Recyclable blister package

Abstract

A recyclable blister package is configured to sealingly enclose at least one multi-layer component and a product, and 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] This application claims priority to U.S. Provisional Application No. 63 / 586,565, titled “RECYCLABLE BLISTER PACK WITH MULTILAYER COMPONENT, AND METHOD OF MAKING AND USING SAME,” and filed September 29, 2023, U.S. Provisional Application No. 63 / 601,575, titled “RECYCLABLE BLISTER PACK WITH MULTILAYER COMPONENT, AND METHOD OF MAKING AND USING SAME,” and filed November 21, 2023, and U.S. Provisional Application No. 63 / 677,647, titled “RECYCLABLE BLISTER PACK WITH MULTILAYER COMPONENT, AND METHOD OF MAKING AND USING SAME.” Each of the above applications is hereby incorporated by reference in its entirety. TECHNICAL FIELD

[0002] The technology of the present disclosure relates to packaging for sensitive or consumable products. More particularly, in optional aspects, the technology of the present disclosure relates to blister packaging for products such as one or more pills, tablets, capsules, and the like. Optionally, the technology of the present disclosure relates to packaging having a recyclable cover adhered to a recyclable backing. BACKGROUND

[0003] Blister packaging is commonly used to package oral solid dosage medications, vitamins, probiotics, pills, tablets, capsules, and the like. Prior art packaging, such as U.S. Patent No. 8,142,603, contains a thermoformed cover that houses the product and a foil backing attached to an open side thereof to enclose the product. Blister packaging 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 parties to fill.

[0004] It is known to place a desiccant or scavenger extruded film in a blister pack. The size and shape of the desiccant or scavenger extruded film can be referred to as the footprint of the film and is at least slightly smaller than the opening of the blister containing the product in the prior art. Such blister packs with desiccant films are disclosed in U.S. Patent No. 6,279,736 (Hekal), International Publication No. WO 2020 / 146556 (Hollinger), and International Publication No. WO 2022 / 236313 (Hollinger), each of which is incorporated by reference herein in its entirety.

[0005] Figure 1 shows a prior art blister pack 10 having four blisters 18. Figure 2 shows a cross-sectional view along line 2-2 of Figure 1 and shows a thermoplastic member 14 forming one of the blisters 18 adhered to the foil backing 12. The width W PA (see Figure 2) An extruded desiccant film 16 less than the width of a single blister 18 is adhered to the foil backing 12.

[0006] Various techniques for recycling plastics are known. For example, recycling sorting of plastics is typically based on a sink-float method, where particles less than 1 g / cm3 are separated from particles greater than 1 gm / cm3 based on whether the particles float or sink in a body of water. Recyclers also use initial sorting by near-infrared spectroscopy to distinguish different types of polymers, such as polystyrene (PS), polyethylene (PE), polypropylene (PP), and the like. Sorting by weight (e.g., with air guns), with sensors, and / or with magnets can also be used. Additional known recycling methods and features are described in “Managing Plastic Waste—Sorting, Recycling, Disposal, and Product Redesign,” Jean-Paul Lange, ACS Sustainable Chem. Eng. 2021, 9, 15722-15738, which is incorporated by reference herein in its entirety.

[0007] In conventional blister packs, the backing and the cover are made of different materials, which prevents recycling or at least makes recycling difficult or inefficient. For example, in conventional blister packs, the backing is formed of foil and the cover is formed of a polymer. Additionally, blister packs containing active ingredients further complicate or prevent recycling due to the different materials used to form the active ingredients. These different materials make recycling prior art blister packs difficult and time consuming at best. In fact, companies are collecting used blister packs, but there is nowhere to recycle them. Therefore, there is a need to provide a recyclable blister pack that is capable of preserving and / or protecting the products therein and / or functioning as a desiccant or oxygen scavenger. SUMMARY

[0008] The above and other needs are met by the technology of the present disclosure, which in one aspect includes a blister pack having a recyclable backing and a cover. The cover can be attached or adhered 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 a side adhered to the cover.

[0009] Optionally, the blister cavity can have a blister or dome portion and a base portion. The base portion can optionally be wider and / or longer than the blister portion.

[0010] Optionally, the blister package can further include an active component, optionally in the form of an extruded film. Optionally, the extruded film can be adhered to the side of the backing adhered to the cover. The extruded film can have a shape proximate to the base portion. The extruded film can include, for example, a desiccant or oxygen scavenger, or another active technology.

[0011] The use of an active component, such as a desiccant, within a blister package can further complicate the blister package and / or prevent the blister package from being recycled. In particular, the active component can undesirably "contaminate" the blister package, such that the blister package cannot be recycled. For example, in some locations or with at least certain known recycling methods, empty (i.e., without product) blister packages can need to be 90% or more olefin polymer and / or not have polyvinyl chloride (PVC) that can be recycled. Optionally, the active component of the technology of the present disclosure can have 5 grams of zeolite, which would allow the blister package to be 90% or more olefin polymer or polyolefin.

[0012] In another optional aspect, the technology of the present disclosure can include a method of making a blister package. Optionally, the method can include placing a product in each blister of the cover. The method can further include attaching or adhering a thermoformed cover to a backing to form a sealed unit package. A longitudinal axis of each blister can extend parallel to an edge of the backing.

[0013] In one optional embodiment, the method can include attaching or adhering an extruded active polymer film to an inner surface of the cavity.

[0014] Optionally, in any embodiment, the product contained in the blister of the blister package can include a pill, which is optionally, for example, a medication, a nutritional supplement, or a probiotic.

[0015] Optionally, 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 can necessitate the use of an active component in the blister cavity. For example, the active component can optionally be an active polymer component having a base formed of PE or PET. The active component can optionally be heat fused to the polymer backing. The molecular sieve component of the active component can precisely or approximately constitute 5% or optionally 4-6% or optionally 2-8% of the total mass of the blister card or package, thereby allowing a recycling step.

[0016] Optionally, the blister pack is push-only, meaning that the product can be or is designed to be removed from the blister pack by pushing the product through the pack.

[0017] Optionally, the blister pack is peel-push, meaning that the product can be or is designed to be removed from the blister pack by peeling a portion of the pack to expose the product and / or pushing the product through the pack. BRIEF DESCRIPTION OF DRAWINGS

[0018] The foregoing summary, as well as the following detailed description of the technology of the present disclosure, will be better understood when read in conjunction with the accompanying drawings, in which like reference features designate identical components throughout the figures. Various illustrative embodiments of the technology of the present disclosure are shown in the drawings. It should be understood, however, that the technology of the present disclosure is not limited to the precise arrangements and instrumentalities shown. In the drawings:

[0019] FIG. 1 is a top plan view of a prior art blister pack;

[0020] FIG. 2 is a cross-sectional view along line 2-2 of FIG. 1 showing an extruded active (e.g., desiccant-entrained) film having a width less than the width of a single blister;

[0021] Figure 3 is a cross-sectional view of a blister pack according to another optional aspect of the technology of the present disclosure, from the same or similar perspective as along line 2-2 of FIG. 1, and showing a backing and cover enclosing the product and a multi-layer assembly;

[0022] Figure 4 is a cross-sectional view of a blister pack according to another optional aspect of the technology of the present disclosure, from the same or similar perspective as along line 2-2 of FIG. 1, and showing a backing and cover enclosing the product and a multi-layer assembly;

[0023] Figure 5 is a cross-sectional view of a blister pack according to another optional aspect of the technology of the present disclosure, from the same or similar perspective as along line 2-2 of FIG. 1, and showing a backing and cover enclosing the product and a non-active layer; and

[0024] Figure 6 shows an enlarged cross-sectional schematic view of a portion of a blister pack according to an optional aspect of the technology of the present disclosure. DETAILED DESCRIPTION

[0025] While systems, devices, and methods are described herein by way of example and embodiments, those skilled in the art will recognize that the technology of the present disclosure is not limited to the embodiments or drawings described. Rather, the technology of the present disclosure covers all modifications, equivalents, and alternatives falling within the spirit and scope of the appended claims.

[0026] Any headings used herein are for organizational purposes only and are not intended to limit the scope of the description or the claims. As used herein, the word “can” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). The terms “a,” “an,” and “the” are not limited to one element, but instead should be interpreted as meaning “at least one” or “one or more.” First and second directions D1 and D2 are shown in certain figures merely for reference and clarity purposes, and are not part of the structure of the technology of the present disclosure. The terminology includes the words above, their derivatives, and words of similar import.

[0027] One or more features of any particular embodiment can be omitted or included (e.g., added) in another embodiment, each of which forms part of the technology of the present disclosure.

[0028] Reference will now be made in detail to various drawings, wherein like reference numerals refer to like parts throughout. Figure 3 Recyclable blister packaging or a package, generally indicated as 110, in accordance with optional aspects of the technology of the present disclosure is shown. Optionally, the recyclable blister package 110 can be used to provide a sustainable form of packaging that can also preserve or extend the shelf life of a product therein.

[0029] Optionally, the blister package 110 includes a backing 112 and a cover 114 attached to the backing 112, for example, by heat sealing. Additionally, 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 that is structured 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, such as disclosed in WO 2020 / 146556.

[0030] The backing 112 can have a first side or surface 112a and an opposite second side or surface 112b. Optionally, at least the first side 112a of the backing 112 can be flat or planar. Optionally, each of the first and second sides 112a and 112b of the backing 112 are flat or planar such that each of the first and second sides 112a and 112b extend in at least a slightly spaced apart plane.

[0031] The cover 114, optionally manufactured by thermoforming or cold forming, may have a first side or surface 114a and an opposing second side or surface 114b. Optionally, at least a portion of the first side 114a and the second side 114b of the cover 114 is flat or planar. At least a portion of the second side 114b of the cover 114 may be attached or bonded to the first side 112a of the backing 112, as by heat sealing, to form a sealed package for containing a product. The thickness of the cover 114 may be the same as or different from the thickness of the backing 112 (e.g., measured in the direction of D2). Optionally, the cover 114 is made or formed of a formable mesh. For example, the formable mesh is made of a thermoplastic material such as a thermoformed film.

[0032] Cover 114 comprises or is formed having at least one blister, typically designated 118. For example, cover 114 may comprise two or more spaced-apart blister packs 118. Optionally, cover 114 may have four or more spaced-apart identical blister packs 118, similar to the configuration shown in FIG. 1. However, depending on specific needs, cover 114 may have more or fewer blister packs, and one or more of the blister packs may have a different size and / or shape than another blister pack 118 of blister pack 110. Optionally, each blister pack 118 may be at least partially egg-shaped or spherical. Alternatively, each blister pack 118 may be at least partially platform-shaped (e.g., when viewed from the side) or cylindrical. When cover 114 is attached to backing 112, a sealed cavity is formed within or by each blister pack 118.

[0033] Optionally, each blister 118 may define a longitudinal or long axis extending parallel to at least one outer edge of the backing 112 and the blister package 110. Optionally, and more specifically, the longitudinal axis of each blister 118 may extend parallel to two opposite sides of the blister package 110 and perpendicular to the top and bottom sides of the blister back. However, the arrangement or orientation of the blister 118 within the blister package 110 is not limited to the arrangement or orientation shown and described herein, as other configurations according to the technology of this disclosure are possible as needed.

[0034] Blister packaging 110 can enclose, preserve and protect one or more products 117 (in Figure 3 (Illustrated schematically) Examples include oral solid dosage medicines, vitamins or other nutritional supplements, foods, small consumer products, probiotics, etc. Such products may be in the form of pills, such as tablets, capsules, etc. Optionally, product 117 may be in the form of powder.

[0035] Optionally, the cover 114 and the backing 112 are formed from the same material and / or recyclable material, which enables the blister package 110 to be easily reused or repurposed, and / or processed in a recycling technique, such as by air classification, sink-float separation, or sensor-based separation, as described in detail below. The ability to reuse and / or recycle stems from the use of a single material to form both the backing 112 and the cover 114. In such embodiments, the blisters 118 of the present embodiments differ from the blisters 18 of the prior art in that the blisters 118 of the present disclosure contain a backing 112 and a cover 114 formed from a single recyclable material, rather than different materials and / or two or more materials.

[0036] Optionally, a multi-layer assembly can be disposed between the backing 112 and the cover 114 within each cavity 118. The product 17 can be positioned between the multi-layer assembly and the cover 114. Optionally, the multi-layer assembly can contain at least two different layers in the form of at least an active layer 116, optionally in the form of a film, and an inactive layer 115, which can optionally be the same or similar in size to the active layer 116. Optionally, the inactive layer 115 can be positioned between the active layer 116 and the backing 112.

[0037] The active layer 116 can be configured to provide a desired condition to the product within the cavity, such as moisture absorption or adsorption by a desiccant. At least a top surface and a side surface of the active layer 116 can be exposed to the cavity 118.

[0038] The inactive layer 115 can be configured to provide an enhanced barrier to moisture or gas passing through the backing 112 into the cavity 118, and / or reduce the force required to remove at least one product 117 from the cavity 118 by piercing the backing 112. The inactive layer 115 increases or augments the thickness of the backing 112, thereby acting as at least a partial barrier. Because the inactive layer 115 reduces the amount of moisture and / or gas passing through the backing 112 into the cavity 118, the presence of the inactive layer 115 allows the active layer 116 to contain less active material and / or be smaller in size (e.g., length, width, and / or thickness).

[0039] Optionally, the multi-layer assembly can be a multi-layer film that is heat fused to the backing to form a heat seal between the multi-layer film and the backing without the need for adhesive material. In another optional embodiment, adhesive is used to attach the non-active layer 115 and / or the multi-layer assembly to the inner surface 112a of the backing 112. Optionally, the non-active layer 115 and / or the multi-layer assembly can be co-extruded and / or laminated. Optionally, the active layer 116 and the non-active layer 115 can be coextensive with one another, e.g., commensurate with one another in shape (e.g., same thickness, width, and / or length). In some optional embodiments, the non-active layer 115 is larger than the active layer 116. In some such embodiments, the length and width of the non-active layer can be less than or greater than the length and width of the active layer 116, such that at least a portion of the active layer 116 extends beyond the perimeter of the non-active layer 115.

[0040] Optionally, in any embodiment, the active layer 116 or active film has a thickness of 0.05 mm to 2.00 mm, optionally 0.2 mm to 1.2 mm, optionally 0.2 mm to 0.6 mm. In one example, the active layer 116 can be made from a single layer or a multi-layer construction. In another example, one of the film layers can be an FDA or EU approved layer for direct contact with a pharmaceutical or food product.

[0041] Optionally, the active layer 116 has a thickness of at least 0.3 mm, and optionally 0.3 mm to 2 mm. Optionally, the active layer 116 can have a thickness in the range of 0.3 mm to 1 mm, 0.3 mm to 0.9 mm, or 0.3 mm to 0.6 mm.

[0042] Optionally, the active layer 116 has a thickness that is less than 75% of the thickness of the multi-layer assembly. Optionally, the active layer 116 has a thickness that is about 50% of the thickness of the multi-layer assembly. Optionally, the active layer 116 has a thickness that is equal to or approximately equal to the thickness of the non-active layer 115 (+ / - 20%). In further optional embodiments, the active layer 116 has a thickness that is greater than the thickness of the non-active layer 115. In another optional embodiment, the active layer 116 has a thickness that is less than the thickness of the non-active layer 115.

[0043] Optionally, the active film can be produced from a base polymer and an active agent. Optionally, a channeling agent can be added to the base polymer and active agent mixture as described in U.S. Patent Nos. 5,911,937, 6,214,255, 6,130,263, 6,080,350, 6,174,952, 6,124,006, 6,194,079, 6,221,446, 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.

[0044] Additionally, in some optional embodiments, the non-active layer 115 is laser perforated or loaded with particles configured to increase the brittleness of the non-active layer 115. In such embodiments, the non-active layer will help to “push through” the product from the cavity through the backing. For example, the non-active layer can be designed to form a point of force and / or a line of force that will puncture the backing when pressed from the side of the cavity to help the user to remove the product from the blister pack. Effectively, the non-active layer in this configuration reduces the force required to remove the product from the cavity through the backing.

[0045] As shown in FIG. 1, the multi-layer assembly 100 includes a backing 112, a cover 114, and at least one product 117. The backing 112 is a flexible, non-porous, and non-elastic film that is configured to be punctured by the user when pressing on the cover 114. The cover 114 is a flexible, non-porous, and non-elastic film that is configured to be pressed by the user to puncture the backing 112 and remove the product 117 from the cavity 118. The at least one product 117 is a solid, semi-solid, or liquid product that is contained within the cavity 118. Figure 3 As shown, there is a gap or spacing between the outer perimeter (e.g., sidewall) of the multi-layer assembly and the inner surface of the cover 114. The gap or spacing can optionally extend around the perimeter of the multi-layer assembly when viewed from above. Optionally, the gap or spacing is exactly or approximately 1 mm wide around the perimeter of the multi-layer assembly. In the same or another optional embodiment, the multi-layer assembly occupies a predetermined area, such as 95-97% or 92-98% or 90-99% of the total surface area of the backing 112 within the cavity 118. The gap or spacing allows the multi-layer assembly and / or the non-active layer to create a point force or line force that allows the backing to be more easily punctured when the user presses on the cover toward the backing over the at least one product 117. The smaller the gap or spacing, the better the barrier quality of the blister pack 110. Optionally, the size of the gap or spacing is a function of the readiness of the film application module used to form the blister pack 110.

[0046] The techniques 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 often sorted through a series of sorting steps. The sorting steps can include sorting by size, sorting manually or through a sieve, such as to remove foreign materials (e.g., metals and glass), sorting by type of plastic material, and / or sizing and pelletizing into plastic recyclates.

[0047] Certain materials can be removed or separated from other materials by using gravity in an air stream (e.g., air classifier) or water stream (e.g., sink-float). An air classifier is a machine that uses air streams and the relationship between inertial forces and drag forces to separate particles of different densities. For example, a strong air stream (e.g., an updraft air column) can be directed or created from the bottom of the machine towards or toward the top, while the material stream falls in the opposite direction from the top of the machine towards the bottom. Optionally, the plastic flakes and / or particles can then be passed through a Z-shaped channel, which can aid the separation process. At the same time, lighter materials (such as labels and dust) can be blown upwards and collected in a filter bag. Thus, high-quality plastic without labels and dust can be collected.

[0048] Metals can be removed, among other things, by exploiting their magnetism, for example by magnetic attraction of ferrous metals or by inductive magnetic repulsion of non-ferrous metals.

[0049] Gravity can also be used to sort some plastics among themselves, for example to separate 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, within a machine or a vertical shaft. Gravity sorting can be refined with the help of electrostatic or magnetic fields.

[0050] Sink-float separation tanks can employ water or another liquid to separate co-mingled materials (e.g., plastics) based on density. For example, water has a density of 1 g / cm 3 As the pieces or items (e.g., plastics) enter or are introduced into the separation tank, any items with a density greater than the liquid (e.g., water) will sink. The heavy item stream collects at the bottom of the tank and can be forced out of the machine, optionally using a screw conveyor. Likewise, any material with a density less than the liquid will float and exit the machine at the top. Additives can be added to the liquid to improve the separation process.

[0051] Certain sensor-based sorting machines are manufactured by TOMRA TM Recycling, of Germany. For example, visual spectrometer sensors can be used to remove certain materials from a waste stream. Eddy currents are another type of separator or sensor that can be used.

[0052] Perhaps most commonly, plastics are sorted by spreading them on a conveyor belt, optionally using infrared detectors (e.g., near-infrared (NIR) or short-wave infrared (SWIR)) to identify the plastics to be sorted, and using actuators or air jets to sort the plastics. Standard infrared (IR) detectors can 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 (CI) and bromine (Br).

[0053] New sorting techniques are continually evolving. For example, trace-based sorting uses fluorescent pigments incorporated into plastic substrates or sleeves. These pigments are only visible under UV light at the sorting facility. Another technique uses digital watermarks, such as codes integrated into packaging designs, and can be detected by cameras on high-speed sorting lines. Watermarks can carry or reveal information about the product and its packaging. Yet another technique is robotic sorting, which applies artificial intelligence to help cameras and robotic arms sort plastic from a conveyor belt. Each of the recycling techniques discussed above can be used with the techniques of the present disclosure.

[0054] Optionally, the backing 112 is made from a first polymer, such as a first polyolefin, and the cover 114 and the non-active layer 115 are made from a second polymer, such as a second polyolefin. In some embodiments, the first polymer (or first polyolefin) is the same polymer or polyolefin as the second polymer (or second polyolefin). Including a non-active layer made from the same polyolefin as the cover and backing reduces the ratio of contaminated material from the active layer by increasing the amount of uncontaminated material within the blister pack. Alternatively, the second polymer (or second polyolefin) can be different from the first polymer (or first polyolefin).

[0055] As used herein, the term “polyolefin” refers to a polymer that can be considered a product from the reaction of an olefin (e.g., ethylene, CH2=CH2) that has been reacted to form a polymer (e.g., polyethylene). Certain polyolefins can be considered to be the polymerization product of an a-olefin (CH2=CHR). Certain polyolefins have the formula (CH2-CHR) n Polyolefins need not be obtained by such a reaction. Examples of polyolefins include polyethylene (PE), polypropylene (PP), polystyrene, polyacrylamide, polyvinyl alcohol, and polyvinyl acetate.

[0056] The backing 112 and the cover 114 can optionally be formed from an optionally transparent thermoformed film, rather than a conventional plastic cover and foil backing, such as the plastic cover and foil backing disclosed in U.S. Patent No. 8,142,603. Alternatively, the backing 112 and the cover 114 can be formed from a co-polyester or co-polyester film. Examples of co-polyesters include PETG (polyethylene terephthalate glycol), PCTG (poly(cyclohexylene dimethylene terephthalate glycol modified), and PCTA (1,4-cyclohexylidene dimethylene terephthalate-co-isophthalate).

[0057] At least based on the materials used to manufacture the backing and the manner in which the backing is constructed or formed, embodiments of the technology of the present disclosure can be distinguished from the technology disclosed in U.S. Patent No. 8,142,603. For example, U.S. Patent No. 8,142,603, column 4, lines 23-37 discloses heating the lidding foil sufficiently that the polymeric seal layer becomes pliable and adheres the active film to the softened polymeric layer of the lidding film. Despite the thin polymeric seal layer, the backing of U.S. Patent No. 8,142,603 itself includes foil, which would destroy or make recycling of the blister pack difficult or impossible.

[0058] In one optional embodiment of the disclosed concept, the backing 112, the cover 114, and / or the active component 116 are made of any of the PX7-PX30 produced by TEKNI-PLEX TM The material of manufacture. For example, the material used can be coated PVC / PVdC, PCTFE laminate (ACLAR TM ), or other PVC film. The material can be rigid or flexible. Optionally, the material can be any of the PX7-PX30 produced by TEKNI-PLEX TM .

[0059] In another optional embodiment of the disclosed concept, the backing 112, the cover 114, the non-active layer 115, and / or the active layer 116 do not contain PVC or other chlorinated polymers.

[0060] In another optional embodiment of the disclosed concept, the backing 112, the cover 114, the non-active layer 115, and / or the active layer 116 do not contain fluorinated polymers.

[0061] In one embodiment, the blister pack 110 of the technology of the present disclosure contains a sufficient amount and / or specific location of active material in order to preserve or extend the shelf life of the product 117 therein without "polluting" the blister pack 110 with too much non-recyclable material that would prevent or prohibit recycling of the blister pack 110 after the product is removed. Optionally, the blister pack 110 contains a mineral active material that has a sufficiently low amount of mineral loading as a portion of the overall blister pack or package on a mass basis so as not to hinder recycling of the blister pack 110.

[0062] In exemplary embodiments, the active layer 116 can be formed from an active polymeric material. In such embodiments, 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. Additionally, the construction enables the backing 112 and / or the cover 114 to preserve or extend the shelf life of the product 117 stored within the cavity. In this optional embodiment, the active polymeric material is a recyclable material and / or a material with a sufficiently low mass of mineral content compared to the overall package such that it does not "contaminate" the remainder of the blister pack 110 in a manner that otherwise prevents or prohibits recyclability.

[0063] Optionally, the blister pack 110 and / or portions thereof can be formed from one or more biodegradable materials.

[0064] The backing 112 and / or the cover 114 can be constructed such that each of the at least one cavities 118 can be opened to dispense the product 117, such as by pushing or pushing and pulling on one of the backing 112 and / or the cover 114. Additionally, each of the at least one cavities can optionally be subsequently sterilized, refilled, and then resealed.

[0065] In one embodiment, the backing 112 and the cover 114 can have a water vapor transmission rate in the range of 0.07 grams / 100 square inches / day - 0.58 grams / 100 square inches / day at or at 38 degrees Celsius ambient temperature and 90% relative humidity. In further embodiments, the backing 112 and the cover 114 can have an oxygen transmission rate in the range of 0.18 cubic centimeters / 100 square inches / day - 1.4 cubic centimeters / 100 square inches / day at or at 23 degrees Celsius ambient temperature and 50% relative humidity.

[0066] Optionally, the active polymeric material contains a desiccant. This would be in embodiments where moisture absorption or adsorption is desired. However, in cases where moisture absorption or moisture adsorption is not desired, the active polymeric material or active component can comprise one or more alternative active agents. For example, in another embodiment, the active polymeric material contains a material selected from the group consisting of activated carbon, carbon black, ketcham black, and diamond powder. In further embodiments, the active agent of one or more layers comprising the active member 116 contains materials such as absorbing microspheres, BaTi03, SrTi03, Si02, AI2O3, ZnO, Ti02, MnO, CuO, Sb203, silica, calcium oxide, and ion exchange resins, among others. In yet another embodiment, the absorbent or adsorbent containing layer of the active polymeric material contains two or more types of absorbent or adsorbent. The appropriate absorbent or adsorbent is selected to achieve removal of a desired vapor or gas for the desired end use (e.g., absorption or adsorption of moisture, oxygen, carbon dioxide, nitrogen, or other unwanted gas or vapor).

[0067] The active polymeric material (whether a desiccant, oxygen scavenger, release material, or pharmaceutical, among others, or a combination thereof) is capable of acting on, interacting with, or reacting with a selected material (e.g., moisture or oxygen). Examples of such action or interaction can include absorption and adsorption (i.e., typically sorption) or release of the selected material.

[0068] The active polymeric material or active component can comprise an "active agent" in the base material. The active agent (i) can be immiscible with the base material (e.g., a polymer, polyolefin, or other synthetic fiber) and will not melt when mixed with the base material and channel-forming agent and heated, i.e., has a higher melting point than the base material or channel-forming agent, and / or (ii) acts on, interacts with, or reacts with a selected material. The term "active agent" can include, but is not limited to, a material that absorbs, adsorbs, or releases a selected material. The active agent according to the technology of the present disclosure can be in the form of a particulate, such as a mineral (e.g., a molecular sieve or silica gel in the case of a desiccant), although the technology of the present disclosure should not be considered as limited to only particulate active agents. For example, in some embodiments, an oxygen scavenging formulation can be made from a resin that acts as the active agent or a component of the active agent.

[0069] As used herein, the term "base material" is the component (optionally a polymer or synthetic fiber) that entrains the active material other than the active agent that provides the structure for the entrained material.

[0070] As used herein, the term "base polymer" is a base material that is an optional polymer having 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 would be water vapor permeability. The primary function of the base polymer is to provide a structure for the entrained polymer. Suitable base polymers can include thermoplastic polymers, for example, polyolefins such as polypropylene and polyethylene, polyisoprene, polybutadiene, polybutene, polysiloxane, polycarbonate, polyamide, ethylene-vinyl acetate copolymer, ethylene-methacrylate copolymer, poly(vinyl chloride), polystyrene, polyester, polyacid anhydride, polyacrylonitrile, polysulfone, polyacrylate, acrylic, polyurethane, and polyacetal, or copolymers or mixtures thereof.

[0071] With reference to such a comparison of the base polymer to the channeling agent water vapor permeability, 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.

[0072] As used herein, the term "channeling agent" or "channeling agents" is defined as a material (preferably a polymeric material) that is immiscible with the base polymer and has an affinity to transport a gas phase material 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. Such channels are capable of transporting the selected material through the entrained polymer at a faster rate than the base polymer alone.

[0073] As used herein, the term "channel" or "interconnected channels" is defined as a passageway that is formed by the channeling agent that penetrates the base polymer and can be interconnected to one another.

[0074] As used herein, the term "entrained polymer" is defined as an overall material formed from at least a base polymer with an active agent distributed therein and optionally also a channel forming agent entrained or distributed throughout. The entrained polymer thus includes both two-phase and three-phase polymers. A "mineral loaded polymer" is a type of entrained polymer in which the active agent is in the form of a mineral, such as a molecular sieve or silica gel, for example, in the form of mineral particles. The term "entrained material" is used herein to indicate an overall material that includes an active agent entrained in a base material, where the base material can or can not be polymeric.

[0075] As used herein, the term "monolith," "monolithic structure," or "monolithic composition" is defined as a composition or material that is not comprised of two or more discrete macroscopic layers or portions. Thus, a "monolithic composition" does not include a multi-layer composite material, although a monolithic composition can constitute a layer of such a composite material.

[0076] As used herein, the term "phase" is defined as a portion or component of a monolithic structure or composition that is uniformly distributed throughout to provide an overall property of the structure or composition.

[0077] As used herein, the term "selected material" is defined as a material that is acted upon or interacts or reacts with the active agent and is capable of being transported through the channels of the entrained polymer. For example, in embodiments where a desiccant is used as the active agent, the selected material can be moisture or a 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 a medicament, such as moisture, a fragrance, or an antimicrobial agent (e.g., chlorine dioxide), that is released by the release material. 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 tri(hydroxymethyl)aminomethane impregnated activated carbon.

[0078] As used herein, the term "three-phase" is defined as a monolithic composition or structure that includes three or more phases. An example of a three-phase composition according to the technology of the present disclosure would be an entrained polymer formed from a base polymer, an active agent, and a channel forming agent. Optionally, the three-phase composition or structure can include additional phases, such as a colorant.

[0079] The entraining polymer can be a two-phase formulation (i.e., including a base polymer and an active agent without a channel-forming agent) or a three-phase formulation (i.e., including a base polymer, an active agent, and a channel-forming agent). Entraining polymers are described, for example, in U.S. Patent Nos. 5,911,937; 6,080,350; 6,124,006; 6,130,263; 6,194,079; 6,214,255; 6,486,231; 7,005,459; and U.S. Patent Publication No. 2016 / 0039955.

[0080] The entraining material or polymer includes a base material (e.g., a polymer) for providing structure, optionally a channel-forming agent, and an active agent. The channel-forming agent forms microscopically interconnected channels through the entraining polymer. At least some of the active agent is contained in these channels, such that the channels communicate between the active agent and the exterior of the entraining polymer through microscopically channel openings formed at the exterior surface of the entraining polymer. The active agent can be, for example, any of a variety of absorbing, adsorbing, or releasing materials described in further detail below. Although a channel-forming agent is preferred, the present disclosure broadly includes entraining materials that optionally do not include a channel-forming agent, e.g., a two-phase polymer.

[0081] In any embodiment, a suitable channel-forming agent can include a polyglycol, such as polyethylene glycol (PEG), ethylene-vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), glycerol polyamine, polyurethane, and polycarboxylic acid including polyacrylic acid or polymethacrylic acid. Alternatively, the channel-forming agent can be, for example, a water-insoluble polymer, such as propylene oxide polymerization product-monobutyl ether produced by CLARIANT, such as Polyglykol B 01 / 240. In other embodiments, the channel-forming agent can be a propylene oxide polymerization product monobutyl ether, such as Polyglykol B 01 / 20 produced by CLARIANT, a propylene oxide polymerization product, such as Polyglykol D 01 / 240 produced by CLARIANT, ethylene vinyl acetate, nylon 6, nylon 66, or any combination of the foregoing.

[0082] A suitable active agent according to the technology of the present disclosure includes an absorbing or adsorbing (typically, sorbing) material, such as a desiccant compound. If the active agent is a desiccant, any suitable desiccant for a given application can be used. Generally, for many applications, a physical adsorption desiccant is preferred. These physical adsorption desiccants can include molecular sieves, silica gel, clays, and starches. Alternatively, the desiccant can be a chemical compound that forms a crystal containing water or a compound that reacts with water to form a new compound.

[0083] Optionally, in any embodiment, the active agent can be an oxygen scavenger, such as an oxygen scavenging resin formulation, such as described in U.S. Patent No. 7,893,145, which is incorporated by reference herein in its entirety.

[0084] In certain optional embodiments, the oxygen scavenger is a metal-based oxygen scavenger. In certain embodiments, the oxygen scavenger comprises zero-valent metal. In certain embodiments, the oxygen scavenger comprises zero-valent metal in particulate or nanoparticulate form. In certain embodiments, the oxygen scavenger comprises ionic metal, optionally in the +1 or +2 oxidation state. In certain embodiments, the oxygen scavenger is a metal complex comprising an organic ligand.

[0085] 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 polyalkene. In certain embodiments, the organic compound is selected from phenol and hydroquinone. In certain embodiments, the organic compound comprises porphyrin. In certain embodiments, the oxygen scavenger is a naturally occurring substance.

[0086] In some optional embodiments, the oxygen scavenger comprises a polyene. In some embodiments, the oxygen scavenger comprises a conjugated polyene. In certain embodiments, the oxygen scavenger is a radical trap. Certain radical traps contain phenol moieties, such as BHA, BHT, caffeic acid, ferulic acid, and alpha-tocopherol. Certain radical traps are enols, such as ascorbic acid (vitamin C). Certain radical traps contain weak X-H bonds (X = N, O, S), including but not limited to mercaptans, uric acid, and bilirubin. Certain radical traps contain polyene moieties, such as beta-carotene and other carotenoids. Certain radical traps contain conjugated or non-conjugated dienes, such as alpha- and gamma-terpinene, respectively, and certain unsaturated fats and fatty acids. In some optional embodiments, the oxygen scavenger comprises ascorbic acid or a salt, ester, lactone, or stereoisomer thereof.

[0087] Optionally, in any embodiment, to facilitate recyclability of the blister pack 110, the active of the active component or the active within the entirety of the blister pack 110 can precisely or approximately comprise 5% or optionally 4-6% or optionally 2-8% of the total mass of the blister pack 110. More specifically, the active component 116 can comprise molecular sieves, and the total mass of all molecular sieves of the blister pack 110 can comprise 5% or less or 4-6% or 2-8% of the total mass of the blister pack 110.

[0088] Optionally, to facilitate recyclability of the blister pack 110, the blister pack 110 can contain 5 grams or less, optionally 1 to 5 grams, optionally 2 to 5 grams, optionally 3 to 5 grams of zeolite.

[0089] Optionally, such a low mineral loading as described herein used in active component 116 as a portion of the total mass of the blister pack (with the substantial remainder of the blister pack being made of the same polymeric 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 that are made from a combination of different types of materials (including foil, paper, plastic, etc.) and are therefore not recyclable or challenging for recycling. In other words, the disclosed concept is unique at least in that it involves a blister pack that is primarily composed of a polymer or the same polymer with a relatively small particulate (or other active) component that is a portion of the total mass of the blister pack. This allows the blister pack according to the disclosed concept to be recycled, whereas prior art blister packs with active components are not recyclable or challenging for recycling.

[0090] The disclosed technology includes methods of manufacturing, using, and / or recycling the blister pack 110. One such method includes (i) providing and / or forming the cover 114 having at least one blister 118 with one or more of the above-mentioned features, (ii) placing the product 117 in each blister 118, (iii) attaching one or more spaced-apart active components 116 to the backing 112, and (iii) attaching or adhering the backing 112 to the cover 114 to form a sealed package around the product 117 and the multi-layer assembly.

[0091] As used herein, the term "providing" is broadly defined to include receiving, obtaining, placing, positioning, placing, locating, and / or using. At least a portion of the backing 112 can be separated (e.g., pushed / pulled or just pulled) or broken away from the cover 114 to expose the product 117 when a user wishes to obtain the product 117.

[0092] Optionally, any film used with the disclosed technology can be formed in any of a variety of ways, such as by extrusion, blowing, or casting.

[0093] Figure 4 Another embodiment of the blister pack 110 of the disclosed technology is shown. Figure 4 The shown blister pack 110 has certain components or aspects similar or identical to those shown and discussed above. Figure 3 Therefore, only for the sake of convenience and brevity, descriptions of certain similarities between the embodiments of Figure 4 and the embodiments of Figure 3 may be omitted herein.

[0094] Distinctive features of this embodiment are that the cover 114 includes a dome portion 120 and a base portion 122, and the multi-layer assembly is positioned within and / or extends into at least the base portion 122. In one embodiment, the active member 116 can 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.

[0095] The multi-layer assembly can be heat fused (adhesive-free) to the first side 112a of the backing 112. Methods of heat fusing a film to a substrate are described in detail in U.S. Patent No. 8,142,603, which is incorporated by reference herein in its entirety. It is contemplated that the multi-layer assembly 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 multi-layer assembly can be attached to the backing 112 in other mechanical or chemical ways, such as by an adhesive or an interference fit, or otherwise substantially restrict its mobility within the cavity.

[0096] Optionally, the multi-layer assembly can be moved relative to the backing 112, although the multi-layer assembly is not attached or secured to the backing 112.

[0097] Figure 5 Another embodiment of a blister pack 110 of the technology of the present disclosure is shown. Figure 5 The blister pack 110 shown has certain components or aspects similar or identical to those shown and discussed above. Figure 3 and Figure 4 The embodiments shown and discussed above. Figure 5 The embodiments shown and discussed above. Figure 3 and 4 The embodiments shown and discussed above.

[0098] Figure 5 Distinctive features of the blister pack 110 shown are that it includes only a product 117 and a non-active layer 115 within the cavity 118. Thus, the active layer 116 of the previous embodiments is omitted. One benefit of this embodiment is cost savings by omitting the active layer 116. The single non-active layer provides additional barrier protection for the product 117. For example, the non-active layer 115 can be formed of polyethylene or polypropylene.

[0099] Figure 6A backing 112 and a lidding 114 of one optional embodiment of the technology of the disclosure are shown. The backing 112 and / or the lidding 114 can each include one or more spaced apart increased thickness portions 113, 119. When the backing 112 and / or the lidding 114 are used to form a blister pack, the increased thickness portions correspond to cavities, thereby increasing barrier properties at the cavities. This enhances the ability of the blister pack to reduce ingress and preserve products therein. A multilayer assembly or a single non-active layer can be included in or omitted from each cavity.

[0100] The following exemplary embodiments further describe optional aspects of the technology of the disclosure and are part of the detailed description. These exemplary embodiments are set forth in substantially similar format as the claims, but are not technically claims of the present application. The following exemplary embodiments refer to each other as “embodiments” rather than “claims” in a dependent relationship.

[0101] 1A. A recyclable blister pack, the blister pack comprising:

[0102] a backing;

[0103] a lidding attached to the backing, wherein the lidding and the backing in combination form at least one cavity for containing at least one product therein; and

[0104] a multilayer assembly located inside or in fluid communication with the cavity, the active component comprising a base,

[0105] wherein the lidding, the backing, and the multilayer assembly are formed from the same material.

[0106] 2A. The recyclable blister pack of embodiment 1A, wherein the material is recyclable.

[0107] 3A. The recyclable blister pack of embodiment 1A or 1B, wherein the material is a polyolefin.

[0108] 4A. The recyclable blister pack of any of embodiments 1A-3A, wherein the lidding and the backing are formed from a transparent thermoformed film.

[0109] 5A. The recyclable blister pack of any of embodiments 1A-4A, wherein the backing and the lidding are formed from a copolyester film.

[0110] 6A. The recyclable blister package of any one of embodiments 1A-5A, wherein the backing and the cover have a water vapor transmission rate in the range of 0.07 grams / 100 square inches / day - 0.58 grams / 100 square inches / day at an ambient temperature of 38 degrees Celsius and a relative humidity of 90%.

[0111] 7A. The recyclable blister package of any one of embodiments 1A-6A, wherein the backing and the cover have an oxygen transmission rate in the range of 0.18 cubic centimeters / 100 square inches / day - 1.4 cubic centimeters / 100 square inches / day at an ambient temperature of 23 degrees Celsius and a relative humidity of 50%.

[0112] 8A. The recyclable blister package of any one of embodiments 1A-7A, wherein the backing and the cover are extruded films, the multi-layer assembly comprising at least one of a desiccant and an oxygen scavenger.

[0113] 9A. The recyclable blister package of any one of embodiments 1A-8A, wherein the backing and the cover are formed from a thermoplastic polymer selected from the group consisting of polypropylene, polyethylene, polyisoprene, polybutadiene, polybutene, polysiloxane, polycarbonate, polyamide, ethylene-vinyl acetate copolymer, ethylene-methacrylate copolymer, poly(vinyl chloride), polystyrene, polyester, polyacid anhydride, polyacrylonitrile, polysulfone, polyacrylate, acrylic, polyurethane, polyacetal, copolymers thereof, and mixtures thereof.

[0114] 10A. The recyclable blister package of any one of embodiments 1A-9A, wherein the multi-layer assembly comprises an active layer in the form of an active polymeric film laminated on a non-active layer of the multi-layer assembly.

[0115] 11A. The method of embodiment 10A, wherein the active polymeric film is formed from a recyclable material.

[0116] 1B. A method of recycling a blister package without a product in the blister package or after the product has been removed from the blister package, the method comprising:

[0117] obtaining a blister package having a backing, a cover, and a multi-layer assembly formed from a polyolefin; and

[0118] processing the blister package by a recycling sorting method.

[0119] 2B. The method of embodiment 1B, wherein the multi-layer assembly comprises an active layer comprising a molecular sieve, the molecular sieve having a mass that is 5% or less of a total mass of the blister package.

[0120] 3B. The method of embodiment 1B, wherein the active layer comprises a molecular sieve, the mass of the molecular sieve comprising 4-6% of the total mass of the blister pack.

[0121] 4B. The method of embodiment 1B, wherein the active layer comprises a molecular sieve, the mass of the molecular sieve comprising 2-8% of the total mass of the blister pack.

[0122] 5B. The method of any one of embodiments 1B-4B, wherein the recycling sorting method is one of an air classifier, a sink-float sorter, and a sensor-based sorting.

[0123] 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:

[0124] obtaining a blister pack having a backing, a cover, and a multilayer assembly formed from synthetic fibers; and

[0125] processing the blister pack by a recycling sorting method.

[0126] 1D. A method of forming at least a portion of a recyclable blister pack, the method comprising:

[0127] heat fusing one or more multilayer assemblies to a polymeric backing, each multilayer assembly comprising an active layer comprising a polymeric base.

[0128] 2D. The method of embodiment 1D, wherein the active layer comprises an active component or a molecular sieve, the mass of the active component or the molecular sieve comprising 8% or less of the total mass of the blister pack.

[0129] 1F. A method of recycling used blister packs, the method comprising:

[0130] processing a plurality of used items comprising one or more blister packs by a sorting process; and

[0131] wherein polymeric components of the plurality of used items are separated from non-polymeric components of the plurality of used items.

[0132] 2F. The method of embodiment 1F, wherein each blister pack of the one or more blister packs comprises a backing, a cover, and a multilayer assembly formed from a polymer.

[0133] 3F. The method of embodiment 1F or 2F, wherein the sorting process is one of air classification, sink-float sorting, or sensor-based sorting.

[0134] 4F. The method of embodiment 1F or 2F, wherein the sorting process comprises generating an ascending air column to separate the plurality of used articles.

[0135] 5F. The method of embodiment 1F or 2F, wherein the sorting process comprises employing one or more magnets to separate metal components of the plurality of used articles from polymeric components of the plurality of used articles.

[0136] 6F. The method of embodiment 1F or 2F, wherein the sorting process comprises dropping the plurality of used articles to separate polyolefin components of the plurality of used articles from non-polyolefin components of the plurality of used articles using gravity.

[0137] 7F. The method of embodiment 1F or 2F, wherein the sorting process comprises employing a water tank or water bath to separate the polymeric components of the plurality of used articles from the non-polymeric components of the plurality of used articles.

[0138] 1G. A recyclable blister pack configured to house 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 pack comprising:

[0139] a backing;

[0140] a cover attached to the backing, the cover and the backing in combination forming at least one cavity configured to house at least one product therein; and

[0141] a multilayer assembly attached to the backing or positioned within the at least one cavity, the multilayer assembly comprising an active layer and an inactive layer, the inactive layer disposed between the active layer and the backing,

[0142] wherein the active layer comprises a molecular sieve, the total mass of the molecular sieve being 8% or less of the total mass of the blister pack, and

[0143] wherein the blister pack is configured to be recycled.

[0144] 2G. The recyclable blister pack of embodiment 1G, wherein the molecular sieve is 2-8% of the total mass of the blister pack.

[0145] 3G. The recyclable blister pack of embodiment 1G, wherein the molecular sieve is 4-6% of the total mass of the blister pack.

[0146] 4G. The recyclable blister pack of claim 1G, wherein the non-active layer is attached to the backing.

[0147] 5G. The recyclable blister pack of claim 1G, wherein the multi-layer assembly is attached to the backing by heat sealing and without a separate adhesive material.

[0148] 6G. The recyclable blister pack of claim 1G, wherein the active layer is a desiccant- entrained film.

[0149] 7G. The recyclable blister pack of claim 1G, wherein the active layer contains a zeolite.

[0150] 8G. The recyclable blister pack of claim 1G, wherein a base of the active layer is formed of a first polyolefin.

[0151] 9G. The recyclable blister pack of claim 8G, wherein the non-active layer and the cover are formed of a second polyolefin.

[0152] 10G. The recyclable blister pack of claim 9G, wherein the first polyolefin is the same polyolefin as the second polyolefin.

[0153] 11G. The recyclable blister pack of claim 9G, wherein the first polyolefin is a different polyolefin than the second polyolefin.

[0154] 12G. The recyclable blister pack of claim 1G, wherein the backing and the cover have a water vapor transmission rate in the range of 0.07 grams / 100 square inches / day - 0.58 grams / 100 square inches / day at an ambient temperature of 38 degrees Celsius and a relative humidity of 90%.

[0155] 13G. The recyclable blister pack of claim 1G, wherein the backing and the cover have an oxygen transmission rate in the range of 0.18 cubic centimeters / 100 square inches / day - 1.4 cubic centimeters / 100 square inches / day at an ambient temperature of 23 degrees Celsius and a relative humidity of 50%.

[0156] 14G. The recyclable blister pack of claim 1G, wherein the non-active layer is loaded with particles configured to embrittle the non-active layer.

[0157] 15G. The recyclable blister pack of claim 1G, wherein the non-active layer provides at least one force point configured to puncture the cover.

[0158] 16G. The recyclable blister pack of claim 1G, wherein an adhesive adheres the non- active layer to the active layer.

[0159] 17G. The recyclable blister pack of claim 1G, wherein the non-active layer has equal length and equal width as the active layer.

[0160] 18G. The recyclable blister pack of claim 1G, wherein the non-active layer has a length and a width that is less than the active layer.

[0161] 19G. The recyclable blister pack of claim 1G, wherein the active layer has a thickness of 0.05 mm to 1.0 mm.

[0162] 20G. The recyclable blister pack of claim 1G, wherein the active layer has a thickness of 0.2 mm to 0.6 mm.

[0163] 21G. The recyclable blister pack of claim 1G, wherein the cover and the backing are formed from a transparent thermoformed film.

[0164] 1H. A method of manufacturing a recyclable blister pack, the method comprising:

[0165] attaching a plurality of multilayer assemblies to a backing, the multilayer assemblies being attached to the backing in a spaced apart arrangement, each multilayer assembly comprising an active layer having a base formed from a first polyolefin, each active layer comprising a molecular sieve, the total mass of the molecular sieve being 8% or less of the total mass of the blister pack;

[0166] placing a product within each blister of a cover, the cover comprising a plurality of the spaced apart arrangement of blisters, the cover being formed from a second polyolefin; and

[0167] attaching the combined active component and backing to the cover such that each active component is located within one of the blisters.

[0168] 2H. The method of claim 1H, wherein a sealed cavity surrounds each product and active component pair.

[0169] 3H. The method of claim 1H, wherein a sealed cavity surrounds each product and active component pair.

[0170] 4H. The method of claim 1H, wherein a longitudinal axis of each blister extends parallel to an edge of the backing.

[0171] 5H. The method according to embodiment 1H, wherein the backing and the cover have a water vapor transmission rate in the range of 0.07 grams / 100 square inches / day - 0.58 grams / 100 square inches / day at an ambient temperature of 38 degrees Celsius and a relative humidity of 90%.

[0172] 6H. The method according to embodiment 1H, wherein the backing and the cover have an oxygen transmission rate in the range of 0.18 cubic centimeters / 100 square inches / day - 1.4 cubic centimeters / 100 square inches / day at an ambient temperature of 23 degrees Celsius and a relative humidity of 50%.

[0173] 7H. The method according to embodiment 1H, wherein the first polyolefin is the same polyolefin as the second polyolefin.

[0174] 8H. The method according to embodiment 1H, wherein the first polyolefin is different than the second polyolefin.

[0175] 1I. A recyclable blister pack configured to house at least one product, the at least one product 117 being a consumable product in the form of a pill, tablet, capsule, or powder, the blister pack comprising:

[0176] a backing 112; and

[0177] a cover 114 attached to the backing 112, the cover 114 and the backing 112 in combination forming at least one cavity configured to house the at least one product 117 therein,

[0178] characterized in that a non-active layer 115 is attached to the backing 112 or positioned within the at least one cavity between the at least one product 117 and the backing 112, the non-active layer 115 being free of active components,

[0179] wherein a gap or spacing exists within the at least one cavity around an entire perimeter of the non-active layer 115 and an inner surface of the backing 112.

[0180] 2I. The recyclable blister pack according to embodiment 1I, wherein the non-active layer 115 is formed of polypropylene or polyethylene.

[0181] 3I. The recyclable blister pack according to embodiment 1I or 2I, wherein the gap or the spacing has a width of 1 mm or less.

[0182] 4I. The recyclable blister pack according to any of the preceding embodiments 1I to 3I, wherein the blister pack 110 is configured to be recyclable.

[0183] 1J. A method of manufacturing a recyclable blister package, the method comprising:

[0184] placing a product 117 within each blister 118 of a cover 114, the cover comprising a plurality of spaced-apart arrangements of the blisters 118, the cover 114 being formed of polyolefin; and

[0185] attaching a backing 112 to the cover 114, the backing 112 being formed of polyolefin, each product 117 being located within one of the blisters 118.

[0186] 2J. The method of embodiment 1J, further comprising: prior to attaching the backing 112 to the cover 114, attaching a plurality of active layers 116 to the backing 112 in a spaced-apart arrangement.

[0187] 3J. The method of embodiment 1J or 2J, wherein the cover 114 comprises one or more spaced-apart portions of increased thickness.

[0188] 4J. The method of any one of embodiments 1J to 3J, wherein the backing 112 comprises one or more spaced-apart portions of increased thickness.

[0189] While the technology of the present disclosure has been described in detail with respect to particular examples thereof, it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. It is therefore intended to cover in the appended claims all such changes and modifications that fall within the spirit and scope of the technology of the present disclosure.

Claims

1. A recyclable blister pack (110) configured to contain at least one product (117), the at least one product (117) being a consumable product in the form of a pill, tablet, capsule, or powder, the blister pack comprising: a backing (112); and a cover (114) attached to the backing (112), the cover (114) and the backing (112) in combination forming at least one cavity (118) configured to contain the at least one product (117) therein, characterized in that a multi-layer assembly is attached to the backing or positioned within the at least one cavity (118), the multi-layer assembly comprising an active layer (116) and an inactive layer (115), the inactive layer (115) disposed between the active layer (116) and the backing (112); wherein the active layer (116) is a film.

2. The recyclable blister pack of claim 1, wherein the active layer (116) comprises a molecular sieve, the total mass of the molecular sieve being 8% or less of the total mass of the blister pack (110).

3. The recyclable blister pack of claim 2, wherein the molecular sieve is 4-6% of the total mass of the blister pack (110).

4. The recyclable blister pack of any one of claims 1-3, wherein the multi-layer assembly is attached to the backing (112) by heat sealing and without a separate adhesive material.

5. The recyclable blister pack of any one of claims 1-3, wherein a base of the active layer (116) is formed of a first polyolefin and the cover (114) and the inactive layer (115) are formed of a second polyolefin.

6. The recyclable blister pack of claim 5, wherein the first polyolefin and the second polyolefin are the same.

7. The recyclable blister pack of any one of claims 1-3, wherein the backing (112) and the cover (114) have a water vapor transmission rate in the range of 0.07 grams / 100 square inches / day -.58 grams / 100 square inches / day at an ambient temperature of 38 degrees Celsius and a relative humidity of 90%.

8. The recyclable blister pack of any one of claims 1-3, wherein the backing (112) and the cover (114) have an oxygen transmission rate in the range of 0.18 cubic centimeters / 100 square inches / day - 1.4 cubic centimeters / 100 square inches / day at an ambient temperature of 23 degrees Celsius and a relative humidity of 50%.

9. The recyclable blister pack of any one of claims 1-3, wherein the inactive layer (115) is loaded with particles configured to embrittle the inactive layer (115).

10. The recyclable blister pack of any one of claims 1-3, wherein an adhesive adheres the inactive layer (115) to the active layer (116). ​ 11. The recyclable blister pack of any one of claims 1 to 3, wherein the non- active layer (115) and the active layer (116) have the same length and width.

12. The recyclable blister pack of any one of claims 1 to 3, wherein the active layer (116) has a thickness of 0.05 mm to 1.0 mm, optionally 0.2 mm to 0.6 mm.

13. The recyclable blister pack of any one of claims 1 to 3, wherein the cover (114) and the backing (112) are formed from a transparent thermoformed film.

14. The recyclable blister pack of any one of claims 1 to 3, wherein the blister pack is configured to be recyclable.

15. The recyclable blister pack of any one of claims 1 to 3, wherein a gap exists around the entire perimeter of the non-active layer (115) and the inner surface of the backing (112).

16. The recyclable blister pack of claim 15, wherein the gap has a width of 1 mm or less.

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