Method and apparatus for cutting and placing a film on a packaging substrate - Patents.com

Abstract

Disclosed is a method and apparatus for making a packaging film, the apparatus being configured to cut segments of a polymeric film containing an active agent at a cutting station, transport the film segments to a sealing station, and then seal the film segments to a base film, preferably comprising a foil, thereby forming the packaging film.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 62 / 886,755, entitled "METHODS AND APPARATUS FOR CUTTING AND PLACING FILM ONTO PACKAGING SUBSTRATES," filed August 14, 2019, the entire contents of which are incorporated herein by reference.

[0002] The disclosed concepts relate to methods and apparatus for making packaging films having a polymeric film layer that includes an active agent, such as a desiccant. The disclosed methods and apparatus are more particularly configured to cut segments of the polymeric film that includes the active agent at a cutting station, transfer the segments of film to a sealing station, and thereafter seal the segments of film to a base film, preferably including a foil, thereby forming the packaging film. [Background technology]

[0003] For example, moisture-sensitive and / or oxygen-sensitive products, such as diagnostic test strips, inhalers, and pharmaceutical tablets, are commonly contained within a packaging assembly. The packaging assembly typically includes a product space for containing the product, an active agent, such as a desiccant-entraining polymer, and a desiccant sachet or canister. The active agent can function to absorb moisture or remove oxygen that would otherwise impair and reduce the efficacy or shelf life of the product.

[0004] In some packaging assemblies, it is desirable to include an active agent in the form of an entrained polymeric film. Such films are typically very thin and are advantageously included in blister packs, pouches and other such flexible or semi-flexible packages. The entrained polymeric film, such as a desiccant film, is preferably integral with the package, rather than being provided in a loose, movable manner. One approach would be to provide an adhesive between the film and the substrate, or to provide a film with an adhesive backing. However, such configurations are very difficult to achieve in automated manufacturing, and the adhesive can generate undesirable volatile substances that can adversely affect the very product that the entrained film is intended to protect.

[0005] Therefore, applicants prefer to use pressure and heat heat stake to bond the entrained polymer film to the substrate without the use of a separate adhesive. Heat stake is described in U.S. Patent No. 8,142,603, assigned to CSP Technologies, Inc. The patent and the heat stake process generally are described in more detail below. While heat stake is preferred, automating the process for high volume applications of heat stake can be difficult. Thus, there is a need for improved methods and automated equipment for making packaging films that include an entrained polymer film containing an active agent and a foil substrate. Summary of the Invention

[0006] Thus, in the disclosed concept, a method and apparatus for making a packaging film is provided. The method includes providing an apparatus configured to make a packaging film for a product that is sensitive to at least one component in the surrounding environment, such as water vapor or oxygen. The apparatus includes a cutting station and a sealing station positioned at a location remote from the cutting station. The method includes conveying a strip of heat-sealable base film on the apparatus. A ribbon of entrained polymer film containing an active agent (e.g., a desiccant or oxygen scavenger) is conveyed on the apparatus and passes through the cutting station. A section of the entrained polymer film is cut. The section of the entrained polymer film is transferred from the cutting station to a sealing station such that the section of the entrained polymer film is sealed to a portion of the heat-sealable base film, thereby forming the packaging film.

[0007] The disclosed concepts are described in conjunction with the following drawings, in which like reference numbers indicate like elements and in which: [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is an isometric view of a first embodiment of an apparatus for making a packaging film, the packaging film including a heat-sealable base film and a film including an active agent configured to absorb, adsorb or release a selected material. [Figure 1A] FIG. 1A is an enlarged view of a portion of the device of FIG. [Diagram 2] FIG. 2 is an alternative isometric view of the device of FIG. [Figure 2A] FIG. 2A is a side isometric view of a portion of the apparatus of FIG. 1 showing the sealing station. [Diagram 3] FIG. 3 is a side isometric view of a portion of the apparatus of FIG. 1 showing the cutting station and film transport apparatus. [Figure 4] FIG. 4 is a front isometric view of one cutting station and film transport apparatus, where a section of film containing an active agent is cut at the cutting station. [Diagram 5] FIG. 5 is an isometric side view similar to that of FIG. 3 showing respective pieces of film containing active agent after they have been cut at the cutting station and placed on respective film transport devices. [Figure 6] FIG. 6 is a side isometric view similar to those of FIGS. 3 and 5 as each transfer device transfers each piece of film containing an active agent to a respective sealing station for sealing onto a base film. [Figure 7] FIG. 7 is a front isometric view of one cutting station and film transport apparatus showing a portion of the film containing an active agent being transported on the transport apparatus from the cutting station to the sealing station. [Figure 8] FIG. 8 is a rear isometric view of a portion of the apparatus of FIG. 1 showing a portion of the strip of film containing an active agent as it is fed onto a cutting station. [Figure 9] FIG. 9 is an isometric view of a second embodiment of an apparatus for making a packaging film, the packaging film including a heat-sealable base film and a film including an active agent configured to absorb, adsorb or release a selected material. [Figure 9A] FIG. 9A is a side isometric view of a portion of the apparatus of FIG. 9 showing the sealing station. [Figure 10] FIG. 10 is a side isometric view of a portion of the apparatus of FIG. 9 showing parallel strips of film containing an active agent being dispensed through the apparatus. [Figure 11] FIG. 11 is a rear isometric view of a portion of the device of FIG. 9 showing a cut piece of film containing an active agent that is transferred and sealed onto a base film that is dispensed from the device. [Figure 12] FIG. 12 is a top isometric view of the apparatus of FIG. 9 showing parallel strips of film containing an active agent being fed through the apparatus. [Figure 13]FIG. 13 is a rear isometric view of the portion of the apparatus of FIG. 9 showing parallel strips of film containing an active agent being fed into respective cutting stations and film transport apparatus ready for cutting and transport. [Figure 14] FIG. 14 is a rear isometric view of a portion of the apparatus of FIG. 9, similar to the rear isometric view of FIG. 13, showing sections of film being cut from the strip of film containing the active agent at each cutting station. [Figure 15] 15 is a rear isometric view of a portion of the apparatus of FIG. 9 similar to the rear isometric view of FIG. 13 showing pieces of film after they have been cut from the strip of film containing an active agent at their respective cutting stations, with each piece of film being placed on a film transport apparatus and about to be transported to a respective sealing station for sealing onto a base film. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Although the systems, devices and methods are described herein as examples and embodiments, those skilled in the art will recognize that the technology of the present disclosure is not limited to the described embodiments or drawings. Instead, the technology of the present disclosure encompasses all modifications, equivalents and alternatives that fall within the spirit and scope of the appended claims. Features of any one embodiment disclosed herein may be omitted or incorporated into another embodiment.

[0010] Any headings used herein are for organizational purposes only and are not meant to limit the scope of the description or claims. As used herein, the word "may" is used in a permissive sense (i.e., meaning "may") rather than a required sense (i.e., meaning "must"). Unless otherwise stated herein, the terms "a," "an," and "the" should be construed to mean "at least one" instead of being limited to one element.

[0011] This specification discloses a method for forming a packaging film using a polymer film entrained with an active agent, i.e., an agent that absorbs, adsorbs, or releases a selected material. For example, the active agent may absorb moisture, adsorb volatile organic compounds, or release antimicrobial gases. A polymer film entrained with an active agent may alternatively be referred to as an entrained polymer film, as described herein. As used herein, the term "entrained polymer" is defined as a monolithic material formed of at least a base polymer that includes an active agent, and optionally, as a channeling agent that is entrained or dispersed throughout. These types of entrained polymers and methods of making and using the same are disclosed, for example, in commonly owned U.S. Patent Nos. 5,911,937, 6,214,255, 6,130,263, 6,080,350, 6,174,952, 6,124,006, and 6,221,446, and U.S. Patent No. 2016 / 0039955, the entire contents of which are incorporated herein by reference. The entrained polymer film can optionally have a thickness of about 0.05 mm to about 2.5 mm, optionally about 0.2 to about 1.8 mm, optionally 0.2 to 1.3 mm.

[0012] The active agent (whether a desiccant, oxygen scavenger, release agent or component, or the like, or a combination thereof) can act, interact, or react with a selected material (e.g., moisture or oxygen). Examples of such action or interaction may include absorption, adsorption (generally, sorption), or release of the selected material. Entrained polymer films are typically made by extrusion.

[0013] The active agent (i) is miscible with the base polymer and does not melt when mixed and heated with the base polymer and the channeling agent, i.e., has a melting point higher than the melting point for either the base polymer or the channeling agent, and / or (ii) acts, interacts, or reacts with the selected material. The active agent of the disclosed technology can be in the form of particles such as minerals (e.g., molecular sieves or silica gel in the case of desiccants), but the disclosed technology should not be viewed as being limited to only particulate active agents. For example, in some embodiments, the oxygen scavenging formulation can be made with a resin that acts as an active agent or as a component thereof. Such resins may include, for example, those described in U.S. Pat. No. 7,893,145, the entire contents of which are incorporated herein by reference.

[0014] As used herein, the term "base polymer" is a polymer that optionally has a gas transmission rate of the selected material that is substantially lower or less than the gas transmission rate of the channeling agent (if the channeling agent is used in the entrained polymer). By way of example, such transmission rate would be the water vapor transmission rate in an embodiment where the selected material is moisture and the active ingredient is a water-absorbing desiccant. In any embodiment (whether or not a channeling agent is included), the primary function of the base polymer is to provide formability and structure to the entrained polymer. Suitable base polymers may include thermoplastic polymers such as, for example, polyolefins such as polypropylene and polyethylene, polyisoprene, polybutadiene, polybutene, polysiloxane, polycarbonate, polyamide, ethylene vinyl acetate copolymer, methacrylate ethylene copolymer, polyvinyl chloride, polystyrene, polyester, polyanhydride, polyacrylonitrile, polysulfone, polyacrylate, acrylic, polyurethane, and polyacetal, or copolymers or mixtures thereof.

[0015] With reference to such a comparison of the moisture vapor transmission rates of the base polymer and the channeling agent, in any embodiment, the channeling agent has a moisture vapor transmission rate that is at least twice that of the base polymer, optionally at least 5 times that of the base polymer, optionally at least 10 times that of the base polymer, optionally at least 20 times that of the base polymer, optionally at least 50 times that of the base polymer, and optionally at least 100 times that of the base polymer.

[0016] The term "channeling agent" or "channeling agents" as used herein is defined as a material that is immiscible with the base polymer and has an affinity for transporting gas phase substances at a faster rate than the base polymer. The channeling agent can optionally form channels with the entrained polymer when formed by mixing the channeling agent into the base polymer. Such channels can optionally transmit selected materials through the entrained polymer at a faster rate than the base polymer alone. As used herein, the term "channel" or "interconnecting channels" is defined as passages formed with the channeling agent that permeate the base polymer and may interconnect with each other.

[0017] As used herein, the terms "monolithic," "monolithic structure," or "monolithic composition" are defined as a composition or material that is not composed of two or more separate macroscopic layers or portions. Thus, a "monolithic composition" does not include a multi-layer composite, although it may function as a layer of such a composite.

[0018] As used herein, the term "phase" is defined as a portion or component of a monolithic structure or composition that is uniformly dispersed throughout to give that structure or composition its monolithic character.

[0019] As used herein, the term "selected material" is defined as a material that acts on, is acted upon by, or interacts or reacts with the active agent and can permeate the channels of the entrained polymer. For example, in embodiments where a desiccant is used as the active agent, the selected material may be moisture or gas that can be absorbed by the desiccant. In embodiments where an emissive material is used as the active agent, the selected material may be a drug released by the emissive material, such as moisture, a fragrance, or an antimicrobial agent (e.g., chlorine dioxide). In embodiments where an adsorbent is used as the active ingredient, the selected material may be a specific volatile organic compound, and the adsorbent may be activated carbon.

[0020] In any embodiment, suitable channeling agents may include polyglycols such as polyethylene glycol (PEG), ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), glycerin polyamines, polyurethanes, and polycarboxylic acids including polyacrylic acid or polymethacrylic acid. Alternatively, the channeling agent may be a water insoluble polymer such as propylene oxide polymerisate monobutyl ether, such as Polyglykol B01 / 240 from CLARIANT. In other embodiments, the channeling agent may be propylene oxide polymerisate monobutyl ether, such as Polyglykol B01 / 20 from CLARIANT, propylene oxide polymerisate, such as Polyglykol D01 / 240 from CLARIANT, ethylene vinyl acetate, nylon 6, nylon 66, or any combination of the above.

[0021] Suitable active ingredients according to the present disclosure include absorbents such as desiccant compounds. When the active agent is a desiccant, any suitable desiccant for a given application may be used. Typically, physical absorbent desiccants are preferred for many applications. These may include molecular sieves, silica gel, clays and starches. Alternatively, the desiccant may be a compound that forms a crystalline body containing water or a compound that reacts with water to form a new compound.

[0022] Optionally, in any embodiment, the activator may be an oxygen scavenger, such as an oxygen scavenging resin formulation.

[0023] Referring now in detail to the various figures of the drawings, in which like reference numbers refer to like parts throughout, in Figs. 1-8, various views of an apparatus 100 for making a packaging film 102 are shown, the packaging film 102 comprising a heat-sealable base film 104 and an active agent-containing film 106 secured (e.g., heat-sealed) to the base film 104, the active agent-containing film 106 being configured to absorb, adsorb or release a selected material. For simplicity, the active agent-containing film 106 is referred to herein primarily as a desiccant film 106, although it will be appreciated that the desiccant film 106 could alternatively be an oxygen scavenging film or any other entrained polymer film. Optional compositions of the desiccant film 106 include the entrained polymers described above. The base film 104 optionally comprises a foil and a sealing layer over the foil. The sealing layer is optionally comprised of, for example, polyethylene (LLDPE), polypropylene or SURYLN ionomer resin from Dow. The selected base film should have a sealing layer that includes a polymeric material that is compatible with the base polymer of the desiccant film. In other words, it should be compatible with a similar polymer. For example, if the base polymer of the desiccant film 106 includes polyethylene, the sealing layer of the base film 104 should also preferably include polyethylene. Selecting a foil that includes a sealing layer that is compatible with the base polymer of the desiccant film 106 facilitates the creation of a smooth bond between the desiccant film 106 and the foil. The sealing layer has a different melting point from manufacturer to manufacturer and is configured to become flexible when sufficient heat is provided to the foil.

[0024] The desiccant film 106 is optionally heat staked to the base film 104 to form the packaging film 102. "Heat stake" means placing the desiccant film on a foil, applying sufficient heat to the foil to activate (e.g., soften or otherwise pliable) the heat seal layer of the foil, and applying sufficient pressure to the combination of the desiccant film and foil to secure the desiccant film to the foil. Preferably, the desiccant film, when heat staked, is adhered to the foil by only applying heat and pressure to the combination and without any additional adhesive material. In an optional heat stake method that can be performed using the apparatus described herein, the foil is provided with a polymeric seal layer. Additionally, not only is the desiccant film provided, but also the flexible packaging is provided. The foil is heated such that the polymeric seal layer becomes pliable. Sealed areas of the foil are selected to form a seal between the foil and the flexible packaging. Additionally, non-sealed areas of the foil that are not sealed to the flexible packaging are also selected. An active film is applied to the polymer seal layer of the heated foil in the non-sealed areas of the heated foil to create an active film-foil combination. Sufficient pressure is applied to the active film-foil combination and sufficient heat is applied to the foil to bond the desiccant film to the polymer seal layer of the foil. The active film-foil combination is bonded to the flexible packaging by forming a seal between the seal area of ​​the foil and the flexible packaging. The process of heat staking in this context is discussed more fully in U.S. Patent No. 8,142,603, the entirety of which is incorporated herein by reference.

[0025] The apparatus 100 includes a frame 108 that supports the components of the apparatus 100. The apparatus 100 includes at least one desiccant film reel spindle 110. As shown, two desiccant film reel spindles 110 are provided, although it is envisioned that a single such spindle or, optionally, three or more spindles may be provided instead. A reel 112 of desiccant film 106 is rotatably mounted on each desiccant film reel spindle 110. From each respective reel 112, a ribbon 118 of desiccant film 106 is fed along a series of guide posts or rollers 114 toward a corresponding cutting station 116 positioned downstream from the reel 112. The guide posts or rollers 114 help to hold the ribbon 118 of desiccant film 106 steady as it is fed from the reel 112 to the cutting station 116. Optionally, a servo motor moves, optionally in a pulsating (i.e., start-stop) manner, the ribbon 118 of desiccant film 106 towards the cutting stations 116. The servo motor may drive feeder rollers 117 that pull the ribbon 118 towards the respective cutting stations 116, as discussed below.

[0026] The apparatus 100 includes at least one base film reel spindle 122. As shown, a single base film reel spindle 122 is provided, but it is envisioned that additional such spindles may be included. A reel 124 of base film 104 is rotatably mounted on the base film reel spindle 122. From the reel 124, a strip 120 of base film 104 is optionally fed under a roller 126 and guided to a platform 128. Optionally, the base film 104 is transported on the apparatus 100 as a long strip 120 in a direction that is optionally transverse or perpendicular to the direction in which the ribbon 118 of desiccant film 106 is fed. In other words, the theoretical vertical planes formed by the respective rotation axes of the spindles will intersect each other orthogonally or transversely.

[0027] The platform 128 includes at least one sealing station 130 (in the embodiment shown, there are two such sealing stations 130). The strip 120 of base film 104 is then fed at the end of the platform 128 to another roller 132, which optionally guides the base film 104 under and away from the platform 128. Optionally, the strip 120 of base film 104 is fed in a continuous motion and at a substantially constant speed.

[0028] The apparatus 100 further comprises at least one transport device 134, which is configured to transport the cut pieces 105 of the desiccant film from the cutting station 116 to the corresponding sealing station 130. The transport device 134 comprises a rotatably mounted disk 136, which is optionally generally cylindrical, although non-circular shapes are also envisaged. For example, instead of a circular shape, the disk may optionally have a central hub, for example with legs projecting radially outwardly therefrom. The disk 136 optionally comprises a number of film supports 138 extending from a radial surface 140 of the disk 136. Optionally, the disk 136 is configured to rotate in the same direction as the movement of the strip 120 of the base film 104 as the strip 120 is fed along the platform 128. In other words, the disk 136 rotates clockwise from the drawing state of FIG. 3.

[0029] The film supports 138 optionally include rubber on at least their outer surfaces. Each film support 138 optionally includes small holes connected to a vacuum source that helps hold the cut desiccant film pieces 105 to the film support 138 by suction from the vacuum source when the cut desiccant film pieces 105 are placed thereon. Alternatively, electrostatic charges or other means (e.g., grippers or notches) may be used to hold the cut desiccant film pieces 105 to the film support 138.

[0030] As best seen in Figures 3-6, a vertically movable platform 142 is provided. The platform 142 is vertically movable from a first (upper) position to a second (lower) position. The platform 142 is optionally pneumatically or servo driven. The platform 142 includes an extension portion 144 corresponding to a respective transport device 134. The extension portions 144 each optionally include a first and a second platen 148a, 148b and a blade 150 therebetween. The platens 148a, 148b may be retained on the extension portion 144 by posts 152, one or more of which optionally include a compression spring member 154 disposed thereabout. The cutting station 116 further includes a cutting surface 155 and a cutting surface end 156. The cutting surface edge 156 can include both an edge of the cutting surface 155 and an edge of the film support 138, both of which are generally collinear for a short period of time (at the time of cutting). The corresponding opposing edge 158 is approximately adjacent to the cutting surface edge 156 at the time the piece of desiccant film 105 is severed from the ribbon 118 of desiccant film 106. As used herein, "approximately adjacent" means that the components are next to each other with only a narrow space between them, e.g., a space large enough for a blade to fit into the gap.

[0031] The cutting station 116 optionally operates as follows: Slightly upstream of the cutting station 116 is a feeder roller 117 that optionally has ridges or a knurled surface pattern to help maintain control and positioning of the ribbon 118 as it feeds it towards the cutting station 116. The feeder roller 117 is servo driven, which optionally functions to pull the ribbon 118 from the reel 112 towards the cutting station 116. Having the feeder roller 117 driven by a servo motor allows for precision in the desired length of each film segment 105.

[0032] As the end of the ribbon 118 of the desiccant film 106 is fed to the cutting station 116, the cradle 142 is in a first position (e.g., as depicted in FIG. 7). At this point, a portion of the end of the ribbon 118 is disposed on the film support 138 and another portion is disposed on the cutting surface 155, approximately adjacent the cutting surface edge 156. The cradle 142 is then moved downward to a second position, thus driving the extension portion 144 in a vertically downward direction. The platens 148a, 148b press down on the portion of the desiccant film 106 beneath them to hold the portion in place. Almost immediately thereafter or simultaneously, the blade 150 descends to cut the desiccant film 106 at the narrow gap between the cutting surface edge 156 and the corresponding opposing edge 158. In this manner, a cut piece of desiccant film 105 is created and disposed on the film support 138.

[0033] The cut desiccant film segments 105 are held against the film support 138 as described above. The disk 136 is then rotated, for example, clockwise from the drawing shown in Figures 3-7, to transfer the cut desiccant film segments 105 from the cutting station 116 to the sealing station 130. At the same time, another film support 138 is positioned to receive another portion of the desiccant film 106 to repeat the cutting and transfer process.

[0034] The film support 138 with the cut desiccant film pieces 105 disposed thereon rotates to the sealing station 130. The cut desiccant film pieces 105 are placed on the base film 104 and pressed onto the base film 104 as a heating element 160 at the sealing station 130 heats the foil of the base film 104, causing the polymeric sealing layer of the foil to pliable. The pressure and heat cause the cut desiccant film pieces 105 to adhere to the packaging base film 104 without the presence of a separate adhesive, thereby forming the packaging film 102.

[0035] 9-15, an alternative embodiment of an apparatus 200 for making a packaging film 202 is shown. Similar to the embodiment of FIGS. 1-8, the packaging film 202 includes a heat-sealable base film 204 and an active agent-containing film 206, configured to absorb, adsorb, or release a selected material, secured (e.g., heat-sealed) to the base film 204. Similar to the above embodiment, the active agent-containing film 206 is also generally referred to herein as a desiccant film 206, even though the film is not limited to a desiccant material as the active agent. The desiccant film 206 and base film 204 may be of the same composition as their counterparts (106 and 104) described with respect to FIGS. 1-8. Additionally, the desiccant film 206 may be heat staked to the base film 204 to form the packaging film 202, as described herein with respect to FIGS. 1-8.

[0036] The apparatus 200 includes a frame 208 that supports the components of the apparatus 200. The apparatus 200 includes at least one desiccant film reel spindle 210. As shown, a single such spindle is provided, although two or more spindles may optionally be included. A reel 212 of desiccant film 206 is rotatably mounted on the desiccant film reel spindle 210. From the reel 212, a ribbon 218 of desiccant film 206 is fed along a series of guide posts or rollers 214 toward one or more cutting stations 216 located downstream from the reel 212. The guide posts or rollers 214 help to keep the ribbon 218 of desiccant film 206 stable as it is fed from the reel 212 to the cutting station 216. Optionally, a servo motor moves the ribbon of film 206 toward the cutting station 216, optionally in a pulsating motion. In the embodiment shown, the ribbon 218 is sliced ​​longitudinally and divided into multiple (in this case three) ribbon strips 218a, 218b, 218c at a location downstream from the reel 212. The ribbon strips 218a, 218b, 218c are pulled towards respective cutting stations 216 by feeder rollers 217, which are driven by servo motors.

[0037] The apparatus 200 comprises at least one base film reel spindle 222. As shown, a single base film reel spindle 222 is provided, but it is envisioned that additional such spindles may be included. A reel 224 of base film 204 is rotatably mounted on the base film reel spindle 222. The base film 204 is transported on the apparatus 200 as a long strip 220, optionally in the same direction along at least one Cartesian coordinate axis along which the ribbon 218 moves. In other words, the axes of rotation of both spindles 210, 222 (if virtually stretched outward in both directions) are parallel or collinear with each other. The strip 220 is optionally fed under rollers 226 and guided to a platform 228. The platform 228 forms part of at least one sealing station 230 (in the illustrated embodiment, three such sealing stations 230 are provided). As the strip of base film 220 exits the apparatus 200, it is then fed to at least one more roller 232. Optionally, the strip of base film 204 is fed in a continuous motion and at a substantially constant speed.

[0038] The apparatus 200 further comprises at least one transport device 234 configured to transport the cut desiccant film pieces 205 from the cutting station 216 to the corresponding sealing station 230. The transport device 234 comprises a rotatably mounted disk 236 including a central hub 236a with a number of legs 236b extending radially therefrom. In the embodiment shown, there are three equally spaced legs 236b, although fewer or additional legs may optionally be provided. Alternatively, the disk may be circular. Each leg 236b comprises at least one film support 238 extending from an end surface 240 of the leg 236b. In the embodiment shown, three film supports 328 per leg 236b are provided. Optionally, the disk 236 is configured to rotate in a direction opposite to the direction of movement of the strip 220 of base film 204 as the strip 220 is fed along the platform 228 .

[0039] The film supports 238 optionally include rubber on at least their outer surfaces. Each film support 238 optionally includes a small hole connected to a vacuum source that helps hold the cut desiccant film pieces 205 to the film support 238 by suction from the vacuum source when the cut desiccant film pieces 205 are placed thereon. Alternatively, electrostatic charges or other means (e.g., grippers or notches) may be used to hold the cut desiccant film pieces 205 to the film support 238.

[0040] As best seen in Figures 13-15, a vertically movable platform 242 is provided. The platform 242 is vertically movable from a first (upper) position to a second (lower) position. The platform 242 is optionally pneumatically or servo driven. The platform 242 includes extensions 244 corresponding to each film support 238. As shown, there are three film supports 238 per leg 236b, and thus three corresponding (aligned) extensions 244. In alternative embodiments, there may be more or fewer film supports in the installation, depending on the number of corresponding extensions per leg. Each extension 244 optionally includes a first platen and a second platen 248a, 248b, and a blade 250 therebetween. The platens 248a, 248b may be retained on the extension portion 244 with posts 252, one or more of which optionally include a compression spring member 254 disposed thereabout. The cutting station 216 further includes a cutting surface 255 and a cutting surface edge 256 that generally abuts a corresponding film support edge 258 at the time the desiccant film segment 205 is severed from the ribbon 218 of desiccant film 206.

[0041] The cutting station 216 optionally operates as follows: As best shown in FIG. 12, slightly upstream of the cutting station 216 is a feeder roller 217 that optionally has ridges or a knurled surface pattern to help maintain control and positioning of the ribbon strips 218a, 218b, 218c as it feeds them towards the cutting station 216. The feeder roller 217 is servo driven, which optionally functions to pull the ribbon strips 218a, 218b, 218c from the reel 212 towards the cutting station 216. Having the feeder roller 217 driven by a servo motor allows for precision in the desired length of each film segment 205.

[0042] The cradle 242 is in a first position as the end of each ribbon strip 218a, 218b, 218c of the desiccant film 206 is fed to the cutting station 216. At this point, a portion of the end of the ribbon strip 218a, 218b, 218c is disposed on the corresponding film support 238 and another portion is disposed on the cutting surface 255, approximately adjacent the cutting surface edge 256. The cradle 242 is then moved downward to a second position, thus driving the extension portion 244 in a vertically downward direction. The platens 248a, 248b press down on the portion of the desiccant film 206 beneath them to hold the portion in place. Almost immediately thereafter or simultaneously, the blade 250 descends to cut the desiccant film 206 in the narrow gap between the cutting surface edge 256 and the corresponding film support edge 258. In this manner, cut desiccant film pieces 205 are created and placed on the film support 238 .

[0043] The cut desiccant film segments 205 are retained on the film support 238 as described above. The disk 236 is then rotated, for example, counterclockwise from the drawing shown in Figures 10, 11 and 13-15, to transfer the cut desiccant film segments 205 from the cutting station 216 to the sealing station 230. At the same time, another film support 238 from another leg 236b is positioned to receive another portion of the desiccant film 206 to repeat the cutting and transfer process steps.

[0044] The film support 238 with the cut desiccant film segments 205 disposed thereon rotates to the sealing station 230. The cut desiccant film segments 205 are placed on the base film 204 and pressed onto the base film 204 as the heating element 260 at the sealing station 230 heats the foil of the base film 204 and causes the polymeric sealing layer of the foil to soften. The pressure and heat cause the cut desiccant film segments 205 to adhere to the packaging base film 204 without the presence of a separate adhesive, thereby forming the packaging film 202. By dividing the ribbon 218 into ribbon strips 218a, 218b, 218c, the apparatus 200 uniquely facilitates a cutting and sealing operation in multiple lanes. In other words, the apparatus 200 is configured to facilitate a method of making a packaging film 202 including a plurality of sealed desiccant film segments 205 positioned in a parallel linear array.

[0045] Optionally, in any embodiment, the entrained polymer film comprises an active agent in an amount of 10% to 80%, optionally 30% to 75%, optionally 30% to 60%, optionally 30% to 50%, optionally 35% to 70%, optionally 35% to 60%, optionally 35% to 55%, optionally 35% to 50%, optionally 40% to 70%, optionally 40% to 60%, optionally 40% to 50%, optionally 45% to 60%, optionally 50% to 60% by weight of the entrained polymer.

[0046] Optionally, in any embodiment, the entrained polymer film comprises an amount of base polymer that can range from 10% to 70%, optionally from 10% to 60%, optionally from 10% to 50%, optionally from 10% to 40%, optionally from 20% to 60%, optionally from 30% to 70%, optionally from 30% to 60%, 30% to 50%, optionally from 40% to 70%, optionally from 40% to 60%, 40% to 50% by weight of the entrained polymer.

[0047] Optionally, in any embodiment utilizing a channeling agent, the entrained polymer film may comprise from 1% to 16%, optionally from 1% to 14%, optionally from 1% to 12%, optionally from 1% to 10%, optionally from 1% to 8%, optionally from 1% to 6%, optionally from 1% to 5%, optionally from 1% to 4%, preferably from 2% to 16%, optionally from 2% to 14%, optionally from 2% to 12%, optionally from 2% to 10 ... , including an amount of channeling agent that may range from 2% to 8% by weight, optionally from 2% to 6% by weight, optionally from 2% to 5% by weight, optionally from 2% to 4% by weight, optionally from 4% to 12% by weight, optionally from 4% to 10% by weight, optionally from 4% to 8% by weight, optionally from 4% to 6% by weight, optionally from 4% to 5% by weight, optionally from 6% to 12% by weight, optionally from 6% to 10% by weight, optionally from 6% to 8% by weight, optionally from 8% to 12% by weight, optionally from 8% to 10% by weight.

[0048] The breadth and scope of the presently disclosed concepts should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

Claims

1. 1. A method of making a packaging film (102, 202) for use in storing a product, comprising: providing an apparatus (100, 200) configured to produce a packaging film (102, 202), the apparatus (100, 200) comprising a cutting station (116, 216) and a sealing station (130, 230) located at a distance from said cutting station (116, 216), said cutting station (116, 216) including a cutting surface (155, 255) and a cutting surface edge (156, 256), said apparatus (100, 200) comprising a plurality of film supports vertically arranged between said cutting station (116, 216) and said sealing station (130, 230); a transfer apparatus (134, 234) including a rotatably mounted disk (136, 236) having a body (138, 238), said cutting surface edge (156, 256) including both an edge of said cutting surface (155, 255) and an edge of a film support (138, 238), said apparatus (100, 200) including a platform (142, 242) vertically movable from a first upper position to a second lower position, said platform (142, 242) including extensions (144, 244), said extensions (144, 244) each including first and second platens (148a, b, 248a, b) and a blade (150, 250) therebetween; - conveying an elongated strip of a heat-sealable base film (104, 204) over said device (100, 200); - conveying on the apparatus (100, 200) a ribbon (118, 218) of entrained polymer film (106, 206) comprising a monolithic material comprising a base polymer and an active agent that absorbs, adsorbs or releases a selected material, and passing the ribbon (118, 218) of entrained polymer film (106, 206) through the cutting station (116, 216), whereby a piece (105, 205) of entrained polymer film (106, 206) is cut from an end of the ribbon (118, 218), conveying and passing the ribbon (118, 218) of entrained polymer film (106, 206) through the cutting station (116, 216), whereby as the end of the ribbon (118, 218) advances to the cutting station (116, 216), a portion of the end of the ribbon (118, 218) is cut from the ribbon (118, 218), a portion of the entrained polymer film is placed on the film support (138, 238) and another portion is placed on the cutting surface (155, 255), after which the cradles (142, 242) move downwardly from the first upper position to the second lower position, the platens (148a, b, 248a, b) press down on a portion of the end of the ribbon (118, 218) beneath them to hold the portion of the end of the ribbon (118, 218) in place, and the blades (150, 250) move down to cut the entrained polymer film in a narrow gap between the end of the cutting surface (155, 255) and the opposite end of the film support (138, 238), thereby creating the segment (105, 205) of cut entrained polymer film which is placed on the film support (138, 238); - rotating said transfer device (134, 234) to transfer said piece (105, 205) of entrained polymeric film (106, 206) from said cutting station (116, 216) to said sealing station (130, 230), wherein said film support (138, 238) applies pressure to said piece (105, 205) of entrained polymeric film (106, 206) and to a portion of said heat-sealable base film (104, 204). and transferring the sealing station (130, 230) while applying heat to the portion of the heat-sealable base film (104, 204) such that, without the presence of a separate adhesive, the piece (105, 205) of entrained polymeric film (106, 206) is sealed to the portion of the heat-sealable base film (104, 204), thereby forming the packaging film (102, 202).

2. The method of claim 1, wherein the active agent comprises from 30% to 75% by weight of the entrained polymer film and the base polymer comprises from 20% to 60% by weight of the entrained polymer film.

3. 3. The method of claim 1 or 2, wherein the entrained polymer film further comprises a channeling agent, the channeling agent comprising from 1% to 16%, optionally from 1% to 14%, optionally from 2% to 12% by weight of the entrained polymer film.

4. The method according to any one of claims 1 to 3, wherein the activator is a desiccant or an oxygen scavenger.

5. The method of any of claims 1 to 4, wherein the base film comprises a foil and a polymeric sealing layer on the foil.

6. The method of any of claims 1 to 5, wherein the entrained polymer film is from 0.05 mm to 1.0 mm thick.

7. The sealing station (130, 230) comprises a platform on which the portion of the heat-sealable base film (104, 204) is placed, the platform having a heating element for applying heat to the portion of the heat-sealable base film (104, 204) to soften an upper polymeric sealing layer of the portion of the heat-sealable base film (104, 204), the sealing station (130, 230) has the piece (105, 205) of the entrained polymeric film (106, 206) held thereon, and thereafter 7. The method of claim 1, further comprising: a film support disposed on the heat-sealable base film (104, 204), the film support applying pressure to the piece (105, 205) of entrained polymeric film (106, 206) and the base film, while the top polymeric sealing layer becomes soft due to heat and adheres the piece (105, 205) of entrained polymeric film (106, 206) to the portion of the heat-sealable base film (104, 204), thereby forming the packaging film (102, 202).

8. The method according to any of the preceding claims, wherein the cutting station (116, 216) and the sealing station (130, 230) are positioned at an angle of at least 90° to each other, optionally at least 120° to each other, optionally 180° to each other.

9. The method according to any of the preceding claims, wherein the pieces (105, 205) of entrained polymeric film (106, 206) are rotated on the rotatable transfer mechanism by at least 90°, optionally at least 120°, optionally 180° from the cutting station (116, 216) to the sealing station (130, 230).

10. An apparatus (100, 200) for making a packaging film (102, 202) for use in the storage of a product, comprising: The apparatus (100, 200) comprises a cutting station (116, 216) and a sealing station (130, 230), the sealing station (130, 230) is located at a location remote from the cutting station (116, 216); the apparatus (100, 200) is configured to convey an elongated strip of heat-sealable base film (104, 204), the apparatus (100, 200) is configured to convey a ribbon (118, 218) of entrained polymer film (106, 206) and pass the ribbon (118, 218) of entrained polymer film (106, 206) through the cutting station (116, 216); The entrained polymer film (106, 206) comprises a monolithic material including a base polymer and an active agent that absorbs, adsorbs, or releases a selected material; the cutting station (116, 216) is configured to cut a section (105, 205) of the entrained polymeric film (106, 206) from an end of the ribbon, the cutting station (116, 216) including a cutting surface (155, 255) and a cutting surface end (156, 256); the apparatus (100, 200) is configured to transfer the section (105, 205) of entrained polymeric film (106, 206) from the cutting station (116, 216) to the sealing station (130, 230); The apparatus (100, 200) includes a transfer device (134, 234) disposed vertically between the cutting station (116, 216) and the sealing station (130, 230) and comprising a rotatably mounted disk (136, 236) having a plurality of film supports (138, 238); each film support (138, 238) is configured to have disposed thereon the segments (105, 205) of entrained polymer film (106, 206) cut from the ribbon (118, 218) of entrained polymer film (106, 206) at the cutting station (116, 216); the cutting surface edge (156, 256) includes both an edge of the cutting surface (155, 255) and an edge of a film support (138, 238), and the transfer device (134, 234) is configured to rotate to transfer the section (105, 205) of entrained polymeric film (106, 206) from the cutting station (116, 216) to the sealing station (130, 230); The apparatus (100, 200) includes a platform (142, 242) vertically movable from a first upper position to a second lower position, the platform (142, 242) including an extension portion (144, 244), the extension portion (144, 244) each including first and second platens (148a, b, 248a, b) and a blade (150, 250) therebetween; The apparatus (100, 200) is configured such that, as the end of the ribbon (118, 218) advances to the cutting station (116, 216), a portion of the end of the ribbon (118, 218) is positioned on the film support (138, 238) and another portion is positioned on the cutting surface (155, 255), and then the carriages (142, 242) move downward from the first upper position to the second lower position, and the platens (148a, b, 248a, b) move the ribbon (118, 218) thereunder. a portion of the end of the ribbon (118, 218) being pressed down to hold a portion of the end of the ribbon (118, 218) in place, and the blade (150, 250) being lowered to cut the entrained polymer film in a narrow gap between the end of the cutting surface (155, 255) and the opposite end of the film support (138, 238), thereby creating and depositing the section (105, 205) of cut entrained polymer film on the film support (138, 238); the sealing station (130, 230) is configured to seal the piece (105, 205) of the associated polymeric film (106, 206) to the portion of the heat-sealable base film (104, 204), and the film support (138, 238) is configured to apply pressure to the piece (105, 205) of the associated polymeric film (106, 206) and the portion of the heat-sealable base film (104, 204), while the sealing station (130, 230) applies heat to the portion of the heat-sealable base film (104, 204), thereby sealing the piece (105, 205) of the associated polymeric film (106, 206) to the portion of the heat-sealable base film (104, 204) without the presence of a separate adhesive, to form the packaging film (102, 202).

11. the sealing station (130, 230) comprising a platform (128, 228) configured to receive the portion of the heat-sealable base film (104, 204) thereon; the platform (128, 228) having a heating element (160, 260) configured to apply heat to the portion of the heat-sealable base film (104, 204) to cause an upper polymeric seal layer of the portion of the heat-sealable base film (104, 204) to pliable; 11. The apparatus (100, 200) of claim 10, wherein the film supports (138, 238) are each configured to position the piece (105, 205) of the associated polymer film (106, 206) over the portion of the heat-sealable base film (104, 204) and apply pressure to the piece (105, 205) of the associated polymer film (106, 206) and the portion of the heat-sealable base film (104, 204), while the upper polymer sealing layer becomes soft due to heat and adheres the piece (105, 205) of the associated polymer film (106, 206) to the portion of the heat-sealable base film (104, 204), thereby forming the packaging film (102, 202).

12. the film support (138, 238) is provided with a small hole connected to a vacuum source; 12. The apparatus (100, 200) of claim 10 or 11, wherein when the piece (105, 205) of entrained polymer film (106, 206) is placed on the film support (138, 238), the small holes are configured to help hold the piece (105, 205) of entrained polymer film (106, 206) to the film support (138, 238) by suction from the vacuum source.

Images