A GAS-PERMEABLE ELEMENT AND A METHOD OF MANUFACTURING THE SAME

Abstract

This disclosure includes a gas-permeable element formed or at least partially placed in a packaging or medical device containing sensitive or odorous products for regulating an atmosphere in the packaging or medical device. The gas-permeable element includes an active structure formed from a mixture including particles of an active material, and a fibrillated polymer as a binder. The fibrillated polymer is a polymer to which shear has been applied which holds the active material by entanglement. The gas-permeable element includes a molded thermoplastic gas-permeable envelope surrounding the active structure in fluid communication with the atmosphere of the packaging or medical device in which the gas-permeable element is placed. Also disclosed is a method of manufacture of the gas-permeable element.

Claims

1. A gas-permeable element at least partially placed in a packaging or medical device for regulating an atmosphere in the packaging or medical device, wherein the gas-permeable element comprises: an active structure formed from a mixture including particles of an active material and a fibrillated polymer as a binder, wherein the fibrillated polymer is a polymer to which shear has been applied and wherein the fibrillated polymer holds the active material by entanglement; and a molded thermoplastic gas-permeable envelope surrounding the active structure such that the active structure is in fluid communication with the atmosphere of the packaging or medical device in which the gas-permeable element is placed.

2. The gas-permeable element of claim 1, wherein the gas-permeable envelope comprises in its inner volume particles of active material held by entanglement in the active structure and particles of active material in a remaining volume inside of the envelope apart from the active structure.

3. The gas-permeable element of claim 1, wherein the gas permeable envelope contains at least one perforation for air exchange between an inside and an outside of the envelope, wherein active structure is arranged in the envelope to cover the at least one perforation.

4. The gas-permeable element of claim 3, wherein the active structure is gas permeable so that a gas passing through the at least one perforation of the envelope can interact not only with particles of active material held by entanglement in the active structure, but also with other particles of active material in the remaining volume inside of the envelope apart from the active structure.

5. The gas-permeable element of claim 1, wherein the mixture of the particles of the active material and the polymer of the active structure comprises between 80% and 99% particles of the active material and between 1% and 20% of polymer by weight, wherein a sum of the active material and the polymer comprises at least 90% of a total of the mixture by weight.

6. The gas-permeable element of claim 1, wherein the particles of active material of the active structure have a particle size in a range of 5 m to 30 m.

7. The gas-permeable element of claim 1, wherein the active structure comprises an active sheet, with a thickness in a range of 0.2 mm to 10 mm.

8. The gas-permeable element of claim 1, wherein the gas-permeable envelope surrounding the active structure comprises a molded envelope comprising a monolithic thermoplastic material.

9. The gas-permeable element of claim 1, wherein the gas-permeable envelope surrounding the active structure comprises thermoplastic walls with at least one ventilation hole or ventilation path for allowing a passage of a fluid.

10. The gas-permeable element of claim 9, wherein a part of the gas-permeable envelope is overmolded over the active structure.

11. A packaging or medical device comprising the gas-permeable element, according to claim 1.

12. A method of manufacturing the gas-permeable element of claim 1, comprising: providing a mixture of particles of an active material, and a dispersion comprising a polymer, fibrillating the polymer by applying shear thereto to form an active structure in which the fibrillated polymer holds the active material by entanglement, and associating a portion of the active structure with a molded thermoplastic gas-permeable envelope so that the gas-permeable envelope surrounds the active structure.

13. The method of claim 12, wherein the portion of the active structure is associated with a component selected from the group consisting of a canister body, a stopper body, and a compartment body.

14. The method of claim 13, wherein the step of associating is performed by inserting the portion of the active structure in a part of the component.

15. The method of claim 13, wherein the step of associating is performed by molding a part of the component over the portion of the active structure.

16. The method of claim 12, wherein the mixture is fibrillated during a step selected from the group consisting of a mixing step, a fibrillation step, a forming step, and a combination thereof.

17. The method of claim 12, wherein the mixture is fibrillated in a mill, wherein shear fibrillates the polymer.

18. The method of claim 12, wherein a fibrillated mixture is formed directly in the form of an active sheet in a single pass through a mill.

19. (canceled)

20. The gas-permeable element of claim 1, wherein the active material is selected from the group consisting of a desiccant, a volatile organic chemical absorber, an odor absorber or emitter, an oxygen absorber, a humectant, and mixtures thereof.

21. The gas-permeable element of claim 9, wherein the at least one ventilation hole or path is covered by a porous membrane.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0079] For a better understanding of the present disclosure and to show how the same may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings, in which:

[0080] The description is given with reference to the accompanying drawings, in which:

[0081] FIG. 1 is a perspective view of an embodiment of a canister for atmosphere control in accordance with this disclosure;

[0082] FIG. 2 is a cross sectional view along plane I-I in FIG. 1;

[0083] FIG. 3 is a cross sectional view of an embodiment of a canister in accordance with the present disclosure;

[0084] FIG. 4 is a cross sectional view of an embodiment of a canister in accordance with the present disclosure;

[0085] FIG. 5 is a cross sectional view of an embodiment of a compartment in a packaging in accordance with the present disclosure;

[0086] FIG. 6 is a perspective view of an embodiment of a stopper for atmosphere control in accordance with the present disclosure;

[0087] FIG. 7 is a cross sectional view along plane II-II in FIG. 6;

[0088] FIG. 8 is a cross sectional view of an embodiment of a stopper for atmosphere control in accordance with the present disclosure;

[0089] FIG. 9 is a perspective view of an embodiment of a card-shaped canister for atmosphere control in accordance with the present disclosure;

[0090] FIG. 10 is a cross sectional view of the card along plane III in FIG. 9.

[0091] FIG. 1 is a perspective view of an embodiment of a canister 10 for atmosphere control in accordance with this disclosure.

[0092] The canister 10 of FIG. 1 is an example of a gas-permeable element 1 in accordance with the present disclosure. The canister 10 is for being placed in a packaging or medical device filled with sensitive and/or odorous products and for regulating an atmosphere in the packaging or medical device.

[0093] The canister 10 comprises a body 11 molded of thermoplastic material as well as a cap 12 that is also molded of thermoplastic material.

[0094] FIG. 2 is a cross sectional view along plane I-I in FIG. 1. As shown by this view, the cap 12 is clipped onto the body 11 to close the canister 10. The cap 12 is provided with a plurality of perforations 13 that allow for air exchange between inside and outside of the canister 10, so that the latter can exert an atmosphere regulating function in a packaging or medical device in which the canister 10 is placed.

[0095] An active structure 2 is placed, e.g. by being punched, into the bottom of the canister 10. Most of the remaining volume inside of the canister 10 (aside of the volume that is occupied by the active structure 2) is, in the case of the embodiment of FIG. 1, filled with silica gel particles 14 (or, in the case of another embodiment, with molecular sieve particles).

[0096] The active structure 2 of FIG. 2 is formed of a mixture including particles of activated carbon and a fibrillated polymer as a binder (a PTFE matrix). Shear has been applied to the PTFE matrix, and the activated carbon particles are held in the PTFE matrix by entanglement.

[0097] The canister 10 comprising the body 11 and the gas-permeable cap 12 is an example of a gas-permeable envelope (in the sense of this disclosure) surrounding the active structure 2. The active structure 2 remains in fluid communication with the outside of the canister 10 by virtue of air exchange through the perforations 13 of the cap 12.

[0098] If the canister 10 is placed in a packaging or a medical device, the active carbon particles thus exert an atmosphere regulating effect. As the active carbon particles are entangled with the PTFE matrix, no powder contamination with carbon particles occurs in the packaging and/or medical device. Moreover, the entangled binding increases the amount of air exchange that takes place with the carbon particles, thus increasing the atmosphere regulating effect. Friction of the active carbon particles with neighboring active carbon and desiccant particles is also reduced, as the active carbon particles are maintained entangled in the fibrillated PTFE matrix. In addition, the monolithic molded thermoplastic gas-permeable envelope surrounding the active structure protects the friable active structure from deformation which may result in friction between particles of active material held by entanglement in the fibrillated polymer and may thus generate small dust particles. This is particularly advantageous when active carbon is part of the active material of the active structure, as active carbon is very friable and liable to break down into small dust particles.

[0099] While the active sheet 2 of the embodiment of the canister 10 of FIG. 1 is pressed into the bottom of the body 11, the canister of another embodiment may be overmolded onto the active sheet (in accordance with some embodiments, the cap 12 is overmolded over the active sheet).

[0100] FIG. 3 depicts a cross sectional view of an embodiment of a canister 10 in accordance with the present disclosure. The canister 10 of FIG. 3 is another example of a gas-permeable element 1 in accordance with the present disclosure.

[0101] The embodiment of FIG. 3 may be considered similar to the embodiment of FIG. 2. The difference is that the active structure 2 is provided at a different position. It is namely placed against the (inside) side wall of the body 11, e.g. in the form of a roll, rather than against the bottom of the body 11. In the case of this embodiment, the active structure 10 (in the form of a sheet) extends around the entire inner circumference of the side wall of the body 11. In the case of other embodiments, the active structure 2 may extend over only a part of the inner side wall.

[0102] The other features of the embodiment of FIG. 3 are analogous to those of the embodiment of FIG. 2 and are denoted by like numerals. The description of those features will not be repeated.

[0103] FIG. 4 depicts a cross sectional view of an embodiment of a canister in accordance with the present disclosure. The canister 10 of FIG. 4 is another example of a gas-permeable element 1 in accordance with the present disclosure. The difference is that the active structure 2 is provided at a different position than in the cases of FIGS. 2 and 3. The active structure 2 is, in the case of the embodiment of FIG. 4, placed against the inner wall of the cap 12, rather than against a part of the body 11. In this example, the active structure 2 may advantageously be placed against the inner wall of the cap 12 before the cap 12, having the active structure 2 placed therein, is clipped onto the body 11 to close the canister 10. It is also understood that, in another embodiment, the perforations 13 of the cap 12 may be replaced by perforations in the bottom of the body 11.

[0104] In the embodiment shown in FIG. 4, the active structure 2 covers the perforations 13 of the cap 12. This arrangement has the advantage that the active structure 2 forms a barrier to the escape of small dust particles that may result either from the active material entangled in the active structure 2, or from the other active material 14 received in bulk in the remaining volume inside of the canister 10 (i.e. aside of the volume that is occupied by the active structure 2). Of course, the active structure 2 is gas permeable so that the gas passing through the perforations 13 of the cap 12 can interact not only with the active material entangled in the active structure 2, but also with the other active material 14 received in bulk in the remaining volume inside of the canister 10.

[0105] The other features of the embodiment of FIG. 4 are analogous to those of the embodiments of FIGS. 2 and 3 and are denoted by like numerals. The description of those features will not be repeated.

[0106] FIG. 5 depicts a cross sectional view of an embodiment of a compartment 15 formed in a packaging in accordance with the present disclosure. The compartment 15 of FIG. 5 is another example of a gas-permeable element in accordance with the present disclosure.

[0107] The compartment 15 is delimited in the bottom of a moisture-proof packaging 10, including a tubular body 11 and a lid 12 for hermetically closing the tubular body 11. A gas-permeable insert 16 is attached inside the tubular body 11 and delimits two compartments located on both sides of the insert 16, including the compartment 15 for an active material on one side and a fillable tank for sensitive products on the other side. The sensitive products may be, e.g. pharmaceutical products, diagnostic products, etc.

[0108] Each one of the tubular body 11 and the insert 16 is molded of thermoplastic material. The insert 16 is provided with a plurality of perforations 17 that allow for air exchange between inside and outside of the compartment 15, so that the latter can exert an atmosphere regulating function in the fillable tank delimited above the insert 16.

[0109] An active structure 2 in the form of a sheet is placed, e.g. by being punched, into the bottom of the compartment 15. Most of the remainder of the compartment 15 is filled with silica gel particles 14 (or, in the case of another embodiment, with molecular sieve particles).

[0110] Here again, the active structure 2 of FIG. 5 is formed of a mixture including particles of activated carbon and a fibrillated polymer as a binder (a PTFE matrix). Shear has been applied to the PTFE matrix, and the activated carbon particles are held in the PTFE matrix by entanglement.

[0111] The compartment 15 comprising the bottom part of the tubular body 11 and the gas-permeable insert 16 is an example of a gas-permeable envelope (in the sense of this disclosure) surrounding the active structure 2. The active structure 2 remains in fluid communication with the outside of the compartment 15 by virtue of air exchange through the perforations 17 of the insert 16.

[0112] FIG. 6 is a perspective view of an embodiment of a stopper 20 for atmosphere control in accordance with the present disclosure. The stopper 20 of FIG. 6 is another example of a gas-permeable element 1 in accordance with the present disclosure.

[0113] The stopper 20 of FIG. 6 is for closing a packaging filled with sensitive and/or odorous products and for regulating an atmosphere in the packaging.

[0114] FIG. 7 is a cross sectional view along plane II-II in FIG. 6. The stopper 20 comprises an active structure 2 that has been placed, e.g. by being punched, against the upper inner surface of a cavity delimited by the stopper 20. The active structure 2 is a sheet made of a mixture of active carbon particles and a PTFE matrix as a binder. Shear has been applied to the PTFE matrix, and the active carbon particles are held in the PTFE matrix by entanglement. Most of a remainder of the inner cavity of the stopper 20 (the remainder with respect to the space occupied by the active structure 2) is filled with desiccant particles 24.

[0115] The side walls of the cavity of the stopper 20 comprise end portions 25 which are thinner than the remainder of the cavity side walls and are crimped to hold a piece of gas-permeable cardboard 26. The cavity delimited in the inner volume of the stopper 20 and closed by the gas-permeable cardboard 26 is an example of a gas-permeable envelope (in the sense of this disclosure) surrounding the active structure 2. The active structure 2 is in fluid communication with the atmosphere of a packaging on which is hermetically closed by the stopper 20. The stopper 20 in this state also partially projects into the packaging and is in this sense (partially) placed in the packaging.

[0116] FIG. 8 is a cross sectional of an embodiment of a stopper 20 for atmosphere control in accordance with the present disclosure. The stopper 20 of FIG. 8 is another example of a gas-permeable element 1 in accordance with the present disclosure.

[0117] The difference with respect to the embodiment of FIG. 7 is that the active structure 2 is provided at a different position than in the case of the embodiment of FIG. 7. The active structure 2 is, in the case of the embodiment of FIG. 8, placed, e.g. in the form of a roll, against the inner side wall of the cavity inside of the stopper 20.

[0118] The other features of the embodiment of FIG. 8 are analogous to those of the embodiment of FIGS. 7 and are denoted by like numerals. The description of these features will not be repeated.

[0119] FIG. 9 is a perspective view of an embodiment of a card 40 for atmosphere control in accordance with the present disclosure. The card 40 of FIG. 9 is an example of a flat canister, i.e., another example of an embodiment of a gas-permeable element 1 in accordance with the present disclosure. FIG. 10 is a cross sectional view of the card along plane III-III in FIG. 9.

[0120] The card 40 in accordance with this embodiment comprises a rigid thermoplastic support 46. However, cards in accordance with other embodiments may, as an alternative, comprise flexible supports (e.g., flexible thermoplastic supports).

[0121] The rigid thermoplastic support 46 is overmolded over an active structure 2 (in the form of a portion of an active sheet with the shape of a parallepiped). The support 46 is provided with perforations 48 allowing for air exchange between a surrounding atmosphere and the active structure 2.

[0122] The active structure 2 of FIGS. 9 and 10 is formed of a mixture including, on the one hand, an active material comprising both particles of activated carbon and particles of silica gel and, on the other hand, a fibrillated polymer as a binder (a PTFE matrix). Shear has been applied to the PTFE matrix, and the particles of activated carbon and particles of silica gel are held in the PTFE matrix by entanglement.

[0123] Moreover, the embodiment of FIG. 9 is provided with a cover 49 that is molded together with the remainder of the support 46 and, specifically, linked therewith via a film hinge 50. A clipping means 51 is provided to lock the cover 49 on the remainder of the support 46 in the closed position. Thus, using the combination of support 46 and cover 49, the active structure 2 can be completely closed inside of the casing and is, hence, fully surrounded (leaving only the perforations 48 for air exchange).

[0124] The card 40 comprising the gas-permeable support 46 and the cover 49 is an example of a gas-permeable envelope (in the sense of this disclosure) surrounding the active structure 2. The active structure 2 remains in fluid communication with the outside of the card 40 by virtue of air exchange through the perforations 48 of the support 46.

[0125] It will be apparent to those skilled in the art that various modifications and variations can be made in the disclosed devices and systems without departing from the scope of the disclosure. Other aspects of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the features disclosed herein. It is intended that the specification and examples be considered as exemplary only. Many additional variations and modifications are possible and are understood to fall within the framework of the disclosure.