Pharmaceutical Packaging System and Method of Manufacturing Same

Abstract

A pharmaceutical packaging system includes a substrate having a first surface, a first hollow cavity accessible through a first opening in the first surface, and a second hollow cavity accessible through a second opening in the first surface. The first and second hollow cavities are spaced apart and isolated from one another on the substrate. A cover is attached to at least a first portion of the first surface of the substrate surrounding the first opening and a second portion of the first surface of the substrate surrounding the second opening so as to provide a first seal for the first hollow cavity and a second seal for the second hollow cavity. At least one orally-administered medicament is contained within one of the first and second hollow cavities, and a first topically-applied medicament is contained within the other of the first and second hollow cavities.

Claims

1. A pharmaceutical packaging system comprising: a substrate having a first surface, a first hollow cavity accessible through a first opening in the first surface, and a second hollow cavity accessible through a second opening in the first surface, the first and second hollow cavities being spaced apart and isolated from one another on the substrate; a cover attached to at least a first portion of the first surface of the substrate surrounding the first opening and a second portion of the first surface of the substrate surrounding the second opening so as to provide a first seal for the first hollow cavity and a second seal for the second hollow cavity; at least one orally-administered medicament contained within one of the first and second hollow cavities; and a first topically-applied medicament contained within the other of the first and second hollow cavities.

2. The pharmaceutical packaging system of claim 1, wherein the substrate further includes a third hollow cavity accessible through a third opening in the first surface, the third hollow cavity being spaced apart and isolated from the first and second hollow cavities on the substrate, wherein the cover is attached to at least a third portion of the first surface of the substrate surrounding the third opening so as to provide a third seal for the third hollow cavity, and further comprising a second topically-applied medicament contained within the third hollow cavity.

3. The pharmaceutical packaging system of claim 1, wherein the at least one orally-administered medicament is one of a capsule, tablet, or soft-gel.

4. The pharmaceutical packaging system of claim 1, wherein the at least one orally-administered medicament is one of a probiotic or a food or nutrient supplement.

5. The pharmaceutical packaging system of claim 1, wherein the at least one orally-administered medicament is a nutricosmetic.

6. The pharmaceutical packaging system of claim 1, wherein the first topically applied medicament is one of a serum, cream, lotion, ointment, paste, or gel.

7. The pharmaceutical packaging system of claim 1, wherein the first topically applied medicament is an anti-aging day cream or a hydrating and anti-aging night cream.

8. The pharmaceutical packaging system of claim 2, wherein the second topically applied medicament is one of a serum, cream, lotion, ointment, paste, or gel.

9. The pharmaceutical packaging system of claim 2, wherein the second topically applied medicament is an oily or dry skin serum.

10. A method of manufacturing a pharmaceutical packaging system containing at least one orally-administered medicament and a first topically-applied medicament, the method comprising: providing, into a first filling cabinet, a substrate having a first surface, a first hollow cavity accessible through a first opening in the first surface, and a second hollow cavity accessible through a second opening in the first surface, the first and second hollow cavities being spaced apart and isolated from one another on the substrate; feeding, while the substrate is in the first filling cabinet, the at least one orally-administered medicament or the first topically-applied medicament into the first hollow cavity; providing a cover for the first surface of the substrate and sealing the cover to the first surface of the substrate at a portion surrounding the first hollow cavity to provide a first seal; providing the substrate into a second filling cabinet having a different internal pressure than the first filling cabinet; partially moving the cover away from the first surface of the substrate to expose the second hollow cavity; feeding, while the substrate is in the second filling cabinet, the other of the at least one orally-administered medicament or the first topically-applied medicament into the second hollow cavity; and sealing the cover to the first surface of the substrate at a portion surrounding the second hollow cavity to provide a second seal.

11. The method of manufacturing a pharmaceutical packaging system of claim 10, wherein the first topically-applied medicament is fed into the second hollow cavity, and wherein the substrate includes a third hollow cavity accessible through a third opening in the first surface, the third hollow cavity being spaced apart and isolated from the first and second hollow cavities on the substrate, the method further comprising: exposing the third hollow cavity when the cover is partially moved away from the first surface of the substrate; feeding, while the substrate is in the second filling cabinet, a second topically-applied medicament into the third hollow cavity; and sealing the cover to the first surface of the substrate at a portion surrounding the third hollow cavity to provide a third seal.

12. The method of manufacturing a pharmaceutical packaging system of claim 10, wherein the second filling cabinet includes a vacuum suction head configured to attach to the cover for partially moving the cover away from the first surface of the substrate, and a cam rail configured to maintain the cover in a position exposing the second hollow cavity until after the other of the at least one orally-administered medicament or the first topically-applied medicament has been fed into the second hollow cavity.

13. The method of manufacturing a pharmaceutical packaging system of claim 10, further comprising: providing a negative internal pressure within the first filling cabinet; and providing a positive internal pressure within the second filling cabinet.

14. The method of manufacturing a pharmaceutical packaging system of claim 13, wherein a first sealing cabinet is provided between the first and second filling cabinets, and wherein the step of providing the cover and sealing the cover to the first surface of the substrate to provide the first seal is performed within the first sealing cabinet.

15. The method of manufacturing a pharmaceutical packaging system of claim 10, wherein the substrate is provided as part of a web containing a plurality of substrates and the cover is provided as a continuous sheet applied to the web, the method further comprising: partially severing the sheet before the substrate enters the second filling cabinet so as to allow the cover to be partially moved away from the first surface of the substrate.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0030] The foregoing summary, as well as the following detailed description of preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:

[0031] FIG. 1 is a bottom perspective view of a pharmaceutical packaging system in accordance with a preferred embodiment of the present invention;

[0032] FIG. 2 is a top plan view of the pharmaceutical packaging system of FIG. 1 with the cover removed;

[0033] FIG. 3 is a bottom plan view of a pharmaceutical packaging system in accordance with another preferred embodiment of the present invention;

[0034] FIG. 4 is a top plan schematic view of a web for manufacturing the pharmaceutical packaging system in accordance with another preferred embodiment of the present invention;

[0035] FIG. 5 is a front side elevational view of a packaging line for manufacturing the pharmaceutical packaging system in accordance with another preferred embodiment of the present invention;

[0036] FIG. 6 is a front side perspective view of a second filling cabinet of the packaging line of FIG. 5;

[0037] FIG. 7 is a front side elevational view of a first filling cabinet of the packaging line of FIG. 5; and

[0038] FIG. 8 is a front side elevational view of a first sealing cabinet of the packaging line of FIG. 5.

DETAILED DESCRIPTION OF THE INVENTION

[0039] Certain terminology is used in the following description for convenience only and is not limiting. The words “right,” “left,” “lower” and “upper” designate directions in the drawings to which the reference is made. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the apparatus and designated parts thereof. The terminology includes the words above specifically mentioned, derivatives thereof and words of similar import.

[0040] It should also be understood that the terms “about,” “approximately,” “generally,” “substantially” and like terms, used herein when referring to a dimension or characteristic of a component of the invention, indicate that the described dimension/characteristic is not a strict boundary or parameter and does not exclude minor variations therefrom that are functionally similar. At a minimum, such references that include a numerical parameter would include variations that, using mathematical and industrial principles accepted in the art (e.g., rounding, measurement or other systematic errors, manufacturing tolerances, etc.), would not vary the least significant digit.

[0041] Referring to FIGS. 1 and 2, there is shown an example of a pharmaceutical packaging system 10 in accordance with a preferred embodiment of the present invention. The pharmaceutical packaging system 10 includes a substrate 12 having a first surface 12a. A first hollow cavity 14 is formed in the substrate 12 and is accessible through a first opening 16 in the first surface 12a. A second hollow cavity 18 is formed in the substrate 12 and is accessible through a second opening 20 in the first surface 12a. A third hollow cavity 22 is formed in the substrate 12 and is accessible through a third opening 24 in the first surface 12a.

[0042] A cover 26 is placed on the first surface 12a of the substrate 12. The cover 26 is at least adhered to first, second, and third portions 27a, 27b, 27c of the first surface 12a. In FIG. 2, the cover 26 is removed, and the first, second, and third portions 27a, 27b, 27c of the first surface 12a are respectively delimited by dashed lines around each of the first, second, and third openings 16, 20, and 24. Connection of the cover 26 to the first, second, and third portions 27a, 27b, 27c thereby provides first, second, and third seals to prevent the ingress or egress of air with respect to the first, second, and third hollow cavities 14, 18, 22.

[0043] In the example of FIG. 2, the first hollow cavity 14 contains a capsule 28 of a nutricosmetic. The second hollow cavity 18 contains an anti-aging day cream 30. The third hollow cavity 22 contains an oily or dry skin serum 32.

[0044] FIG. 3 shows an alternative embodiment of a pharmaceutical packaging system 10′, having a substrate 12′ with first, second, and third hollow cavities 14′, 18′, and 22′. In this embodiment, the first hollow cavity 14′ is sized and shaped to accommodate two tablets of a nutricosmetic (not shown) stored side-by-side. The second hollow cavity 18′ contains a hydrating and anti-aging night cream (not shown). The third hollow cavity 22′ contains an oily or dry skin serum (not shown).

[0045] Referring to FIG. 5, there is shown a packaging line 100 for manufacturing the pharmaceutical packaging system 10 in accordance with a preferred embodiment of the present invention. The packaging line 100 includes, in a downstream order, a first filling cabinet 102, a first sealing cabinet 104, a second filling cabinet 106, and a second sealing cabinet 108. Substrates 12 are provided as part of a web 101 (FIG. 4) from a roll 110, which is moved between the various cabinets 102, 104, 106, 108 by a conveyor belt 112. As seen in FIG. 4, the web 101 includes a plurality of substrates 12 arranged in two rows extending in the travel direction of the web 101.

[0046] The first filling cabinet 102 is shown in greater detail in FIG. 7. The first filling cabinet 102 is kept at a negative internal pressure by an air flow ventilation system (not shown). In the present embodiment shown, the first filling cabinet 102 is responsible for feeding the orally-administered medicament 28 into the first hollow cavity 14 of the substrate 12. Accordingly, the first filling cabinet 102 includes a hopper 120 in which capsules, tablets, or the like 28 may be placed in bulk for alignment and disbursement. A feeding tube 122 is connected to the hopper 120 for receiving the capsules, tablets, or the like and transporting them to the first hollow cavity 14 of each substrate 12.

[0047] After receiving the orally-administered medicament 28, the substrate 12 exits the first filling cabinet 102 and proceeds to the first sealing cabinet 104, shown in greater detail in FIG. 8. The first sealing cabinet 104 supplies the cover 26 as a continuous sheet 103 on a roll 130. The sheet 103 is brought into contact with the web 101 just prior to the web 101 being subjected to a first sealing head 132. In the embodiment shown, the first sealing head 132 is configured to create the first seal on four substrates 12 at a time, i.e., two adjacent substrates 12 in one row and two correspondingly adjacent substrates 12 in the second row of the web 101. Downstream of the first sealing head 132 is a first cutting tool 134 configured to partially sever the sheet 103 and the web 101 at the cut locations 109 shown in FIG. 4. In particular, a partial cut is made from an edge of the web 101 between every two substrates 12 in each row.

[0048] Upon exiting the first sealing cabinet 104, the substrate 12 enters the second filling cabinet 106, which is shown in greater detail in FIG. 6. The second filling cabinet 106 is kept at a positive internal pressure by an air ventilation system (not shown), thereby preventing air exchange between the first and second filling cabinets 102, 106. Near the entrance to the second filling cabinet 106 there is a vacuum suction head 140. The vacuum suction head 140 adheres to the cover sheet 103 near opposing edges thereof, to lift the edges of the cover sheet 103 away from the web 101. The locations of the cuts 109 (FIG. 4) ensures that only a portion of the cover sheet 103 overlying four adjacent substrates 12 on the web 101 is lifted at a time by the vacuum suction head 140. The action of raising the edges of the cover sheet 103 allows “flaps” 139 to engage opposing cam rails 142, each of which initially angle toward a center of the web 101, further lifting the cover sheet 103 away from the substrates 12 so as to expose the second and third hollow cavities 18, 22, thereof.

[0049] In the present embodiment shown, the second filling cabinet 106 is responsible for feeding the first and second topically-applied medicaments 30, 32 respectively into the second and third hollow cavities 18, 22 of the substrate 12. Accordingly, the second filling cabinet 106 includes a plurality of feeding tubes 144a, 144b, each having a nozzle 146. One set of the feeding tubes 144a supplies the first topically-applied medicament 30 while a second set of the feeding tubes 144b supplies the second topically-applied medicament 32. Preferably, each set includes four feeding tubes 144a, 144b, so that four substrates 12 can be filled generally simultaneously. The feeding tubes 144a, 144b are connected to one or more chambers 148 to supply the first and second topically-applied medicaments 30, 32. The cam rail 142 extends behind the nozzles 146 to allow access to the second and third hollow cavities 18, 22. After the second and third hollow cavities 18, 22 have been filled, each cam rail 142 angles back towards an edge of the web 101, allowing the “flap” 139 to lower and the cover sheet 103 to come back into contact with the web 101 as the substrate 12 exits the second filling cabinet 106.

[0050] Downstream of the second filling cabinet 106, the substrate 12 enters the second sealing cabinet 108. Much like the first sealing cabinet 104, the second sealing cabinet 108 includes a second sealing head 150, which is used to create the second and third seals on four substrates 12 at a time. A second cutting tool 152 is also provided, which applies pre-cuts 107 (FIG. 4) to the substrates 12, to allow later separation by an end user of individual portions of the substrate 12. A third cutting tool 154, near a downstream exit of the second sealing cabinet 108, performs final separation of the substrate 12 from the web 101 and cover 26 from the sheet 103 into the final triangular shape shown in FIGS. 1 and 2.

[0051] Those skilled in the art will recognize that boundaries between the above-described operations are merely illustrative. The multiple operations may be combined into a single operation, a single operation may be distributed in additional operations and operations may be executed at least partially overlapping in time. Further, alternative embodiments may include multiple instances of a particular operation, and the order of operations may be altered in various other embodiments.

[0052] It will be appreciated by those skilled in the art that changes can be made to the embodiments described above without departing from the broad inventive concept of the invention. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention.