Patent Application
20090107873
Small articles or products such as medication pills are commonly packaged in blister packs. These products are often placed in blister or bubble shaped plastic receptacles and sealed with a thin layer of aluminum foil. The products are dispensed from the blister pack by applying pressure to the receptacle and pushing the product out through the foil.
Children may be able to access the products sealed in each of the blisters by performing the above steps or chewing, tearing up or otherwise rupturing such a blister pack. To make these blister packs child-resistant (“CR”), there have been attempts to (a) reinforce the plastic receptacles to make it more difficult for children to push the product through, or (b) attach additional layers of plastic or cardboard to the blister pack whereby each of the layers have to first be individually removed to gain access to the products therein.
Accordingly, there is a need for improved blister packaging that is child-resistant. There is a need for improved blister packaging that is senior friendly.
The systems and methods described herein are directed to a child-resistant and senior friendly packaging for items such as solid dosage forms of medication. The solid dosage form may be a pill, a tablet, a capsule, a lozenge or any other dosage form. However, it will be understood that the systems and methods described herein may be applied to provide for any packaging system associated with any article or product.
The systems and methods provide packaging systems having a blister pack (e.g., a collapsible receptacle combined with a rupturable membrane) sandwiched between a plurality of protective layers. One or more protective layers disposed above the blister pack may include weak zones running along a package perimeter region. A child attempting to separate the protective layers from the blister pack may only be able to strip away the perimeter region thereby improving the security of the items in the blister pack.
The systems and methods described herein may include systems for packaging at least one item. The systems comprise a blister pack for housing the item, the blister pack including a receptacle layer having at least one collapsible receptacle and a rupturable layer extending over the at least one receptacle. The systems further comprise a first rigid layer disposed on the receptacle layer, having a perimeter region including a zone of reduced strength (e.g., for preferential material failure), and a second rigid layer disposed on the rupturable layer. The first rigid layer may include an opening feature that may be substantially aligned with the receptacle. In some embodiments, the second rigid layer is attached to the first rigid layer and has an opening feature substantially aligned with the receptacle.
The receptacle layer may be formed from any suitable material that can be caused to collapse by application of an appropriate amount of force, such as polymeric sheets such as polyvinyl chloride. The receptacle layer may include a plurality of receptacles that may project outwardly from a surface such that each receptacle may be separated from the nearest other receptacle by a separation distance. The separation distance may be about 3 mm to about 6 mm. The separation distance may be about 3 mm to about 15 mm. The separation distance may be any suitable distance. The receptacle may have any suitable shape. The shape may in plan view be round. The shape may in plan view be rectilinear. The shape may in plan view be curvilinear. The maximum extent in plan view of the receptacle is referred to herein as the receptacle diameter. The diameter may be about 8 mm to about 9 mm. The diameter may be up to about 25 mm. The diameter may be suitable to accommodate any suitable dosage form. The maximum linear dimension, in any direction, of the dosage form is referred to herein as the dosage form diameter. The receptacle may be sized and shaped to accommodate any suitable dosage form diameter. For example, the dosage form diameter may be up to about 7 mm. The dosage form diameter may be between about 7 mm and about 21 mm. The dosage form diameter may be between about 21 mm and about 23 mm. The dosage form diameter may be greater than about 23 mm.
In some embodiments, the plurality of receptacles may be arranged as a rectangular grid on the receptacle layer. In such embodiments, the receptacle layer may be a rectangular sheet having a length from about 100 mm to about 120 mm, and width from about 65 mm to about 80 mm.
In some embodiments, the rupturable layer includes any material capable of being ruptured easily with the application of force. The rupturable layer may include an aluminum foil and/or a paper sheet. In some embodiments, the rupturable layer extends over substantially the entire receptacle layer. The rupturable layer may extend over portions, not necessarily the entirety, of the receptacle layer.
In some embodiments, the first and/or second rigid layers includes at least one of cardboard and plastic. In particular, the first and/or second rigid layers may include any suitable polymeric material and may include a laminated rigid sheet. For example, the first and/or second rigid layers may include any derivatives of ethylene or propylene, for example high density or low density polyethylene or terepthalate. At least one of the first rigid layer and the second rigid layer may include an adhesive. At least one of the first and second rigid layer may be a rigid rectangular sheet. The sheet may have any suitable dimensions. For example, the sheet may have any suitable length and any suitable width. In some embodiments, the length may be up to about 10 cm. In some embodiments, the length may be between about 10 cm and about 20 cm. In some embodiments, the length may be more than about 20 cm. In some embodiments, the width may be up to about 5 cm. In some embodiments, the length may be between about 5 cm and about 10 cm. In some embodiments, the width may be more than about 10 cm. In some embodiments, the opening in the first rigid layer has a diameter that is about 10 mm to about 13 mm. The second rigid layer may also include a plurality of layers of rigid materials. The first rigid layer may be attached to the second rigid layer along an edge. In some embodiments, the first rigid layer may include an opening feature that is dimensioned to correspond to one or more dimensions of the item.
In some embodiments, the second rigid layer may include an opening feature aligned with the receptacle. The opening feature may include or be in the shape of a wedge. The opening feature may have a substantially central region and a local perimeter, about the central region, that corresponds to a single receptacle. The wedge may include an apex that is proximate to the central region and a base that is proximate the local perimeter. In some embodiments, the wedge may be supported, at the base, by the second rigid layer, as a cantilever. The wedge is one of a number of so supported wedges. The number may be 2, 3, 4, 5, 6 or any suitable number.
In some embodiments, the systems for packaging a pill further comprise a barrier layer disposed on the second rigid layer, the barrier layer extending over the collapsible receptacle. The barrier layer may include at least one of plastic, polyethylene and paper. In some embodiments, the barrier layer may include an inner and outer barrier layer. In other embodiments, the barrier layer may be combined with a label layer serving as an outer barrier. The inner barrier layer may be disposed on the second rigid layer and may extend over the collapsible receptacle. The outer barrier layer may be disposed over the inner barrier layer and may extend over the collapsible receptacle. In some embodiments, a label layer may be present and in contact with the rupturable layer.
In some embodiments, the barrier layer (at times the inner and outer barrier layers) and/or the label layer includes perforations. The perforations may include two parallel lines of perforation and a line of perforation connecting the two parallel perforation lines, such that a portion of at least one of the inner barrier layer and outer barrier layer is made removable. In such embodiments, the region of at least one of the inner barrier layer and outer barrier layer near the line of perforation connecting the two parallel lines may be unattached thereby allowing space for a finger nail penetrate therein. In some embodiments, the perforations include a line of perforation near the center of the region underneath the collapsible receptacle, such that a portion of at least one of the inner barrier layer and outer barrier layer is made rupturable.
The systems and methods described herein may include methods for manufacturing a pill package. The methods include the steps of providing a receptacle layer having at least one collapsible receptacle, introducing a pill into the receptacle, and attaching to the receptacle layer a rupturable layer that extends over the receptacle, thereby enclosing the pill. The methods further include disposing on the rupturable layer a rigid layer having at least one opening such that the opening aligns with the receptacle and disposing on the rigid layer at least one barrier layer. In some embodiments, the barrier layer includes at least one zone of reduced strength corresponding to a region near the opening.
In some embodiments, the methods further include disposing a top rigid layer on the receptacle layer. The top rigid layer may include at least one zone of reduced thickness extending along a portion of a perimeter region. The top rigid layer may optionally be attached directly to the rigid layer underneath the rupturable layer.
In another aspect, the systems and methods described herein include methods for extracting a pill from a package. The methods comprise providing a package that includes a blister pack housing the pill and including a receptacle layer having at least one receptacle and a rupturable layer extending over the at least one receptacle, and a plurality of barrier layers disposed in series with the receptacle and the rupturable layer, wherein each of the barrier layers includes at least one zone of reduced strength corresponding to a region near at least one opening in a rigid layer adjacent the rupturable layer. The methods further comprise severing each of the plurality of barrier layers separately along the respective zone of reduced strength, thereby revealing an underlying one of the plurality of barrier layers, and applying force to the receptacle, thereby causing the pill to break through the rupturable layer.
In still another aspect, the systems and methods described herein include systems for packaging a plurality of pills. The systems comprise a blister pack housing that includes a receptacle layer having a plurality of receptacles and a rupturable layer extending over the plurality of receptacles and a casing. The casing includes a first rigid section disposed on the blister pack adjacent the receptacle layer, a second rigid section attached to the first rigid section and disposed on the blister pack adjacent the rupturable layer, and a third rigid section, hingedly attached to the second rigid section such that the third rigid section is configured to fold over to enclose the blister pack. In some embodiments, the second rigid section includes a plurality of openings aligned with the plurality of receptacles. The casing further includes at least one barrier layer disposed on the second rigid section and extending over the plurality of openings. The barrier layer may include a zone of reduced strength corresponding to one of the openings.
The following Figures depict illustrative embodiments of the invention in which like reference numerals refer to like elements.
As will be seen from the following description, the systems and methods described herein relate to a packaging system having a blister pack sandwiched between a plurality of protective layers. One or more protective layers disposed above the blister pack may include perforations running along the perimeter region. A child attempting to separate the protective layers from the blister pack may only be able to strip away the perimeter region thereby securing the blister pack.
The illustrative apparatuses, systems and methods are described below in the following order: First, an illustrative wallet-sized packaging system (See packaging system 100,
Second rigid layer 114 is disposed below blister pack 112 and may include openings aligned with each of the collapsible receptacles 122. As will be described with reference to
Panel composite 102 may further include one or more barrier layers 116, which may be attached to second rigid layer 114, and one or more label layers 118 attached to barrier layer 116. Label layer 118 may include any suitable material. Label layer 118 may include oriented polyamide nylon (OPA). Barrier layer 116 and label layer 118 serve as obstacles to hinder a child from accessing pill 124 in blister pack 112. During operation, a user may carefully remove a portion of label layer 118 and then one or more barrier layers 116. The user may also have to remove a portion of second rigid layer 114 thereby gaining access to blister pack 112 from below. The user may then apply pressure to collapsible receptacle 122 to push pill 124 out of blister pack 112 and through each of the opened protective layers 114, 116 and 118.
Panel composite 102 may be attached to additional panels 104, 106 and 108 by hinges 132 that allow panels 104, 106 and 108 to hingedly fold about each other. Panels 104, 106 and 108 may provide information to a user. Panels may provide protection to blister pack 112. Panels 104, 106 and 108 may include additional information about pill 124, dosage information and/or other related information about the company. Panels 104, 106 and 108 may include identifiers such as bar codes and serial numbers. Panels 104, 106 and 108 may help to protect blister pack 112 and panel composite 102 from accidental puncture and collapse of blister housing 120.
In some embodiments, as described with reference to
Packaging system 100 may include one or more child resistant features, described below, that are compliant with the U.S. Consumer Product Safety Commission's “Standard Classification of Child-Resistant Packages ASTM—Designation D3475—95.” Packaging system 100 may include one or more child resistant features, described below, that pass test procedures conducted under the Poison Prevention Packaging Act, 21 C.F.R. 295.1, in which packaging systems are given to children for a given period of time to determine accessibility.
Blister pack 112 includes a plurality of blister or bubble shaped collapsible receptacles 122 that project outwardly from the surface of receptacle layer 202. Receptacle layer 202 may include transparent or translucent thermoformable materials such as polyvinyl chloride or polystyrene. Rupturable layer 206 may include rupturable materials including aluminum lidding foil or paper sheets. Rupturable layer 206 may additionally serve to seal out ambient dust and contaminants.
Blister pack 112 may be sized and shaped to house pill 124. Collapsible receptacle 122 may be dome shaped, having a semi-circular cross-section. Collapsible receptacle 122 may have other cross-sections including rectangular having curved corners. Collapsible receptacle 122 may be sized and shaped as desired depending on the nature of the application and of the contents of the packaging system. For example, receptacle 122 may be sized and shaped to somewhat forcibly hold pill 124 in place. In another example, when pill 124 is relatively soft and breakable, receptacle 122 may be sized and shaped to define a larger cavity 204 to reduce the likelihood that the tablet will be crushed.
In some embodiments, collapsible receptacles 122 are arranged as a rectangular grid on the rectangularly shaped receptacle layer 202. Receptacle layer 202, in such embodiments, may have a length of about 100 mm to about 120 mm, and a width of about 65 mm to about 80 mm. Collapsible receptacles 122 may be separated from each other by a distance of about 3 mm to about 6 mm, either between the centers or the edges of the collapsible receptacles 122. Receptacles may have a diameter of about 10 mm to about 13 mm. Generally, collapsible receptacle 122 may have any size and any shape depending on, among other things, the size and shape of the product contained within, without departing from the scope of the invention.
First rigid layer 110 is disposed on the top surface of receptacle layer 202. First rigid layer 110 includes one or more openings 126 that are aligned with collapsible receptacle 122. Collapsible receptacle 122 fits in opening 126, thereby allowing rigid layer 110 to be disposed adjacent to the portion of first rigid layer 110 that surrounds collapsible receptacle 122. First rigid layer 110 may be formed from cardboard and/or plastic materials. In some embodiments, first rigid layer 110 may be formed from polyethylene laminated rigid cardboard sheet. First rigid layer 110 may be sized and shaped as desired depending on the application without departing from the scope of the invention. First rigid layer 110 may be attached to the receptacle layer 110 with an adhesive.
The adhesive may be applied to one or more regions of first rigid layer 110 and/or receptacle layer 202. As noted earlier, blister housing 120 depicted in
Rupturable layer 206 of blister pack 112 is disposed on second rigid layer 114. Second rigid layer 110 may be formed from cardboard and/or plastic materials. In some embodiments, second rigid layer 110 may be formed from polyethylene laminated rigid cardboard sheet. Second rigid layer 114 may include an opening or an openable closure aligned with collapsible receptacle 122 of blister pack 112. As depicted, second rigid layer 114 is attached to barrier layer 116, which is attached to label layer 118.
Barrier layer 116 may be formed from any plastics including polyethylene, and/or paper materials and/or any other suitable materials. Barrier layer 116 may additionally include one or more perforation lines 208 to allow a portion of barrier layer 116 to be separated out and thereby allow access to the underlying second rigid layer 114 and blister pack 112. Various embodiments of barrier layer 116 are depicted in
Label layer 118 may be formed from plastic, paper or any other suitable materials. Label layer 118 may be formed from polyethylene materials. Label layer 118 includes printed material that may be used to provide the user with additional information about pill 124 such as dosage, timing and chemical ingredients. Label layer 118 may also serve as an additional protective layer. Various embodiments of label layer 118 are depicted in
Turning to
Second rigid layer 314 includes orifice 350 that may be sized and shaped based on the size and shape of pill 124. As evident in
Barrier layer 316 includes tab 356 that are defined by perforation lines 352 on bottom surface 360 (
During operation, as depicted in
In some embodiments, as depicted in
In some embodiments, second rigid layer is configured with one or more cuts or incisions that bend away to allow pill 124 to pass out from blister pack 112.
During operation, tab 356 (
In alternative embodiments, second rigid layer 514 may include a plurality of intersecting cuts 550 to generate a plurality of leaves 572. As an example, second rigid layer 514 may include four intersecting cuts 550 that define eight leaves 572. In other embodiments, cuts 550 may be configured in other geometrical patterns such as an “I” shape with one central cut and two cuts on both ends of the central cut.
As noted earlier, the blister housing may also include label layer 118 which may be configured to serve as an additional protective layer.
During operation, a user peels away tab 756 of label layer 118 to reveal the underlying barrier layer 116. The user may then peel away tab 758 associated with barrier layer 116 to reveal the opening 750 and underlying rupturable layer 206. The user may remove the pill 124 by applying pressure to collapsible receptacle 122 to force the pill through rupturable layer 206 and each of second rigid layer 114, barrier layer 116 and label layer 118.
In some embodiments, barrier layer 116 and label layer 118 are attached to each other using adhesives. In such embodiments, tabs 758 and 756 may be attached to each other using a weaker temporary adhesive while the rest of barrier layer 116 and label layer 118 may be attached to each other using a stronger more permanent adhesive.
Turning now to
As depicted in
Having described exemplary packaging systems with a blister pack and one or more protective layers, and exemplary materials, applications and other features, exemplary methods of manufacturing such apparatuses and systems are now described with reference to
At least one of panels 104, 106 and 108 and first rigid layer 310, second rigid layer 314 and barrier layer 316 may be formed from plastic and cardboard based materials. Panels 104 and layers 310, 314 and 316 may be sized and shaped as desired depending on the application. In one embodiment, panels 104, 106 and 108 and layers 310, 314 and 316 are rigid rectangular sheets having a length from about 130 mm to about 140 mm, and a width from about 85 mm to about 95 mm.
As depicted, first rigid layer 310 includes a plurality of openings 126, each sized and shaped to receive the protruding portion of a collapsible receptacle of a blister pack. In some embodiments, openings 126 have a circular shape with diameter of about 10 mm to about 13 mm. Second rigid layer 314 includes a plurality of orifices 350, each sized and shaped to allow a pill to pass through. Second rigid layer 314 further includes zone of reduced strength 128 that defines a perimeter region. Barrier layer 316 includes a plurality of removable tabs 356 defined by perforation lines 352. Barrier layer 316 also includes slots 356 adjacent tabs 352 to allow a user to grip a corner of tab 352.
In some embodiments, one or more layers of adhesives are applied to second rigid layer 314 and/or barrier layer 316. In some embodiments, a layer of adhesive is also applied to first rigid layer 310. The layer of adhesive may include lines of adhesive material applied between orifices 350 or tabs 356 or openings 126. Panel sheet 1000 may be passed through an adhesive applicator device configured to apply one or more parallel lines of adhesive onto at least one of first rigid layer 310, second rigid layer 314 and barrier layer 316.
As depicted in
Blister pack 112 is placed on folded second rigid layer 314. In some embodiments, blister pack 112 is attached, using adhesives, to second rigid layer 314. First rigid layer 310 is then folded over to overlap blister pack 112 thereby sandwiching it between first rigid layer 310 and second rigid layer 314. First rigid layer 310 may be attached to blister pack 112. In some embodiments, blister pack 112 is sized and shaped to have a smaller surface area than first rigid layer 310 or second rigid layer 314. In such embodiments, first rigid layer 310 may be directly attached to second rigid layer 314 along the edges. Is some embodiments,
In other embodiments, label layer 118 is affixed to the bottom surface of barrier layer 316. As noted earlier, label layer 118 may include tabs and perforation lines and serve as a layer of protection for blister pack 112. In some embodiments, label layer 118 may be placed between blister pack 112 and rigid layer 314. Label layer 118 and panels 104, 106 and 108 may also include text that provides a user with additional information about the contents of blister pack 112 and other related information. Packaging system 100 formed from the manufacturing process shown in
In embodiments in which layers or sheets are attached by adhesives, any suitable adhesive may be used. One example adhesive is hot-melt adhesive Model No. 34-252A, which is available from National Adhesives, Bridgewater, N.J., under the trademark COOL-LOK. Other examples include cold adhesives such as those available from Henkel, Dusseldorf, Germany. Adhesive may be applied near edges-either along a length or a width or both. Adhesive may be applied to a layer or sheet between openings or opening features. Adhesive may be applied to a layer or sheet between patterns of openings or patterns of opening features. For example, adhesive may be applied between adjacent rows of openings.
Panel sheets similar to panel sheet 1000 may be used to manufacture packaging systems having other embodiments of blister housings similar to those shown in
In some embodiments, the panel sheets have one or more layers that provide reinforcement and rigidity to the packaging system.
Variations, modifications, and other implementations of what is described may be employed without departing from the spirit and scope of the invention. More specifically, any of the method, system and device features described above or incorporated by reference may be combined with any other suitable method, system or device features disclosed herein or incorporated by reference, and is within the scope of the contemplated inventions. The systems and methods may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative, rather than limiting of the invention. The teachings of all references cited herein are hereby incorporated by reference in their entirety.
