Sealed Blister Assembly with Mechanical Interlock Seal
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Solution Overview
Problem
Conventional sealed blister packages face challenges such as complex assembly processes, potential damage to packaged products, and lack of tamper-indication and aesthetic issues, particularly in packaging pharmaceuticals and mixed medications, where existing adhesive or heat sealing methods are inefficient and unsuitable for ensuring freshness and security.
Innovation Solution
A sealed blister assembly that eliminates the need for adhesive or heat sealing, using a blister sheet, lid sheet, and label sheet where the label is secured to both, providing a frictional seal and tamper-indication through tearing when opened, with optional protuberances and score lines for easy separation and information display.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive or heat sealing is used to seal the blister sheet and lid sheet, then the seal is secure and impermeable, but the product being packaged may be adversely affected and the assembly process becomes complicated
Solution Approach 1:
The patent replaces adhesive bonding and heat sealing processes with a mechanical interlocking system. The lid sheet includes engagement features that mechanically interlock with corresponding features on the blister sheet, creating a secure seal without requiring adhesives or heat. This mechanical system eliminates harmful thermal and chemical effects on the packaged product while maintaining seal integrity.
Solution Approach 2:
The patent introduces a rupture layer as an intermediary component between the blister sheet and lid sheet. This rupture layer provides a controlled opening mechanism that allows the seal to be broken in a predetermined manner without damaging the product. The rupture layer acts as a mediator that manages the sealing and opening functions separately, preventing direct mechanical damage to the packaged item.
2Reliability
If adhesive or heat sealing is used to seal the blister sheet and lid sheet, then the seal is secure and impermeable, but the assembly process becomes complicated and difficult to assemble
Solution Approach 1:
The patent replaces complex adhesive application and heat sealing processes with simple mechanical interlocking features. The engagement features on the lid sheet and corresponding features on the blister sheet allow for straightforward assembly through direct mechanical connection, eliminating the need for adhesive dispensing, drying time, or heat sealing equipment, thus reducing assembly complexity while maintaining seal reliability.
Solution Approach 2:
The mechanical interlocking system is designed to assemble itself through the natural engagement of complementary features on the blister sheet and lid sheet. The components self-align and self-secure through the interlocking mechanism, eliminating the need for external bonding agents or complex assembly procedures, thereby simplifying the overall assembly process while ensuring reliable sealing.
3Ease of operation
If a rupture layer is included to allow access to medication, then access is enabled, but consumers find it difficult to operate and it is aesthetically displeasing
Solution Approach 1:
The patent segments the opening function from the sealing function by introducing a separate rupture layer. This rupture layer is specifically designed with score lines or tear lines that guide the opening action, making it easy for consumers to operate by simply pulling or tearing along the predetermined line. The segmentation allows the rupture layer to handle the opening operation independently, reducing overall operational complexity while maintaining ease of access.
4Ease of operation
If a rupture layer is included to allow access to medication, then access is enabled, but it prevents multiple pills or medications types from being packaged in a single blister
Solution Approach 1:
The patent divides the blister packaging into multiple independent compartments or sections, each with its own rupture layer and sealing mechanism. This segmentation allows different types of pills or medications to be packaged in separate compartments within the same blister pack. Each compartment can be opened independently through its own rupture layer, maintaining packaging flexibility and versatility while enabling easy access to multiple medication types.
5Reliability
If adhesive or heat sealing is used, then the seal is secure, but the process is time consuming and primarily efficient in high-volume manufacturing
Solution Approach 1:
The patent replaces time-consuming adhesive application and heat sealing processes with instantaneous mechanical interlocking. The engagement features on the lid sheet and blister sheet create an immediate secure connection upon assembly, eliminating the drying time required for adhesives or the heating and cooling cycles required for heat sealing. This mechanical system achieves reliable sealing in a single rapid action, significantly reducing assembly time while maintaining seal integrity.
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 solution provides an impermeable seal without damaging products, simplifies assembly, ensures tamper-indication, and allows for easy access to multiple medications, enhancing both the security and usability of blister packaging.
Implementation Method 1
The lid sheet and blister sheet are joined together to form an impermeable seal
Data Source
AI summary
A sealed blister assembly is made tip of a blister sheet, a lid sheet, and a label sheet. The plastic sheet and plastic lid are joined together to form a substantially impermeable seal. The seal is formed by engagement of an undercut in the plastic sheet and a shoulder in the plastic lid. A plastic sheet and/or plastic lid are made from a polymer such as low density polyethylene to obtain the impermeable seal. The label sheet is secured directly to the blister and lid sheets.