Patent Publication Number: US-2003234203-A1

Title: Blister package

Description:
FIELD OF THE INVENTION  
       [0001] The present invention relates to packaging, and more specifically to child-resistant packaging for dosed products.  
       BACKGROUND OF THE INVENTION  
       [0002] It is known to use blister packages to contain small articles such as pharmaceutical or dose form products. These packages allow the user to access the product by applying pressure to the blister to force the product from an individual blister or capsule through a rupturable layer.  
       [0003] Known blister packages comprise a first sheet of transparent or translucent thermoformable material such as polyvinyl chloride or polystyrene having a plurality of flexible bubbles or blisters preformed therein and projecting outwardly from one surface to define separate compartments for individual doses of a product,typically a single pill or capsule, and a second sheet to cover the product. The second layer is often made from a rupturable foil so that the user can push the product from the bubble side out through the foil. This construction did not offer much in the way of child resistance, and presented a potential hazard to children.  
       [0004] In order to render blister packages resistant to access by children, improved child-resistant blister packages have been developed. Exemplary structures of such child-resistant blister packages, as well as exemplary methods of forming such packages, are disclosed in U.S. Pat. No. 6,161,699 to Gartland, which is hereby incorporated by reference herein.  
       [0005] Despite the fact that such child-resistant packages have improved safety characteristics, there is room for further improvements. Many of the known package-forming methods and package constructions, although offering varying degrees of child resistance, sometimes compromised accessibility. Specifically, in some cases, known methods and constructions made the product so inaccessible that even adults had trouble accessing the product. This later case is especially problematic where older adults or others who have lost some degree of manual dexterity are the users of the products.  
       [0006] Thus, there remains a need for an improved packaging method and construction that provide the desired level of resistance to a child while maintaining acceptable levels of accessibility for adults.  
       SUMMARY OF THE INVENTION  
       [0007] The present invention includes a child-resistant package for a dose form product and a method of forming a child-resistant package for such a dose form product. According to one exemplary embodiment, the invention provides a child-resistant package for a product comprising a double cover comprised of separate outer and inner layers, wherein the outer layer is disposed adjacent the inner layer, and a barrier is disposed adjacent the inner layer of the double cover. The inner layer and the barrier together define at least one compartment into which a product can be positioned.  
       [0008] In another exemplary embodiment of the invention, a child-resistant package for a product is provided which comprises a cover and a double barrier disposed adjacent the cover, where the double barrier comprises separate outer and inner layers. In this embodiment, the outer layer is disposed adjacent the inner layer and the inner layer of the double barrier and the cover together define at least one compartment into which a product can be positioned.  
       [0009] The invention also provides a method of forming a child-resistant package for a product. According to one exemplary embodiment, the method includes the steps of forming a double cover by disposing an outer layer adjacent an inner layer, the double cover defining at least one cavity. The method also includes the steps of placing a product in the cavity of the double cover and disposing a barrier adjacent the inner layer of the double cover, thereby defining at least one compartment between the inner layer of the double cover and the barrier in which the product is contained.  
       [0010] Yet another embodiment of the method according to the present invention includes a method of forming a child-resistant package for a product including the steps of forming a double barrier by disposing an outer layer adjacent an inner layer, placing a product in a cavity of a cover, and disposing the cover adjacent the inner layer of the double barrier. In this way, at least one compartment is formed between the inner layer of the double barrier and the cover in which the product is contained.  
       [0011] The present invention also includes embodiments where both the cover and barrier are multi-layered. In such embodiments, the cover is multi-layered and the product is disposed between the multi-layered cover and a multi-layered barrier. 
     
    
    
     BRIEF DESCRIPTION OF THE FIGURES  
     [0012] The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description that follows taken in conjunction with the accompanying drawings in which:  
     [0013]FIG. 1 is a cross-sectional side view of a portion of one embodiment of the present invention in which a double cover is disposed atop a barrier;  
     [0014]FIG. 2 is an illustration of the embodiment of FIG. 1 but with an exaggerated view of bonding adhesives for illustration purposes;  
     [0015]FIG. 3 is a cross-sectional side view of a portion of another embodiment of the present invention in which a cover is disposed atop a double barrier;  
     [0016]FIG. 4 is a cross-sectional side view of a portion of yet another exemplary embodiment in which both the cover is double layered and the barrier is double layered;  
     [0017]FIG. 5 is a cross-sectional side view of yet another embodiment in which each of the layers of a double barrier is multi-layered;  
     [0018]FIG. 6 shows an exemplary embodiment of a ten-product package consistent with aspects of the present invention;  
     [0019]FIG. 7 shows the embodiment of FIG. 5 but with a card disposed atop the cover of the package; and  
     [0020]FIG. 8 shows the compilation of each layer in accordance with an exemplary embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
     [0021] This invention will now be described with reference to specific embodiments selected for illustration in the figures. It will be appreciated that the spirit and scope of this invention is not limited to the embodiments selected for illustration. Instead, the scope of this invention is defined separately in the appended claims. Also, it will be appreciated that the drawings are not rendered to any particular proportion or scale.  
     [0022] The present invention includes child-resistant packages and methods for packaging dose form products. Generally, the packages according to the present invention are optionally formed with three or more layers, with the packaged product disposed within a bubble or other compartment formed between an inner layer and an outer layer. The products which can be packaged in accordance with the present invention include many varieties, most notably dose form products such as pharmaceuticals in pill or capsule form. Other products to which the present invention can be applied include, without limitation, medicaments (in pill, tablet, capsule, or lozenge form), drugs, vitamins, cosmetics, foods, pharmaceutical products; pharmaceutical products, devices, and any other product for which dose-form consumption, or use, is desired.  
     [0023] One embodiment of the present invention includes a child-resistant package for a dose form product comprising a double cover and a single barrier. This embodiment is comprised of separate outer and inner layers, wherein the outer layer is disposed adjacent the inner layer, and a barrier is disposed adjacent the inner layer of the double cover. The inner layer and the barrier together define at least one compartment into which a product can be positioned.  
     [0024]FIG. 1 shows such a package embodiment of the present invention, generally designated by the numeral “ 10 ,” where the cover is formed from two layers and the barrier layer is formed from one layer. The package  10  has a cover including an outer cover layer  100  and an inner cover layer  110 . More specifically, outer cover layer  100  of package  10  is disposed atop, but adjacent to, inner cover layer  110 . Together outer cover layer  100  and inner cover layer  110  therefore form a double-layered cover that, in the illustrated embodiment, includes a bubble  120 . Disposed below the two layered-cover is a barrier such as a backing layer  130 . Barrier  130  is disposed adjacent inner cover layer  110  of the double cover to enclose a product  140  within the compartment formed by the bubble  120  and barrier  130 .  
     [0025] Generally, each layer can be comprised of either foil, film, plastic or paper, or combinations thereof. Each respective layer is optionally bonded, using an appropriate adhesive or other attachment material or method, to its adjacent layers, where contact is made between them. In other words, with the exception of the bubble area, inner cover layer  110  can be bonded to barrier  130 , and with the exception of the air space  150  defined between the inner cover layer  110  and the outer cover layer  100  (discussed below), outer cover layer  100  can be bonded to inner cover layer  110 .  
     [0026] In an exemplary embodiment, outer cover layer  100  is comprised of a transparent film, such as a polyethylene or polyvinyl chloride or other polymeric film, and inner cover layer  110  is comprised of either a similar transparent polymeric film, plastic, paper, or opaque foil material. In the former embodiment, the user is allowed to see product  140 , but where light could be damaging to the product, such as reducing its shelf life, opaque foil or some other light-blocking or light-reducing material would be preferred. In this embodiment, the outer cover layer can be comprised if a tough, penetration resistant polymeric film such that access to the product can only be made through the barrier.  
     [0027] It is also optional that a space, either air, vacuum or inert gas, is provided between inner cover layer  110  and outer cover layer  100 . This, interstitial space  150  allows penetration through outer cover layer  100  (when penetration occurs, although outer cover layer  110  is designed, as noted above, to be penetration-resistant) without penetration of inner cover layer  110 .  
     [0028] Barrier  130  is optionally comprised of paper, plastic, film, or foil, or other suitable materially, and is optionally bonded to, in the case of the embodiment illustrated in FIG. 1, inner cover layer  110  over at least a portion of inner cover layer  110  that is not raised to form a compartment such as bubble  120  for product  140 .  
     [0029] In an exemplary embodiment, generally designated by the numeral “ 20 ” in FIG. 2, there is a region of contact between inner cover layer  110  and barrier  130  immediately adjacent bubble  120  where no bonding exists. No-bond region  200  is shown in FIG. 2 and allows for the peeling away of barrier  130  in that no-bond region so that product  140  can be accessed. FIG. 2 shows such an embodiment in detail, with features deliberately exaggerated and shown out of scale for the purpose of illustration. FIG. 2 shows adhesive  230  in exemplary locations as well as no-bond region  200  set apart from bonded region  210  by a perforation  220 . The user can thus peel barrier  130  away from inner cover layer  110  beginning at perforation  220 , thereby providing access to the product  140 .  
     [0030] In another embodiment of the invention, a child-resistant package for a product is provided which comprises a cover and a double barrier disposed adjacent the cover, where the double barrier comprises separate outer and inner layers. In this embodiment, the outer layer is disposed adjacent the inner layer and the inner layer of the double barrier and the cover together define at least one compartment into which a product can be positioned. This embodiment is similar to the first embodiment described above but the bubble is comprised of only one layer and the barrier is comprised of multiple layers.  
     [0031]FIG. 3 shows an embodiment, generally designated by the numeral “ 30 ,” with cover layer  300  disposed around product  140 . Inner barrier, layer  310  and cover layer  300  together define a compartment optionally configured in the form of a bubble  320 . Outer barrier layer  330  is disposed adjacent inner barrier layer  310 . Materials and adhesives or other bonding methods are the same as those described above in regard to FIG. 1. In this embodiment, the main difference is that the user must first peel away outer barrier layer  330  before being able to penetrate or otherwise remove inner barrier  310 .  
     [0032]FIG. 4 shows yet another exemplary embodiment of the present invention, generally designated by the numeral “ 40 ,” which is essentially a combination of the embodiments shown in FIGS. 1 and 3. Specifically, FIG. 4 shows an embodiment that can be considered a double-double containment embodiment. Product  140  is disposed within a compartment such as a bubble  400 , which is formed by inner cover layer  410  and outer cover layer  420 . An optional air space  430  is disposed between layers  410  and  420 . A double barrier layer is disposed below product  140  and is comprised of inner barrier layer  440  and outer barrier layer  450 .  
     [0033] In order to access product  140  from the blister package  40  shown in FIG. 4, the user can peel away outer barrier layer  450  and then remove inner barrier layer  440 . Removal of inner barrier layer  440  is typically accomplished by the user pulling on a tap or perforated portion of inner barrier layer  440 , and peeling or tearing it away.  
     [0034] Alternatively, the user can peel away outer barrier layer  450  and then remove a product-containing blister (formed from a portion of the inner cover layer  410  and the inner barrier layer  440 ) from the space between the outer barrier layer  450  and the outer cover layer  420 . The removal of the blister can be facilitated by the absence of adhesion between (1) the inner cover layer  410  of the product-containing blister and the outer cover layer  420  and (2) the inner barrier layer  440  of the, product-containing blister and the outer barrier layer  450 . Once removed from the outer barrier layer  450  and the outer cover layer  420 , the product-containing blister can be opened by the user either by removing the inner barrier layer  440  to access the product  140  or by pushing the product  140  through the inner barrier layer  440  by pressing the inner cover layer  410  against the product  140 .  
     [0035]FIG. 5 shows yet a more specific embodiment, generally designated by the numeral “ 50 ,” wherein each of inner barrier layer  440  and outer barrier layer  450  are comprised of two or more layers. In this embodiment, inner barrier layer  440  is a laminate of outer paper layer  510  and inner foil layer  520 . Outer barrier layer  450  is comprised of perforated paper layer  530  and peel-away polymeric layer  540 .  
     [0036] In order to access product  140  for the exemplary embodiment of package  50 , peel-away polymeric layer  540  is peeled-away, perforated paper layer  530  is torn away, and inner barrier  440  (comprised of a combination or lamination of the paper layer  510  and foil layer  520 ) is peeled away or otherwise removed or pierced to access product  140 .  
     [0037]FIG. 6 shows another version of the embodiment shown in FIG. 5, which is generally designated by the numeral “ 60 .” Package  60  is a double-double containment blistercard package for ten (10) dose-form products. FIG. 6 shows the outer cover layer  420  having recesses  611  disposed therein to assist in a user&#39;s grabbing and peeling away of portions of the inner barrier layer  440 . In FIG. 6, inner cover layer  410  is shown together with inner barrier layer  440 , and the inner barrier layer  440  is provided with lines of perforations so that distinct portions of the inner barrier layer  440  can be separated from the inner cover layer  410 . The inner cover layer  410  and the inner barrier layer  440  together define the bubbles or compartments in which the product is placed.  
     [0038] Outer barrier layer  450  is comprised of perforated paper layer  530  and a pair of peel-away polymeric layers  540 . This outer barrier layer  450  is disposed on or adjacent inner barrier layer  440 , which in turn is placed adjacent inner cover layer  410 , which is in turn placed adjacent or into outer cover layer  420  as shown by the arrows in FIG. 6. In order to access product  140  in this embodiment  60 , peel-away polymeric layer  540  is peeled-away, along with perforated paper layer  530 , and inner barrier layer  440  (comprised of the paper layer  510 /foil layer  520  laminate) is peeled away or otherwise removed to access product  140  disposed within inner cover layer  410 .  
     [0039]FIG. 7 shows an additional embodiment, generally designated by the numeral “ 70 ,” where outer card  700  is disposed on top of the blistercard packages described above. Typically, outer card  700  is disposed atop the package for labeling or other packaging purposes. Outer card  700  simply has holes disposed therein to allow for the presence of each blister or bubble  120 .  
     [0040]FIG. 8 shows an embodiment, generally designated by the numeral “ 80 ,” similar to that shown in FIG. 6 but with the addition of outer card  700  shown in FIG. 7. In this embodiment, and consistent with the method described below, the product is put into inner cover layer  410 , before inner barrier layer  440  is placed thereon. At this point, a product is disposed within and between inner cover layer  410  and inner barrier layer  440 . This combination is then inserted into outer cover layer  420 , which together are put into outer card  700  so that individual blisters extend through openings in the outer card  700 . Outer card  700  is attached to outer barrier  450 , which is then folded along line  800  to enclose the product, inner barrier layer  440 , inner cover layer  410 , and outer cover layer  420 . Bonding, using adhesives or other methods, is contemplated between layers as appropriate and consistent with the above description.  
     [0041] The invention also includes a method of forming a child-resistant package for a product. The method comprises the steps of forming a double cover by disposing an outer layer adjacent an inner layer, the double cover defining at least one cavity. The double cover is as defined above. The method also includes the steps of placing a product in the cavity of the double cover and disposing a barrier adjacent the inner layer of the double cover, thereby defining at least one compartment between the inner layer of the double cover and the barrier in which the product is contained. The barrier is as defined above. In this embodiment, the cover or bubble formed is comprised of two layers.  
     [0042] Yet another embodiment of the method according to the present invention includes a method of forming a child-resistant package for a product comprising the steps of forming a double barrier by disposing an outer layer adjacent an inner layer, placing a product in a cavity of a cover, and disposing the cover adjacent the inner layer of the double barrier. The cover and barrier are as defined above. In this way, at least one compartment is formed between the inner layer of the double barrier and the cover in which the product is contained. This embodiment of the method is similar to the one described just above but the cover or bubble formed is comprised of only one layer.  
     [0043] Accordingly, while illustrated and described herein with reference to certain specific embodiments, the present invention is not intended to be limited to the embodiments and details shown. Rather, the appended claims are intended to include all embodiments and modifications that may be made to these embodiments and details, which are nevertheless within the true spirit and scope of the present invention.