Systems and methods for forming blister packages with support members for pharmaceutical product packaging

Abstract

Systems and methods are provided for forming both backing and support members of a solid pharmaceutical product package as well as the blister portions for the packages. The disclosed solid pharmaceutical product packaging solutions utilize fewer machines and processing steps in order to form an overall solid pharmaceutical product package. In accordance with the preferred exemplary embodiments of the present invention, the manufacturing processing steps associated with the formation of the blister members in the clear plastic sheets is integrated in line with manufacturing of the backing material.

Description

[0001] 1. Field of the Invention[0002] The present invention relates generally to field of pharmaceutical product packaging systems and methods. More specifically, the present invention is directed to systems and methods for automatically forming the blister portions of a solid pharmaceutical product package and the corresponding packaging support members for an overall pharmaceutical product package. The two distinct portions are preferably formed in a single in-line process into a unitary package member.[0003] 2. Description of the Related Art[0004] Currently in the field of pharmaceutical product packaging systems and methods, typical conventional solutions for the manufacture of the solid pharmaceutical product packaging include clear plastic sheets with blister package cavities formed into the plastic sheets. The cavities formed into the clear plastic sheets are sealed with either foil or paper or cardboard backing that is adhesively secured to the perimeter around the cavities...

AI Technical Summary

Benefits of technology

[0013] Systems and methods are provided for more efficiently forming both backing and support members of a solid pharmaceutical product package as well as the blister cavity portions for the packages. The solid pharmaceutical product packaging solutions of the present invention utilize fewer machines and processing steps in order to form an overall solid pharmaceutical product package.

[0017] The material is then preferably run through a rotary male-female matched set of punches that indents each blister in line prior to sheeting into separate individual punch cards. It is believed that processing speeds of 100 feet per minute or greater can be achieved through utilization of the systems and methods of the present invention. In accordance with the systems and methods of the present invention, greater manufacturing efficiency is achieved with fewer manufacturing steps and less machinery. Accordingly, as a result, utilization of the systems and methods of the present invention provide a significant economic advantage over previous approaches to the formation of solid pharmaceutical product packaging.

[0018] Those skilled in the art will appreciate that a variety of different processing techniques may be utilized in order to achieve the results of the present invention. More specifically, it should be recognized that it is not necessary to immediately form the blister or cavity portions of the package member during the in-line process. Those skilled in the art will recognize that the cavity member may also be subsequently formed when the solid pharmaceutical products are being inserted into the package. In this alternate embodiment, shipping of the package material is easier because less volume is required.

[0019] In an alternate preferred exemplary embodiment, a male-female punch that is preferably of a rotary design may not be utilized in the original in-line manufacturing process. In this alternate approach, a flat bed forming station maybe used. In this exemplary embodiment, the material is routed through an accumulator after the preferably clear plastic material has been laminated to the board or backing material. Thereafter, the combined structure is passed to an intermittent forming station where the material can be heated and then intermittently formed in a vacuum or pressure former. This approach is not the preferred approach due to the anticipated reduced productivity in the overall process but it should be recognized that this approach may ultimately prove easier to functionally achieve.

Problems solved by technology

Yet another shortcoming and deficiency is that the plastic sheets with the blister cavities formed therein consume a significant amount of space and therefore require larger storage space.

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