Technologies for recyclable plastic packaging

Abstract

In an illustrative embodiment, a blister packaging includes a blister sheet, a front cardboard sheet, and a back cardboard sheet. The front cardboard sheet is adhered to the back cardboard sheet, forming adhered regions. Indentations are defined in the blister sheet, and the adhered regions extend into the indentations. The indentations and the adhered regions interact such that the blister sheet cannot be separated from the front sheet and back sheet without damaging the front sheet and / or the back sheet, improving security of the blister packaging.

Description

TECHNOLOGIES FOR RECYCLABLE PLASTIC PACKAGINGCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority from U.S. Provisional Patent Application Serial No. 63 / 620,160, filed January 11, 2024, and entitled, “TECHNOLOGIES FOR RECYCLABLE PLASTIC PACKAGING.” The disclosure of the prior application is considered part of and hereby incorporated by reference in its entirety in the disclosure of this application.BACKGROUND

[0002] Corporations and consumers are, in many instances, seeking to reduce the use of plastic and, when possible, facilitate the recycling of materials such as plastics used in packaging. One common plastic packaging is clamshell packaging, which is a type of container made of molded plastic, featuring a hinge that allows it to open like a clamshell, often used for retail products to provide visibility and security.

[0003] Plastic use can be reduced by using a thermoformed plastic cover that is adhered to a backing sheet, such as a sheet of cardboard. However, the adhesive holding the plastic to the cardboard will generally hold on to at least part of the cardboard backing when the package is opened. The cardboard adhered to the plastic can inhibit or prevent recycling of the plastic.BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The concepts described herein are illustrated by way of example and not by way of limitation in the accompanying figures. For simplicity and clarity of illustration, elements illustrated in the figures are not necessarily drawn to scale. Where considered appropriate, reference labels have been repeated among the figures to indicate corresponding or analogous elements.

[0005] FIG. 1 is a perspective view of a plastic blister packaged in cardboard sheet backing without adhesive contacting the plastic blister sheet.

[0006] FIG. 2 is a top-down view of the plastic blister packaged in cardboard sheet backing shown in FIG. 1.

[0007] FIG. 3 is an exploded view of the plastic blister packaged in cardboard sheet backing of FIG. 1.

[0008] FIG. 4 is a top-down view of the plastic blister of FIG. 1.

[0009] FIG. 5 is a flowchart of one embodiment of a method of forming the plastic blister packaged in cardboard sheet backing of FIG 1.

[0010] FIG. 6 shows one embodiment at one stage of the method of the flowchart of FIG. 5.

[0011] FIG. 7 shows one embodiment at one stage of the method of the flowchart of FIG. 5.

[0012] FIG. 8 shows one embodiment at one stage of the method of the flowchart of FIG. 5.

[0013] FIG. 9 shows one embodiment at one stage of the method of the flowchart of FIG. 5.

[0014] FIG. 10 shows one embodiment at one stage of the method of the flowchart of FIG. 5.DETAILED DESCRIPTION

[0015] In various embodiments disclosed herein, a blister package includes a plastic blister sheet, a cardboard backing sheet, and a cardboard front sheet. The cardboard backing sheet and the cardboard front sheet are adhered together with an adhesive to form an adhered region of the backing sheet and front sheet. The blister package has one or more protrusions that are at least partially surrounded by the adhered region. The interaction of the adhered region of the backing sheet and front sheet and the protrusions of the blister sheet interact to prevent the blister sheet from being removed from the blister package without damaging the backing sheet and / or front sheet, enhancing security of the blister package.

[0016] In the following description, specific details are set forth, but embodiments of the technologies described herein may be practiced without these specific details. Well-known structures, and techniques have not been shown in detail to avoid obscuring an understanding of this description. Phrases such as “an embodiment,” “various embodiments,” “some embodiments,” and the like may include features, structures, or characteristics, but not every embodiment necessarily includes the particular features, structures, or characteristics.

[0017] Some embodiments may have some, all, or none of the features described for other embodiments. “First,” “second,” “third,” and the like describe a common object andindicate different instances of like objects being referred to. Such adjectives do not imply objects so described must be in a given sequence, either temporally or spatially, in ranking, or any other manner. “Connected” may indicate elements are in direct physical, and “coupled” may indicate elements co-operate or interact, but they may or may not be in direct physical contact. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present disclosure, are synonymous. Terms modified by the word “substantially” include arrangements, orientations, spacings, or positions that vary slightly from the meaning of the unmodified term. It will be understood that in the examples shown and described further below, the figures may not be drawn to scale and may not include all possible layers and / or components.

[0018] Reference is now made to the drawings, which are not necessarily drawn to scale, wherein similar or same numbers may be used to designate the same or similar parts in different figures. The use of similar or same numbers in different figures does not mean all figures including similar or same numbers constitute a single or same embodiment. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

[0019] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the novel embodiments can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate a description thereof. The intention is to cover all modifications, equivalents, and alternatives within the scope of the claims.

[0020] As used herein, the phrase “located on” in the context of a first layer or component located on a second layer or component refers to the first layer or component being directly physically attached to the second part or component (no layers or components between the first and second layers or components) or physically attached to the second layer or component with one or more intervening layers or components.

[0021] As used herein, the term “adjacent” refers to layers or components that are in physical contact with each other. That is, there is no layer or component between the stated adjacent layers or components. For example, a layer X that is adjacent to a layer Y refers to a layer that is in physical contact with layer Y.

[0022] Referring now to FIGS. 1-4, in one embodiment, a blister package 100 is shown.FIG. 1 shows a perspective view of the blister package, FIG. 2 shows a top-down view of theblister package 100, FIG. 3 shows an exploded view of the blister package 100, and FIG. 4 shows a top-down view of a blister sheet 102 of the blister package.

[0023] The blister package 100 includes a blister sheet 102, a front sheet 106, and a back sheet 108. The blister sheet 102 includes a blister 104 extending from a flange area 302 in the blister sheet 102. The blister 104 can hold a product for, e.g., retail display and / or sale. In an illustrative embodiment, one or more protrusions 304 extend from the flange 302, forming one or more indentations 306. It should be appreciated that an outline of the blister sheet 102 (e.g., the outline shown in a dotted line in FIG. 2) has a non-convex shape due to the protrusions 304 and indentations 306. A cutout 110 may be present at one end through all layers (i.e., through the back sheet 108, the blister sheet 102, and the front sheet 106) for hanging the blister sheet 102.

[0024] In the illustrative embodiment, the front sheet 106 and the back sheet 108 are adhered together with an adhesive 308. Where the adhesive 308 adheres to the front sheet 106 and the back sheet 108, an adhered region is formed. In an illustrative embodiment, the adhesive 308 and the adhered region extend into the indentations 306 defined in the blister sheet 102. As a result, the blister sheet 102 cannot be removed from the blister package 100. For example, if a person tries to pull on the blister 104 to remove the blister sheet 102, the protrusions 304 will engage with the adhesive 308 in the indentations 306, preventing the blister sheet 102 from being removed. If enough force is applied to remove the blister sheet 102, the front sheet 106 and / or the back sheet 108 will be damaged. The front sheet 106 may have a cut-out region 312 for the blister 104 to extend through.

[0025] It should be appreciated that the adhesive 308 does not contact the blister sheet 102. The blister sheet 102 is held in place by the interaction of the protrusions 304 and indentations 306 with the adhered regions where the adhesive 308 adheres the front sheet 106 and back sheet 108. As a result, when the blister package 100 is opened, the blister sheet 102 is completely free of any adhesive 308 or parts of the front sheet 106 or back sheet 108, making the blister sheet 102 is better condition for recycling.

[0026] In the illustrative embodiment, the blister sheet 102 is polyethylene terephthalate (PET). Additionally or alternatively, in some embodiments, other materials may be used, such as amorphous polyethylene terephthalate (APET), recycled polyethylene terephthalate (RPET), polyethylene terephthalate glycol (PETG), polystyrene (PS), polycarbonate (PC), polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), or any other clear thermoplastic material. Although the illustrative embodiment is manufactured using thermoforming, other manufacturing techniques such as injection molding may be used in someembodiments. The blister sheet 102 may have any suitable dimensions, such as a length and / or width of 5-500 millimeters. The blister 104 may have any suitable dimensions, such as a length and / or width of 2-450 millimeters and a height of 0.1-200 millimeters. The blister sheet 102 may have any suitable thickness, 0.05-2 millimeters.

[0027] The back sheet 108 and / or the front sheet 106 may be made of any suitable material, such as cardboard (e.g., paperboard or other suitable cardboard), paper, and / or the like. The adhesive 308 may be any suitable adhesive, such as a heat-activated adhesive, a pressure-sensitive, a solvent-based adhesive, a water-based adhesive, and / or the like.

[0028] In an illustrative embodiment, the protrusions 304 / indentations 310 are disposed on the right and left edges of an approximately rectangular-shaped blister sheet 102, as shown in the figures. The blister sheet 102 may include any suitable number of protrusions 304 / indentations 310, such as 1-100. The protrusions 304 / indentations 310 may be arranged in any suitable positions around the blister sheet 102, such as disposed at the top and / or bottom in addition to or in place of the right and / or left sides. The blister sheet 102 may have any suitable approximate outline shape, such as a square, circle, hexagon, polygon, and / or the like, with similar protrusions 304 / indentations 310 as shown in the figures.

[0029] Referring now to FIG. 5, in one embodiment, a flowchart for a method 500 for packaging a product with blister packaging 100 is shown. The method 500 may be executed by a technician and / or by one or more automated machines. In some embodiments, one or more machines may be programmed to do some or all of the steps of the method 500. Such a machine may include, e.g., a memory, a processor, data storage, etc. The memory and / or data storage may store instructions that, when executed by the machine, causes the machine to perform some or all of the steps of the method 500. It should be appreciated that the method 500 is merely one embodiment of a method to create one embodiment of blister packaging 100 and other methods may be used to create any suitable embodiment of the blister packaging 100. In some embodiments, steps of the method 500 may be performed in a different order than that shown in the flowchart.

[0030] The method 500 begins in block 502, in which several blisters 104 are thermoformed in a plastic sheet 602, as shown in FIG. 6. In block 504, indentations 306 are die cut in the plastic sheet 602. In block 506, the plastic sheet 602 is cut into several plastic sheets 102, as shown in FIG. 7. It should be appreciated that, in some embodiments, blocks 502-506 may be performed continually on a long sheet of plastic, with blisters 104 being formed in part of the sheet, while indentations 306 are die cut in another part of the long sheet of plastic, while another part of the long sheet of plastic is being cut into individual plastic sheets 602.

[0031] In block 508, a cardboard back sheet 108 and a cardboard front sheet 106 are prepared, such as by cutting cutouts 110, 312 in the sheets 106, 108, as shown in FIG. 8. In block 510, adhesive 308 is applied to the cardboard back sheet 108 and / or the cardboard front sheet 106, as shown in FIG. 9.

[0032] In block 512, the product being packaged is placed in the blister 104 of the blister sheet 102. In block 514, the blister sheet 102 is placed on the cardboard back sheet 108. It should be appreciated that a gap 1002 is present between the edge of the adhesive 308 and the edge of the blister sheet 102, so that the adhesive 308 does not come into contact with the blister sheet 102, as shown in FIG. 10. The gap 1002 may be any suitable amount, such as 0.1- 5 millimeters. In block 516, the cardboard front sheet 106 is placed on the cardboard back sheet 108 and over the flange area 302 of the blister sheet 102. In block 518, the cardboard back sheet 108 is adhered to the cardboard front sheet 106 with the adhesive 308, such as by heating the adhesive 308, applying pressure to the adhesive 308, and / or the like.

[0033] It should be appreciated that different parts of the method 500 may be performed in different places and / or by different entities. For example, the blister sheets 102 may be formed in one facility and sent to another facility, where they are integrated into the blister packaging 100.EXAMPLES

[0034] Illustrative examples of the technologies disclosed herein are provided below. An embodiment of the technologies may include any one or more, and any combination of, the examples described below.

[0035] Example 1 includes an apparatus with blister packaging comprising a blister sheet; a back sheet; a front sheet; and an adhesive, wherein the adhesive is in contact with the back sheet and the front sheet, wherein the adhesive holds the back sheet and the front sheet together to form one or more adhered regions, wherein an outline of the blister sheet is non- convex with one or more indentations defined in the blister sheet, wherein at least part of the one or more adhered regions are within the one or more indentations.

[0036] Example 2 includes the subject matter of Example 1, and wherein the one or more adhered regions prevent the blister sheet from being removed without damage to the one or more adhered regions.

[0037] Example 3 includes the subject matter of any of Examples 1 and 2, and wherein the blister sheet is not adhered to by any adhesive.

[0038] Example 4 includes the subject matter of any of Examples 1-3, and wherein a blister is defined in the blister sheet, wherein a product is disposed within the blister.

[0039] Example 5 includes the subject matter of any of Examples 1-4, and wherein the blister sheet is polyethylene terephthalate.

[0040] Example 6 includes the subject matter of any of Examples 1-5, and wherein, when the blister sheet is removed from the blister packaging, the blister sheet does not have any adhesive on it.

[0041] Example 7 includes the subject matter of any of Examples 1-6, and wherein the back sheet is cardboard, wherein the front sheet is cardboard.

[0042] Example 8 includes the subject matter of any of Examples 1-7, and wherein the back sheet is paperboard, wherein the front sheet is paperboard.

[0043] Example 9 includes an apparatus with blister packaging comprising a blister sheet; a back sheet; a front sheet; and an adhesive, wherein the adhesive is in contact with the back sheet and the front sheet, wherein the adhesive holds the back sheet and the front sheet together to form one or more adhered regions, wherein one or more indentations are defined in the blister sheet, wherein at least part of the one or more adhered regions are within the one or more indentations.

[0044] Example 10 includes the subject matter of Example 9, and wherein the one or more adhered regions prevent the blister sheet from being removed without damage to the one or more adhered regions.

[0045] Example 11 includes the subject matter of any of Examples 9 and 10, and wherein the blister sheet is not adhered to by any adhesive.

[0046] Example 12 includes the subject matter of any of Examples 9-11, and wherein a blister is defined in the blister sheet, wherein a product is disposed within the blister.

[0047] Example 13 includes the subject matter of any of Examples 9-12, and wherein the blister sheet is polyethylene terephthalate.

[0048] Example 14 includes the subject matter of any of Examples 9-13, and wherein, when the blister sheet is removed from the blister packaging, the blister sheet does not have any adhesive on it.

[0049] Example 15 includes the subject matter of any of Examples 9-14, and wherein the back sheet is cardboard, wherein the front sheet is cardboard.

[0050] Example 16 includes the subject matter of any of Examples 9-15, and wherein the back sheet is paperboard, wherein the front sheet is paperboard.

[0051] Example 17 includes a method comprising thermoforming a blister in a blister sheet; cutting one or more indentations in the blister sheet; applying an adhesive to a first cardboard piece; disposing the blister sheet on the first cardboard piece without touching theblister sheet to the adhesive; and disposing a second cardboard piece on the first cardboard piece such that the adhesive adheres the first cardboard piece to the second cardboard piece to form one or more adhered regions, wherein at least part of the one or more adhered regions are within the one or more indentations.

[0052] Example 18 includes the subject matter of Example 17, and wherein the one or more adhered regions prevent the blister sheet from being removed without damage to the one or more adhered regions.

[0053] Example 19 includes the subject matter of any of Examples 17 and 18, and wherein the blister sheet is not adhered to by any adhesive.

[0054] Example 20 includes the subject matter of any of Examples 17-19, and wherein a blister is defined in the blister sheet, wherein a product is disposed within the blister.

[0055] Example 21 includes the subject matter of any of Examples 17-20, and wherein the blister sheet is polyethylene terephthalate.

[0056] Example 22 includes the subject matter of any of Examples 17-21, and wherein the blister sheet, the first cardboard piece, and the second cardboard piece make up a blister packaging, wherein, when the blister sheet is removed from the blister packaging, the blister sheet does not have any adhesive on it.

[0057] Example 23 includes the subject matter of any of Examples 17-22, and wherein the first cardboard piece is paperboard, wherein the second cardboard piece is paperboard.

[0058] Example 24 includes the subject matter of any of Examples 17-23, and further including removing the blister sheet from the first cardboard piece and the second cardboard piece; and recycling the blister sheet without removing any adhesive or cardboard adhering to the blister sheet.

Claims

CLAIMS1. An apparatus with blister packaging comprising: a blister sheet; a back sheet; a front sheet; and an adhesive, wherein the adhesive is in contact with the back sheet and the front sheet, wherein the adhesive holds the back sheet and the front sheet together to form one or more adhered regions, wherein an outline of the blister sheet is non-convex with one or more indentations defined in the blister sheet, wherein at least part of the one or more adhered regions are within the one or more indentations.

2. The apparatus of claim 1, wherein the one or more adhered regions prevent the blister sheet from being removed without damage to the one or more adhered regions.

3. The apparatus of claim 1, wherein the blister sheet is not adhered to by any adhesive.

4. The apparatus of claim 1, wherein a blister is defined in the blister sheet, wherein a product is disposed within the blister.

5. The apparatus of claim 1 , wherein the blister sheet is polyethylene terephthalate.

6. The apparatus of claim 1, wherein, when the blister sheet is removed from the blister packaging, the blister sheet does not have any adhesive on it.

7. The apparatus of claim 1, wherein the back sheet is cardboard, wherein the front sheet is cardboard.

8. The apparatus of claim 7, wherein the back sheet is paperboard, wherein the front sheet is paperboard.

9. An apparatus with blister packaging comprising: a blister sheet; a back sheet;a front sheet; and an adhesive, wherein the adhesive is in contact with the back sheet and the front sheet, wherein the adhesive holds the back sheet and the front sheet together to form one or more adhered regions, wherein one or more indentations are defined in the blister sheet, wherein at least part of the one or more adhered regions are within the one or more indentations.

10. The apparatus of claim 9, wherein the one or more adhered regions prevent the blister sheet from being removed without damage to the one or more adhered regions.

11. The apparatus of claim 9, wherein the blister sheet is not adhered to by any adhesive.

12. The apparatus of claim 9, wherein a blister is defined in the blister sheet, wherein a product is disposed within the blister.

13. The apparatus of claim 9, wherein the blister sheet is polyethylene terephthalate.

14. The apparatus of claim 9, wherein, when the blister sheet is removed from the blister packaging, the blister sheet does not have any adhesive on it.

15. The apparatus of claim 9, wherein the back sheet is cardboard, wherein the front sheet is cardboard.

16. The apparatus of claim 15, wherein the back sheet is paperboard, wherein the front sheet is paperboard.

17. A method comprising: thermoforming a blister in a blister sheet; cutting one or more indentations in the blister sheet; applying an adhesive to a first cardboard piece; disposing the blister sheet on the first cardboard piece without touching the blister sheet to the adhesive; and disposing a second cardboard piece on the first cardboard piece such that the adhesive adheres the first cardboard piece to the second cardboard piece to form one or more adhered regions,wherein at least part of the one or more adhered regions are within the one or more indentations.

18. The method of claim 17, wherein the one or more adhered regions prevent the blister sheet from being removed without damage to the one or more adhered regions.

19. The method of claim 17, wherein the blister sheet is not adhered to by any adhesive.

20. The method of claim 17, wherein a blister is defined in the blister sheet, wherein a product is disposed within the blister.

21. The method of claim 17, wherein the blister sheet is polyethylene terephthalate.

22. The method of claim 17, wherein the blister sheet, the first cardboard piece, and the second cardboard piece make up a blister packaging, wherein, when the blister sheet is removed from the blister packaging, the blister sheet does not have any adhesive on it.

23. The method of claim 17, wherein the first cardboard piece is paperboard, wherein the second cardboard piece is paperboard.

24. The method of claim 17, further comprising: removing the blister sheet from the first cardboard piece and the second cardboard piece; and recycling the blister sheet without removing any adhesive or cardboard adhering to the blister sheet.

Images