CROSS-SECTION TO RELATED APPLICATION

[0001] The present application claims priority to U.S. Provisional Patent Application No. 63/366,872, filed June 23, 2022, and titled “RECYCLABLE BLISTER PACK AND METHODS OF MAKING AND USING SAME”, the disclosure of which is hereby incorporated by reference in its entirety.

FIELD

[0002] The presently disclosed technology relates to packages for sensitive or consumable product. More specifically, in one embodiment, the present disclosed technology is directed to a blister package for product, such as one or more pills, tablets, capsules, and the like. In one optional embodiment, the presently disclosed technology is directed to a package having a recyclable cover bonded to a recyclable backing, both of which can be optionally formed of a thermoformed material.

BACKGROUND AND DESCRIPTION OF RELATED ART

[0003] Blister packaging is commonly used to package oral solid dose medications, vitamins, probiotics, pills, tablets, capsules, and the like. Prior art packaging, such as U.S. Patent No. 8,142,603, which is hereby incorporated by reference, includes a thermoformed cover, which holds the product, and a foil backing attached to an open side thereof to enclose the product. Blister packaging or “blister packs” are typically used both by pharmaceutical companies and health care facilities. Blister packs are also manufactured by companies in the business of providing unfilled or empty blister packs for filling by third parties.

[0004] It is known to place a desiccant or scavenger extruded film in a blister pack. The size and shape of the desiccant or scavenger extruded film may be called the footprint of the film, and in the prior art is at least slightly less than the opening of the blister containing the product. Such blister packaging with desiccant film is disclosed in U.S. Pat. No. 6,279,736 (Hekal), International Publication No. WO 2020/146556 (Hollinger), and International Publication No. WO 2022/236313 (Hollinger), each of which is incorporated by reference.

[0005] Fig. 1 shows a prior art blister pack 10 having four blisters 18. Fig. 2 shows a cross- sectional view through line 2-2 of Fig. 1, and shows a thermoplastic member 14, forming one of the blisters 18, adhered to foil backing 12. Extruded desiccant film 16 having a width WPA (see Fig. 2) less than that of a single blister 18 is adhered to the foil backing 12.

[0006] Various techniques are known to recycle plastics. For example, recycling sorting for plastics is often based on the sink- float process, where particles of less than 1 g/cm3 are separated from particles of greater than 1 gm/cm3 based on whether the particles float or sink in a body of water. Recyclers also use initial sorting by near-infrared spectroscopy to differentiate different types of polymers, such as polystyrene (PS), polyethylene (PE), polypropylene (PP), and the like. Sorting by weight (e.g., with an air gun), with sensors, and/or with magnets can also be used. Additional known recycling processes and features are described in “Managing Plastic Waste — Sorting, Recycling, Disposal, and Product Redesign,” by Jean-Paul Lange, ACS Sustainable Chem. Eng. 2021, 9, 15722-15738, which is hereby incorporated by reference.

[0007] In conventional blister packaging, the backing and the cover are made of different materials, which prevents recycling or at least makes recycling difficult or inefficient. For example, in conventional blister packaging, the backing is formed of foil and the cover is formed of a polymer. In addition, blister packaging that includes an active component further complicates or prevents recycling, due to the different materials used to form the active component. These different materials make recycling prior art blister packaging difficult and time consuming at best. In fact, companies are collecting used blister packaging, but have nowhere to recycle them.

BRIEF SUMMARY

[0008] There is a need to provide a recyclable blister package that is capable of preserving and/or protecting product therein, and/or functioning as a desiccant or oxygen scavenger.

[0009] The above and other needs are addressed by the presently disclosed technology, which includes, in one aspect, a blister pack having a recyclable backing and cover. The cover can be attached or bonded to the backing to form a sealed unit package for containing a product. The cover can have at least one blister cavity with an open side. The backing can have a side bonded to the cover.

[0010] In one optional embodiment, the blister cavity can have a blister or dome portion and a base portion. The base portion can be wider and/or longer than the blister portion.

[0011] Optionally, the blister pack can further include an active component, optionally in the form of extruded film. In one optional embodiment, the extruded film can be adhered to the side of the backing bonded to the cover. The extruded film can have a shape approximating the base portion. The extruded film can include a desiccant or oxygen scavenger, for example, or another active technology.

[0012] Use of an active component, such as a desiccant, within the blister package can further complicate and/or prevent the blister package from being recycled. In particular, the active component can undesirably contaminate the blister package so that it cannot be recycled. For example, in some locations or with at least certain known recycling processes, the empty (i.e., without product) blister package may need to be 90% or more of olefin polymer and/or have no polyvinyl chloride (PVC) to be able to be recycled. Optionally, the active component of the presently disclosed technology can have 5 grams of zeolite, which would allow the blister package to be 90% or more of an olefin polymer or a polyolefin.

[0013] In another aspect, the presently disclosed technology can include a method of making a blister pack. In one embodiment, the method can include placing product in each blister of the cover. The method may further include attaching or bonding a thermoformed cover to a backing to form a sealed unit package. A longitudinal axis of each blister may extend parallel to an edge of the backing.

[0014] In one optional embodiment, the method can include attaching or adhering an extruded active polymer film to an interior surface of the cavity.

[0015] Optionally, in any embodiment, the product contained in a blister of a blister pack may include a pill, which is optionally a medicine, a nutritional supplement or a probiotic, for example.

[0016] In one optional embodiment, the foil backing of conventional blister packs is replaced by one or more polymers, such as polyethylene (PE) or polyethylene terephthalate (PET). Such polymers or films cause an increase in the moisture vapor transmission rate, which may necessitate the use of an active component in the blister cavity. The active component can optionally be an active polymer component having a based formed of PE or PET, for example. The active component can optionally be heat staked onto the polymer backing. A molecular sieve component of the active component could be exactly or approximately 5%, or optionally between 4-6%, or optionally between 2-8%, of the total mass of the blister card or pack, thereby allowing a recycling step.

[0017] Optionally, the blister packaging is of the push-only variety, which means that the product can or is designed to be removed from the blister packaging by pushing on the product through the packaging.

[0018] Optionally, the blister packaging is of the peel-push variety, which means that the product can or is designed to be removed from the blister packaging by peeling a portion of the packaging to expose the product and/or pushing on the product through the packaging.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The foregoing summary, as well as the following detailed description of the presently disclosed technology, will be better understood when read in conjunction with the appended drawings, wherein like numerals designate like elements throughout. For the purpose of illustrating the presently disclosed technology, there are shown in the drawings various illustrative embodiments. It should be understood, however, that the presently disclosed technology is not limited to the precise arrangements and instrumentalities shown. In the drawings:

[0020] Fig. 1 is a top plan view of a blister pack of the prior art;

[0021] Fig. 2 is a cross-sectional view through line 2-2 of Fig. 1, which shows extruded film having a width less than that of a width of an individual blister;

[0022] Fig. 3 is a cross-sectional view of a blister pack according to one embodiment of the presently disclosed technology, from the same or a similar perspective as that through line 2-2 of Fig. 1, and shows the backing and cover enclosed around a product;

[0023] Fig. 4 is a cross-sectional view according to one embodiment of the presently disclosed technology, from the same or a similar perspective as that through line 2-2 of Fig. 1, according to one embodiment of the presently disclosed technology, and shows an active polymer film layered onto and/or attached to the backing;

[0024] Fig. 5 is a cross-sectional view according to one embodiment of the presently disclosed technology, from the same or a similar perspective as that through line 2-2 of Fig. 1, according to one embodiment of the presently disclosed technology, and shows an active polymer film layered within a cavity formed by the backing and the cover;

[0025] Fig. 6 is a cross-sectional view according to one embodiment of the presently disclosed technology, from the same or a similar perspective as that through line 2-2 of Fig. 1, according to one embodiment of the presently disclosed technology, and shows an active polymer film integrated into the walls of the cavity formed by the backing and cover;

[0026] Fig. 7 A is a magnified cross-sectional view of a backing according to one embodiment of the presently disclosed technology; and

[0027] Fig. 7B is a magnified cross-sectional view of a backing according to another embodiment of the presently disclosed technology.

DETAILED DESCRIPTION

[0028] While systems, devices and methods are described herein by way of examples and embodiments, those skilled in the art recognize that the presently disclosed technology is not limited to the embodiments or drawings described. Rather, the presently disclosed technology covers all modifications, equivalents and alternatives falling within the spirit and scope of the appended claims. Features of any one embodiment disclosed herein can be omitted or incorporated into another embodiment.

[0029] Any headings used herein are for organizational purposes only and are not meant to limit the scope of the description or the claims. As used herein, the word “may” is used in a permissive sense (i.e., meaning having the potential to) rather than the mandatory sense (i.e., meaning must). Unless specifically set forth herein, the terms “a,” “an” and “the” are not limited to one element but instead should be read as meaning “at least one.” A first direction Di and a second direction D2 are shown in certain drawings for reference and clarity only, and are not part of the structure of the presently disclosed technology. The terminology includes the words noted above, derivatives thereof and words of similar import.

[0030] Referring now in detail to the various figures, wherein like reference numerals refer to like parts throughout, Figs. 3-7 illustrate embodiments of a blister packaging or pack, generally designated 110, of the presently disclosed technology. Optionally, the recyclable blister pack 110 can be used to provide a sustainable form of packaging that can also preserve or extend the shelf-life of the product(s) therein.

[0031] In an exemplary embodiment, the blister pack 110 includes a backing 112 and a cover 114 that is attached to the backing 112. Further, the cover 114 is attached to the backing 112 such that at least one cavity is formed therebetween or a plurality of spaced-apart cavities are formed by the combined cover 114 and backing 112. As a result, the cover 114 and the backing 112 form at least one enclosure that is structured and/or configured to store at least one product 117. Optionally, the cover 114 can have any of a variety of shapes and/or configurations, such as disclosed in WO 2020/146556.

[0032] The backing 112 can have a first side or surface 112a and an opposing second side or surface 112b. Optionally, at least the first side 112a of the backing 112 may be flat or planar. In one embodiment, each of the first and second sides 112a, 112b of the backing 112 are flat or planar, such that each of the first and second sides 112a, 112b extends in a plane, which are at least slightly spaced-apart.

[0033] The cover 114 can have a first side or surface 114a and an opposing second side or surface 114b. Optionally, at least a portion of the first and second sides 114a, 114b of the cover 114 are flat or planar. At least a portion of the second side 114b of the cover 114 can be attached or adhered, such as by thermoforming or cold forming, to the first side 112a of the backing 112 to form a sealed package for containing product(s). The cover 114 can have the same or a different thickness (as measured in the direction of D2) as the backing 112. In one embodiment, the cover 114 is made or formed of a formable web. In one embodiment, the formable web is made from a thermoplastic material, such as a Lhermoformed film.

[0034] The cover 114 includes or is formed to have at least one blister, generally designated 118. For example, the cover 114 can include two or more spaced-apart blisters 118. The embodiments shown in Figs. 3-6 show the cover 114 having four, spaced-apart, identical blisters 118, similar to the configuration shown in Fig. 1. However, the cover 114 can have more or fewer blisters and one or more of the blisters can have a different size and/or shape than another one of the blisters 118 of the blister pack 110, depending upon the particular need. Optionally, each blister 118 can have at least a partial egg shape or a bulbous shape. Alternatively, in one embodiment, each blister 118 can have at least a partial plateau shape (e.g., when viewed from the side) or a cylindrical shape. When the cover 114 is attached to the backing 112, a sealed cavity is formed within or by each blister 118.

[0035] In one optional embodiment, each blister 118 can define a longitudinal or long axis that extends parallel to at least one outer edge of the backing 112 and the blister pack 110. Optionally, and more specifically, the longitudinal axis of each blister 118 can extend parallel to two opposing lateral sides of the blister pack 110 and perpendicularly to top and bottom sides of the blister back, as shown in Fig. 3. However, the arrangement or orientation of the blister(s) 118 within the blister pack 110 is not limited to that shown and described herein, as other configurations are possible depending upon the particular need.

[0036] The blister pack 110 can enclose, preserve, and protect one or more products 117 (shown schematically in Fig. 3), such as oral solid dose medications, vitamins or other nutritional supplements, foodstuff, small consumer goods, probiotics, etc. Such products may be in the form of pills, e.g., tablets, capsules, and the like. In one optional embodiment, the products 117 can be in powder form.

[0037] In one optional embodiment, the cover 114 and the backing 112 are formed from the same material and/or a recyclable material that enables the blister pack 110 to be easily reused or repurposed, and/or processed in a recycling technique, such as through air classification, sink-float sorting, or sensor-based sorting, as described in detail below. The ability to be reused and/or recycled is derived from the usage of a single material to form both the backing 112 and the cover 114. In such an embodiment, the blister 118 of the present embodiment is distinguishable from the blister 18 of the prior art in that the blister 118 of the presently disclosed technology includes a backing 112 and a cover 114 that are formed from a single recyclable material rather than different materials and/or two or more materials.

[0038] The presently disclosed technology can be used with any of a variety of recycling techniques, including mechanical, chemical, or a combination thereof. For example, plastic waste is often sorted through a sequence of sorting steps. The sorting steps can include sorting by size, either manually or by means of sieves, for example, removal of foreign materials (e.g., metal and glass), sorting by types of plastic materials, and/or sizing and granulation into plastic recyclate.

[0039] Certain materials can be removed or separated from other materials by using gravity in air flow (e.g., air classifier) or water stream (e.g., sink-float). Air classifiers are a type of machine that separates particles of different densities using an air flow and the relationship between the force of inertia and/or gravity and the drag. For example, a strong airflow (e.g., a column of rising air) can be directed or generated from a bottom of a machine toward or to the top, while a stream of materials falls in the opposite direction from the top of the machine toward the bottom. Optionally, plastic flakes and/or granules can then go through a zigzag channel, which can help with the separation process. In the meantime, lighter materials like labels and dust can be blown upward and collected in filter bags. As a result, high-quality plastics can be collected without labels and dust.

[0040] Metals in particular can be removed by exploiting their magnetic properties, e.g., by magnetic attraction of ferrous metal or by induced magnetic repulsion of nonferrous metals. [0041] Gravity can also be used to sort some plastics among themselves, e.g., to separate the polyolefins (e.g., density of approximately 0.9 g/ mL) from PET or PVC (e.g., density of approximately 1.4 g/mL). This can be done within a machine or a vertical shaft, for example. The gravity sorting can be refined with the assistance of electrostatic or magnetic fields.

[0042] A sink-float separation tank can employ water or another liquid to separate comingled materials (e.g., plastics) based on densities. Water, for example, has a density of 1 g/cm ³ . As pieces or items (e.g., plastic) enter or are introduced into the separation tank, any items with density greater than the liquid (e.g., water) will sink. The heavy item stream collects at the bottom of the tank and can be forced to exit the machine, optionally using a screw conveyor. Likewise, any material with density less than the liquid will float and exits the machine at the top. Additives can be added to the liquid to improve the separation process.

[0043] Certain sensor-based sorting machines are manufactured by TOMRA™ Recycling of Germany. For example, a visual spectrometer sensor can be used to remove certain material from a waste stream. An eddy current is another type of separator or sensor that can be used.

[0044] It is perhaps most common to sort various plastics by spreading them out on a conveyor belt, optionally identifying the plastic to sort using an infrared detector (e.g., near infrared (NIR) or short wave infrared (SWIR)) and sorting the plastic with an actuator or air jet. The standard infrared (IR) detector can be replaced or complemented by hyperspectral imaging spectroscopy (HIS) to recognize a full-shape product or by an X-ray fluorescence detector to recognize heavy elements, such as chlorine (Cl) and Bromine (Br). [0045] New sorting technologies are constantly be developed. For example, trace-based sorting uses fluorescent pigments incorporated into the plastic substrate or in the sleeve. These pigments are only visible under UV light at the sorting plant. Another technology uses digital watermarks, e.g., codes that are integrated into the design of the packaging, and can be detected by cameras on high-speed sorting lines. A watermark can carry or reveal information about the product and its packaging. Yet another technology is robotic sorting, which applies artificial intelligence to help cameras and robotic arms to sort plastics from a conveyor belts. Each of the above-discussed recycling techniques can be employed with the presently disclosed technology.

[0046] In one embodiment, the backing and the cover are formed of a polymer, such as a polyolefin or another synthetic fiber. As used herein, the term “polyolefin” refers to a polymer that can be considered as the product from an olefin (e.g., ethylene, CH2=CH2) which has been reacted to form a polymer e.g., polyethylene). Certain polyolefins can be considered as the polymerization product of an a-olefin (CH2=CHR). Certain polyolefins have the formula (CH ₂ -CHR) _n . The polyolefin need not be obtained by such a reaction. Examples of polyolefins include polyethylene (PE), polypropylene (PP), polystyrene, polyacrylamide, poly (vinyl alcohol), and poly (vinyl acetate)

[0047] The backing 112 and the cover 114 can optionally be formed from an optionally transparent thermoformed film rather than a conventional plastic cover and a foil backing, such as that disclosed in U.S. Patent No. 8,142,603. Alternatively, the backing 112 and the cover 114 may be formed of copolyester or a copolyester film. Examples of copolyester include PETG (Polyethylene Terephthalate Glycol), PCTG (Poly Cyclohexylenedimethylene Terephthalate glycol-modified), and PCTA (1,4-cyclohexylene dimethylene terephthalate-co- isophthalate).

[0048] Embodiments of the presently disclosed technology are distinguishable from the technology disclosed in U.S. Patent No. 8,142,603 based at least on the material used to make the backing and the way the backing is constructed or formed. For example, lines 23-37 of column 4 of U.S. Patent No. 8,142,603 discloses sufficiently heating a lidding foil so that a polymer sealing layer becomes pliable, and adhering an active film to the softened polymer layer of the lidding film. Despite the thin polymer sealing layer, the backing itself of U.S. Patent No. 8,142,603 includes foil, which would disrupt or make recycling that blister pack difficult or impossible.

[0049] In one optional embodiment of the disclosed concept, the backing 112, the cover, 114, and/or the active component 116 are formed from a material made by TEKNI-PLEX™ of Holland, Ohio. For example, the material used can be coated PVC/PVdC, PCTFE laminates (ACLAR™), or other PVC films. The material could be rigid or flexible. Optionally, the material could be any one of PX7-PX30 produced by TEKNI-PLEX™.

[0050] In another optional embodiment of the disclosed concept, the backing 112, the cover 114, and/or the active component 116 contain no PVC or other chlorinated polymers.

[0051] In another optional embodiment of the disclosed concept, the backing 112, the cover 114, and/or the active component 116 contain no fluorinated polymers.

[0052] In one embodiment, the blister pack 110 of the presently disclosed technology includes a sufficient amount and/or specific location of active material to preserve or extend the shelf-life of the product(s) 117 therein without “contaminating” the blister pack 110 with too much non-recyclable material that would prevent or prohibit recycling of the blister pack 110 after the product(s) is/are removed. Optionally, the blister pack 110 contains mineral active material that has a sufficient low amount of mineral loading as a proportion of the entire blister pack or package on a mass basis, so as not to prevent the blister pack 110 from being recycled.

[0053] In an exemplary embodiment, the backing 112 and/or the cover 114 are formed from, attached to, and/or include an active component or an active polymer material. In such an embodiment, the backing 112 and/or the cover 114 are able to moderate the environment within the cavity, such as through sorption of moisture, scavenging of oxygen, scavenging of volatile compounds, or releasing a gas that has an effect on the product(s) 117 within the cavity, for example. Further, this construction enables the backing 112 and/or the cover 114 to preserve or extend the shelf life of the product 117 stored within the cavity. In this optional embodiment, the active polymer material is a recyclable material and/or a material that has a sufficiently low mass of mineral content compared to the entire package such that it would not “contaminate” the remainder of the blister pack 110 in a manner that would otherwise prevent or prohibit recyclability.

[0054] In an exemplary embodiment, the backing 112 and/or the cover 114 are in the form of and/or formed at least partially of a desiccant entrained polymer or an oxygen scavenger entrained polymer. This configuration reduces the need for additional components and enables the blister pack 110 to be recycled without sacrificing any product 117 preserving capabilities. [0055] Optionally, the blister pack 110 and/or portions thereof can be formed of one or more biodegradable materials.

[0056] The backing 112 and/or the cover 114 can be constructed such that each of the at least one cavities can be opened to dispense the product 117, such as by pushing only, or by pushing and pulling, on one of the backing 112 and/or the cover 114. Further, each of the at least one cavities can optionally be subsequently sterilized, refilled, and then resealed.

[0057] In one optional embodiment, the backing 112 includes at least two distinct layers. For example, as shown in Figs. 7A and 7B, a first, outer, or lower layer 132 of the backing 112 can be formed purely of polymer without any other material. The second, interior, or upper layer 130 of the backing 112 can be formed of a mixture of material that contains polymer and another component, such as a mineral component. In particular, this mixture can include an active within polymer. Examples of the active include zeolite, molecular sieve, and silica gel. [0058] In the above-described two layer embodiment, the second layer 130 of the backing 112 can be coextensive with and/or extend the entire length and/or width of the first layer 132, as shown in Fig. 7A. Alternatively, the second layer 130 of the backing 112 can extend along only a portion of the length and/or width of the first layer 132 (see Fig. 7B), such as only within the cavity of the respective blister 118. In this latter embodiment, the first layer 132 can be more easily ruptured when it is desired to remove the product 112 from the blister 118 due to the pressure concentration that the second layer 130 of the backing 112 creates on the portions of the first layer 132 of the backing 112 at the locations or at certain locations where the two layers do not overlap. The former embodiment increases the absorbing or adsorbing capability as compared to the latter embodiment, because additional active is available or present.

[0059] Optionally, in an embodiment where the second layer 130 of the backing 112 extends along only a portion of the length and/or width of the first layer 132, such as only within the cavity of the respective blister 118, the second layer 130 can be a relatively thin tablet. Optionally, the tablet can be formed from a die cast. Alternatively, the tablet can be extruded, such as in the form of an extruded film. This thin tablet can be heat staked or otherwise attached to the first layer 130 only at a location or area that represents, is coextensive with, or is smaller than the respective blister 118.

[0060] In any version of the above-described two layer embodiment, the backing 112 can be formed or the second, interior, or upper layer of the backing 112 can be attached to the first, outer, or lower layer of the backing 112 in any of a variety of ways. For example, the two layers can be heat staked together, or the two layers can be coextruded. Optionally, the first layer is formed entirely of a polyolefin, and the second layer is formed of a combination of a polyolefin with zeolite or another active (e.g., mineral active agent) distributed therein.

[0061] In further exemplary embodiments, the backing 112 and/or the cover 114 can include embossed or structured surfaces. The structured surfaces add rigidity to the blister pack 110 without diminishing the recyclable nature of the disclosed technology. The backing 112 and/or the cover 114 may be constructed as multicomponent assemblies.

[0062] In an exemplary embodiment, discrete quantities of the active polymer material are formed into an active polymer film 116 is optionally integrated into an interior surface of each of the at least one cavity and/or at least a portion of the cover 114, as shown in Fig. 5. In an alternative embodiment, the active can be imbedded or included within the backing 112 and not the cover 114, or in both the backing 112 and the cover 114. When embedded in the backing 112, the active can be limited to locations only beneath the blister 118, which would reduce the force required to push the product 117 through the backing 112.

[0063] In any of the above embodiments, the quantity of active polymer film 116 being used would have a negligible effect on the recyclable characteristics of the backing 112 and the cover 114 and, therefore, does not “contaminate” the blister package 110 for the recycling process. This enables an otherwise non-recyclable active polymer material 116 (non- recyclable due to the significant mineral content of the material 116 with respect to its own total mass) to be used with the recyclable backing 112 and cover 114, since the mineral content of the total package 110 would be below the threshold requirements for recyclability of the package 110.

[0064] Alternatively, the active polymer film 116 is optionally a liner that is superimposed or otherwise attached onto the interior surface of at least a portion or the entirety of each of the at least one cavity, as shown in Fig. 6. Thus, in one optional embodiment, the active polymer film 116 forms an envelope around the product 117 without compromising the recyclable characteristics of the backing 112 and the cover 114.

[0065] In another optional embodiment, the active polymer film 116 is merely a layer attached to a portion of the polymer backing 112 or the cover 114 within each cavity, as shown in Fig. 4.

[0066] In one embodiment, the backing 112 and the cover 114 can have a water vapor transmission rate ranging from 0.07 g/100in ² /d - .58 g/100in ² /d in or at an ambient temperature of 38 degrees Celsius and 90% relative humidity. In a further embodiment, the backing 112 and the cover 114 may have an oxygen transmission rate ranging from 0.18 cm ³ /100in ² /d - 1.4 cm ³ /100in ² /d in or at an ambient temperature of 23 degrees Celsius and 50% relative humidity. [0067] In one embodiment, at least one recyclable active member 116 is positioned within at least the base portion 122 of each blister 118. In one embodiment, the active member 116 can be in the form of a recyclable extruded film, such as but not limited to a desiccant entrained polymer film or an oxygen scavenger entrained polymer film.

[0068] The active member 116 can be heat staked (without an adhesive) to the first side in U.S. Patent No. 8,142,603. It is contemplated whether through heat staking or otherwise, the active member 116 may be attached to the backing 112 by a heat seal (via a thermal bond) and without a separate adhesive material. The active member 116 can be attached to the backing 112 or otherwise substantially restricted in its movability within the cavity in other mechanical or chemical ways, such as by adhesive or interference fit. In one optional embodiment, the active member 116 is not attached or fixed to the backing 112, but the active member 112 can be movable with respect to the backing 112.

[0069] In one embodiment, the active polymer material contains a desiccant. This would be an embodiment where moisture absorption or adsorption is desired. However, where moisture absorption or moisture adsorption is not desired, the active polymer material or active component can include one or more alternative active agents. For example, in another embodiment, the active polymer material contains a material selected from the group consisting of activated carbon, carbon black, ketcham black and diamond powder. In a further embodiment, an active agent including one or more layers of the active member 116 contains a material such as absorption microspheres, BaTiO3, SrTiO3, SiO2, A12O3, ZnO, TiO2, MnO, CuO, Sb2O3, silica, calcium oxide and ion exchange resins. In yet another embodiment, the absorbing agent containing layer of the active polymer material contains two or more types of absorbing agents. The suitable absorbing agent is chosen so as to achieve absorption of the desired vapor or gas for the desired end use (e.g., absorption of moisture, oxygen, carbon dioxide, nitrogen or other undesired gases or vapors).

[0070] The active polymer material (whether desiccant, oxygen scavenger, a releasing material or agent, etc., or combination thereof) is capable of acting on, interacting with or reacting with a selected material (e.g., moisture or oxygen). Examples of such actions or interactions may include absorption and adsorption (i.e., sorption, generally), or release of a selected material.

[0071] The active polymer material or the active component can include an “active agent” in a base material. The active agent (i) can be immiscible with the base material (e.g., polymer, polyolefin, or other synthetic fiber) and when mixed and heated with the base material and a channeling agent, will not melt, i.e., has a melting point that is higher than the melting point for either the base material or the channeling agent, and/or (ii) acts on, interacts or reacts with a selected material. The term “active agent” may include but is not limited to materials that absorb, adsorb, or release the selected material(s). Active agents according to the presently disclosed technology may be in the form of particles such as minerals (e.g., molecular sieve or silica gel, in the case of desiccants), but the presently disclosed technology should not be viewed as limited only to particulate active agents. For example, in some embodiments, an oxygen scavenging formulation may be made from a resin which acts as, or as a component of, the active agent.

[0072] As used herein, the term “base material” is a component (optionally a polymer or a synthetic fiber) of an entrained active material, other than the active agent, that provides structure for the entrained material.

[0073] As used herein, the term “base polymer” is a base material that is a polymer optionally having a gas transmission rate of a selected material that is substantially lower than, lower than or substantially equivalent to, that of the channeling agent (where a channeling agent is used). By way of example, such a transmission rate would be a water vapor transmission rate in embodiments where the selected material is moisture and the active agent is a water absorbing desiccant. The primary function of the base polymer is to provide structure for the entrained polymer. Suitable base polymers may include thermoplastic polymers, e.g., polyolefins such as polypropylene and polyethylene, polyisoprene, polybutadiene, polybutene, polysiloxane, polycarbonates, polyamides, ethylene-vinyl acetate copolymers, ethylenemethacrylate copolymer, poly(vinyl chloride), polystyrene, polyesters, poly anhydrides, polyacrylianitrile, polysulfones, polyacrylic ester, acrylic, polyurethane and polyacetal, or copolymers or mixtures thereof.

[0074] Referring to such a comparison of the base polymer and channeling agent water vapor transmission rate, in one embodiment, the channeling agent has a water vapor transmission rate of at least two times that of the base polymer. In another embodiment, the channeling agent has a water vapor transmission rate of at least five times that of the base polymer. In another embodiment, the channeling agent has a water vapor transmission rate of at least ten times that of the base polymer. In still another embodiment, the channeling agent has a water vapor transmission rate of at least twenty times that of the base polymer. In still another embodiment, the channeling agent has a water vapor transmission rate of at least fifty times that of the base polymer. In still another embodiment, the channeling agent has a water vapor transmission rate of at least one hundred times that of the base polymer.

[0075] As used herein, the term “channeling agent” or “channeling agents” is defined as a material (preferably a polymer material) that is immiscible with the base polymer and has an affinity to transport a gas phase substance at a faster rate than the base polymer. Optionally, a channeling agent is capable of forming channels through the entrained polymer when formed by mixing the channeling agent with the base polymer. Optionally, such channels are capable of transmitting a selected material through the entrained polymer at a faster rate than in solely the base polymer.

[0076] As used herein, the term “channels” or “interconnecting channels” is defined as passages formed of the channeling agent that penetrate through the base polymer and may be interconnected with each other.

[0077] As used herein, the term “entrained polymer” is defined as a monolithic material formed of at least a base polymer with an active agent and optionally also a channeling agent entrained or distributed throughout. An entrained polymer thus includes two-phase polymers and three phase polymers. A “mineral loaded polymer” is a type of entrained polymer, wherein the active agent is in the form of minerals, e.g., mineral particles such as molecular sieve or silica gel. The term “entrained material” is used herein to connote a monolithic material comprising an active agent entrained in a base material wherein the base material may or may not be polymeric.

[0078] As used herein, the term “monolithic,” “monolithic structure” or “monolithic composition” is defined as a composition or material that does not consist of two or more discrete macroscopic layers or portions. Accordingly, a “monolithic composition” does not include a multi-layer composite.

[0079] As used herein, the term “phase” is defined as a portion or component of a monolithic structure or composition that is uniformly distributed throughout, to give the structure or composition it’s monolithic characteristics.

[0080] As used herein, the term “selected material” is defined as a material that is acted upon, by, or interacts or reacts with an active agent and is capable of being transmitted through the channels of an entrained polymer. For example, in embodiments in which a desiccant is used as an active agent, the selected material may be moisture or a gas that can be absorbed by the desiccant. In embodiments in which a releasing material is used as an active agent, the selected material may be an agent released by the releasing material, such as moisture, fragrance, or an antimicrobial agent (e.g., chlorine dioxide). In embodiments in which an adsorbing material is used as an active agent, the selected material may be certain volatile organic compounds and the adsorbing material may be activated carbon, optionally tris(hydroxymethyl)aminomethane impregnated activated carbon.

[0081] As used herein, the term “three phase” is defined as a monolithic composition or structure comprising three or more phases. An example of a three phase composition according to the presently disclosed technology would be an entrained polymer formed of a base polymer, active agent, and channeling agent. Optionally, a three phase composition or structure may include an additional phase, e.g., a colorant.

[0082] Entrained polymers may be two phase formulations (i.e., comprising a base polymer and active agent, without a channeling agent) or three phase formulations (i.e., comprising a base polymer, active agent and channeling agent). Entrained polymers are described, for example, in U.S. Patent Nos. 5,911,937, 6,080,350, 6,124,006, 6,130,263, 6,194,079, 6,214,255, 6,486,231, 7,005,459, and U.S. Pat. Pub. No. 2016/0039955, each of which is incorporated by reference herein in its entirety.

[0083] An entrained material or polymer includes a base material (e.g., polymer) for providing structure, optionally a channeling agent and an active agent. The channeling agent forms microscopic interconnecting channels through the entrained polymer. At least some of the active agent is contained within these channels, such that the channels communicate between the active agent and the exterior of the entrained polymer via microscopic channel openings formed at outer surfaces of the entrained polymer. The active agent can be, for example, any one of a variety of absorbing, adsorbing or releasing materials, as described in further detail below. While a channeling agent is preferred, the invention broadly includes entrained materials that optionally do not include channeling agents, e.g., two phase polymers. [0084] In any embodiment, suitable channeling agents may include a polyglycol such as polyethylene glycol (PEG), ethylene-vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), glycerin polyamine, polyurethane and polycarboxylic acid including polyacrylic acid or polymethacrylic acid. Alternatively, the channeling agent can be, for example, a water insoluble polymer, such as a propylene oxide polymerisate-monobutyl ether, such as Polyglykol B01/240, produced by CLARIANT. In other embodiments, the channeling agent could be a propylene oxide polymerisate monobutyl ether, such as Polyglykol B01/20, produced by CLARIANT, propylene oxide polymerisate, such as Polyglykol D01/240, produced by CLARIANT, ethylene vinyl acetate, nylon 6, nylon 66, or any combination of the foregoing.

[0085] Suitable active agents according to the presently disclosed technology include absorbing or adsorbing (generally, sorbing) materials, such as desiccating compounds. If the active agent is a desiccant, any suitable desiccant for a given application may be used. Typically, physical sorption desiccants are preferred for many applications. These may include molecular sieves, silica gels, clays and starches. Alternatively, the desiccant may be a chemical compound that forms crystals containing water or compounds which react with water to form new compounds.

[0086] Optionally, in any embodiment, the active agent may be an oxygen scavenger, e.g., an oxygen scavenging resin formulation.

[0087] In certain optional embodiments, the oxygen scavenger is a metal-based oxygen scavenger. In certain embodiments, the oxygen scavenger includes a zerovalent metal. In certain embodiments, the oxygen scavenger includes a zerovalent metal in particle or nanoparticle form. In certain embodiments, the oxygen scavenger includes an ionic metal, optionally in the +1 or +2 oxidation state. In certain embodiments, the oxygen scavenger is a metal complex including an organic ligand.

[0088] In certain optional embodiments, the oxygen scavenger is a nonmetal. In certain embodiments, the nonmetal is an organic compound. In certain embodiments, the organic compound is a polyolefin. In certain embodiments, the organic compound is chosen from a phenol and a hydroquinone. In certain embodiments, the organic compound includes a porphyrin. In certain embodiments, the oxygen scavenger is a naturally occurring substance.

[0089] In some optional embodiments, the oxygen scavenger includes a polyene. In some embodiments, the oxygen scavenger includes a conjugated polyene. In certain embodiments, the oxygen scavenger is a free radical trap. Certain free radical traps contain phenol moieties, such as BHA, BHT, caffeic acid, ferulic acid, and ot-tocopherol. Certain free radical traps are enols, such as ascorbic acid (Vitamin C). Certain free radical traps contain a weak X-H bond (X=N, O, S), including but not limited to thiols, uric acid, and bilirubin. Certain free radical traps contain polyene moieties, such as such as P-carotene and other carotenoids. Certain free radical traps contain conjugated or nonconjugated dienes, such as a-terpinene and y-terpinene, respectively, as well as certain unsaturated fats and fatty acids. In some optional embodiments, the oxygen scavenger includes ascorbic acid, or a salt, ester, lactone, or stereoisomer thereof.

[0090] Optionally, in any embodiment, to facilitate recyclability of the blister pack 110, an active of the active component or the active within the entire blister pack 110 can be exactly or approximately 5%, or optionally from 4-6%, or optionally from 2-8%, of the total mass of the blister pack 110. More specifically, the active component 116 can include molecular sieve, and a total mass of all of the molecular sieve of the blister pack 110 can be 5% or less, or from 4-6%, or from 2-8% of the total mass of the blister pack 110.

[0091] Optionally, to facilitate recyclability of the blister pack 110, the blister pack 110 can contain 5 grams or less of zeolite, optionally 1 to 5 grams, optionally 2 to 5 grams, optionally 3 to 5 grams.

[0092] Optionally, such a low mineral loading as described herein, used in the active component 116 as a proportion of total mass of the blister pack with the substantial remainder of the blister pack being made from the same polymer material, prevents “contamination” of the blister pack 110 for recycling purposes, while still helping to preserve the product(s) 117 within the blister pack 110. This is unique compared to prior art blister packs, which are made from a combination of different types of materials (including foil, paper, plastic, etc.) and which thus are non-recyclable or challenging to recycle. In other words, the disclosed concept is unique at least in that it is directed to a blister pack that is mostly composed of a polymer or the same polymer with a relatively small particulate (or other active) component as a proportion of the total mass of the blister pack. This allows for blister packs according to the disclosed concept to be recycled, whereas prior art blister packs with active components are not recyclable or challenging to recycle.

[0093] The presently disclosed technology includes methods of making, using, and/or recycling the blister pack(s) 110. One of the methods includes (i) providing and/or forming a cover 114 having at least one blister 118 with one or more of the features described above, (ii) placing a product 117 in each blister 118, (iii) attaching one or more spaced-apart active components 116 to a backing 112, and (iii) attaching or bonding the backing 112 to the cover 114 to form a sealed package around the product 117 and active component 116.

[0094] As used herein, the term “providing” is broadly defined to include receiving, taking, putting, positioning, situating, and/or using. When a user wishes to access the product 117, at least a portion of the backing 112 can be separated from the cover 114 (e.g., push/pull or pull only) or broken through to expose the product 117.

[0095] Optionally, any of the films used with the presently disclosed technology can be formed in any of a variety of ways, such as by extruding, blowing, or casting.

[0096] The following exemplary embodiments further describe optional aspects of the presently disclosed technology and are part of this Detailed Description. These exemplary embodiments are set forth in a format substantially akin to claims, although they are not technically claims of the present application. The following exemplary embodiments refer to each other in dependent relationships as “embodiments” instead of “claims”.

[0097] 1A. A recyclable blister pack, the blister pack comprising: a backing; a cover attached to the backing, wherein the cover and backing in combination form at least one cavity for containing at least one product therein; and an active component located within or in fluid communication with an inside of the cavity, the active component including a base, wherein the cover, the backing, and the base of the active component are formed of the same material. [0098] 2A. The recyclable blister pack of embodiment 1A, wherein the material is recyclable.

[0099] 3 A. The recyclable blister pack of embodiment 1A or IB, wherein the material is a polyolefin.

[00100] 4A. The recyclable blister pack of any one embodiments 1 A-3A, wherein the cover and the backing are formed of a transparent thermoformed film.

[00101] 5A. The recyclable blister pack of any one embodiments 1A-4A, wherein the backing and the cover are formed of copolyester film.

[00102] 6A. The recyclable blister pack of any one of embodiments 1A-5A, wherein the backing and the cover have a water vapor transmission rate ranging from 0.07 g/100in ² /d - .58 g/100in ² /d in an ambient temperature of 38 degrees Celsius and 90% relative humidity.

[00103] 7 A. The recyclable blister pack of any one of embodiments 1A-6A, wherein the backing and the cover have an oxygen transmission rate ranging from 0.18 cm ³ /100in ² /d - 1.4 cm ³ /100in ² /d in an ambient temperature of 23 degrees Celsius and 50% relative humidity.

[00104] 8 A. The recyclable blister pack of any one of embodiments 1A-7A, wherein the backing and the cover are an extruded film, the active component comprises at least one of a desiccant and an oxygen scavenger.

[00105] 9A. The recyclable blister pack of any one of embodiments 1A-8A, wherein the backing and the cover are formed from a thermoplastic polymer selected from the group consisting of polypropylene, polyethylene, polyisoprene, polybutadiene, polybutene, polysiloxane, polycarbonate, polyamide, ethylene-vinyl acetate copolymer, ethylenemethacrylate copolymer, poly(vinyl chloride), polystyrene, polyesters, poly anhydrides, polyacrylianitrile, polysulfones, polyacrylic ester, acrylic, polyurethane, polyacetal, copolymers thereof, and mixtures thereof.

[00106] 10A. The recyclable blister pack of any one of embodiments 1B-5B, wherein the active component is an active polymer film layered onto at least one of the backing and the cover or included in the cavity.

[00107] 11 A. The method of embodiment 10A, wherein the active polymer film is formed of a recyclable material.

[00108] IB. A method of recycling a blister pack without product therein or after the product has been removed from the blister pack, the method comprising: obtaining a blister pack having a backing, a cover, and a base of an active component formed of a polyolefin; and processing the blister packing through a recycling sorting method. [00109] 2B. The method of embodiment IB, wherein the active component includes a molecular sieve having a mass of 5% or less than a total mass of the blister pack.

[00110] 3B. The method of embodiment IB, wherein the active component includes a molecular sieve having a mass of 4-6% of a total mass of the blister pack.

[00111] 4B. The method of embodiment IB, wherein the active component includes a molecular sieve having a mass of 2-8% of a total mass of the blister pack.

[00112] 5B. The method of any one of embodiments 1A-4B, wherein the recycling sorting method is one of an air classifier, a sink-float sorter, and sessor-based sorting.

[00113] 1C. A method of recycling a blister pack without product therein or after the product has been removed from the blister pack, the method comprising: obtaining a blister pack having a backing, a cover, and a base of an active component formed of a synthetic fiber; and processing the blister packing through a recycling sorting method.

[00114] ID. A method of forming at least a portion of a recyclable blister pack, the method comprising: heat staking one or more active components to a polymer backing, each active component includes a polymer base.

[00115] 2D. The method of embodiment ID, wherein the active component includes an active component or molecular sieve, the active component or the molecular sieve having a mass of 8% or less of a total mass of the blister pack.

[00116] IF. A method of recycling used blister packs, the method comprising: processing a plurality of used items through a sorting process, the plurality of used items including one or more blister packs; and wherein polymer components of the plurality of used items are separated from nonpolymer components of the plurality of used items.

[00117] 2F. The method of embodiment IF, wherein each of the one or more blister packs includes a backing, a cover, and a base of an active component formed of a polymer.

[00118] 3F. The method of embodiment IF or 2F, wherein the sorting process is one of air classification, sink-float sorting, or sensor-based sorting.

[00119] 4F. The method of embodiment IF or 2F, wherein the sorting process includes creating a column of rising air to separate the plurality of used items.

[00120] 5F. The method of embodiment IF or 2F, wherein the sorting process includes employing one or more magnets to separate metal components of the plurality of used items from the polymer components of the plurality of used items. [00121] 6F. The method of embodiment IF or 2F, wherein the sorting process includes dropping the plurality of used items to utilize gravity to separate polyolefin components of the plurality of used items from non-polyolefin components of the plurality of used items.

[00122] 7F. The method of embodiment IF or 2F, wherein the sorting process includes employing a water tank or water bath to separate the polymer components of the plurality of used items from the non-polymer components of the plurality of used items.

[00123] While the presently disclosed technology has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. It is understood, therefore, that the presently disclosed technology is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the presently disclosed technology as defined by the appended claims.