US20020166790A1

US20020166790A1 - Multi-cell blister package having a thermoformed cap and associated methods

Info

Publication number: US20020166790A1
Application number: US10/060,943
Authority: US
Inventors: John Aylward
Original assignee: Aylward Enterprises Inc
Current assignee: Aylward Enterprises Inc
Priority date: 2000-06-28
Filing date: 2002-01-30
Publication date: 2002-11-14

Abstract

A thermoformed package for a pill-like product is provided. Such a package comprises a first enclosure portion defining a plurality of receptacles, each receptacle being adapted to house the product therein. A sealing layer operably engages the first enclosure portion so as to seal each of the receptacles. A second enclosure portion operably engages the first enclosure portion so as to form a plurality of cells, wherein the second enclosure portion defines a plurality of caps corresponding to the plurality of receptacles. Each cell comprises one of the plurality of receptacles sealed by the sealing layer and the corresponding one of the plurality of caps operably engaged with the receptacle. The plurality of receptacles and/or the plurality of caps are separably engaged so as to allow the cells to be separated. Each cell also comprises a locking mechanism having a first component operably engaging the receptacle and a second component operably engaging the corresponding cap, wherein the first component operably engages the second component so as to secure the cap to the corresponding receptacle. The components of the locking mechanism are further configured to be separable so as to allow separation of the cap from the corresponding receptacle and to thereby allow the product to be selectively extracted from the cell. An alternative embodiment provides a cover layer disposed between the sealing member and the second enclosure portion, the second enclosure portion being separable from the first enclosure portion as a single continuous piece, or as individual caps, so as to allow access to the cover layer. Associated methods are also provided.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 09/891,232, filed on Jun. 25, 2001, which is hereby incorporated herein in its entirety by reference.[0001]

FIELD OF THE INVENTION

The present invention relates to product packages and, more particularly, to a multi-cell blister package having a thermoformed cap and associated methods.

BACKGROUND OF THE INVENTION

In the packaging of pharmaceuticals, such as pills, capsules, caplets, tablets, and the like, various package constructions have been proposed. For example, various packages have been created that generally allow such pharmaceuticals to be dispensed from a mass container such as a pill bottle or from an individual receptacle of a blister package. For convenience, such pharmaceuticals are referred to herein as “pills” or “pill-like products,” though it will be understood that such terms are meant to cover many different types, shapes, and forms of pharmaceuticals mentioned above, as well as non-pharmaceutical items such as candies, vitamins, or the like.

Pill bottles typically contain a predetermined number of pills or have a number of pills dispensed therein by, for example, a pharmacist. Pill bottles often include a “child-proof” cap which requires the user to perform a certain sequence of steps in order to remove the cap. For example, the user may have to simultaneously push the cap toward the bottle, or squeeze retaining tabs on diametrically-opposed sides of the bottle, while turning the cap. Such a feature desirably serves to deter children from accessing the pills within the bottle. However, the pills within the bottle are typically not sealed from the environment and may be affected by ambient humidity, other forms of moisture, or other contaminants entering the bottle. In addition, the dispensing of the desired number of pills may be difficult to control. Further, pill-to-pill contact may cause damage to the pills. Still further, such pill bottles may not provide tamper-evident features for the user.

Another form of pharmaceutical packaging comprises, for example, a blister package, wherein one or more pills are packaged in individual blisters. The blisters are generally arranged in a matrix, in a circle, or in other forms so as to define the pill package. Typically, the pills are inserted into individual blisters formed in a thermoplastic web and sealed by a foil layer. Accordingly, a pill is usually dispensed by pushing the blister against the foil layer until the foil layer tears and the pill can be extracted. However, such packaging generally does not provide child-proof features.

Other related packaging designs may, for instance, encase the blister package in an outer package formed from paper or cardboard stock. In such instances, a perforated portion of the outer package must be removed before the pill in a particular blister can be accessed through the foil layer. However, the blister package may be easily removed from the outer package or the pill may be simultaneously pushed through both the foil layer and the perforated portion of the outer package, making the desired child-proof features lacking in such a design.

Still another design provides, for example, a second material layer, such as a heavy paperstock, over the foil layer, wherein the second material layer must be removed prior to the pill being extracted. However, the second material layer may sometimes have a loosely-tabbed corner, such that the second material layer may be easily removed for ready access to the pill with no resulting child-proof feature. In other instances, the second material layer may be overly difficult to remove by, for example, a user having an arthritic condition of the hands. Yet another design provides, for example, a blister which must be folded and/or torn in order to remove the pill. Again, such a design, while possibly providing a child-proof feature, may prove overly difficult to use by, for example, a user having an arthritic condition of the hands. Thus, blister packaging provides for sealed packaging of one or more pills in individual blisters, thereby resulting in advantages, such as less risk of contamination, degradation, or other damage to the pills, precise dispensing of the desired number of pills, and tamper-evident features, over traditional pill bottles. However, such blister packaging design is still lacking an effective child-proof feature which does not render the packaging too difficult to be used by a wide range of adult users.

A manufacturing technique that has been used in connection with, for example, blister packages for pharmaceuticals, involves thermoforming a thermoplastic web of material into a desired shape. A generally flat web of material is advanced through a thermoforming station which is provided with opposed dies having corresponding projections and depressions. The dies are closed and heat and pressure are applied to the web of material to plastically deform the material into the desired shape. Upon cooling, at least part of a package is formed, such as the blister portion of a conventional blister package. A foil lidstock is often then heat sealed to the blister portion to seal the package closed. As noted above, a heavy paperstock can then be laminated over the foil (such that the paperstock can be peeled off the foil) to add a second child-deterrent and tamper-evident feature. The thermoforming process is relatively inexpensive and can provide high throughput.

Thus, there is a need in the industry for a blister-type package which achieves the benefits of thermoforming processes, namely lower cost and higher processing speeds, while at the same time providing an effective child-proof feature without rendering such a package too difficult to be used by a wide range of adult users. Such desirable attributes are advantageously provided by embodiments of the present invention as discussed further herein.

SUMMARY OF THE INVENTION

The above and other needs are met by the present invention which, in one embodiment, provides a thermoformed package for a pill-like product. Such a package comprises a first enclosure portion defining a plurality of receptacles, wherein each receptacle is adapted to house the product therein. A sealing layer is configured to operably engage the first enclosure portion so as to seal each of the receptacles and a cover layer may be applied over the sealing layer. A second enclosure portion is configured to operably engage the first enclosure portion so as to, in one embodiment, form a plurality of cells, wherein the second enclosure portion defines a plurality of caps corresponding to the plurality of receptacles and each cell comprises one of the plurality of receptacles sealed by the sealing layer and the corresponding one of the plurality of caps operably engaging the receptacle. Further, the plurality of receptacles and/or the plurality of caps are separably engaged so as to allow the cells to be separated. Each cell also comprises a locking mechanism having a first component operably engaging the receptacle and a second component operably engaging the corresponding cap, wherein the first component corresponds to and is configured to operably engage the second component so as to secure the cap to the corresponding receptacle. The components of the locking mechanism are further configured to be separable so as to allow separation of the cap from the corresponding receptacle and to thereby allow the product to be selectively extracted from the cell.

Another advantageous aspect of the present invention comprises a method of forming a thermoformed package for a pill-like product. A first enclosure portion is first operably engaged with a sealing member, wherein the first enclosure portion defines a plurality of receptacles adapted to house the product and the sealing member is adapted to seal the product within the respective receptacle. A second enclosure portion is then operably engaged with the first enclosure portion, wherein the second enclosure portion defines a plurality of caps corresponding to the plurality of receptacles. Each cap is configured to operably engage the respective receptacle so as to form a corresponding cell, and the plurality of receptacles and/or the plurality of caps are separably engaged so as to allow the cells to be separated. A component of a locking mechanism for each cell is then formed following formation of the cell, wherein the locking mechanism comprises a first component operably engaging the receptacle and a second component operably engaging the corresponding cap. The first component corresponds to and is configured to operably engage the second component to secure the cap to the corresponding receptacle. The components of the locking mechanism are further configured to be separable so as to allow separation of the cap from the corresponding receptacle and to thereby allow the product to be selectively extracted from the respective cell.

Still another advantageous aspect of the present invention comprises a method of extracting a pill-like product from a cell of a thermoformed package comprising a plurality of cells joined by a connecting member, wherein each cell has a cap component operably engaging a receptacle component adapted to house the product, and a sealing member operably engaging the receptacle so as to seal the product therein. First, the connecting member is severed so as to separate a selected cell from the plurality of cells. A first component of a locking mechanism operably engaging the cap is then separated from a second component of the locking mechanism operably engaging the receptacle so as to expose the sealing member sealing the receptacle. The product is then extracted from the receptacle.

Yet another advantageous aspect of the present invention comprises a thermoformed package for a pill-like product. A first enclosure portion defines a plurality of receptacles, wherein each receptacle is adapted to house the product therein. A sealing member operably engages the first enclosure portion so as to seal each of the receptacles. A cover layer then operably engages the sealing member such that a portion of the cover layer must be separated from a corresponding portion of the sealing member in order to access the respective receptacle. A second enclosure portion corresponds to and is configured to operably engage the first enclosure portion such that the second enclosure portion must be separated from the first enclosure portion in order to access the cover layer. The package further comprises a locking mechanism having a first component operably engaging the first enclosure portion and a second component operably engaging the second enclosure portion. The first component corresponds to and is configured to operably engage the second component so as to secure the first enclosure portion to the second enclosure portion. The components of the locking mechanism are further configured to be separable so as to allow separation of the first enclosure portion from the second enclosure portion and to thereby allow the portion of the cover layer to be removed such that the product can be selectively extracted from the corresponding receptacle past the sealing member. Other associated advantageous aspects further comprise a method of forming, and a method of extracting a pill from, such a package.

Thus, embodiments of the present invention provide a blister-type package which achieves the benefits of thermoforming processes, namely lower cost and higher processing speeds, while at the same time providing an effective child-proof feature without rendering such a package too difficult to be used by a wide range of adult users. Accordingly, embodiments of the present invention provide significant advantages as further described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: [0015]
FIG. 1A is a plan view of a thermoformed package for containing a pill-like product according to one embodiment of the present invention. [0016]
FIG. 1B is a cross-sectional view of a thermoformed package for containing a pill-like product according to one embodiment of the present invention taken along [0017] line 1B-1B of FIG. 1A.
FIG. 1C is a plan view of a thermoformed package for containing a pill-like product according to one embodiment of the present invention illustrating the separation of a cell from the plurality of cells comprising the package. [0018]
FIG. 2A is a plan view of a cell having a locking mechanism according to an alternate embodiment of the present invention. [0019]
FIG. 2B is a cross-sectional view of a cell having a locking mechanism according to an alternate embodiment of the present invention taken along [0020] line 2B-2B of FIG. 2A.
FIG. 2C is a schematic side view of a cell having a locking mechanism according to an alternate embodiment of the present invention illustrating removal of the cap component of the cell. [0021]
FIG. 3A is a plan view of a cell having a locking mechanism according to one embodiment of the present invention. [0022]
FIG. 3B is a cross-sectional view of a cell having a locking mechanism according to one embodiment of the present invention taken along [0023] line 3B-3B of FIG. 3A.
FIG. 3C is a side view of a locking mechanism according to one embodiment of the present invention corresponding to [0024] area 3C of FIG. 3A.
FIG. 3D is a schematic side view of a cell having a locking mechanism according to one embodiment of the present invention illustrating removal of the cap component of the cell. [0025]
FIG. 4A is a schematic side view of a pill-like product being extracted from the receptacle through the sealing member according to one embodiment of the present invention. [0026]
FIG. 4B is a schematic side view of a pill-like product being extracted from the receptacle, after the sealing member has been separated from the receptacle, according to one embodiment of the present invention. [0027]
FIG. 5A is a plan view of a cell having a plurality of locking mechanisms disposed about the corners thereof according to one embodiment of the present invention. [0028]
FIG. 5B is a plan view of a cell having a plurality of locking mechanisms disposed about the side edges thereof according to one embodiment of the present invention. [0029]
FIG. 6 is a schematic side view of an apparatus for forming a multi-cell blister package having a thermoformed cap for each cell according to one embodiment of the present invention. [0030]
FIG. 7A is a plan view of a thermoformed package for containing a pill-like product according to an alternate embodiment of the present invention. [0031]
FIG. 7B is a cross-sectional view of a thermoformed package for containing a pill-like product according to an alternate embodiment of the present invention taken along [0032] line 7B-7B of FIG. 7A.
FIG. 7C is a cross-sectional view of a thermoformed package for containing a pill-like product according to an alternate embodiment of the present invention illustrating the separation of an enclosure portion and removal of a cover layer so as to allow extraction of a pill from one of the plurality of cells comprising the package.[0033]

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. [0034]
FIGS. [0035] 1A-1C illustrate a package 100 according to one embodiment of the present invention, the package 100 being configured for packaging pills or pill-like products 110. As used herein, the terms “pills” or “pill-like products” are intended to be broad and to cover all types of items which may be packaged, including candies, vitamins, pharmaceutical products such as pills, tablets and the like, and any other products of use to a consumer which can be packaged in packaging of the type discussed herein. The package 100 comprises a plurality of thermoformed blisters or receptacles 120 forming a first enclosure portion, each receptacle 120 being configured to house one or more pills 110. Such receptacles 120 are generally produced in a thermoforming process whereby a thermoplastic web of material is formed into a desired shape, as will be appreciated and understood by one skilled in the art. For example, a sheet of thermoformable material may be advanced continuously or indexed into a thermoformer that has corresponding projections and depressions in a matching pair of forming dies. More particularly, for the receptacles 120 forming the first enclosure portion of the package 100, the upper forming die may include a projection having a shape corresponding to the upper surface of the first enclosure portion and the lower forming die may have a corresponding depression corresponding to the lower surface of the first enclosure portion. As would be further understood by one of ordinary skill in the art, the sheet of thermoformable material may include multiple rows and columns of blanks each corresponding to an individual package 100. At some subsequent point in the manufacturing process, a cutting die or other sharp member can be used to cut the sheet between the blanks to form individual packages 100. Further, the receptacles 120 forming each package 100 may be arranged in a matrix, whereby a 2×5 matrix is illustrated for the purpose of example. However, it will be understood that embodiments of the present invention contemplate many different arrangements of receptacles 120 to form the package 100, within the spirit and scope of the present invention. For example, the receptacles 120 may be arranged in a 1×10 matrix or in a 31-receptacle circular configuration.
Once the [0036] pills 110 have been disposed in the receptacles 120, a sealing member 130 such as, for example, an aluminum foil layer, is applied over the receptacles 120 by, for instance, heat sealing, so as to hermetically seal the pills 110 therein. The sealing member 130 thus cooperates with the receptacles 120 to, for instance, protect the pills 110 from contamination or ambient humidity, provide a tamper-evident feature, and lessen damage from pill-to-pill contact. It will be understood, however, that a foil layer is but one example of a suitable sealing member 130, wherein any suitable material could be used having appropriate barrier properties and/or tamper-evident indication capabilities. An example of an alternative material is polyester film.
The [0037] package 100, according to one embodiment, also includes a plurality of thermoformed caps 140, forming a second enclosure portion. The caps 140 are configured to correspond to the plurality of receptacles 120 and may also be formed from an appropriate continuous web of thermoplastic material that can be rigid or flexible. The caps 140 of the second enclosure portion are then engaged with the receptacles 120 of the first enclosure portion, as will be described in further detail below, to form a corresponding plurality of cells 150. Further, one advantageous aspect of the present invention is that each cap 140 is configured to cover the sealing member 130 engaged with the corresponding receptacle 120 to such an extent that the pill 110 cannot be removed from the receptacle 120 while the cap 140 is engaged with the receptacle 120. Accordingly, the cap 140 may be configured to cover all or part of the sealing member 130 sealing the receptacle 120.
Once the plurality of [0038] cells 150 is formed into the package 100, upon engagement of the caps 140 with the receptacles 120, FIGS. 1A-1C illustrate that adjacent cells 150 are connected by one or more connecting members 160. According to embodiments of the present invention, the connecting members 160 may be extensions of the web from which the receptacles 120 are formed, the web from which the caps 140 are formed, and/or the sealing member 130. However, in some embodiments, the connecting members 160 comprise extensions of all three components 120, 130, 140. In addition, though the connecting members 160 are shown as discrete components extending between adjacent cells 150, the cells 150 may, in some instances, be interconnected by a single continuous connecting member 160. According to another advantageous aspect of the present invention, the connecting member 160 is configured to facilitate the separation of individual cells 150 from the package 100. For example, the connecting member 160 may comprise a frangible material or may be configured to be frangible, such as by having a reduced cross-sectional area. In other instances, the connecting member 160 may be scored or perforated so as to facilitate separation of individual cells 150 from the package 100, though it will be understood that many different configurations of the connecting member 160 may be implemented in order to facilitate separation of the cells 150. An example of a cell 150 being separated from the package 100 is shown in FIG. 1C.
FIGS. [0039] 2A-2C show an example of a cell 150 separated from a package 100 according to one embodiment of the present invention. As shown, both the receptacle 120 and the cap 140 may also include respective peripheral flanges 125, 145, whereby the receptacle 120 and corresponding cap 140 are secured together at the peripheral flanges 125, 145. In order to secure the cap 140 to the receptacle 120, each cell 150 includes one or more locking mechanisms 170 formed about the peripheral flanges 125, 145. According to one advantageous embodiment of the present invention, the one or more locking mechanisms 170 are formed following the assembly of the cell 150 from the receptacle 120, the sealing member 130, and the corresponding cap 140. In addition, the embodiments illustrated herein show a circular receptacle 120 with a corresponding square peripheral flange 125 as but one example of a possible configuration. In such an embodiment, the locking mechanism 170 may be conveniently disposed about a corner of the peripheral flange 125 where a larger area of the thermoformable material is available for forming the locking mechanism 170. However, it will be understood and appreciated by one skilled in the art that the shapes of the receptacle 120 and the corresponding peripheral flange 125 may vary greatly and, accordingly, the locking mechanism 170 may be disposed in different positions about the peripheral flange 125, where such disposition would facilitate the implementation of the invention as presented herein.
As further illustrated in FIGS. [0040] 2A-2C, one component of a locking mechanism 170 according to one embodiment of the present invention may comprise, for example, a thermoformed projection 180 extending from the peripheral flange 145 about the cap 140 which, as discussed in more detail below, secures the cap 140 to the receptacle 120. The projection 180 is received and engaged by a corresponding opening or aperture 190 defined by the peripheral flange 125 about the receptacle 120 of the cell 150. In the plan view shown in FIG. 2A, the locking mechanism 170 is shown in a closed position such that only the upper side of the projection 180 is visible. Accordingly, once the sealing member 130 is applied to the receptacle 120 to seal the pill 110 therein, one or more apertures 190 are formed through the peripheral flange 125 of the receptacle 120 and, in some instances, the sealing member 130 if the sealing member 130 extends across the peripheral flange 125. The aperture 190 can be formed in any conventional way including die punching and the like, provided that the resulting opening has relatively well-defined edges for securely retaining the projection 180. In addition, the shape of the openings is not necessarily circular as illustrated.
The [0041] cap 140 of the second enclosure portion, which may be formed of the same material as the receptacle 120 of the first enclosure portion, is then placed over the sealing member 130 and the peripheral flange 145 thereof is engaged with the upper surface of the sealing member 130 or directly to the peripheral flange 125 of the receptacle 120. In some instances, a lacquer is applied to all or part of the lower surface of the peripheral flange 145 of the cap 140 or a separately applied adhesive is heated during a sealing operation to seal all or part of the peripheral flange 145 of the cap 140 to the peripheral flange 125 of the receptacle 120 and/or the sealing member 130. For example, in some instances, both peripheral flanges 125, 145 may be sealed together about the periphery, but the area about the locking mechanism 170 may be free of the adhesive. However, in other instances, even the locking mechanism 170 area may include some adhesive between the peripheral flanges 125, 145. Further, in some instances, a distal corner of the peripheral flange 145 of the cap 140 may extend beyond the corresponding distal corner of the peripheral flange 125 of the receptacle 120 by a small distance. The purpose for the slight overhang 200 of the peripheral flange 145 of the cap 140 is to assist in separating the cap 140 from the receptacle 120.
As will be appreciated and understood by one skilled in the art, and as described in detail in co-pending U.S. patent application Ser. No. 09/891,232, which has been incorporated herein by reference, the plurality of [0042] cells 150 forming the package 100 is then advanced into a thermoforming station, wherein heated dies are used to form the projection 180. For example, a heated upper die defining an opening above the aperture 190 may cooperate with a lower die defining a corresponding cavity, which is sized at its top edge slightly larger than the aperture 190 to produce the projection 180. For instance, air may be pressurized through the opening in the upper die toward the lower die. The heat from the upper die heats and plasticizes the thermoplastic material of the peripheral flange 145 of the cap 140 and the air forces the plasticized thermoplastic material through the aperture 190 and into the cavity of the lower die. In some instances, if necessary, a die member, which may be heated, can be pushed into the opening to create a “plug assist” for helping to move the molten material into the aperture 190. The lower die is then cooled and the molten thermoplastic material of the peripheral flange 145 of the cap 140 is cooled and solidified in the shape of the cavity to form the projection 180, before the upper and lower dies are then withdrawn. The resulting cell 150 and its structure is shown in FIG. 2B. Thereafter, the projection 180 must be separated from the aperture 190 in order to remove the cap 140 from the cell 150 and to expose the sealing member 130, as shown in FIG. 2C.
FIGS. [0043] 3A-3D illustrate an alternate embodiment of a locking mechanism 170 according to the present invention, wherein such a locking mechanism has been described in detail in co-pending U.S. patent application Ser. No. 09/891,232, which has been incorporated herein by reference. As shown in FIG. 3A, the corner portion 210 of the engaged peripheral flanges 125, 145 in which the locking mechanism 170 is disposed includes a lip 220 for securing the corner portion 210 to the peripheral flange 125 of the receptacle 120. The lip 220 is engaged by a portion of the peripheral flange 125 of the receptacle 120. The corner portion 210 is shown in a closed position in FIGS. 3A and 3B. As shown, the lip 220 extends along the periphery of the corner portion 210 about the corner of the cell 150. The lip 220 is defined by a cut 230 extending through the peripheral flange 125 of the receptacle 120 to the peripheral flange 145 of the cap 140. Preferably, the cut 230 is angled with respect to the vertical plane so as to extend into the peripheral flange 125 of the receptacle 120 at an angle directed away from the receptacle 120, as shown in FIG. 3C and corresponding to the encircled area 3C of FIG. 3A. The cut 230 thereby forms the locking mechanism 170 between the lip 220 and the portion of the peripheral flange 125 of the receptacle 120. In some instances, the lip 220 comprises a portion of the peripheral flange 125 of the receptacle 120. More particularly, the peripheral flange 145 of the cap 140 is first sealed to the peripheral flange 125 of the receptacle 120 according to a process as previously described. Subsequently, the cell 150 is subjected to a perforation process whereby the cut 230 is formed through the peripheral flange 125 of the receptacle 120. The cut 230 may be formed with, for example, a knife or a steel rule and die. It will also be appreciated by one skilled in the art that, though a contoured cut 230 is shown, the cut 230 may take many different forms consistent with the locking mechanism 170 described herein, wherein, for example, the cut 230 may be straight. As shown in FIGS. 3B-3D, the angled cut 230 results in an underlying edge 240 a on the lip 220 generally opposing an overhanging edge 240 b on the corresponding portion of the peripheral flange 125 of the receptacle 120 in an interference fit. As the corner portion 210 is opened by lifting the lip 220, as shown in FIG. 3D, the underlying edge 240 a must be forced past the overhanging edge 240 b. As such, the interaction of the underlying edge 240 a and the overhanging edge 240 b comprises the locking mechanism 170 securing the cap 140 to the receptacle 120.
As shown in, for example, FIGS. 2C and 3D, once the components of the [0044] locking mechanism 170 have been separated, the cap 140 may be removed from the cell 150. In some instances, removal of the cap 140 may include breaking the adhesion between the peripheral flanges 125, 145 due to application of an adhesive in previous steps. Accordingly, the locking mechanism 170 and/or the adhesion between the peripheral flanges 125,145 may provide a child-proof features for each cell 150. In addition, tamper-evidence features may be provided where, for example, lack of adhesion between the flanges 125, 145 and/or deformation or a change in color of the material about the locking mechanism 170 may indicate that the cap 140 has been previously removed from the cell 150. Thus, as shown in FIGS. 4A and 4B, once the cap 140 has been removed from the cell 150, the pill 110 can be extracted from the receptacle 120. In one instance, as shown in FIG. 4A, the receptacle 120 may be deformed so as to force the pill 110 out of the receptacle 120 by tearing through the sealing member 130. However, in another instance, as shown in FIG. 4B, the sealing member 130 may be configured to be separated or peeled back from the receptacle 120 so as to allow the pill 110 to be extracted therefrom. Accordingly, the sealing member 130 also serves as a tamper-evidence feature.
As described herein, embodiments of a [0045] package 100 according to the present invention comprise a plurality of cells 150 connected by one or more connecting members 160. Each of the cells 150 comprises a receptacle 120 having one or more pills 110 therein and sealed by a sealing member 130. A cap 140 is engaged with the receptacle 120 and secured thereto by one or more locking mechanisms 170. Accordingly, in order to extract a pill 110 from a cell 150, the selected cell 150 is first separated from the package 100 by severing the connecting member 160. The locking mechanism securing the cap 140 to the receptacle 120 is then opened or separated so as to allow the cap 140 to be removed from the receptacle 120 and exposing the sealing member 130. The pill 110 can then be extracted through the sealing member 130 or by removing the sealing member 130 from the receptacle 120. Thus, the thermoforming methods used to produce such a package 100 allow high throughput at a lower cost, wherein a package 100 is realized which serves to protect the pills from contamination and damage, provides tamper-evidence features, and provides child-proof features desirable for the storing and dispensing of pharmaceuticals.
FIGS. 5A and 5B illustrate alternate embodiments of the present invention which may provide further advantages in addition to those previously described. As shown in FIG. 5A, each [0046] cell 150 may include a plurality of locking mechanisms 170, wherein at least one of the locking mechanisms 170 is disposed inwardly of the outer edge of the package 100. For example, where four adjacent rectangular cells meet at a point, a locking mechanism may be disposed at the corner of each cell extending to the point. Such a configuration may add to the child-proof features of the package 100 by requiring a cell 150 to be separated from the package 100 in order for a user to have access to the locking mechanism 170 of that cell 150 and thus be able to remove the cap 140. In addition, as shown in FIG. 5B, the locking mechanisms 170 may also be disposed along the edges of the cell 150. In this manner, a locking mechanism 170 may be readily disposed on one cell 150 so as to face an adjacent cell 150. Such a configuration also serves to require a user to first separate the cell 150 from the package 100 so as to be able access the locking mechanism 170 to remove the cap 140. Further, a portion of the connecting member 160 may remain with the cell 150 upon separation thereof from the package 100. In some instances, where the connecting member 160 is formed from the second enclosure portion forming the plurality of caps 140, the portion of the connecting member 160 remaining with the cell 150 may be used as the overhang 200 for facilitating the separation of the locking mechanism 170 and removal of the cap 140 from the receptacle 120. This adds further child-deterrence for the package 100 since the individual cell 150 must first be removed from the package 100 to allow the overhang 200 to be usable to open the cell 150. In addition, the use of a plurality of locking mechanisms 170 about the peripheral flanges 125, 145 may, in some instances, obviate the need for an adhesive for securing the peripheral flanges 125, 145 together.
FIG. 6 schematically illustrates an apparatus capable of forming a multi-cell blister package having a thermoformed cap for each cell according to one embodiment of the present invention, the apparatus being indicated generally by the numeral [0047] 300. The apparatus 300 includes a thermoformable material 320 supplied in a continuous web from a rotatably-supported thermoformable material reel 310. After being removed from the reel 310, the thermoformable material 320 is advanced into a thermoformer 330, sometimes referred to in the art as a forming station or a molding tool. In one embodiment, the thermoformer 330 generally comprises a male die plate 340 and a female die plate 350 disposed in a spaced relationship on either side of the continuous web of the thermoformable material 320. The thermoformer 330 includes a heating element (not shown) for heating the thermoformable material 320 until soft and plastically deformable. As the thermoformable material 320 is pressed between the male die plate 340 and the female die plate 350, the heating element heats the thermoformable material 320. The male portions of the male die plate 340 thereby cooperate with the female portions of the female die plate 350 to form the heated thermoformable material 320 disposed therebetween into an array or matrix of blisters or receptacles 120 as shown in FIG. 1. This and many other methods and devices for forming blisters in a thermoformable material will be understood and appreciated by one skilled in the art and, therefore, will not be discussed in any additional detail herein.
The [0048] thermoformable material 320 having the newly-formed array of receptacles 120 is then advanced through a packaging station 360, where a product 110, as shown in FIG. 1, is dispensed into the receptacles 120. As with the thermoformer 330, many different methods and devices for dispensing a product into blisters will be understood and appreciated by one skilled in the art and, therefore, will not be discussed in any additional detail herein. For example, one such device and method are disclosed in U.S. Pat. No. 5,737,902, which is incorporated herein by reference in its entirety.
A [0049] lidstock 370, also shown as a sealing member 130 in FIG. 1, is then supplied from a lidstock reel 380 over a set of guide rollers 390 and into a generally parallel arrangement with the advancing continuous web of the thermoformable material 320, the thermoformable material 320 now having the array of receptacles 120 with the product 110 disposed therein. The lidstock 370 may be comprised of for example, aluminum, an aluminum alloy, or various other materials such as metal-coated paper, paper, or other material capable of adhering to the thermoformable material 320 as known to one skilled in the art. The thermoformable material 320 and lidstock 370 thereafter converge at a sealing station 400. The sealing station 400 is configured to seal the lidstock 370 to the thermoformable material 320 using, for example, heat and pressure, so as to seal the product 110 within the receptacle 120. This and many other methods and devices for sealing a lidstock to a blister package formed of a thermoformable material will be understood and appreciated by one skilled in the art and, therefore, will not be discussed in any additional detail herein.
A second [0050] thermoformable material 410 is then supplied in a continuous web from a second rotatably-supported thermoformable material reel 420 so as to provide a coverstock 410 over the lidstock 370. The coverstock 410 may be configured so as to form a continuous web of thermoformed caps 140 corresponding to the array of receptacles 120 as discussed above or the continuous enclosure portion 135 discussed below. If necessary, the coverstock 140 may be directed through a second thermoformer (not shown), after leaving the reel 420 and before engaging the lidstock covering the thermoformable material 320, so as to provide a shaped or otherwise textured cap 140 for each receptacle 120. The coverstock 410 is directed from the reel 420 over a set of guide rollers 430 and into a generally parallel arrangement with the advancing continuous web of the thermoformable material 320 sealed with the lidstock 370. The coverstock 410 and the thermoformable web 320 sealed with the lidstock 370 then converge at a second sealing station 440. The second sealing station 440 is configured to seal the coverstock 410 to the lidstock 370 covering the thermoformable material 320 using, for example, heat and pressure, so as to form a cap 140 over each of the receptacles 120.
The web of the [0051] thermoformable material 320, now having an array of receptacles 120 having product 110 sealed therein by a lidstock 370 and a coverstock 410, is then directed into a processing device 450 configured to form additional features of the multi-cell blister package 100. For example, the processing device 450 may be configured to score, perforate, or otherwise form a weakened section of the connecting member 160, as shown in FIG. 1, so as to facilitate separation of the individual cells 150 from the package 100. In addition, the processing device 450 may be configured with a thermoforming device (not shown) for forming the projection 180 of the locking mechanism 170 as shown in FIGS. 2A-2C. Alternatively, the processing device 450 may be configured with a knife or a steel rule and die so as to form the cut 230 for the locking mechanism 170 as shown in FIGS. 3A-3D. Though several configurations of the processing device 450 have been mentioned, it will be understood by one skilled in the art the processing device 450 may be configured as necessary so as to be capable of providing features of the package 100 facilitating separable cells 150 and individual thermoformed caps 140 for each cell 150 as described herein.
Still further alternative embodiments are envisioned as being within the scope of the present invention. For example, the embodiments shown in FIGS. [0052] 2A-2C and 3A-3D may further comprise a cover layer 132 disposed between the sealing member 130 and the cap 140. The cover layer 132 may be comprised of, for example, metal-coated paper, paper, cardstock, or other material capable being separably adhered to the sealing member 130. Accordingly, upon removal of the cap 140 from operable engagement with the receptacle 120, the cover layer 132 would need to be peeled or otherwise removed from the sealing member 130 before the pill 110 could be extracted from the receptacle 120, either by removing the sealing member 130 from the receptacle 120 or by urging the pill 110 through the sealing member 130. In addition, such alternative embodiments may include instances where the one or more locking mechanisms 170 securing the cap 140 to the receptacle 120 are eliminated and the cap 140 instead separably secured to the receptacle 120, the cover layer, and/or the sealing member 130 with a suitable adhesive or the like.
Further, as shown in FIG. 7, the [0053] receptacles 120, sealing member 130, and cover layer 132 may be covered with a single continuous enclosure portion 135. The single continuous enclosure portion 135 thus provides a third child-deterrent, tamper-evident feature beyond the cover layer 132 and the sealing member 130. In some instances, the enclosure portion 135 may be engaged with the receptacles 120 through one or more locking mechanisms (not shown), as previously described. In other instances, the enclosure portion 135 may be separably secured to the cover layer 132, the sealing member 130, and/or the receptacles 120 with a suitable adhesive or the like. Accordingly, the enclosure portion 135 must first be removed prior in order to expose the cover layer 132. A cell 155, comprising a receptacle 120 sealed with a portion of the sealing layer 130 and covered with a portion of the cover layer 132, may then be removed from the remainder of the cells 155 or the cells 155 may be configured to remain contiguously engaged. In either instance, the portion of the cover layer 132 over a corresponding receptacle 120 is then peeled back or otherwise removed from the cell 155 so as to expose the sealing member 130. The pill 110 may then be removed from the receptacle 120 as shown in FIGS. 4A and 4B.
Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. [0054]

Claims

That which is claimed:

1. A thermoformed package for a pill-like product, said package comprising:

a first enclosure portion defining a plurality of receptacles, each receptacle being adapted to house the product therein;

a sealing layer configured to operably engage the first enclosure portion so as to seal each of the receptacles; and

a second enclosure portion defining a plurality of caps corresponding to the plurality of receptacles, the second enclosure portion being configured to operably engage the first enclosure portion so as to form a plurality of cells, each cell comprising one of the plurality of receptacles sealed by the sealing layer and the corresponding one of the plurality of caps operably engaging the receptacle, at least one of the plurality of receptacles and the plurality of caps being separably engaged so as to allow the cells to be separated;

each cell comprising a locking mechanism having a first component operably engaging the receptacle and a second component operably engaging the corresponding cap, the first component corresponding to and being configured to operably engage the second component so as to secure the cap to the corresponding receptacle, the components of the locking mechanism being further configured to be separable so as to allow separation of the cap from the corresponding receptacle and to thereby allow the product to be selectively extracted from the cell.

2. A package according to claim 1 further comprising a connecting member extending between at least one of receptacles of the first enclosure portion and caps of the second enclosure portion.

3. A package according to claim 1 wherein the connecting member is configured to be at least one of frangible, perforated and scored so as to facilitate separation of the cells.

4. A package according to claim 1 wherein the cell is configured such that the cap must be removed from the receptacle in order for the product to be extracted from the cell.

5. A package according to claim 1 wherein the cell is configured such that the product is urged through the sealing member in order to extract the product from the cell.

6. A package according to claim 1 wherein the cell is configured such that the sealing member is separated from the receptacle in order to extract the product from the cell.

7. A package according to claim 1 wherein the second component comprises an aperture defined by the receptacle and the first component comprises a projection from the cap, and wherein the projection is capable of operably engaging the aperture so as to secure the cap to the receptacle.

8. A package according to claim 1 wherein the receptacle further comprises a peripheral flange, the peripheral flange being undercut such that one portion of the peripheral flange is operably engaged with the cap and defines the first component of the locking mechanism, while the other portion of the peripheral flange defines the second component of the locking mechanism, the first and second components being further configured in an interference fit therebetween.

9. A method of forming a thermoformed package for a pill-like product, said method comprising:

operably engaging a first enclosure portion with a sealing member, the first enclosure portion defining a plurality of receptacles adapted to house the product, and the sealing member being adapted to seal the product within the respective receptacle;

operably engaging a second enclosure portion with the first enclosure portion, the second enclosure portion defining a plurality of caps corresponding to the plurality of receptacles, each cap being configured to operably engage the respective receptacle so as to form a corresponding cell, at least one of the plurality of receptacles and the plurality of caps being separably engaged so as to allow the cells to be separated; and

forming a component of a locking mechanism for each cell following formation of the cell, the locking mechanism comprising a first component operably engaging the receptacle and a second component operably engaging the corresponding cap, the first component corresponding to and configured to operably engage the second component to secure the cap to the corresponding receptacle, the components of the locking mechanism being further configured to be separable so as to allow separation of the cap from the corresponding receptacle and to thereby allow the product to be selectively extracted from the respective cell.

10. A method according to claim 9 wherein the second component comprises an aperture defined by the receptacle and forming a component of the locking mechanism further comprises forming the first component by fabricating a projection from the cap such that the projection is capable of removably engaging the aperture.

11. A method according to claim 9 wherein the receptacle further comprises a peripheral flange and forming a component of the locking mechanism further comprises undercutting the peripheral flange of the receptacle such that one portion of the peripheral flange is operably engaged with the cap and defines the first component of the locking mechanism, while the other portion of the peripheral flange defines the second component of the locking mechanism, the first and second components being further configured in an interference fit therebetween.

12. A method according to claim 9 further comprising housing the product within the first enclosure portion prior to operably engaging the sealing member with the first enclosure portion.

13. A method according to claim 9 further comprising plasticizing a portion of the cap.

14. A method according to claim 13 further comprising reshaping the plasticized portion of the cap so as to form a projection therefrom, the projection being capable of operably engaging an aperture defined by the receptacle.

15. A method according to claim 14 wherein the portion of the cap is plasticized by a heated die operably engaged therewith and reshaping the plasticized portion further comprises reshaping the plasticized portion of the cap, with a mechanism configured to engage the cap, so as to form the projection, the mechanism comprising at least one of a heated member extending through the die and pressurized air introduced through the die.

16. A method of forming a thermoformed package for a pill-like product, said method comprising:

forming a projection component of a locking mechanism for each cell following formation of the cell, the projection component configured to operably engage an aperture component of the locking mechanism defined by the corresponding cap so as to secure the cap to the corresponding receptacle, the components of the locking mechanism being further configured to be separable so as to allow separation of the cap from the corresponding receptacle and to thereby allow the product to be selectively extracted from the respective cell.

17. A method according to claim 16 further comprising disposing the product within the first enclosure portion prior to operably engaging the sealing member with the first enclosure portion.

18. A method according to claim 16 further comprising plasticizing a portion of the cap about a point opposing the aperture component.

19. A method according to claim 18 further comprising reshaping the cap about the point, following plasticization thereof, so as to form the projection component in a configuration capable of operably engaging the aperture component.

20. A method according to claim 16 further comprising plasticizing the cap about a point opposing the aperture with a heated die operably engaged with the cap.

21. A method according to claim 20 further comprising reshaping the cap about the point, following plasticization thereof, with a mechanism capable of engaging the cap, so as to form the projection component, the projection component extending through the aperture component defined by the receptacle, the mechanism comprising at least one of a heated member extending through the die and pressurized air introduced through the die.

22. A method according to claim 21 further comprising receiving a portion of the projection component extending through the aperture component with a receiving die operably engaged with the receptacle, the receiving die being configured to reshape the portion of the projection component extending through the aperture component.

23. A method according to claim 22 further comprising rigidifying the cap about the point and the projection component following reception of the portion of the projection component with the receiving die.

24. A method of forming a thermoformed package for a pill-like product, said method comprising:

operably engaging a first enclosure portion with a sealing member, the first enclosure portion defining a plurality of receptacles, each having a peripheral flange and being adapted to house the product, and the sealing member being adapted to seal the product within the respective receptacle;

operably engaging a second enclosure portion with the first enclosure portion, the second enclosure portion defining a plurality of caps corresponding to the plurality of receptacles, each cap having a peripheral flange configured to operably engage the peripheral flange of the respective receptacle so as to form a corresponding cell, at least one of the plurality of receptacles and the plurality of caps being separably engaged so as to allow the cells to be separated; and

undercutting a portion of the peripheral flange of the receptacle so as to form opposing first and second components of a locking mechanism, the components of the locking mechanism being operably engageable and configured in an interference fit to secure the cap to the receptacle, the components of the locking mechanism being further configured to be separable so as to allow separation of the cap from the corresponding receptacle and to thereby allow the product to be selectively extracted from the respective cell.

25. A method according to claim 24 further comprising disposing the product within the first enclosure portion prior to operably engaging the sealing member with the first enclosure portion.

26. A method according to claim 24 wherein undercutting a portion of the peripheral flange of the receptacle further comprises forming an angled cut in the peripheral flange of the receptacle such that a first part of the peripheral flange is operably engaged with the peripheral flange of the cap and a second part of the peripheral flange includes an overhang generally overlying the first part of the peripheral flange.

27. A method according to claim 24 wherein undercutting a portion of the peripheral flange of the receptacle further comprises undercutting a portion of the peripheral flange of the receptacle using at least one of a cutting mechanism and a rule and die mechanism.

28. A method of extracting a pill-like product from a cell of a thermoformed package comprising a plurality of cells joined by a connecting member, each cell having a cap component operably engaging a receptacle component adapted to house the product, and a sealing member operably engaging the receptacle so as to seal the product therein, said method comprising:

severing the connecting member so as to separate a selected cell from the plurality of cells;

separating a first component of a locking mechanism operably engaging the cap from a second component of the locking mechanism operably engaging the receptacle so as to expose the sealing member sealing the receptacle; and

extracting the product from the receptacle.

29. A method according to claim 28 wherein the package further comprises a frangible connecting member and severing the connecting member further comprises breaking the frangible connecting member so as to separate the selected cell from the plurality of cells.

30. A method according to claim 28 wherein the connecting member is configured to be at least one of perforated and scored so as to facilitate separation of the cells, and severing the connecting member further comprises breaking the connecting member along at least one of the perforation and the score so as to separate the selected cell from the plurality of cells.

31. A method according to claim 28 wherein the first component of the locking mechanism comprises a projection and the second component of the locking mechanism comprises a corresponding aperture for receiving the projection, and separating the components of the locking mechanism further comprises removing the projection from the aperture.

32. A method according to claim 28 wherein each of the cap and the receptacle further comprises a peripheral flange, the peripheral flanges being operably engaged whereby an angled cut is formed in a portion of the peripheral flange of the receptacle such that a first part of the peripheral flange is operably engaged with the peripheral flange of the cap so as to form the first component of the locking mechanism and a second part of the peripheral flange includes an overhang generally overlying the first part of the peripheral flange and forming the second component of the locking mechanism, and separating the components of the locking mechanism further comprises urging the first part of the peripheral flange past the overhang.

33. A method according to claim 28 further comprising removing the cap from the receptacle following separation of the components of the locking mechanism and prior to the extraction of the product from the receptacle.

34. A method according to claim 28 wherein extracting the product from the receptacle further comprises extracting the product from the receptacle through the sealing member.

35. A method according to claim 28 further comprising separating the sealing member from the receptacle before extracting the product from the receptacle.

36. A thermoformed package for a pill-like product, said package comprising:

a sealing member configured to operably engage the first enclosure portion so as to seal each of the receptacles;

a cover layer configured to operably engage the sealing member such that a portion of the cover layer must be separated from a corresponding portion of the sealing member in order to access the respective receptacle;

a second enclosure portion corresponding to and configured to operably engage the first enclosure portion such that the second enclosure portion must be separated from the first enclosure portion in order to access the cover layer; and

a locking mechanism having a first component operably engaging the first enclosure portion and a second component operably engaging the second enclosure portion, the first component corresponding to and being configured to operably engage the second component so as to secure the first enclosure portion to the second enclosure portion, the components of the locking mechanism being further configured to be separable so as to allow separation of the first enclosure portion from the second enclosure portion and to thereby allow the portion of the cover layer to be removed such that the product can be selectively extracted from the corresponding receptacle past the sealing member.

37. A package according to claim 36 wherein the second enclosure portion is further configured as a single continuous piece which must be removed in total from the first enclosure portion.

38. A package according to claim 36 wherein the second enclosure portion is further configured as a plurality of caps, corresponding to the plurality of receptacles, each cap being individually removable from the first enclosure portion.

39. A package according to claim 36 further comprising a connecting member extending between the receptacles of the first enclosure portion, the connecting member being configured to be at least one of frangible, perforated and scored so as to facilitate separation of the receptacles.

40. A package according to claim 36 wherein the second component comprises an aperture defined by the first enclosure portion and the first component comprises a projection from the second enclosure portion, and wherein the projection is capable of operably engaging the aperture so as to secure the first enclosure portion to the second enclosure portion.

41. A method of forming a thermoformed package for a pill-like product, said method comprising:

operably engaging a cover layer with the sealing member such that a portion of the cover layer must be separated from a corresponding portion of the sealing member in order to access the respective receptacle;

operably engaging a corresponding second enclosure portion with the first enclosure portion such that the second enclosure portion must be separated from the first enclosure portion in order to access the cover layer; and

forming a component of a locking mechanism, the locking mechanism comprising a first component operably engaging the first enclosure portion and a second component operably engaging the second enclosure portion, the first component corresponding to and configured to operably engage the second component to secure the first enclosure portion to the second enclosure portion, the components of the locking mechanism being further configured to be separable so as to allow separation of the first enclosure portion from the second enclosure portion and to thereby allow the portion of the cover layer to be removed such that the product can be selectively extracted from the corresponding receptacle.

42. A method according to claim 41 wherein the second component comprises an aperture defined by the first enclosure portion and forming a component of the locking mechanism further comprises forming the first component by fabricating a projection from the second enclosure portion such that the projection is capable of removably engaging the aperture.

43. A method according to claim 41 further comprising housing the product within the first enclosure portion prior to operably engaging the sealing member with the first enclosure portion.

44. A method according to claim 41 further comprising plasticizing a portion of the second enclosure portion.

45. A method according to claim 44 further comprising reshaping the plasticized portion of the second enclosure portion so as to form a projection therefrom, the projection being capable of operably engaging an aperture defined by the first enclosure portion.

46. A method according to claim 45 wherein the portion of the second enclosure portion is plasticized by a heated die operably engaged therewith and reshaping the plasticized portion further comprises reshaping the plasticized portion of the second enclosure portion with a mechanism engaged therewith so as to form the projection, the mechanism comprising at least one of a heated member extending through the die and pressurized air introduced through the die.

47. A method of extracting a pill-like product from a receptacle of a thermoformed package comprising a first enclosure portion having a plurality of receptacles joined by a connecting member, each receptacle having a sealing member operably engaging therewith so as to seal the product therein and a cover layer operably engaged with and covering the sealing member, the package further comprising a second enclosure portion operably engaging the first enclosure portion and covering the cover layer, said method comprising:

separating a first component of a locking mechanism operably engaging the first enclosure portion from a second component of the locking mechanism operably engaging the second enclosure portion so as to separate the first enclosure portion from the second enclosure portion and to expose the cover layer;

separating a portion of the cover layer from a corresponding portion of the sealing member so as to expose the sealing member over a receptacle; and

extracting the product from the receptacle past the corresponding portion of the sealing member.

48. A method according to claim 47 further comprising severing the connecting member so as to separate the selected receptacle, with the corresponding portions of the sealing member and the cover member, from the plurality of receptacles prior to separating the portion of the cover layer.

49. A method according to claim 47 wherein the connecting member is configured to be at least one of perforated and scored so as to facilitate separation of the receptacles, and the method further comprises severing the connecting member along at least one of the perforation and the score so as to separate the selected receptacle, with the corresponding portions of the sealing member and the cover member, from the plurality of receptacles prior to separating the portion of the cover layer.

50. A method according to claim 47 wherein the first component of the locking mechanism comprises a projection and the second component of the locking mechanism comprises a corresponding aperture for receiving the projection, and separating the components of the locking mechanism further comprises removing the projection from the aperture.