Blister Card Package with Perforated Child-Resistant Edges
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Solution Overview
Problem
Existing pharmaceutical blister card packaging that achieves F-1 status for child resistance and senior friendliness is costly and lacks consistency due to the use of specialty tear-resistant paperboard and adhesive labels, leading to material availability issues and high production costs.
Innovation Solution
A pharmaceutical blister card package design using non-tear-resistant conventional card stock with die-cut holes and perforation lines, combined with thermoformed or cold-formed blisters, eliminates the need for expensive specialty paperboard and adhesive labels by creating secure, sealed edges and allowing easy access for senior adults while maintaining child resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tear-resistant paperboard and adhesive labels are used to achieve F-1 status, then child resistance and senior friendliness are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent removes the expensive adhesive labels from the packaging system entirely. Instead of using labels to prevent child opening, the invention uses a die-cut hole with a tear-resistant edge that allows children to tear the edge but cannot open the package, eliminating the need for separate adhesive labeling processes and materials.
Solution Approach 2:
The patent replaces expensive tear-resistant paperboard with conventional paperboard that is cheaper and more readily available. The packaging uses a disposable die-cut hole design that provides the necessary security function without requiring costly specialty materials, making the solution economically viable for small to medium pharmaceutical companies.
2Reliability
If tear-resistant paperboard is used to ensure child resistance, then package security is improved, but material availability becomes unpredictable with long lead times
Solution Approach 1:
The patent substitutes specialty tear-resistant paperboard with conventional paperboard that has standard, predictable availability. The security function is achieved through the die-cut hole design and adhesive application method rather than through specialty paperboard properties, eliminating the 6-12 week lead time issue associated with specialty material production.
3Reliability
If adhesive labels are applied to tear-resistant paperboard to trap and protect the blister, then child resistance is improved, but production cost increases due to separate label production and application processes
Solution Approach 1:
The patent combines the child resistance function and the blister protection function into a single integrated die-cut hole structure. The adhesive is applied directly to the cardstock at the hole location, eliminating the need for separate label production, handling, storage, and application processes, thereby reducing production complexity and cost.
Solution Approach 2:
The invention extracts and eliminates the separate adhesive label component from the packaging system. The adhesive is applied directly to the cardstock at the die-cut hole location, integrating the sealing function into the main packaging structure and removing the need for separate label manufacturing and application steps.
4Reliability
If specialty paperboard and adhesive labels are used to achieve F-1 status, then package security is improved, but consistency and quality control deteriorate due to separate production processes
Solution Approach 1:
The patent merges the security function and blister containment function into a single die-cut hole structure with adhesive applied at the same location. This integration ensures consistent positioning and quality control, as there is only one production step to align the security feature with the blister location, eliminating the inconsistencies that arise from separate label production and application processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design reduces material costs by at least 40% and improves consistency, enabling efficient production and cost-effective F-1 status packaging, suitable for small to medium-sized pharmaceutical companies, while eliminating the need for expensive adhesive labels and minimizing lead times.
Implementation Method 1
a paperboard fold-over card containing thermoformed or cold formed blisters which hold tablets
Implementation Method 2
a paperboard fold-over card containing thermoformed or cold formed blisters which hold tablets
Implementation Method 3
adhesive material that straddles such first set of perforation lines, and other adhesive material outside of such perforated window area, on the bottom side of the front panel and the top side of the rear panel, so such top, middle, and rear panels are affixedly aligned
Implementation Method 4
a first set of perforation lines in such card along and approximately one quarter inch inside of each outside exposed perimeter edge of each such panel
Data Source
AI summary
A pharmaceutical child-resistant fold-over card package with secure, sealed edges having: front, middle and rear panels of non-tear-resistant conventional card stock; at least one hole in such front panel, and at least one formed blister with a closed portion and an open portion, and a thin sheet of material covering such open portion of such blister to retain the position of such preparation inside such blister. A first set of perforation lines in such card along and approximately one quarter inch inside of each outside exposed perimeter edge of each such panel; a set of perforated holes in middle panel aligned with such hole in such top panel; a second set of perforation lines in the interior of such middle and rear panels and surrounding the area under the at least one blister, to form a perforated window under such blister and to form a tear tab.