Method for packaging a plurality of containers for substances for medical, pharmaceutical or cosmetic applications, and packaging structure

Abstract

Disclosed is a method for packaging a plurality of containers for substances for medical, pharmaceutical or cosmetic applications in a packaging structure. The structure has a box-shaped upper part and a box-shaped lower part, forming a box-shaped receptacle in which the containers are accommodated. The plurality of containers are disposed directly on the bottom of the lower part that the containers are supported vertically on the bottom of the lower part, and the upper part is put onto the upper ends of the containers. The positions of the containers on the lower part are secured using side walls that project vertically from the bottom of the lower part and/or of the upper part, and the upper part and/or the lower part is configured and provided in a way that the containers are in direct contact with each other in the box-shaped receptacle and cannot be displaced relative to each other.

Claims

1. A method for packaging a plurality of containers for substances for medical, pharmaceutical or cosmetic applications in a packaging structure that comprises an upper part and a lower part and that forms a box-shaped receptacle in which the containers are accommodated, each container having a cylindrical side wall and a bottom or a lower edge extending perpendicularly to the side wall thereof, the method comprising the steps of: disposing the containers directly on a flat surface so that the containers are supported perpendicularly on the flat surface; placing the upper part or an intermediate part on upper ends of the containers, wherein the upper part or the intermediate part is box-shaped; displacing the containers from the flat surface to a bottom of the lower part; and sealing the packaging structure comprising the upper and lower part and the containers accommodated therein by insertion into a sleeve or re-sealable bag of plastic material and closing the sleeve or re-sealable bag or by a gas-permeable plastic foil, wherein the side walls of the upper part or of the intermediate part projecting perpendicularly from a bottom of the upper part or of the intermediate part serve as guiding devices during the displacement of the containers onto the bottom of the lower part.

2. The method as claimed in claim 1, wherein the upper part and/or the lower part is configured and provided so that the containers in the box-shaped receptacle are in a direct contact with each other and cannot be displaced relative to each other.

3. The method as claimed in claim 1, wherein for the displacement onto the bottom of the lower part the containers are disposed on the flat surface between at least three side walls of an accommodation jig in a configuration having a shape which corresponds to the shape of the box-shaped receptacle formed by the packaging structure, if viewed in a plan view.

4. The method as claimed in claim 3, wherein the containers are disposed between the at least three side walls of the accommodating jig by a sliding movement on the flat surface.

5. The method as claimed in claim 4, wherein the containers are pushed onto the bottom of the lower part by the accommodation jig or by the upper part put onto the upper ends of the containers or by a corresponding intermediate part having a bottom and side walls projecting perpendicularly therefrom.

6. The method as claimed in claim 5, wherein the lower part comprises front side lugs that are secured in an unfolded position, and the lower part comprises a front side wall and/or a rear side wall of is/are secured in a folded-down position when the containers are pushed onto the bottom of the lower part.

7. The method as claimed in claim 1, wherein the containers are disposed on the flat surface in direct contact with each other and are disposed in a configuration and are pushed into the lower part by the box-shaped upper part or the intermediate part after placing the box-shaped upper part or the box-shaped intermediate part on the upper ends of the containers.

8. The method as claimed in claim 5, wherein the box-shaped intermediate part is placed on the upper ends of the containers, the box-shaped upper part is placed on the intermediate part and the upper part, and the intermediate part are pushed together with the containers into the lower part.

9. The method as claimed in claim 1, wherein the bottom of the upper part and/or of the lower part and/or the side walls of the upper part and/or of the lower part comprise perforations which are sealed by a gas-permeable plastic foil.

10. The method as claimed in claim 9, wherein the gas-permeable plastic foil is a mesh made of synthetic fibers or a Tyvek protective film.

11. The method as claimed in claim 8, wherein the lower part and the upper part are detachably connected with each other.

12. The method as claimed in claim 11, wherein the lower part and the upper part are latched to each other.

13. The method as claimed in claim 1, further comprising guiding structures that extend in the longitudinal direction of the lower part, wherein the guiding structures are guided by side walls of the upper part upon insertion of the lower part into the upper part and are formed alongside walls of the lower part.

14. The method as claimed in claim 13, wherein the guiding structures are accommodated by positive locking or friction locking by correspondingly shaped side wall sections of the upper part.

15. The method as claimed in claim 1, further comprising: opening the packaging structure and pushing the containers in the packaging structure in a manner free of particles out of the lower part by displacement of the intermediate part placed on the containers, or by a pusher.

16. A packaging structure for packaging a plurality of containers for substances for medical, pharmaceutical or cosmetic applications, the containers having a cylindrical side wall and a bottom or a lower edge extending perpendicularly to the side wall, wherein the packaging structure together form a box-shaped receptacle in which the containers are accommodated, comprising a box-shaped upper part and a flat or box-shaped lower part, wherein the plurality of containers is disposed directly on a bottom of the lower part and perpendicularly to the bottom, the upper part is placed on the upper ends of the containers or on a box-shaped intermediate part, which is placed on the upper ends of the containers, the positions of the containers on the bottom of the lower part are fixed by side walls protruding perpendicularly from the bottom of the lower part and/or of the upper part, and the packaging structure with the upper and the lower part and with the containers accommodated therein is sealed by insertion into a sleeve or re-sealable bag made of a plastic material and sealing the sleeve or re-sealable bag or by a gas permeable plastic foil, wherein at least one side wall of the lower part is open or can be removed or opened so that the plurality of containers together with the upper part placed on the upper ends of the containers or on the intermediate part can be displaced from a flat surface onto the bottom of the lower part.

17. The packaging structure as claimed in claim 16, wherein the lower part comprises at least one side wall that can be removed or opened by folding downward or laterally.

18. The packaging structure as claimed in claim 16, wherein the upper part and/or the lower part is configured such that the containers contact each other directly in the box-shaped receptacle and cannot be displaced relative to each other.

19. The packaging structure as claimed in claim 16, wherein the lower part is made of a material or is provided with a slide coating having a coefficient of friction with respect to the material of the containers of less than 0.6.

20. The packaging structure as claimed in claim 16, wherein the bottom of the lower part and/or the upper part comprises lateral edges that are folded along folding lines to form the side walls of the lower part and/or of the upper part.

21. The packaging structure as claimed in claim 20, wherein the front side wall and/or rear side wall of the lower part is double-walled and formed by insertion of protrusions formed along an edge of the side wall into corresponding recesses at the bottom of the lower part.

22. The packaging structure as claimed in claim 16, wherein the lower part comprises front side lugs that can be folded up to an unfolded position, the lower part comprises a front side wall and/or a rear side wall of that can be folded down to a folded-down position, and wherein the front lugs form protrusions and recesses, which positively engage each other in an unfolded position such that the side lugs are secured in the unfolded position and that the front side wall and/or the rear side wall is secured in the folded-down position.

23. The packaging structure as claimed in claim 16, wherein the bottom of the upper part and/or of the lower part and/or the side walls of the upper part and/or of the lower part have perforations, which are sealed by the gas-permeable plastic foil.

24. The packaging structure as claimed in claim 16, wherein the gas-permeable plastic foil is a web of synthetic fibers or a Tyvek protective film.

25. The packaging structure as claimed in claim 16, wherein the lower part and the upper part are detachably connected with each other

26. The packaging structure as claimed in claim 25, wherein the lower part and the upper part are latched to each other.

27. The packaging structure as claimed in claim 26, further comprising guiding structures that are formed along side walls of the lower part, the guiding structures extending in the longitudinal direction of the lower part and which are guided by side walls of the upper part upon insertion of the lower part into the upper part.

28. The packaging structure as claimed in claim 27, wherein the guiding structures are accommodated by correspondingly shaped side wall portions of the upper part by positive locking or frictional locking.

29. The packaging structure as claimed in claim 16, wherein the side walls of the lower part and/or of the upper part and/or an insert in the box-shaped receptacle are elastic at least in sections, so that the containers are accommodated in the box-shaped receptacle so as to be biased resiliently against each other and so that a slippage of the containers relative to each other in the box-shaped receptacle is prevented.

30. The packaging structure as claimed in claim 29, wherein the side walls of the lower part and/or of the upper part and/or the insert are formed at least in sections from a thermoplastic, thermosetting or elastomeric plastic, which is foamed or is formed as a twin-walled sheet having hollow chambers.

Description

OVERVIEW ON DRAWINGS

[0041] The invention is described by way of example and with reference to the accompanying drawings, from which further features, advantages and problems to be solved will become apparent. In the drawings:

[0042] FIG. 1a shows a packaging structure according to a first embodiment of the present invention in a schematic view before its completion;

[0043] FIG. 1b is an example of a container for use in a packaging structure according to the present invention;

[0044] FIGS. 2a-2d show the steps for producing a packaging structure as shown in FIG. 1a.

[0045] FIGS. 3a-3h show the steps for producing a packaging structure according to a further embodiment of the present invention;

[0046] FIGS. 4a-4d show further details of the packaging structure according to FIGS. 3a-3h;

[0047] FIGS. 5a-5f show details upon opening a packaging structure according to a further embodiment of the present invention;

[0048] FIGS. 6a-6c show the steps for producing a packaging structure according to a further embodiment of the present invention;

[0049] FIGS. 7a-7d show details of a packaging structure according to a further embodiment of the present invention;

[0050] FIGS. 8a-8c show details of packaging structures according to further embodiments of the present invention;

[0051] FIGS. 9a-9b show a packaging structure according to a further embodiment of the present invention;

[0052] FIGS. 10a-10d show details of a packaging structure according to a further embodiment of the present invention;

[0053] FIGS. 10e-10h show details of a packaging structure according to a further embodiment of the present invention;

[0054] FIGS. 11a-11e show details of a packaging structure according to a further embodiment of the present invention;

[0055] FIGS. 12a-12d show details of a packaging structure according to a further embodiment of the present invention; and

[0056] FIG. 13 is a schematic flow diagram of a method for producing a packaging structure according to the present invention.

[0057] In the drawings, identical reference numerals designate identical or substantially equivalent elements or groups of elements.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0058] FIG. 1 shows a packaging structure according to a first embodiment of the present invention in a schematic view before its completion. The packaging structure 1 comprises a box-shaped upper part 10 and a box-shaped lower part 20, which is shown in FIG. 1a in a partly finalized state. The upper part 10 has a flat, rectangular bottom 11 and two side walls 12 and a front and rear side wall 13, each projecting perpendicularly from the bottom 11. The lower part 20 is formed in a corresponding manner and has a flat, rectangular bottom 21 and two side walls 22, each projecting perpendicularly from the bottom 21. The front and rear side wall 23 is shown in FIG. 1a still folded down and forms a common plane (flat surface) together with the bottom 21 and is folded upward at a later stage for forming a box-shaped lower part.

[0059] Because according to FIG. 1a the front side wall 23 is folded down, the containers 2 can be pushed easily into the lower part 20 from a shelf (not shown), which is preferably flush with the top surface of bottom 21 and of the front side wall 23 that is folded down. Upon insertion of the containers 2 into the lower part 20 the side walls 22 serve as lateral guiding devices. After the containers are arranged in the lower part 20, the side lugs 26, which are formed at the front ends of the side walls 22, and the front side wall 23 are turned over and connected to each other to form a front side wall, which also protrudes perpendicularly from the bottom 21 of the lower part 20. In this state, a box-shaped receptacle is formed by the side walls 22 and the front and rear side wall 23 of the lower part, in which the containers 2 are accommodated. The height of the side walls 22, 23 is less than the height of the containers 2.

[0060] FIG. 1b shows a vial 2 as an example of a container for which a packaging structure according to the present invention is suited. The vial 2 has a cylindrical basic shape, having a cylindrical side wall 4 withwithin tolerancesa constant inner and outer diameter, which projects vertically from a flat vial bottom, which merges in a constricted neck portion 5 of a relatively short axial length near the upper open end of the vial and then merges in an expanded upper rim 6, which has a larger outer diameter than the associated neck portion 5 and is configured for connection to a closure member. The neck portion 5 may be formed with smooth walls and without an external thread or may be provided with an external thread for screwing on a closure member. For example, a stopper (not shown) may be inserted in the inner bore of the neck portion 5 and of the upper rim 6, whose upper end is connected with the upper rim 6 of the vial in a gas-tight manner and protected against the intrusion of contaminants into the vial, for example by crimping or beading a metal protective foil which is not shown. Such vials are radial symmetric and are made of a transparent or colored glass or of a suitable plastic material by blow molding or plastic injection molding techniques, and in general can be internally coated so that the material of the vial emits minimal impurities to the agent to be accommodated.

[0061] Further examples of a medication container in the sense of the present application are ampoules, carpoules (cartridges) or syringes or injection containers.

[0062] In the sense of the present invention, such containers are used for the storage of substances or agents for medical, pharmaceutical or cosmetic applications, which are to be stored in one or several components in solid or liquid form in the container. Especially in the case of glass containers storage periods can amount many years, notably depending on the hydrolytic resistance of the glass type used. While, in the following, cylindrical containers are disclosed, it should be noted that the containers, in the sense of the present invention, may also have a different profile, for example a square, rectangular or polygonal profile. If containers 2 in the sense of the present invention do not have a substantially flat bottom 3, in any case a circumferential edge is formed at a height of the container 2 so that the containers can be displaced on a supporting surface, if these are supported vertically on the supporting surface.

[0063] According to FIG. 1b, the bottom 3 or the lower edge of the side wall 4 extends exactly perpendicular to the side wall 4 of the container 2 so that the container 2 is arranged exactly vertically upright on the bottom 21 of the lower part 20 (see FIG. 1a). This prevents excessive forces acting on the side walls of the containers, which could lead to scratches, abrasion of material or even a bursting of the containers, even if the containers 2 are supported so as to be biased or clamped against each other.

[0064] As shown in FIG. 1a, the containers 2 are accommodated in the lower part 20 with direct wall-to-wall contact so that the greatest possible packing density can be achieved. According to further embodiments inserts may be provided between all containers, for example in the form of partition walls, which prevent a contact of the directly adjacent containers in the lower part or in the subsequent packaging structure. According to further embodiments, such partition walls may also be provided as partition strips partitioning rows of containers from each other. As explained below, such partition walls or partition strips may also be used for displacement of the containers on a flat surface.

[0065] FIG. 2a shows the lower part according to FIG. 1a. After insertion of the containers 2 into the lower part 20 and closing of the lower part 20 by folding the front side wall 23 and the side lugs 26 (not shown in FIG. 2b), according to FIG. 2b the box-shaped upper part 10 is placed directly onto the upper ends of the containers 2. Of course, also an intermediate layer, for example, a thin plastic plate or plastic foil, may be placed on the upper ends of the container 2 before the upper part 10 placed on.

[0066] In this way finally the packaging structure shown in FIG. 2c is formed. Finally, the packaging structure 1 thus formed is sealed in a tube or sleeve 9 made of a plastic material or placed in a plastic bag that may be sealed and is from a plastic material, in which the containers are accommodated sterile and aseptically packaged (see FIG. 2d).

[0067] The containers are preferably accommodated in the lower part or in the upper part of the packaging structure 1 without play, i.e. they are accommodated therein in such a manner that they cannot be displaced, neither relative to each other nor relative to the side walls or bottoms of the lower and upper part. For this purpose, a clamping (mechanical biasing) of the containers in the box-shaped receptacle of the packaging structure 1 is not mandatory. Rather, the box-shaped receptacle of the lower part and/or of the upper part may also be mated to the arrangement of the containersassuming a direct wall-to-wall contact of all containersso precisely that any relative displacement of the containers relative to each other is excluded.

[0068] According to a preferred embodiment, the containers may be accommodated in the box-shaped receptacle of the lower part and/or of the upper part in a clamped state (a permanent mechanical, elastic biasing against each other). For this purpose, an elastic insert may be inserted into the lower part and/or upper part, which biases the containers accommodated therein permanently, so that they are held clamped in the packaging structure. Such an elastic insert may extend, for example, like the strip-shaped insert 38 shown in FIG. 6a along a side wall of the lower part and/or of the upper part. Alternatively, the side walls of the lower part and/or of the upper part may be formed at least in sections from an elastic material, wherein the side walls are stretched or elongated during insertion of the containers into the lower part and/or upper part and the force required for this purpose is then released again so that the side walls seek to return to their initial position, namely until they get in contact with the arrangement of containers accommodated in the lower part and/or upper part and these are held clamped. As another alternative, partition walls or partition strips may be inserted between all containers or between rows of containers as an insert of an elastic material, which permanently biases the containers accommodated in the packaging structure against each other so that they are held clamped.

[0069] Such partition walls or separating strips may also be used for pushing the containers when forming the packaging structure according to the present invention, e.g. for displacing entire rows of containers, as explained below.

[0070] FIGS. 3a-3h illustrate the steps of forming a packaging structure according to a further embodiment of the present invention. FIG. 3a shows an accommodating jig 50 in which the containers are to be disposed in a desired arrangement in advance before they are pushed in this arrangement into the lower or upper part or before they are accommodated therein. For this purpose, the accommodating jig 50 shown in FIG. 3a comprises a flat bottom 51 (flat surface), wherein the two mutually parallel side walls 52 and a rear wall 53 each project perpendicularly. The side walls 52 and the rear wall 53 together form a box-shaped receptacle having an open front end. A U-shaped spacer is inserted into the accommodating jig 50, which consists of two mutually parallel side walls 60 and a rear wall 61.

[0071] According to FIG. 3b, a plurality of containers 2 are placed between the side walls 60 of the spacer in the desired arrangement. This can be done by pushing the containers 2 via the open front end of the accommodating jig 50, for example from a supporting surface, a transport container or a conveying belt.

[0072] As will be readily apparent to the person skilled in the art, the bottom 51 is not absolutely necessary for this purpose. Rather, the accommodating jig 50 may also be disposed on a flat surface (not shown), on which the containers are then pushed.

[0073] Subsequently, the U-shaped spacer is removed, as shown in FIG. 3c. In this state a gap remains between the side walls of the outermost container 2 of the rectangular arrangement of containers 2 and the side walls 52 and the rear wall 53 of the accommodating jig 50, wherein the width of the gap corresponds to the thickness of the side walls 60 and of the rear wall 61 of the spacer.

[0074] According to FIG. 3d, subsequently a box-shaped upper part 10 with a correspondingly rectangular base is placed onto the upper ends of the containers 2. Here, the wall thickness of the side walls of the upper part 10 should be smaller or equal to the thickness of the side walls 60 and of the rear wall 61 of the spacer.

[0075] As shown in FIG. 3e and FIG. 3f, the containers are pushed out of the accommodating jig 50 by means of the upper part 10, namely in the region of an insertion opening of a lower part 20 thatcontrary to the aforementioned embodimentsis not formed open at the upper end, but further comprises an upper cover 24. FIG. 3f shows a state in which the upper part 20 is pushed completely out of the accommodating jig 50. Subsequently, the upper part 10 is pushed into the lower part 20 via the insertion opening (see side view of FIG. 3g), until the packaging structure of FIG. 3h is formed.

[0076] In this procedure, it is advantageous if the lower ends or bottoms of the containers are always pushed on a flat support surface that has no elevations. This can be accomplished either by accommodation of the accommodating jig 50 (see FIG. 3a) and of the lower part 20 in a recess 20 having a depth which is dimensioned such that the upper side of the bottom 51 of the accommodating jig 50 (see FIG. 3a) and of the lower part 20 is flush with adjacent surface portions. Alternatively, this can be accomplished by supporting the accommodating jig 50 (see FIG. 3a) and the lower part 20 on a supporting surface, wherein those regions of the supporting surface, which are not located below the accommodating jig 50 and the lower part 20, are formed slightly elevated, namely elevated by the thickness of the bottom of the accommodating jig 50 and of the lower part 20, so that the containers can be displaced without height offset. A smooth displacement of all containers can also be accomplished by the formation of ramp-like inclined transition zones at the front edge of the accommodating jig 50 and of the bottom 21 of the lower part 20. Alternatively, the accommodating jig 50 may also be formed without a bottom.

[0077] In this embodiment, the containers are accommodated in the upper part 10 preferably without play and with a direct wall-to-wall contact. In particular, the containers may also be held clamped in the upper part 10. In the latter case, the clamping of the containers in the upper part 10 particularly may be such that the upper part together with the containers accommodated therein in a clamped state is raised and inserted into a lower part, rather that the upper part 10 displaces the containers. Basically, the containers may also be accommodated in the packaging structure loosely and with lateral play.

[0078] As will readily be apparent to the person skilled in the art, also the front end of the accommodating jig 50 (see FIG. 3a) may be closed by an upright side wall, so that there will be no need to push the containers into the accommodating jig 50 but instead the need that the containers are to inserted from above, which is more complex though, but may be implemented for example by means of gripper arms or the like.

[0079] FIGS. 4a-4d show further details of the packaging structure according to FIGS. 3a-3h. According to FIG. 4a, a sealing member 29 is provided along the front edge of the lower part 20, which may be accomplished, for example, by an elastic insert made of a rubber or plastic material which may also be injected into the bottom 21 of the lower part 20 using 2K technology, or by forming an elastic sealing member directly in the bottom 21 of the lower part 20. According to FIGS. 4c and 4d, the sealing member is implemented by a bead 29, which protrudes inwardly from the bottom 21. Thus an elastic resistance needs to be overcome when pushing the upper part 10 into the lower part 20.

[0080] FIGS. 5a-5f show details of the procedure for opening of a packaging structure according to a further embodiment of the present invention. As shown in FIG. 5b, a box-shaped intermediate part 40 is placed onto the upper ends of the containers, which comprises a flat bottom 41 and side walls 42 projecting perpendicularly therefrom. This intermediate part 40 may rest permanently on the upper ends of the containers to prevent intrusion of particles into the open ends of containers even when the upper part 10 has been removed, as shown in FIG. 5c. Here, the side walls 42 prevent an inadvertent lateral slipping off of the intermediate part 40.

[0081] According to FIG. 5c, the front side wall 23 of the lower part 20 is folded down to allow a pushing out of the containers 2 by displacement of the intermediate part 40. In order to prevent a disturbing folding back of the front side wall 23, the side lugs 26 of the lower part 20 hold the front side wall 23 pushed down, namely in a position in which the front side wall 23 is flush with the plane of the bottom 21 of the lower part 20. As shown in FIG. 5d, for this purpose rectangular recesses 27 are formed in the side lugs 26, into which rectangular protrusions 28 engage, which are formed correspondingly on the side edge of the front wall 23. In this position, the intermediate part 40 together with the containers 2 accommodated therein can be pushed out of the lower part 20, as shown in FIG. 5e. Subsequently, by lifting the upper part 10 access to the containers 2 is made possible for the treatment or further processing.

[0082] As shown in FIGS. 6a-6c, rather than by means of the intermediate part 40 shown in FIGS. 5a-5e all the containers 2 can also be pushed out of the lower part 20 by means of a pusher 37. The strip-shaped pusher 37 shown in FIG. 6a extends along the rear wall 23 of the lower part, wherein the front ends of a bracket 39 acting as a displacement device are inserted into blind holes 38 in the pusher 37. This strip-shaped pusher 37 may be in particular an elastic insert, which biases and permanently clamps the containers 2 accommodated in the box-shaped lower part 20 due to its elasticity, as set forth above. In order to accomplish that the front side wall 23 is not rocketing upward when the containers 2 are pushed out of the lower part 20 according to FIG. 6b, the front side wall 23 is pushed or pressed down by the side lugs 26, as described above with reference to FIG. 5d. Finally, the state of FIG. 6c is reached, in which all containers 2 are completely pushed out of the box-shaped lower part 20.

[0083] Alternatively, the containers 2 may also be pushed out of the box-shaped lower part 20 in rows or individually by means of a strip-shaped plate. Such a strip-shaped plate may in particular also be a partitioning strip, which prevents a collision of directly adjacent containers in the packaging structure, as set forth above. Such a partitioning strip may also consist of an elastic material, as set forth above.

[0084] As shown in FIG. 7a, a box-shaped lower part 20, as described above, may also be punched out from a material sheet and produced by suitable folding. In FIG. 7a, the corresponding folding lines are designated by the reference numerals 34a-34e. By punching out recesses 27 on the rear side lugs 31 and protrusions 28 on the rear wall 30, it is possible to permanently press down the rear wall 30, as described above with reference to FIG. 5d. In this embodiment, the front side wall 23 is formed doubled, namely by folding along the folding line 34e and folding the doubled side wall 23a in the direction of the side wall 23. By inserting the protrusions 33 formed at the upper edge of the doubled side wall 23a into correspondingly formed recesses 32 on the bottom 21 of the lower part 20, the front side wall 23 optionally can be folded up (for retaining the containers) or folded down (for pushing the containers in or out). In the folded-up position the side lugs 26 are inserted into the gap between the front side walls 23, 23a. When folding up the front side wall and the rear wall of the lower part, these may thereby be stretched in order to implement the above-described permanent clamping of the containers in the lower part.

[0085] FIG. 7b explains again the permanent pressing down of the front side wall by means of interlocking protrusions 28 and recesses, wherein the displacement required for taking and releasing this position are indicated by the displacement arrows. FIGS. 7c and 7d show an alternative for the permanent pressing down of the front side wall, wherein a diagonal folding line 34f extends in the front side plate 26, wherein the front side wall 23 and the side lugs 26 are connected to each other (see FIG. 7d) and wherein the position according to FIG. 7c with the front side wall 23 folded upward can be accomplished by pressing along the folding line 34f and pivoting the side lugs 26 about the folding line 34d and wherein the open state according to the FIG. 7d can be accomplished again in the reverse sequence.

[0086] FIG. 8a shows a three-part packaging structure as described above, having a lower part 20 in which the containers are accommodated, an intermediate part 40 placed on the upper ends of the containers and an upper part 10 placed on the intermediate part 40.

[0087] FIG. 8b shows a further embodiment, wherein the containers 2 are initially positioned on the bottom 21 of the lower part 20 in a state in which the front and rear side wall 23 is not yet folded upward. In this state, the containers 2 can be pushed inward, in particular via the open front and rear ends. Then, the upper part 10 is placed on the upper ends of the containers 2. According to FIG. 8b, recesses are formed in the bottom 11 of the upper part 10, into which the side lugs 26a are inserted when folding up the front and rear side walls 23 and when further folding the doubled side walls 23b on which the side lugs 26a are provided. In this way the upper part 10 and the lower part 20 are connected by means of a plug connection.

[0088] FIG. 8c shows a further embodiment, wherein the two longer side walls 22 are formed doubled by double-folding in a corresponding manner, but wherein there are not provided any front and rear side walls, because it is sufficient that the containers 2 are retained in the packaging structure by means of the side walls 12, 13 of the upper part 10. After folding twice the side walls 22, the side lugs 26, which are formed at the front ends thereof, are inserted into the recesses 14 in the bottom 11 of the upper part 10 in the manner described above with reference to FIG. 8b for connecting the upper part 10 and lower part 20 directly to each other.

[0089] FIGS. 9a and 9b show a packaging structure 1 according to a further embodiment, wherein the side walls 22 of the lower part 20 are provided with apertures 22a and wherein the bottom 11 of the upper part 10 is provided with a grid structure 11a formed by a plurality of intersecting webs with through holes or perforations formed therebetween. These through holes or perforations are sealed by a gas-permeable plastic foil, in particular by a web of synthetic fibers such as polypropylene fibers (PP) or by a Tyvek protective film. This gas-permeable plastic foil may also be added subsequently, e.g. by bonding on the edges of the through holes, and enables a sterile and aseptic packaging of the containers within the packaging structure. Sterilization of the containers may also be accomplished in the packaging structure by providing a gas flowing in from the outside via the plastic foil and via the box-shaped receptacle of the packaging structure into the interiors of the containers 2 for the sterilization of the containers. Finally, the packaging structure further may be sealed in a sleeve or placed in a sealable bag (see FIG. 2d) or be placed in a sterile transport and packaging container.

[0090] The aforementioned through holes or perforations may in principle be provided also in the bottom of the lower part, wherein the containers may slide easily over the bottom into the lower part and pushed out of it again if the grid of the aforementioned mesh structure 11a is appropriate.

[0091] FIGS. 10a to 10d show details of a packaging structure according to a further embodiment of the present invention. In this embodiment the upper part 10 is box-shaped, having a bottom 11 and side walls 12 and 13 projecting perpendicularly therefrom, wherein a flange 15 projects perpendicularly along the two longer side walls 12. This upper part 10 is formed preferably as a thermal molding member of a plastic material.

[0092] The lower part 20 is formed by folding of a plastic sheet having a bottom 21 and two lateral clamping webs 200 at each end of which a rectangular protrusion 201 is formed. The clamping webs 200 are connected to the bottom 21 via a film hinge and can thus be folded. In the corner regions of the rectangular bottom 21 mushroom-shaped protrusions 203 (or openings) are formed which engage with correspondingly shaped openings 202 (or mushroom-shaped protrusions) of the extension 201 after folding the lateral clamping webs 200. The lower part 20 is preferably formed as an injection molding member from a plastic material. In the area 209 of bottom 21 indicated by dotted lines (or also in the upper part 10) through holes may be formed as a grid structure of a plurality of intersecting webs, which can be sealed by means of a gas-permeable plastic foil, in particular by means of a mesh made of synthetic fibers, and by means of which the containers in the packaging structure can be sterilized by a gas flowing in, as described above.

[0093] The packaging process begins according to FIG. 10b with insertion of the containers 2 into the box-shaped receptacle of the upper part 10, for example, by placing the containers 2 on a flat surface with a high packing density and placing the box-shaped upper part 10 on the containers 2, so that the arrangement of the containers 2 shown in FIG. 10b is automatically obtained. The upper part 10 together with the containers 2 accommodated therein is then pushed onto the bottom 21 of the lower part 20. The upper part 10 is then connected to the lower part 20, in particular by latching.

[0094] For this purpose, according to FIG. 10c the lateral clamping webs 200 of the lower part 20 can be folded and the protrusions 203 can be pressed into the openings 202 of the extensions 201. The folded extensions 201, on which the front and rear side wall 13 of the upper part rests, precisely define the position of the lower part 10 relative to the lower par 20. The fixing of this position is implemented by means of the clamping webs 201, which clamp the respective flange 15 (see FIG. 10a) of the upper part 10, and by latching of the protrusions 203 into the openings of the extensions 201.

[0095] Opening of this packaging structure 1 is performed in reverse sequence, wherein the first step, namely releasing the mushroom-shaped protrusions 203 from the openings of the protrusions 201 and pivoting back of the lateral clamping webs 200, is shown in FIG. 10d.

[0096] FIGS. 10e to 10h show details of a further packaging structure, wherein the lower part is fixed in the upper part of positive-locking (form-fitting) or clamping. According to FIG. 10e, guiding tracks 205 are formed along the side walls 23 of the lower part 20, which are rectangular in profile, which can be implemented easily e.g. by thermal deformation of lateral portions of lower part 20. Flat connecting webs 204 are formed between the guiding tracks 205 and the side walls 23, the undersides of which preferably lie in a common plane together with the lower edge of the box-shaped lower part 20.

[0097] According to FIG. 10e, the front and rear ends of the upper part 10 are designed to be open, so that the lower part 20 can be pushed in. The bottom 11 of the upper part 10 is designed to be closed, but may in principle be provided with perforations which can be sealed by a gas permeable plastic foil, as described above. Furthermore, the edge portions of the upper part 10 are formed in correspondence to the guiding tracks 205 of the lower part 20 so that these can be accommodated in a positive fit manner or clamped in the edge portions of the upper part 10 after pushing the lower part 20 into the upper part 10.

[0098] This state, in which the upper part 10 is positively accommodated or clamped in the edge portions of the upper part 10 is shown in the right-hand part II of the greatly enlarged partial section of FIGS. 10f and 10g. As shown, the edge portions of the upper part 10 are formed by a vertical side wall 102, a horizontal connecting web 103 and a vertical connecting web. In the locked or clamped state II of the lower part 20, the side wall 102 extends in parallel with and at a small or virtually vanishing distance to the side wall of the guiding track 205 and the horizontal connecting web 103 extends in parallel with and at a small or virtually vanishing distance to the upper side of the guiding track 205. Instead of clamping, additional form-fitting structures may be provided in this area, for example pushbuttons or elements positively cooperating with each other, such as recesses and protrusions corresponding thereto.

[0099] In order to permit simple insertion of the lower part 20 into the upper part 10, the edge portions of the upper part 10 may be adjusted according to the left part I of FIGS. 10f and 10g, for example, by providing folding lines in the edge portions about which the connecting webs and side walls can be pivoted. In the unfolded or open state I, which is shown in FIG. 10f, folding lines are e.g. provided in the transition areas 100->104, 104->103 and 103->102 in parallel to the side walls 12 of the upper part 10, about which the associated webs 103, 104, 100 can be pivoted upwardly to release the lower part 20 from the upper part 10 or to permit an insertion. In order to stably maintain the state II according to FIGS. 10f and 10g, it may be of advantage if the aforementioned side wall portions of the upper part 10 are elastically biased to the position of the state II due to their material characteristics. Or additional form-fitting structures in this region, as stated above, fix the state II.

[0100] To further seal the packaging structure, according to the enlarged partial sectional view of a further embodiment, as shown in the FIG. 10h, an elastic sealing member 109 may be provided between the underside of the horizontal connecting web 204 of the lower part 20 and the bottom 11 of the upper part, which may, for example, be implemented as an elastic insert of a rubber or plastic material, which may also be injected into the bottom 11 of the upper part 10 using 2K (two-component) technology, or by forming an elastic sealing member directly in the bottom 11 of the upper part 10 or on the underside of the connecting web 204.

[0101] Such a sealing between the upper and lower part may, of course, also be provided in all other embodiments described herein at a suitable location to seal the packaging structure against the environment, preferably to seal the packaging structure sterile.

[0102] FIGS. 11a to 11d show details of a packaging structure according to a further embodiment of the present invention. The lower part 20 is basically formed similar to FIG. 1a. Here, in the region 209 indicated by dotted lines in principle also perforations may be provided in the bottom 21, which may be covered by a gas permeable plastic film, as described above. The lower part 20 according to FIG. 11a is folded in a manner similar to FIG. 8a to a box-shaped lower part. For this purpose, the front side walls 23 are further folded at the level of the side walls 22. When folding the front side walls 23 upward, the side lugs 26 are inserted into the gap between the inside of the side walls 22 and the upper part 10 (see FIG. 11b). When folding the foremost portion 23b of the side wall 23, the side flaps 26b formed thereon are inserted into recesses 230 formed on the upper edge of the side walls 22.

[0103] For forming the packaging structure 1, according to FIG. 11b the containers 2 are first inserted into the interior of the lower part 20 between the side walls 22 in the desired arrangement, with the front side walls 23, 23b still folded down or at least with the front side lugs 26b not yet inserted into the recesses 230. Alternatively, the containers 2 are first inserted into the box-shaped upper part 10 and then pushed into the interior of the lower part 20 by means of the upper part 10. Subsequently, the front side panels 23, 23b are folded in the manner described above and, finally, the front side lugs 26b are inserted into the recesses 230. Such a packaging structure 1 is shown in FIG. 11c. Here, the two front side walls 23b secure the upper part 10 in the lower part 20. Further, the upper ends of the containers are always covered by the bottom 11 of the upper part 10, so that impurities cannot intrude into the interior of the containers.

[0104] For opening the packaging structure 1, the above procedure is carried out in reverse sequence, i.e. the front side lugs 26b (see FIG. 11b) are first withdrawn from the recesses 230, then the front side walls 23, 23b are folded downward and finally the upper part 10 either together with the containers 2 is pushed out of the lower part 20 or the upper part 10 is removed and lifted upwards to release the containers 2 for further processing.

[0105] The upper part 10 is preferably formed as a thermal molding member of a plastic material.

[0106] FIGS. 11d and 11e show a further embodiment in which the lower part 20 comprises, in the manner of the lower part according to FIG. 3e, an upper cover having two openings 240, which enable a conditional engagement into the interior of the lower part 20. The front side walls 23 can be folded down. For securing the packaging structure, the front side walls 23 are folded upward after the insertion of the upper part 10 shown in FIG. 11e into the lower part 23 and thereby the side lugs 26 are inserted into the gap between the inner walls 22 of the lower part 20 (see FIG. 11d) and the side walls 12 of the upper part 10.

[0107] The openings 240 can be sealed by a plastic foil, in particular a gas-permeable plastic film, as described above, whereby a sterile packaging structure is formed.

[0108] Of course, the upper and lower part 10, 20 may also be arranged reversed for forming the packaging structure so that the containers 2 rest on the bottom 11 of the upper part 10 with their front ends upside down and that the upper part 10 is then inserted into the lower part 20. In the orientation shown in FIG. 11e, however, the underside of the upper part 10 may first be supplemented by an intermediate bottom (not shown), on which the containers 2 are supported at their lower ends, and on which the upper part 10 is then inserted into the lower part 10 in the orientation of FIG. 11e.

[0109] Referring to FIGS. 12a to 12d, in the following a packaging structure according to a further embodiment will be described. In this package structure, the lower part is formed by a plane base plate 70, whose circumferential edge 71 is formed elevated, whereby a central trough-shaped depression 72 for accommodating the box-shaped upper part 10 together with the containers (not shown) accommodated therein is formed. The height of the peripheral edge 71 corresponds to the thickness of the flange 15 of the upper part 10 or is larger than this thickness, so that the flange 15 can be accommodated completely in the recess 72 without protruding from the edge 71.

[0110] For sealing or sterile packaging of the structure formed by base plate 70 and upper part 10 a box-shaped hood 80 is used which has a bottom, a circumferential side wall 81 and a horizontal flange 83. The enlarged partial section in FIG. 12c shows an edge portion of this packaging structure before sealing. As shown, a bonding or adhesive strip 73 is formed circumferentially on the upper edge 71. As shown in FIG. 12d, the flange 83 of the hood 80 is connected to the upper edge 71 of the base plate 70 by means of the bonding strip or adhesive strip 73 by pressing down the upper part 10 into the trough-shaped receptacle 72 of the base plate 70. For bonding, a heat sealing may also be used, effected by a thermal treatment of the edge region of the assembly after placing the upper part 10 on the base plate 70 and putting on the hood 80. FIG. 12b shows the completed packaging structure.

[0111] FIG. 13 shows in a schematic flow diagram the steps of a method according to the present invention for forming and re-opening of a package structure.

[0112] First, in step S1, the plurality of containers is inserted into the upper or lower part of the packaging structure. This can be done by placing a plurality of containers on a flat surface and then pushing the containers into the upper or lower part, wherein the side walls thereof can serve as guiding devices for guiding the containers automatically to the desired arrangement. A closest packing can be achieved automatically, for example, during insertion of the containers by means of a pusher or the like. Alternatively, the containers can be arranged in a box-shaped upper or lower part, for example by putting on the upper or lower part, wherein the side walls of the upper or lower part serve as guiding devices for the containers to define the arrangement of the containers therein. Alternatively, the containers can be inserted into the upper or lower part of the packaging structure in principle also by means of any transport device, particularly by means of gripping arms or belt conveyors.

[0113] For insertion of the containers, the upper or lower part can be used, into which the containers are first inserted. The containers and/or the upper or lower part accommodating the latter can also be inserted by means of a pusher or the like. For this purpose, it may be of advantage if a gap remains in the packaging structure between the upper and lower part or an intermediate part, which is the case for example in the packaging structure according to FIG. 5b, because a pusher or the like can pass through this gap to mechanically operate directly on the containers.

[0114] Subsequently, in step S3, the sealing of the packaging structure is performed. For this purpose, the upper or lower part with the containers accommodated therein can be pushed into the corresponding lower or upper part. Or the upper part is simply placed on the lower part with the containers accommodated therein and is possibly further connected to the lower part, for example by inserting tabs provided on the top or bottom into corresponding apertures or recesses provided at the lower or upper part. A processing of the containers in an intermediate step S2 may be performed before this step, while these are accommodated in the upper or lower part of the packaging structure, e.g. a heat treatment, sterilization or filling of the containers with a substance.

[0115] Finally, the packaging structure can be sealed in step S4 in order to complete the packaging structure, for example by insertion into a tube or into sealable bag of a suitable sterile plastic material, or by placing on and connecting a hood, as described above with reference to FIGS. 12a to 12d.

[0116] The opening of the packaging structure in step S5 and a further processing of the containers in step S6 may follow as a further method steps. These steps can be carried out at purchaser of the packaging structure, for example at a producer of pharmaceuticals.

[0117] In this method, there is no need to turn the containers, contrary to the prior art, but these can be transported and further processed in the same orientation.

[0118] Furthermore, preferably the containers can be pushed out of the packaging structure free of particles. Free of particles in the sense of the present application means in particular that no foreign particles of a diameter greater than 20 microns remain in the container.

Preferred Materials and Methods of Manufacturing

[0119] As elastic inserts, partition walls or side walls for biasing the containers against each other or for elastically clamping the containers in the packaging structure as described above, preferably elastic or compressible foamed plastic materials are used, in particular thermoplastic foams (e.g. PS-E PP-E and PVC-E), elastomeric foams (e.g. soft PUR foam, NBR) or thermosetting foams (e.g. rigid PUR foam, PF).

[0120] The plastic foams can be produced particularly by foam extrusion, a molding process, by a thermoplastic foam molding process (TSG) or, when using PUR foams, also by continuous belt foaming, discontinuous RSG (reaction foam molding), RIM (reaction injection molding) or low-pressure processes and high-pressure processes or RRIM (Reinforced Reaction Injection Molding).

[0121] In any case, the upper or lower part that accommodates the containers in a clamped state is formed at least in sections of a thermoplastic, thermosetting or elastomeric plastic material, which has a certain elasticity. More preferably, the material Akylux is considered for use, which consists of polypropylene with twin-walled sheets. Akylux is durable and reusable, mold resistant and moisture resistant, suitable for hygienic applications, because no fiber formation occurs at the surface, shock-absorbing, sufficiently rigid, chemically inert, non-toxic (the raw material as well as most colors are food-safe), 100% recyclable, printable (for example, by screen printing or flexo printing), resistant against gamma rays (tested with a load of 25 kGy), allows a sterilization process with ethylene oxide (gas), allows a thermal treatment (e.g. for 72 hours between 50 C. and 60 C. depending on the conditions of use), has a sufficiently high softening point (Vicat: 145 C. at 10N (ISO R 306)) and a sufficiently high melting point (160 C.-165 C. (DSC)).

[0122] The bottom particularly of the lower part or of the planar support surface used, on which the containers are temporarily disposed, may be coated with a sliding layer to facilitate the above-insertion of the upper part with the containers accommodated therein into the lower part, as described above. The sliding layer may consist of a polymer and a layer of a bonding agent. The sliding layer should preferably consist at least of a mixture of an aromatic silane and an aliphatic silane. Other suitable materials for the lower part are, for example, polyamide or polyoxymethylene (POM).

[0123] As will become apparent to the person skilled in the art upon reading the foregoing description, various changes and modifications can be made without departing from the general spirit and scope of the present invention as defined in the appended claims. It is therefore intended that such changes and modifications shall be covered by the scope of protection of the present invention.

LIST OF REFERENCE NUMBERS

[0124] 1 packaging structure [0125] 2 containers [0126] 3 bottom [0127] 4 side wall [0128] 5 neck/constricted neck portion [0129] 6 upper edge [0130] 7 filling opening [0131] 9 sleeve or plastic bag [0132] 10 upper part [0133] 100 lower clamping web [0134] 101 side wall of the lateral extension [0135] 102 upper surface of lateral extension [0136] 103 upper clamping web [0137] 104 connecting web [0138] 105 folding line [0139] 109 sealing member [0140] 11 bottom [0141] 11a grid structure [0142] 12 side wall [0143] 13 front side wall [0144] 14 recess/opening [0145] 15 flange [0146] 16 latching recess [0147] 17 guiding groove [0148] 20 lower part [0149] 200 clamping web [0150] 201 stop [0151] 202 recess [0152] 203 protrusion [0153] 204 lateral extension [0154] 205 lateral clamping and guiding track [0155] 209 region with perforations [0156] 21 bottom [0157] 22 side wall [0158] 22a perforation [0159] 22b doubled side wall [0160] 23 front side wall or rear wall [0161] 23b doubled front side wall [0162] 230 recess/opening [0163] 24 upper cover [0164] 240 opening [0165] 25 insertion opening [0166] 26 front side lug [0167] 26a additional side lug [0168] 27 recess [0169] 28 protrusion [0170] 29 sealing member [0171] 30 rear wall [0172] 31 rear side lug [0173] 32 recess [0174] 33 protrusion [0175] 34a-34f folding lines [0176] 35 lug [0177] 37 elastic insert or pusher [0178] 38 blind hole, bore [0179] 39 displacement device [0180] 40 intermediate part [0181] 41 bottom [0182] 42 side wall [0183] 43 front wall [0184] 50 accommodating jig [0185] 51 flat surface [0186] 52 side wall [0187] 53 rear wall [0188] 60 side wall of spacer [0189] 61 rear wall of spacer [0190] 62 displacement device [0191] 70 base plate [0192] 71 elevated edge of base plate [0193] 72 receptacle in base plate [0194] 73 adhesive edge or heat sealing edge [0195] 80 sterile hood [0196] 81 side wall of hood [0197] 82 front side wall of hood [0198] 83 flange/circumferential edge