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

Abstract

A recyclable blister package configured to sealingly enclose at least one active member 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 adheres 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

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 366,872, filed on June 23, 2022, and entitled “RECYCLABLE BLISTER PACK AND METHODS OF MAKING AND USING SAME,” the disclosure of which is hereby incorporated by reference in its entirety. Technical Field

[0003] The technology of the present disclosure relates to packaging for sensitive or consumable products. More specifically, in one embodiment, the technology of the present disclosure relates to blister packaging for products such as one or more pills, tablets, capsules, etc. In an optional embodiment, the technology of the present disclosure relates to a package having a recyclable cover bonded to a recyclable backing, both of which can optionally be formed from thermoformed materials. Background Art

[0004] Blister packages are commonly used to package oral solid dose medications, vitamins, probiotics, pills, tablets, capsules, etc. Prior art packaging (such as U.S. Pat. No. 8,142,603, which is hereby incorporated by reference) includes a thermoformed cover to contain 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 packs are also manufactured by companies that provide unfilled or empty blister packs for third party filling.

[0005] It is known to place a desiccant or scavenger extruded film in a blister package. The size and shape of the desiccant or scavenger extruded film may be referred to as the footprint of the film, and in the prior art is at least slightly smaller than the opening of the blister containing the product. Such blister packages with desiccant films are disclosed in the following documents: 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.

[0006] FIG1 shows a prior art blister package 10 having four blisters 18. FIG2 shows a cross-sectional view along line 2-2 of FIG1 and shows the thermoplastic member 14 forming one of the blisters 18 adhered to the foil backing 12. The width W PA (See FIG. 2 ) Adhered to the foil backing 12 is an extruded desiccant film 16 that is smaller than the width of a single blister 18 .

[0007] Various technologies for recycling plastics are known. For example, the recycling sorting of plastics is usually based on the sink-float method, in which particles less than 1g / cm3 are separated from particles greater than 1gm / cm3 based on whether the particles float or settle in the water body. Recyclers also use initial sorting by near-infrared spectroscopy to distinguish different types of polymers, such as polystyrene (PS), polyethylene (PE), polypropylene (PP), etc. Sorting by weight (e.g., with an air gun), with sensors and / or with magnets can also be used. In "Managing Plastic Waste—Sorting, Recycling, Disposal, and Product Redesign", Jean-Paul Lange, "ACS Sustainable Chem. Eng. 2021, 9, 15722-15738, the document is hereby incorporated by reference.

[0008] 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 including active components further complicate or prevent recycling due to the different materials used to form the active components. These different materials make recycling the blister packages of the prior art difficult and time-consuming. In fact, companies are collecting used blister packages, but there is no place to recycle them. Summary of the invention

[0009] It would be desirable to provide a recyclable blister package that can preserve and / or protect the product therein and / or act as a desiccant or oxygen scavenger.

[0010] The above and other needs are addressed by the technology of the present disclosure, which, in one aspect, includes a blister package having a recyclable backing and a cover. The cover can be attached or bonded to the backing to form a sealed unit package for containing a product. The cover can have at least one blister cavity with an open side. The backing can have one side bonded to the cover.

[0011] 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.

[0012] Optionally, the blister package may further include an active component, optionally in the form of an extruded film. In an optional embodiment, the extruded film may be adhered to the side of the backing that is bonded 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 a deoxidizer, or another active technology.

[0013] The use of active components (such as desiccants) within blister packages can further complicate and / or prevent the blister packages from being recycled. Specifically, the active components may undesirably contaminate the blister packages, making them incapable of being recycled. For example, in some locations or using at least some known recycling methods, an empty (i.e., no product) blister package may require 90% or more olefin polymers and / or not have polyvinyl chloride (PVC) that can be recycled. Optionally, the active component of the disclosed technology can have 5 grams of zeolite, which will allow the blister package to be 90% or more olefin polymers or polyolefins.

[0014] In another aspect, the technology of the present disclosure may include a method of preparing 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 a backing to form a sealed unit package. The longitudinal axis of each blister may extend parallel to an edge of the backing.

[0015] In an optional embodiment, the method may include attaching or bonding an extruded active polymer film to an inner surface of the cavity.

[0016] Optionally, in any embodiment, the product contained in the blisters of the blister pack may include a pill, optionally a medication, a nutritional supplement, or a probiotic, for example.

[0017] In an optional embodiment, the foil backing of a conventional blister package is replaced by 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 an active component 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 heat fused to the polymer backing. The molecular sieve component of the active component may account for exactly or approximately 5% or optionally 4-6% or optionally 2-8% of the total mass of the blister card or package, thereby allowing a recycling step.

[0018] Optionally, the blister pack is of the push-only type, meaning that the product can be or is designed to be removed from the blister pack by pushing the product through the pack.

[0019] Optionally, the blister package is of the peel-push type, meaning that the product can be or is designed to be removed from the blister package by peeling off a portion of the package to expose the product and / or pushing the product through the package. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The foregoing summary of the technology of the present disclosure and the following detailed description will be better understood when read in conjunction with the accompanying drawings, wherein like reference numerals represent like elements throughout. For the purpose of illustrating the technology of the present disclosure, various illustrative embodiments are shown in the accompanying drawings. However, it should be understood that the technology of the present disclosure is not limited to the precise arrangements and instruments shown. In the drawings:

[0021] FIG1 is a top plan view of a blister package of the prior art;

[0022] FIG2 is a cross-sectional view taken along line 2-2 of FIG1 showing an extruded film having a width less than the width of a single blister;

[0023] Figure 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 along line 2-2 of FIG. 1 and showing a backing and cover enclosed around a product;

[0024] Figure 4 is a cross-sectional view of one embodiment of the presently disclosed technology from the same or similar perspective as that taken along line 2-2 of FIG. 1 according to one embodiment of the presently disclosed technology, and showing an active polymer film laminated on and / or attached to a backing;

[0025] Figure 5 is a cross-sectional view of one embodiment of the disclosed technology from the same or similar perspective as that taken along line 2-2 of FIG. 1 according to one embodiment of the disclosed technology, and shows an active polymer film laminated within a cavity formed by a backing and a cover;

[0026] Figure 6 is a cross-sectional view of one embodiment of the presently disclosed technology from the same or similar perspective as that taken along line 2-2 of FIG. 1 of one embodiment of the presently disclosed technology and showing an active polymer film integrated into the walls of a cavity formed by a backing and a cover;

[0027] Fig. 7A is an enlarged cross-sectional view of a backing according to one embodiment of the presently disclosed technology; and

[0028] Figure 7B is an enlarged cross-sectional view of a backing according to another embodiment of the disclosed technology. DETAILED DESCRIPTION

[0029] Although systems, devices and methods are described herein by way of examples and embodiments, those skilled in the art recognize that the technology disclosed herein is not limited to the described embodiments or drawings. On the contrary, the technology currently disclosed covers all modifications, equivalents and alternatives that fall within the spirit and scope of the appended claims. The features of any one embodiment disclosed herein may be omitted or incorporated into another embodiment.

[0030] Any headings used herein are for organizational purposes only and are not intended to limit the scope of the specification or claims. As used herein, the word "may" is used in a permissive sense (i.e., meaning possible), rather than a mandatory sense (i.e., meaning must). Unless specifically set forth herein, the terms "a", "an", and "the" are not limited to one element but are instead read with the meaning "at least one". For reference and clarity only, a first direction D1 and a second direction D2 are shown in certain drawings, and the first direction and the second direction are not part of the structure of the technology disclosed herein. The terms include the words mentioned above, their derivatives, and words of similar meanings.

[0031] Referring now in detail to the drawings, wherein like reference numerals refer to like parts throughout, Figure 3 -7 illustrates an embodiment of a blister pack or package of the presently disclosed technology, generally designated 110. Optionally, a recyclable blister pack 110 may be used to provide a sustainable form of packaging that may also preserve or extend the shelf life of the product therein.

[0032] In an exemplary embodiment, the blister package 110 includes a backing 112 and a cover 114 attached to the 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 the 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 can have any of a variety of shapes and / or configurations, as disclosed in WO 2020 / 146556.

[0033] The backing 112 can have a first side or surface 112a and an opposing second side or surface 112b. Optionally, at least the first side 112a of the backing 112 can be flat or planar. In one embodiment, each of the first side 112a and the second side 112b of the backing 112 is flat or planar, such that each of the first side 112a and the second side 112b extends in at least slightly spaced apart planes.

[0034] The cover 114 can 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 cover 114 are flat or planar. At least a portion of the second side 114b of the cover 114 can 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 cover 114 can be the same or different from the thickness of the backing 112 (as measured in the direction of D2). In one embodiment, the cover 114 is made or formed of a formable mesh. In one embodiment, the formable mesh is made of a thermoplastic material such as a thermoforming film.

[0035] 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 blisters 118 that are spaced apart. Figure 3-6 The illustrated embodiment shows that the cover 114 has four spaced-apart identical blisters 118, similar to the configuration shown in FIG. 1. However, the cover 114 can have more or fewer blisters, and one or more of the blisters can have a size and / or shape different from another blister in the blisters 118 of the blister package 110, depending on specific needs. Optionally, each blister 118 can have at least a partial egg shape or a spherical shape. Alternatively, in one embodiment, each blister 118 can have at least a partial platform 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 in or by each blister 118.

[0036] In an optional embodiment, each blister 118 can define a longitudinal or long axis extending parallel to the backing 112 and at least one outer edge of the blister pack 110. Optionally, and more specifically, the longitudinal axis of each blister 118 can extend parallel to two opposing sides of the blister pack 110 and perpendicular to the top and bottom sides of the blister back, such as Figure 3 However, the arrangement or orientation of the blisters 118 within the blister pack 110 is not limited to the arrangement or orientation shown and described herein, as other configurations are possible depending on the particular needs.

[0037] Blister package 110 can enclose, preserve and protect one or more products 117 (in Figure 3 Schematically shown in FIG), such as oral solid dosage medications, vitamins or other nutritional supplements, foods, small consumer products, probiotics, etc. Such products can be in the form of pills, for example, tablets, capsules, etc. In an optional embodiment, the product 117 can be in the form of a powder.

[0038] In an optional embodiment, the cover 114 and the backing 112 are formed of the same material and / or a recyclable material, which enables the blister package 110 to be easily reused or repurposed, and / or processed 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 derives from the use of a single material to form both the backing 112 and the cover 114. In such embodiments, the blister 118 of the present embodiment is distinguished from the blister 18 of the prior art in that the blister 118 of the disclosed technology includes a backing 112 and a cover 114 formed of a single recyclable material rather than different materials and / or two or more materials.

[0039] The technology of the present disclosure can be used with any of a variety of recycling technologies, including mechanical recycling technologies, chemical recycling technologies, or combinations thereof. For example, plastic waste is typically sorted through a series of sorting steps. The sorting steps may include sorting by size, sorting manually or by sieves, such as removing foreign materials (e.g., metal and glass), sorting by type of plastic material, and / or sizing and granulating into plastic recyclables.

[0040] Certain materials can be removed or separated from other materials by using gravity in an air flow (e.g., air classifier) ​​or water flow (e.g., sink and float). An air classifier is a machine that uses air flow and the relationship between inertial forces and / or gravity and resistance to separate particles of different densities. For example, a strong air flow (e.g., a rising air column) can be directed or generated from the bottom of the machine toward or toward the top, while the material flow descends from the top of the machine toward the bottom in the opposite direction. Optionally, the plastic flakes and / or particles can then be passed through a zigzag channel, which can assist in the separation process. At the same time, lighter materials (such as labels and dust) can be blown upward and collected in a filter bag. Thus, high-quality plastics without labels and dust can be collected.

[0041] Metals in particular can be removed by exploiting their magnetic properties, for example by magnetic attraction for ferrous metals or by induced magnetic repulsion for non-ferrous metals.

[0042] Gravity can also be used to sort some plastics among themselves, such as separating polyolefins (e.g., density of about 0.9 g / mL) from PET or PVC (e.g., density of about 1.4 g / mL). This can be done, for example, in a machine or vertical axis. Gravity sorting can be refined with the help of electrostatic or magnetic fields.

[0043] A sink-float separation tank can use water or another liquid to separate mixed materials (e.g., plastics) based on density. For example, the density of water is 1 g / cm 3As debris or items (e.g., plastics) enter or are introduced into the separation tank, anything denser than the liquid (e.g., water) will sink. The heavy stream collects 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.

[0044] Some sensor-based sorting machines are made by TOMRA in Germany. TM Recycling companies make them. For example, visual spectrometer sensors can be used to remove certain materials from the waste stream. Eddy current is another type of separator or sensor that can be used.

[0045] Perhaps most commonly, various 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 plastic to be sorted, and using an actuator or air jet to sort the plastic. 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).

[0046] New sorting technologies are constantly being developed. For example, trace-based sorting uses fluorescent pigments incorporated into the plastic substrate or sleeve. These pigments are only visible under UV light at the sorting plant. Another technology uses digital watermarks, such as codes integrated into the packaging design and can be detected by cameras on high-speed sorting lines. The watermark can carry or reveal information about the product and its packaging. Yet another technology is robotic sorting, which applies artificial intelligence to help cameras and robotic arms sort plastics from conveyor belts. Each of the recycling technologies discussed above can be used with the technology of the present disclosure.

[0047] In one embodiment, the backing and cover are formed of a polymer, such as a polyolefin or another synthetic fiber. As used herein, the term "polyolefin" refers to a polymer that can be considered a product from an olefin (e.g., ethylene, CH2=CH2) that has reacted to form a polymer (e.g., polyethylene). Certain polyolefins can be considered the polymerization product of an alpha-olefin (CH2=CHR). Certain polyolefins have the formula (CH2-CHR) n The polyolefin need not be obtained by such a reaction. Examples of the polyolefin include polyethylene (PE), polypropylene (PP), polystyrene, polyacrylamide, polyvinyl alcohol, and polyvinyl acetate.

[0048] The backing 112 and the cover 114 may optionally be formed of an optionally transparent thermoformed film, rather than a conventional plastic cover and foil backing, such as that disclosed in U.S. Pat. No. 8,142,603. Alternatively, the backing 112 and the cover 114 may be formed of a copolyester or copolyester film. Examples of copolyesters include PETG (polyethylene terephthalate), PCTG (polyethylene terephthalate modified with cyclohexylene dimethylene glycol), and PCTA (1,4-cyclohexylene dimethylene terephthalate-co-isophthalate).

[0049] Embodiments of the disclosed technology can be distinguished from the technology disclosed in U.S. Pat. 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. Pat. No. 8,142,603, column 4, lines 23-37, discloses heating the lidding foil sufficiently to make the polymer sealing layer pliable and adhere the active film to the softened polymer layer of the lidding film. Despite the thin polymer sealing layer, the backing of U.S. Pat. No. 8,142,603 ​​itself includes a foil that would destroy or make recycling of the blister package difficult or impossible.

[0050] In an optional embodiment of the disclosed concept, the backing 112, cover 114, and / or active component 116 are manufactured by TEKNI-PLEX of Holland, Ohio. TM The material used can be a coated PVC / PVdC, PCTFE laminate (ACLAR TM ) or other PVC film. The material can be rigid or flexible. Optionally, the material can be made of TEKNI-PLEX TM Any of the PX7-PX30 produced.

[0051] In another optional embodiment of the disclosed concept, the backing 112, cover 114, and / or active component 116 are free of PVC or other chlorinated polymers.

[0052] In another optional embodiment of the disclosed concept, the backing 112, cover 114, and / or active component 116 do not contain fluorinated polymers.

[0053] In one embodiment, the blister pack 110 of the presently disclosed technology includes active materials in sufficient amounts and / or specific locations to preserve or extend the shelf life of the product 117 therein without "contaminating" the blister pack 110 with so much non-recyclable material that would prevent or prohibit recycling of the blister pack 110 after the product has been removed. Optionally, the blister pack 110 contains a mineral active material that has a sufficiently low amount of mineral loading on a mass basis as a portion of the entire blister pack or package so as not to prevent the blister pack 110 from being recycled.

[0054] In an exemplary embodiment, the backing 112 and / or the cover 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 cover 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 polymer material is a recyclable material and / or a material with a sufficiently low mass mineral content compared to the entire package so that it does not "contaminate" the remainder of the blister package 110 in a manner that otherwise prevents or prohibits recyclability.

[0055] In an exemplary embodiment, the backing 112 and / or the cover 114 are in the form of and / or are at least partially formed of a desiccant-entrained polymer or a desiccant-entrained polymer. This configuration reduces the need for additional components and enables the blister package 110 to be recycled without sacrificing any product 117 preservation ability.

[0056] Optionally, blister pack 110 and / or portions thereof may be formed from one or more biodegradable materials.

[0057] The backing 112 and / or the cover 114 can be configured such that each of the at least one cavity can be opened to dispense the product 117, such as by simply pushing or pushing and pulling on one of the backing 112 and / or the cover 114. Additionally, each of the at least one cavity can optionally be subsequently sterilized, refilled, and then resealed.

[0058] In an optional embodiment, the backing 112 includes at least two different layers. Fig. 7A and 7BAs shown, the first, outer or lower layer 132 of the backing 112 can be formed entirely of a polymer without any other material. The second, inner or upper layer 130 of the backing 112 can be formed of a material mixture containing a polymer and another component (such as a mineral component). Specifically, this mixture can include an active substance in the polymer. Examples of active substances include zeolites, molecular sieves, and silica gel.

[0059] In the above two-layer embodiment, the second layer 130 of the backing 112 can be coextensive and / or extend across the entire length and / or width of the first layer 132, such as 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 Figure 7B ), such as extending only within the cavity of the corresponding 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 easily ruptured due to the pressure concentration created by the second layer 130 of the backing 112 on the portion of the first layer 132 of the backing 112 at locations or certain locations where the two layers do not overlap. Compared to the latter embodiment, the former embodiment has increased absorption or adsorption capacity because additional actives are available or present.

[0060] Optionally, in embodiments where the second layer 130 of the backing 112 extends only along 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 can be a relatively thin tablet. Optionally, the tablet can be formed by a die casting. Alternatively, the tablet can be extruded, such as in the form of an extruded film. This thin tablet can be heat fused or otherwise attached to the first layer 130 only at a position or region that represents, is coextensive with, or is smaller than the corresponding blister 118.

[0061] In any version of the two-layer embodiment described above, backing 112 can be formed, or the second, inner or upper layer of backing 112 can be attached to the first, outer or lower layer of backing 112 in any of a variety of ways. For example, the two layers can be heat fused together, or the two layers can be coextruded. Optionally, the first layer is formed entirely of a polyolefin, and the second layer is formed of a combination of a polyolefin with a zeolite or another active (e.g., a mineral active) distributed therein.

[0062] 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 the blister package 110 without reducing the recyclable properties of the disclosed technology. The backing 112 and / or the cover 114 may be constructed as a multi-component assembly.

[0063] In an exemplary embodiment, discrete amounts of active polymer material are formed into active polymer film 116, which is optionally integrated into the interior surface of each of at least one cavity and / or at least a portion of cover 114, such as Figure 5 In an alternative embodiment, the active may be embedded or included in the backing 112 instead of the cover 114, or in both the backing 112 and the cover 114. When embedded in the backing 112, the active may be confined to a location just below the blister 118, which will reduce the force required to push the product 117 through the backing 112.

[0064] In any of the above embodiments, the amount of active polymer film 116 used has a negligible effect on the recyclability characteristics of the backing 112 and cover 114, and therefore does not "contaminate" the blister package 110 during the recycling process. This enables otherwise non-recyclable active polymer materials 116 (non-recyclable due to the significant mineral content of the material 116 relative to its own total mass) to be used with recyclable backings 112 and covers 114, as the mineral content of the entire package 110 will be below the threshold requirement for the recyclability of the package 110.

[0065] 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, such as Figure 6 Thus, in an optional embodiment, the active polymer film 116 forms an envelope around the product 117 without compromising the recyclable properties of the backing 112 and the cover 114 .

[0066] In another optional embodiment, the active polymer film 116 is only a layer attached to a portion of the polymer backing 112 or cover 114 within each cavity, such as Figure 4 shown.

[0067] 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% can be in the range of 0.07 g / 100 square inches / day to .58 g / 100 square inches / day. In another embodiment, 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% can be in the range of 0.18 cubic centimeters / 100 square inches / day to 1.4 cubic centimeters / 100 square inches / day.

[0068] In one embodiment, at least one recyclable active component 116 is positioned within at least the base 122 of each blister 118. In one embodiment, the active component 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.

[0069] The active member 116 can be heat fused (without adhesive) to the first side 112a of the backing 112. Methods for heat fusing a film to a substrate are described in detail in U.S. Pat. No. 8,142,603. It is contemplated that the active member 116 can be attached to the backing 112 by heat sealing (by thermal bonding) and without a separate adhesive material, whether by heat fusion or otherwise. The active member 116 can be attached to the backing 112 by other mechanical or chemical means (such as by adhesive or interference fit) or otherwise substantially restrict its mobility within the cavity. In an optional embodiment, although the active member 116 is not attached or fixed to the backing 112, the active member 112 can move relative to the backing 112.

[0070] In one embodiment, the active polymer material contains a desiccant. This will be in an embodiment where moisture absorption or adsorption is required. However, in the case where moisture absorption or moisture adsorption is not required, the active polymer material or active component may include one or more alternative active agents. For example, in another embodiment, the active polymer material contains a material selected from the group consisting of: activated carbon, carbon black, ketcham black and diamond powder. In other embodiments, the active agent comprising one or more layers of active component 116 contains materials such as absorbing microspheres, BaTiO3, SrTiO3, SiO2, Al2O3, ZnO, TiO2, MnO, CuO, Sb2O3, silicon dioxide, calcium oxide and ion exchange resins. In another embodiment, the absorbent-containing layer of the active polymer material contains two or more types of absorbents. Select a suitable absorbent to achieve absorption of the desired vapor or gas for the desired end use (e.g., absorbing moisture, oxygen, carbon dioxide, nitrogen or other unwanted gases or vapors).

[0071] Active polymer materials (whether desiccants, oxygen scavengers, release materials or agents, etc. or combinations thereof) are capable of acting on a selected material (e.g., moisture or oxygen), interacting with a selected material, or reacting with a selected material. Examples of such actions or interactions may include absorption and adsorption (i.e., typically sorption) or release of a selected material.

[0072] Active polymer materials or active components may include "active agents" in base materials. The active agent (i) may be immiscible with the base material (e.g., polymers, polyolefins or other synthetic fibers) and will not melt when mixed with the base material and the channel former and heated, i.e., the melting point is higher than the melting point of the base material or the channel former, and / or (ii) acts on the selected material, interacts with the selected material, or reacts with the selected material. The term "active agent" may include, but is not limited to, materials that absorb, adsorb, or release the selected material. The active agent according to the technology of the present disclosure may be in the form of particles, such as minerals (e.g., in the case of desiccants, molecular sieves or silica gel), but the technology of the present disclosure should not be considered to be limited to particulate active agents. For example, in some embodiments, the deoxygenation formulation may be made of a resin that acts as an active agent or a component of an active agent.

[0073] As used herein, the term "base material" is a component (optionally a polymer or synthetic fiber) that entraps the active material, other than the active agent, and that provides the structure for the entrapped material.

[0074] As used herein, the term "base polymer" is a base material that is a polymer that optionally has a gas permeability of a selected material that is substantially lower than, lower than, or substantially equal to the gas permeability of the channeling agent (when a channeling agent is used). For example, in embodiments where the selected material is moisture and the active agent is a water-absorbing desiccant, this permeability will be a water vapor permeability. The primary function of the base polymer is to provide a structure for entraining the polymer. Suitable base polymers may include thermoplastic polymers, for example, polyolefins such as polypropylene and 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 and polyacetal, or copolymers or mixtures thereof.

[0075] With reference to such comparison of the water vapor permeability of the base polymer and the channeling agent, in one embodiment, the water vapor permeability of the channeling agent is at least twice the water vapor permeability of the base polymer. In another embodiment, the water vapor permeability of the channeling agent is at least five times the water vapor permeability of the base polymer. In another embodiment, the water vapor permeability of the channeling agent is at least ten times the water vapor permeability of the base polymer. In yet another embodiment, the water vapor permeability of the channeling agent is at least twenty times the water vapor permeability of the base polymer. In yet another embodiment, the water vapor permeability of the channeling agent is at least fifty times the water vapor permeability of the base polymer. In yet another embodiment, the water vapor permeability of the channeling agent is at least one hundred times the water vapor permeability of the base polymer.

[0076] As used herein, the term "channeling agent" or "channeling agents" is defined as a material (preferably a polymeric material) that is immiscible with a base polymer and has an affinity for transporting gas-phase materials 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 are capable of transporting a selected material through the entrained polymer at a faster rate than in the base polymer alone.

[0077] As used herein, the term "channel" or "interconnected channels" is defined as passages formed by a channel former that penetrate a base polymer and may be interconnected with each other.

[0078] 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 monolithically distributed channeling agent. Entrained polymers therefore include two-phase polymers and three-phase polymers. "Mineral-loaded polymers" are a type of entrained polymer in which the active agent is in the form of a mineral, such as mineral particles, such as molecular sieves or silica gel. The term "entrained material" is used herein to indicate a monolithic material comprising an active agent entrained in a base material, wherein the base material may or may not be polymeric.

[0079] As used herein, the term "monolithic", "monolithic structure" or "monolithic composition" is defined as a composition or material that is not composed of two or more discrete macroscopic layers or parts. Thus, a "monolithic composition" does not include multi-layer composites.

[0080] As used herein, the term "phase" is defined as a part or component that is uniformly distributed throughout a bulk structure or composition so as to provide the structure or composition with its bulk properties.

[0081] As used herein, the term "selected material" is defined as a material that acts through an active agent or interacts or reacts with an active agent and can be transmitted through the channel of the entrained polymer. For example, in embodiments where a desiccant is used as the active agent, the selected material can be moisture or gas that can be absorbed by the desiccant. In embodiments where a release material is used as the active agent, the selected material can be an agent released by the release material, such as moisture, fragrance, or antimicrobial agent (e.g., chlorine dioxide). In embodiments where an adsorbent material is used as the active agent, the selected material can be certain volatile organic compounds, and the adsorbent material can be activated carbon, optionally activated carbon impregnated with tris(hydroxymethyl)aminomethane.

[0082] As used herein, the term "three-phase" is defined as an overall composition or structure comprising three or more phases. An example of a three-phase composition according to the technology disclosed herein would be an entrained polymer formed by 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.

[0083] The entrained polymer can be a two-phase formulation (i.e., comprising a base polymer and an active agent without a channeling agent) or a three-phase formulation (i.e., comprising a base polymer, an active agent, and a channeling agent). Entrained polymers are described, for example, in U.S. Pat. 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 No. 2016 / 0039955, each of which is incorporated herein by reference in its entirety.

[0084] Entrained material or polymer comprises the base material (for example, polymer) for providing structure, optionally channel former and activating agent.Channel former forms microscopic interconnected channels by entrained polymer.At least some activating agents in the activating agent are contained in these channels, and the channel is communicated between the activating agent and the outside of the entrained polymer by the microscopic channel opening formed at the outer surface of the entrained polymer.Activating agent can be any of the multiple absorption, adsorption or release materials described in further detail below.Although channel former is preferred, the present invention widely comprises the entrained material that optionally does not comprise channel former, for example, two-phase polymer.

[0085] In any embodiment, suitable channel forming agents may include polyglycols, such as polyethylene glycol (PEG), ethylene-vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), glycerol polyamines, polyurethanes, and polycarboxylic acids containing polyacrylic acid or polymethacrylic acid. Alternatively, the channel forming agent may be, for example, a water-insoluble polymer, such as propylene oxide polymerized product-monobutyl ether produced by Clariant, such as Polyglykol B01 / 240. In other embodiments, the channel forming agent may be propylene oxide polymerized product monobutyl ether such as Polyglykol B01 / 20 produced by Clariant, propylene oxide polymerized product such as Polyglykol D01 / 240 produced by Clariant, ethylene vinyl acetate, nylon 6, nylon 66, or any combination of the foregoing.

[0086] Suitable active agents according to the technology disclosed herein include absorbing or adsorbing (usually sorbing) materials, such as desiccating compounds. If the active agent is a desiccant, any suitable desiccant for a given application can be used. Generally, for many applications, physical adsorption desiccants are preferred. These physical adsorption desiccants can include molecular sieves, silica gel, clay and starch. Alternatively, the desiccant can be a chemical compound that forms crystals containing water or a compound that reacts with water to form a new compound.

[0087] Optionally, in any embodiment, the active agent can be an oxygen scavenger, for example, an oxygen scavenging resin formulation.

[0088] 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 a +1 or +2 oxidation state. In certain embodiments, the oxygen scavenger is a metal complex comprising an organic ligand.

[0089] In certain optional embodiments, the oxygen scavenger is a non-metal. In certain embodiments, the non-metal is an organic compound. In certain embodiments, the organic compound is a polyolefin. In certain embodiments, the organic compound is selected from phenol and hydroquinone. In certain embodiments, the organic compound includes porphyrin. In certain embodiments, the oxygen scavenger is a naturally occurring substance.

[0090] In some optional embodiments, the oxygen scavenger includes a polyene. In some embodiments, the oxygen scavenger includes a conjugated polyene. In certain embodiments, the oxygen scavenger is a free radical trap. Some free radical traps contain a phenolic moiety, such as BHA, BHT, caffeic acid, ferulic acid, and α-tocopherol. Some free radical traps are enols, such as ascorbic acid (vitamin C). Some free radical traps contain weak XH bonds (X=N, O, S), including but not limited to thiols, uric acid, and bilirubin. Some free radical traps contain a polyene moiety, such as β-carotene and other carotenoids. Some free radical traps contain conjugated or unconjugated dienes, such as α-terpinene and γ-terpinene, respectively, and some unsaturated fats and fatty acids. In some optional embodiments, the oxygen scavenger includes ascorbic acid or its salts, esters, lactones, or stereoisomers.

[0091] Optionally, in any embodiment, to facilitate recyclability of the blister package 110, the active of the active component or the active within the entire blister package 110 may be exactly or approximately 5% or optionally 4-6% or optionally 2-8% of the total mass of the blister package 110. More specifically, the active component 116 may include a molecular sieve, 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.

[0092] Optionally, to facilitate recyclability of the blister pack 110, the blister pack 110 may contain 5 grams or less, optionally 1 to 5 grams, optionally 2 to 5 grams, optionally 3 to 5 grams of zeolite.

[0093] Optionally, such low mineral loading as described herein, used as a portion of the total mass of the blister pack in the active component 116 (where substantially the remainder of the blister pack is made of the same polymer material) prevents "contamination" of the blister pack 110 for recycling purposes, while still helping to preserve the product 117 within the blister pack 110. This is unique compared to prior art blister packs, which are made of 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 involves a blister pack composed primarily of a polymer or the same polymer with a relatively small particulate (or other active) component that accounts for a portion of the total mass of the blister pack. This allows blister packs according to the disclosed concept to be recycled, whereas prior art blister packs with active components are non-recyclable or challenging to recycle.

[0094] The technology of the present disclosure includes methods of making, using and / or recycling blister packages 110. One of the methods 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 a backing 112, and (iii) attaching or bonding the backing 112 to the cover 114 to form a sealed package around the product 117 and the active component 116.

[0095] As used herein, the term "providing" is broadly defined to include receiving, obtaining, placing, positioning, locating and / or using. When a user wishes to obtain product 117, at least a portion of backing 112 can be separated (e.g., pushed / pulled or just pulled) or broken from cover 114 to expose product 117.

[0096] Optionally, any film used with the technology of the present disclosure may be formed in any of a variety of ways, such as by extrusion, blowing, or casting.

[0097] The following exemplary embodiments further describe optional aspects of the technology 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 they are not technically claims of the present application. The following exemplary embodiments refer to each other as "embodiments" rather than "claims" in a subordinate relationship.

[0098] 1A. A recyclable blister package, comprising:

[0099] Backing;

[0100] a cover attached to the backing, wherein the cover and the backing in combination form at least one cavity for receiving at least one product therein; and

[0101] an active component, the active component being located inside the cavity or being in fluid communication with the interior of the cavity, the active component comprising a base,

[0102] Wherein the cover, the backing and the base of the active component are formed from the same material.

[0103] 2A. The recyclable blister package of Embodiment 1A, wherein the material is recyclable.

[0104] 3A. The recyclable blister package of Embodiment 1A or 1B, wherein the material is a polyolefin.

[0105] 4A. The recyclable blister package of any of Embodiments 1A to 3A, wherein the cover and the backing are formed from a transparent thermoformed film.

[0106] 5A. The recyclable blister package of any of Embodiments 1A to 4A, wherein the backing and the cover are formed from a copolyester film.

[0107] 6A. The recyclable blister package of any of Embodiments 1A to 5A, wherein the backing and the cover have a water vapor transmission rate in the range of 0.07 g / 100 sq. in. / day to .58 g / 100 sq. in. / day at an ambient temperature of 38 degrees Celsius and 90% relative humidity.

[0108] 7A. The recyclable blister package of any of Embodiments 1A to 6A, wherein the backing and the cover have an oxygen transmission rate in the range of 0.18 cc / 100 sq in / day to 1.4 cc / 100 sq in / day at an ambient temperature of 23 degrees Celsius and a relative humidity of 50%.

[0109] 8A. The recyclable blister package of any of Embodiments 1A to 7A, wherein the backing and the cover are extruded films and the active component comprises at least one of a desiccant and an oxygen scavenger.

[0110] 9A. A recyclable blister package according to any of Embodiments 1A to 8A, wherein the backing and the cover are formed of 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, polyurethane, polyacetal, their copolymers and their mixtures.

[0111] 10A. The recyclable blister package of any of Embodiments 1B to 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.

[0112] 11A. The method of Embodiment 10A, wherein the active polymer membrane is formed from a recyclable material.

[0113] 1B. A method of recycling a blister pack without a product in the blister pack or after the product has been removed from the blister pack, the method comprising:

[0114] obtaining a blister package having a backing, a cover and a base of an active component formed of a polyolefin; and

[0115] Blister packs are processed through a recycling sorting method.

[0116] 2B. The method of embodiment 1B, wherein the active component comprises a molecular sieve, the mass of the molecular sieve comprising 5% or less of the total mass of the blister package.

[0117] 3B. The method of embodiment 1B, wherein the active component comprises a molecular sieve, the mass of the molecular sieve accounting for 4-6% of the total mass of the blister package.

[0118] 4B. The method of embodiment 1B, wherein the active component comprises a molecular sieve, the mass of the molecular sieve accounting for 2-8% of the total mass of the blister package.

[0119] 5B. The method of any one of Embodiments 1A to 4B, wherein the recirculation sorting method is one of an air classifier, a sink-float sorter, and a sensor-based sorting.

[0120] 1C. A method of recycling a blister pack without a product in the blister pack or after the product has been removed from the blister pack, the method comprising:

[0121] obtaining a blister package having a backing, a cover and a base of active components formed of synthetic fibers; and

[0122] Blister packs are processed through a recycling sorting method.

[0123] 1D. A method of forming at least a portion of a recyclable blister package, the method comprising:

[0124] One or more active components are thermally fused to a polymer backing, each active component comprising a polymer base.

[0125] 2D. The method of embodiment 1D, wherein the active component comprises an active component or a molecular sieve, and the mass of the active component or the molecular sieve accounts for 8% or less of the total mass of the blister package.

[0126] 1F. A method for recycling used blister packages, the method comprising:

[0127] processing a plurality of used articles through a sorting process, the plurality of used articles comprising one or more blister packages; and

[0128] Wherein polymeric components of the plurality of used articles are separated from non-polymeric components of the plurality of used articles.

[0129] 2F. 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 from a polymer.

[0130] 3F. The method of embodiment 1F or 2F, wherein the sorting process is one of air sorting, sink-float sorting, or sensor-based sorting.

[0131] 4F. The method of embodiment 1F or 2F, wherein the sorting process includes generating a rising air column to separate the plurality of used items.

[0132] 5F. The method of Embodiment 1F or 2F, wherein the sorting process comprises using one or more magnets to separate metal components of the plurality of used items from polymer components of the plurality of used items.

[0133] 6F. The method of Embodiment 1F or 2F, wherein the sorting process includes dropping the plurality of used articles to utilize gravity to separate polyolefin components of the plurality of used articles from non-polyolefin components of the plurality of used articles.

[0134] 7F. The method of Embodiment 1F or 2F, wherein the sorting process comprises using a water tank or a water bath to separate the polymer components of the plurality of used items from the non-polymer components of the plurality of used items.

[0135] Although the technology of the present disclosure has been described in detail with reference to its specific examples, it is apparent to those skilled in the art that various changes and modifications may be made therein without departing from its spirit and scope. Therefore, it should be understood that the technology of the present disclosure is not limited to the specific embodiments disclosed, but is intended to cover modifications within the spirit and scope of the technology of the present disclosure as defined by the appended claims.

Claims

1. A recyclable blister package configured to contain at least one product, the at least one product being 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 being attached to the backing, the cover and the backing in combination forming at least one cavity configured to receive the at least one product therein; and an active component located inside the cavity or in fluid communication with the interior of the cavity, the active component comprising a base formed of a polyolefin, Wherein the blister pack is configured to be recycled.

2. The recyclable blister packaging machine according to claim 1, wherein the active component comprises a molecular sieve, and the total mass of all the molecular sieves in the blister package accounts for 8% or less of the total mass of the blister package, optionally 2-8% of the total mass of the blister package, optionally 4-6% of the total mass of the blister package, and optionally 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. The recyclable blister package of 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 film entrained with a desiccant.

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

7. A 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 of any preceding claim, wherein the backing and the cover have a water vapor transmission rate in the range of 0.07 g / 100 sq. in. / day to .58 g / 100 sq. in. / day at an ambient temperature of 38 degrees Celsius and 90% relative humidity.

10. The recyclable blister package of any preceding claim, wherein the backing and the cover have an oxygen transmission rate in the range of 0.18 cc / 100 sq in / day to 1.4 cc / 100 sq in / day at an ambient temperature of 23 degrees Celsius and a relative humidity of 50%.

11. A method of making a recyclable blister package, the method comprising: attaching a plurality of active components to a backing formed of a polyolefin, the active components being attached to the backing in a spaced-apart arrangement, each active component comprising a base formed of a polyolefin, the active components comprising a molecular sieve, the total mass of all of the molecular sieves of the blister package being 8% or less of the total mass of the blister package; placing a product within each blister of a cover comprising a plurality of said blisters arranged in a spaced relationship, said cover being formed of a polyolefin; and The combined active component and backing are attached to the cover, which includes a plurality of spaced-apart blisters, with each active component being located within one of the blisters.

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

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

14. A method according to any one of claims 11 to 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 g / 100 sq. in. / day - .58 g / 100 sq. in. / day at an ambient temperature of 38 degrees Celsius and 90% relative humidity.

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 cc / 100 sq in / day to 1.4 cc / 100 sq in / day at an ambient temperature of 23 degrees Celsius and a relative humidity of 50%.

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. A method according to 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 attaching the plurality of active components to the backing comprises heat 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 a polyolefin, wherein the at least one active component is configured to absorb or adsorb moisture within the blister package, each active component comprising a molecular sieve, and the total mass of all the molecular sieves in the blister package accounts for 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 heat fused to the backing.

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

25. A recyclable blister pack according to any one of claims 21 to 24, wherein each active component contains zeolite.

26. The recyclable blister package of any one 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 packs according to any one of claims 21 to 27, the method comprising recycling the recyclable blister packs through a sorting process, the sorting process comprising one of air sorting, sink-float sorting and sensor-based sorting.

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

30. The method of claim 28, wherein the sorting process includes using one or more magnets to separate metal components of the plurality of used articles from polymer components of the plurality of used articles.

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

32. The method of claim 28, wherein the sorting process includes using a water tank or bath to separate polymeric components of the plurality of used articles from non-polymeric components of the plurality of used articles.

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