Method for producing blister packs for medicinal products and blister pack

Abstract

The method for producing blister packs for medicinal products comprises the steps of forming blister pockets in a bottom film, wherein each blister pocket has an at least two-level shape with a first recess and a second, lower recess, filling the second recesses of the blister pockets with the medicinal products, placing a strip of active material in the first recess of each blister pocket above the medicinal product, wherein the strip of active material rests on at least one support surface of the first recess next to the second recess, sealing a lidding film to webs of the bottom film arranged around the blister pockets and simultaneously to the strips of active material, thus forming a sealed blister web, and stamping out individual blister packs from the blister web.

Claims

1. A method for producing blister packs for medicinal products, comprising the steps of: providing a bottom film and forming a plurality of blister pockets in the bottom film, wherein each blister pocket has an at least two-level shape with a first recess, which defines a first level of the blister pocket, and a second recess, which is formed in a subsection of a two-dimensional area over which the first recess extends and is situated lower down than the first recess; filling the second recesses of the blister pockets with the medicinal products; providing strips of active material and placing a strip of active material in the first recess of each blister pocket above the medicinal product, wherein the strip of active material rests on at least one support surface of the first recess, which at least one support surface is arranged next to the second recess; providing a lidding film and sealing the lidding film to webs of the bottom film arranged around the blister pockets and simultaneously to the strips of active material, thus forming a sealed blister web; and stamping out individual blister packs from the blister web.

2. The method of claim 1, wherein providing the strips of active material is accomplished by providing a web of active material wound up into a roll and by stamping out the strips of active material from the unwound web.

3. The method of claim 1, wherein the strips of active material are sections of a film.

4. The method of claim 1, wherein the strips of active material have a thickness in the range of 0.2-2 mm.

5. The method of claim 1, wherein, as a result of its material properties, the active material has an absorption function for absorbing at least one substance or a release function for releasing at least one substance.

6. The method of claim 1, wherein placing of the strips of active material is carried out by means of a pick-and-place device.

7. The method of claim 1, wherein, after the strips of active material have been placed on the at least one support surface of the first recess, the strips of active material project above the webs of the bottom film by 0.05-0.5 mm.

8. The method of claim 1, wherein, during forming of the plurality of blister pockets in the bottom film, an upward-projecting rib extending around the second recess is, or at least two upward-projecting knobs spaced a certain distance apart are, formed in the bottom film in an area of the first recess, which rib forms, or which knobs form, the support surface or support surfaces for the strip of active material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of part of one embodiment of a blister pack according to the disclosure, in which the lidding film has been omitted for the sake of clarity;

(2) FIG. 2 is a top view of a blister pocket of the blister pack of FIG. 1, wherein the lidding film has been omitted for the sake of clarity;

(3) FIG. 3 is a cross-sectional view of a blister pocket of the blister pack of FIG. 1;

(4) FIG. 4 is a perspective view of part of another embodiment of a blister pack according to the disclosure, in which the lidding film has been omitted for the sake of clarity;

(5) FIG. 5 is a top view of a blister pocket of the blister pack of FIG. 4, wherein the lidding film has been omitted for the sake of clarity;

(6) FIG. 6 is a cross-sectional view of a blister pocket of the blister pack of FIG. 4 with a sealed-on lidding film in a first cross-sectional direction;

(7) FIG. 7 is a cross-sectional view of a blister pocket of the blister pack of FIG. 4 with a sealed-on lidding film in a second cross-sectional direction perpendicular to the cross-sectional direction of FIG. 6;

(8) FIG. 8 is a perspective view of a part of another embodiment of a blister pack according to the disclosure, wherein the lidding film has been omitted for the sake of clarity;

(9) FIG. 9 is a top view of a blister pocket of the blister pack of FIG. 8, wherein the lidding film has been omitted for the sake of clarity;

(10) FIG. 10 is a cross-sectional view of a blister pocket of the blister pack of FIG. 8 with a sealed-on lidding film, in a first cross-sectional direction;

(11) FIG. 11 is a cross-sectional view of blister pocket of the blister pack of FIG. 8 with a sealed-on lidding film, in a second cross-sectional direction perpendicular to the cross-sectional direction of FIG. 10;

(12) FIG. 12 is a schematic diagram of a system for carrying out the method according to the disclosure for producing blister packs;

(13) FIG. 13 is a schematic, cross-sectional view of a forming device which can be used in the method according to the disclosure for producing blister packs;

(14) FIG. 14 is a top view of the recess in the lower forming tool of FIG. 13;

(15) FIG. 15 is a schematic, cross-sectional view of a sealing device which can be used in the method according to the disclosure for producing blister packs, in an opened position;

(16) FIG. 16 is a schematic, cross-sectional view of the sealing device of FIG. 15 in a closed sealing position;

(17) FIG. 17 is a perspective view of a part of another embodiment of a blister pack according to the disclosure, wherein the lidding film has been omitted for the sake of clarity;

(18) FIG. 18 is a top view of a blister pocket of the blister pack of FIG. 17, wherein the lidding film has been omitted for the sake of clarity;

(19) FIG. 19 is a cross-sectional view of a blister pocket of the blister pack of FIG. 17 with a sealed-on lidding film;

(20) FIG. 20 is a perspective view of a part of another embodiment of a blister pack according to the disclosure, wherein the lidding film has been omitted for the sake of clarity;

(21) FIG. 21 is a top view of a blister pocket of the blister pack of FIG. 20, wherein the lidding film has been omitted for the sake of clarity;

(22) FIG. 22 is a cross-sectional view of a blister pocket of the blister pack of FIG. 20 with a sealed-on lidding film;

(23) FIG. 23 is a perspective view of a part of another embodiment of a blister pack according to the disclosure, wherein the lidding film has been omitted for the sake of clarity;

(24) FIG. 24 is a top view of a blister pocket of the blister pack of FIG. 23, wherein the lidding film has been omitted for the sake of clarity;

(25) FIG. 25 is a cross-sectional view of a blister pocket of the blister pack of FIG. 23 with a sealed-on lidding film;

(26) FIG. 26 is a schematic, cross-sectional view of another forming device which can be used in the method according to the disclosure for producing blister packs;

(27) FIG. 27 is a top view of the recess in the lower forming tool of FIG. 26;

(28) FIG. 28 is a schematic, cross-sectional view of another sealing device which can be used in the method according to the disclosure for producing blister packs, in an opened position;

(29) FIG. 29 is a schematic, cross-sectional view of the sealing device of FIG. 28 in a closed sealing position;

(30) FIG. 30 is a schematic cross-sectional view of another sealing device which can be used in the method according to the disclosure for producing blister packs, in an opened position;

(31) FIG. 31 is a schematic, cross-sectional view of the sealing device of FIG. 30 in a closed sealing position;

(32) FIG. 32 is a cross-sectional view of a blister pocket of another embodiment of the blister pack according to the disclosure with a sealed-on lidding film;

(33) FIG. 33 is a schematic, cross-sectional view of another forming device which can be used in the method according to the disclosure for producing blister packs;

(34) FIG. 34 is a schematic, cross-sectional view of another sealing device which can be used in the method according to the disclosure for producing blister packs, in an opened position; and

(35) FIG. 35 is a schematic, cross-sectional view of another sealing device which can be used in the method according to the disclosure for producing blister packs, in an opened position.

DETAILED DESCRIPTION

(36) FIGS. 1-3 show a first embodiment of a blister pack 2 according to the disclosure for medicinal products 4, especially tablets, capsules, or sugar-coated pills. The blister pack 2 comprises a bottom film 6, in which at least one blister pocket 8 is formed, which is surrounded by webs 10 of the bottom film 6. The part of the blister pack 2 illustrated in FIG. 1 shows only one blister pocket 8. Blister packs 2 usually comprise a plurality of blister pockets 8, which are usually distributed in a regular pattern over the blister pack 2. A frequently used arrangement of blister pockets 8 in a blister pack 2 is a matrix of rows and columns.

(37) A lidding film 12, which covers at least one blister pocket 8, is sealed to the webs 10 of the bottom film 6 and closes off the at least one blister pocket 8. The lidding film 12 is shown only in FIG. 3, whereas, for the sake of clarity, it has been omitted in FIGS. 1 and 2.

(38) Materials which can be used for the bottom film include in particular PVC, PVDC, Aclar, aluminum, PETG, and laminated films. Materials which can be used for the lidding film include in particular aluminum, polyethylene, polypropylene, paper-laminated films and other types of composite films.

(39) A strip 14 of active material is arranged in the at least one blister pocket 8 and is sealed to the lidding film 12. The entire surface of the strip 14 can be sealed to the lidding film 12, or only certain areas of the strip 14, e.g., along lines or only at certain points, can be sealed to it.

(40) As a result of its material properties, the active material usually has an absorption function for absorbing at least one substance or a release function for releasing at least one substance. The most widely encountered purpose is for the absorption of moisture. In the case of strips 14 with an absorption function, the strips 14 of active material can also absorb oxygen, CO.sub.2, reactive impurities, or odors, for example. In the case of strips 14 with a release function, the strips 14 of active material can release nitrogen or carbon dioxide, for example.

(41) A strip 14 of active material preferably has a thickness in the range of 0.2-2 mm, more preferably of 0.3-1.2 mm. The material of the strip 14 preferably has at least some stiffness to facilitate handling. The material of the strip 14 is preferably a film, more preferably a polymer, and even more preferably a three-phase polymer. The film can be produced by extrusion, for example, wherein the active particles are added to the polymer. Channels within the polymer allow the movement of gases. The active particles are preferably present in the strip 14 as spheres.

(42) In the embodiment according to FIGS. 1-3, the product 4 has an oblong shape, and the strip 14 of active material has a substantially rectangular base surface. The strip 14 is arranged transversely to the product 4, preferably at an angle of approximately 45. Standard dimensions of the strip 14 in the longitudinal and transverse directions are approximately in the range of 5-50 mm.

(43) As can be seen in FIG. 3, each blister pocket 8 comprises a two-level shape, in which a first recess 16 defines a first level of the blister pocket 8. A second recess 18 is formed in a subsection of the two-dimensional area over which the first recess 16 extends and is situated lower down that the first recess 16. The medicinal product 4 is accommodated in the second recess 18, whereas the strip 14 of active material is accommodated in the first recess 16. The strip 14 of active material rests on the support surfaces 20 of the first recess 16, which are arranged next to the second recess 18. The strip 14 and the product 4 are therefore preferably a certain distance apart from each other in the vertical direction.

(44) The two support surfaces 20 for the strip 14 of active material lie on two sides of the second recess 18, diametrically opposite each other. The strip 14 of active material therefore covers a large part of the second recess 18 and rests by two opposite corner areas on the support surfaces 20.

(45) The embodiment of the blister pack 2 according to the disclosure shown in FIGS. 4-7 has a structure similar to that shown in FIGS. 1-3 and as previously described. Elements which are the same have been provided with the same reference numbers. In contrast to the embodiment of FIGS. 1-3, the medicinal product 4 has here a circular base surface. The strip 14 of active material again has a substantially rectangular base surface and rests by its two narrower edge areas on the support surfaces 20, which are arranged on opposite sides of the second recess 18. The strip 14 of active material therefore covers a large part of the product 4.

(46) The embodiment of the blister pack 2 according to the disclosure shown in FIGS. 8-11 is again substantially identical to the embodiment according to FIGS. 1-3. Elements which are the same have been provided with the same reference numbers. The medicinal product 4 is configured here as a sphere. In contrast to the previously described embodiments, the strip 14 of active material has an opening 22, which is arranged above the medicinal product 4. The medicinal product 4 can therefore pass through the opening 22 in the strip 14 when it is being squeezed out. The area of the lidding film 12 sealed to the strip 14 of active material is therefore not broken open when the product 4 is squeezed out, but only the area of the lidding film 12 above the opening 22 is broken.

(47) The shape of the blister pockets 8 can depart from the configurations described so far. Any geometric configuration is conceivable, as long as the blister pocket 8 has an at least two-level shape. The shape of the second recess 18 depends preferably on the shape of the product 4 to be packaged, which can have any possible geometric shape. In addition to the oblong form, the sugar-coated pill form, or the spherical form discussed so far, triangular or polygonal shapes of the medicinal products 4 can also be present.

(48) Finally, the shape of the strip 14 of active material can depart from the exemplary embodiments described so far. In addition to the rectangular base surface illustrated, the strips 14 can also have a round, an oval, or a triangular base surface. In each of these configurations, it is possible to provide an opening 22 in the strip. The strips 14 are usually cut-to-size blanks.

(49) The support surfaces 20 for the strips 14 of active material can be arranged on two opposite sides of the second recess 18, as illustrated in the previous exemplary embodiments. It is also possible, however, for more than two support surfaces 20 to be arranged around the second recess 18 or for a single continuous support surface 20 to extend all the way around the second recess 18.

(50) A method according to the disclosure for producing blister packs 2 will now be described with reference to FIG. 12. First, a bottom film 6 in the form of a roll is provided and unwound. In a forming station 24, the blister pockets 8 are formed in the unwound bottom film 6, wherein each blister pocket 8 has the previously described shape with at least two levels. Then, in a filling station 26, the second recesses 18 of the blister pockets 8 are filled with the medicinal products 4.

(51) In a feed station 28, the strips 14 of active material are then provided, and a strip 14 of active material is placed in the first recess 16 of each blister pocket 8 above the medicinal product 4, i.e., on the at least one support surface 20 of the first recess 16. The at least one support surface 20 of the first recess 16 is therefore preferably arranged above the medicinal product 4, more preferably a certain distance away from it. The step of providing the strips 14 of active material is preferably achieved by providing a web of active material wound up into a roll and by stamping out the strips 14 of active material from the unwound web. The placing of the strips 14 of active material is preferably achieved by means of a pick-and-place device. It is also possible, however, to provide other means of transferring the strips 14 of active material.

(52) The lidding film 12 is provided in a following sealing station 30 and sealed to the webs 10 of the bottom film 6. At the same time, the lidding film 12 is also sealed to the strips 14 of active material. All these steps taken together thus lead to the formation of a sealed blister web. Finally, the individual blister packs 2 are stamped out of the blister web in a downline stamping station 32. The individual blister packs 2 are then sent onward for further processing measures.

(53) A first forming tool 34 and a second forming tool 36, which cooperate in the forming station 24 to form the blister pockets 8 in the bottom film 6, are sketched in FIG. 13. The two forming tools 34, 36 can be moved relative to each other between an opened position and a closed or forming position. For this purpose, at least one of the two forming tools 34, 36, preferably both of them, must be movable. In the closed forming position, the two forming tools 34, 36 clamp the bottom film 6 between them for the forming operation. A source of compressed air 38 is connected to the second forming tool 36 to bring about the formation of the blister pocket 8 in the firmly clamped bottom film 6.

(54) The first forming tool 34 comprises at least one, preferably a plurality, of troughs 40 for forming at least one blister pocket 8 in the bottom film 6. The at least one trough 40 has an at least two-level shape. A first recess 42 of the trough 40 defines a first level of the trough 40. A second recess 44 of the trough 40 is arranged in a subsection of a two-dimensional area over which the first recess 42 extends and is situated lower down than the first recess 42. The shape of the trough 40 corresponds to the shape of the blister pockets 8 to be formed. The shape of the trough 40 shown in FIG. 14 corresponds, for example, to the shape of the blister pocket 8 of the blister pack 2 of FIGS. 1-3.

(55) A first sealing tool 54 and a second sealing tool 56, which cooperate in the sealing station 30 to seal the lidding film 12 to the webs 10 of the bottom film 6 and to the strips 14 of active material, are sketched in FIGS. 15 and 16. The two sealing tools 54, 56 are movable relative to each other between an opened position (FIG. 15) and a closed sealing position (FIG. 16). For this purpose, at least one of the two sealing tools 54, 56, preferably both of them, must be movable. In the closed sealing position, the two sealing tools 54, 56 press the lidding film 12 against the webs 10 of the bottom film 6 and against the strips 14 of active material. The second sealing tool 56 comprises at least one heating means 58. The first sealing tool 54 can comprise a cooling means (not shown).

(56) The first sealing tool 54 comprises at least one, preferably a plurality, of troughs 60 for accommodating at least one blister pocket 8 of the bottom film 6. The at least one trough 60 comprises an at least two-level shape. A first recess 62 of the trough 60 defines a first level of the trough 60. A second recess 64 of the trough 60 is arranged in a subsection of the two-dimensional area over which the first recess 62 extends and is situated lower down than the first recess 62. The shape of the trough 60 corresponds substantially to the shape of the blister pockets 8 previously formed in the forming station 24. In this concrete example, the shape of the trough 60 corresponds to that of the blister pack of FIGS. 1-3.

(57) When the strips 14 of active material are placed on the at least one support surface 20 of the first recess 16, it is advantageous for the strips 14 of active material to project upward beyond the webs 10 of the bottom film by an amount in the range of 0.05-0.5 mm, more preferably of 0.08-0.2 mm. The geometry of the blister pocket 8 and of the first recess 62 in the first sealing tool 54 is therefore to be adapted correspondingly to the thickness of the strip 14 of active material, so that the strip 14 projects by this amount prior to the sealing operation in the sealing station 30. This projection of the strip 14 guarantees that the lidding film 12 will be sealed not only to the webs 10 of the bottom film 6 but also to the strips 14 of active material.

(58) Another embodiment of the blister pack 2 according to the disclosure is shown in FIGS. 17-19. This embodiment corresponds in its essential features to the embodiment of FIGS. 1-3. FIG. 17 corresponds to the illustration in FIG. 1, FIG. 18 to the illustration in FIG. 2, and FIG. 19 to the illustration in FIG. 3. To this extent, the description of FIGS. 1-3 applies to the present embodiment unless otherwise indicated. Elements which are the same have been provided with the same reference numbers.

(59) In a departure from the embodiment of FIGS. 1-3, the support surfaces 20 for the strip 14 of active material are formed by two upward-projecting knobs 50 in the bottom film 6, located in the area of the first recess 16. The two knobs 50 can be seen only in the cross-sectional view of FIG. 19, because they are concealed by the strip 14 in the other two views.

(60) Another possible configuration of the forming tools 34, 36 is shown in FIGS. 26 and 27. This configuration corresponds in its essential features to the embodiment of FIGS. 13 and 14. FIG. 26 corresponds to the illustration in FIG. 13, FIG. 27 to the illustration in FIG. 14. To this extent, the description of FIGS. 13 and 14 applies to the present configuration unless otherwise indicated. Elements which are the same have been provided with the same reference numbers.

(61) In a departure from the embodiment of FIGS. 13 and 14, the first forming tool 34 comprises two upright projections 46 in the area of the first recess 42 of the trough 40; these projections are arranged next to the second recess 44. As a result, when the blister pockets 8 are being formed in the bottom film 6, two upward-projecting knobs 50 are formed in the bottom film 6, which serve as the support surfaces for the strips 14 of active material. In FIG. 27, the two projections 46 can again be seen, this time in a top view. The blister pack 2 of FIGS. 1-3 is formed by means of the forming tool 34 shown here.

(62) Another possible configuration of the sealing tools 54, 56 is shown in FIGS. 28 and 29. This configuration corresponds in its essential features to the embodiment of FIGS. 15 and 16. FIG. 28 corresponds to the illustration in FIG. 15, FIG. 29 to the illustration in FIG. 16. To this extent, the description of FIGS. 15 and 16 applies to the present configuration unless otherwise indicated. Elements which are the same have been provided with the same reference numbers.

(63) As a modification of the sealing tools of FIGS. 15 and 16, the first sealing tool 54 comprises here two upright projections 66, which correspond to the shape of the knobs 50 formed in the bottom film 6 and are arranged in such a way that that, during the sealing process, the knobs 50 come to rest on the projections 66. The projections 66 serve to support the knobs 50 of the bottom film 6 during the sealing process.

(64) The sealing tools 54, 56 shown in FIGS. 30 and 31 correspond in their essential features to the sealing tools 54, 56 shown in FIGS. 28 and 29. Elements which are the same have been provided with the same reference numbers. As a modification of the embodiment of FIGS. 28 and 29, the projections 66 in the first sealing tool 54 are replaced by pins 68, which extend upward, beyond the bottom area of the first recess 62 of the trough 60. The pins 68 serve to support the knobs 50 of the bottom film 6 during the sealing process. The pins 68 can be spring-loaded, as shown. The pins 68 can be mounted in the first sealing tool 54 in such a way that they can be extended.

(65) The knobs 50 in the bottom film 6 preferably comprise a height in the range of 0.5-5 mm, preferably of 1-3 mm. Accordingly, the projections 46 in the first forming tool 34 and possibly the projections 66 in the first sealing tool 54 have a height in the range of 0.5-5 mm, preferably of 1-3 mm. If pins 68 are being used, these project preferably by an amount in the range of 0.5-5 mm, preferably of 1-3 mm, above the bottom area of the first recess 62 of the trough 60 or are extended by this amount.

(66) In the embodiments shown, the knobs 50 are illustrated as rounded elevations. Other shapes for the knobs 50 are also conceivable; for example, the knobs 50 could have a triangular cross-sectional shape with a rounded tip or with a flat plateau surface at the top, on which the strips 14 of active material rest. The knobs 50 could also be elongated objects extending along a line (straight or curved). The shape of the projections 46, 66 and/or of the tips of the pins 68 preferably corresponds in each case to the shape of the knobs 50 in the bottom film 6.

(67) It is also possible that a peripheral rib could be formed instead of several knobs 50. This is conceivable especially in the case of the embodiment according to FIGS. 8-11. FIG. 32 shows a cross-sectional view of this modification. The peripheral rib 70, when seen from above, can have any desired ring-like shape; e.g., it can appear as a circular ring, as an oval ring, a polygonal ring, etc.

(68) For the production of blister packs like those in FIG. 32, the only measure which must be taken with respect to the first forming tool 34 is to produce a peripheral projection 76 of the same shape as that of the rib 70. FIG. 33 shows a cross-sectional view of a configuration of this type.

(69) With respect to the first sealing tool 54, the only measure to be taken is preferably to produce a similarly shaped peripheral projection 86, as can be seen in the cross-sectional view of FIG. 34.

(70) Alternatively, it would be possible to use a peripheral, extendable support element 78 in the first sealing tool, the apex of which element would correspond to the shape of the rib 70. FIG. 35 shows a cross-sectional view of a configuration of this type. The support element 78 is preferably spring-loaded.

(71) With respect to the cross-sectional shape of the rib 70, of the projection 76, of the projection 86, or of the apex of the support element 78, what was said concerning the cross-sectional shape of the knobs 50 also applies.