Patent Description:
Moisture sensitive and/or oxygen sensitive products such as, for example, diagnostic test strips, inhalers and pharmaceutical tablets, are commonly contained in packaging assemblies. The packaging assemblies typically include a product space which houses the product, and an active agent, such as a desiccant entrained polymer, desiccant sachet or desiccant canister, e.g. as shown in <CIT>, <CIT>, <CIT> and <CIT>. The active agent can function to, e.g., absorb moisture or scavenge oxygen that would otherwise compromise and reduce the efficacy or shelf life of the product.

In some packaging assemblies, it is desirable to include the active agent in the form of an entrained polymer film. Such films are typically very thin and are advantageously included in blister packs, pouches and other such flexible or semi-flexible packaging. It is preferred that entrained polymer film, e.g., desiccant film, be integral with the packaging rather than provided in a loose, movable manner. One approach would be to provide an adhesive between the film and the substrate or provide the film with an adhesive backing. However, such a configuration is very difficult to effectuate in automated manufacturing and the adhesives can emit undesirable volatiles that may adversely affect the very product the entrained film is intended to protect.

Applicant therefore prefers utilizing heat staking via pressure and heat, to adhere the entrained polymer film to a substrate, without using a separate adhesive. Heat staking is described in <CIT>, to applicant CSP Technologies, Inc. That patent and the heat staking process generally are described in greater detail below. While heat staking is preferred, automating a method for applying heat staking at high volume can be challenging. There is thus a need for improved methods and automated equipment for producing packaging film comprising an entrained polymer film with active agent and a foil substrate.

Accordingly, in the disclosed concept, a method and apparatus of manufacturing a packaging film is provided. The method includes providing the apparatus configured to produce a packaging film for products that are sensitive to at least one component in the ambient environment, e.g., moisture or oxygen. The apparatus includes a cutting station and a sealing station that is positioned at a separate location from the cutting station. The method includes conveying a strip of a heat sealable base film on the apparatus. A ribbon of entrained polymer film comprising an active agent (e.g., desiccant or oxygen scavenger) is conveyed on the apparatus and is passed through the cutting station. A piece of the entrained polymer film is cut. The piece of entrained polymer film is transferred from the cutting station to the sealing station, whereupon the piece of entrained polymer film is sealed to a portion of the heat sealable base film, thereby forming the packaging film.

The disclosed concept will be described in conjunction with the following drawings in which like reference numerals designate like elements and wherein:.

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 scope of the appended claims.

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.

This specification discloses methods for forming packaging films using polymer films entrained with an active agent, i.e., an agent that absorbs, adsorbs or releases a selected material. For example, an active agent may absorb moisture, adsorb volatile organic compounds or release antimicrobial gas. Polymer films entrained with an active agent, as disclosed herein, may alternatively be referred to as entrained polymer films. 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. These types of entrained polymers and methods of making and using the same are disclosed, e.g., in Applicant's <CIT>, <CIT>,<CIT>,<CIT>, <CIT>, <CIT> and<CIT>, and <CIT>. Optionally, entrained polymer films may have a thickness of about <NUM> to about <NUM>, optionally about <NUM> to about <NUM>, optionally <NUM> to <NUM>.

The active agent (whether desiccant, oxygen scavenger, a releasing material or ingredient, etc., or combination thereof) is capable of acting on, interacting 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. Entrained polymer films are typically made by extrusion.

The active agents (i) can be immiscible with the base 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. 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 serves as, or as a component of, the active agent. Such resin may include, for example, one as described in <CIT>.

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 or lower than, that of the channeling agent (where a channeling agent is used in the entrained polymer). 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 ingredient is a water absorbing desiccant. In any embodiment (whether or not a channeling agent is included), the primary functions of the base polymer are to provide moldability and 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 any embodiment, the channeling agent has a water vapor transmission rate of at least two times that of the base polymer, optionally at least five times that of the base polymer, optionally at least ten times that of the base polymer, optionally at least twenty times that of the base polymer, optionally at least fifty times that of the base polymer, optionally 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 "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, although it could serve as a layer of such a 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 ingredient, the selected material may be certain volatile organic compounds and the adsorbing material may be activated carbon.

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/<NUM>, produced by CLARIANT. In other embodiments, the channeling agent could be a propylene oxide polymerisate monobutyl ether, such as Polyglykol B01/<NUM>, produced by CLARIANT, propylene oxide polymerisate, such as Polyglykol D01/<NUM>, produced by CLARIANT, ethylene vinyl acetate, nylon <NUM>, nylon <NUM>, or any combination of the foregoing.

Suitable active ingredients 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.

Referring now in detail to the various figures of the drawings wherein like reference numerals refer to like parts throughout, there is shown in <FIG> various views of an apparatus <NUM> for producing a packaging film <NUM>, wherein the packaging film <NUM> includes a heat sealable base film <NUM> and a film <NUM> comprising an active agent that is configured to absorb, adsorb or release a selected material(s), secured (e.g., heat sealed) to the base film <NUM>. For simplicity, the film <NUM> comprising an active agent is predominantly referred to herein as a desiccant film <NUM>, however, it should be understood that the desiccant film <NUM> could alternatively be an oxygen scavenging film or any other entrained polymer film. Optional compositions of the desiccant film <NUM> include entrained polymers discussed above. The base film <NUM> optionally comprises a foil and a seal layer atop the foil. Optionally, the seal layer is composed of polyethylene (LLDPE), polypropylene or SURYLN ionomer resin from Dow, for example. The base film chosen should have a seal layer comprising a polymer material that is compatible with the base polymer of the desiccant film. In other words, like polymers should be matched. For example, if the base polymer of the desiccant film <NUM> includes polyethylene, then the seal layer of the base film <NUM> should preferably also include polyethylene. Choosing a foil with a sealing layer that is compatible with the base polymer of the desiccant film <NUM> facilitates creation of a successful bond between the desiccant film <NUM> and the foil. The seal layer has a melting point that will vary by manufacturer and is configured to become pliable when sufficient heat is supplied to the foil.

Optionally, the desiccant film <NUM> is heat staked to the base film <NUM> to form the packaging film <NUM>. "Heat staking" means disposing the desiccant film onto foil, applying sufficient heat to the foil so as to activate (e.g., soften or otherwise make pliable) a heat seal layer of the foil and applying sufficient pressure to the desiccant film and foil combination so as to secure the desiccant film to the foil. Preferably, when heat staked, the desiccant film adheres to the foil solely by the heat and pressure applied to the combination and without any additional adhesive materials. In an optional heat staking method that may be performed using apparatus described herein, a foil is provided having a polymer sealing layer. Additionally, a desiccant film is provided as well as a flexible package. The foil is heated such that the polymer sealing layer becomes pliable. A sealing area of the foil is selected for forming a seal between the foil and the flexible package. A non-sealing area of the foil not to be sealed to the flexible package is also selected. The active film is applied to the polymer sealing layer of the heated foil in the non-sealing area of the heated foil to produce an active film and foil combination. Sufficient pressure is applied to the active film and foil combination and sufficient heat is applied to the foil so that the desiccant film adheres to the polymer sealing layer of the foil. The active film and foil combination is adhered to the flexible package by forming a seal between the sealing area of the foil and the flexible package. The process of heat staking in this context is discussed more fully in <CIT>.

The apparatus <NUM> comprises a frame <NUM> that supports components of the apparatus <NUM>. The apparatus <NUM> comprises at least one desiccant film reel spindle <NUM>. As shown, two desiccant film reel spindles <NUM> are provided, however it is contemplated that a single such spindle or optionally three or more may alternatively be provided. A reel <NUM> of desiccant film <NUM> is rotatably mounted to each desiccant film reel spindle <NUM>. From each respective reel <NUM>, a ribbon <NUM> of desiccant film <NUM> is fed along a series of guideposts or rollers <NUM> towards a corresponding cutting station <NUM> located downstream from the reel <NUM>. The guideposts or rollers <NUM> help to keep the ribbon <NUM> of desiccant film <NUM> stable as it is fed from the reel <NUM> to the cutting station <NUM>. Optionally, a servo motor moves the ribbon <NUM> of desiccant film <NUM> towards the cutting station <NUM>, optionally in a pulsing motion (i.e., start-stop). The servo motor may drive feeder rollers <NUM>, which pull the ribbon <NUM> towards a respective cutting station <NUM>, as discussed below.

The apparatus <NUM> comprises at least one base film reel spindle <NUM>. As shown, a single base film reel spindle <NUM> is provided, but it is contemplated that additional such spindles may be included. A reel <NUM> of base film <NUM> is rotatably mounted to the base film reel spindle <NUM>. From the reel <NUM>, the strip <NUM> of base film <NUM> is fed optionally beneath a roller <NUM> and guided to a platform <NUM>. Optionally, the base film <NUM> is conveyed on the apparatus <NUM> as a lengthy strip <NUM>, optionally in a direction that is transverse or perpendicular to the direction in which the ribbon <NUM> of desiccant film <NUM> is fed. In other words, theoretical vertical planes formed by respective axes of rotation of the spindles, would intersect each other perpendicularly or transversely.

The platform <NUM> includes at least one sealing station <NUM> (in the illustrated embodiment, there are two such sealing stations <NUM>). The strip <NUM> of base film <NUM> is then fed to another roller <NUM> at the end of the platform <NUM>, which optionally guides the base film <NUM> underneath and away from the platform <NUM>. Optionally, the strip <NUM> of base film <NUM> is advanced with continuous motion and substantially constant speed.

The apparatus <NUM> further comprises at least one transfer device <NUM>, which is configured to transfer a cut desiccant film piece <NUM> from a cutting station <NUM> to a corresponding sealing station <NUM>. The transfer device <NUM> comprises a rotatably mounted disk <NUM>, which is optionally substantially cylindrical, although non-round shapes are also contemplated. For example, instead of a round shape, the disk may optionally have a central hub with legs radially projecting outward from the hub, for example. The disk <NUM> optionally comprises a plurality of film supports <NUM> extending from a radial surface <NUM> of the disk <NUM>. Optionally, the disk <NUM> is configured to rotate in the same direction as the movement of the strip <NUM> of base film <NUM>, as the strip <NUM> is advanced along the platform <NUM>. In other words, the disk <NUM> rotates clockwise from the vantage of the view in <FIG>.

The film supports <NUM> optionally comprise rubber, at least on their outer surfaces. Each film support <NUM> optionally includes small holes connected to a vacuum source, which help retain the cut desiccant film piece <NUM> to the film support <NUM> via suction from the vacuum source, when the cut desiccant film piece <NUM> is disposed thereon. Alternatively, an electrostatic charge or other means (e.g., grippers or knurls) may be employed to retain a cut desiccant film piece <NUM> to the film support <NUM>.

As best seen in <FIG>, a vertically displaceable mount <NUM> is provided. The mount <NUM> is vertically displaceable from a first (up) position to a second (down) position. The mount <NUM> is optionally driven pneumatically or is servo-driven. The mount <NUM> comprises extensions <NUM> corresponding to respective transfer devices <NUM>. The extensions <NUM> each optionally include first and second platens 148a,b and a blade <NUM> therebetween. The platens 148a,b may be retained to the extensions <NUM> with posts <NUM>, one or more of which optionally includes a compression spring member <NUM> disposed about it. The cutting station <NUM> further includes a cutting surface <NUM> and cutting surface edge <NUM>. The cutting surface edge <NUM> may include both an edge of the cutting surface <NUM> and an edge of the film support <NUM>, which are both generally collinear for a brief moment (at the time of cutting). A corresponding opposing edge <NUM> is nearly adjacent the cutting surface edge <NUM> at the time a desiccant film piece <NUM> is cut from the ribbon <NUM> of desiccant film <NUM>. As used in this specification, "nearly adj acent" means the components are next to each other with only a narrow space in between, e.g., a space large enough for a blade to fit with clearance.

The cutting station <NUM> optionally operates as follows. Slightly upstream of the cutting station <NUM> is a feeder roller <NUM>, which optionally has ridges or a knurled surface pattern to help maintain control and placement of the ribbon <NUM>, as the feeder roller <NUM> advances the ribbon <NUM> towards the cutting station <NUM>. The feeder roller <NUM> is servo-driven and is what optionally functions to pull the ribbon <NUM> from the reel <NUM> towards the cutting station <NUM>. Having the feeder roller <NUM> driven by a servo motor allows for precision in the desired length of each film piece <NUM>.

As the end of the ribbon <NUM> of desiccant film <NUM> is advanced to the cutting station <NUM>, the mount <NUM> is in the first position (e.g., as shown in <FIG>). At this point, a portion of the end of the ribbon <NUM> is disposed upon the film support <NUM> and another portion is disposed upon the cutting surface <NUM>, nearly adjacent the cutting surface edge <NUM>. The mount <NUM> is then displaced downwardly to the second position, thus driving the extension(s) <NUM> in a vertically downward direction. The platens 148a,b press down upon the portions of desiccant film <NUM> beneath them so as to retain the portions of desiccant film <NUM> in place. Nearly immediately thereafter or simultaneously, the blade <NUM> descends to cut the desiccant film <NUM> at the narrow gap between the cutting surface edge <NUM> and the corresponding opposing edge <NUM>. In this way, the cut desiccant film piece <NUM> is created and disposed upon the film support <NUM>.

The cut desiccant film piece <NUM> is retained to the film support <NUM>, as discussed above. The disk <NUM> then rotates, e.g., clockwise from the vantage of the view shown in <FIG>, to transport the cut desiccant film piece <NUM> from the cutting station <NUM> to the sealing station <NUM>. At the same time, another film support <NUM> is positioned to receive another portion of desiccant film <NUM> to repeat the cutting and transporting process.

The film support <NUM> with the cut desiccant film piece <NUM> disposed thereon rotates to the sealing station <NUM>. The cut desiccant film piece <NUM> is placed atop the base film <NUM> and pressed thereon as a heating element <NUM> at the sealing station <NUM> heats the foil of the base film <NUM>, causing the polymer sealing layer of foil to become pliable. The pressure and the heat cause the cut desiccant film piece <NUM> to adhere to the packaging base film <NUM> without the presence of a separate adhesive, thereby forming the packaging film <NUM>.

Referring now to <FIG>, there is shown an alternative embodiment of an apparatus <NUM> for producing a packaging film <NUM>. As with the embodiment of <FIG>, the packaging film <NUM> includes a heat sealable base film <NUM> and a film <NUM> comprising an active agent that is configured to absorb, adsorb or release a selected material(s), secured (e.g., heat sealed) to the base film <NUM>. As with the previous embodiment, the film <NUM> comprising an active agent is also predominantly referred to herein as a desiccant film <NUM>, even though the film is not limited to a desiccant material as the active agent. Desiccant film <NUM> and base film <NUM> may be of the same composition as their counterparts (<NUM> and <NUM>) described with respect to <FIG>. Also, desiccant film <NUM> may be heat staked to the base film <NUM> to form the packaging film <NUM>, as described herein with respect to <FIG>.

The apparatus <NUM> comprises a frame <NUM> that supports components of the apparatus <NUM>. The apparatus <NUM> comprises at least one desiccant film real spindle <NUM>. As shown, a single such spindle is provided, but optionally more than one may be included. A reel <NUM> of desiccant film <NUM> is rotatably mounted to the desiccant film reel spindle <NUM>. From the reel <NUM>, a ribbon <NUM> of desiccant film <NUM> is fed along a series of guideposts or rollers <NUM> towards one or more cutting stations <NUM> located downstream from the reel <NUM>. The guideposts or rollers <NUM> help to keep the ribbon <NUM> of desiccant film <NUM> stable as it is fed from the reel <NUM> to the cutting stations <NUM>. Optionally, a servo motor moves the ribbon of film <NUM> towards the cutting stations <NUM>, optionally in a pulsing motion. In the embodiment shown, the ribbon <NUM>, at a position downstream from the reel <NUM>, is sliced longitudinally and separated into a plurality of (in this case, three) ribbon strips 218a,b,c. The ribbon strips 218a,b,c are pulled towards respective cutting stations <NUM> by feeder rollers <NUM>, which are driven by the servo motor.

The apparatus <NUM> comprises at least one base film reel spindle <NUM>. As shown, a single base film reel spindle <NUM> is provided, but it is contemplated that additional such spindles may be included. A reel <NUM> of base film <NUM> is rotatably mounted to the base film reel spindle <NUM>. The base film <NUM> is conveyed on the apparatus <NUM> as a lengthy strip <NUM>, optionally in the same direction, at least along one Cartesian coordinate axis, that the ribbon <NUM> moves. In other words, the axes of rotation (if hypothetically extended outward in both directions) of both spindles <NUM>,<NUM> are parallel to each other or collinear. The strip <NUM> is fed optionally beneath a roller <NUM> and guided to a platform <NUM>. The platform <NUM> forms a portion of at least one sealing station <NUM> (in the illustrated embodiment, there are three such sealing stations <NUM>). The strip <NUM> of base film is then fed to at least one more roller <NUM> as it exits the apparatus <NUM>. Optionally, the strip <NUM> of base film <NUM> is advanced with continuous motion and substantially constant speed.

The apparatus <NUM> further comprises at least one transfer device <NUM>, which is configured to transfer a cut desiccant film piece <NUM> from a cutting station <NUM> to a corresponding sealing station <NUM>. The transfer device <NUM> comprises a rotatably mounted disk <NUM> comprising a central hub 236a with a plurality of legs 236b extending radially from the hub 236a. In the embodiment shown, there are three equally spaced legs 236b, but fewer or additional legs may optionally be provided. Alternatively, the disk may be circular. Each leg 236b comprises at least one film support <NUM> extending from an end surface <NUM> of the leg 236b. In the embodiment shown, three film supports <NUM> per leg 236b are provided. Optionally, the disk <NUM> is configured to rotate against the direction of movement of the strip <NUM> of base film <NUM>, as the strip <NUM> is advanced along the platform <NUM>.

As best seen in <FIG>, a vertically displaceable mount <NUM> is provided. The mount <NUM> is vertically displaceable from a first (up) position to a second (down) position. The mount <NUM> is optionally driven pneumatically or is servo-driven. The mount <NUM> comprises extensions <NUM> corresponding to respective film supports <NUM>. As shown, since there are three film supports <NUM> per leg 236b, there are three corresponding (aligned) extensions <NUM>. In alternative embodiments, there may be greater or fewer film supports depending on the number of corresponding extensions per leg. The extensions <NUM> each optionally include first and second platens 248a,b and a blade <NUM> therebetween. The platens 248a,b may be retained to the extensions <NUM> with posts <NUM>, one or more of which optionally includes a compression spring member <NUM> disposed about it. The cutting station <NUM> further includes a cutting surface <NUM> and a cutting surface edge <NUM>, to which a corresponding film support edge <NUM> is nearly adjacent at the time a desiccant film piece <NUM> is cut from the ribbon <NUM> of desiccant film <NUM>.

The cutting station <NUM> optionally operates as follows. As best seen in <FIG>, slightly upstream of the cutting station <NUM> are feeder rollers <NUM>, which optionally have ridges or a knurled surface pattern to help maintain control and placement of the ribbon strips 218a,b,c, as the feeder rollers <NUM> advance the ribbon strips 218a,b,c towards the cutting station <NUM>. The feeder rollers <NUM> are servo-driven and are what optionally function to pull the ribbon strips 218a,b,c from the reel <NUM> towards the cutting stations <NUM>. Having the feeder rollers <NUM> driven by a servo motor allows for precision in the desired length of each film piece <NUM>.

As the end of a respective ribbon strip 218a,b,c of desiccant film <NUM> is advanced to the cutting station <NUM>, the mount <NUM> is in the first position. At this point, a portion of the end of the ribbon strip 218a,b,c is disposed upon a corresponding film support <NUM> and another portion is disposed upon the cutting surface <NUM>, nearly adjacent the cutting surface edge <NUM>. The mount <NUM> is then displaced downwardly to the second position, thus driving the extension(s) <NUM> in a vertically downward direction. The platens 248a,b press down upon the portions of desiccant film <NUM> beneath them so as to retain the portions of desiccant film <NUM> in place. Nearly immediately thereafter or simultaneously, the blade <NUM> descends to cut the desiccant film <NUM> at the narrow gap between the cutting surface edge <NUM> and the corresponding film support edge <NUM>. In this way, the cut desiccant film piece <NUM> is created and disposed upon the film support <NUM>.

The cut desiccant film piece <NUM> is retained to the film support <NUM>, as discussed above. The disk <NUM> then rotates, e.g., counter-clockwise from the vantage of the view shown in <FIG>, <FIG> and <FIG>, to transport the cut desiccant film piece <NUM> from the cutting station <NUM> to the sealing station <NUM>. At the same time, another film support <NUM> from another leg 236b is positioned to receive another portion of the desiccant film <NUM> to repeat the cutting and transporting process steps.

The film support <NUM> with the cut desiccant film piece <NUM> disposed thereon rotates to the sealing station <NUM>. The cut desiccant film piece <NUM> is placed atop the base film <NUM> and pressed thereon as a heating element <NUM> at the sealing station <NUM> heats the foil of the base film <NUM>, causing the polymer sealing layer of foil to become pliable. The pressure and the heat cause the cut desiccant film piece <NUM> to adhere to the packaging base film <NUM> without the presence of a separate adhesive, thereby forming the packaging film <NUM>. By separating the ribbon <NUM> into ribbon strips 218a,b,c, the apparatus <NUM> uniquely facilitates cutting and sealing operations in multiple lanes. In other words, the apparatus <NUM> is configured to facilitate a method of making a packaging film <NUM> that includes a plurality of sealed desiccant film pieces <NUM> positioned in a parallel linear arrangement.

Optionally, in any embodiment, the entrained polymer film includes an amount of active agent that is from <NUM>% to <NUM>%, optionally <NUM>% to <NUM>%, optionally <NUM>% to <NUM>%, optionally <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, by weight of the entrained polymer.

Optionally, in any embodiment, the entrained polymer film includes an amount of base polymer that may range from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, from <NUM>% to <NUM>%, by weight of the entrained polymer.

Optionally, in any embodiment that utilizes channeling agent, the entrained polymer film includes an amount of channeling agent that may range from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, preferably from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, by weight of the entrained polymer.

Claim 1:
A method of manufacturing a packaging film (<NUM>, <NUM>) for use in storage of products being sensitive to at least one component in the ambient environment, the method comprising the following steps:
- providing an apparatus (<NUM>, <NUM>) configured to produce a packaging film (<NUM>, <NUM>), the apparatus (<NUM>, <NUM>) comprising a cutting station (<NUM>, <NUM>), a sealing station (<NUM>, <NUM>) that is positioned at a separate location from the cutting station (<NUM>, <NUM>), and a transfer device (<NUM>, <NUM>) comprising a rotatably mounted disk (<NUM>, <NUM>) having a plurality of film supports (<NUM>, <NUM>);
- conveying an elongated strip of a heat sealable base film (<NUM>, <NUM>) on the apparatus (<NUM>, <NUM>), wherein the base film comprises a foil and a polymer seal layer atop the foil;
- conveying a ribbon (<NUM>, <NUM>) of entrained polymer film (<NUM>, <NUM>) on the apparatus (<NUM>, <NUM>), wherein the entrained polymer is a monolithic material comprising a base polymer and an active agent that absorbs, adsorbs or releases a selected material, and passing the ribbon (<NUM>, <NUM>) of entrained polymer film (<NUM>, <NUM>) through the cutting station (<NUM>, <NUM>) wherein a piece (<NUM>, <NUM>) of entrained polymer film (<NUM>, <NUM>) is cut from an end section of the ribbon;
- transferring the piece (<NUM>, <NUM>) of entrained polymer film (<NUM>, <NUM>) cut from the ribbon (<NUM>, <NUM>) of entrained polymer film (<NUM>, <NUM>) from the cutting station (<NUM>, <NUM>) to the sealing station (<NUM>, <NUM>) by disposing the piece (<NUM>, <NUM>) of entrained polymer film (<NUM>, <NUM>) on a respective film support (<NUM>, <NUM>) and by rotating the transfer device (<NUM>, <NUM>), whereupon the piece (<NUM>, <NUM>) of entrained polymer film (<NUM>, <NUM>) is sealed to a portion of the heat sealable base film (<NUM>, <NUM>), thereby forming the packaging film (<NUM>, <NUM>).