CN119325445A

CN119325445A - Recyclable blister package, method of manufacturing a recyclable blister package, and method of recycling a recyclable blister package

Info

Publication number: CN119325445A
Application number: CN202380045436.XA
Authority: CN
Inventors: 弗朗索瓦·彼得特
Original assignee: Polye Inc
Current assignee: Polye Inc
Priority date: 2022-06-23
Filing date: 2023-06-21
Publication date: 2025-01-17
Also published as: WO2023249981A1

Abstract

A recyclable blister package configured to sealably enclose at least one active component and a product includes a backing having a first side and an opposing second side. Each of the first side and the second side is flat or planar. The blister package may also include a cover having a first side and an opposing second side. At least a portion of the second side of the cover is adhered to the first side of the backing to form a sealed package for containing a product. The cover may include at least one blister. The blister package may be formed from one or more recyclable materials.

Description

Recyclable blister package, method of manufacturing a recyclable blister package, and method of recycling a recyclable blister package

Cross Reference to Related Applications

The present application claims priority from U.S. provisional patent application No. 63/366,872, filed on month 23 of 2022, entitled "recyclable blister package, and methods of making and USING SAME thereof (RECYCLABLE BLISTER PACK AND METHODS OF MAKING AND USING SAME), the disclosure of which is hereby incorporated by reference in its entirety.

Technical Field

The technology of the present disclosure relates to packaging for sensitive or consumable products. More particularly, in one embodiment, the technology of the present disclosure relates to blister packages for products (e.g., one or more pills, tablets, capsules, etc.). In one optional embodiment, the techniques of the present disclosure relate to a package having a recyclable covering bonded to a recyclable backing, both of which may optionally be formed from a thermoformed material.

Background

Blister packs are commonly used to package oral solid dose medications, vitamins, probiotics, pills, tablets, capsules, and the like. Prior art packages (such as U.S. patent 8,142,603, incorporated herein by reference) include a thermoformed cover containing the product and a foil backing attached to its open side to enclose the product. Blister packages or "blister packs" are commonly used by both pharmaceutical companies and health institutions. Blister packages are also manufactured by companies that provide unfilled or empty blister packages for third party filling.

It is known to place desiccant or scavenger squeeze films in blister packages. The size and shape of the desiccant or scavenger extruded film may be referred to as the footprint of the film and is at least slightly smaller than the opening of the blister containing the product in the prior art. Such blister packages with desiccant films are disclosed in U.S. patent No. 6,279,736 (Hekal), international publication No. WO 2020/146556 (Hollinger) and international publication No. WO 2022/236313 (Hollinger), each of which is incorporated by reference.

Fig. 1 shows a prior art blister package 10 having four blisters 18. Fig. 2 shows a cross-sectional view along line 2-2 of fig. 1 and illustrates the thermoplastic member 14 forming one of the blisters 18 adhered to the foil backing 12. An extruded desiccant film 16 having a width W _PA (see fig. 2) less than the width of the individual blisters 18 is adhered to the foil backing 12.

Various techniques for recycling plastics are known. For example, recycle sorting of plastics is typically based on a sedimentation process, wherein particles less than 1g/cm3 are separated from particles greater than 1gm/cm3 based on whether the particles float or sediment in a body of water. Recyclers also use initial sorting by near infrared spectroscopy to distinguish between different types of polymers, such as Polystyrene (PS), polyethylene (PE), polypropylene (PP), and the like. Sorting by weight (e.g., with an air gun), with a sensor, and/or with a magnet may also be used. The literature is hereby incorporated by reference in "manage plastic waste-sorting, recycling, disposal and product redesign (MANAGING PLASTIC WASTE-Sorting, recycling, dispensing, and Product Redesign)", jean-Paul Lange, ACS sustainable chemistry and engineering (ACS Sustainable chem. Eng.) "2021,9,15722-15738.

In conventional blister packages, the backing and cover are made of different materials, which prevents recycling or at least makes recycling difficult or inefficient. For example, in conventional blister packages, the backing is formed of foil and the cover is formed of polymer. In addition, blister packages that include active components further complicate or prevent recycling due to the different materials used to form the active components. These different materials make recycling prior art blister packages difficult and time consuming the most. In fact, companies are collecting used blister packages, but there is no place to recycle them.

Disclosure of Invention

It is desirable to provide a recyclable blister package capable of preserving and/or protecting the product therein and/or acting as a desiccant or oxygen scavenger.

The above and other needs are addressed by the techniques of the present disclosure, which in one aspect include a blister package having a recyclable backing and cover. The cover may be attached or adhered to the backing to form a sealed unit package for containing a product. The cover may have at least one blister cavity with an open side. The backing may have one side bonded to the cover.

In an optional embodiment, the blister cavity may have a blister or dome portion and a base portion. The base portion may be wider and/or longer than the blister portion.

Optionally, the blister package may further comprise an active component, optionally in the form of an extruded film. In one optional embodiment, the extruded film may be adhered to the side of the backing that is adhered to the cover. The extruded film may have a shape that approximates the base portion. The extruded film may include, for example, a desiccant or oxygen scavenger, or another active technique.

The use of active components (e.g., desiccants) within a blister package may further complicate and/or prevent recirculation of the blister package. In particular, the active component may undesirably contaminate the blister package such that the blister package cannot be recycled. For example, in some locations or with at least some known recycling methods, an empty (i.e., no product) blister package may require 90% or more of olefin polymer and/or have no polyvinyl chloride (PVC) that can be recycled. Optionally, the active component of the presently disclosed technology may have 5 grams of zeolite, which would allow the blister package to be 90% or more of an olefin polymer or polyolefin.

In another aspect, the techniques of this disclosure may include a method of making a blister package. In one embodiment, the method may include placing a product in each blister of the cover. The method may further include attaching or bonding the thermoformed cover to the backing to form the sealed unit package. The longitudinal axis of each blister may extend parallel to the edge of the backing.

In an optional embodiment, the method may include attaching or bonding an extruded active polymer film to an inner surface of the cavity.

Optionally, in any embodiment, the product contained in the blister of the blister package may comprise a pill, optionally a medicament, nutritional supplement or probiotic, for example.

In an optional embodiment, the foil backing of conventional blister packages is replaced with one or more polymers, such as Polyethylene (PE) or polyethylene terephthalate (PET). Such polymers or films cause an increase in moisture vapor transmission rate, which may necessitate the use of active components in the blister cavity. For example, the active component may optionally be an active polymer component having a base formed of PE or PET. The active component may optionally be thermally fused to a polymeric backing. The molecular sieve component of the active component may be precisely or about 5% or optionally 4-6% or optionally 2-8% of the total mass of the blister card or package, thereby allowing for a recycling step.

Optionally, the blister package is push only, meaning that the product may be or designed to be removed from the blister package by pushing the product through the package.

Optionally, the blister package is of the peel-push type, which means that the product may be or designed to be removed from the blister package by peeling a portion of the package to expose the product and/or pushing the product through the package.

Drawings

The foregoing summary, as well as the following detailed description of the presently disclosed technology, will be better understood when read in conjunction with the appended drawings, wherein like reference numerals refer to like elements throughout. For the purpose of illustrating the disclosed technology, various illustrative embodiments are shown in the drawings. However, it should be understood that the techniques of this disclosure are not limited to the precise arrangements and instrumentalities shown. In the drawings:

FIG. 1 is a top plan view of a prior art blister package;

FIG. 2 is a cross-sectional view along line 2-2 of FIG. 1 showing an extruded film having a width less than the width of a single blister;

FIG. 3 is a cross-sectional view of a blister package according to one embodiment of the disclosed technology from the same or similar perspective as that along line 2-2 of FIG. 1, and showing the backing and cover enclosed around the product;

FIG. 4 is a cross-sectional view from the same or similar perspective as that along line 2-2 of FIG. 1 in accordance with one embodiment of the disclosed technology, and showing an active polymer film laminated on and/or attached to a backing;

FIG. 5 is a cross-sectional view from the same or similar perspective as that along line 2-2 of FIG. 1 in accordance with one embodiment of the disclosed technology, and showing an active polymer film laminated within a cavity formed by a backing and a cover;

FIG. 6 is a cross-sectional view, from the same or similar perspective as that along line 2-2 of FIG. 1, according to one embodiment of the disclosed technology, and showing an active polymer film integrated into the walls of the cavity formed by the backing and the cover;

FIG. 7A is an enlarged cross-sectional view of a backing in accordance with one embodiment of the disclosed technology, and

Fig. 7B is an enlarged cross-sectional view of a backing according to another embodiment of the disclosed technology.

Detailed Description

Although systems, devices, and methods have been described herein by way of example and embodiments, those of ordinary skill in the art will recognize that the techniques of the present disclosure are not limited to the embodiments or figures described. On the contrary, the presently disclosed technology is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the appended claims. Features of any one embodiment disclosed herein may be omitted or incorporated into another embodiment.

Any headings used herein are for organizational purposes only and are not meant to be used 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 stated otherwise herein, the terms "a," an, "and" the "are not limited to one element but rather are to be read in the sense of" at least one. For reference and clarity only, first direction D ₁ and second direction D ₂ are shown in some of the figures and are not part of the structure of the techniques of the present disclosure. The terminology includes the words above mentioned, derivatives thereof and words of similar import.

Referring now in detail to the drawings in which like reference numerals refer to like parts throughout, FIGS. 3-7 illustrate an embodiment of a blister package or package, generally designated 110, of the presently disclosed technology. Optionally, recyclable blister package 110 may be used to provide a sustainable form of packaging that may also preserve or extend the shelf life of the products therein.

In an exemplary embodiment, blister package 110 includes a backing 112 and a cover 114 attached to backing 112. Further, the cover 114 is attached to the backing 112 such that at least one cavity is formed between the cover and the backing, or a plurality of spaced apart cavities are formed by a combination of the cover 114 and the backing 112. Thus, the cover 114 and the backing 112 form at least one enclosure constructed and/or configured to store at least one product 117. Optionally, the cover 114 may have any of a variety of shapes and/or configurations, as disclosed in WO 2020/146556.

The backing 112 may have a first side or surface 112a and an opposite second side or surface 112b. Optionally, at least the first side 112a of the backing 112 may be flat or planar. In one embodiment, each of the first and second sides 112a, 112b of the backing 112 is flat or planar such that each of the first and second sides 112a, 112b extend in at least slightly spaced planes.

The covering 114 may have a first side or surface 114a and an opposite second side or surface 114b. Optionally, at least a portion of the first side 114a and the second side 114b of the covering 114 are flat or planar. At least a portion of the second side 114b of the cover 114 may be attached or bonded to the first side 112a of the backing 112, such as by thermoforming or cold forming, to form a sealed package for containing a product. The thickness of the covering 114 may be the same as or different from the thickness of the backing 112 (as measured in the direction of D ₂). In one embodiment, the covering 114 is made or formed from a formable mesh. In one embodiment, the formable web is made of a thermoplastic material, such as a thermoformed film.

The cover 114 includes or is formed with at least one blister, generally indicated at 118. For example, the cover 114 may include two or more spaced apart blisters 118. The embodiment shown in fig. 3-6 shows a cover 114 having four identical blisters 118 spaced apart, similar to the configuration shown in fig. 1. However, the cover 114 may have more or fewer blisters, and one or more of the blisters may have a different size and/or shape than another of the blisters 118 of the blister package 110, depending on the particular needs. Optionally, each blister 118 may have an at least partially egg-shape or a sphere shape. Alternatively, in one embodiment, each blister 118 may have an at least partially plateau shape (e.g., when viewed from the side) or a cylindrical shape. When the cover 114 is attached to the backing 112, a sealed cavity is formed within or by each blister 118.

In an optional embodiment, each blister 118 may define a longitudinal or long axis extending parallel to at least one outer edge of the backing 112 and blister package 110. Optionally, and more specifically, the longitudinal axis of each blister 118 may extend parallel to two opposing sides of the blister package 110 and perpendicular to the top and bottom sides of the blister back, as shown in fig. 3. However, the arrangement or orientation of the blisters 118 within the blister package 110 is not limited to the arrangement or orientation shown and described herein, as other configurations are possible according to particular needs.

The blister package 110 may enclose, store, and protect one or more products 117 (shown schematically in fig. 3), such as oral solid dose medications, vitamins, or other nutritional supplements, food products, small consumer products, probiotics, and the like. Such products may be in the form of pills, e.g., tablets, capsules, and the like. In an optional embodiment, the product 117 may be in the form of a powder.

In an optional embodiment, the cover 114 and backing 112 are formed of the same material and/or recyclable material, which enables the blister package 110 to be easily reused or changed in use, and/or treated with recycling techniques, such as by air sorting, sink-float sorting, or sensor-based sorting, as described in detail below. The ability to reuse and/or recycle results from the use of a single material to form both the backing 112 and the covering 114. In such embodiments, the blister 118 of the present embodiment differs from the prior art blister 18 in that the blister 118 of the presently disclosed technology includes a backing 112 and cover 114 formed of a single recyclable material rather than different materials and/or two or more materials.

The techniques of this disclosure may be used with any of a variety of recycling techniques, including mechanical recycling techniques, chemical recycling techniques, or combinations thereof. For example, plastic waste is typically sorted through a series of sorting steps. The sorting step may include sorting by size, sorting manually or through a screen, such as removing foreign materials (e.g., metal and glass), sorting by type of plastic material, and/or sizing and granulating into plastic recyclates.

Some materials may be removed or separated from other materials by using gravity in an air stream (e.g., an air classifier) or a water stream (e.g., a sink-float). An air classifier is a machine that uses air flow and the relationship between inertial and/or gravitational forces and drag forces to separate particles of different densities. For example, a strong air flow (e.g., a rising air column) may be directed or generated from the bottom of the machine toward or toward the top, while the material flow descends in the opposite direction from the top toward the bottom of the machine. Optionally, plastic flakes and/or particles may then be passed through the zig-zag channel, which may aid in the separation process. At the same time, lighter materials (such as labels and dust) may be blown upward and collected in the filter bag. Thus, high quality plastic without labels and dust can be collected.

Metals can be removed in particular by exploiting their magnetism, for example by magnetic attraction of ferrous metals or by induced magnetic repulsion of nonferrous metals.

Gravity can also be used to sort some plastics between themselves, such as separating polyolefin (e.g., a density of about 0.9 g/mL) from PET or PVC (e.g., a density of about 1.4 g/mL). This can be done in a machine or in a vertical shaft, for example. Gravity separation can be refined with the aid of electrostatic or magnetic fields.

The sink-float separator tank may employ water or another liquid to separate the blended materials (e.g., plastic) based on density. For example, the density of water is 1g/cm ³. As chips or items (e.g., plastic) enter or are introduced into the separator tank, any items having a density greater than the liquid (e.g., water) will sink. The heavy stream is collected at the bottom of the tank and may be forced out of the machine, optionally using a screw conveyor. Likewise, any material less dense than the liquid will float and leave the machine at the top. Additives may be added to the liquid to improve the separation process.

Some sensor-based sorting machines are manufactured by TOMRA ^TM recycling company, germany. For example, visual spectrometer sensors may be used to remove certain materials from waste streams. Eddy currents are another type of separator or sensor that may be used.

Perhaps most commonly, the plastics are sorted by spreading them on a conveyor belt, optionally using an infrared detector (e.g., near Infrared (NIR) or Short Wave Infrared (SWIR)) to identify the plastics to be sorted, and an actuator or air jet to sort the plastics. Standard Infrared (IR) detectors may be replaced or supplemented by Hyperspectral Imaging Spectroscopy (HIS) to identify full-shape products, or by X-ray fluorescence detectors to identify heavy elements such as chlorine (Cl) and bromine (Br).

New sorting techniques are continually evolving. For example, trace-based sorting uses fluorescent pigments incorporated into a plastic substrate or sleeve. These pigments are only visible under the UV light of the sorting mill. Another technique uses digital watermarking, such as code integrated into the packaging design, and can be detected by cameras on high-speed sorting lines. The watermark may carry or reveal information about the product and its packaging. Yet another technique is robotic sorting, which employs artificial intelligence to assist cameras and robotic arms in sorting plastics from a conveyor belt. Each of the recycling techniques discussed above may be used with the techniques of the present disclosure.

In one embodiment, the backing and cover are formed from a polymer, such as a polyolefin or another synthetic fiber. As used herein, the term "polyolefin" refers to a polymer that may be considered to be the product of olefins (e.g., ethylene, CH ₂＝CH₂) that have reacted to form a polymer (e.g., polyethylene). Some polyolefins may be considered as polymerization products of alpha-olefins (CH ₂ =chr). Examples of polyolefins include Polyethylene (PE), polypropylene (PP), polystyrene, polyacrylamide, polyvinyl alcohol, and polyvinyl acetate.

The backing 112 and the covering 114 may optionally be formed from an optionally transparent thermoformed film, rather than a conventional plastic covering and foil backing, such as disclosed in U.S. patent No. 8,142,603. Alternatively, the backing 112 and the cover 114 may be formed from a copolyester or a copolyester film. Examples of copolyesters include PETG (polyethylene terephthalate), PCTG (polycyclohexylene dimethylene glycol modified terephthalate), and PCTA (1, 4-cyclohexylene dimethylene terephthalate-co-isophthalate).

Embodiments of the disclosed technology may be distinguished from the technology disclosed in U.S. patent No. 8,142,603, based at least on the materials used to make the backing and the manner in which the backing is constructed or formed. For example, U.S. patent 8,142,603, column 4, lines 23-37, discloses heating the lidding foil sufficiently that the polymeric seal layer becomes pliable and adheres the active film to the softened polymeric layer of the lidding film. Despite the thin polymeric sealing layer, the backing of U.S. patent 8,142,603 itself comprises foil, which would destroy or make recycling of the blister package difficult or impossible.

In one optional embodiment of the disclosed concept, backing 112, covering 114, and/or active component 116 are formed from materials manufactured by TEKNI-PLEX ^TM of Holland, ohio. For example, the material used may be coated PVC/PVdC, PCTFE laminate (ACLAR ^TM) or other PVC film. The material may be rigid or flexible. Optionally, the material may be any of PX7-PX30 produced by TEKNI-PLEX ^TM.

In another optional embodiment of the disclosed concept, the backing 112, the covering 114, and/or the active component 116 do not contain PVC or other chlorinated polymers.

In another optional embodiment of the disclosed concept, the backing 112, the covering 114, and/or the active component 116 do not contain fluorinated polymers.

In one embodiment, blister package 110 of the presently disclosed technology includes a sufficient amount and/or location of active material to preserve or extend the shelf life of product 117 therein without "contaminating" blister package 110 with too much non-recyclable material that would prevent or inhibit recycling of blister package 110 after the product is removed. Optionally, blister package 110 contains a mineral active material that has a mineral loading in a sufficiently low amount on a mass basis as part of the overall blister package or package so as not to interfere with blister package 110 being recycled.

In an exemplary embodiment, the backing 112 and/or the covering 114 are formed of, attached to, and/or include an active component or active polymer material. In such embodiments, for example, the backing 112 and/or the covering 114 can regulate the environment within the cavity, such as by absorbing moisture, scavenging oxygen, scavenging volatile compounds, or releasing gases that have an effect on the product 117 within the cavity. In addition, this configuration enables the backing 112 and/or the cover 114 to preserve or extend the shelf life of the product 117 stored within the cavity. In this optional embodiment, the active polymeric material is a recyclable material and/or a material having a mineral content of sufficiently low mass compared to the overall package that it does not "contaminate" the remainder of blister package 110 in a manner that otherwise prevents or inhibits recyclability.

In an exemplary embodiment, the backing 112 and/or the covering 114 are in the form of and/or are at least partially formed from a desiccant entrained polymer or an oxygen scavenger entrained polymer. This configuration reduces the need for additional components and enables blister package 110 to be recycled without sacrificing the holding capacity of any of the products 117.

Optionally, blister package 110 and/or portions thereof may be formed from one or more biodegradable materials.

The backing 112 and/or the covering 114 may be configured such that each of the at least one cavity may be opened to dispense the product 117, such as by pushing or pushing and pulling on only one of the backing 112 and/or the covering 114. In addition, each of the at least one cavity may optionally be subsequently sterilized, refilled, and then resealed.

In an optional embodiment, the backing 112 includes at least two different layers. For example, as shown in fig. 7A and 7B, the first, outer or lower layer 132 of the backing 112 may be formed entirely of a polymer, without any other material. The second, inner or upper layer 130 of the backing 112 may be formed from a material mixture containing a polymer and another component (e.g., a mineral component). In particular, the mixture may include an active within the polymer. Examples of actives include zeolites, molecular sieves, and silica gels.

In the two-layer embodiment described above, the second layer 130 of the backing 112 may be coextensive and/or extend with the entire length and/or width of the first layer 132, as shown in fig. 7A. Alternatively, the second layer 130 of the backing 112 may extend along only a portion of the length and/or width of the first layer 132 (see fig. 7B), such as only within the cavity of the respective blister 118. In this latter embodiment, when it is desired to remove the product 112 from the blister 118, the first layer 132 is more prone to rupture due to the concentration of pressure created by the second layer 130 of the backing 112 on portions of the backing 112 where the two layers of the first layer 132 do not overlap or at certain locations. The former embodiment increases the absorption or adsorption capacity compared to the latter embodiment, as additional actives are available or present.

Optionally, in embodiments in which the second layer 130 of the backing 112 extends along only a portion of the length and/or width of the first layer 132 (e.g., only within the cavity of the corresponding blister 118), the second layer 130 may be a relatively thin tablet. Optionally, the tablet may be formed from die cast. Alternatively, the tablet may be extruded, such as in the form of an extruded film. This thin tablet may be heat fused or otherwise attached to the first layer 130 only at locations or areas representing, coextensive with, or smaller than the respective blister 118.

In any version of the two-layer embodiment described above, the backing 112 may be formed, or a second, inner or upper layer of the backing 112 may be attached to a first, outer or lower layer of the backing 112 in any of a variety of ways. For example, the two layers may be thermally fused together, or the two layers may be co-extruded. Optionally, the first layer is formed entirely of polyolefin and the second layer is formed of a combination of polyolefin with zeolite or another active (e.g., a mineral active agent) distributed therein.

In further exemplary embodiments, the backing 112 and/or the cover 114 may include an embossed or structured surface. The structured surface increases the rigidity of blister package 110 without reducing the recyclable nature of the disclosed technology. The backing 112 and/or the covering 114 may be constructed as a multi-component assembly.

In the exemplary embodiment, discrete amounts of active polymer material are formed into active polymer film 116 that is optionally integrated into an inner surface of each of at least one cavity and/or at least a portion of shroud 114, as shown in FIG. 5. In an alternative embodiment, the active may be embedded or included within the backing 112 instead of the covering 114, or within the backing 112 and covering 114. When embedded in the backing 112, the active may be limited to a position just below the blister 118, which will reduce the force required to push the product 117 through the backing 112.

In any of the above embodiments, the amount of active polymer film 116 used has a negligible effect on the recyclable properties of backing 112 and cover 114, and thus does not "contaminate" blister package 110 during recycling. This enables otherwise non-recyclable active polymeric material 116 (which is not recyclable due to the significant mineral content of the material 116 relative to its own total mass) to be used with the recyclable backing 112 and covering 114, as the mineral content of the overall package 110 will be below the threshold requirement for recyclability of the package 110.

Alternatively, the active polymer film 116 is optionally a liner that is superimposed or otherwise attached to at least a portion or all of the inner surface of each of the at least one cavity, as shown in fig. 6. Thus, in one optional embodiment, the active polymer film 116 forms an envelope around the product 117 without compromising the recyclable nature of the backing 112 and the covering 114.

In another optional embodiment, the active polymer film 116 is only a layer attached to a portion of the polymer backing 112 or covering 114 within each cavity, as shown in fig. 4.

In one embodiment, the water vapor transmission rate of the backing 112 and the cover 114 at or at an ambient temperature of 38 degrees celsius and a relative humidity of 90% may be in the range of 0.07 grams per 100 square inches per day-58 grams per 100 square inches per day. In further embodiments, the oxygen transmission rate of the backing 112 and the cover 114 at or at an ambient temperature of 23 degrees celsius and a relative humidity of 50% may be in the range of 0.18 cubic centimeters per 100 square inches per day to 1.4 cubic centimeters per 100 square inches per day.

In one embodiment, at least one recyclable active member 116 is positioned within at least the base 122 of each blister 118. In one embodiment, the active member 116 may be in the form of a recyclable extruded film, such as, but not limited to, a desiccant entrained polymer film or an oxygen scavenger entrained polymer film.

The active member 116 may be thermally fused (without adhesive) to the first side 112a of the backing 112. A method of thermally fusing a film to a substrate is described in detail in U.S. patent No.8,142,603. It is contemplated that the active member 116 may be attached to the backing 112 by heat sealing (by thermal bonding) and without a separate adhesive material, whether by thermal fusion or otherwise. The active member 116 may be attached to the backing 112 or otherwise substantially limit its mobility within the cavity in other mechanical or chemical manners (e.g., by an adhesive or interference fit). In an optional embodiment, the active member 112 may move relative to the backing 112, although the active member 116 is not attached or fixed to the backing 112.

In one embodiment, the active polymeric material contains a desiccant. This would be in embodiments where moisture absorption or adsorption is required. However, the active polymeric material or active component may include one or more alternative active agents without the need for moisture absorption or moisture adsorption. For example, in another embodiment, the active polymeric material contains a material selected from the group consisting of activated carbon, carbon black, kevlar black (ketcham black), and diamond powder. In further embodiments, the active agent comprising one or more layers of the active member 116 contains materials such as absorbing microspheres, baTiO3, srTiO3, siO2, al2O3, znO, tiO2, mnO, cuO, sb O3, silica, calcium oxide, and ion exchange resins. In yet another embodiment, the absorbent-containing layer of active polymeric material contains two or more types of absorbent. The appropriate absorber is selected to achieve absorption of the desired vapor or gas for the desired end use (e.g., absorption of moisture, oxygen, carbon dioxide, nitrogen, or other undesired gases or vapors).

The active polymeric material (whether a desiccant, oxygen scavenger, release material or agent, or the like, or a combination thereof) is capable of acting on, interacting with, or reacting with the selected material (e.g., moisture or oxygen). Examples of such effects or interactions may include absorption and adsorption (i.e., typically, sorption) or release of the selected material.

The active polymeric material or active component may include an "active agent" in the base material. The active agent (i) may be immiscible with the base material (e.g., polymer, polyolefin, or other synthetic fiber) and will not melt when mixed and heated with the base material and the channeling agent, i.e., the melting point is higher than that of the base material or channeling agent, and/or (ii) acts on, interacts with, or reacts with the selected material. The term "active agent" may include, but is not limited to, a material that absorbs, adsorbs or releases a selected material. The active agent according to the techniques of this disclosure may be in the form of particles, such as minerals (e.g., molecular sieves or silica gels in the case of desiccants), but the techniques of this disclosure should not be considered as limited to particulate active agents only. For example, in some embodiments, the oxygen scavenging formulation may be made of a resin that acts as an active agent or component of an active agent.

As used herein, the term "base material" is a component (optionally a polymer or synthetic fiber) of entrained active material other than an active agent that provides a structure of entrained material.

As used herein, the term "base polymer" is a base material that is a polymer that optionally has a gas transmission rate of the selected material that is substantially lower, or substantially equal to the gas transmission rate of the channeling agent (when the channeling agent is used). For example, in embodiments where the material of choice is moisture and the active agent is a water-absorbing desiccant, this transmission will be water vapor transmission. The primary function of the base polymer is to provide a structure that entraps the polymer. Suitable base polymers may include thermoplastic polymers, for example, polyolefins such as polypropylene and polyethylene, polyisoprene, polybutadiene, polybutylene, polysiloxanes, polycarbonates, polyamides, ethylene-vinyl acetate copolymers, ethylene-methacrylate copolymers, poly (vinyl chloride), polystyrene, polyesters, polyanhydrides, polyacrylonitrile, polysulfones, polyacrylates, acrylic acid, polyurethane, polyacetal, or copolymers or mixtures thereof.

Referring to such comparison of the water vapor transmission rate of the base polymer and the channeling agent, in one embodiment, the water vapor transmission rate of the channeling agent is at least twice that of the base polymer. In another embodiment, the channel former has a water vapor transmission rate that is at least five times greater than the water vapor transmission rate of the base polymer. In another embodiment, the channel former has a water vapor transmission rate at least ten times greater than the water vapor transmission rate of the base polymer. In yet another embodiment, the channel former has a water vapor transmission rate that is at least twenty times greater than the water vapor transmission rate of the base polymer. In yet another embodiment, the channel former has a water vapor transmission rate that is at least fifty times greater than the water vapor transmission rate of the base polymer. In yet another embodiment, the channel former has a water vapor transmission rate that is at least one hundred times the water vapor transmission rate of the base polymer.

As used herein, the term "channeling agent (CHANNELING AGENT)" or "channeling agent (CHANNELING AGENTS)" is defined as a material (preferably a polymeric material) that is immiscible with the base polymer and has an affinity to transport gas phase species at a faster rate than the base polymer. Optionally, the 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 can transport the selected material through the entrained polymer at a faster rate than in the base polymer alone.

As used herein, the term "channel" or "interconnecting channel" is defined as a passageway formed by a channel forming agent that penetrates the base polymer and can interconnect with one another.

As used herein, the term "entrained polymer" is defined as a monolithic material formed from at least a base polymer together with an active agent and optionally also an entrained or bulk distributed channeling agent. The entrained polymer thus includes both two-phase and three-phase polymers. A "mineral loaded polymer" is a type of entrained polymer in which the active agent is in the form of a mineral, for example mineral particles, such as molecular sieves or silica gels. The term "entrainment material" is used herein to refer to a monolithic material comprising an active agent entrained in a base material, which may or may not be polymeric.

As used herein, the terms "integral", "integral structure" or "integral composition" are defined as a composition or material that is not composed of two or more discrete macroscopic layers or parts. Thus, "monolithic composition" does not include a multi-layer composite.

As used herein, the term "phase" is defined as a portion or component of an overall structure or composition that is uniformly distributed throughout to provide the structure or composition with its overall characteristics.

As used herein, the term "selected material" is defined as a material that functions by or interacts or reacts with an active agent and is capable of being transported through channels that entrain polymer. For example, in embodiments where a desiccant is used as the active agent, the material selected may be moisture or gas that may be absorbed by the desiccant. In embodiments where the release material is used as an active agent, the material of choice may be a medicament released by the release material, such as moisture, fragrance, or an antimicrobial agent (e.g., chlorine dioxide). In embodiments where the adsorbent material is used as the active agent, the material of choice may be some volatile organic compound, and the adsorbent material may be activated carbon, optionally tris (hydroxymethyl) aminomethane impregnated activated carbon.

As used herein, the term "three-phase" is defined as a monolithic composition or structure comprising three or more phases. An example of a three-phase composition according to the techniques of this disclosure would be an entrained polymer formed from a base polymer, an active agent, and a channeling agent. Optionally, the three-phase composition or structure may include additional phases, such as a colorant.

The entrained polymer may be a two-phase formulation (i.e., comprising the base polymer and the active agent without the channeling agent) or a three-phase formulation (i.e., comprising the base polymer, the active agent, and the channeling agent). Entrained polymers are described, for example, in U.S. patent nos. 5,911,937, 6,080,350, 6,124,006, 6,130,263, 6,194,079, 6,214,255, 6,486,231, 7,005,459, and U.S. patent publication nos. 2016/0039955, each of which are incorporated herein by reference in their entirety.

The entraining material or polymer includes a base material (e.g., a polymer) for providing a structure, optionally a channeling agent and an active agent. The channeling agent forms microscopic interconnecting channels by entraining the polymer. At least some of the active agent is contained in the channels such that the channels communicate between the active agent and the exterior of the entrained polymer through microscopic channel openings formed at the exterior surface of the entrained polymer. The active agent may be, for example, any of a variety of absorbent, adsorbent, or release materials, as described in further detail below. Although channeling agents are preferred, the present invention broadly encompasses entrainment materials that optionally do not include channeling agents, e.g., two-phase polymers.

In any embodiment, suitable channeling agents may include polyglycols such as polyethylene glycol (PEG), ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), glycerol polyamines, polyurethanes, and polycarboxylic acids including polyacrylic or polymethacrylic acid. Alternatively, the channeling agent may be, for example, a water insoluble polymer such as propylene oxide polymerization product-monobutyl ether produced by Clariant, inc., such as Polyglykol B01/240. In other embodiments, the channeling agent may be a propylene oxide polymer product monobutyl ether such as Polyglykol B01/20, manufactured by Craien, inc., a propylene oxide polymer product such as Polyglykol D01/240, manufactured by Craien, inc., ethylene vinyl acetate, nylon 6, nylon 66, or any combination of the foregoing.

Suitable active agents according to the techniques of the present disclosure include absorbing or adsorbing (typically, sorption) materials, such as dry compounds. If the active agent is a desiccant, any suitable desiccant for a given application may be used. In general, a physical adsorption desiccant is preferred for many applications. These physical adsorption desiccants may include molecular sieves, silica gels, clays, and starches. Alternatively, the desiccant may be a chemical compound that forms crystals containing water or a compound that reacts 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.

In certain optional embodiments, the oxygen scavenger is a metal-based oxygen scavenger. In certain embodiments, the oxygen scavenger comprises a zero valent metal. In certain embodiments, the oxygen scavenger comprises a zero valent metal in the form of particles or nanoparticles. In certain embodiments, the oxygen scavenger comprises an ionic metal optionally in the +1 or +2 oxidation state. In certain embodiments, the oxygen scavenger is a metal complex comprising an organic ligand.

In certain optional embodiments, the oxygen scavenger is a nonmetallic material. In certain embodiments, the nonmetal is an organic compound. In certain embodiments, the organic compound is a polyolefin. In certain embodiments, the organic compound is selected from the group consisting of phenol and hydroquinone. In certain embodiments, the organic compound comprises a porphyrin. In certain embodiments, the oxygen scavenger is a naturally occurring substance.

In some optional embodiments, the oxygen scavenger comprises a polyene. In some embodiments, the oxygen scavenger comprises a conjugated polyene. In certain embodiments, the oxygen scavenger is a radical scavenger. Some radical traps contain phenol moieties such as BHA, BHT, caffeic acid, ferulic acid and alpha-tocopherol. Some radical trapping agents are enols, such as ascorbic acid (vitamin C). Some radical traps contain weak X-H bonds (x= N, O, S), including but not limited to thiols, uric acid, and bilirubin. Some radical trapping agents contain polyene moieties such as beta-carotene and other carotenoids. Some radical traps contain conjugated or unconjugated dienes, such as alpha-terpinene and gamma-terpinene, respectively, as well as some unsaturated fats and fatty acids. In some optional embodiments, the oxygen scavenger comprises ascorbic acid or a salt, ester, lactone, or stereoisomer thereof.

Optionally, in any embodiment, to facilitate recyclability of blister package 110, the active of the active component or the active within the entire blister package 110 may be precisely or about 5% or optionally 4-6% or optionally 2-8% of the total mass of blister package 110. More specifically, the active component 116 may include molecular sieves, and the total mass of all molecular sieves of the blister package 110 may be 5% or less or 4-6% or 2-8% of the total mass of the blister package 110.

Optionally, to facilitate recyclability of blister package 110, blister package 110 may contain 5 grams or less, optionally 1 to 5 grams, optionally 2 to 5 grams, optionally 3 to 5 grams of zeolite.

Optionally, such low mineral loadings as described herein (wherein substantially the remainder of the blister package is made of the same polymeric material) used as part of the total mass of the blister package in the active assembly 116 prevents "contaminating" the blister package 110 for recycling purposes while still helping to retain the product 117 within the blister package 110. This is unique compared to prior art blister packages that are made from a combination of different types of materials (including foil, paper, plastic, etc.) and are therefore non-recyclable or challenging to recycle. In other words, the disclosed concept is unique, at least in that it relates to a blister package that is composed primarily of a polymer or the same polymer with a relatively small particulate (or other active) component that is a fraction of the total mass of the blister package. This allows blister packages according to the disclosed concepts to be recycled, whereas prior art blister packages with active components are either non-recyclable or challenging to recycle.

The techniques of this disclosure include methods of manufacturing, using, and/or recycling blister packages 110. One method includes (i) providing and/or forming a cover 114 having at least one blister 118 having one or more of the above-described features, (ii) placing a product 117 in each blister 118, (iii) attaching one or more spaced apart active components 116 to the backing 112, and (iii) attaching or bonding the backing 112 to the cover 114 to form a sealed package around the product 117 and active components 116.

As used herein, the term "providing" is defined broadly to include receiving, obtaining, placing, locating and/or using. When a user wishes to access the product 117, at least a portion of the backing 112 may be separated (e.g., pushed/pulled or merely pulled) or broken away from the cover 114 to expose the product 117.

Optionally, any film used with the techniques of the present disclosure may be formed in any of a variety of ways, such as by extrusion, blowing, or casting.

The following exemplary embodiments further describe optional aspects of the techniques of the present disclosure and are part of this detailed description. These exemplary embodiments are set forth in a format substantially similar to the claims, but are not technically equivalent to the claims of the present application. The following exemplary embodiments will be referred to each other in a subordinate relationship as "embodiments" rather than "claims".

A recyclable blister package, the blister package comprising:

A backing;

A cover attached to the backing, wherein the cover and the backing combine to form at least one cavity for containing at least one product therein, and

An active component located within or in fluid communication with the interior of the cavity, the active component comprising a base,

Wherein the cover, the backing, and the base of the active component are formed of the same material.

2A. The recyclable blister package as described in example 1A, wherein the material is recyclable.

The recyclable blister package according to examples 1A or 1B, wherein the material is a polyolefin.

The recyclable blister package according to any of embodiments 1A-3A, wherein the cover and the backing are formed from a transparent thermoformed film.

The recyclable blister package according to any of embodiments 1A-4A, wherein the backing and the cover are formed from a copolyester film.

The recyclable blister package of any of embodiments 1A-5A, wherein the backing and the cover have a water vapor transmission rate in the range of 0.07 grams per 100 square inches per day-58 grams per 100 square inches per day at an ambient temperature of 38 degrees celsius and a relative humidity of 90%.

The recyclable blister package of any of embodiments 1A-6A, wherein the backing and the cover have an oxygen transmission rate in the range of 0.18 cubic centimeters per 100 square inches per day to 1.4 cubic centimeters per 100 square inches per day at an ambient temperature of 23 degrees celsius and a relative humidity of 50 percent.

The recyclable blister package according to any of embodiments 1A-7A, wherein the backing and the cover are extruded films, the active component comprising at least one of a desiccant and an oxygen scavenger.

The recyclable blister package of any of embodiments 1A-8A, wherein the backing and the cover are formed from a thermoplastic polymer selected from the group consisting of polypropylene, polyethylene, polyisoprene, polybutadiene, polybutylene, polysiloxane, polycarbonate, polyamide, ethylene-vinyl acetate copolymer, ethylene-methacrylate copolymer, poly (vinyl chloride), polystyrene, polyester, polyanhydride, polyacrylonitrile, polysulfone, polyacrylate, acrylic acid, polyurethane, polyacetal, copolymers thereof, and mixtures thereof.

The recyclable blister package according to any of embodiments 1B-5B, wherein the active component is an active polymer film laminated to at least one of the backing and the cover or included in the cavity.

The method of embodiment 10A wherein the active polymer film is formed from a recyclable material.

A method of recycling a blister package without product in the blister package or after the product has been removed from the blister package, the method comprising:

Obtaining a blister package having a backing, a cover and a base of an active component formed of polyolefin, and

The blister pack is processed by a recycle sorting method.

The method of embodiment 1B, wherein the active component comprises a molecular sieve having a mass of 5% or less of the total mass of the blister package.

The method of embodiment 1B wherein the active component comprises a molecular sieve having a mass of 4-6% of the total mass of the blister package.

4B. the method of embodiment 1B, wherein the active component comprises a molecular sieve, the mass of the molecular sieve comprising 2-8% of the total mass of the blister package.

The method of any one of embodiments 1A-4B, wherein the recirculating sorting method is one of an air classifier, a sink-float classifier, and a sensor-based sorting.

a blister package having a backing, a cover and a base of an active component formed of synthetic fibers, and

The blister pack is processed by a recycle sorting method.

A method of forming at least a portion of a recyclable blister package, the method comprising:

One or more active components are thermally fused to the polymeric backing, each active component comprising a polymeric base.

The method of embodiment 1D, wherein the active component comprises an active component or a molecular sieve, the mass of the active component or the molecular sieve comprising 8% or less of the total mass of the blister package.

A method of recycling used blister packages, the method comprising:

Processing a plurality of used articles by a sorting process, the plurality of used articles including one or more blister packages, and

Wherein the polymeric components of the plurality of used articles are separated from the non-polymeric components of the plurality of used articles.

The method of embodiment 1F, wherein each of the one or more blister packages comprises a backing, a cover, and a base of an active component formed of a polymer.

The method of embodiment 1F or 2F, wherein the sorting process is one of air sorting, sink-float sorting, or sensor-based sorting.

The method of embodiment 1F or 2F, wherein the sorting process comprises generating a rising column of air to separate the plurality of used articles.

The method of embodiment 1F or 2F, wherein the sorting process comprises employing one or more magnets to separate the metal components of the plurality of used articles from the polymer components of the plurality of used articles.

The method of embodiment 1F or 2F, wherein the sorting process comprises dropping the plurality of used articles to separate the polyolefin component of the plurality of used articles from the non-polyolefin component of the plurality of used articles using gravity.

The method of embodiment 1F or 2F, wherein the sorting process comprises separating the polymeric component of the plurality of used articles from the non-polymeric component of the plurality of used articles using a water tank or water bath.

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

Claims

1. A recyclable blister package configured to hold at least one product that is a consumable product in the form of a pill, tablet, capsule, or powder, the blister package comprising:

A backing formed of a polyolefin;

A cover formed of a polyolefin, the cover attached to the backing, the cover and backing combining to form at least one cavity configured to receive the at least one product therein, and

A reactive component located within or in fluid communication with the interior of the cavity, the reactive component comprising a base formed of a polyolefin,

Wherein the blister package is configured to be recycled.

2. The recyclable blister packaging machine of claim 1, wherein the active component comprises a molecular sieve, the total mass of all the molecular sieves of the blister package accounting for 8% or less of the total mass of the blister package, optionally accounting for 2-8% of the total mass of the blister package, optionally accounting for 4-6% of the total mass of the blister package, optionally accounting for 5% or less of the total mass of the blister package.

3. The recyclable blister package of claim 1, wherein the active component is in the form of a film attached to the backing.

4. A recyclable blister package according to claim 3, wherein the film is attached to the backing by heat sealing and without a separate adhesive material.

5. The recyclable blister package of claim 4, wherein the active component is a desiccant entrained film.

6. The recyclable blister package according to any preceding claim, wherein the active component comprises zeolite.

7. The recyclable blister package according to any preceding claim, wherein the base of the active component is the same polyolefin as the backing.

8. The recyclable blister package of claim 6, wherein the cover is formed from the same polyolefin as the backing.

9. The recyclable blister package according to any preceding claim, wherein the backing and the cover have a water vapor transmission rate in the range of 0.07 grams per 100 square inches per day to 58 grams per 100 square inches per day at an ambient temperature of 38 degrees celsius and a relative humidity of 90%.

10. The recyclable blister package according to any preceding claim, wherein the backing and the cover have an oxygen transmission rate in the range of 0.18 cubic centimeters per 100 square inches per day to 1.4 cubic centimeters per 100 square inches per day at ambient temperature of 23 degrees celsius and 50 percent relative humidity.

11. A method of manufacturing a recyclable blister package, the method comprising:

attaching a plurality of active components to a backing formed of polyolefin, the active components being attached to the backing in a spaced apart arrangement, each active component comprising a base formed of polyolefin, the active components comprising molecular sieves, the total mass of all of the molecular sieves of the blister package accounting for 8% or less of the total mass of the blister package;

Placing a product within each blister of a cover comprising a plurality of spaced apart blisters, the cover being formed of a polyolefin, and

A combined active component and backing is attached to the cover, the cover comprising a plurality of spaced apart blisters, each active component being located within one of the blisters.

12. The method of claim 11, wherein the sealed cavity encloses each product and active component pairing.

13. The method of claim 11 or 12, wherein the longitudinal axis of each blister extends parallel to the edge of the backing.

14. The method of any one of claims 11-13, wherein the cover and the backing are formed from a transparent thermoformed film.

15. The method of any one of claims 11 to 14, wherein the backing and the cover have a water vapor transmission rate in the range of 0.07 grams per 100 square inches per day-58 grams per 100 square inches per day at an ambient temperature of 38 degrees celsius and a relative humidity of 90%.

16. The method of any one of claims 11 to 15, wherein the backing and the cover have an oxygen transmission rate in the range of 0.18 cubic centimeters per 100 square inches per day to 1.4 cubic centimeters per 100 square inches per day at an ambient temperature of 23 degrees celsius and a relative humidity of 50 percent.

17. The method of any one of claims 11 to 16, wherein each active component comprises at least one of a zeolite, a desiccant, and an oxygen scavenger.

18. The method of any one of claims 11 to 17, wherein the base of each active component is the same polyolefin as the backing.

19. The method of claim 18, wherein the cover is formed from the same polyolefin as the backing.

20. The method of claim 11, wherein the step of attaching the plurality of active components to the backing comprises thermally fusing each active component to the backing.

21. A recyclable blister package comprising a backing, a cover, and a base of at least one active component formed of polyolefin, the at least one active component configured to absorb or adsorb moisture within the blister package, each active component comprising a molecular sieve, the total mass of all of the molecular sieves of the blister package comprising 8% or less of the total mass of the blister package.

22. The recyclable blister package of claim 21, wherein each active component is in the form of a film attached to the backing.

23. The recyclable blister package of claim 22, wherein the film is thermally fused to the backing.

24. The recyclable blister package of claim 23, wherein each active component is a desiccant entrained film.

25. The recyclable blister package according to any of claims 21 to 24, wherein each active component contains zeolite.

26. The recyclable blister package according to any of claims 21 to 25, wherein the base of the active component is the same polyolefin as the backing.

27. The recyclable blister package of claim 26, wherein the cover is formed from the same olefin polymer or polyolefin as the backing.

28. A method of recycling the recyclable blister package of any of claims 21-27, the method comprising recycling the recyclable blister package by a sorting process comprising one of air sorting, sink-float sorting, and sensor-based sorting.

29. The method of claim 28, wherein the sorting process comprises generating a rising column of air to separate a plurality of used items.

30. The method of claim 28, wherein the sorting process comprises employing one or more magnets to separate a metal component of a plurality of used articles from a polymer component of the plurality of used articles.

31. The method of claim 28, wherein the sorting process comprises dropping a plurality of used articles to separate polyolefin components of the plurality of used articles from non-polyolefin components of the plurality of used articles using gravity.

32. The method of claim 28, wherein the sorting process comprises separating a polymer component of a plurality of used articles from a non-polymer component of the plurality of used articles using a water tank or water bath.