RELATED APPLICATION/S

This application claims the benefit of priority under 35 USC § 119(e) of U.S. Provisional Patent Application No. 61/605,223 filed 1 March 2012 and Provisional Patent Application No. 61/747,441 filed 31 Dec. 2012, the contents of which are incorporated herein by reference in their entirety.

FIELD AND BACKGROUND OF THE INVENTION

The present invention, in some embodiments thereof, relates to a method and system folding a blister chain and, more particularly, but not exclusively, to a method and system for mass producing a continuous folded blister chain.

United States Patent No. 6,253,920 to Kallgren discloses a blister pack, comprising at least a first and a second parallel row of blisters, and of the type in which a base foil formed with blisters is connected to a substantially flat lid foil wherein between the at least first and second rows of blisters, an intermediate part having at least one folding line parallel to said first and second rows is defined, said pack being foldable along said folding line, and that said blisters of said first row being so offset relative to the blisters of said second row that after folding the blisters in the rows engage between each other.

According to Kallgren '920 the foldable blister packs described therein may be advantageous over conventional blister packs which are bulky and voluminous owing to the construction of the blisters, and therefore the package must be voluminous. The voluminous package involves heavy expenses, e.g. heavy expenses for the handling and transport and heavy stock-keeping expenses. Furthermore, due to its measures, e.g. large sides, the voluminous package will be rather unstable, which will also render the manufacturing and handling of the package difficult.

United States Patent No. 3,659,706 to Serrel discloses a pharmacal package construction wherein a pair of blister sheets are closed by respective backing sheets and arranged with the blisters in proximate relation so that the backing sheets are outermost, the blister sheets being provided with detachably inter-fitting formations, to releasably retain the blister sheets and their backing sheets in position defining a package effectively protected by the backing sheets.

United States Patent No. 6,024,222 to Friberg discloses a blister pack comprising at least one blister assembly including two blister parts, each having a set of blisters and being of the type in which a base foil formed with blisters is connected to a substantially flat lid foil, the blister parts being interconnected and foldable towards each other, the blisters of one blister part being so offset relative to the blisters of the other blister part that, after folding, the blisters of the two blister parts engage between each other.

International Patent Application Publication No. WO/2010/004566 to the same inventor discloses a medicament dispensing device comprises at least one container adapted for accommodating and dispensing at least one elongate packagible elongate blister pack carrying a plurality of blisters containing the medicament; transporting means adapted for transporting the blister pack toward opening of the container; dispensing means adapted for releasing a fragment of the blister pack bearing a predetermined number of the blisters from the container through the opening to a patient; and controlling means adapted for identifying the patient before dispensing the blister to the patient, activating the dispensing means, recording actions of dispensing. The blister pack is foldable and configured to be folded within the container. The dispensing means is adapted to cut off the blister bearing fragment. The dispensing means is adapted to cut off the blister bearing fragment such that the blisters remain intact.

Additional background art includes United States Patent No. 3,743,084; United States Patent No. 8,251,219; United States Patent No. 4,340,141; United States Published Application No. 2004/0026293; and United States Published Application No. 2006/0042988.

SUMMARY OF THE INVENTION

According to an aspect of some embodiments of the present invention there is provided a method of folding a chain of a blisters sheets including: supplying a continuous chain of blisters sheets; folding together pair of sheets of the continuous chain and simultaneously moving a pair of sheets or an interconnector between the pair of sheets out of a plane or path the chain during the folding. According to some embodiments of the invention, the pair of sheets remain connected to the chain during the folding.

According to some embodiments of the invention, the method further includes stacking the pair of sheets along a path of advancement.

According to some embodiments of the invention, the stacking is of at least two substantially parallel layers.

According to some embodiments of the invention, the folded chain includes at least 6 adjacent sheets and the stacking is into at least six substantially parallel layers.

According to some embodiments of the invention, the moving includes buckling the interconnector out of the plane or path of advancement.

According to some embodiments of the invention, the moving includes advancing the interconnector over an edge.

According to some embodiments of the invention, the moving includes pulling the interconnector out of the plane or path of advancement.

According to some embodiments of the invention, the moving includes pressing the interconnector out of the plane or path of advancement.

According to some embodiments of the invention, the folding further includes advancing a trailing end of the pair of sheets faster than a leading end of the two sheets.

According to some embodiments of the invention, during the moving a leading end of the two sheets and a trailing end of the two sheets remain in the path of advancement.

According to some embodiments of the invention, the moving is performed by an arm moving in a continuous orbit.

According to some embodiments of the invention, the method further includes restraining the continuous chain from twisting.

According to an aspect of some embodiments of the present invention there is provided a system for folding a continuous blister chain including: a feeder configured to feed the continuous chain of blister sheets to an out of plane folder configured for folding an interconnector between two of the blister sheets out of a plane or path of advancement of the feeder to form the continuous chain into a stack of connected blister sheets. According to some embodiments of the invention, the system further includes a presser for pressing the interconnector out of the plane.

According to some embodiments of the invention, the system further includes a puller for pulling the interconnector out of the plane.

According to some embodiments of the invention, the system further includes an edge and wherein the folding occurs over the edge.

According to some embodiments of the invention, the system further includes an advancer, and wherein the folding results from the advancer advancing a trailing edge of the two blisters sheets toward a leading edge thereby bucking the sheets across the interconnector.

According to some embodiments of the invention, the folder is configured to fold the two sheets into substantially parallel connected layers, substantially perpendicular to the plane of advancement.

According to some embodiments of the invention, the folder is synchronized with the feeder.

According to some embodiments of the invention, the folder is configured receives the chain continuously.

According to some embodiments of the invention, the system further includes a stacker for stacking at least three of the sheets as connected layers, the layers substantially perpendicular to the plane of advancement.

According to some embodiments of the invention, the system further includes a guide preventing twisting of the chain.

According to an aspect of some embodiments of the present invention there is provided a continuous blister chain packaged for distribution including a plurality of blister containing sheets wherein the sheets are folded to form substantially parallel layers, and at least one blister protrudes from both sides of at least one of the sheets, wherein the distance between the layers is less than the height of the at least one blister.

According to some embodiments of the invention, blisters of at least two of the layers mesh together.

According to some embodiments of the invention, the blister chain includes at least three of the sheets folded into at least three of the layers. According to some embodiments of the invention, the blister chain includes at least five of the sheets folded into at least five of the layers.

According to some embodiments of the invention, the blister chain includes at least one blister protruding from only one side of at least one of the sheets.

According to some embodiments of the invention, the at least one blister protruding from at least one side has a lesser height than the at least one blister protruding from both sides.

According to some embodiments of the invention, the at least one blister protruding from at least one side and the at least one blister protruding from both sides are both on a single sheet of the sheets.

According to an aspect of some embodiments of the present invention there is provided a continuous blister chain packaged for distribution including: a plurality of sheets containing blister, the sheets folded to form layers of a stack, and one or more spacers interconnecting between two of the sheets and wherein the spacers include at least one blister.

According to some embodiments of the invention, the blister chain includes at least three of the layers.

According to some embodiments of the invention, the blister chain includes at least two of the spacers.

According to some embodiments of the invention, the blister chain includes at least five of the layers.

According to some embodiments of the invention, the blister chain includes at least two of the spacers.

According to some embodiments of the invention, the layers are substantially parallel.

According to some embodiments of the invention, each of the blisters contains a medicament dose.

According to some embodiments of the invention, the blisters on the spacers contain of first of the medicament doses.

According to some embodiments of the invention, a space between two of the layers is less than twice the height of a blister of the blisters. According to some embodiments of the invention, a space between two of the layers is less than the height of a blister of the blisters of the sheets.

According to an aspect of some embodiments of the present invention there is provided a method of adapting a blister producing machine to produce a foldable blister chain. The method may include setting up a pocket forming unit to emboss a plurality of folding lines into a continuous strip of blister substrate, the folding lines demarcating a continuous chain of connected blister sheets, and setting up a cutting unit to trim an edge of the continuous strip of blister substrate while the continuous chain of sheets remains intact.

According to an aspect of some embodiments of the present invention there is provided a method of producing a foldable blister chain using a conventional blistering machine including a pocket forming unit and cutting unit. The method may include embossing a plurality of folding lines into a continuous strip of blister substrate with the pocket forming unit, the folding lines demarcating a continuous chain of connected blister sheets, and trimming an edge of the continuous strip of blister substrate with the cutting unit without severing the continuous chain.

According to some embodiments of the invention, the folding lines include at least one element of the group consisting of a 90° folding line and a 180° folding line.

According to some embodiments of the invention, the continuous chain further includes a plurality of spacers, the length of at least one spacer being substantially the height of a blister.

According to some embodiments of the invention, at least one of the folding lines is configured to fold in an opposite direction of at least one other of the folding lines.

According to some embodiments of the invention, a spacer surrounded by two

90° folding lines alternates with a 180° folding line, folding in the opposite direction.

According to some embodiments of the invention, a spacer surrounded by two 90° folding lines alternates with a spacer surrounded by two 90° folding lines folding in the opposite direction.

According to some embodiments of the invention, a method of producing a foldable blister chain may further include excising a cut out from the blister chain with the cutting unit. According to some embodiments of the invention, a method of producing a foldable blister chain may further include folding the continuous blister chain according claim.

According to an aspect of some embodiments of the present invention there is provided a system for producing a blister chain. The system may include a pocket forming unit set up for embossing a plurality of folding lines into a continuous strip of blister substrate, the folding lines demarcating a continuous chain of connected blister sheets, and a cutting unit set up for trimming an edge of the continuous strip of blister substrate without severing the continuous chain.

According to some embodiments of the invention, a system for producing a foldable blister chain may further include a system for folding the continuous blister chain.

According to an aspect of some embodiments of the present invention there is provided a method of packaging a stack of blister sheets. The method may include supplying a continuous folded stack of at least six blister sheets, and inserting the continuous folded stack into a secondary package.

According to some embodiments of the invention, the stack may include at least 10 blister sheets.

According to some embodiments of the invention, the method may further include supplying a user opening to the secondary package. A plane of the user opening may be directed parallel to a folding line of the stack.

According to some embodiments of the invention, the method may further include supplying a user opening to the secondary package, the user opening being configured such that unfolding a blister sheet from the stack causes the blister sheet to extend out of the opening.

Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting. BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.

In the drawings:

FIG. 1 is a Flow chart illustrating an exemplary method of folding a continuous blister chain in accordance with an embodiment of the present invention;

FIG. 2A is a schematic perspective view of an exemplary embodiment of a continuous blister chain folder in accordance with an embodiment of the present invention;

FIG. 2B is a schematic side view illustrating the exemplary embodiment of a continuous blister chain folder of FIG. 2A in accordance with an embodiment of the present invention;

FIG. 2C is a schematic side view of the exemplary embodiment of a continuous blister chain folder of FIG. 2B in a later stage of folding in accordance with an embodiment of the present invention;

FIG. 3A is a schematic perspective view of an alternative exemplary embodiment of a folder in accordance with an embodiment of the present invention;

FIG. 3B is a schematic perspective view of an alternative exemplary embodiment of a folder in accordance with an embodiment of the present invention;

FIG. 3C is a schematic perspective view of an alternative exemplary embodiment of a folder in accordance with an embodiment of the present invention;

FIG. 3D is a schematic view of an exemplary embodiment of a puller in accordance with an embodiment of the present invention;

FIG. 3E is a schematic view of an alternative exemplary embodiment of a puller in accordance with an embodiment of the present invention;

FIG. 4A is a schematic perspective view of an exemplary alternative embodiment of a guide wheel in accordance with an embodiment of the present invention; FIG. 4B is a schematic perspective view of an exemplary embodiment of a guide flange in accordance with an embodiment of the present invention;

FIG. 5A is a schematic perspective view of an exemplary embodiment of a stacker in accordance with an embodiment of the present invention;

FIG. 5B is a schematic perspective view of an exemplary alternative embodiment of a stacker in accordance with an embodiment of the present invention;

FIG. 6A is a schematic perspective view of an exemplary embodiment of an output channel in accordance with an embodiment of the present invention;

FIG. 6B is a schematic perspective view of an exemplary alternative embodiment of an output channel in accordance with an embodiment of the present invention;

FIG. 6C is a schematic perspective view of an exemplary alternative embodiment of an output channel in accordance with an embodiment of the present invention;

FIGs. 6D-F are perspective views of an exemplary embodiment of packing and dispensing a folded continuous blister strip in a secondary package in accordance with an embodiment of the present invention;

FIGs. 6G-I are perspective views of another exemplary embodiment of packing and dispensing a folded continuous blister strip in a secondary package in accordance with an embodiment of the present invention;

FIGs. 7A-H are schematic perspective views of an exemplary embodiment of a complete folding system at different stages of the folding process in accordance with an embodiment of the present invention;

FIG. 8A is a schematic view of an exemplary embodiment of five sheets of a foldable blister chain in accordance with an embodiment of the present invention;

FIG. 8B is a schematic cutaway side view of an exemplary embodiment of a folded layer blister stack in accordance with an embodiment of the present invention;

FIG. 9A is a schematic view of an exemplary alternative embodiment of five sheets of a foldable blister chain in accordance with an embodiment of the present invention;

FIG. 9B is a schematic cutaway side view of an exemplary alternative embodiment of a folded blister stack in accordance with an embodiment of the present invention; FIG. 10 is a schematic view of an exemplary alternative embodiment of five sheets of a foldable blister chain in accordance with an embodiment of the present invention;

FIG. 11A is a schematic view of an exemplary embodiment of a chain of four sheets of an unfolded blister stack configured for folding into wallets in accordance with an embodiment of the present invention;

FIG. 1 IB is a schematic cutaway side view of an exemplary embodiment of a portion of a blister stack folded into a two layer wallet in accordance with an embodiment of the present invention;

FIG. l lC is a schematic top view of an exemplary embodiment of a portion of a blister stack folded into a two layer wallet in accordance with an embodiment of the present invention;

FIG. 12A is a schematic view of an exemplary embodiment of a chain of four sheets of an unfolded blister stack configured for folding into wallets in accordance with an embodiment of the present invention;

FIG. 12B is a schematic cutaway side view of an exemplary embodiment of a portion of a blister stack folded into a two layer wallet in accordance with an embodiment of the present invention;

FIG. 12C is a schematic top view of an exemplary embodiment of a portion of a blister stack folded into a two layer wallet in accordance with an embodiment of the present invention;

FIG. 13A is a schematic view of an alternative exemplary embodiment of six sheets of an unfolded blister chain in accordance with an embodiment of the present invention;

FIG. 13B is a schematic side cutaway view of an exemplary embodiment of an alternative folded blister chain in accordance with an embodiment of the present invention;

FIG. 13C is a schematic overhead view of an exemplary embodiment of an alternative folded blister chain in accordance with an embodiment of the present invention; FIG. 14A is a schematic view of an alternative exemplary embodiment of a chain of four sheets of an unfolded blister stack configured for folding into wallets in accordance with an embodiment of the present invention;

FIG. 14B is a schematic cutaway side view of an alternative exemplary embodiment of a portion of a blister stack folded into a two layer wallet in accordance with an embodiment of the present invention;

FIG. 14C is a schematic top view of an alternative exemplary embodiment of a portion of a blister stack folded into a two layer wallet in accordance with an embodiment of the present invention;

FIG. 15A is a schematic view of an alternative exemplary embodiment of six sheets of an unfolded blister chain in accordance with an embodiment of the present invention;

FIG. 15B is a schematic side view of an alternative exemplary embodiment of an alternative folded blister chain in accordance with an embodiment of the present invention;

FIG. 15C is a schematic side view of an alternative exemplary embodiment of an alternative folded blister chain in accordance with an embodiment of the present invention;

FIG. 16A is a schematic view of an alternative exemplary embodiment of six sheets of an unfolded blister chain in accordance with an embodiment of the present invention;

FIG. 16B is a schematic side view of an alternative exemplary embodiment of an alternative folded blister chain in accordance with an embodiment of the present invention;

FIG. 17A is a schematic view of an alternative exemplary embodiment of a foldable blister chain in accordance with an embodiment of the present invention;

FIGs. 17B-C are schematic views of an alternative exemplary embodiment of a reconfigurable foldable blister chain in an unfolded and folded configuration respectively in accordance with an embodiment of the present invention;

FIG. 18 is a perspective view of an exemplary embodiment of a standard blister machine; FIG. 19 is a flow chart illustration of an exemplary embodiment of a method of producing a foldable continuous blister chain in accordance with an embodiment of the present invention;

FIG. 20 is a perspective view of an exemplary embodiment of a blister producing and folding system in accordance with an embodiment of the present invention;

FIGs. 21A,A',B,B' are schematic views of exemplary embodiments of folding lines for 180° folds in accordance with an embodiment of the present invention;

FIGs. 22A,A',B,B' are schematic views of exemplary embodiments of folding lines for 90° folds in accordance with an embodiment of the present invention;

FIGs. 22C,D are schematic views of the orientation of folding lines for two exemplary embodiments of a folding blister chain in accordance with an embodiment of the present invention;

FIGs. 23A-E are schematic views of exemplary steps in a method of folding a blister chain in accordance with an embodiment of the present invention, and

FIGs. 24A-H' are schematic views of exemplary steps in an alternative method of folding a blister chain in accordance with an embodiment of the present invention.

DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION

The present invention, in some embodiments thereof, relates to a method and system folding a blister chain and, more particularly, but not exclusively, to a method and system for mass producing a continuous folded blister chain.

OVERVIEW

An aspect of some embodiments of the current invention relates to folding and packaging blister strips in a way which may reduce the volume of secondary packaging. The secondary packaging may be reduced by, for example, between 10% to 50%. Such a reduction could possible save billions of dollars on storage and/or shipment and/or packaging materials. Alternatively or additionally, when secondary packing includes cardboard boxes, the more compact packaging may decrease the emission of the pollutant C02.

An aspect of some embodiments of the current invention relates to carrying out the new process of folding a continuous blister strip. The continuous blister strip may include a specially configured chain of blister sheets. The chain may optionally be produced on line with a blistering machine. Optionally the blistering machine may be a standard blistering machine. Optionally the standard blistering machine may be specially set up to form the chain. The folding may optionally be continuous and/or on line with production of the blister strip. Optionally, the system may produce a folded continuous strip. For example the system of folding the blisters may be located on the standard blistering machines, immediately after the blister cutting unit. Optionally the blisters may include one or more of cold form blisters and/or thermoform blisters and/or tropicalised blisters and/or blisters created by another technology.

An aspect of some embodiments of the current invention relates to adapting a conventional blister forming system to produce a foldable chain of blister sheets. For example, a conventional pocket forming unit (cavity forming machine) may be set up to produce folding lines. In some embodiments, the pocking forming unit may be adapted so that, upon folding, the blisters of opposite pages mesh together. Folding lines may be embossed into the substrate for example of cold forming and/or thermoforming. The substrate may include for example one or more of Polyvinyl Chloride (PVC) and/or Polychlorotrifluoro ethylene (PCTFE) and/or polyethylene (PE) and/or Cyclic olefin copolymers (COC) and/or Cyclic olefin polymers (COP) and/or polypropylene (PP) and/or glycol-modified polyethylene terephthalate (PETg) and/or a foil (for example aluminum).

A conventional cutting unit may optionally be set up to cut blister sheets in a continuous strip. Optionally, the format enables folding the blisters in continuous manner.

An aspect of some embodiments of the current invention relates to loading a folded blister chain into a secondary container. For example, a boxer apparatus may optionally insert a folded blister chain including a stack of connected blister sheets into a box. The box may be configured such that when a user opens the box blisters sheets of the chain may be removed one at a time and cut off without removing the entire stack from the box. Insertion of the blister stack may include for example pushing the stack into the box and/or suspending the stack on a track and inserting it into the box. In some embodiments, the interconnection between blister sheets may stabilize the stack and facilitate loading. For example, this may allow loading a larger stack than conventional loading of loose blister sheets, which may become disordered during loading. For example, in some embodiments, the current invention a stack of between 10 and 30 blisters sheets may be loaded into a secondary package. In some embodiments the length of the unfolded blister strip may be greater than 20 cm. In some embodiments the length of the unfolded blister strip may be greater than 30 cm. In some embodiments the length of the unfolded blister strip may be greater than 70 cm. For example a stack of more than 20 blister sheets or in some examples more than 30 blister sheets may be loaded into a secondary package.

A package containing a large number of stacked blister sheets may be distributed for example to a hospital and/or a pharmacists and/or a patient. In some embodiments, a stack a blister sheets will be packaged in an alternative container. For example, a stack of blister sheets may be packaged in one or more of a foil pack and/or a bag and/or a wrapping (for example in shrink wrap and/or foil and/or paper) and/or a plastic box and/or a delivery machine and/or another kind of container. In some embodiments a folded blister chain may be packaged in multiple containers, for example a foil pack inside of a cardboard box. A possible advantage of the folded blister strip over a loose stack of blister pages is the ease of refolding. Optionally restacking may be facilitated for a blister chain of current invention. For example, if a loose stack of blister sheets becomes disheveled it may be difficult for a user to orient and restack the sheets such that they can be returned to their package. For example, in the case of a folded strip, even after unfolding the blister sheets may optionally retain their orientation. Refolding may be particularly advantageous when a stack of blisters is packed in two packages, for example a foil pack inside a box. Upon opening a user may optionally wish to remove the blisters from the inner pack and restack them into the outer pack. In the case of loose blister sheets, this may be difficult. For a folding blister pack, restacking along the original folds may be facilitated.

Fold strip to produce continuous folded stack

An aspect of some embodiments of the current invention relates to mass producing a continuous folded chain of blister sheets. The production may be continuous and/or intermittent. Optionally an input feed including a continuous blister strip and an output including a folded stack of blister sheets may advance along a single path without turning out of the path. In some embodiments, a system may fold, stack and package the strips in-line. In some embodiments, the direction of advancement may be substantially perpendicular to the folding lines of the blister chain.

In some embodiments, a pair of connected blister sheets may be folded out of the plane or path of advancement of the input feed. Optionally the pair may be folded in line while still connected to the rest of the chain. Optionally the pair blister sheets may include an interconnected. For example the interconnection may include a hinge between the adjacent blister sheets. Alternatively or additionally the adjacent blister sheets may be interconnected by one or more spacers and one or more joints may connect the spacers to the adjacent blisters sheets and/or the joints may connect two adjacent spacers. Optionally folding may be achieved by moving the interconnection out of the plane or path of advancement. Optionally a leading and/or following edge of the pair of blister sheets may remain in the plane or path of advancement. Optionally, an interconnection may be moved out of the plane or path by buckling the pair of blister sheets. For example, buckling may include pushing together a trailing edge and a leading edge of a pair of blister sheets. Alternatively or additionally, an interconnection may be moved out of the plane or path by pressing or pulling the interconnection. In some embodiments advancement may be along a curved path. The plane of advancement and/or the path of advancement may change during processing of the blister chain. Optionally, a spacer may include a blister protruding from either and/or both sides. Continuous chain of blister sheets

An aspect of some embodiments of the current invention relates to a foldable continuous chain blister chain. The chain may include a plurality of blister sheets configured for folding into stacked in substantially parallel layers. Optionally, blisters may protrude from either and/or both sides of each sheet.

In some embodiments the foldable blister chain may be made of conventional blister strip materials without adding extra backing and/or connecting material. Alternately, backing and/or connecting material may be added to a blister strip.

In some embodiments, after folding, layers may alternate between adjacent layers connected by an intrinsic hinge and facing layers connected by one or more spacers. In some embodiments an intrinsic hinges may connect one or more of adjacent sheets of blisters and/or a blister sheet and an adjacent spacer and/or a pairs of adjacent spacers one to another. Optionally, the blister sheets and/or spacers may have a generally rectangular shape and/or may have rounded corners and/or cut out portions. The hinges may optionally be configured to fold preferentially in a particular direction. The direction of folding of hinges in a blister chain may optionally reverse at various points along the chain, for example for folding in a zigzag manner.

In some embodiments the input blister strip may be configured to facilitate folding. Optionally, the input strip may be configured by adding an intrinsic hinge. For example, an intrinsic hinge may be formed including one or more of a line of perforations and/or a scored line and/or a cut out and/or a line embossed in a continuous blister strip. Optionally the input strip may be configured by adding a spacer. For example, a spacer may include a cut out portion. Optionally, a blister sheet and/or a cut out portion may include a rounded edge.

In some embodiments blisters in facing layers may be arranged to mesh together. Optionally after folding, the distance between facing sheets may be the substantially the height of a single blister and/or half the height of a single blister. Optionally, blisters in adjacent sheets may be aligned back to back. Alternatively or additionally blisters in adjacent sheets may not be aligned.

In some embodiments, the blister chain may be configured for various packing options. Some packaging options may save packing materials and/or space in transport and/or be more convenient for consumers and/or be configured for use in automatic dispensing devices. For example, a blister chain may be configured for packaging in a large folding chain. Alternatively or additionally a chain may be configured for cutting into wallets of 2, 3, 4, 5 or more blister sheets. A single blister sheet and/or different blister sheets within a single chain may include one or more than one medication. A blister chain may be configured for cutting into fragments, each fragment containing a predetermined dose of one or more medicines. The fragments may optionally be cut along joints of the blister chain and/or within a single sheet. A blister chain may be configured for access directly by user and/or the chain may be configured for loading into an automated distribution machine.

A blister chain may optionally include one or more of a cut out and/or a guide hole and/or a rounded corner and/or perforations and/or a scored line and/or an embossed line. Guide holes may be used for example for stringing a blister sheet on a track. Perforations may be used for example for marking a folding line and/or a tear line (tearing off and/or separating a fragment of the chain) and/or as a track for a cogwheel). Score lines may be used, for example, to mark folding lines and/or tearing lines.

Machine to produce blister chains

An aspect of some embodiments of the current invention relates to mass producing a folded blister chain. Optionally, the system may include one or more of an in-line folder and/or an output channel and/or a boxer and/or a stacker.

In some embodiments, the system may include an in-line folding apparatus. The folding apparatus may optionally include a presser and/or a puller. For example, a presser may optionally press an interconnection out of the plane or path of advancement of the blister strip. For example, a puller may optionally pull an interconnection out of the plane or path of advancement of the blister strip. Alternatively or additionally, the folding apparatus may include an advancer. The advancer may for example advance a trailing end of a pair of blister sheets. Optionally the system may include a detainer. For example detain may hold back a leading edge of a pair of sheets. The advancing and or detaining may cause the pair of sheets to buckle and/or fold along the interconnection. Alternatively or additionally, a folding apparatus may include a brink. For example, a joint may fold and/or buckle over the brink.

In some embodiments, a blister folding system may include a stacker. A stacker may, for example, included one or more of an advancer and/or a pusher and/or a detainer and/or a resistor to push together a leading edge and a trailing edge of a pair of adjacent blister sheets until they are stacked in nearly parallel layers. The pair of sheets may for example be interconnected by a hinge and/or the pair of sheets may for example be interconnected by one or more spacers. Optionally, the adjacent layers may be stacked back to back and/or face to face and/or face to back. As used herein, the phrase face of a blister sheet means a side of a blister sheet from which a blister protrudes. As used herein, the phrase back of a blister sheet means a side of a blister sheet from which no blister protrudes.

In some embodiments, a blister folding system may include an output channel. An output channel may optionally include an advancer and a resister. The advancer may, for example, push a stack of folded blisters along path of advancement. The resister may optionally keep pressure on the stack so that it doesn't open. Alternatively or additionally, the stack may be pushed into the box out of the plane of advancement. Alternatively or additionally, a box may be placed around the stack. The opening of the box may optionally be parallel to the layers of the stack and/or perpendicular to the layers of the stack.

DETAILED EMBODIMENTS

Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details of construction and the arrangement of the components and/or methods set forth in the following description and/or illustrated in the drawings and/or the Examples. The invention is capable of other embodiments or of being practiced or carried out in various ways.

Method of producing a folded blister chain

Referring now to the drawings, Figure 1 illustrates an exemplary method of producing a continuous folded blister chain. Steps in producing and folding the chain are illustrated. In the method, a pair of adjacent blister sheets may optionally be folded out of the plane of advancement of the chain. The folding may optionally be done while the pair of folded sheets remains connected to the rest of the chain. Optionally the folded chain may be stacked and/or transported and/or boxed in-line. More detailed examples of some of the steps in the method are described in some of the embodiments herein below.

In some embodiments the method may start by supplying 102 a chain of blister sheets. The blisters in the sheets may optionally be arranged to mesh together upon folding. As used herein, the term mesh together may mean for example that blisters are intermeshed and/or adjacent as illustrated herein below. Optionally, the chain supplied as input to the folder may include empty areas, for example to serve as spacers between some of the sheets.

In some embodiments, the blister chain may be trimmed 103. Trimming 103 may include, for example, one or more of cutting away extra material near the edges of the chain and/or excising a cut out area in the chain and/or perforating the chain and/or scoring the chain, for example, scoring may be used to mark folding lines and/or cutting lines on the chain. In some embodiments, two adjacent blister sheets may be folded together 104. Optionally the folding may be carried out while the two blister sheets are still connected to the blister chain. Optionally, the folding may be performed while the leading and trailing edges of the two blister sheets remain in the line of advancement of the blister chain.

In some embodiments folding 104 may include, for example, by moving 105 an interconnection out of the plane or path of advancement of the blister chain. Optionally, moving 105 the interconnection may cause blisters sheets on either side of the interconnection to fold together. Optionally, the interconnection may join the two adjacent blister sheets and/or the interconnection may include one or more spacers blister sheets.

In some embodiments, folding 104 may include buckling 108 the pair of adjacent blister sheets. Optionally, an advancer may advance a first end of the pair towards the second end. Optionally, the second end may be held up by a detainer. In the example, as the two ends are brought together, the middle may buckle out of the plane or path of advancement of the blister chain, perpendicular to the face of the blister sheets, as the adjacent blister sheets fold together. For example the advancer may advance the trailing end of the pair of blister sheets longitudinally along the path of advancement while the detainer holds up the leading end. Optionally, a guide may be supplied to prevent the blister chain from twisting during the buckling. Additionally or alternatively, a guide may prevent the blister chain from buckling sideways (along the face of the blisters).

In some embodiments, the blister sheets of a folded blister chain may be stacked 109. Optionally, the blisters sheets may be stacked 109 in substantially parallel layers. For example, pairs of blister sheets may be stacked 109 alternating face to face and back to back. Optionally, a pair of face to face stacked blister sheets may be joined by a spacer. For example, the length of the spacer may be about the height of a single blister. Optionally, the distance between a stacked pair of face to face blisters sheets may be the height of one blister. Optionally, a pair of back to back blisters may be connected by a hinge. Optionally the backs of a stacked pair of back to back blisters may be adjoining and or butt up against each other.

Optionally, the stack may continue to be transported 110 in the direction of advancement of the blister chain. During transport the stack may optionally be held together. For example there may be a track and/or resistors. A track may for example direct the stack along the path of advance. Resistors may, for example, keep the stack from unfolding during transport 110.

In some embodiments a stack of blister sheets may be boxed 111. Boxing may optionally be done on-line. For example, a box may be supplied with an opening in the path of advancement of the stacked blister chain. Optionally, as the stack of blister chains advances it may enter the box. Alternatively and or additionally, once the stack gets big enough, a section of the stack may be boxed.

In some embodiments pairs of blisters will continue 112 to be folded and/or stacked and/or transported and/or boxed until a section of the stack is cut off 114. A box containing the cut off section may optionally be closed. The process may then continue processing the next box 116. Alternatively, the process may end 118. Cutting off 114 of a section of the blister chain may optionally be done after the section is boxed 111 and/or before the section is boxed 111 and/or after the section is transported 110 and/or before the section is transported 110.

Folding

Referring now to the drawings, Figure 2A-C illustrate an exemplary embodiment 200 of a system and method of folding a continuous blister chain. Steps in producing and folding the chain are illustrated in the sequence of Figures 2A-C. For orientation, a coordinate axes 201 are depicted. In the method, a pair of adjacent blister sheets may optionally be folded out of the plane of advancement of the chain (in the illustration the direction of advance 205 is in the positive x direction as illustrated by the arrow and the plane or path of advance is the x-y plane). The plane of the chain and/or the plane of advancement may include the shared plane of the blisters sheets (for example sheets 220a,b and spacer 222a) before folding. In embodiment 200 direction of advance 205 is perpendicular to the folding lines of joints 226a-k. Folding may optionally be done while the pair of folded sheets remains connected to the rest of the chain. Optionally the folded chain may be stacked and/or packaged into a secondary package in-line. The folding lines may optionally demark the boundary of a blister sheet (for example lines 226b,c demark blister sheet 220b and/or lines may demark the border of a spacer, for example lines 226a,b demark spacer 222a). In some embodiments the folding and/or stacking may be achieved without adding extra material to the chain, for example backing material and/or connecting material. This may save material in production and/or space in shipment.

In some embodiments the chain may be folded and/or stacked in-line. For example the folding and/or stacking may be achieved without separating the folded sheets from the rest of the chain. Alternatively and/or additionally, the folding may be achieved while the ends of the folded pair remained aligned with the direction of advancement of the chain. Alternatively or additionally, the folding may occur without interrupting the advance of the chain.

In some embodiments an unfolded blister chain may serve as input to a folding machine. The input blister chain may optionally be may be made with standard blister making materials and equipment. For example, the input chain may include a blister layer having blisters stamped into it and a cover layer. The blister layer and/or the cover layer may be made of for example PVC and/or aluminum. In exemplary embodiment 200, the input blister chain includes, for example, blister sheets 220a and 220b and corresponding blisters 24.

In some embodiments, a blister chain may include spacers and/or joints. For example, spacer 222a and joints 226a,b connect sheets 220a and 220b. For example, joint 226c connect sheets 220b and 220c. The spacers and/or joints may optionally be intrinsic to the blister chain in that they may include no added material extrinsic to the original chain. For example, joints 226a,b,c are formed by scoring a conventional blister. For example, spacer 222a is formed by scoring its boundaries, joints 226a,b. A joint between two blister sheets may serve as an intrinsic hinge. For example, joint 226c acts and an intrinsic hinge between sheets 220b,c. Alternatively or additionally, spacers and/or joints may be formed by cutting out parts of a blister sheet and or by embossing an indented and/or a protruding line across the blister chain. Optionally, in embodiment 200, blisters sheets 220a-h and spacers 222a-d may have a generally rectangular form.

In exemplary embodiment 200, a pair of pressers 230 pushes a interconnection including spacer 222b and joints 226d and 226e in the positive z-direction up and out of the x-y plane of advancement of the blister chain. As spacer 222b moves upward the pair of blister sheets 220c and 220d is optionally folded together face to face. The corresponding facing blisters 24' and 24" optionally fold into the space between pressers 230. For example, in embodiment 200, blisters 24' and 24" are arranged in an alternating staggered pattern along facing blister sheets 220c,d. Optionally, upon folding blister sheets 220c,d face each other at a distance of approximately the height of a single blisters 24. Blisters 24' and 24" which are associated to the facing sheets 220c,d may optionally mesh together.

Exemplary embodiment 200 is an intermittent production system. Optionally, as presser 230 press spacer 222b out of the plane of advancement, they also move forward in direction of advancement (the positive jc-direction). This motion is illustrated, for example, in the sequence of Figs. 2A and 2B. The forward movement may optionally pull the feed chain (for example sheets 220a,b) forward. Alternatively and/or additionally, forward movement may optionally push forward a folded stack in the output chain (for example sheets 220e,f,g,h, spacers 222c,d, and joints 226f,g,h,ij,k) forward. For example, while folding a pair of sheets (for example sheets 220c,d), pressers 230 may pull the input chain forward a distance equal to the length of a pair of blister sheets and their connector, for example a distance equal to blister sheets 220a,b and spacer 222a. For example, while folding a pair of sheets (for example sheets 220c,d), pressers 230 may push the output stack forward a distance equal to a single layer (for example, the space between facing layers which may optionally be equal to the height of spacer 222a and/or the height of a blister 24). Optionally, the output stack may be pushed forward at the end of folding. Optionally, after folding sheets 220c,d, pressers may be pulled downward and backward and return to fold the next pair of blister sheets 220a,b.

Alternatively or additionally, embodiment 200 may be a continuous feed system. For example, the input feed may move at a constant rate and movement of pressers 230 may be timed to fold blister sheets 220c,d and advance the output stack in a manner coordinated to the continuous input feed.

In some embodiments, as illustrated for example in the output stack of embodiment 200, blisters on facing layers (for example blisters 24' and 24"as described above) may be staggered. Additionally or alternatively, blisters on back to back layers may optionally be aligned. For example, blisters 24 of folded blister sheets 220f and 220g fall back to back directly opposite each other. Referring now to the drawings, Figure 3A illustrates an alternative exemplary embodiment 300a of a folding system. Exemplary embodiment 300a does not include an optional presser.

Optionally, in embodiment 300a, when a joint 326a' between two blister sheets 320a' and 320a" reaches an edge 342 of a conveyer 332a', the forward blister sheet 320" folds downward over the edge under the force of gravity. In the exemplary embodiment, as sheet 320a" folds, the interconnection between sheets 320a" and 320a'" moves downward out of the place of advancement of the input feed (for example the plane of sheet 320a'). In exemplary embodiment 300a, the interconnection includes a spacer 322a' and joints 326a'. As spacer 322a' moves downward, the pair of blister sheets 320a" and 320a'" optionally fold together face to face. Spacer 322a' continues to descend until it reaches a second conveyer 332a". Optionally spacer 322a' reaches the second conveyer next to stacked pacers 322a. Optionally sheets 320a" and 320a'" are folding into the output stack along with sheets 320a. The output stack may continue along a path of advance which continues in the same direction along a different plane. Alternatively or additionally, the path of advancement may be curved. In some embodiments, the path advancement of the blister chain may be continuous.

Referring now to the drawings, Figure 3B illustrates an alternative exemplary embodiment 300b of a folding system. For example in embodiment 300b a pair of blister sheets 320b is optionally squeezed between an optional advancer 338 and an optional detainer 334 until an interconnection, for example joint 326b', buckles up out of the plane of advancement. Optionally, as joint 326b' buckles sheets 320b to fold together.

In exemplary embodiment 300b, the buckling may optionally be started by a presser 330b that presses up slightly on joint 326b'. Exemplary embodiment 300b, may include optional spacers 322b' and 322b" and/or joints 326b at the leading and trailing edges respectively of the pair of blisters sheets 320b. Spacers 322b' and 322b" may optionally, include cut portions 336b' and 336b" respectively. For example advancer 338 may optionally extend through cut portion 336b' to advance the trailing edge of the pair of sheets 320b. For example detainer 334 may extend through cut portion 336b" to hold up the leading edge of sheets 320b. Optionally folded blisters are stacked into a track 346 for transport to the next step in processing (for example a boxer). Referring now to the drawings, Figure 3C illustrates an alternative exemplary embodiment 300c of a folding system. For example in embodiment 300c an optional spacer 322c' interconnecting a pair of blister sheets 320c' and 320c" is optionally pulled by an optional puller 330c' until sheets 320c' and 320c" to fold together.

Figure 3D illustrates an optional embodiment of puller 330c. Puller 330c optionally includes two spurs 339d and/or two legs 337c and/or a cross bar 335. For example, legs 337c may be squeezed together and inserted into optional cut out 336c'. Then legs 337c are optionally freed to spread apart. Spurs 339d may optionally catch the bottom of spacer 322c'. Pulling puller 330c then may optionally pull spacer 322c' out of the plane of advancement of the blister chain, optionally folding the chain along joints 326c and/or folding together pair of blister sheets 320c' and 320c".

Figure 3E illustrates an alternate exemplary embodiment of a puller 330e. Optionally puller 330e may grasp a blister chain from the outside. For example a puller may optionally have spurs 339e on the inside of its legs 337e. To grasp the blister chain legs 337d may for example open and straddle the blister chain. Then the legs may close, inserting spurs 339e under the outside edges of the chain, allowing puller 330e to pull the chain.

Exemplary embodiment 300c and/or 300d may optionally include spacers 322c and/or joints 326c and/or blister pages 320c and/or cut portions 336c. Guiding

Referring now to the drawings, Fig. 4A illustrates an exemplary embodiment of 400a of guides 440a to prevent twisting on an input feed blister chain. Guides 440a include optional guide wheels. Optionally, as sheets 20 roll over conveyer 432, guides 440a hold the edges of a sheet 20 flat against conveyer 432. For example, guide 440a may hold sheet 320a flat against conveyer 432. For example this may prevent the blister chain from twisting out of a plane tangent to conveyer 432.

Referring now to the drawings, Fig. 4B illustrates an exemplary embodiment of 400b of a guide 440b that prevents twisting on an input feed blister chain. Optionally, as sheets 20 are fed to a folding apparatus, guide 440b holds the edges of the sheets 20 flat. Optionally guide 440b may include a rail. For example, the rail prevents the chain from twisting out of the jc-direction of advancement. For example guide 440b may include a groove. For example, the groove may prevent the chain from twisting and/or buckling out of the x-y plane of advancement. In Figure 4B there are also marked joints 26, a spacer 22, and a cut out section 36.

Alternatively or additionally, guides may be provided at various parts of a blister folding machine, for example on the output stack and/or in folding area. For example guides may hold a spacer and/or a joint while it is being moved by a presser and/or a puller. Optionally, guides may include walls and/or ceilings to limit movement of the blister chain. For example output guides may include a channel, an example of which is described below.

Stacking

Referring now to the drawings, Figures 5A and 5B illustrates exemplary embodiments 500a and 550b of a stacker. Optionally, a stacker may push together a partially folded blister chain until the sheets stack as nearly vertical layers.

In exemplary embodiment 500a (Fig. 5A) of a stacker, an optional advancer 538 advances a trailing edge of a pair of blister sheets 520' along the direction of advancement of an output stack. Optionally the leading end of the stack is held back by a resister 545, for example a spring. The result is a stack of nearly parallel layers of blister sheets 520'.

Referring now to the drawings, Figure 5B illustrates an alternative exemplary embodiment 500b of a stacker. In embodiment 500b an optional advancer 38 advances a trailing end of a blister pair towards a leading end which is held up by an optional detainer 34. The pair of sheets between advancer 38 and detainer 34 may be pushed together until they stand up as parallel layers.

In exemplary embodiment 500b advancer 38, optionally includes two upright members. The two upright members push on opposite sides on the trailing blister sheet keeping progress of both sides even. Even movement of the two sides may optionally prevent the blister chain from twisting. Optionally, each advancer 38 advances the majority of the height of the trailing blister sheet. Pushing along a large portion of the height of the sheet may in some embodiments hold the trailing blister sheet straight.

Transport blister stack

Referring now to the drawings, Figure 6A,B,C illustrate exemplary embodiments

600a,b,c of a transporter for a folded blister stack. A transporter optionally includes a conveyer to move the stack forward and/or a resister to keep the blister sheets stacked together tightly and/or a track to direct movement of the stack. The track and/or the resistor may be stationary and/or mobile.

Figure 6A illustrates exemplary embodiment 600a of a transporter. Embodiment 600a may include an optional track 646a. For example, track 646a is a rectangular channel. Optionally, the channel walls direct the blister stack and keep it from twisting. Track 646a optionally includes resisters 650a, for example in the form of nubbles on the inside walls of the channel. A row or multiple rows of nubbles may be located one or both sides of track 646a and/or on the ceiling and or floor of track 646a. In the example of embodiment 600a, three rows of nubbles are provided on each side of track 646a. Optionally the nubble are the rows on one side of the track are located directly opposite those on the opposite side. Optionally, a blister sheet is pushed down track 646a by the preceding sheet. As the first sheet moves forward, the two sides of the sheet are detained by a set of nibbles until pressure from the preceding sheet pushes it past the first set of nubbles to the next set of nubbles. Thus, the nubbles keep the sheets directed vertically along the track and/or pressed together. Track 646a and the resistors 650a (the nubbles) are an example of a stationary track and resistors. The track and resistor remain stationary as the blister stack moves along. Embodiment 600a may optionally include an advancer, for example similar to advancer 38 of Figure 4B. An advancer may optionally serves as a conveyer, pushing the stack along track 646a.

Figure 6B illustrates alternate exemplary embodiment 600b of a transporter. Embodiment 600b includes an optional conveyer 632. Conveyer 632 may optionally transport a blister stack towards a resistor 650b. For example resistor 650b may be a plate pushed by a spring 645. Conveyer 632 may optionally include guide 658 for positioning blister sheets 620 and/or spacers 22.

In some embodiments optional box 654b may be provided. For example, when a blister stack reaches the end of conveyer 632 it may optionally push resistor 650b back to its fully retracted position. A cutter 656 may optionally be released cutting off, for example the last six blister sheets 620'. Cutter 656 may optionally act as a detainer, holding up the rest of the blister stack. Box 654b may then optionally be lowered over the six cut-off blister sheets 620'. Blister sheets 620' and box 654b may then optionally be taken away. Then spring 645 may be released to push resistor 650b up against cutter 656. Cutter 656 may then optionally be retracted and the next set of six blisters sheets 620 may be conveyed forward to be boxed.

Figure 6C illustrates an alternate embodiment 600c of a transporter. Embodiment 600c includes a notched track 646c which may have form, for example of one or more notched bars. Blister sheets 20 may include optional guide holes for example similar to holes 868 of Figure 8A). When blister sheets 20 are stacked, the guide holes may line up. The folded stack may then optionally be strung on bars (for example track 646c). Optional notches serve as resistors 650c. When the stack is static, each blister sheet 20 may optionally settle into a notch. Spaces between notches are optionally approximately equal to the width of a spacer 22 of the blister chain. Track 646c, may optionally hold the blister sheets a vertical layers of a stack.

In some embodiments, an advancer 638c may convey the stack along track 646c. Optionally as advancer 638c pushes the back of the stack, each blister sheet 20 pushes the sheet 20 ahead of it. When the force is sufficient, each blister sheet is forced up out of its notch and conveyed along track 646c until it settles into the next notch. The notches may optionally keep blister sheets 20 together as a stack while being conveyed.

One advantage of track 646c is that it may optionally be inserted into a box 654c and/or the box may be placed around track 646c. Blister sheets 20 may be optionally conveyed as a stack along track 646c directly into box 654c. Alternatively or additionally, track 646c may be slide into a box with blister sheets are already suspended. When box 654c is full, the end of the stack inside the box may optionally be cut off. The full box may optionally be retracted and replaced with an empty box and/or track 646c may be retracted from the box. The remaining stack of blisters may then optionally be conveyed forward for filling the new box etc.

Tracks 646a,b,c are illustrated as straight. Optionally a track may be curved and/or have any convenient shape. Tracks and/or resistors may be stationary (as illustrated for example in embodiments 600a,c) and/or mobile (as illustrated for example in embodiment 600b).

Figure 6D-F illustrate an exemplary embodiment 600d of a continuous folded blister chain and a cardboard medicine box 645d configured for holding and dispensing the folded chain. Fig. 6D illustrates loading the chain into box 645d and Figs. 6E,F illustrate dispensing of a blister sheet 20 from box 645d. In the example of Figs. 6E-F, blisters sheets 20 can optionally be folded out of the box 654d one at a time.

Referring now to the drawings, in Fig. 6D, an advancer 638d pushes a continuous folded stack of blister sheets 20 in to box 654d. In the example of Fig. 6D, the stack may optionally be pushed into box 654d along the direction of advancement of a blister manufacturing machine and/or perpendicular to the folding lines 26 of the blister chain. Optionally, the interconnection between blister sheets 20 may stabilize the stack and facilitate loading into the box 654d. For example, this may allow loading a larger stack than when loading loose blister sheets which may become disordered during loading. For example a stack of more than 10 blister sheets or in some examples more than 30 blister sheets may be loaded into a secondary package. Alternatively or additionally, the stack of blister sheets may be packaged in a bag and/or a foil pack and/or wrapped (for example in shrink wrap, plastic, paper and/or foil) and/or another secondary packaging. In some embodiments, a stack of blisters will be packaged with an instruction sheet and/or a package insert. For example, a package insert may be fully or partially wrapped around the stack during insertion into box 654d.

Referring now to figures 6E and 6F, removal of a blister sheet 20 from box 654d is illustrated. The opening 692d of box 654d is oriented such that as the chain unfolds, each blister sheet 20 exits opening 692d. Optionally a sheet 20 can be unfolded and/or cut off without requiring removal of the entire chain. For example, the folding lines 26 of the blister chain may be parallel to the plane of opening 692d such that as it is unfolded, a blister sheet 20 extends out of the opening 692d.

In the example of Figs. 6D-F the same opening 692d is used for filling box 654d and dispensing blister sheets 20. In some embodiments, the end of the blister stack opposite the opening 692d may be fastened (for example, stapled and/or pasted) to the opposite end 696d of box 654d so that the remainder of the chain remains in the box during dispensing a blister sheet 20.

Drawings 6G-I illustrate an alternative embodiment of loading a secondary package and dispensing blister sheets. An exemplary embodiment 600g of a stack of blister sheets 20 is inserted into a secondary package (for example, box 654g) through a loading opening 692g. Once the package is loaded, loading opening 692g may be sealed. Optionally, blisters sheets 20 may be dispensed through a user opening 694. In embodiment 600g folding lines 26 of the stack are perpendicular to the plane of loading opening 692g and parallel to the plane of dispensing opening 694.

Referring now to the drawings, in Fig. 6G, an advancer 630 pushes a continuous folded stack of blister sheets in to box 654g. In the example of Fig. 6G, the stack may optionally be pushed into box 654g perpendicular to the direction of advancement of the blister producing machinery and/or parallel to the folding lines 26 of the blister chain. Optionally, the interconnection between blister sheets may stabilize the stack and facilitate loading into the box 654g. For example, this may allow loading a larger stack than when loading loose blister sheets which may become disordered during loading. For example a stack of more than 10 blister sheets or in some examples more than 30 blister sheets may be loaded into a secondary package. Alternatively or additionally, the stack of blister sheets may be packaged in a bag or a foil pack or another secondary packaging. In some embodiments, a stack of blisters will be packaged with an instruction sheet or a package insert. For example, a package insert may be fully or partially wrapped around the stack during insertion into box 654g.

Referring now to drawings 6H and 61 illustrate removal of a blister sheet 20 from box 654g. Dispensing opening 694 of box 654g is perpendicular to insertion opening 692g. Dispensing opening 692g is oriented such that as the chain unfolds, blister sheets 20 exits opening 694 individually. Optionally a sheet 20 can be unfolded and/or cut off without requiring removal of the entire chain. For example, the folding lines 26 of the blister chain may be parallel to the plane of opening 694 such that as it is unfolded, a blister sheet 20 extends out of the opening 694.

An exemplary integrated system

Referring now to the drawings, Figures 7A-G illustrate an exemplary embodiment 700 of an integrated system for guiding, folding, stacking and conveying a blister chain. Optionally embodiment 700 may be powered by a simple rotary actuator moving at a constant rate. Embodiment 700 may optionally be operated in a continuous or intermittent mode.

Exemplary embodiment 700 optionally includes a rotary actuator 760. Actuator 760 may optionally include a simple electric motor. Rotary motion of actuator 760 optionally turns a bent arm 763. Optionally, bent arm 763 moves in a continuous circular orbit. Bent arm 763 optionally activates advancers 738 (see Figure 7B) and/or a presser arm 762 which turns a pin 764 in a diagonal slot 756 to raise up a presser 730 (see Figure 7C) and/or a detainer 734.

In some embodiments, actuator 760 may be powered by a driver 759. Driver 759 may optionally be controlled by a controller 761. Controller 761 and/or Driver 759 may optionally be synchronized with a blister producing machine that supplies an input blister chain to the folding system. Alternatively or additionally, actuator 760 may be connected to a transmission and may also supply power to a blister producing machine and/or a boxer. Optionally and output track may be supplied, for example output track 746.

Figure 7A illustrates an optional first step in the folding process. A blister chain is optionally fed into the folding system through a guide 740 groove. The chain includes, for example, blister sheets 720 with rounded corners, spacers 722, cutouts 736' and 736", and joints 726.

Figure 7B illustrates an optional further step in the folding process. As actuator 760 turns, advancers 738 may optionally be raised up through a trailing cut out 736'. Optionally, at the same time, bent arm 763 may contact presser arm 762.

Figure 7C illustrates an optional further step in the folding process. In Fig. 7C, the blister strip is not shown. As actuator 760 continues to turn, advancers 738 optionally move forward, squeezing a pair of blister sheets 720' and 720"between advancers 738 and detainers 734. Detainers 734 are optionally protruding through leading cut out 736". Simultaneously, bent arm 763 pushes presser arm 764 forward, turning pin 764 up diagonal slot 766 pushing up presser 730. Presser optionally presses upward on joint 726' which interconnects sheets 720' and 720". The squeezing pressure and the upwards pressing optionally cause the pair of sheets 720' and 720" to buckle along joint 726'. Joint 726' moves upward out of the plane of advancement of the blister chain.

Figure 7D illustrates an optional further step in the folding process. In Fig. 7D, the blister strip is not shown. As actuator 760 continues to turn, advancers 738 move forward and upward further folding the pair of blister sheets 720' and 720" and also steadying them to prevent them from twisting. Simultaneously, bent arm 763 clears presser arm 762 allowing presser 730 to retract and clear the way for further advancement of the blister chain. Figure 7E illustrates an optional further step in the folding process. In Fig. 7E, the blister strip is not shown. As actuator 760 continues to turn, advancers 738 stack approximately vertically against detainer 734.

Figure 7F illustrates an optional further step in the folding process. In Fig. 7F, the blister strip is not shown. As actuator 760 continues to turn, the base of advancers 738 optionally contact the base of detainers 734. As advancers 738 move forward and/or retract downward, detainers 734 are retracted downward. Detainers 734 are optionally forced downward out of the way of the stack pair of blister sheets 720' and 720". Advancers 738, optionally push folded stacked blister sheets 720' and 720" into track 746. Optionally blister sheets 720' and 720" may push the entire blister stack along track 746.

Figure 7G illustrates optional details of the mechanism for retracting detainers 734. In Fig. 7G, the blister strip is not shown. Bent arm 763 includes an optional bumper 749. As bent arm 763 rotates after stacking a pair of sheets, bumper 749 optionally contacts a support arm 751 of detainers 734. Pressure from bumper 749 optionally causes support arm 751 to rotate around an axis 747 retracting and lowering detainers 734. After retracting detainers 734, bent arm 763 optionally continues rotating, lowering bumper 749 below support arm 749. Once free of bumper 734, support arm is pulled back up by a spring 745.

Figure 7H illustrates an optional further step in the folding process. As actuator

760 continues to turn, advancers 738 are optionally retracted downward. The system may optionally restart with a new pair of blister sheets 720"' and 720"", for example as depicted for blisters sheets 720' and 720" in Figure 7 A.

Exemplary blister strip geometries

Referring now to the drawings, Figure 8A-14C illustrate various exemplary embodiments of foldable blister chains. Blisters on facing layers of a folded blister chain may be optionally staggered so that they mesh together upon folding. After folding the distance between facing blisters sheets may be approximately the height of one blister. On sheets positioned back to back, the blisters may optionally be aligned directly opposite each other. Alternatively or additionally, on sheets positioned back to back, the blisters may optionally be intermeshed. In some embodiments, a foldable blister chain may optionally be configured to be packaged as a wallet of two and/or three and/or more layers having a set number of doses, for example for a single treatment (for example ten tablets) and/or for a week (for example seven tablets). Each layer may optionally be configured to be separated from the stack. Alternatively, the stack may be configured to be divided every two and/or three and/or more layers. A foldable blister chain may optionally be configured to be packaged as a strip of an arbitrary number of layers. A foldable blister strip may include a single medicine and/or a single dosage and/or multiple medicines and/or multiple dosages. A blister sheet and/or a spacer may optionally include a cut out and/or a guide hole and/or a rounded corner and/or perforations and/or a scored line and/or an embossed line. Guide holes may be used for example for stringing a blister sheet on a track. Perforations may be used for example for marking a folding line and/or a tear line (tearing off and/or separating a fragment of the chain) and/or as a track for a cogwheel). Score lines may be used, for example, to mark folding lines and/or tearing lines. Embossed lines may serve for example as folding lines. Embossed lines may include for example indentations and/or projections.

Figures 8A,B illustrate an exemplary embodiment 800 of a foldable blister chain. Figure 8A illustrates five blister sheets 820, 820a,b,c,d,e of embodiment 800 in an unfolded state. Optionally, each blister sheet 820a-e includes four blisters 24. Blister sheets 820a-e are optionally interconnected by alternating spacers 822a,b and intrinsic hinges (for example joints 826c and 826f). In embodiment 800, adjacent sheets interconnected by an intrinsic hinge without a spacer are oriented back to back upon folding. In embodiment 800, adjacent sheets interconnected by a spacer are oriented face to face upon folding. For example, sheet 820a is interconnected to sheet 820b by a spacer 822a and two joints 826a,b; as illustrated in Figure 8B, when the chain is folded, sheets 820a and 820b are optionally oriented face to face. For example, sheet 820b is interconnected to sheet 820c by an intrinsic hinge, joint 826c; as illustrated in Figure 8B, when the chain is folded, sheets 820b and 820c are optionally oriented back to back. Each spacer 822a,b includes an optional cut out 836. Cut outs 836 and/or blister sheets 820a-e optionally have rounded edges. Rounded edges may optionally protect users from cutting themselves of sharp edges. Joints 826a,b,c,d,e,f may be made, for example, by scoring and/or perforating and/or folding the blister chain. Embodiment 800 includes guide holes 868. Guide holes may be used for stringing a blister chain on a track, for example as illustrated in Figure 6C.

In Figures 8A,B, blisters 24 are numbered to help clarify the geometric of the blisters in the folded and unfolded blister chain.

Figure 8B illustrates five blister sheets 820 and 820a-e of embodiment 800 in a folded state. Optionally, blisters 24 of one sheet are arranged adjacent to blisters 24 of an adjacent sheet such that upon folding, the blisters mesh and do not interfere with each other. Optionally, facing sheets approach each other to within approximately one blister height. For example, upon folding along joints 826a,b, blisters 24 of sheet 820a (numbered 1-4) fall adjacent to blisters 24 of sheet 820b (numbered 5-8).

In embodiment 800, back to back blisters are aligned so that they fall on top of each other. Locating back to back blisters, one against the other may prevent accidental bursting of blisters if the stack is compressed.

Figures 9A,B illustrate an alternate exemplary embodiment of a foldable blister chain in an unfolded (Figure 9A) and a folded (Figure 9B) configuration. In the exemplary embodiment of Figure 9A,B, in the folded configuration, blisters 24 of facing blister sheets 20 are optionally intermeshed. Each blister sheet 20 of the embodiment of Figure 9A,B optionally includes a weekly dose of medicine (for example 7 tablets). Each folding line 26 of the embodiment of Figure 9A,B may optionally serve as a tear line. For example, a user may buy a box containing a chain of folding blister sheets. The user may, for example, separate one sheet each week and take a daily capsule from the sheet. In the embodiment of Figure 9A,B blisters on back to back sheets are optionally not aligned.

Figures 10 illustrate an alternate the exemplary embodiment of a foldable blister chain in an unfolded configuration. In the exemplary embodiment of Figure 10, each blister sheet optionally contains different kinds and/or doses of medicine in different shaped blisters 24. Optionally, a single blister sheet may include multiple related medicines that are commonly taken together. Alternatively or additionally, a blister sheet may optionally include a custom set of medicines for a particular person's dosage regime.

Figures 11A,B,C illustrate an alternate exemplary embodiment of a foldable blister chain. Figure 11A illustrates four blister sheets 20 of the embodiment of Figure 11A,B,C in an unfolded state. The blister chain may optionally be of an arbitrary length. Figures 11B,C illustrate a pair of folded blister sheets 20 of the embodiment of Figure 11 A,B,C in a folded state.

In embodiment of Figure 11A,B,C, facing pairs of blisters sheets are optionally configured to be cut out together. For example, the chain of Figure 11 A is configured to be cut along line C-C. Optionally, a pair of blister sheets may be folded as a blister wallet 1170, for example as illustrated in Figures 11B,C. A wallet may contain, for example ten doses of a medicine. Alternatively or additionally, a wallet may contain, for example, 7 doses and/or an arbitrary number of doses. In the folded configuration (as illustrated for example in Figures 11B,C) pages of blister wallet 1170 may optionally overlap. Alternatively or additionally, a blister wallet may include 3, 4, 5 and/or more sheets.

Figures 12A,B,C illustrate an alternate exemplary embodiment of a foldable blister chain. Figure 12A illustrates four blister sheets 20 of the embodiment of Figure 12A,B,C in an unfolded state; the blister chain may optionally be of an arbitrary length. Figures 12B,C illustrate a pair of folded blister sheets 20 of embodiment of Fig. 12A,B,C in a folded state.

In the embodiment of Figure 12A,B,C, facing pairs of blisters sheets are optionally configured to cut out together. For example, the chain of Figure 12A is configured to be cut along line D-D. Optionally, a pair of blister sheets may be folded as a blister wallet 1270, for example as illustrated in Figures 12B,C. A wallet may contain, for example ten doses of a medicine. Alternatively or additionally, a wallet may contain, for example, 7 doses and/or an arbitrary number of doses. In the folded configuration (as illustrated for example in Figures 12B,C) pages of blister wallet 1270 may optionally be aligned without overlap.

Figures 13A,B,C illustrate an alternate exemplary embodiment of a foldable blister chain. Figure 13A illustrates six blister sheets 20 of the embodiment of Figure 13A,B,C in an unfolded state; the blister chain may optionally be of an arbitrary length. Figures 13B,C illustrate a pair of folded blister sheets 20 of the embodiment of Figure 13A,B,C in a folded state.

Figures 14A,B,C illustrate an alternate exemplary embodiment of a foldable blister chain. Figure 14A illustrates four blister sheets 20 of the embodiment of Figure 14A,B,C in an unfolded state; the blister chain may optionally be of an arbitrary length. Figures 14B,C illustrate a pair of folded blister sheets 20 of the embodiment of Figure 14A,B,C in a folded state. Optionally, the blister chain of the embodiment of Figure 14A,B,C can be folded into a wallet including multiple medicines and/or doses. Other embodiments, for example as illustrated above, may optionally contain one or more doses and/or kinds of medicines.

Figures 15A,B illustrate an alternate exemplary embodiment 1500 of a foldable blister chain. Each blister 1524 of embodiment 1500 optionally protrudes on both sides of its respective blister sheet 1520. Each blister sheet 1520 has two faces and no back. Optionally, spacers 1522 of embodiment 1500 are shorter than the height of a blister 1524. For example, a spacer may be approximately half the height of a blister 1524. When stacked, the space between adjacent sheets 20 may optionally be less than the height of a blister 1524. For example, the space may be about half the height of a blister 1524.

Figure 15A illustrates four blister sheets 1520 of embodiment 1500 in an unfolded state; the blister chain may optionally be of an arbitrary length. Figure 15B illustrates a stack of six of folded blister sheets 1520 of embodiment 1500 in a folded state. Optionally, a sheet 1520 of the blister chain of embodiment 1500 may include multiple medicines and/or doses. Other embodiments, for example as illustrated in embodiments above and below, may optionally contain one or more doses and/or kinds of medicines. Alternatively or additionally a blister chain may include some sheets having blisters protruding from both sides and other sheets having blisters protruding from one said.

Referring now to the Figures, Fig. 15C illustrates a schematic side view of an alternate exemplary embodiment 1500' of a blister chain. A blister sheet 1520 of the chain may including a blister 1524 protruding on both sides and another blister 1524' protruding on only one side. Optionally, blister 1524 which protrudes on both sides may be taller than blister 1524' which protrudes on only one side.

Figures 16A,B illustrate an alternate exemplary embodiment 1600 of a foldable blister chain. In exemplary embodiment 1600, blisters 24 are optionally located on blister sheets 20 and also on spacers 1622. Figure 16A illustrates four blister sheets 20 of embodiment 1600 in an unfolded state; the blister chain may optionally be of an arbitrary length. Figure 16B illustrates a stack of six of folded blister sheets 20 of embodiment 1600 in a folded state. Optionally, a sheet 20 of the blister chain of embodiment 1600 may include multiple medicines and/or doses. Other embodiments, for example as illustrated above, may optionally contain one or more doses and/or kinds of medicines. Optionally, a blister may protrude from either and/or both sides of a spacer 1622. In some embodiments the blisters on the spacers may have a different dose from the blisters on the sheets. For example, the sheets may contain large blisters while the spacers contain small blisters and/or vice versa etc.

Figure 17A illustrates an alternative exemplary embodiment of a blister chain. In some embodiments, each blister 1724, 1724' in the blister chain contains a drug pills and/or tablet. Optionally, the drug cavity locations on the blisters surface are in a format that each blister cavity on a sheet fits in the space between two other blisters on an opposing blister sheet when the chain is folded. For example, sheet 1720 is folded opposite (face to face) with sheet 1720' and the blisters 1724' of sheet 1720' fit between the blisters 1724 of sheet 1720.

In some embodiments, adjacent blister sheets (for example sheets 1720 and 1720') may be separated by a spacer 22. The width (w) of a spacer may optionally be approximately equal to the height of a pill cavity plus twice the thickness of the blister substrate. Optionally adjacent pages that fold opposite one another front to front (for example sheets 1720 and 1720') are separated one of the other by a spacer (for example spacer 22) and/or two 90° joints (for example joints 1726 and 1726'). Optionally adjacent pages that fold against one another back to back, (for example sheets 1720' and 1720") are separated by a 180° joint (for example joint 1726").

Figure 17B illustrates an alternative exemplary embodiment of a blister chain in an unfolded form. In some embodiments each blister sheet 1720b will be separated from the next blister sheet by a reconfigurable space 1722b. In some embodiments, each reconfigurable spacer may have three optional folding lines 1726b.

Figure 17C illustrates a side view of the blister chain of Fig. 17a after folding.

Reconfigurable spacers 1722b are optionally folded with 90° angles on the two outer folding lines 1726b to make a spacer between two front to front blister sheets. Reconfigurable spacer 1722b' is folded with a 180° angle on the center folding line 1726b to make a joint between two back to back blister sheets. Reconfigurable spacer 1722b" is folded with 180° angles on each of the three fold lines 1726b to make a joint between two back to back blister sheets. Thus each spacer 1722b, 1722b', 1722b" may be reconfigured to a spacer and/or a joint and the form of the folded chain may also be reconfigured at will.

Adapting a standard blistering system

Figs. 18-20 illustrate a method of adapting a standard medicine blister system to produce a continuous folded blister chain. Optionally the method may include setting up a standard blister machine to produce a foldable blister chain. The chain may include, for example, a continuous chain of blister sheets and/or spacers and/or 90° joints and/or 180° joints. The foldable chain may optionally be folded and/or stacked and/or cut and/or packaged using devices, for example as described herein.

For purposes of better understanding some embodiments of the present invention, for example, as illustrated in Figures 19 and 20 of the drawings, reference is first made to the construction and operation of an example of a standard blister packaging system 1800 as illustrated in Figure 18.

In exemplary system 1800 a blister packaging process begins with a roll 1801 of substrate, for example of PVC (alternatively or additionally the substrate may include aluminum and/or other materials). The material continues to a pill/tablets pocket forming unit 1802. Pill/tablets pocket forming unit 1802 makes cavities 1803 in the substrate for the pills. Cavities 1803 are then filled with the pill/tablets by a pill feeder 1805. The PVC with the pill/tablet filled cavities 1806 is covered with a protective covering of, for example, aluminum foil 1807. Fiol 1807 may optionally be ironed to the PVC by an ironing unit 1808.

The output of ironing unit 1808 includes a continuous aluminum covered PVC blister strip 1809 with blisters containing the tablets. Blister sheets 1812 are then cut out of blister strip 1809 by a cutting unit 1810. Each blister sheet 1812 falls separately into a boxing machine. Leftover material 1811 is rolled away 1814. Blister sheets 1812 are then loaded into package, for example a cardboard patient drug box 1813. Fig. 19 is a flow chart illustration of an exemplary embodiment of method of adapting a convention a blister production system for producing a continuous foldable blister strip. The method starts by supplying 1971 a blister production system. The system may optionally include a standard blister system. Optionally, a standard blister system may include some or all of the components illustrated in Fig. 18, for example, a standard roll 1801 substrate, a standard pill/tablets pocket forming unit 1802, a standard pill feeder 1805, a standard ironing unit 1808, and/or a standards cutting unit 1810. The system may further include a folding unit (for example as illustrated in Figs. 2A-C, 3A- D, 7A-H, 20-24B) and/or a stacking unit (for example as illustrated in Figs. 5A,B and/or a packaging unit (for example as illustrated in Figs. 6A-I).

In some embodiments, method may include a special set up 1972 of the conventional parts of the system. For example a pocket forming unit may optionally be set up 1973a to produce folding lines. For example, folding lines may include 180° and/or 90° joints (for example joints 26 of Figs. 9A-17, and more specifically for example 180° joint 826c of Fig. 8A,B and/or joints 2126a,b of Figs. 21A,B, for example 90° joints 826a,b,d,e of Fig. 8A,B and/or joints 2226 Figs. 22A,B).

Set up 1972 may optionally include, for example, setting up 1973b a cutting unit to cut off the edges and/or cut out portions from the blister chain (for example as illustrated for example in Figs. 8A-16B and/or 20) while leaving the blister sheets connected as a long chain.

In some embodiments, a folding line may be formed 1974. Optionally, folding lines may be formed 1974 by a pocket forming unit. For example, a folding line could be formed as an indentation on one side of the blister substrate with a protrusion on the other side, for example as illustrated in Figs. 21A, 21A', 22A and 22A' . Alternatively or additionally, a folding line could be formed as indentation on both sides of the blister substrate Figs. 2 IB, and 22B.

In some embodiments, extra material will be trimmed 1975 from the blister chain. For example, excess material may be cut off the edges of the blister chain and/or cut outs could be formed within the blister chain. Alternatively or additionally, perforations may be made in the blister chain for example to facilitate separation of blister sheets by the end user. Optionally, a cutting unit may perform trimming 1975. In some embodiments the continuous blister chain may be folded 1976. Optionally, folding 1976 may be performed by a folding apparatus.

In some embodiments connected blisters sheets of the continuous folded blister chain may be stacked 1977. Optionally, stacking may be performed by a stacking unit.

In some embodiments the stacked chain of blister sheets may be packaged 1978.

Packaging 1978 may include for example, pushing a stack of connected blister sheets through a channel into a box. Alternatively or additionally, packing 1978 may include moving a track holding the blister sheets into a box and then removing the track. Alternatively or additionally packaging 1978 may include inserting the stack into another form of package such as a foil pack and or a bag.

Figure 20, illustrates an exemplary embodiment 2000 of a folding unit 2019 connected in line with a standard blister forming system.

In some embodiments, a standard pocket forming unit (for example unit 1802) may be set up to form folding lines 26 and/or to place blisters that mesh when blister strip 1809 is folded.

In some embodiments, a cutting unit 2015 may be a standard cutting unit (for example cutting unit 1810). Cutting unit 2015 may optionally be set up differently from the standard format (that separate the blister to the regular blister format as seen in Fig. 18). Some optional differences in the cutting format are explained in the explanation of Fig 19. For example, blisters sheets may not be cut apart, thereby forming a continuous chain 2018 of connected blister sheets (unseparated). Leftover materials 2017 may optionally be rolled away.

Optionally, folding unit 2019 may be located after cutting unit 2015. The continuous chain 2018 of connected blister sheets may optionally enter folding unit 2019 which may optionally fold the continuous chain into a continuous folded stack 2020. Stack 2020 may optionally be loaded into a package, for example cardboard patient drug box 2021.

Details of folding lines

Figure 21 A illustrates an exemplary embodiment of a folding line 2126a for a 180° fold. For example, a folding line may include an indentation 2180a and a protrusion 2181. Indentation 2180a and protrusion 2181 may optionally be on opposite sides of the substrate. For a 180° fold, the length of protrusion 2181 may optionally be approximately twice the thickness (h) of the substrate. For example, the length of protrusion 2181 may range between 1.2 and 2.8 times the thickness (h) of the substrate. The length of indentation 2180a may optionally be less than the length of protrusion 2181.

Figure 21A' illustrates the substrate of Fig. 21A after folding. For example, folding may stretch the outer side of the substrate. Protrusion 2181 may be thinned out by stretching to form a rounded corner of. Protrusions 2181 may prevent the corner from thinning out/or and becoming brittle.

Figure 2 IB illustrates an alternative exemplary embodiment of a folding line

2126b for a 180° fold.

For example, a folding line may include indentations 2180b and 2180b'. Indentations 2180b and 2180b' may optionally be on opposite sides of the substrate. For a 180° fold, the length of indentations 2180b,b' may be approximately twice the thickness (h) of the substrate. For example, the length of indentations 2180b,b' may range between 1.2 and 2.8 times the thickness (h) of the substrate.

Figure 21B' illustrates the substrate of Fig. 21B after folding. In some embodiments, indentations 2180b,b' may make it easy to fold the substrate along line 2126b. The corner may optionally thin out during folding.

Figure 22A illustrates an exemplary embodiment of a folding line 2226a for a

90° fold. For example, a folding line may include an indentation 2280a and a protrusion 2281. Indentation 2280a and protrusion 2281 may optionally be on opposite sides of the substrate. For a 90° fold, the length of protrusion 2281 may optionally be approximately the thickness (h) of the substrate. For example, the length of protrusion 2181 may range between 0.6 and 1.4 times the thickness (h) of the substrate. The length of indentation 2280a may optionally be less than the length of protrusion 2281. The length of indentation may optionally be approximately half the thickness of the substrate. For example, the length of indentation 2280a may optionally ranges between 0.2 and 0.8 times the thickness of the substrate.

Figure 22A' illustrates the substrate of Fig. 22A after folding. For example, folding may stretch the outer side of the substrate. Protrusion 2281 may be thinned out by stretching to form a rounded corner of. Protrusions 2281 may prevent the corner from thinning out and becoming brittle.

Figure 22B illustrates an alternative exemplary embodiment of a folding line 2226b for a 90° fold. For example, a folding line may include indentations 2280b and 2280b'. Indentations 2280b and 2280b' may optionally be on opposite sides of the substrate. For a 90° fold, the length of indentations 2280b,b' may be approximately the thickness (h) of the substrate. For example, the length of indentations 2280b,b' may range between 0.6 and 1.4 times the thickness (h) of the substrate.

Figure 22B' illustrates the substrate of Fig. 22B after folding. In some embodiments, indentations 2280b,b' may make it easy to fold the substrate along line 2226b. The corner may optionally thin out during folding.

Figure 22C is a schematic view illustrating the orientation of folding lines in an exemplary continuous blister chain. The orientation of folding lines in Fig. 22C corresponds for example to embodiments 800, 900, and 1600. In the exemplary embodiment of Fig. 22C, blister sheets 20 are alternatingly separated by a spacer 22 with two upward folding 90° joints 2226, followed by a downwardly folding 180° joint 2126 (folding in the opposite direction).

Figure 22D is a schematic view illustrating the orientation of folding lines in an exemplary continuous blister chain. The orientation of folding lines in Fig. 22C corresponds for example to embodiment 1500. In the exemplary embodiment, blister sheets 20 are alternatingly separated by a spacer 22 with two upward folding 90° joints 2226, followed by a spacer 22 with two downwardly folding 90° joints 2226 (folding in the opposite direction from the previous pair of joints),Alternative embodiments of folding machines

Figs. 23A-E illustrate five exemplary steps of a process of folding a blister chain.

The process may optionally repeat itself in a continuous manner.

Fig. 23 A step-1, illustrates an exemplary starting configuration. For example, the drawing illustrates six blisters 2324a-f; blisters 2324a-c are already in folded position, and blisters 2324d-f are on standby to be folded.

Fig. 23B, Step-2 illustrates an example of initiating folding. In step two an advancer 2338a optionally advances a trailing spacer 2322a while a second advancer optionally retains a leading spacer 2322b in place squeezing sheets containing blisters 2324d,e between them. The squeezing buckles a joint 26. For example, joint 26 and blisters 2324d,e are buckled upward out of the plane of advancement of the blister chain. Optionally, a presser 2330 pushes joint 26 located between blisters 2324d,e upward. Pushing joint 26 upward may for example help initiate folding on the correct line (joint 26).

Fig. 23C, Step-3 illustrates an example of advancers 2338a,b continuing to buckle joint 26 and blisters 2324d,e. In the example presser 2330 has completed its job of initiating the folding and moves downward out of the path of advancement of the blister chain.

Fig. 23D, Step-4 illustrates an example of removal of advancer 2338b so blister 2324d can be stacked in position in front of blister 2324c. Optionally, advancer 2338a continues pressing blister 2324e forward until blisters 2324d,e are stacked in their places.

Fig. 23E, Step-5 illustrates the exemplary system completing a cycle and returning to the configuration of Fig. 23 A except that now blisters 2324d,e are in the same position that blisters 2324b,c where in Fig. 23A. The folding cycle may optionally continue from step-1 (Fig. 23 A) with blisters 2324f,g on standby to be folded. Advancers 2338a,b and presser 2330 have returned to their position as in Fig. 23A.

Figures 24A-H illustrate a side view of an alternative example of a folding machine and a method of folding a blister strip. Figs. 24A'-H' show a front view of the folding machine. In the exemplary method folding is done by a dual motion rotary presser 2430 while stacking is done by a two piece advancer 2338.

In Fig. 24A for example, six sheets are shown each containing a blister 2424a-f. Blisters 2424a-c are already in their folded positions and blisters 2424d-f are waiting to be folded. An advancer 2438 is located at the trailing end of the pair of sheets containing blisters 2424d,e. As illustrated in Fig. 24A', advancer 2438 may optionally include of two separate parts. The plane of advancement 2490 of the blister chain is labeled. In Figs. 24A,A', a rotary presser 2430 is shown in a ready position parallel to plane of advancement 2490.

Figs. 24B,B' illustrate an exemplary subsequent step in folding. Optionally advancer 2438 advances a trailing edge of blister pair 2424d,e while presser 2430 rotates, raising blisters 2424d,e out of plane of advancement 2490. As advancer 2438 moves forward it pulls along the trailing portion of the blister chain, for example blisters 2424f,g.

Figs. 24C,C illustrate an exemplary subsequent step in folding. Optionally advancer 2438 keeps advancing the trailing edge of blister pair 2424d,e while presser 2430 continues to rotate, until presser 2430 is perpendicular to plane of advancement 2490 and blisters 2424d,e are stacked up against blisters 2424a,b,c.

Figs. 24D,D' illustrate an exemplary subsequent step in folding. Presser 2430 has been lowered out of the path of advancement of the blister stack.

Figs. 24E,E' illustrate an exemplary subsequent step in folding. Optionally advancer 2438 advances the blister stack pulling forward blisters 2424f,g into a position ready to fold. In Figs. 24E,E' rotates back to be parallel to plane of advancement 2490.

Figs. 24F,F' illustrate an exemplary subsequent step in folding. In Figs. 24F,F' presser 2430 has optionally be raised back to its ready position for folding a new pair of blisters 2424f,g. Optionally, the two parts of advancer 2438 spread apart (as is seen in Fig. 24F') disengaging from the blister stack.

Figs. 24F,F' illustrate an exemplary subsequent step in folding. Advancer 2438 optionally returns to the trailing edge of blister pair 2424f,g.

Figs. 24G,G' illustrate an exemplary subsequent step in folding. The two parts of Advancer 2438 optionally come back together (as illustrated for example in Fig. 24F') such that the apparatus is now ready to restart the process, folding blisters 2424f,g.

It is expected that during the life of a patent maturing from this application many relevant technologies will be developed and the scope of the terms is intended to include all such new technologies a priori

As used herein the term "about" refers to ± 5%

The terms "comprises", "comprising", "includes", "including", "having" and their conjugates mean "including but not limited to".

The term "consisting of means "including and limited to".

The term "consisting essentially of" means that the composition, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure. As used herein, the singular form "a", "an" and "the" include plural references unless the context clearly dictates otherwise. For example, the term "a compound" or "at least one compound" may include a plurality of compounds, including mixtures thereof.

Throughout this application, various embodiments of this invention may be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

Whenever a numerical range is indicated herein, it is meant to include any cited numeral (fractional or integral) within the indicated range. The phrases "ranging/ranges between" a first indicate number and a second indicate number and "ranging/ranges from" a first indicate number "to" a second indicate number are used herein interchangeably and are meant to include the first and second indicated numbers and all the fractional and integral numerals therebetween.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements.

Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention. To the extent that section headings are used, they should not be construed as necessarily limiting.