STICK PACK DESIGN

Abstract

A stick pack having a top sealed portion with a top edge, a horizontal notch parallel with the top edge and passing through the stick pack, and further including a horizontal perforation line parallel with the top edge. The stick pack also has a bottom edge portion with a bottom sealed edge, a longitudinal seal extending from the top sealed edge to the bottom edge; and a spout formed at least partially in the top sealed portion but not extending past the top sealed edge. The stick pack is configured to be folded along its longitudinal axis to fold the notch, and only when the notch is folded can a user easily tear the top sealed edge along the horizontal perforation line to expose the spout.

Claims

1. A stick pack comprising: a top sealed portion comprising a top edge, a horizontal notch parallel with the top edge and passing through the stick pack, and further comprising a horizontal perforation line parallel with the top edge; a bottom edge portion, wherein the bottom edge portion comprises an elongated sealed portion proximate a central compartment of the stick pack; a longitudinal seal extending from the top sealed edge to the bottom edge; and a spout formed at least partially in the top sealed portion but not extending past the top sealed edge; wherein the stick pack is configured to be folded along its longitudinal axis to fold the notch, wherein only when the notch is folded can a user easily tear the top sealed edge along the horizontal perforation line to expose the spout.

2. The stick pack of claim 1, wherein the stick pack packaging comprises a foil laminate.

3. The stick pack of claim 1, wherein the horizontal perforation line is a laser-scored perforation line.

4. The stick pack of claim 1, wherein the horizontal perforation line is intermittent.

5. The stick pack of claim 1, wherein the central compartment comprises an inert gas.

6. The stick pack of claim 1, wherein the stick pack packaging comprises a polyethylene terephthalate layer.

7. The stick pack of claim 1, further comprising a security feature.

8. The stick pack of claim 1, further comprising a plurality of central sealed portions formed in the central compartment, wherein the plurality of central sealed portions are configured to impart a complex flow pattern on the contents within the central compartment when a user squeezes the central compartment.

9. The stick pack of claim 1, wherein the spout comprises a plurality of channels.

10. The stick pack of claim 9, wherein the spout is bifurcated along at least a portion of its length, the bifurcation defined at least in part by a central sealed region.

11. The stick pack of claim 1, wherein the bottom edge portion comprises an outer wall that extends downwardly from the sealed portion to a bottom edge to define a central cylindrical space configured to receive at least a portion of a user's finger.

12. A stick pack comprising: a central compartment; a top sealed portion comprising a top edge, a horizontal notch parallel with the top edge and passing through the foil laminate, and further comprising a horizontal perforation line parallel with the top edge; a bottom sealed portion comprising a bottom sealed edge; a spout extending from the central compartment and formed at least partially in the top sealed portion; a plurality of central sealed portions formed in the central compartment, wherein the plurality of central sealed portions are configured to impart a complex flow pattern on the contents within the central compartment when a user squeezes the central compartment wherein the stick pack is configured to be folded along its longitudinal axis to fold the notch, wherein only when the notch is folded can a user easily tear the top sealed edge along the horizontal perforation line to expose the spout.

13. The stick pack of claim 12, wherein the stick pack packaging comprises a foil laminate.

14. The stick pack of claim 12, wherein the horizontal perforation line is formed in the outermost layer of the foil laminate.

15. The stick pack of claim 12, wherein the horizontal perforation line is a laser-scored perforation line.

16. The stick pack of claim 12, wherein the horizontal perforation line is intermittent.

17. The stick pack of claim 12, wherein the central compartment comprises an inert gas.

18. The stick pack of claim 12, wherein the stick pack packaging comprises a polyethylene terephthalate layer.

19. The stick pack of claim 12, further comprising a security feature.

20. The stick pack of claim 12, wherein the bottom sealed edge is proximate the central compartment of the stick pack, and wherein the bottom sealed portion further comprises an outer wall that extends downwardly from the sealed portion to a bottom edge to define a central cylindrical space configured to receive at least a portion of a user's finger.

21. The stick pack of claim 12, wherein the spout comprises a plurality of channels.

22. The stick pack of claim 21, wherein the spout is bifurcated along at least a portion of its length, the bifurcation defined at least in part by a central sealed region.

23. A stick pack comprising: a central compartment; a top sealed portion comprising a top edge, a horizontal notch parallel with the top edge and passing through the foil laminate, and further comprising a horizontal perforation line parallel with the top edge; a bottom sealed portion comprising a bottom sealed edge; and a spout extending from the central compartment and formed at least partially in the top sealed portion, wherein the spout is bifurcated along at least a portion of its length, the bifurcation defined at least in part by a central sealed region; wherein the stick pack is configured to be folded along its longitudinal axis to fold the notch, wherein only when the notch is folded can a user easily tear the top sealed edge along the horizontal perforation line to expose the spout.

24. The stick pack of claim 23, wherein the stick pack packaging comprises a foil laminate.

25. The stick pack of claim 23, wherein the horizontal perforation line is formed in the outermost layer of the foil laminate.

26. The stick pack of claim 23, wherein the horizontal perforation line is intermittent.

27. The stick pack of claim 23, wherein the central compartment comprises an insert gas.

28. The stick pack of claim 23, wherein the stick pack packaging comprises a polyethylene terephthalate layer.

29. The stick pack of claim 23, further comprising a security feature.

30. The stick pack of claim 23, further comprising a plurality of central sealed portions formed in the central compartment, wherein the plurality of central sealed portions are configured to impart a complex flow pattern on the contents within the central compartment when a user squeezes the central compartment.

31. The stick pack of claim 23, wherein the bottom sealed edge is proximate the central compartment of the stick pack, and wherein the bottom sealed portion further comprises an outer wall that extends downwardly from the sealed portion to a bottom edge to define a central cylindrical space configured to receive at least a portion of a user's finger.

32. A method of manufacturing a stick pack, the method comprising the steps of: cutting a stick pack out of a laminate material, wherein the stick pack comprises a top edge, a bottom edge, and two opposing longitudinal edges; scoring, using a laser, a horizontal perforation line into the outermost layer of the laminate material from one longitudinal edge to the other longitudinal edge; creating a horizontal notch through the laminate material near the top edge, wherein the horizontal notch is aligned along the horizontal perforation line; sealing the two opposing longitudinal edges together to form a longitudinal sealed edge; sealing the bottom edge of the stick pack to form a central compartment which is open at the top edge; filling, through the top edge, the central compartment at least partially with a content; and sealing the top edge to enclose the contents within the central compartment, wherein a spout is formed in the top region near the top edge.

33. The method of claim 32, further comprising the step of filling, through the top edge, the central compartment at least partially with an inert gas.

34. The method of claim 32, further comprising the step of forming a plurality of central sealed elements in the central compartment, wherein the plurality of central sealed portions are configured to impart a complex flow pattern on the contents within the central compartment when a user squeezes the central compartment.

35. The method of claim 32, wherein the bottom edge of the stick pack is sealed to comprise a sealed portion proximate a central compartment of the stick pack, and to further comprise an outer wall that extends downwardly from the sealed portion to a bottom edge to define a central cylindrical space configured to receive at least a portion of a user's finger.

36. The method of claim 32, wherein the spout comprises a plurality of channels.

37. The method of claim 36, wherein the spout is bifurcated along at least a portion of its length.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The present invention will be more fully understood and appreciated by reading the Following Detailed description of the invention in conjunction with the accompanying drawings, in which:

[0029] FIG. 1 is a schematic representation of a front view and a reverse view of stick pack, in accordance with an embodiment.

[0030] FIG. 2 is a schematic representation of a stick pack with a longitudinal axis, in accordance with an embodiment.

[0031] FIG. 3 is a schematic representation of a folded stick pack, in accordance with an embodiment.

[0032] FIG. 4 is a schematic representation of a stick pack which has been opened to expose the spout, in accordance with an embodiment.

[0033] FIG. 5 is a schematic representation of a stick pack prior to folding or sealing, in accordance with an embodiment.

[0034] FIG. 6 is a schematic representation of a stick pack with an administration tab, in accordance with an embodiment.

[0035] FIG. 7 is a schematic representation of a stick pack with a bifurcated spout, in accordance with an embodiment.

[0036] FIG. 8 is multiple schematic representations of stick packs with central sealed elements, in accordance with an embodiment.

[0037] FIG. 9 is a flowchart of a method for manufacturing a stick pack, in accordance with an embodiment.

DETAILED DESCRIPTION

[0038] The present disclosure describes various embodiments of stick pack packaging. The stick packs include an upper sealed edge, a lower sealed edge, and a longitudinal edge. The upper region has a notch and a horizontal perforation line parallel with the top edge, and a spout formed at least partially in the upper region but not extending past the upper sealed edge. The stick pack is configured to be folded along its longitudinal axis to fold the notch, and when the notch is folded a user can easily tear the top sealed edge along the horizontal perforation line to expose the spout. The stick pack can also include an administration tab or region that facilitates administration of the contents by one person to another person. The stick pack can also include a plurality of central sealed elements that impart a complex flow pattern on the contents within the central compartment when a user squeezes the central compartment.

[0039] Referring now to the drawings, wherein like reference numerals indicate identical or corresponding parts throughout the several views, there is shown in FIG. 1 a FRONT and REVERSE view of stick pack 10. Stick pack 10 has top edge 12, bottom edge 14, and side edges 16 and 18. Stick pack 10 also has a sealed edge 20 extending outwardly from the reverse side 22 of the pack, and extending longitudinally along the length of the stick pack.

[0040] Stick pack 10 is sealed at three different regions to keep the contents within the closed packaging. The stick pack is sealed at the top region 24, at bottom region 26, and all along sealed edge 20, also called a fin. When the stick pack is filled with a predetermined amount of liquid or powdershown by dashed fill line 30, although the amount can vary significantly from the shown amountthe contents and the top region seal 24 results in a headspace 28 which contains air or an inert gas. Headspace 28 also prevents spilling or loss of the contents during opening of the stick pack. Headspace 28 allows for resuspension of an oral suspension, such as when the user shakes or kneads the stick pack. The headspace also allows mixing or kneading of the stick pack for gels and solutions, including but not limited to thixotropic gels and solutions.

[0041] According to an embodiment, the stick pack contains variable amounts of the contents. A stick pack containing a liquid or gel can comprise, for example, anywhere from 1 ml to 20 mls of liquid or gel, or more. For example, the size of the stick pack 10 can vary depending on the amount of liquid, gel, or powder intended to be stored inside the packaging. Accordingly, smaller stick packs may comprise less than 1 ml, while larger stick packs may comprise more than 20 mls. Common dosages are 2.5, 5, 10, and 20 mls, among many others.

[0042] Stick pack 10 comprises a multi-step child-resistant opening mechanism that balances safety with ease of opening. To open the stick pack 10, a user first folds the stick pack 10 longitudinally along axis A-A, shown in FIG. 2. Folding the stick pack along axis A-A exposes a notch 32, as shown in FIG. 3, which is pre-formed all the way through the stick pack. Prior to folding the stick pack along axis A-A, however notch 32 is inaccessible to the user. When notch 32 is accessible, the user can utilize the notch to rip the top of the stick pack along a pre-scored perforation line 34 to expose the spout 36, as shown in FIG. 4.

[0043] According to an embodiment, the scored perforation line 34 is created in the film prior to formation of the stick pack, or before sealing of any of the edges. The perforation line 34 can be formed, for example, by laser ablation of only the outermost layer of the stick pack, by mechanical knife, or by other methods. According to an embodiment, therefore, perforation line 34 is formed by laser ablation of an outermost aluminum layer of a multi-layer film laminate. A laser-scored perforation line 34 allows for thicker films for the stick pack 10 without significantly increasing the force required to tear along the perforation and open the stick pack. Additionally, according to an embodiment the perforation is formed along both sides of fin 20, which allows the user to easily rip through the fin when opening the stick pack.

[0044] Referring to FIG. 5, in one embodiment, is a stick pack 10 prior to sealing at the top region 24, at bottom region 26, and along sealed edge 20. The stick pack is approximately rectangular and can be cut or punched out of a larger piece of material during manufacturing. To form the stick pack, the two sides of longitudinal seal 20 are placed next to each other and sealed to form a single fin 20. Top region 24 can be sealed, except for the spout region 36, and bottom region 26 can be sealed. Sealing can be accomplished, for example, by heating the region to be sealed. At a point during the manufacturing and/or sealing process, the stick pack 10 is scored and notch 34 is formed.

[0045] Stick pack 10 can be made of any suitable material, and can comprise one or a plurality of layers. For example, the innermost layer of the stick pack is preferably made of a material that does not interact with the contents of the stick pack, and does not absorb or otherwise let the contents stick to or diffuse through the material. Examples of suitable layer materials include paper, aluminum, polyethylene (PE), and polyethylene terephthalate (PET), among many others. According to one embodiment, the outermost layer of the stick pack is a paper or aluminum layer upon which logos, instructions, and other labeling materials can be printed. The next layer may be a PET layer, and the innermost layer may be a PE layer. Accordingly, the layers may be aluminum/adhesive/PET/adhesive/PE, in one embodiment.

[0046] Referring to FIG. 6 is a FRONT view of an embodiment of stick pack 10. The stick pack has a top edge 12, bottom edge 14, and side edges 16 and 18. Stick pack 10 also has a sealed edge 20 extending outwardly from the reverse side 22 of the pack, and extending longitudinally along the length of the stick pack. Stick pack 10 is sealed at top region 24, bottom region 26, and sealed edge 20. When the stick pack is filled with a predetermined amount of liquid or powdershown by dashed fill line 30, although the amount can vary significantly from the shown amountthe contents and the top region seal 24 results in a headspace 28 which contains air or an inert gas. For some pharmaceutical products, for example, an inert gas can help prevent oxidation or degradation of the product. Inert gasses can include, for example, nitrogen and/or argon, among others.

[0047] Bottom region or tab 26 of this embodiment provides additional material for gripping during administration. Bottom tab 26 can be completely sealed, or can define a hollow central gripping region. For example, instead of being completely sealed, bottom region 26 of this embodiment can be only sealed at two places; along seal 20 (not shown in the FRONT view of FIG. 6), and at sealed portion 38. The walls of stick pack 10 therefore define an administration tab or space 40 into which a user can insert a finger to assist with administration of the contents of the stick pack to another individual. For example, a user can insert a first finger into the empty space of administration tab 40 and grip one or more sides of the tab, thereby providing a way to grip stick pack 10 without the risk of spilling or blocking the contents of the stick pack. A user can alternatively insert a thumb or other finger into the space of administration tab 40 to grip the stick pack.

[0048] Referring again to FIG. 6, in one embodiment, the spout 36 is narrow and elongated, while in FIG. 4 the spout 36 is much wider. The length and width of spout 36 controls the rate at which the contents of stick pack 10 are dispensed to the user. A narrow and/or elongated spout, for example, slows the dispensing speed, which can increase the residence time of the product in the mouth and/or esophagus for some products and therapies.

[0049] Referring to FIG. 7 in one embodiment, is an alternative spout design for stick pack 10. In the figure, for example, the spout 36 is bifurcated by a sealed region 36a. The bifurcated spout not only controls the flow rate of the content, but also helps mix or re-suspend the contents. Trifurcated spouts are also possible, as are other designs. In most cases, the spout is created by controlling the sealing of the top region 24. When top region 24 is sealed, for example, the portion of the top region that will be the spout is not heated and therefore does not seal. To accomplish this, according to another embodiment, the cross-seal jaws of a sealing mechanism can be designed or patterned such that there is no pressure or sealing applied in the area of the spout. Although heat will be applied to the entire jaw, the film will not be pressed together in the area of the spout, and thus the opposed layers of the film will not form a seal in that area.

[0050] Referring to FIG. 8, in various embodiments, is a stick pack 10 with a plurality of central sealed elements 44. The plurality of central sealed elements 44 provides a mechanism for mixing contents, such as re-suspending liquid suspensions, and/or to shear the contents of, for example, thixotropic pharmaceuticals. Often, mixing a suspension prior to dosing can be important to the efficacy and proper dosage of the content. For some contents, if the viscosity of the content is low enough, the stick pack can be shaken by the user and the headspace will allow for mixing of products. For other contents, shearing can be vital to liquefy a thixotropic drug product or to re-suspend a suspension prior to dosing. The plurality of central sealed elements 44 provides a mechanism for lowering the viscosity of the content and/or re-suspending by imparting a complex flow pattern on the contents when a user squeezes the central compartment of the stick pack. For example, the stick pack 10 can be kneaded by a user prior to dosage. Kneading will move the contents inside the stick pack, forcing the contents to interact with the plurality of central sealed elements. Both sharp edges and curved portions of the central sealed elements will facilitate the mixing of the contents. For example, FIG. 8 depicts a variety of central sealed elements 44, including elongated diamond shapes, rectangles, and teardrops, although many other shapes are possible. In several of these designs, neighboring sealed elements create narrow passageways that facilitate mixing and shearing. The plurality of central sealed elements 44 can be formed during or after the initial sealing process.

[0051] According to an embodiment, stick pack 10 can comprise one or more security features. For example, stick packs can be serialized for tracking and identification. Serializing can comprise, for example, labeling with a unique bar code, QR code, or other code that allows for specific identification of the stick pack. All stick packs can be serialized with a similar code format, while some stick packs may be labeled with a specific code format for an individual manufacturer, date, and/or content. As another security feature, the stick pack can be labeled using a specialty or anti-counterfeiting ink. One or more security features allow for increased tracking and identification of pharmaceuticals. For example, a stick pack sold illegally to another individual can be tracked back to the manufacturer, seller, and/or intended user of the stick pack. Using the bar code, QR code, or other unique code. As another example, suspect stick pack can be authenticated by examining the presence or authenticity of anti-counterfeiting ink or other anti-counterfeiting feature.

[0052] Referring to FIG. 9, in accordance with an embodiment, is a method 200 of manufacturing a stick pack 10. At a first step 210, the stick pack material is provided and the stick pack is cut out of the stick pack material. The material can be any of the materials described or otherwise envisioned herein. At step 220, a perforation line is formed in the stick pack material from one longitudinal edge to the other longitudinal edge. Additionally, a notch is formed in the stick pack. According to a preferred embodiment, the perforation line is formed only in the outermost layer of a foil laminate using laser scoring. Step 220 can be performed prior to cutting the stick pack out of the stick pack material.

[0053] At step 230, the stick pack is folded to align the two longitudinal edges which are sealed to form the longitudinal sealed edge 20. At step 240, the bottom edge of the stick pack is sealed, forming a central compartment that is open at the top.

[0054] At step 250 of the method, the contents are introduced to the central compartment. At step 260 of the method, the top edge of the stick pack is sealed. According to an embodiment, a spout is formed in the top edge as it is sealed. The spout can be any of the shapes and sizes disclosed or otherwise envisioned herein.

[0055] At optional step 245 of the method, a plurality of central sealed portions is formed in the central compartment. As described above, the plurality of central sealed portions imparts a complex flow pattern on the contents the central compartment when a user squeezes the central compartment. The plurality of central sealed portions can be formed, for example, by heating specific patterns or shapes into the folded stick pack, which causes the opposing internal sides of the central compartment to adhere in the shape or pattern.

[0056] While various embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, embodiments may be practiced otherwise than as specifically described and claimed. Embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure.