUMMARY

There is a need to increase the desiccant or scavenger capacity of a blister package. This and other needs are addressed by the presently disclosed technology, which includes, in one aspect, a blister pack having a thermoformed cover and a foil backing. The cover can be attached or bonded to the foil backing to form a sealed unit package for containing a product. The cover can have at least one blister cavity with an open side. The foil backing can have a side bonded to the cover. The blister cavity can have a blister or dome portion and a base portion. The base portion can be wider and/or longer than the blister portion.

The blister pack can further include an extruded film. In one embodiment, the extruded film can be adhered to the side of the foil backing bonded to the cover. The extruded film can have a shape approximating the base portion. The extruded film can include a desiccant or oxygen scavenger.

In another aspect, the presently disclosed technology can include a method of making a blister pack. In one embodiment, the method can include attaching or bonding a thermoformed cover to a foil backing to form a sealed unit package. The cover can have at least one blister cavity containing a product. The at least one blister cavity can have an open side. The blister cavity can have a blister or dome portion and a base portion. The base portion can be wider and/or longer than the blister portion.

In one embodiment, the method can include attaching or adhering an extruded film to a side of the foil backing, which is then attached or bonded to the thermoformed cover. In another embodiment, the extruded film is not adhered to the foil backing.

In another aspect, the presently disclosed technology includes a backing and a cover attached to the backing that forms at least one sealed cavity for containing product. The sealed cavity includes a dome portion and a base portion. At least a section of the base portion extends laterally outwardly beyond the dome portion in a first direction. The dome portion extending upwardly beyond an outer peripheral portion of the cover in a second direction. At least one active member is positioned within at least the base portion of the sealed cavity.

In yet another aspect, the presently disclosed technology includes a blister pack including a backing and a cover having at least one blister with a dome portion and a base portion. At least a section of the base portion extends outwardly beyond the dome portion in a first direction. The base portion extends outwardly beyond an outer peripheral portion of the cover in a second direction. The second direction is perpendicular to the first direction. The cover is attached to the backing to form a sealed package for containing product in the dome portion of the blister. At least one active member is positioned within at least the base portion of the blister.

In still a further aspect, the presently disclosed technology includes a blister pack including a backing and a cover attached to the backing. The combined cover and backing form at least one sealed cavity for containing product. The sealed cavity includes a dome portion and a base portion. At least a section of the base portion extends beyond the dome portion in a first direction. The dome portion extends beyond an outer peripheral portion of the cover in a second direction. The second direction is perpendicular to the first direction. At least one active member is positioned within at least the base portion of the sealed cavity.

Optionally, in any embodiment, the product contained in a blister of a blister pack may include a pill, which is optionally a medicine, a nutritional supplement or a probiotic, for example.

DETAILED DESCRIPTION

While systems, devices and methods are described herein by way of examples and embodiments, those skilled in the art recognize that the presently disclosed technology is not limited to the embodiments or drawings described. Rather, the presently disclosed technology covers all modifications, equivalents and alternatives falling within the spirit and scope of the appended claims. Features of any one embodiment disclosed herein can be omitted or incorporated into another embodiment.

Any headings used herein are for organizational purposes only and are not meant to limit the scope of the description or the claims. As used herein, the word “may” is used in a permissive sense (i.e., meaning having the potential to) rather than the mandatory sense (i.e., meaning must). Unless specifically set forth herein, the terms “a,” “an” and “the” are not limited to one element but instead should be read as meaning “at least one.” A first direction D1and a second direction D2are shown in certain drawings for reference and clarity only, and are not part of the structure of the presently disclosed technology. The terminology includes the words noted above, derivatives thereof and words of similar import.

Referring now in detail to the various figures, wherein like reference numerals refer to like parts throughout,FIGS. 3-5illustrate one embodiment of a blister packaging or pack, generally designated110, of the presently disclosed technology. The blister pack110can include a backing112, a cover114, and at least one active member116. The blister pack110can enclose, preserve and protect one or more products117(shown schematically inFIG. 4), such as oral solid dose medications, vitamins or other nutritional supplements, foodstuff, small consumer goods, probiotics, etc. Such products may be in the form of pills, e.g., tablets, capsules, and the like.

The backing112can have a first side or surface112aand an opposing second side or surface112b. Optionally, at least the first side112aof the backing112being flat or planar. In one embodiment, each of the first and second sides112a,112bof the backing112are flat or planar, such that each of the first and second sides112a,112bextends in a plane, which are at least slightly spaced-apart. In one embodiment, the backing112is formed at least in part of foil, such as aluminum foil, and/or of a plastic material. Optionally, the backing112can include paperboard.

The cover114can have a first side or surface114aand an opposing second side or surface114b. Optionally, at least a portion of the first and second sides114a,114bof the cover114are flat or planar. At least a portion of the second side114bof the cover114can be attached or adhered, such as by thermoforming or cold forming, to the first side112aof the backing112to form a sealed package for containing product(s). The cover114can have the same or a different thickness (as measured in the direction of D2) as the backing112. In one embodiment, the cover114is made or formed of a formable web. In one embodiment, the formable web is made from a thermoplastic material, such as a thermoformed film. Optionally, the cover114can be formed of polyvinyl chloride (PVC), which can be transparent or opaque. In one embodiment, the cover114and/or the backing112can be formed on two or more layers.

The cover114includes or is formed to have at least one blister, generally designated118. For example, the cover114can include two or more spaced-apart blisters118. The embodiment shown inFIGS. 3-5shows the cover114having four, spaced-apart, identical blisters118. However, the cover114can have more or fewer blisters and one or more of the blisters can have a different size and/or shape than another one of the blisters118of the blister pack110, depending upon the particular need. Optionally, each blister118can have at least a partial egg shape or a bulbous shape. Alternatively, in one embodiment, each blister118can have at least a partial plateau shape (e.g., when viewed from the side) or a cylindrical shape. When the cover114is attached to the backing112, a sealed cavity is formed within or by each blister118.

As shown inFIG. 3, in one embodiment, each blister118can define a longitudinal or long axis that extends parallel to at least one outer edge of the blister pack110. Optionally, and more specifically, the longitudinal axis of each blister118can extend parallel to two opposing lateral sides of the blister pack110and perpendicularly to top and bottom sides of the blister back, as shown inFIG. 3. However, the arrangement or orientation of the blister(s)118within the blister pack110is not limited to that shown and described herein, as other configurations are possible depending upon the particular need.

In one embodiment, each blister118has a blister or dome portion120and a base portion122. The base portion122has a different size, shape, configuration and/or footprint than the dome portion120. Optionally, at least a section of the base portion122extends laterally outwardly beyond the dome portion120in the first direction D1. For example, in one embodiment, the base portion122has a larger footprint than the dome portion120, such that the base portion122surrounds or encircles the entire dome portion120(seeFIGS. 3 and 4). In other words, in such an embodiment, the base portion122is longer and wider than the dome portion120. In such a configuration, when viewing the blister pack110from above (seeFIG. 3), each base portion122has the same outer peripheral shape as each dome portion120, and the difference being that the base portion122is larger. Optionally, both the dome portion120and the base portion122have a generally oval shape when viewed from above (seeFIG. 3). In another embodiment, only a section of the base portion122extends laterally outwardly beyond the dome portion120in the first direction D1, such that the base portion122has a different shape than the dome portion120when viewed from above.

Optionally, both the dome portion120and the base portion122extend outwardly (i.e., upwardly) beyond the first side114aof the cover114and/or away from the backing112in the second direction D2. As shown inFIG. 4, the second direction D2is perpendicular to the first direction D1. In one embodiment, the dome portion120extends outwardly beyond or further than the base portion122in the second direction D2away from the first side114aof the cover114.

In one embodiment, the dome portion120is sized, shaped and/or configured to contain product117therein, while the base portion122is not. In other words, in such an embodiment, the size, shape and/or configuration of the base portion122does not permit product(s)117to be positioned therein. More particularly, the combined cover114attached to the backing112forms a cavity therebetween within each blister118. As shown inFIG. 5, the cavity can include at least a product compartment124and a base compartment126. In one embodiment, at least a section of the base compartment126extends outwardly beyond the product compartment in the first direction D1. In one embodiment, the product117is positioned entirely in the product compartment124. At least a first portion (e.g., a mid-section) of the active member116is positioned in or below the product compartment124and/or the product117, and at least a second portion (e.g., one or both outer or lateral ends and/or the outer periphery thereof) of the active member116is positioned in the base compartment126.

Optionally, as shown inFIG. 4, the dome portion120can have the shape of an arch in cross-section, while the base portion122can be rectilinear, square or rectangular in shape. In other words, in one embodiment, the shape of the dome portion120is distinct from that of the base portion122, such that the base portion122does not continue the shape or angle or trajectory of the dome portion120. The base portion122separates the dome portion120from a remainder of the cover114, or the base portion122attaches the dome portion120to the remainder of the cover114. In one embodiment, the base portion122includes a flat or linear sidewall122aand a flat or linear top wall122b, and the dome portion120has an entirely arcuate or bulbous shape. Optionally, as shown inFIG. 4, the sidewall122aof the base portion122can extend perpendicularly to the top wall122bof the base portion122. The top wall122bof the base portion122can attach or connect the sidewall122aof the base portion122to the dome portion120.

Optionally, the dome portion120has approximately or exactly the same size and/or shape as the blister18of the prior art (seeFIG. 2). However, in such an embodiment, the blister118of the present embodiment is distinguishable from the blister18of the prior art in that the blister118of the present embodiment includes the base portion122.

In one embodiment, at least one active member116is positioned within at least the base portion122of each blister118. More specifically, as mentioned above, in one embodiment at least one active member116can be in both the base portion122and the dome portion120of the blister118. In one embodiment, the active member116can be in the form of an extruded film, such as a desiccant entrained polymer film or an oxygen scavenger entrained polymer film. Optionally, each active member116can be in the form of a rectangular or square piece of film, as shown inFIG. 4. However, the active member(s)116is not limited to the particular size, shape and/or configuration shown and described herein, as other shapes, for example, can be employed.

Optionally, the active member116is adhered, e.g., using an adhesive, to the first side112aof the backing112. For example, the active member116can include a first or top side and an opposing second or bottom side. The second side of the active member116can contact the first side112aof the backing112.

Alternatively, the active member116can be heat staked (without an adhesive) to the first side112aof the backing112. The process of heat staking film onto a substrate is described in detail in U.S. Pat. No. 8,142,603, which is incorporated herein by reference in its entirety.

As another alternative, the active member116is not adhered to the backing112. In such an embodiment, the active member116is loosely placed in the blister118after the product117is placed in the blister118. In one embodiment, the active member116is approximately 0.3 mm in thickness or height (i.e., the direction perpendicular to the backing112shown inFIG. 4).

As shown inFIG. 4, in one embodiment, a width W of the active member116is at least slightly less than a width of the base portion122. Similarly and optionally, a length of the active member116is at least slightly less than a length of the base portion122. However, the width W and/or length of the active member116is at least slightly greater than that of the dome portion120. As evident when comparingFIG. 2toFIG. 4, the width W of the active member116is greater than a width WPAof the active member16. In one embodiment, the width W and/or the length of the active member116is significantly greater than the width and/or the length of the dome portion120. For example, the difference in width and/or length between the dome portion120and the active member116can be greater (such as two times greater) than the difference in width and/or length between the base portion122and the active member116. In another embodiment in which each active member116is not rectangular or square in shape, an entire outer periphery, or at least a portion of the outer periphery, of each active member116is greater than that of the respective dome portion120.

Thus, the blister118of the presently disclosed technology provides a larger surface area for active material than the blister18of the prior art would provide. This, in turn, facilitates greater activity (e.g., moisture absorption in the case of a desiccant film) than would be provided with a surface area of active film limited to the confines of the profile of the prior art blister18alone.

In one embodiment, each active material116contains a desiccant. This would be an embodiment where moisture absorption is desired. However, where moisture absorption is not desired, the active member116can include alternative active agents. For example, in another embodiment, the active member116contains a material selected from the group consisting of activated carbon, carbon black, ketcham black and diamond powder. In a further embodiment, an active agent including one or more layers of the active member116contains a material such as absorption microspheres, BaTiO3, SrTiO3, SiO2, Al2O3, ZnO, TiO2, MnO, CuO, Sb2O3, silica, calcium oxide and ion exchange resins. In yet another embodiment, the absorbing agent containing layer of the active member116contains two or more types of absorbing agents. The suitable absorbing agent is chosen so as to achieve absorption of the desired vapor or gas for the desired end use (e.g. absorption of moisture, oxygen, carbon dioxide, nitrogen or other undesired gases or vapors).

The active member116(whether desiccant, oxygen scavenger, a releasing material or agent, etc., or combination thereof) is capable of acting on, interacting with or reacting with a selected material (e.g., moisture or oxygen). Examples of such actions or interactions may include absorption, adsorption (sorption, generally) or release of the selected material.

The active member116can include an “active agent” in a base material. The active agent (i) can be immiscible with the base material (e.g., polymer) and when mixed and heated with the base polymer and a channeling agent, will not melt, i.e., has a melting point that is higher than the melting point for either the base polymer or the channeling agent, and/or (ii) acts on, interacts or reacts with a selected material. The term “active agent” may include but is not limited to materials that absorb, adsorb or release the selected material(s). Active agents according to the presently disclosed technology may be in the form of particles such as minerals (e.g., molecular sieve or silica gel, in the case of desiccants), but the presently disclosed technology should not be viewed as limited only to particulate active agents. For example, in some embodiments, an oxygen scavenging formulation may be made from a resin which acts as, or as a component of, the active agent.

As used herein, the term “base material” is a component (preferably a polymer) of an entrained active material, other than the active agent, that provides structure for the entrained material.

As used herein, the term “base polymer” is a polymer optionally having a gas transmission rate of a selected material that is substantially lower than, lower than or substantially equivalent to, that of the channeling agent. By way of example, such a transmission rate would be a water vapor transmission rate in embodiments where the selected material is moisture and the active agent is a water absorbing desiccant. The primary function of the base polymer is to provide structure for the entrained polymer. Suitable base polymers may include thermoplastic polymers, e.g., polyolefins such as polypropylene and polyethylene, polyisoprene, polybutadiene, polybutene, polysiloxane, polycarbonates, polyamides, ethylene-vinyl acetate copolymers, ethylene-methacrylate copolymer, poly(vinyl chloride), polystyrene, polyesters, polyanhydrides, polyacrylianitrile, polysulfones, polyacrylic ester, acrylic, polyurethane and polyacetal, or copolymers or mixtures thereof.

Referring to such a comparison of the base polymer and channeling agent water vapor transmission rate, in one embodiment, the channeling agent has a water vapor transmission rate of at least two times that of the base polymer. In another embodiment, the channeling agent has a water vapor transmission rate of at least five times that of the base polymer. In another embodiment, the channeling agent has a water vapor transmission rate of at least ten times that of the base polymer. In still another embodiment, the channeling agent has a water vapor transmission rate of at least twenty times that of the base polymer. In still another embodiment, the channeling agent has a water vapor transmission rate of at least fifty times that of the base polymer. In still another embodiment, the channeling agent has a water vapor transmission rate of at least one hundred times that of the base polymer.

As used herein, the term “channeling agent” or “channeling agents” is defined as a material that is immiscible with the base polymer and has an affinity to transport a gas phase substance at a faster rate than the base polymer. Optionally, a channeling agent is capable of forming channels through the entrained polymer when formed by mixing the channeling agent with the base polymer. Optionally, such channels are capable of transmitting a selected material through the entrained polymer at a faster rate than in solely the base polymer.

As used herein, the term “channels” or “interconnecting channels” is defined as passages formed of the channeling agent that penetrate through the base polymer and may be interconnected with each other.

As used herein, the term “entrained polymer” is defined as a monolithic material formed of at least a base polymer with an active agent and optionally also a channeling agent entrained or distributed throughout. An entrained polymer thus includes two-phase polymers and three phase polymers. A “mineral loaded polymer” is a type of entrained polymer, wherein the active agent is in the form of minerals, e.g., mineral particles such as molecular sieve or silica gel. The term “entrained material” is used herein to connote a monolithic material comprising an active agent entrained in a base material wherein the base material may or may not be polymeric.

As used herein, the term “monolithic,” “monolithic structure” or “monolithic composition” is defined as a composition or material that does not consist of two or more discrete macroscopic layers or portions. Accordingly, a “monolithic composition” does not include a multi-layer composite.

As used herein, the term “phase” is defined as a portion or component of a monolithic structure or composition that is uniformly distributed throughout, to give the structure or composition it's monolithic characteristics.

As used herein, the term “selected material” is defined as a material that is acted upon, by, or interacts or reacts with an active agent and is capable of being transmitted through the channels of an entrained polymer. For example, in embodiments in which a desiccant is used as an active agent, the selected material may be moisture or a gas that can be absorbed by the desiccant. In embodiments in which a releasing material is used as an active agent, the selected material may be an agent released by the releasing material, such as moisture, fragrance, or an antimicrobial agent (e.g., chlorine dioxide). In embodiments in which an adsorbing material is used as an active agent, the selected material may be certain volatile organic compounds and the adsorbing material may be activated carbon.

As used herein, the term “three phase” is defined as a monolithic composition or structure comprising three or more phases. An example of a three phase composition according to the presently disclosed technology would be an entrained polymer formed of a base polymer, active agent, and channeling agent. Optionally, a three phase composition or structure may include an additional phase, e.g., a colorant.

Entrained polymers may be two phase formulations (i.e., comprising a base polymer and active agent, without a channeling agent) or three phase formulations (i.e., comprising a base polymer, active agent and channeling agent). Entrained polymers are described, for example, in U.S. Pat. Nos. 5,911,937, 6,080,350, 6,124,006, 6,130,263, 6,194,079, 6,214,255, 6,486,231, 7,005,459, and U.S. Pat. Pub. No. 2016/0039955, each of which is incorporated herein by reference in its entirety.

An entrained material or polymer includes a base material (e.g., polymer) for providing structure, optionally a channeling agent and an active agent. The channeling agent forms microscopic interconnecting channels through the entrained polymer. At least some of the active agent is contained within these channels, such that the channels communicate between the active agent and the exterior of the entrained polymer via microscopic channel openings formed at outer surfaces of the entrained polymer. The active agent can be, for example, any one of a variety of absorbing, adsorbing or releasing materials, as described in further detail below. While a channeling agent is preferred, the invention broadly includes entrained materials that optionally do not include channeling agents, e.g., two phase polymers.

In any embodiment, suitable channeling agents may include a polyglycol such as polyethylene glycol (PEG), ethylene-vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), glycerin polyamine, polyurethane and polycarboxylic acid including polyacrylic acid or polymethacrylic acid. Alternatively, the channeling agent can be, for example, a water insoluble polymer, such as a propylene oxide polymerisate-monobutyl ether, such as Polyglykol B01/240, produced by CLARIANT. In other embodiments, the channeling agent could be a propylene oxide polymerisate monobutyl ether, such as Polyglykol B01/20, produced by CLARIANT, propylene oxide polymerisate, such as Polyglykol D01/240, produced by CLARIANT, ethylene vinyl acetate, nylon 6, nylon 66, or any combination of the foregoing.

Suitable active agents according to the presently disclosed technology include absorbing materials, such as desiccating compounds. If the active agent is a desiccant, any suitable desiccant for a given application may be used. Typically, physical absorption desiccants are preferred for many applications. These may include molecular sieves, silica gels, clays and starches. Alternatively, the desiccant may be a chemical compound that forms crystals containing water or compounds which react with water to form new compounds.

Optionally, in any embodiment, the active agent may be an oxygen scavenger, e.g., an oxygen scavenging resin formulation.

FIGS. 6 and 6Ashow another embodiment of the presently disclosed technology. Similar or identical structure as between the embodiment ofFIGS. 3-5and the embodiment ofFIGS. 6-6Ais distinguished inFIGS. 6-6Aby a reference number with a magnitude one hundred (100) greater than that ofFIGS. 3-5. Description of certain similarities between the embodiment ofFIGS. 3-5and the embodiment ofFIGS. 6-6Amay be omitted herein for convenience and brevity only.

As shown inFIGS. 6 and 6A, at least a portion of a top side or surface of the active member216can contact and/or engage at least a portion of an interior surface (underside) of the top wall222bof the base portion222of the blister218. Optionally, despite this contact, the active member216is not (or is only minimally) compressed when positioned in the base portion222. As such, the contact preferably does not create an air tight seal between the engaged surfaces, so that air may be accessible therebetween. This would thus enable portions of the active member216contacting the top wall222bto absorb or adsorb, for example, components (e.g., moisture or oxygen) in the air between the engaged surfaces. The contact between the surfaces may result from the base portion222having a lower or smaller thickness or height (as shown inFIG. 6), or the result of the active member216being thicker or having a greater height. This configuration permits the concealed active member216to have the same or similar active properties or capabilities as the active member116of the earlier embodiment. In other words, the functionality of the active member216is not hampered by the contact between the active member216and the base portion222.

FIG. 7shows another embodiment of the presently disclosed technology. Similar or identical structure as between the embodiment ofFIGS. 3-5and the embodiment ofFIG. 7is distinguished inFIG. 7by a reference number with a magnitude two hundred (200) greater than that ofFIGS. 3-5. Description of certain similarities between the embodiment ofFIGS. 3-5and the embodiment ofFIG. 7may be omitted herein for convenience and brevity only.

As shown inFIG. 7, the base portion322can be formed in or by the backing312. Thus, the blister318(without a base portion, as described above) can be formed in the cover314and the base portion322can be formed in the backing312. In this embodiment, the base portion322can be a depression or cut-out formed in the top surface of the backing312. Optionally, the base portion322can be entirely in the backing312. In another option, the base portion can be partially formed in the backing and partially formed in the cover. Regardless, the cover314attached to the backing312forms at least one sealed cavity for containing product. The sealed cavity includes a dome portion or the blister318and a base portion322.

The presently disclosed technology includes methods of making and/or using the blister packs110,210. One of the methods includes (i) providing and/or forming a cover114,214having at least one blister118,218with one or more of the features described above, (ii) placing a product117in each blister118,218, (iii) placing active material116,216in each blister118,218, and (iv) attaching or bonding a backing112,212to the cover114,214to form a sealed package around the product117. As used herein, the term “providing” is broadly defined to include receiving, taking and/or using. When a user wishes to access the product117, at least a portion of the backing112,212can be separated from the cover114,214or broken through to expose the product117.

While the presently disclosed technology has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. It is understood, therefore, that the presently disclosed technology is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present presently disclosed technology as defined by the appended claims.