U.S. patent application number 12/740400 was filed with the patent office on 2011-07-07 for systems and methods for child-resistant and senior friendly packaging.
Invention is credited to Gary Paul Cotton, Juliet Gail Mcquillan, Mani Sundararajan.
Application Number | 20110162330 12/740400 |
Document ID | / |
Family ID | 44223879 |
Filed Date | 2011-07-07 |
United States Patent
Application |
20110162330 |
Kind Code |
A1 |
Cotton; Gary Paul ; et
al. |
July 7, 2011 |
SYSTEMS AND METHODS FOR CHILD-RESISTANT AND SENIOR FRIENDLY
PACKAGING
Abstract
Systems and methods related 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.
Inventors: |
Cotton; Gary Paul; (Newark,
DE) ; Mcquillan; Juliet Gail; (Wilmington, DE)
; Sundararajan; Mani; (Wilmington, DE) |
Family ID: |
44223879 |
Appl. No.: |
12/740400 |
Filed: |
October 28, 2008 |
PCT Filed: |
October 28, 2008 |
PCT NO: |
PCT/US2008/081411 |
371 Date: |
March 1, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11932376 |
Oct 31, 2007 |
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12740400 |
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Current U.S.
Class: |
53/476 ;
53/389.1 |
Current CPC
Class: |
B65D 2575/3227 20130101;
B65D 75/327 20130101; B65D 83/0463 20130101 |
Class at
Publication: |
53/476 ;
53/389.1 |
International
Class: |
B65B 7/00 20060101
B65B007/00; B65B 41/00 20060101 B65B041/00 |
Claims
1-25. (canceled)
26. A system for packaging at least one solid dosage form, the
system comprising: a blister pack for housing the form, the blister
pack including a receptacle layer having at least one collapsible
receptacle and a rupturable layer extending over the at least one
receptacle; a first rigid layer disposed on the receptacle layer
and having a perimeter region including a zone of reduced strength;
and a second rigid layer disposed on the rupturable layer.
27. The system of claim 26 wherein the second rigid layer has an
opening feature aligned with the receptacle.
28. The system of claim 27 wherein the opening feature includes a
wedge.
29. The system of claim 28 wherein: the opening feature has a
substantially central region and a local perimeter about the
central region, the local perimeter corresponding to a single
receptacle; the wedge comprises: an apex proximate the central
region; and a base proximate the local perimeter.
30. The system of claim 29 wherein the wedge is supported, at the
base, by the second rigid layer, as a cantilever.
31. The system of claim 30 wherein the wedge is one of four
supported wedges.
32. The system of claim 30 wherein the wedge is one of six
supported wedges.
33. The system of claim 26 wherein the receptacle layer includes a
plurality of receptacles.
34. The system of claim 26 further comprising a barrier layer
disposed on the second rigid layer, the barrier layer extending
over the collapsible receptacle.
35. The system of claim 34 wherein: the barrier layer comprises an
inner barrier layer that is disposed on the second rigid layer and
extends over the collapsible receptacle; and an outer barrier layer
that is disposed over the inner barrier layer and extends over the
collapsible receptacle.
36. The system of claim 35 wherein at least one of the inner
barrier layer and outer barrier layer includes perforations near an
opening feature in the second rigid layer.
37. The system of claim 36 wherein the perforations include: a
first perforated segment; a second perforated segment parallel the
first perforated segment; and a third perforated segment running
from the first perforated segment to the second segment; such that
a portion of the barrier layer is made deflectable by the motion of
an item being ejected from the receptacle.
38. The system of claim 37 further comprising, adjacent the third
perforated segment, a space for a finger nail to penetrate under a
portion of the barrier layer to rupture the barrier layer along the
third perforated segment.
39. The system of claim 26 wherein the rupturable layer extends
continuously across all receptacles.
40. A method for manufacturing a solid dosage form package, the
method comprising: providing a receptacle layer having at least one
collapsible receptacle; introducing a solid dosage form into the
receptacle; attaching to the receptacle layer a rupturable layer
that extends over the receptacle, thereby enclosing the solid
dosage form; disposing on the rupturable layer a first rigid layer
having at least one opening feature that is substantially aligned
with the receptacle; and disposing on the first rigid layer at
least one barrier layer; wherein the at least one barrier layer
includes at least one perforation pattern disposed in a region
corresponding to the opening feature.
41. The method of claim 40 further comprising disposing a top rigid
layer on the receptacle layer, the top rigid layer having an
opening to accommodate the receptacle.
42. The method of claim 41 wherein the top rigid layer includes a
zone of reduced strength extending along a portion of a perimeter
region.
43. The method of claim 41 wherein the top rigid layer is attached
to the first rigid layer.
44. The method of claim 43 wherein the top rigid layer is hinged to
the first rigid layer.
45. A system for packaging a plurality of pills, the system
comprising: a blister pack housing that includes a receptacle layer
having a plurality of receptacles and a rupturable layer extending
over the plurality of receptacles; a casing including: 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, the
second rigid section including a plurality of opening features
aligned with the plurality of receptacles; a third rigid section
hingedly attached to the second rigid section such that the third
rigid section is configured to fold on top of first rigid section
to enclose the blister pack; and at least one barrier layer
disposed on the second rigid section and extending over the
plurality of opening features; wherein the barrier layer includes a
zone of reduced strength corresponding to the opening features.
Description
BACKGROUND OF THE INVENTION
[0001] 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.
[0002] 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.
[0003] 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.
SUMMARY
[0004] 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.
[0005] 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.
[0006] 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.
[0007] 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.
[0008] 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.
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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.
[0014] 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.
[0015] 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.
[0016] 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.
[0017] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The following FIGS. depict illustrative embodiments of the
invention in which like reference numerals refer to like
elements.
[0019] FIG. 1 shows an illustrative packaging system in accordance
with the principles of the invention.
[0020] FIG. 2 shows a cross-sectional view of one exemplary pill
housing of the packaging system of FIG. 1 in accordance with the
principles of the invention.
[0021] FIGS. 3A-3D show an illustrative process for accessing the
contents of an exemplary packaging system in accordance with the
principles of the invention.
[0022] FIGS. 4A-4D show an illustrative process for accessing the
contents of an exemplary packaging system in accordance with the
principles of the invention.
[0023] FIGS. 5A-5C and 6A-6C show an illustrative process for
accessing the contents of an exemplary packaging system in
accordance with the principles of the invention.
[0024] FIGS. 7A-7D show an illustrative process for accessing the
contents of an exemplary packaging system in accordance with the
principles of the invention.
[0025] FIGS. 8A-8D show an illustrative process for accessing the
contents of an exemplary packaging system in accordance with the
principles of the invention.
[0026] FIGS. 9A and 9B show an exemplary perimeter region of the
packaging system of FIG. 1, in accordance with the principles of
the invention.
[0027] FIG. 10 shows an illustrative unassembled packaging system,
in accordance with the principles of the invention.
[0028] FIGS. 11A-11C show an illustrative process for assembling
the packaging system in accordance with the principles of the
invention.
[0029] FIGS. 12-14 show illustrative unassembled packaging systems,
in accordance with the principles of the invention.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0030] 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.
[0031] The illustrative apparatuses, systems and methods are
described below in the following order: First, an illustrative
wallet-sized packaging system (See packaging system 100, FIG. 1)
having a blister pack sandwiched between a plurality of protective
layers is described. Second, various embodiments describing
different types of protective layers are described along with
corresponding mechanisms for accessing and extracting a pill.
Third, a protection scheme provided along the perimeter region of
the packaging system is described to prevent a child from stripping
the protective layers away from the underlying blister pack.
Fourth, systems and processes for assembling and manufacturing the
packaging system are presented.
[0032] FIG. 1 depicts packaging system 100 configured to house a
plurality of pills 124. The packaging system 100 includes panel
composite 102 and panels 104, 106 and 108. Panel composite 102
includes blister pack 112 sandwiched between first rigid layer 110
and second rigid layer 114. Blister pack 112 includes a plurality
of collapsible receptacles 122 sized and shaped to house one or
more pills 124 therein. First rigid layer 110 is disposed on top of
blister pack 112 and includes a plurality of openings 126 to
accommodate collapsible receptacle 122 of the blister pack 112. The
first rigid layer 110 also includes zone of reduced strength 128
running along perimeter region 130. As will be described with
reference to FIGS. 9A and 9B, zone of reduced strength 128 may
include perforations that allow perimeter region 130 to separate
from the rest of panel composite 102 thereby protecting underlying
blister pack 112.
[0033] 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 FIGS. 2-8D,
in some embodiments, second rigid layer 114 may include tabs and
cuts that control access to pills 124 in blister pack 112. The tabs
and cuts may provide protection against children attempting to
access pills 124, but may still allow seniors to access
medication.
[0034] 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.
[0035] 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.
[0036] In some embodiments, as described with reference to FIG.
11C, panel 104 may be folded over panel composite 102 thereby
covering collapsible receptacles 122 of each of the blister
housings 120. Panels 106 and 108 may then wrap around panel
composite 102 to reduce the overall dimension of packaging system
100 to about the length and width of a single wallet-sized panel
102, 104, 106 and 108.
[0037] 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.
[0038] FIG. 2 depicts a cross-sectional view of an unassembled
exemplary blister housing 120 in packaging system 100 of FIG. 1.
Blister housing 120 includes blister pack 112. Blister pack 112
includes receptacle layer 202 attached to rupturable layer 206.
Receptacle layer 202 further includes collapsible receptacle 122
that defines cavity 204 that may be sized and shaped to house pill
124. Once pill 124 is placed in cavity 204, rupturable layer 206 is
disposed on a surface of receptacle layer 202 such that pill 124 is
sealed in cavity 204.
[0039] 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.
[0040] 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.
[0041] 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.
[0042] 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.
[0043] 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 FIG. 2 may be one of many such
blister housings 120 distributed throughout packaging system 100.
Depending on the location of blister housing 120, the depicted
cross section in FIG. 2 may or may not include perimeter region 130
of panel composite 102. In the illustrated embodiment, blister
housing 120 (See FIG. 1) includes perimeter region 130 defined by
zone of reduced strength 128. In some embodiments, first rigid
layer 110 may include adhesives in one or more regions other than
perimeter region 130. In some embodiments, first rigid layer 110
may include a different types of adhesives for different regions.
As an example, perimeter region 130 may include a weaker adhesive
than the rest of first rigid layer 110. As another example,
perimeter region 130 may include a temporary adhesive while one or
more other regions of first rigid layer 110 may include a permanent
adhesive. Similarly, receptacle layer 202 may include one or more
regions having different types of adhesives that correspond with
perimeter region 130 of first rigid layer 110.
[0044] 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.
[0045] 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 FIGS. 3A-8D.
[0046] 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 FIGS.
7A-8D.
[0047] Turning to FIGS. 3A-8D, various mechanisms for accessing and
extracting pill 124 are described. In particular, FIGS. 3A-3D
depict a process for accessing and extracting the contents of
blister housing 300 of an exemplary packaging system. Blister
housing 300 may be similar to blister housing 120. Blister housing
300 includes blister pack 312 that may be sandwiched between first
rigid layer 310 and second rigid layer 314. Blister pack 312
includes receptacle layer 332 disposed on rupturable layer 336.
Receptacle layer 332 includes collapsible receptacle 322 that
defines cavity 334 that is sized and shaped to house the pill 124.
Blister housing 300 further includes barrier layer 316.
[0048] 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 FIG. 3D, orifice 350 may have a circular shape. The
diameter of orifice 350 may be selected to substantially match the
width of pill 124. Generally, any dimension of orifice 350 (having
any shape) may be selected to match any dimension of pill 124
without departing from the scope of the invention. In housing 300,
since pill 124 and orifice 350 are of substantially similar
dimensions, pill 124 may be pushed through second rigid layer 314
only when oriented and positioned to align with orifice 350.
Therefore, such a mechanism may impede but not prevent the
extraction of pill 124.
[0049] Barrier layer 316 includes tab 356 that are defined by
perforation lines 352 on bottom surface 360 (FIG. 3D) of blister
housing 300. In the depicted embodiment, perforation lines 352 may
form the circumference of a disk shaped region such that tab 356
forms the disc shaped region therein. A portion of the disk shaped
region may be removed to form slot 354. Slot 354 allows a user to
grip tab 356 and thereby aid in its removal.
[0050] During operation, as depicted in FIG. 3B, a user may grip
and pull tab 356 by inserting a fingernail in slot 354 to release
tab 356. The user may then pull tab 356 along perforation lines 352
to reveal the underlying orifice 350. As shown in FIGS. 3C and 3D,
to remove pill 124 from blister housing 300, the user may first
align pill 124 with a region near orifice 350 and applies pressure
to collapsible receptacle 322 to cause it to collapse 322' and
force pill 124 out. If aligned in proximity to orifice 350, pill
124 may be forced out by rupturing rupturable layer 336 and sliding
pill 124 out through orifice 350 and blister housing 300.
[0051] In some embodiments, as depicted in FIGS. 4A-4D, second
rigid layer 414 may be modified to include semi-circular opening
450. In such embodiments, opening 450 may be sized and shaped to
align with a portion of collapsible receptacle 322. A user
attempting to extract pill 124 would have to move pill 124 by
tilting entire blister housing 400 such that pill 124 lies above
opening 450. The user may then extract the pill by collapsing
collapsible receptacle 322 to force pill 124 out through rupturable
layer 336, second rigid layer 414 via opening 450, and barrier
layer 316.
[0052] 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. FIGS. 5A-5D depict cross-sectional
views of such an embodiment and FIGS. 6A-6C depict a bottom
perspective view of such an embodiment. In particular, second rigid
layer 514 includes set of cuts 550 that are configured as a
cross-hair or intersecting cut lines to define four triangular
leaves 572a, 572b, 572c, and 572d (generally, "leaves 572"). Other
embodiments may include a different number of leaves, such as 2, 3,
5, 6, 7, 8 or any other suitable number of leaves.
[0053] During operation, tab 356 (FIGS. 3A-3D), may be peeled away
along perforation lines 352 to reveal the underlying second rigid
layer 514 as shown in FIG. 6B. A user may apply pressure to
collapsible receptacle 322 to force pill 124 through rupturable
layer 336 and second rigid layer 514 such that leaves 572 bend away
to allow pill 124 to pass through.
[0054] 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.
[0055] As noted earlier, the blister housing may also include label
layer 118 which may be configured to serve as an additional
protective layer. FIGS. 7A-7D and 8A-8D depict two types of blister
housings 700 and 800 having a label layer 118, and the
corresponding processes for accessing and extracting pill 124. In
particular, FIGS. 7A-7D depict blister housing 700 that requires a
user to peel away two layers prior to forcing pill 124 from blister
pack 112. Blister housing 700 includes blister pack 112 sandwiched
between first rigid layer 110 and second rigid layer 114. Second
rigid layer 114 includes opening 750 that is aligned with
collapsible receptacle 122 of blister pack 112. Barrier layer 116
and label layer 118 are disposed on blister pack 112 adjacent
second rigid layer 114. Both barrier layer 116 and label layer 118
include one or more perforation lines that define peelable tabs 756
and 758. Barrier layer 116 includes tab 758 and label layer 118
includes tab 756. In some embodiments, the perforation lines
include two parallel lines of perforation and a terminating line of
perforation connecting the two parallel lines, such that tabs 756
and 758 may be removed by lifting the tabs at the terminating
perforation and peeling the tabs between the parallel perforation
lines.
[0056] 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.
[0057] 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.
[0058] FIGS. 8A-8D depict blister housing 800 that requires a user
to peel away outer label layer 118 and then push to puncture a
portion of inner barrier layer 816, prior to forcing pill 124 from
blister pack 112. Inner barrier layer 816 may include one or more
lines 852, such as clean cuts, perforations or partial cuts. During
operation, a user peels away tab 756 of label layer 118 to reveal
the underlying barrier layer 816. The user may then apply pressure
to a region on or near lines 852 to puncture a portion of barrier
layer 816 thereby gaining access to rupturable layer 206. The user
may remove pill 124 by applying pressure to the collapsible
receptacle 122 to force pill through rupturable layer 206 and each
of second rigid layer 114, barrier layer 116 and label layer
118.
[0059] Turning now to FIGS. 9A and 9B, a protection scheme provided
along the perimeter region of the first rigid layer is described to
prevent a child from stripping the protective layers away from the
underlying blister pack. In particular, FIGS. 9A and 9B depict
exemplary corner region 900 of packaging system 100 of FIG. 1.
Corner region 900 of panel composite 102 (FIG. 1) includes zone of
reduced strength 128 (e.g., a line of perforated cuts) the runs
along an edge to define perimeter region 130. In some embodiments,
zone of reduced strength 128 includes various types of
perforations, clean cuts or partial cuts.
[0060] As depicted in FIG. 9A, the protective layers may be
separated from blister pack 112 by releasing the first rigid layer
at corner 902. However, corner 902 is located in perimeter region
130 defined by zone of reduced strength 128. Therefore, when corner
902 is pulled, instead of separating or delaminating the entirety
of one or more protective layers, only perimeter region 130 is
removed along zone of reduced strength 128, as shown in FIG.
9B.
[0061] 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
FIGS. 10, 11A-11C. In some embodiments, wallet-shaped packaging
system 100 of FIG. 1 is manufactured by combining one or more rigid
panels with the blister pack as shown in FIG. 10. In particular,
FIG. 10 depicts panel sheet 1000 that may be assembled together
with a blister pack to yield a packaging system having blister
housings similar to blister housing 300 of FIG. 3. Panel sheet 1000
includes a plurality of panels including panels corresponding to
first rigid layer 310, second rigid layer 314, barrier layer 316
and panels 104, 106 and 108. As depicted, panels 104, 106, 108,
barrier layer 316 and first rigid layer 310 are arranged in series
and separated by hinge lines 132. Panel sheet 1000 is configured to
accommodate a blister pack having a plurality of blister housings,
each configured to house at least one pill.
[0062] 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.
[0063] 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.
[0064] 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.
[0065] As depicted in FIGS. 11A and 11B, second rigid layer 314 is
folded over along an edge onto barrier layer 316. In some
embodiments, one or more layers of adhesive on at least one of
barrier layer 316 and second rigid layer 314 attaches second rigid
layer 314 to barrier layer 316. Second rigid layer 314 may be
aligned with barrier layer 316 such that orifices 350 are aligned
with tabs 356.
[0066] 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,
[0067] 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 FIGS. 11A and
11B may be sized and shaped to fit into a carry-bag. As depicted in
FIG. 11C, panels 104, 106 and 108 may wrap around panel composite
102 having blister pack 112.
[0068] 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.
[0069] 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 FIGS. 4A-4D, 5A-6C, 7A-7D and
8A-8D. In particular, FIG. 12 depicts panel sheet 1200 that may be
assembled together with a blister pack to yield a packaging system
having blister housings similar to blister housing 500 of FIG.
5A-6C. Panel sheet 1200 includes a second rigid layer 514 having
one or more cuts 550 that bend away when a pill is being pushed out
from blister pack 112. In some embodiments, second rigid layer 514
may include lamina that are glued together. In those embodiments, a
cold glue may be used to glue the lamina to each other.
[0070] FIG. 13 depicts a panel sheet 1300 having a second rigid
layer 1314 comprising a plurality of tabs 1356 defined by cut lines
1352. In some embodiments, tabs 1356 may be peeled out prior to
pushing the pill from the blister pack 112. In other embodiments,
tabs 1356 may be forced out when the pill is pushed through. In
such embodiments, the force applied by the user to push the pill is
transferred to second rigid layer 1314 to separate tab 1356 along
cut lines 1352.
[0071] In some embodiments, the panel sheets have one or more
layers that provide reinforcement and rigidity to the packaging
system. FIG. 14 depicts panel sheet 1400 having layer 1480 attached
to barrier layer 316. Layer 1480 includes a plurality of openings
1482 that may be aligned with the collapsible receptacles in
blister pack 112. During manufacture, layer 1480 may be folded over
onto second rigid layer 1314 prior to attaching blister pack
112.
[0072] 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.
* * * * *