An embodiment relates to a blister-board article that includes an adhesive layer disposed between a substrate and an information layer. One embodiment includes at least one substrate surface treatment layer beneath the adhesive layer.
During the converting of a carded blister package substrate, a special adhesive coating material must be applied to the printed surface. Thereafter, the contents of the package are placed on the substrate, the printed surface is overlaid with a translucent blister material and it is bonded to the adhesive coating material. The blister material is often a translucent polyvinyl chloride that can be molded around the package contents under a heat load. Adhesion of the substrate to the blister material, is possible because of the special adhesive coating material that has been applied. However, the special adhesive coating material is expensive. Processing includes a deposition process of the special adhesive coating material after the finished surface has been produced. Additionally, there are special handling issues because of the adhesive quality of the special adhesive coating.
What is needed in the art is a system of bonding a blister material to a substrate that overcomes problems in the prior art, including a number of which have been mentioned.
An embodiment of the present invention includes a blister-board article. A substrate supports a series of layers including a sizing layer, a first surface treatment layer disposed above the sizing layer, and an adhesive material layer disposed above the first surface treatment layer. Another embodiment includes an information layer disposed above the adhesive material layer, and a blister layer disposed above the information layer.
Another embodiment includes various intrusions and permeabilities of the adhesive material layer through the information layer. One embodiment includes an adhesive material layer that is transformed into a depleted adhesive material layer. The information layer is breached by thermal intrusions from the adhesive material layer. A concentration gradient of the adhesive material proceeds from the adhesive material layer to the blister layer.
Another embodiment includes an adhesive material layer that is transformed into a depleted adhesive material layer. The information layer includes substantially uniform thermal diffusion from the adhesive material layer.
Another embodiment includes an adhesive material layer that is transformed into a depleted adhesive material layer. This embodiment includes a combination of permeated portions of the information layer, and thermal intrusions through the information layer.
Another embodiment includes a substrate and sizing layer disposed above the substrate. A first surface treatment layer and a second surface treatment layer are respectively disposed above the sizing layer. An adhesive material layer is disposed above the second surface treatment layer, and an information layer is disposed above the adhesive material layer. A blister layer is disposed above the information layer. In this embodiment, the various thermal intrusion and thermal diffusion embodiments are provided.
Another embodiment includes a substrate and a first surface treatment layer disposed above the substrate. A second surface treatment layer is disposed above the first surface treatment layer, and an adhesive material layer is disposed above the second surface treatment layer. The adhesive material layer is covered with an information layer that in turn is covered with a blister layer. In this embodiment, the various thermal intrusion and thermal diffusion embodiments are provided.
Another embodiment includes a blister-board article without a sizing layer or a bottom coat layer per se. A substrate is provided with an adhesive material layer disposed above and on the substrate. The adhesive material layer also acts as both a sizing layer, and a coating layer. An information layer is disposed above the adhesive material layer, and a blister layer is disposed above and on the information layer. In this embodiment, the various thermal intrusion and thermal diffusion embodiments are provided.
Another embodiment includes a blister-board package system. This embodiment includes any of the aforementioned embodiments, plus a commercial article that is disposed between the adhesive material layer and the blister layer.
Another embodiment includes a process. In this embodiment the various blister-board articles set forth in this disclosure are manufactured. In this embodiment, the various blister-pack systems are also assembled. Additionally, a blister-board article is manufactured without the information layer, or with the information layer disposed upon the blister layer before bonding.
In order to illustrate the manner in which embodiments of the present invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention that are not necessarily drawn to scale and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying figures in which:
In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown, by way of illustration, specific ways which embodiments may be practiced. In the drawings, like numerals describe substantially similar components throughout the several views for general embodiments. These embodiments are described in sufficient detail to enable those skilled in the art to practice various embodiments. Other embodiments may be utilized and structural, system, and process changes may be made without departing from the scope of the various embodiments.
As used herein, “substrate” refers to a packaging base material that is produced in various embodiments. In one embodiment, the substrate is a wood-fiber structure such as a paperboard material. In one embodiment, the substrate is a starch-bound matrix material. In one embodiment, the substrate is a thermoplastic material. In one embodiment the substrate is a thermoplastic starch material. In one embodiment, a combination of at least two substrates are included.
The phrases “mass producible” or manufactured in a “commercial” or “economic” manner are intended in the specification and the appended claims to refer to a capability of the blister board- and blister pack systems described herein to be rapidly produced at a rate that make their manufacture economically viable. Process embodiments are directed to the manufacture of articles and systems which solve the prior art problems of high cost and complicated processing schemes.
The term “solids” or “total solids” is intended to include any admixture that is a solid before being mixed with diluent such as water. This includes adhesive materials, fibers, pigments, inorganic fillers, starch sizing, etc.
A first surface treatment layer 114 is disposed above the starch sizing layer 112. The first surface treatment layer 114 can be referred to as a base coating layer. In one embodiment, the first surface treatment layer 114 is a composition from about 50% to about 99% pigments. The pigments can include clay, calcium carbonate, other naturally occurring mineral pigments, or synthetic polystyrene pigments. Additionally, a binder can be included such as from about 1% to about 50% synthetic or natural binders. In one embodiment, the binders can include a latex base. In another embodiment, the binders can include a starch base. In yet another embodiment, the binders can include a protein base. In one embodiment, the binders can be a mixture of at least two of a latex, starch, or protein. In the binder composition, at least one of various additives can be used such as are conventional in the art for paper or paperboard pigmented coatings.
Where the binder includes a latex composition, the latex in one embodiment includes a styrene polymer. In one embodiment, the latex includes at least one styrene copolymer. In one embodiment, the latex includes at least one styrene acrylic copolymer. In one embodiment, the latex includes at least one styrene butadiene copolymer. In one embodiment, the latex includes at least one styrene butadiene vinylidene chloride copolymer. In one embodiment, the latex includes at least one styrene isobutylene copolymer. In one embodiment, the latex includes at least one vinyl acetate copolymer. In one embodiment, the latex includes at least one acrylic copolymer. In one embodiment, the latex includes at least one acrylonitrile copolymer. In one embodiment, the latex includes at least one vinyl chloride copolymer. In one embodiment, the latex includes at least two of the polymer and/or copolymers set forth herein.
The first surface treatment layer 114 is formed above the starch sizing layer 112 in order to achieve a more homogenous finish to the substrate 110. The first surface treatment layer 114 can impart a substantially monochromatic appearance to the blister-board article 100 and can be an ink stabilizer to resist ink bleed. Additionally, the first surface treatment layer 114 is a barrier material that resists excessive permeation through it into the substrate 110.
An adhesive material layer 116 is disposed above the first surface treatment layer 114. The adhesive material layer 116 is a composition that has a permeative quality when it flows against various barriers. In one embodiment, the adhesive material layer 116 is a thermoplastic composition that has a glass transition temperature TG below about 40° C. In one embodiment, the adhesive layer 116 is a thermoplastic material such as a latex base. The latex base can be any one of several latex families as are known in the art for thermoplastic latex adhesive applications.
In one embodiment, the adhesive material layer 116 includes a thermoplastic composition and a pigment composition. In one embodiment, the pigment composition includes a solid plastic or hollow sphere material such as a polystyrene pigment as is known in the art.
An information layer 118 is disposed above the adhesive material layer 116. By “information layer” it is understood that the blister-board article 100 includes a layer that contains a printed appearance such as for a commercial application. In one embodiment, the information layer 118 is a printed film such as an ink or other pigment that has been deposited upon the adhesive material layer 116. The printed film has a quality of a permeable matrix with respect to permeability of the adhesive material layer 116.
A blister layer 120 is disposed above the information layer 118. In one embodiment, the blister layer 120 is a translucent polyvinyl chloride film that can be molded around package contents under a heat load. Other heat-moldable films can be used in connection with specific selected materials of the adhesive material layer 116.
In an example of the first general embodiment, the substrate 110 is a wood-fiber material, and the sizing layer 112 is a starch sizing layer that is applied according to conventional technique. In one embodiment, the first surface treatment layer 114 is a composition of naturally occurring mineral pigments such as clay, calcium carbonate, and the like. In one embodiment, the first surface treatment layer 114 is a composition of a synthetic pigments such as a polystyrene pigment and the like. The pigments are present in a range from about 50% to about 99%. The first surface treatment layer also includes from about 1% to about 50% binders. In one embodiment, the binders are synthetic, and can include various additives as are known in the art for paper or paperboard pigmented coatings. In one embodiment, the binders are natural substances such as latex, starch, protein, and the like, with the balance being various additives as are known in the art for paper or paperboard pigmented coatings. The first surface treatment layer 114 has a thickness in a range from about 5 microns to about 50 microns. The adhesive material layer 116 is a latex-pigment mixture that includes about 10% to about 99% latex, and about 1% to about 90% polystyrene solids and/or spheres. In one embodiment, the adhesive material layer 116 is about 40% latex and about 60% polystyrene solids and/or spheres.
The adhesive material layer has a thickness in a range from about 0.5 microns to about 25 microns.
After the deposition of a latex-pigment mixture, a drying process is carried out according to conventional technique, to remove at least a portion of the liquid in the latex-pigment mixture. In one embodiment, a convective heating process is done. In one embodiment, an infrared heating process is done. The information layer 118 is a film of ink that is printed directly upon the adhesive material layer 116. The information layer 118 has a thickness in a range from about 0.5 microns to about 5 mils.
In one embodiment, the blister layer 120 is a polyvinyl chloride translucent film that has a thickness in a range from about 0.25 mils to about 50 mils. Other translucent films can be used according to conventional technique.
A starch sizing layer 112 is formed upon the substrate 110 according to conventional technique. In one embodiment, the starch sizing layer 112 acts to reduce overall roughness of the substrate 110 that remains after the intertwining web effect has been achieved in paper making.
In one embodiment, the first surface treatment layer 114 includes a carbonate pigment that can be natural or synthetic. In one embodiment, the first surface treatment layer 114 includes a natural clay pigment. In one embodiment, the first surface treatment layer 114 includes a blend of a carbonate and a clay pigment. In one embodiment, the first surface treatment layer 114 contains from about 1% to about 50% synthetic or natural binders. The binder in one embodiment includes a latex. In one embodiment, the binder is a starch. In one embodiment, the binder is a protein. In one embodiment, the binder is a combination of at least two of a latex, a starch, and a protein. Other compositions can be in the binder such as are conventional in binder compositions. The first surface treatment layer 114 is designed in part to be compatible with an adhesive material layer.
In one embodiment, the adhesive material 116 is a thermoplastic composition. In one embodiment, the adhesive material layer includes a thermoplastic composition from about 10% to about 99%, and the balance includes a pigment composition.
The thermoplastic composition can be a latex-containing material or the like. In one embodiment, the thermoplastic composition includes polyvinyl acetate (PVAc) or the like. In one embodiment, the thermoplastic composition includes styrene butadiene (SB) latex or the like. In one embodiment, the thermoplastic composition includes styrene butadiene acrylonitrile (SBA) or the like. In one embodiment, the thermoplastic composition includes ethylene vinyl acetate (EVA) or the like. In one embodiment, the thermoplastic material is a thermoplastic starch or the like. In one embodiment, the thermoplastic material is a combination at least two of the thermoplastic materials that are set forth in this disclosure, or another conventional thermoplastic material.
In one embodiment, the adhesive material layer 116 includes a thermoplastic composition and a pigment composition. The pigment composition can be supplied as substantially hollow spheres, or as solids that pass a mesh size typical for use in the manufacture of finished paperboard according to conventional technique. In one embodiment, the pigment composition includes a polystyrene material.
In one embodiment, application of adhesive material layer 116 is carried out by blending a dispersion of a thermoplastic composition, with a pigment composition. In one embodiment, a water-based dispersion of synthetic latex is mixed to a 60% ratio (dry weight base) with a balance of the adhesive material layer 116 a pigment composition. The synthetic latex can include styrene butadiene latex in a water dispersion. The synthetic latex can be obtained commercially such as from the Dow Chemical Co., of Midland, Mich.
Application of the thermoplastic composition-pigment composition mixture is carried out by a method such as a conventional coater blade, roll, rod, or according to other conventional technique.
In
In one embodiment, the thermal intrusions 219 occur in regions through the information layer 216 that are less resistant to intrusion and/or diffusion that other regions. In
In
In
In one embodiment, the thermal intrusions 219 occur in regions through the information layer 216 that are less resistant to intrusion and/or diffusion that other regions. In
It is noted that structures depicted in
A first surface treatment layer 314 is disposed above the starch sizing layer 312. The first surface treatment layer 314 can be referred to as a base coating layer. The first surface treatment layer 314 can be any one of the compositions set forth herein for the first surface treatment layer 114 as illustrated in
In one embodiment, the first surface treatment layer 314 is a composition of natural and/or synthetic carbonate pigments. The first surface treatment layer 314 is formed above the starch sizing layer 312 in order to achieve a more homogenous finish to the substrate 310. The first surface treatment layer 314 can impart a substantially monochromatic appearance to the blister-board article 300 and can be an ink stabilizer to resist ink bleed. Additionally, the first surface treatment layer 314 is a barrier material that resists excessive permeation through it into the substrate 310.
A second surface treatment layer 316 is disposed above the first surface treatment layer 314. The second surface treatment layer 316 can be referred to as a top coating layer. The second surface treatment layer 316 can be any one of the compositions set forth herein for the first surface treatment layer 314. The first surface treatment layer 314 is formed to achieve a more homogenous finish to the substrate 310. The second surface treatment layer 316 can impart a substantially monochromatic appearance to the blister-board article 300 and can be an ink stabilizer to resist ink bleed. Additionally, the second surface treatment layer 316 is a barrier material that resists excessive permeation through it into the substrate 310.
An adhesive material layer 318 is disposed above the second surface treatment layer 316. The adhesive material layer 318 is a composition that has a permeative quality when it flows against various barriers. In one embodiment, the adhesive material layer 318 is a thermoplastic composition that has a glass transition temperature TG below about 40° C. In one embodiment, the adhesive layer 318 is a thermoplastic material such as a latex base. The latex base can be any one of several latex families as are known in the art for adhesive applications.
In one embodiment, the adhesive layer 318 includes a thermoplastic composition and a pigment composition. In one embodiment, the pigment composition includes a solid plastic or hollow sphere material such as a polystyrene pigment as is known in the art.
An information layer 320 is disposed above the adhesive material layer 318 according to embodiments set forth in this disclosure for the first general embodiment.
A blister layer 322 is disposed above the information layer 320. In one embodiment, the blister layer 322 is a translucent polyvinyl chloride film that can be molded around package contents under a heat load. Other heat-moldable films can be used in connection with specific selected materials of the adhesive material layer 318.
In an example of the second general embodiment, the substrate 310 is a wood-fiber material, and the sizing layer 312 is a starch sizing layer that is applied according to conventional technique. In one embodiment, the first surface treatment layer 314 is a composition of naturally occurring mineral pigments such as clay, calcium carbonate, and the like. In one embodiment, the first surface treatment layer 314 is a composition of a synthetic pigments such as a polystyrene pigment and the like. The pigments are present in a range from about 50% to about 99%. The first surface treatment layer also includes from about 1% to about 50% binders. In one embodiment, the binders are synthetic, and can include various additives as are known in the art for paper or paperboard pigmented coatings. In one embodiment, the binders are natural substances such as latex, starch, protein, and the like, with the balance being various additives as are known in the art for paper or paperboard pigmented coatings.
The first surface treatment layer 314 is a bottom coating and has a thickness in a range from about 5 microns to about 50 microns. The second surface treatment layer 316 is a top coating has a thickness in a range from about 5 microns to about 50 microns. In one embodiment, the second surface treatment layer 316 is a composition of naturally occurring mineral pigments such as clay, calcium carbonate, and the like. In one embodiment, the first surface treatment layer 316 is a composition of a synthetic pigments such as a polystyrene pigment and the like. The pigments are present in a range from about 50% to about 99%. The first surface treatment layer also includes from about 1% to about 50% binders. In one embodiment, the binders are synthetic, and can include various additives as are known in the art for paper or paperboard pigmented coatings. In one embodiment, the binders are natural substances such as latex, starch, protein, and the like, with the balance being various additives as are known in the art for paper or paperboard pigmented coatings.
The adhesive material layer 318 is a latex-pigment mixture that includes about 10% to about 99% latex, and 1% to about 90% polystyrene solids and/or spheres.
After the deposition of a latex-pigment mixture, a drying process is carried out according to conventional technique, to remove at least a portion of the liquid in the latex-pigment mixture.
The adhesive material layer 318 has a thickness in a range from about 0.5 microns to about 25 microns.
The information layer 320 is a film of ink that is printed directly upon the adhesive material layer 318. The information layer 320 has a thickness in a range from about 0.5 microns to about 5 microns. In one embodiment, the blister layer 322 is a polyvinyl chloride translucent film that has a thickness in a range from about 0.25 mils to about 50 mils. Other translucent films can be used according to conventional technique.
The surface treatment layers 314 and 316 act as respective bottom and top coatings. The coatings can include fumed silica, organic or inorganic fillers, particles, or the like that is assists in making a useful printing surface with regard to ink bleed and drying time characteristics among others. In one embodiment, a kaolin clay based pigment is used in place of or in addition to a calcium carbonate pigment. In one embodiment, where a kaolin clay and/or a calcium carbonate material is used as the pigment, a binder can be included such as from about 1% to about 50% synthetic or natural binders. In one embodiment, the binders can include a latex base. In another embodiment, the binders can include a starch base. In yet another embodiment, the binders can include a protein base. In one embodiment, the binders can be a mixture of at least two of a latex, starch, or protein. In the binder composition, at least one of various additives can be used such as are conventional in the art for paper or paperboard pigmented coatings.
In one embodiment, the adhesive material 318 is a thermoplastic composition. In one embodiment, the adhesive material layer 318 includes a thermoplastic composition and a pigment composition. The pigment composition can be supplied as substantially hollow spheres, or as solids that pass a mesh size typical for use in the manufacture of finished paperboard according to conventional technique. In one embodiment, the pigment composition includes a polystyrene material. In one embodiment, the adhesive material layer 318 includes a thermoplastic composition from about 10% to about 99%, and the balance includes a pigment composition. In one embodiment, the amount of the pigment composition is lower than the amount of the adhesive material composition. The lower requirement for pigment composition is made possible by the pigments in the bottom- and top coatings in layers 314 and 316.
The thermoplastic composition can be a latex-containing material or the like. In one embodiment, the thermoplastic composition includes PVAc or the like. In one embodiment, the thermoplastic composition includes styrene butadiene latex (SB) latex or the like. In one embodiment, the thermoplastic composition includes styrene butadiene acrylonitrile (SBA) or the like. In one embodiment, the thermoplastic composition includes ethylene vinyl acetate (EVA) or the like. In one embodiment, the thermoplastic material is a thermoplastic starch or the like. In one embodiment, the thermoplastic material is a combination of at least two of the thermoplastic materials that are set forth in this disclosure or other conventional thermoplastic material.
In one embodiment, application of the adhesive material layer 318 is carried out by blending a dispersion of a thermoplastic composition, with a pigment composition. In one embodiment, a water-based dispersion of synthetic latex is mixed to a 50% ratio (dry weight base) with a balance of the adhesive material layer 318 as a pigment composition. The synthetic latex includes styrene butadiene latex in a water dispersion. The synthetic latex can be obtained commercially such as from the Dow Chemical Company of Midland, Mich., USA.
Application of the thermoplastic composition-pigment composition mixture is carried out by a method such as a conventional coater blade, roll, or rod according to conventional technique.
After formation of the adhesive material layer 318, an information layer 320 is formed. By “information layer” it is understood that the article 303 includes a layer that contains a printed appearance such as for a commercial application. The information layer 320 can carry ink patterns that convey product information. The information layer 320 can carry ink patterns that convey utility information. The information layer 320 can carry ink patterns that convey a trademark. The information layer 320 can carry ink patterns that convey a trade dress design. In one embodiment, the information layer 320 can carry ink patterns that convey a combination of at least two types of information set forth in this disclosure.
In one embodiment, the information layer 320 is a printed film such as an ink or other pigment that has been deposited upon the adhesive material layer 318. The printed film has a quality of a permeable matrix with respect to permeability of the adhesive material layer 318.
In one embodiment, the first surface treatment layer 412 is a composition of natural and/or synthetic carbonate pigments. The first surface treatment layer 412 is formed above the substrate 410 in order to achieve a more homogenous finish. The first surface treatment layer 412 can impart a substantially monochromatic appearance to the blister-board article 400 and can be an ink stabilizer to resist ink bleed. Additionally, the first surface treatment layer 412 is a barrier material that resists excessive permeation through it into the substrate 410.
A second surface treatment layer 414 is disposed above the first surface treatment layer 412. The second surface treatment layer 414 can be referred to as a top coating layer. The second surface treatment layer 414 can be any one of the compositions set forth herein for the first surface treatment layer 414. The first surface treatment layer 412 and the second surface treatment layer 414 can impart a substantially monochromatic appearance to the blister-board article 400 and can be an ink stabilizer to resist ink bleed. Additionally, the second surface treatment layer 414 is a barrier material that resists excessive permeation through it into the substrate 410.
An adhesive material layer 416 is disposed above the second surface treatment layer 414. The adhesive material layer 416 is a composition that has a permeative quality when it flows against various barriers. In one embodiment, the adhesive material layer 416 is a thermoplastic composition that has a glass transition temperature TG below about 40° C. In one embodiment, the adhesive layer 416 is a thermoplastic material such as a latex base. The latex base can be any one of several latex families as are known in the art for adhesive applications.
In one embodiment, the adhesive material layer 416 includes a thermoplastic composition and a pigment composition. In one embodiment, the pigment composition includes a solid plastic or hollow sphere material such as a polystyrene pigment as is known in the art.
An information layer 418 is disposed above the adhesive material layer 416. By “information layer” it is understood that the blister-board article 400 includes a layer that contains a printed appearance such as for a commercial application. In one embodiment, the information layer 418 is a printed film such as an ink or other pigment that has been deposited upon the adhesive material layer 416. The printed film has a quality of a permeable matrix with respect to permeability of the adhesive material layer 416.
A blister layer 420 is disposed above the information layer 418. In one embodiment, the blister layer 420 is a translucent polyvinyl chloride film that can be molded around package contents under a heat load. Other heat-moldable films can be used in connection with specific selected materials of the adhesive material layer 416.
According to a process embodiment, the blister-board article 400 is manufactured according to techniques set forth in this disclosure and according to conventional technique.
In an example of the third general embodiment, the substrate 410 is a wood-fiber material. In one embodiment, the first surface treatment layer 412 is a composition of naturally occurring mineral pigments such as clay, calcium carbonate, and the like. In one embodiment, the first surface treatment layer 412 is a composition of a synthetic pigments such as a polystyrene pigment and the like. The pigments are present in a range from about 50% to about 99%. The first surface treatment layer also includes from about 1% to about 50% binders. In one embodiment, the binders are synthetic, and can include various additives as are known in the art for paper or paperboard pigmented coatings. In one embodiment, the binders are natural substances such as latex, starch, protein, and the like, with the balance being various additives as are known in the art for paper or paperboard pigmented coatings.
The first surface treatment layer 412 as a bottom coating has a thickness in a range from about 5 microns to about 50 microns.
The second surface treatment layer 414 is a top coating has a thickness in a range from about 5 microns to about 50 microns.
Page 21, line 27: In one embodiment, the second surface treatment layer 414 is a composition of naturally occurring mineral pigments such as clay, calcium carbonate, and the like. In one embodiment, the second surface treatment layer 414 is a composition of a synthetic pigments such as a polystyrene pigment and the like. The pigments are present in a range from about 50% to about 99%. The first surface treatment layer also includes from about 1% to about 50% binders. In one embodiment, the binders are synthetic, and can include various additives as are known in the art for paper or paperboard pigmented coatings. In one embodiment, the binders are natural substances such as latex, starch, protein, and the like, with the balance being various additives as are known in the art for paper or paperboard pigmented coatings.
The adhesive material layer 416 is a latex-pigment mixture that includes about 10% to about 99% latex, and about 1% to about 90% polystyrene solids and/or spheres. The adhesive material layer 416 has a thickness in a range from about 0.5 microns to about 25 microns.
After the deposition of a latex-pigment mixture, a drying process is carried out according to conventional technique, to remove at least a portion of the liquid in the latex-pigment mixture.
The information layer 418 is a film of ink that is printed directly upon the adhesive material layer 416. The information layer 418 has a thickness in a range from about 0.5 microns to about 5 microns. The blister layer 420 is a polyvinyl chloride translucent film that has a thickness in a range from about 0.25 mils to about 50 mils.
A substrate 510 is prepared from a wood fiber-based material, or anther substrate material as set forth in this disclosure. An adhesive material layer 512 is disposed above and on the substrate 510. The adhesive material layer 512 is a composition that has a permeative quality when it flows against various barriers. In one embodiment, the adhesive material layer 512 is a thermoplastic composition that has a glass transition temperature TG below about 40° C. In one embodiment, the adhesive material layer 512 is a thermoplastic material such as a latex base. The latex base can be any one of several latex families as are known in the art for adhesive applications.
In one embodiment, the adhesive material layer 512 includes a thermoplastic composition and a pigment composition. In one embodiment, the pigment composition includes a solid plastic or hollow sphere material such as a polystyrene pigment as is known in the art.
Besides the utility of thermal adhesion, the adhesive material layer 512 also acts as both a sizing layer, and a coating layer for the qualities set forth in this disclosure among others.
In one embodiment, the adhesive material layer 512 includes a thermoplastic composition from about 10% to about 99%, and the balance includes a pigment composition. In one embodiment, the amount of the pigment composition is higher than the amount of the adhesive material composition. The higher amount of pigment composition can impart a substantially monochromatic appearance to the blister-board article 500 and can be an ink stabilizer to resist ink bleed.
An information layer 514 is disposed above the adhesive material layer 512. By “information layer” it is understood that the blister-board article 500 includes a layer that contains a printed appearance such as for a commercial application. In one embodiment, the information layer 514 is a printed film such as an ink or other pigment that has been deposited upon the adhesive material layer 512. The printed film has a quality of a permeable matrix with respect to permeability of the adhesive material layer 512.
A blister layer 516 is disposed above the information layer 514. In one embodiment, the blister layer 516 is a translucent polyvinyl chloride film that can be molded around package contents under a heat load. Other heat-moldable films can be used in connection with specific selected materials of the adhesive material layer 512.
According to a process embodiment, the blister-board article 500 is manufactured according to techniques set forth in this disclosure and according to conventional technique.
A first surface treatment layer 614 is disposed above the starch sizing layer 612. The first surface treatment layer 614 can be referred to as a base coating layer.
The first surface treatment layer 614 is formed above the starch sizing layer 612 in order to achieve a more homogenous finish to the substrate 610. The first surface treatment layer 614 can impart a substantially monochromatic appearance to the blister-board package system 600 and can be an ink stabilizer to resist ink bleed. Additionally, the first surface treatment layer 614 is a barrier material that resists excessive permeation through it into the substrate 610.
An adhesive material layer 616 is disposed above the first surface treatment layer 614. The adhesive material layer 616 is a composition that has a permeative quality when it flows against various barriers. In one embodiment, the adhesive material layer 616 is a thermoplastic composition that has a glass transition temperature TG below about 40° C. In one embodiment, the adhesive material layer 616 is a thermoplastic material such as a latex base. The latex base can be any one of several latex families as are known in the art for adhesive applications.
In one embodiment, the adhesive material layer 616 includes a thermoplastic composition and a pigment composition. In one embodiment, the pigment composition includes a solid plastic or hollow sphere material such as a polystyrene pigment as is known in the art.
An information layer 618 is disposed above the adhesive material layer 616. By “information layer” it is understood that the blister-board package system 600 includes a layer that contains a printed appearance such as for a commercial application. In one embodiment, the information layer 618 is a printed film such as an ink or other pigment that has been deposited upon the adhesive material layer 616. The printed film has a quality of a permeable matrix with respect to permeability of the adhesive material layer 616.
A blister layer 620 is disposed above the information layer 618. The blister layer also is deflected around a packaged product 622. In one embodiment, the blister layer 620 is a translucent polyvinyl chloride film that can be molded around package contents under a heat load. Other heat-moldable films can be used in connection with specific selected materials of the adhesive material layer 616.
The packaged product 622 can include a commercial article. By “commercial article” it is meant any article of manufacture, device, apparatus, composition of matter, other goods, and combinations thereof that is capable of being packaged in a blister package. Further, “commercial article” can be any article of manufacture, device, apparatus, composition of matter, other goods, and combinations thereof that is fabricated by an individual, a business entity, a research entity, or others.
At 720, an optional base coat, referred to also herein as a first treatment layer is formed over the substrate. In one embodiment, no sizing layer is formed and at least one base coat is formed above the substrate.
At 730 an adhesive material layer is formed above the substrate. In one embodiment, the adhesive material layer is formed above and on the substrate. In another embodiment, the adhesive material layer is formed above and on a sizing layer. In another embodiment, the adhesive material layer is formed above and on a base coat that has been in turn formed above and on the substrate. In another embodiment, the adhesive material layer is formed above and on at least one base coat that has been in turn formed above and on the substrate.
In one embodiment, a converting process is completed at 730 on the substrate.
At 740 further processing can be carried out by forming an information layer above and on the adhesive material layer. In one embodiment, a process embodiment begins at 740. Typically, the information layer is a printed film that communicates commercial and utilitarian messages. In one embodiment, a galley sheet is printed, die-cut, and optionally folded to meet the requirements of an application.
In one embodiment, a converting process is completed at 740 on the substrate.
At 750, an optional process path is taken. In one embodiment, a process embodiment begins at 750. The information layer if at all present, is above the adhesive material layer, but an article to be blister packaged is disposed between the adhesive material layer and the information layer. In this embodiment, the information layer can be an integral part of the blister layer, such as a reverse-image printing onto a translucent blister layer. In another embodiment depicted at 750, no information layer is present.
At 760, further processing can be carried out by bonding a blister layer with the adhesive material layer. As set forth herein, the adhesive material layer flows upon the application of a thermal load to permeate and/or intrude at least a portion of the information layer, if present, such that an integral bond forms with the blister layer, the information layer, and the adhesive material layer. In one embodiment, a commercial article is blister-packed article between the substrate and the blister layer.
It is emphasized that the Abstract is provided to comply with 37 C.F.R. § 1.72(b) requiring an Abstract that will allow the reader to quickly ascertain the nature and gist of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
In the foregoing Detailed Description, various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the invention require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description of Embodiments of the Invention, with each claim standing on its own as a separate preferred embodiment.
It will be readily understood to those skilled in the art that various other changes in the details, material, and arrangements of the parts and method stages which have been described and illustrated in order to explain the nature of this invention may be made without departing from the principles and scope of the invention as expressed in the subjoined claims.
Number | Date | Country | |
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Parent | 10323124 | Dec 2002 | US |
Child | 11526339 | Sep 2006 | US |