Recyclable blister pack, method for manufacturing a recyclable blister pack, and recycling method for a recyclable blister pack

Abstract

A recyclable blister pack configured to enclose at least one active member and a product includes a backing material having a first side and a second side opposite thereto. Each of the first side and the second side is flat or planar. The blister pack can also include a lid material having a first side and a second side opposite thereto. At least a portion of the second side of the lid material is adhered to the first side of the backing material to form a sealed package for containing the product. The lid material can include at least one blister. The blister pack can be formed from one or more recyclable materials.

Description

Technical Field

[0001] This application was filed on June 23, 2022, and claims priority to U.S. Provisional Patent Application No. 63 / 366,872, entitled "RECYCLABLE BLISTER PACK AND METHODS OF MAKING AND USING SAME", the disclosure of which is hereby incorporated by reference in its entirety.

[0002] The present disclosure relates to packages for sensitive or consumable products. More specifically, in one embodiment, the present disclosure relates to blister packages for products such as one or more pills, tablets, capsules, etc. In one optional embodiment, the present disclosure relates to a package in which a recyclable lid is coupled to a recyclable backing, both of which may optionally be formed of a thermoformed material.

Background Art

[0003] Blister packaging is commonly used to package oral solid dose drugs, vitamins, probiotics, pills, tablets, capsules, etc. Prior art packaging, such as U.S. Patent No. 8,142,603, which is hereby incorporated by reference, includes a thermoformed lid that holds the product and a foil backing attached to the open side thereof for enclosing the product. Blister packaging, or "blister packs", are typically used by both pharmaceutical companies and medical facilities. Blister packs are also manufactured by companies that conduct a business of providing unfilled or empty blister packs for filling by third parties.

[0004] It is known to place an extruded film of a desiccant or scavenger within a blister pack. The size and shape of the extruded film of the desiccant or scavenger may be referred to as the film footprint and, in the prior art, is at least slightly smaller than the opening of the blister that houses the product. Such blister packaging having a desiccant film is disclosed in U.S. Patent No. 6,279,736 (Hekal), International Publication No. WO2020 / 146556 (Hollinger), and International Publication No. WO2022 / 236313 (Hollinger), which are hereby incorporated by reference in their 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 a foil backing 12. An extruded desiccant film 16 having a width W PA (see Figure 2) smaller 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, plastic recycling sorting is often performed based on a flotation method, in which particles float or sink in water, and particles less than 1 g / cm 3 and particles less than 1 g / cm 3It is separated from the super particles. 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., using an air gun), sorting using sensors, and / or sorting using magnets can also be used. For further known recycling processes and characteristics, reference is made to "Managing Plastic Waste-Sorting, Recycling, Disposal, and Product Redesign", by Jean-Paul Lange, ACS Sustainable Chem. Eng. 2021, 9, 15722-15738, which is incorporated herein by reference.

[0007] In conventional blister packaging, the backsheet and the lid are made of different materials, which hinders recycling or at least makes recycling difficult or inefficient. For example, in conventional blister packaging, the backsheet is formed of foil and the lid is formed of a polymer. Further, in blister packaging containing active elements, recycling is further complicated or hindered because different materials are used to form the active elements. Due to these different materials, recycling of prior art blister packaging is at best difficult and time-consuming. In fact, companies are collecting used blister packaging, but there is no place to recycle it.

Summary of the Invention

Problems to be Solved by the Invention

[0008] There is a need to provide a recyclable blister package that can store and / or protect a product inside and / or can function as a desiccant or an oxygen scavenger.

Means for Solving the Problems

[0009] The foregoing and other needs are addressed by the disclosed technology, and in one aspect, a blister pack having a recyclable backing material and lid material is included. The lid material can be attached or joined to the backing material to form a sealed unit package for containing the product. The lid material can have at least one blister cavity having an open side. The backing material can have a side joined to the lid material.

[0010] In one optional embodiment, the blister cavity can have a blister portion or dome portion and a substrate portion. The substrate portion can be wider and / or longer than the blister portion.

[0011] Optionally, the blister pack can further include an active element, optionally in the form of an extruded film. In one optional embodiment, the extruded film can adhere to the side of the backing material joined to the lid material. The extruded film can have a shape approximating the substrate portion. The extruded film can include a desiccant, an oxygen scavenger, for example, or other active technologies.

[0012] Using an active element such as a desiccant within the blister pack can further complicate and / or prevent the recycling of the blister pack. In particular, the active element can undesirably contaminate the blister pack such that it cannot be recycled. For example, depending on the location or at least in certain known recycling processes, an empty (i.e., product-free) blister pack needs to be at least 90% olefin polymer and / or not have polyvinyl chloride (PVC) in order to be recyclable. Optionally, the active element of the disclosed technology can have 5 grams of zeolite to enable the blister pack to be at least 90% olefin polymer or polyolefin.

[0013] In another aspect, the disclosed technology can include a method of manufacturing a blister pack. In one embodiment, the method can include placing a product within each blister of a lidstock. The method can further include attaching or joining a thermoformed lidstock to a backing sheet to form a sealed unit package. The longitudinal axis of each blister may extend parallel to the edge of the backing sheet.

[0014] In one optional embodiment, the method can include attaching or adhering an extruded active polymer film to the inner surface of the cavity.

[0015] Optionally, in any embodiment, the product contained within the blisters of the blister pack may include, for example, tablets (optionally pharmaceuticals, nutraceuticals, or probiotics).

[0016] In one optional embodiment, the foil backing sheet of a conventional blister pack is replaced with one or more polymers such as polyethylene (PE) or polyethylene terephthalate (PET). Such polymers or films can cause an increase in water vapor transmission rate, which may thereby require the use of an active element within the blister cavity. The active element can optionally be an active polymer component having a substrate formed of, for example, PE or PET. The active element can optionally be heat welded onto the polymer backing sheet. The molecular sieve component of the active element may be exactly or approximately 5% of the total mass of the blister card or pack, or optionally 4 - 6%, or optionally 2 - 8%, thereby enabling a recycling step.

[0017] Optionally, the blister packaging is push - only type, which means that the product can be removed or is designed to be removed from the blister packaging by pushing the product through the packaging.

[0018] Optionally, the blister packaging is of the peel - push type, which means that the product can be removed from, or is designed to be removed from, the blister packaging by peeling a part of the packaging to expose the product and / or pushing the product through the packaging.

[0019] The foregoing summary and the following detailed description of the disclosed technology will be better understood when read in conjunction with the accompanying drawings. Like reference numerals throughout refer to like elements. For purposes of illustrating the disclosed technology, various exemplary embodiments are shown in the drawings. However, it is to be understood that the disclosed technology is not limited to the exact arrangements and instrumentalities shown. The drawings are as follows.

Brief Description of the Drawings

[0020]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7A

Figure 7B

DETAILED DESCRIPTION OF THE INVENTION

[0021] Systems, devices and methods are described herein by way of examples and embodiments, but those skilled in the art will recognize that the present disclosure is not limited to the embodiments or drawings described. Rather, the present disclosure encompasses all modifications, equivalents and alternatives within the spirit and scope of the appended claims. The features of any embodiment disclosed herein may be omitted or incorporated into another embodiment.

[0022] Any headings used herein are for organizational purposes only and are not intended to limit the scope of the description or claims herein. The term "may" as used herein is not used in an obligatory sense (i.e., "must") but in a permissive sense (i.e., "having the potential to"). Unless otherwise specified herein, the terms "a", "an" and "the" are not limited to one element and must be read to mean "at least one". The first direction D1 and the second direction D2 are shown in a particular drawing for reference and clarification only and are not part of the structure of the present disclosure. The terms include the words above, their derivatives, and words having similar meanings.

[0023] Referring now in detail to various figures in which like reference numerals indicate like parts throughout, FIGS. 3-7 illustrate embodiments of a blister packaging or pack (generally indicated at 110) of the present disclosure technology. Optionally, the recyclable blister pack 110 can be used to provide a sustainable form of packaging that can maintain or extend the shelf life of the product(s) therein.

[0024] In an exemplary embodiment, the blister pack 110 includes a backing member 112 and a lid member 114 attached to the backing member 112. Further, the lid member 114 is attached to the backing member 112 such that at least one cavity is formed therebetween, or a plurality of spaced cavities are formed by the combination of the lid member 114 and the backing member 112. As a result, the lid member 114 and the backing member 112 form at least one enclosure structured and / or configured to receive at least one product 117. Optionally, the lid member 114 can have any of a variety of shapes and / or configurations as disclosed in WO2020 / 146556.

[0025] The backing member 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 member 112 can be flat or planar. In one embodiment, each of the first side 112a and the second side 112b of the backing member 112 is flat or planar, whereby each of the first side 112a and the second side 112b extends at least slightly spaced within a plane.

[0026] The lid material 114 can have a first side or surface 114a and a second side or surface 114b on the opposite side. Optionally, at least a part of the first side 114a and the second side 114b of the lid material 114 is flat or planar. At least a part of the second side 114b of the lid material 114 can be attached or adhered to the first side 112a of the backsheet 112 by thermoforming or cold forming so as to form a sealed package for accommodating the product(s). The lid material 114 can have the same or different (measured in the direction of D2) thickness as the backsheet 112. In one embodiment, the lid material 114 is manufactured or formed from a formable web. In one embodiment, the formable web is manufactured from a thermoplastic material, such as a thermoformed film.

[0027] The lid material 114 includes or is formed to have at least one blister (generally indicated by 118). For example, the lid material 114 can include two or more spaced-apart blisters 118. The embodiments shown in FIGS. 3-6 show a lid material 114 having four spaced-apart identical blisters 118, similar to the configuration shown in FIG. 1. However, the lid material 114 can have more or fewer blisters according to specific requirements, and one or more of the blisters can have a different size and / or shape from another one of the blisters 118 of the blister pack 110. Optionally, each blister 118 can have at least a partial oval or bulbous shape. Alternatively, in one embodiment, each blister 118 can have at least a partial plateau shape (e.g., when viewed from the side) or a cylindrical shape. When the lid material 114 is attached to the backsheet 112, a sealed cavity is formed within or by each blister 118.

[0028] In one optional embodiment, each blister 118 can define a longitudinal axis or major axis that extends parallel to at least one outer edge of the backing 112 and the blister pack 110. Optionally, and more specifically, the longitudinal axis of each blister 118 can extend parallel to two opposite side surfaces of the blister pack 110 and perpendicular to the upper and lower side surfaces of the blister back, as shown in FIG. 3. However, the arrangement or orientation of the blister(s) 118 within the blister pack 110 is not limited to those shown and described herein, and other configurations are possible depending on specific needs.

[0029] The blister pack 110 can surround, store, and protect one or more products 117 (schematically shown in FIG. 3), such as orally administered solid drugs, vitamins or other dietary supplements, foods, small consumer goods, probiotics, etc. Such products may be in the form of pills, for example, tablets, capsules, etc. In one optional embodiment, the product 117 may be in powder form.

[0030] In one optional embodiment, the lid 114 and the backing 112 are formed from the same material and / or recyclable materials that enable the blister pack 110 to be easily reused or diverted and / or, as described in detail below, to be processed with recycling techniques, such as air classification, flotation separation, or sensor-based separation. The ability to be reused and / or recycled results from using a single material to form both the backing 112 and the lid 114. In such an embodiment, the blister 118 of the present embodiment is distinguishable from the prior art blister 18 in that the blister 118 of the present disclosed technology includes a backing 112 and a lid 114 formed from a single recyclable material rather than different materials and / or more than two materials.

[0031] The disclosed technology can be used with any of a variety of recycling technologies, including mechanical, chemical, or combinations thereof. For example, plastic waste is often sorted through a series of sorting steps. The sorting steps can include size sorting, either manually or using sieves, such as removing foreign objects (e.g., metals and glass), sorting by the type of plastic material, and / or sizing and granulating the plastic recyclables.

[0032] Certain materials can be removed or separated from other materials by gravity in an air stream (e.g., an air classifier) or a water stream (e.g., a flotation machine). An air classifier is a type of machine that uses an air stream and the relationship between inertial forces and / or gravity and drag to separate particles of different densities. For example, a strong air stream (e.g., an upward air column) can be induced or generated from the bottom to the top or towards the top of the machine, while the flow of the material is allowed to fall in the opposite direction from the top to the bottom of the machine. Optionally, the plastic flakes or granules can then be passed through a zigzag channel, which aids in the separation process. During this time, lighter materials such as labels and dust are blown upward and can be collected in a filter bag. As a result, high-quality plastic without labels and dust can be collected.

[0033] In particular, metals can be removed by utilizing their magnetic properties, for example, by the magnetic attraction of ferrous metals or the induced magnetic repulsion of non-ferrous metals.

[0034] Gravity can also be used to sort some things from plastic, for example, to separate polyolefins (e.g., with a density of about 0.9 g / mL) from PET or PVC (e.g., with a density of about 1.4 g / mL). This can be done, for example, within a machine or a vertical shaft. Gravity sorting can be improved using the assistance of an electrostatic or magnetic field.

[0035] A sink-float separation tank can use water or other liquids to separate mixed materials (e.g., plastics) based on density. For example, water has a density of 1 g / cm 3 ³. When pieces or items (e.g., plastics) enter or are introduced into the separation tank, anything denser than the liquid (e.g., water) will sink. The flow of heavy items collects at the bottom of the tank and can optionally be forced out of the machine using a screw conveyor. Similarly, anything less dense than the liquid will float and be discharged from the top of the machine. To improve the separation process, additives can be added to the liquid.

[0036] Certain sensor-based sorters are manufactured by TOMRA® Recycling in Germany. For example, a visual spectrometer sensor can be used to remove certain materials from the waste stream. Eddy currents are another type of separator or sensor that can be used.

[0037] Probably the most common way to sort plastics is to spread various plastics on a conveyor belt, optionally identify the plastics for sorting using an infrared detector (such as near-infrared (NIR) or short-wave infrared (SWIR)), and then sort the plastics by using an actuator or air jet. A standard infrared (IR) detector can be replaced with, or complemented by, hyperspectral imaging spectroscopy (HIS) to recognize fully formed products or an X-ray fluorescence detector to recognize heavy elements such as chlorine (Cl) or bromine (Br).

[0038] New sorting technologies are constantly being developed. For example, in the sorting of trace substrates, fluorescent pigments incorporated into plastic substrates or sleeves are used. These pigments are visible only under ultraviolet light in a sorting plant. In another technique, digital watermarks, such as codes incorporated into the design of the packaging and detectable by cameras on high-speed sorting lines, are used. The watermark can carry or reveal information about the product and its packaging. Yet another technique is robotic sorting, which applies artificial intelligence to assist cameras and robotic arms in sorting plastics from a conveyor belt. Each of the recycling technologies described above can be employed together with the disclosed technology.

[0039] In one embodiment, the backing material and the lid material are formed from a polymer such as a polyolefin or another synthetic fiber. As used herein, the term "polyolefin" refers to a polymer that is considered a product derived from an olefin (e.g., ethylene, CH2=CH2) that has reacted to form a polymer (e.g., polyethylene). A particular polyolefin can be considered a polymerization product of an α-olefin (CH2=CHR). A particular polyolefin has the formula (CH2-CHR) n . The polyolefin need not be obtained by such a reaction. Examples of polyolefins include polyethylene (PE), polypropylene (PP), polystyrene, polyacrylamide, polyvinyl alcohol, polyvinyl acetate, and the like.

[0040] Optionally, the backsheet 112 and the lid 114 can be formed from an optionally transparent thermoformed film, as disclosed in U.S. Patent No. 8,142,603, rather than conventional plastic lids and foil backsheets. Alternatively, the backsheet 112 and the lid 114 may be formed of copolyester or a copolyester film. Examples of copolyesters include PETG (polyethylene terephthalate glycol), PCTG (policyclohexylene dimethylene terephthalate glycol modified), and PCTA (1,4-cyclohexylene dimethylene terephthalate-co-isophthalate).

[0041] Embodiments of the disclosed technology are distinguishable from the technology disclosed in U.S. Patent No. 8,142,603, based at least on the materials used in the manufacture of the backsheet and the method of constructing or forming the backsheet. For example, columns 4, lines 23-37 of U.S. Patent No. 8,142,603 disclose sufficiently heating a lid foil to soften a polymer seal layer and adhering an active film to the softened polymer layer of the lid film. Despite the thin polymer seal layer, the backsheet itself of U.S. Patent No. 8,142,603 contains foil, which would disrupt or make difficult or impossible the recycling of its blister pack.

[0042] In one optional embodiment of the disclosed concept, the backsheet 112, the lid 114, and / or the active element 116 are formed from materials manufactured by TEKNI-PLEX® of Holland, Ohio. For example, the materials used are coated PVC / PVdC, PCTFE laminate (ACLAR®), or other PVC films. The materials may be rigid or flexible. Optionally, the materials may be any one of PX7-PX30 manufactured by TEKNI-PLEX®.

[0043] In another optional embodiment of the disclosed concept, the backsheet 112, the lid 114, and / or the active element 116 do not contain PVC or other chlorinated polymers.

[0044] In another alternative embodiment of the disclosed concept, the backing material 112, the lid material 114, and / or the active element 116 do not include a fluorinated polymer.

[0045] In one embodiment, the blister pack 110 of the disclosed technology contains an active material in an amount and / or at a specific location sufficient to maintain or extend the shelf life of the product(s) 117 without "contaminating" the blister pack 110 with an excessive amount of non-recyclable material that would prevent recycling of the blister pack 110 after the product(s) 117 have been removed. Optionally, the blister pack 110 includes a mineral active material having a mineral formulation in an amount that is sufficiently low as a percentage of the entire blister pack or the entire blister package on a mass basis so as not to prevent recycling of the blister pack 110.

[0046] In an exemplary embodiment, the backing material 112 and / or the lid material 114 are formed from, attached to, and / or include an active element or an active polymer material. In such an embodiment, the backing material 112 and / or the lid material 114 can regulate the environment within the cavity, for example, by adsorbing moisture, capturing oxygen, capturing volatile compounds, or releasing gases that affect the product(s) 117 within the cavity. Further, this structure allows the backing material 112 and / or the lid material 114 to preserve the product(s) 117 stored within the cavity or extend its shelf life. In this alternative embodiment, the active polymer material is a recyclable material and / or a material having a sufficiently low mineral content compared to the entire package so as not to "contaminate" the remaining portion of the blister pack 110 in such a way as to prevent or make impossible recyclability.

[0047] In an exemplary embodiment, the backing material 112 and / or the lid material 114 are in the form of a polymer mixed with a desiccant or a polymer mixed with an oxygen scavenger and / or are at least partially formed therefrom. This configuration reduces the need for additional elements and enables the blister pack 110 to be recycled without sacrificing the storage function of the product 117.

[0048] Optionally, the blister pack 110 and / or a part thereof can be formed of one or more biodegradable materials.

[0049] The backing material 112 and / or the lid material 114 can be constructed so that each of the at least one cavity can be opened to dispense the product 117, for example, by merely pressing one of the backing material 112 and / or the lid material 114 or by pushing and pulling. Further, each of the at least one cavity can optionally be subsequently sterilized, refilled, and then resealed.

[0050] In one optional embodiment, the backing material 112 includes at least two separate layers. For example, as shown in FIGS. 7A and 7B, the first layer, outer layer, or lower layer 132 of the backing material 112 can be formed purely of a polymer without using other materials. The second layer, inner layer, or upper layer 130 of the backing material 112 can be formed from a mixture of materials including a polymer and another component such as a mineral component. In particular, this mixture can include an active material within the polymer. Examples of the active material include zeolite, molecular sieve, silica gel, and the like.

[0051] In the above-described two-layer embodiment, as shown in FIG. 7A, the second layer 130 of the backing material 112 can have the same extent as the entire length and / or width of the first layer 132 and / or can extend across the entire length and / or width of the first layer 132. Alternatively, the second layer 130 of the backing material 112 can extend only along a portion of the length and / or width of the first layer 132 (see FIG. 7B), such as only within each cavity of the blister 118. In this latter embodiment, when it is desired to remove the product 112 from the blister 118, the first layer 132 can rupture more easily because the second layer 130 of the backing material 112 causes a pressure concentration at a location where the two layers do not overlap or at a specific location on a portion of the first layer 132 of the backing material 112. In the former embodiment, the absorption capacity or adsorption capacity is increased compared to the latter embodiment because additional active material is available or present.

[0052] Optionally, in embodiments where the second layer 130 of the backing material 112 extends only along a portion of the length and / or width of the first layer 132, such as only within each cavity of the blister 118, the second layer 130 can be a relatively thin sheet. Optionally, the sheet can also be formed by die casting. Alternatively, the sheet can also be extruded, for example, in the form of an extruded film. This thin sheet can be heat welded or otherwise attached to the first layer 130 only at a location or area that represents or has the same extent as or is smaller than each of the blisters 118.

[0053] In any version of the two-layer embodiments described above, the backing layer 112 can be formed by any of a variety of methods, and the second layer, inner layer, or upper layer of the backing layer 112 can be attached to the first layer, outer layer, or lower layer of the backing layer 112. For example, the two layers can be heat-sealed together or co-extruded. Optionally, the first layer is formed of only polyolefin, and the second layer is formed of a combination of polyolefin and zeolite or other active materials (e.g., mineral activators) dispersed therein.

[0054] In a further exemplary embodiment, the backing layer 112 and / or the lid layer 114 can include an embossed surface or a structured surface. The structured surface adds rigidity to the blister pack 110 without compromising the recyclable nature of the disclosed technology. The backing layer 112 and / or the lid layer 114 may be configured as an assembly consisting of multiple elements.

[0055] In an exemplary embodiment, as shown in FIG. 5, individual amounts of active polymer material are formed in the active polymer film 116 and are optionally integrated into at least one inner surface and / or at least a portion of the lid layer 114. In an alternative embodiment, the active material may be incorporated in the backing layer 112 and not in the lid layer 114, or may be incorporated in both the backing layer 112 and the lid layer 114. When incorporated in the backing layer 112, the active material can be limited to only the location under the blister 118, which reduces the force required to push the product 117 through the backing layer 112.

[0056] In any of the above embodiments, the amount of the active polymer film 116 used is so small that it has a negligible impact on the recyclable properties of the backsheet 112 and the lid 114, and thus does not "contaminate" the blister pack 110 for the recycling process. As a result, since the mineral content of the entire package 110 is below the threshold requirement for the recyclability of the package 110, an otherwise non-recyclable active polymer material 116 (the mineral content of the material 116 is quite high relative to its total mass, making it non-recyclable) can be used together with the recyclable backsheet 112 and lid 114.

[0057] Alternatively, the active polymer film 116 is, optionally, a liner that is superimposed or otherwise attached to at least a part or the whole of the inner surface of each of at least one cavity, as shown in FIG. 6. Thus, in one optional embodiment, the active polymer film 116 forms an envelope around the product 117 without impairing the recyclable properties of the backsheet 112 and the lid 114.

[0058] In another alternative embodiment, the active polymer film 116 is merely a layer attached to a part of the polymer backsheet 112 or the lid 114 within each cavity, as shown in FIG. 4.

[0059] In one embodiment, the backsheet 112 and the lid 114 can have a water vapor transmission rate in the range of 0.07 g / 100 in 2 / day to 0.58 g / 100 in 2 / day at an environmental temperature of 38 °C and a relative humidity of 90%. In a further embodiment, they can have an oxygen transmission rate in the range of 0.18 cm 3 / 100 in 2 / day to 1.4 cm 3 / 100 in 2 / day at an ambient temperature of 23 °C and a relative humidity of 50%.

[0060] In one embodiment, at least one recyclable active member 116 is disposed within at least the base material portion 122 of each blister 118. In one embodiment, the active member 116 can be in the form of a recyclable extruded film such as a polymer film mixed with a desiccant or a polymer film mixed with an oxygen scavenger.

[0061] The active member 116 can be heat-sealed (without using an adhesive) to the first side surface 112a of the backing material 112. The heat-sealing process of the film to the base material is described in detail in U.S. Patent No. 8,142,603. Whether by heat-sealing or other methods, it is contemplated that the active member 116 may be attached to the backing material 112 by heat-sealing (through thermal bonding) without using a separate adhesive material. The active member 116 can be attached to the backing material 112 by other mechanical or chemical methods such as adhesives or press-fitting. In one alternative embodiment, the active member 116 is not attached or fixed to the backing material 112, and the active member 112 can be movable relative to the backing material 112.

[0062] In one embodiment, the active polymer material contains a desiccant. This is an embodiment where moisture absorption or adsorption is desired. However, if moisture absorption or adsorption is not desired, the active polymer material or active element can include one or more alternative active agents. For example, in another embodiment, the active polymer material includes a material selected from the group consisting of activated carbon, carbon black, ketjen black, and diamond powder. In a further embodiment, the active agent including one or more layers of the active member 116 includes materials such as absorption microspheres, BaTiO3, SrTiO3, SiO2, Al2O3, ZnO, TiO2, MnO, CuO, Sb2O3, silica, calcium oxide, and ion exchange resins. In yet another embodiment, the absorbent-containing layer of the active polymer material includes two or more absorbents. Suitable absorbents are selected to absorb the desired vapor or gas for the desired end use (e.g., absorption of moisture, oxygen, carbon dioxide, nitrogen, or other undesirable gases or vapors).

[0063] The active polymer material (such as a desiccant, oxygen scavenger, release material or releasing agent, or a combination thereof) is capable of acting on, interacting with, or reacting with a selected material (such as moisture or oxygen). Examples of such an action or interaction include absorption and adsorption (i.e., generally sorption) or release of the selected material.

[0064] The active polymer material or active element can contain an active agent in the base material. The active agent is (i) immiscible with the base material (such as a polymer, polyolefin, or other synthetic fiber), and when mixed and heated with the base material and a channeling agent, does not melt, that is, when mixed and heated with the base material and the channeling agent, has a melting point higher than the melting point of either the base material or the channeling agent, and / or (ii) acts on, interacts with, or reacts with the selected material. The term "active agent" includes, but is not limited to, materials that absorb, adsorb, or release the selected material(s). The active agent according to the present disclosed technology may be in the form of particles such as minerals (molecular sieves, silica gel in the case of desiccants), but the present disclosed technology should not be considered limited only to particulate active agents. For example, in some embodiments, the oxygen scavenging formulation is produced from a resin that acts as an active agent or as a component of an active agent.

[0065] As used herein, the term "base polymer" is a component other than the active material agent that gives the structure of the active material admixture (optionally a polymer or synthetic fiber).

[0066] As used herein, the term "base polymer" is optionally a polymer in which the gas permeability of the selected material is substantially lower than or substantially equivalent 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, such permeability is the water vapor permeability. The main function of the base polymer is to provide a structure for the incorporated polymer. Suitable base polymers can include thermoplastic polymers such as polyolefins like polypropylene and polyethylene, polyisoprene, polybutadiene, polybutene, polysiloxane, polycarbonate, polyamide, ethylene vinyl acetate copolymer, ethylene-methacrylate copolymer, poly(vinyl chloride), polystyrene, polyester, polyanhydride, polyacrylianitrile, polysulfone, polyacrylate ester, acrylic acid, polyurethane, and polyacetal, or copolymers or mixtures thereof.

[0067] Referring to such a comparison of the water vapor permeabilities of the base polymer and the channeling agent, in one embodiment, the channeling agent has a water vapor permeability of at least twice that of the base polymer. In another embodiment, the channeling agent has a water vapor permeability of at least five times that of the base polymer. In another embodiment, the channeling agent has a water vapor permeability of at least ten times that of the base polymer. In yet another embodiment, the channeling agent has a water vapor permeability of at least twenty times that of the base polymer. In yet another embodiment, the channeling agent has a water vapor permeability of at least fifty times that of the base polymer. In yet another embodiment, the channeling agent has a water vapor permeability of at least one hundred times that of the base polymer.

[0068] 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 for transporting the gas-phase material at a faster rate than the base polymer. Optionally, the channeling agent can form channels through the incorporated polymer when formed by mixing the base polymer and the channeling agent. Optionally, such channels can allow a selected material to permeate through the incorporated polymer at a faster rate than in the case of the base polymer alone.

[0069] As used herein, the term "channel" or "interconnected channels" is defined as passages formed of a channeling agent that penetrate the base polymer and can be interconnected with each other.

[0070] As used herein, the term "incorporated polymer" is defined as a monolithic material formed from a base polymer having at least an active agent and, optionally, a channeling agent incorporated or distributed throughout. Thus, incorporated polymers include two-phase polymers and three-phase polymers. "Mineral-filled polymer" is a type of incorporated polymer where the active agent is in the form of a mineral, such as mineral particles of a molecular sieve or silica gel. The term "incorporated material" is used herein to mean a monolithic material containing an active agent incorporated into a base material, where the base material may or may not be a polymer.

[0071] As used herein, the term "monolithic", "monolithic structure", or "monolithic composition" is defined as a composition or material that does not consist of two or more distinct macroscopic layers or parts. Thus, "monolithic compositions" do not include multilayer composites.

[0072] As used herein, the term "phase" is defined as a part or component of a monolithic structure or monolithic composition that is uniformly distributed throughout the structure or composition such that it imparts its monolithic properties thereto.

[0073] As used herein, the term "selected material" is defined as a material upon which an active agent acts, or with which or to which the active agent interacts or reacts and can be transmitted through the channels of the incorporated polymer. For example, in embodiments where a desiccant is used as the active agent, the selected material may 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 may be a drug released by the release material such as moisture, a fragrance, or an antibacterial agent (e.g., chlorine dioxide). In embodiments where an adsorbent material is used as the active agent, the selected material may be a particular volatile organic compound, and the adsorbent material may be activated carbon, optionally activated carbon impregnated with tris(hydroxymethyl)aminomethane.

[0074] 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 disclosed technology would be an incorporated polymer formed from a base polymer, an active agent, and a channeling agent. Optionally, the three-phase composition or three-phase structure may include additional phases, such as a colorant.

[0075] The incorporated polymer can be a two-phase formulation (i.e., including a base polymer and an active agent without a channeling agent), or a three-phase formulation (i.e., including a base polymer, an active agent, and a channeling agent). The incorporated polymer is 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.

[0076] The incorporated material or polymer includes a base material (e.g., a polymer) for providing structure, optionally a channeling agent, and an activator. The channeling agent forms microscopic interconnecting channels through the incorporated polymer. At least a portion of the activator is included within these channels such that these channels communicate between the activator and the outside of the incorporated polymer through microscopic channel openings formed on the outer surface of the incorporated polymer. The activator can be, for example, any one of various absorbent materials, adsorbent materials, or release materials, as will be described in more detail below. The channeling agent is preferred, but the present invention broadly includes incorporated materials, such as two-phase polymers, that optionally do not include a channeling agent.

[0077] In any embodiment, suitable channeling agents can include polyglycols such as polyethylene glycol (PEG), ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), glycerin polyamine, polyurethane, and polycarboxylic acids including polyacrylic acid or polymethacrylic acid. Alternatively, the channeling agent can be a water-insoluble polymer such as a propylene oxide polymesate - monobutyl ether, such as Polyglykol B01 / 240 manufactured by CLARIANT. In other embodiments, the channeling agent can be a propylene oxide polymesate - monobutyl ether such as Polyglykol B01 / 20 manufactured by CLARIANT, a propylene oxide polymesate such as Polyglykol D01 / 240 manufactured by CLARIANT, ethylene vinyl acetate, nylon 6, nylon 66, or any combination of the foregoing.

[0078] Suitable activators according to the disclosed technology include absorption or adsorption (generally sorption) materials such as dry compounds. When the activator is a desiccant, any desiccant suitable for a given application can be used. Usually, physical sorption desiccants are preferred for many applications. These can include molecular sieves, silica gel, clay, starch, and the like. Alternatively, the desiccant may be a chemical compound that forms crystals containing water or a compound that reacts with water to form a new compound.

[0079] Optionally, in any embodiment, the activator may be an oxygen scavenger, such as an oxygen scavenging resin formulation.

[0080] In certain alternative embodiments, the oxygen scavenger is a metal-based oxygen scavenger. In certain embodiments, the oxygen scavenger contains zero-valent metal. In certain embodiments, the oxygen scavenger contains zero-valent metal in the form of particles or nanoparticles. In certain embodiments, the oxygen scavenger contains ionic metal, optionally ionic metal in the +1 or +2 oxidation state. In certain embodiments, the oxygen scavenger is a metal complex containing an organic ligand.

[0081] In certain alternative embodiments, the oxygen scavenger is non-metallic. 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 contains porphyrin. In certain embodiments, the oxygen scavenger is a naturally occurring substance.

[0082] 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 free radical trap. Certain free radical traps include phenolic moieties such as BHA, BHT, caffeic acid, ferulic acid, α-tocopherol, etc. Certain free radical traps are enols such as ascorbic acid (vitamin C). Certain free radical traps include weak X-H bonds (X = N, O, S) including but not limited to thiols, uric acid, and bilirubin. Certain free radical traps include polyene moieties such as β-carotene and other carotenoids. Certain free radical traps include conjugated or non-conjugated dienes such as α-terpinene and γ-terpinene, as well as certain unsaturated fats and fatty acids. In some optional embodiments, the oxygen scavenger comprises ascorbic acid, or a salt, ester, lactone or stereoisomer thereof.

[0083] Optionally, in any embodiment, to promote the recyclability of blister pack 110, the active material of the active element or the active agent throughout blister pack 110 is exactly or approximately 5% of the total mass of blister pack 110, optionally 4 - 6%, optionally 2 - 8%. More specifically, the active element 116 can include a molecular sieve, and the total mass of all the molecular sieves in blister pack 110 can be 5% or less, or 4 - 6%, or 2 - 8% of the total mass of blister pack 110.

[0084] Optionally, to promote the recyclability of blister pack 110, blister pack 110 can contain 5 grams or less of zeolite, optionally 1 - 5 grams, optionally 2 - 5 grams, optionally 3 - 5 grams.

[0085] Optionally used as a percentage of the total mass of the blister pack, and with the substantial remainder of the blister pack being made from the same polymeric material and used for the active element 116, the low mineral loading as described herein helps to still preserve the product(s) 117 within the blister pack 110 while preventing "contamination" of the blister pack 110 for recycling purposes. This is unique compared to conventional blister packs made from combinations of heterogeneous materials (including foil, paper, plastic, etc.) and thus being non-recyclable or difficult to recycle. In other words, the disclosed concept is unique in that it relates at least to blister packs that are predominantly composed of a polymer or the same polymer with a relatively small particulate (or other active) component as a ratio of the total mass of the blister pack. This enables the blister packs according to the disclosed concept to be recycled, whereas prior art blister packs with active elements are not recyclable or are difficult to recycle.

[0086] The disclosed technology includes methods of manufacturing, using, and / or recycling blister pack(s) 110. One method includes (i) providing and / or forming a lid member 114 having at least one blister 118 having one or more of the above-described features, (ii) disposing a product 117 in each blister 118, (iii) attaching one or more spaced-apart active elements 116 to the back member 112, and (iii) attaching or adhering the back member 112 to the lid member 114 to form a package sealed around the product 117 and the active element 116.

[0087] As used herein, the term "providing" is broadly defined to include receiving, incorporating, inserting, positioning, disposing, and / or using. When the user desires access to the product 117, at least a portion of the back member 112 can be separated from the lid member 114 (e.g., pushed / pulled or pushed only) or broken to expose the product 117.

[0088] Optionally, any of the films used in the disclosed technology can be formed by any of various methods such as extrusion, blowing, or casting.

[0089] The following exemplary embodiments further illustrate optional aspects of the disclosed technology and are part of the forms for implementing the invention. These exemplary embodiments are not strictly the claims of this application but are presented in a form substantially similar to the claims. In the following exemplary embodiments, instead of "claims", they are referred to as "embodiments" and cross-reference each other in a dependent relationship.

[0090] 1A. A recyclable blister pack, wherein the blister pack comprises a backsheet, a lid attached to the backsheet, wherein the lid and the backsheet are combined to form at least one cavity for accommodating at least one product, and an active element located inside the cavity or in fluid communication with the inside of the cavity and having a substrate, A recyclable blister pack, wherein the lid, the backsheet, and the substrate of the active element are formed of the same material.

[0091] 2A. The recyclable blister pack of Embodiment 1A, wherein the material is recyclable.

[0092] 3A. The recyclable blister pack of Embodiment 1A or 1B, wherein the material is a polyolefin.

[0093] 4A. The recyclable blister pack of any one of Embodiments 1A - 3A, wherein the lid and the backsheet are formed of a transparent thermoformed film.

[0094] 5A. The recyclable blister pack of any one of Embodiments 1A - 4A, wherein the backsheet and the lid are formed of a copolyester film.

[0095] 6A. The backsheet and the lid sheet have a water vapor transmission rate in the range of 0.07 g / 100 in 2 / day to 0.58 g / 100 in 2 / day at an ambient temperature of 38°C and a relative humidity of 90%, and is any one of the recyclable blister packs of Embodiments 1A to 5A.

[0096] 7A. The backsheet and the lid sheet have an oxygen transmission rate in the range of 0.18 cm 3 / 100 in 2 / day to 1.4 cm 3 / 100 in 2 / day at an ambient temperature of 23°C and a relative humidity of 50%, and is any one of the recyclable blister packs of Embodiments 1A to 6A.

[0097] 8A. The backsheet and the lid sheet are extrusion films, and the active element contains at least one of a desiccant and an oxygen scavenger, and is any one of the recyclable blister packs of Embodiments 1A to 7A.

[0098] 9A. The backsheet and the lid sheet are formed of 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, polyanhydride, polyacrylianitrile, polysulfone, polyacrylate ester, acrylic acid, polyurethane, polyacetal, their copolymers, and mixtures thereof, and is any one of the recyclable blister packs of Embodiments 1A to 8A.

[0099] 10A. The active element is an active polymer film laminated to at least one of the backsheet and the lid sheet or contained in the cavity, and is any one of the recyclable blister packs of Embodiments 1B to 5B.

[0100] 11A. The method of Embodiment 10A, wherein the active polymer film is formed of recyclable material.

[0101] 1B. A method of recycling a blister pack without containing a product therein or after the product is removed from the blister pack, the method comprising: obtaining a blister pack having a backsheet, a lid, and a substrate of an active element, the blister pack formed of a polyolefin; processing the blister packaging by a recycling sorting method.

[0102] 2B. The method of Embodiment 1B, wherein the active element comprises a molecular sieve having a mass of 5% or less of the total mass of the blister pack.

[0103] 3B. The method of Embodiment 1B, wherein the active element comprises a molecular sieve having a mass of 4 - 6% of the total mass of the blister pack.

[0104] 4B. The method of Embodiment 1B, wherein the active element comprises a molecular sieve having a mass of 2 - 8% of the total mass of the blister pack.

[0105] 5B. The method of any one of Embodiments 1A - 4B, wherein the recycling sorting method is one of air classification, flotation separation, and sensor - based sorting.

[0106] 1C. A method of recycling a blister pack without containing a product therein or after the product is removed from the blister pack, the method comprising: obtaining a blister pack having a backsheet, a lid, and a substrate of an active element formed of a synthetic fiber; processing the blister packaging by a recycling sorting method.

[0107] 1D. A method of forming at least a part of a recyclable blister pack, the method comprising: Welding one or more active elements to a polymer backing, each active element including a polymer substrate, the method including the welding.

[0108] 2D. The method of embodiment 1D, wherein the active element includes an active element or a molecular sieve, and the active element or the molecular sieve has a mass of 8% or less of the total mass of the pre-buried star pack.

[0109] 1F. A method for recycling a used blister pack, the method including processing a plurality of used items including one or more blister packs by a sorting process, the method in which the polymer component of the plurality of used items is separated from the non-polymer component of the plurality of used items.

[0110] 2F. The method of embodiment 1F, wherein each of the one or more blister packs includes a backing formed of a polymer, a lid, and a substrate of an active element.

[0111] 3F. The method of embodiment 1F or 2F, wherein the sorting process is one of air classification, flotation separation, or sensor-based sorting.

[0112] 4F. The method of embodiment 1F or 2F, wherein the sorting process includes generating an ascending air column to separate the plurality of used items.

[0113] 5F. The method of embodiment 1F or 2F, wherein the sorting process includes using one or more magnets to separate the metal component of the plurality of used items from the polymer component of the plurality of used items.

[0114] 6F. The method of embodiment 1F or 2F, wherein the sorting process includes dropping the plurality of used items and using gravity to separate the polyolefin component of the plurality of used items from the non-polyolefin component of the plurality of used items.

[0115] 7F. The sorting process of Embodiment 1F or 2F includes separating the polymer component of the plurality of used items from the non-polymer component of the plurality of used items using a water tank or a water bath.

[0116] Although the disclosed technology has been described in detail and with reference to its specific examples, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from its spirit and scope. Accordingly, it is understood that the disclosed technology is not limited to the specific embodiments disclosed, and is intended to cover modifications within the spirit and scope of the disclosed technology as defined by the appended claims.

Claims

1. A recyclable blister pack configured to hold at least one product, wherein the at least one product is a consumable in the form of a pill, tablet, capsule, or powder, and the blister pack comprises a backsheet formed of a polyolefin, and a lid formed of a polyolefin, the lid being attached to the backsheet, the lid and the backsheet being combined to form at least one cavity configured to contain the at least one product therein, a lid, and an active element located inside the cavity or in fluid communication with the inside of the cavity, the active element comprising a substrate formed of a polyolefin, an active element, and The blister pack is a recyclable blister pack configured to be recycled.

2. The active element includes a molecular sieve, and the total mass of all the molecular sieves in the blister pack is 8% or less of the total mass of the blister pack, optionally 2-8% of the total mass of the blister pack, optionally 4-6% of the total mass of the blister pack, and optionally 5% or less of the total mass of the blister pack. The recyclable blister pack according to claim 1.

3. The active element is in the form of a film attached to the backsheet. The recyclable blister pack according to claim 1.

4. The film is attached to the backsheet by heat sealing without using a separate adhesive material. The recyclable blister pack according to claim 3.

5. The active element is a desiccant-impregnated film. The recyclable blister pack according to claim 4.

6. The active element includes zeolite. The recyclable blister pack according to any one of the preceding claims.

7. The substrate of the active element is the same polyolefin as the backsheet. The recyclable blister pack according to any one of the preceding claims.

8. The lid is formed of the same polyolefin as the backsheet. The recyclable blister pack according to claim 6.

9. The backing and the cover have a thermal resistance of 0.07 g / 100 in at an ambient temperature of 38° C. and a relative humidity of 90%. ２ / day ~ 0.58g / 100in ２ 13. A recyclable blister pack according to any one of the preceding claims, having a water vapour transmission rate in the range of 100 / day.

10. The backing material and the lid material have an oxygen transmission rate in the range of 0.18 cm ３ / 100 in ２ / day to 1.4 cm ３ / 100 in ２ / day at an ambient temperature of 23°C and a relative humidity of 50%, and the recyclable blister pack according to any one of the preceding claims.

11. A method of manufacturing a recyclable blister pack, the method comprising Attaching a plurality of active elements to a backing material formed of a polyolefin, wherein the active elements are attached to the backing material in a spaced-apart arrangement, each active element includes a substrate formed of a polyolefin, the active element includes a molecular sieve, and the total mass of all the molecular sieves in the blister pack is 8% or less of the total mass of the blister pack, and attaching; Placing a product within each blister of a lid material that includes a plurality of spaced-apart blisters, wherein the lid material is formed of a polyolefin, and placing; Attaching the combined active elements and backing material to the lid material that includes a plurality of spaced-apart blisters, wherein each active element is disposed within one of the blisters, and attaching, a method.

12. The method according to claim 11, wherein a sealed cavity surrounds each pair of a product and an active element.

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

14. The method according to any one of claims 11 to 13, wherein the lid material and the backing material are formed of a transparent thermoformed film.

15. The backsheet and the cover sheet have a water vapor transmission rate in the range of 0.07 g / 100 in ２ / day to 0.58 g / 100 in ２ / day at a surrounding temperature of 38 °C and a relative humidity of 90%, according to any one of claims 11 to 14.

16. The back material and the lid material have an oxygen transmission rate in the range of 0.18 cm ３ / 100 in ２ / day to 1.4 cm ３ / 100 in ２ / day, and the method according to any one of claims 11 to 15.

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

18. The method according to any one of claims 11 to 17, wherein the substrate of each active element is the same polyolefin as the backing material.

19. The method according to claim 18, wherein the lid material is formed of the same polyolefin as the backing material.

20. The method according to claim 11, wherein the step of attaching the plurality of active elements to the backing material includes heat-sealing each active element to the backing material.

21. A recyclable blister pack, comprising a backing material, a lid material, and a substrate of at least one active element, all formed of a polyolefin, wherein the at least one active element is configured to absorb or adsorb moisture within the blister pack, each active element includes a molecular sieve, and the total mass of all the molecular sieves in the blister pack is 8% or less of the total mass of the blister pack, a recyclable blister pack.

22. The recyclable blister pack according to claim 21, wherein each active element is in the form of a film attached to the backing material.

23. The recyclable blister pack according to claim 22, wherein the film is heat-sealed to the backing material.

24. The recyclable blister pack according to claim 23, wherein each active element is a desiccant-containing film.

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

26. The recyclable blister pack according to any one of claims 21 to 25, wherein the base material of the active element is the same polyolefin as the backing material.

27. The recyclable blister pack according to claim 26, wherein the lid material is formed of the same olefin polymer or polyolefin as the backing material.

28. A method of recycling a recyclable blister pack according to any one of claims 21 to 27, the method comprising recycling the recyclable blister pack by a sorting process including one of air classification, float-sink separation, and sensor-based separation.

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

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

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

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

Images