WATER-SOLUBLE PRODUCT PACKAGE AND PRODUCT

Abstract

A product package comprises a primary package formed within a secondary package. The primary package comprises an edible or non-edible, water-soluble film container. The secondary package comprises a blister-card having at least one blister defining a cavity, and a foil backing. In one embodiment, the film container comprises a first film layer portion and a second film layer portion. The first film layer portion is formed intimately within the cavity of the at least one blister of the blister-pack. The second film layer portion is formed adjacent to the first film layer portion to define a container cavity between the first and second film layer portions.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

The priority benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Nos. 60/985,857, filed Nov. 6, 2007, and 61/031,525, filed Feb. 26, 2008, is claimed.

FIELD OF THE INVENTION

The present invention relates to packages for products, and more particularly, to products provided in water-soluble packaging.

BACKGROUND

Blister packs are generally well-known for storing individual doses of medicine, or individual servings of gum, for example. Moreover, water-soluble films are generally known for packaging, waste source reduction, composite and sheet goods fabrication, and edible applications.

SUMMARY

One embodiment of the invention comprises a package for an edible or non-edible product. The package comprises a primary package formed within a secondary package. The primary package comprises an edible or non-edible, water-soluble film container. The secondary package comprises a blister-card having at least one blister defining a cavity, and a foil backing. In one embodiment, the film container comprises a first film layer portion and a second film layer portion. The first film layer portion is formed intimately within the cavity of the at least one blister of the blister-pack. The second film layer portion is formed adjacent to the first film layer portion to define a container cavity between the first and second film layer portions.

In one embodiment, the first film layer portion can be formed of a first edible or non-edible, water-soluble material, and the second film layer portion can be formed of a second edible or non-edible, water-soluble material that is different than the first water-soluble material. For example, the second water-soluble material can be harder, more inelastic, more brittle, and/or less ductile than the first water-soluble film.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one product package constructed in accordance with the principles of the present invention;

FIG. 2 is a cross-sectional side view of the product package of FIG. 1 taken through line II-II of FIG. 1;

FIG. 3 is a perspective view of one embodiment of a dose card of the product package of FIG. 1 including a pull-tab mechanism;

FIG. 4 is a perspective view of another embodiment of a dose card of the product package of FIG. 1 including a pull-string mechanism;

FIG. 5 is a cross-sectional side view of an alternative product package constructed in accordance with the present invention and taken through line II-II of FIG. 1;

FIG. 6 is a perspective view of an alternative product package constructed in accordance with the principles of the present invention; and

FIG. 7 is a cross-sectional side view of the product package of FIG. 6 taken through line VII-VII of FIG. 6.

DETAILED DESCRIPTION

FIG. 1 depicts one embodiment of a product package 100 constructed in accordance with the present invention. In general, the product package 100 is a blister-pack comprising a blister card 102 and a backing material 108 (shown in FIG. 2). The blister card 102 includes a base portion 103 and a plurality of blisters 104a-104f. The blisters 104a-104f are adapted to contain a product such as an ingestible product, for example, as will be described. The backing material 108 is adhered to the base portion 103 of the blister card 102 or a film layer disposed thereon and encloses the blisters 104a-104f. To retrieve the product from the blisters 104a-104f, a user must remove the backing material 108 either by breaking the backing material 108, or by some other means.

In the disclosed embodiment of FIG. 1, the blister card 102 includes a plurality of perforated seams 106a-106c. The seams 106a-106c are located on the base portion 103 and divide the blister card 102 into a plurality of individual dose cards 102a-102f. Each dose card 102a-102f carries one of the blisters 104a-104f, respectively. As illustrated, the dose cards 102a-102f, and therefore the blisters 104a-104f, are arranged in a matrix. In the disclosed embodiment of FIG. 1, the dose cards 102a-102f and blisters 104a-104f are arranged in a 2×3 matrix. The perforated seams 106a-106c enable a user to detach one or more of the dose cards 102a-102f from the remainder of the package 100 such that the user may carry them away in their pocket or purse, for example.

Referring to FIGS. 1 and 2, the blisters 104a-104f of the disclosed embodiment of the blister card 102 generally comprise cylindrical containers. The blister card 102 includes a thin piece of material such as a plastic material having an external surface 105a and an internal surface 105b. The blister card 102 can be molded to define the plurality of blisters 104a-104f. In one embodiment, the blister card 102 can be constructed of polyethylene terephthalate (PET), polystyrene, a blend of polystyrene, polypropylene, a biodegradable polymer such as polylactic acid, and combinations thereof. The blister card 102 can be constructed of any other material suitable for the intended purpose.

As illustrated in FIG. 2, the package 100 additionally includes a first film layer 110 and a second film layer 112 disposed between the blister card 102 and the backing material 108.

The first film layer 110 includes a first surface 115a and a second surface 115b. The first surface 115a of the first film layer 110 is shaped and configured to intimately correspond to the contours of the internal surface 105b of the blister card 102, and particularly, to the blisters 104a-104f. For example, in one embodiment, the first surface 115a of the first film layer 110 can be removably adhered to the internal surface 105b of the blister card 102. As illustrated, the first film layer 110 is generally uniform in thickness, and thus, the second surface 115b of the first film layer 110 is also shaped and configured to correspond to the internal surface 105b of the blister card 102. So configured, the second surface 115b of the first film layer 110 of the embodiment of the package 100 depicted in FIG. 2 defines a plurality of cavities 114a-114f, which correspond to the plurality of blisters 104a-104f, respectively. The cavities 114a-114f are accordingly cylindrical cavities.

In alternative embodiments, however, the first film layer 110 does not have to be uniform in thickness, and as such, the second surface 115b of the first film layer 110 is not required to correspond to the contours of the blister card 102. In such an embodiment, the cavities 114a-114f can be shaped other than cylindrical.

The second film layer 112 of the package 100 depicted in FIGS. 1 and 2 also includes a first surface 125a and a second surface 125b. As depicted in FIG. 2, the second film layer 112 of the disclosed embodiment is generally planar. The first surface 125a of the second film layer 112 is adhered to the second surface 115b of the first film layer 110 everywhere, except in the regions of the blisters 104a-104f, thereby enclosing the cavities 114a-114f defined by the first film layers 110a-110f. As such, the first surface 125a of the second film layer 112 is adhered to the second surface 115b of the first film layer 110 at a location adjacent to the base portion 103 of the blister card 102.

In one embodiment, the first and second film layers 110, 112 can be each constructed of an edible, water-soluble material. For example, the first and second film layers 110, 112 can include a base polymer which is a polysaccharide polymer, and one or more additives. The polysaccharide polymer can comprise one or more polymers including, but not limited to pullulan, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), and combinations thereof. Any other polysaccharide polymer can also be used.

Suitable optional film additives are known in the art, for providing various functionalities. The film composition and film can thus contain one or more auxiliary film agents and processing agents, such as, but not limited to, plasticizers, lubricants, release agents, fillers, extenders, antiblocking agents, detackifying agents, antifoams and other functional ingredients, in amounts suitable for their intended purpose.

Preferred optional additives include gelatin, lecithin, such as sunflower lecithin (commercially available as GIRALEC), sorbitol, glycerol, propylene glycol, polysorbate 80, sodium lauryl sulfate, and combinations thereof.

Additionally, in one embodiment, the first and second film layers 110, 112 can be constructed of identical materials having identical physical properties. In alternative embodiments, however, the first and second film layers 110, 112 can be constructed of similar or different materials composed, however, to have different physical properties. For example, in one embodiment, the second film layer 112 can be constructed of an edible, water-soluble material that exhibits one or more properties such as increased hardness, decreased elasticity, increased brittleness, and decreased ductility than the first film layer 110 or vice versa. Such differing compositions of the first and second film layers 110, 112 can lend to the functionality of the package. For example, in one embodiment where the first film layer 110 is constructed of a composition of edible, water-soluble material that is softer than the composition of the second film layer 112, the first film layer 110 can more readily dissolve when submersed in fluid such as water. The harder, more inelastic, more brittle, and/or less ductile second film layer 112, however, can more readily break through the backing material 108 upon a user pressing the opposing sides of the blisters 104a-104f.

The backing material 108, as depicted in FIG. 2, also includes a first surface 108a and a second surface 108b. The first surface 108a of the backing material 108 is adhered to the second surface 125b of the second film layer 112. In one embodiment, the backing material 108 comprises a foil backing material such as aluminum foil. In alternative embodiments, however, the backing material 108 can comprise a paper material coated or treated with a moisture-proof substance, a moisture-resistant substance, or any other suitable removable material.

As mentioned above, the package 100 includes a plurality of perforated seams 160a-106c. As depicted in FIG. 2, the perforated seams 106a-106c extend through the base portion 103 of the blister card 102, through the first film layer 110, through the second film layer 112, and through the backing material 108. So configured, the first and second film layers 110, 112 define a plurality of primary packages 116a-116f (primary packages 116d-116f are shown in FIG. 2) that are bounded between the perforated seams 106a-106c and the various edges of the blister card 102.

The primary packages 116a-116f are adapted to contain a product 118 within the cavities 114a-114f defined by the first film layers 110a-110f. In one embodiment, the primary packages 116a-116f can constitute edible, water-soluble containers. Further, the product 118 can include an edible product such as a powdered beverage mix, an oatmeal mix, a powdered soup mix, powdered vitamins, powdered medications, or any other product that may be added to an aqueous liquid, for example, for ingestion. In one preferred embodiment, the edible product is also water-soluble or at least includes a water-soluble component. The edible product preferably is in the form of a powder or a granulate, for ease of filling the cavities 114a-114f, although in other embodiments the product can be a similarly-shaped solid, aqueous or non-aqueous liquid.

During use, a user removes one of the primary packages 116 from the blister card 102 and then submerses the primary package 116 in a glass of water, for example. The first and second film layers 110, 112 dissolve in the water. Then, the product 118 dissolves or disperses in the water. In some cases, the user may have to stir the water to uniformly disperse or dissolve the product 118 prior to ingestion.

In one embodiment, as suggested above, the user merely pushes one of the blisters 104a-104f, opposite the backing material 108, to remove a primary package 116a-116f. The force applied by the user disengages any adhesion between the first surface 115a of the first film layer 110 from the internal surface 105b of the blister card 102, and forces the second film layer 112 to break the backing material 108. With the backing material 108 broken, the user can retrieve the primary package 116. In an alternative embodiment, the backing material 108 may include a pull-tab 120, as depicted in FIG. 3, for each of the dose cards 102a-102f. So configured, a user grasps the pull-tab 120 to remove the backing material 108 from the specific dose card 102a-102f to gain access to the primary package 116. In yet another alternative embodiment, the backing material 108 can be equipped with an embedded pull-string 122, as depicted in FIG. 4, for each of the dose cards 102a-102f. So configured, a user grasps the pull-string 122 and pulls. As the user pulls the pull-string 122, the pull-string 122 tears the backing material 108 along a circular path indicated by dashed lines in FIG. 4. Completely removing the pull-string 122 therefore removes the portion of the backing material 108 within the dashed line in FIG. 4 and enables the user to gain access to the primary package 116. This embodiment can be particularly useful in connection with the primary packages 116a-116f described in connection with FIG. 5.

While the embedded portion of the pull-string 122 has been depicted and described as including a circular pull-string, alternative embodiments can include a linear pull-string, or any other configuration pull-string. For example, in one embodiment, the embedded portions of the pull-strings can extend in a straight line across the centers of the blisters 104a-104f. So configured, pulling the pull-strings would tear the backing material 108 in a straight line across the centers of the respective blisters 104a-104f, thereby providing an opening in the form of a slit, for example, sufficient for the respective primary packages 116 to pass through, or at least begin passing through prior to further tearing the backing material 108.

Still referring to FIG. 2, the product package 100 can be manufactured by utilizing a vacuum thermo-forming process. In one embodiment, the process can include the use of a forming block, e.g., a die, for forming the blister card 102 and the first film layer 110 substantially simultaneously. The forming block can include a steel plate, for example, comprising a plurality of cylindrical recesses and a plurality of through-bores communicating with the cylindrical recesses. The cylindrical recesses would be shaped and configured to correspond to the plurality of blisters 104, which are ultimately formed in the blister card 102. In one embodiment, the through-bores would be connected to a suctioning source such as a vacuum for forming the product package 100, as will be described.

With the forming block so configured, a planar sheet of plastic material, which constitutes the material to be formed into the blister card 102, is positioned immediately adjacent the forming block over the plurality of recesses. Additionally, in one embodiment, a planar sheet of edible, water-soluble film, which constitutes the material to be formed into the first film layer 110, is positioned on top of the plastic material of the blister card 102.

The plastic material of the blister card 102 and the film layer of the first film layer 110 are then heated such that the first surface 115a of the first film layer 110 begins to melt and adheres to the internal surface 105b of the plastic material forming the blister card 102. With continued heating, the suctioning device is activated to create a vacuum in the plurality of recesses of the forming block. The vacuum works, i.e., draws, the plastic material into the recesses, thereby forming the plurality of blisters 104 in the blister card 102. Additionally, because the first film layer 110 is adhered to the blister card 102, the vacuum also draws the first film layer 110 into the recesses. Thus, the first surface 115a of the first film layer 110 forms intimately with the contours of the internal surface 105b of the blister card 102, as depicted in FIG. 2. At this point in the process, the first film layer 110 defines the cavities 114a-114f, and the suctioning device can be deactivated. The product 118 is then poured, placed, or otherwise filled into the cavities 114a-114f.

With the cavities 114a-114f filled with product 118, the second film layer 112 is positioned immediately adjacent the first film layer 110. With continued heating of the first and second film layers 110, 112, the second film layer 112 can begin to melt such that the first surface 125a of the second film layer 112 adheres to the second surface 115b of the first film layer 110. However, because the first film layer 110 forms to the contours of the blisters 104, the second film layers 112 only adheres to the first film layer 110 in the region of the base portion 103 of the blister card 102.

Next, with the second film layer 112 sealed over the first film layer 110, the backing material 108 is positioned adjacent the second surface 125b of the second film layer 112. With continued heating, the first surface 108a of the backing material 108 adheres to the second surface 125b of the second film layer 112. Finally, the perforated seams 106a-106c are cut, stamped, or otherwise provided in the product package 100 with an appropriate tool such as a toothed wheel, a press, or other suitable device.

FIG. 5 depicts an alternative embodiment of the product package 100 described above with reference to FIG. 1. The package 100 is substantially similar to the package 100 described above, and therefore, like components will be identified with like reference characters. For example, the package 100 includes a blister card 102 and a backing material 108. Identical to that described above, the blister card 102 includes a base portion 103 and a plurality of blisters 104a-104f. FIG. 5 illustrates a cross-section of the package 100 depicted in FIG. 1, taken through line V-V, and therefore only blisters 104d-104f are shown.

Additionally, as depicted, the package 100 depicted in FIG. 5 includes a plurality of first film layer portions 110a-110f and a plurality of second film layer portions 112a-112f. Each of the first and second film layer portions 110a-110f, 112a-112f correspond to one of the plurality of blisters 104a-104f. The first film layer portions 110a-110feach include first surfaces 115a and second surfaces 115b.

Each of the first film layer portions 110a-110f are disposed within a corresponding blister 104a-104f. The first surfaces 115a of the first film layer portions 110a-110f intimately correspond to the contours of the internal surface 105b of the blisters 104a-104f. So configured, each of the first film layer portions 110a-110f includes a top wall 117 and a cylindrical sidewall 119. In one embodiment, the first surfaces 115a of the first film layer portions 110a-110f can be removably adhered to the internal surface 105b of the blister card 102. In the disclosed embodiment, the first film layer portions 110a-110f are generally uniform in thickness, and thus, the second surfaces 115b of the first film layer portions 110a-110f are also shaped and configured to correspond to the internal surface 105b of the blister card 102. So configured, each of the second surfaces 115b of the first film layer portions 110a-110f of the embodiment of the package 100 depicted in FIG. 5 defines a cavity 114a-114f similar to the cavities 114a-114f described above with reference to FIG. 2.

In alternative embodiments, however, the first film layer portions 110a-110f do not have to be uniform in thickness, and as such, the second surfaces 115b are not required to correspond to the contours of the blister card 102 as discussed above.

Each of the second film layer portions 112a-112f of the embodiment of the package 100 depicted in FIG. 5 also include a first surface 125a and a second surface 125b. As depicted, the second film layer portions 112a-112f of the disclosed embodiment are generally planar. Perimeter regions of the first surfaces 125a of the second film layer portions 112a-112f are adhered to the sidewalls 119 of the first film layer portions 110a-110f. As such, the second film layer portions 112a-112f enclose the cavities 114a-114f defined by the first film layer portions 110a-110f, and in combination with the first film layer portions 110a-110f define a plurality of primary packages 116a-116f containing a product 118. The primary packages 116a-116f constitute edible, water-soluble containers.

Identical to that described above, the backing material 108 includes a first surface 108a and a second surface 108b. The first surface 108a of the backing material 108 is adhered to the internal surface 105b of the blister card 102 in the region of the base portion 103, as well as to the second surfaces 125b of the second film layer portions 112a-112f. So configured, the backing material 108 retains the plurality of primary packages 116a-116f within the blisters 104a-104f by enclosing the blisters 104a-104f.

Removing the primary packages 116 from the blister card 102 can be performed in any of the manners discussed above with respect to the embodiment depicted in FIGS. 2-4. Moreover, the blister card 102, the first and second film layer portions 110a-110f, 112a-112f, and the backing material 108 can be constructed of any of the materials discussed above.

Moreover, a method of manufacturing the product package 100 depicted in FIG. 5 can be similar to the process described above with reference to the package 100 depicted in FIG. 2, with the exception that two additional steps can be required. Specifically, as described above, a planar sheet of plastic material, which constitutes the blister card 102 and a first sheet of edible, water soluble film, portions of which ultimately constitute the first film layer portions 110a-110f, are positioned adjacent a forming block. The forming block includes a plurality of recesses and through-bores connected to a suctioning device. Once positioned, the blister card 102 and the first film layer 110 are heated and the suctioning device is activated to draw the materials into the recesses, thereby forming the blisters 104 and the cavities 114. Prior to filling the cavities 114 with the product 118, excess material outside of the blisters 104 must be removed from the first film layer 110 to define the plurality of first film layer portions 110a-110f, as depicted in FIG. 5. In one embodiment, the excess material can be removed via a stamping operation, for example, that includes a plurality of circular blades that cut the first sheet of film around the blisters 104 to define the plurality of first film layer portions 110a-110f. Once the first sheet of film is cut, the excess material can be removed and discarded, or recycled.

Next, the cavities 114a-114f are filled with the product 118 and a second sheet of edible, water-soluble film, portions of which will ultimately constitute the plurality of second film layer portions 112a-112f, is positioned onto the blister card 102, thereby sealing the cavities 114a-114f. The second sheet of film, at this point, would actually engage the internal surface 105b of the blister card 102 only in the region of the base portion 103. Additionally, due to the presence of heat, portions of the second sheet of film would sink into the cavities 114a-114f and into engagement with the sidewalls 119 of the first film layer portions 110a-110f, as depicted in FIG. 5. Continued heating causes the second sheet of film to adhere to the sidewalls 119 of the first film layer portions 110a-110f. Next, the excess material located outside of the blisters 104 must be removed from the second sheet of film to define the plurality of second film layer portions 112a-112f, as depicted in FIG. 5. The excess material can be removed via a stamping operation that includes a plurality of circular blades that cut the second sheet of film around the blisters 104. Once the second film layer portions 112a-112f are appropriately cut, the excess material can be removed and discarded, or recycled.

At this point, the first and second film layer portions 110a-110f, 112a-112f are completely formed into the primary packages 116a-116f. The internal surface 105b of the blister card 102 is exposed in the region of the base portion 103. So exposed, the backing material 108 is positioned adjacent to the internal surface 105b of the blister card 102 and the second surfaces 125b of the second film layer portions 112a-112f. With continued heating, the first surface 108a of the backing material 108 adheres to the second surfaces 125 of the second film layer portions 112a-112f and the base portion 103 of the blister card 102, as illustrated. Finally, the perforated seams 106a-106c (shown in FIG. 1) are cut, stamped, or otherwise provided in the product package 100 with an appropriate tool such as a toothed wheel, a press, or other suitable device.

FIGS. 6 and 7 depict an alternative embodiment of a product package 200 constructed in accordance with the present invention. The product package 200 is similar to the package 100 described above in that it includes a blister card 202 and a backing material 208. The blister card 202 includes a base portion 203 and a plurality of blisters 204a-204f. The blisters 204a-204f are adapted to contain a product such as an ingestible product, as will be described. In the disclosed embodiment, the backing material 208 is resealably adhered to the blister card 202 or a film layer disposed thereon, as will also be described.

The blister card 202 includes a plurality of perforated seams 206a-206c. The seams 206a-206c are located on the base portion 203 and divide the blister card 202 into a plurality of individual dose cards 202a-202f. Each dose card 202a-202f carries one of the blisters 204a-204f. As illustrated, the dose cards 202a-202f, and therefore the blisters 204a-204f, are arranged in a matrix. In the disclosed embodiment, the dose cards 202a-202f and blisters 204a-204f are arranged in a 2×3 matrix. The perforated seams 206a-206c enable a user to detach one or more of the dose cards 202a-202f from the remainder of the package 200 such that the user may carry them away in their pocket or purse, for example.

With continued reference to FIGS. 6 and 7, the blisters 204a-204f of the disclosed embodiment of the package 200 generally comprise elongated box-shaped blisters. The blister card 202 includes a thin piece of material such as a plastic material having an external surface 205a and an internal surface 205b. The blister card 202 can be molded to define the plurality of blisters 204a-204f and can be constructed of any of the materials described above in connection with the blister card 102 in FIGS. 1, 2, and 5.

Additionally, as illustrated in FIG. 7, the package 200 includes a first film layer 210 and a second film layer 212 disposed between the blister card 202 and the backing material 208.

The first film layer 210 includes a first surface 215a and a second surface 215b. The first surface 215a of the first film layer 210 is shaped and configured to intimately correspond to the contours of the internal surface 205b of the blister card 202, and particularly, to the blisters 204a-204f. For example, in one embodiment, the first surface 215a of the first film layer 210 can be removably adhered to the internal surface 205b of the blister card 202. As illustrated, the first film layer 210 is generally uniform in thickness, and thus, the second surface 215b of the first film layer 210 is also shaped and configured to correspond to the internal surface 205b of the blister card 202. So configured, the second surface 215b of the first film layer 210 of the embodiment of the package 200 depicted in FIG. 7 defines a plurality of cavities 214a-214f, which correspond to the plurality of blisters 204a-204f. The cavities 214a-214f are accordingly elongated box-shaped cavities.

In alternative embodiments, however, the first film layer 210 does not have to be uniform in thickness, and as such, the second surface 215b of the first film layer 210 is not required to correspond to the contours of the blister card 202. In such an embodiment, the cavities 214a-214f can be shaped other than elongated boxes.

The second film layer 212 of the package 200 depicted in FIGS. 6 and 7 also includes a first surface 225a and a second surface 225b. As depicted in FIG. 7, the second film layer 212 of the disclosed embodiment is generally planar. The first surface 225a of the second film layer 212 is adhered to the second surface 215b of the first film layer 210 everywhere, except in the regions of the blisters 204a-204f, thereby enclosing the cavities 214a-214f defined by the first film layers 210a-210f. As such, the first surface 225a of the second film layer 212 is adhered to the second surface 215b of the first film layer 210 at a location adjacent to the base portion 203 of the blister card 202. The first and second film layers 210, 212 can be constructed of any of the edible, water-soluble materials described above with reference to FIGS. 1-5.

In addition to the first and second edible, water-soluble film layers 210, 212, the package 200 depicted in FIGS. 6 and 7 also includes first and second edible, water-soluble barriers 207a-207f, 209a-209f disposed within each of the cavities 214a-214f. The first and second barriers 207a-207f, 209a-209f divide the cavities 214a-214f into three compartments 224a-224c. The compartments 224a-224c are adapted to store different ingredients 218a-218c of the product 218, for example, as will be described. In an alternative embodiment, the barriers 207, 209 can be part of the blister card 202.

The backing material 208, as depicted in FIG. 7, also includes a first surface 208a and a second surface 208b. Moreover, the backing material 208 of the present embodiment includes a first half 222a and a second half 222b. The first surface 208a of the backing material 208 is removable and resealably adhered to the second surface 225b of the second film layer 212. The backing material 208 can be constructed of any of the materials associated with the backing material 108 described above for the package 100 depicted in FIGS. 1-5.

As mentioned above, the package 200 includes a plurality of perforated seams 206a-206c. As depicted in FIG. 7, the perforated seams 206a-206c extend through the base portion 203 of the blister card 202, through the first film layer 210, and through the second film layer 212. The perforated seams 206a-206c can optionally perforate the backing material 208, but preferably do not in this embodiment. So configured, the first and second film layers 210, 212 define a plurality of primary packages 216a-216f (primary packages 216c and 216f are shown in FIG. 7) that are defined by the perforated seams 206a-206c and the various edges of the blister card 202. Moreover, each of the first and second halves 222a, 222b of the backing material 208 are independently removable from and resealable to the second film layer 212 such that a user can gain access to the blisters 204a-204f, as will be described.

The primary packages 216 are adapted to contain a product 218 within the cavities 214a-214f defined between the first film layer 210 and the second film layer 212. Moreover, as mentioned, the various compartments 224a-224c within the cavities 214a-214f are adapted to contain different ingredients 218a-218c of the product 218. For example, in one embodiment one ingredient 218a contained in one compartment 224a can constitute instant coffee crystals, another ingredient 218 contained in another compartment 224b can constitute powdered creamer, and the last ingredient 218c contained in the last compartment 224c can constitute a sweetener such as granulated sugar. So configured, a user can make a cup of coffee including cream and sugar by simply placing a single primary package 216a-216f into a cup of hot water.

During use, to retrieve a primary package 216a-216f from its respective blister 204a-204f, a user must peel one of the halves 222a, 222b of the backing material 208 from engagement with the second surface 225b of the second film layer 212. FIGS. 6 and 7 depicts the package 200 with the one half 222a peeled back. Once the half 222a, 222b of the backing material 208 is peeled back, the user can push on the desired blister 104a-104f to force a primary package 216a-216f out of the blister card 202. It should be appreciated that the first and second film layers 210, 212 would tear along the adjacent perforated seams 206a-206c as the user forces the primary package 216a-216f out of the blister card 202. Once removed from the blister card 202, the entire primary package 216a-216f can be submersed into a container of water, for example, to be dissolved prior to ingestion. The user can then return the half 222a of the backing material 208 into position engaging the remaining portions of the second surface 225b of the second film layer 212. In one embodiment, the second surface 225b of the second film layer 212 or the first surface 208a of the backing material 208 includes an adhesive that allows the backing material 208 to be removably and resealably attached to the second film layer 212.

A method of manufacturing the product package 200 depicted in FIGS. 6 and 7 can be generally similar to that described above with reference to the product package 100 depicted in FIG. 2. The entire process will therefore not be repeated. An additional manufacturing step, however, can include positioning the barriers 207, 209 in the cavities 214 prior to filling the cavities 214 with product 218. Moreover, additional manufacturing steps can include filling the different compartments 224a-224c of the cavities 114a-114f with the different ingredients 218a-218c.

It should be appreciated that positioning the plastic material that forms the blister cards 102, 202, the films that constitute the first and second film layers 110, 112, 210, 212, the films that constitute the first and second film layer portions 110a-110f, 112a-112f, and the backing material 108 relative to the forming block during manufacture of the packages 100, 200 can be accomplished manually or with one or more feeding machines.

In one embodiment, the feeding machines can be equipped with stock of the respective materials stored on rolls, for example. The materials could then be delivered to the forming block in the form of webs, which are cut from the remainder of the roll when appropriately positioned.

In another embodiment, the feeding machines can be equipped with sheets of the respective materials, stored in magazines, for example. So configured, the machines can deliver the sheets directly to the forming block, without having to cut the material.

While the first film layers 110, 210 and first film layer portions 110a-110f have been described herein as being adhered to the blister cards 102, 202 during the thermoforming process, in an alternative embodiment these materials can be adhered together prior to being placed adjacent the forming block. In one embodiment, the plastic material forming the blister cards 102, 202 and the sheet of edible, water-soluble film that ultimately forms the first film layer 110, or the first film layer portions 110a-110f, can be pre-formed as a composite material through a casting process, for example, or any other process.

Moreover, while the plastic material forming the blister cards 102, 202 and the sheet of edible, water-soluble film that ultimately forms the first film layer 110, 210, or the first film layer portions 110a-110f, have been described herein as being adhered together via a thermal adhesion process, in alternative embodiments, the materials could be adhered together with an edible, water-soluble adhesive, for example, that is applied to one or both of the materials prior to or during the manufacturing process. In another method, a water-soluble film can be adhered to a blister card, another water-soluble film, or a backing material simply by moistening one or more of the adjoining surfaces with a small amount of water, for example.

Additionally, while the first and second film layer portions 110a-110f, 112a-112f described above with reference to FIG. 5 have been described herein as being cut during the manufacturing process, in alternative embodiments, the first and second film layer portions 110a-110f, 112a-112f can be pre-cut and subsequently positioned adjacent to the blister card 102 for any necessary thermoforming and adhesion.

Further still, while the methods for manufacturing the product packages 100, 200 have been described herein as utilizing a forming block operatively connected to a suctioning device, in alternative embodiments, the blister cards 102, 202 and first film layers 110, 210 (or first film layer portions 110a-110f) can be worked into the recesses in the forming blocks by other means. For example, in one embodiment, the blister cards 102, 202 and first film layers 110, 210 (or first film layer portions 110a-110f) can be blown into the recesses, poured into the recesses, or otherwise. Moreover, while the methods of manufacture have been described as including a vacuum thermoforming process, the product packages 100, 200 can alternatively be formed via injection molding, casting, stamping, or any other suitable method.

Accordingly, one embodiment of a process for manufacturing a product package 100, 200 in accordance with the present invention can comprise the following steps (not necessarily in the disclosed order and including more or less steps as appropriate): (1) positing a plastic sheet of material adjacent to a forming block having a plurality of recesses; (2) positioning a first sheet of edible, water-soluble film adjacent to the plastic sheet of material at a location opposite the plastic sheet of film from the forming block; (3) working the plastic sheet of material into the recesses of the forming block to form a plurality of blisters; (4) working the first sheet of edible, water-soluble film into the recesses of the forming block such that the first sheet of edible, water-soluble film intimately engages and corresponds to the contours of the blisters to define a plurality of cavities within the blisters; (5) filling the cavities with a product; (6) positioning a second sheet of edible, water-soluble film adjacent to the first sheet of edible, water-soluble film at a location opposite the first sheet of plastic material; and (7) adhering at least portions of the first and second sheets of edible, water-soluble film together to seal the product in the cavities.

In light of the foregoing, it should be appreciated that the product packages 100, 200 including the primary packages 116, 216 provide for a robust edible, water-soluble packaging. Particularly, because the primary packages 116, 216 are constructed and stored in intimate relationship with the blisters 104, 204, the primary packages 116, 216 do not vibrate within the blisters 104, 204 under the physical stresses involved with transportation and handling. For example, conventional water-soluble packaging can be vulnerable to film dehydration, plasticizer loss, and the concomitant risk of a phenomenon known as “cold cracking” during low temperature transportation, wherein the package literally cracks, thereby compromising the quantity and quality of the product stored therein. Moreover, the individual storage prevents contamination of stored primary packages 116, 216 when a user retrieves one or more of the other primary packages 116, 216.

Further still, it should be appreciated that the disclosed polysaccharide polymer-based materials, which constitute the first and second film layers 110, 112, 210, 212 and first and second film layer portions 110a-110f, 112a-112f, can have very good oxygen barrier properties when dry. As such, the backing material 108 and blister card 102 can be constructed of simpler materials. For example, traditional backing material 108 can comprise a foil or metallized film material that provides moisture protection, physical protection, and oxygen protection. Utilizing the disclosed polysaccharide polymer-based materials therefore enables the use of a backing material 108 that does not have to provide for oxygen protection, for example. Thus, in one embodiment, one or both of the backing material 108 and blister card 102 will have poor or substandard oxygen barrier properties. For example, one or both of the backing material 108 and blister card 102 can have a permeability coefficient greater than or equal to 2 cm³·mil/100 in²/day·atm at 23° C., 75% RH, as measured according to ASTM D-1434. It is generally accepted that a fair/good barrier material would have a permeability coefficient an order of magnitude lower and that a good barrier material would have a permeability coefficient two orders of magnitude lower (eg., certain polyvinylidene chloride (PVDC) resins and ethylene vinyl alcohol (EVOH) resins at about 0.02 cm³·mil/100 in²/day·atm at 23° C., 75% RH).

Finally, while the first and second film layers 110, 112, 210, 212 and film layer portions 110a-110f, 112a-112f of the primary packages 116, 216 have been described herein as being constructed of edible, water-soluble films, alternative embodiments can be constructed of non-edible films, or combinations of edible and non-edible films. As such, the primary packages 116, 216 can contain non-edible products.

For example, the film layers 110, 112, 210, 212 and film layer portions 110a-110f, 112a-112f can be constructed of fully or partially hydrolyzed polyvinyl alcohol (PVOH) including PVOH copolymers, for example, saponified copolymers of vinyl acetate and methyl acrylate, vinyl acetate and itaconic acid, vinyl acetate and maleic acid, vinyl acetate and 2-acrylamido-2-propane-1-sulfonic acid, and combinations thereof. Further alternative embodiments of the films 110, 112, 210, 212 and/or film layers 110a-110f, 112a-112f can include one or more of the following: polyalkylene oxides, e.g., polyethylene oxide; polyvinyl pyrrolidone and vinyl pyrrolidone copolymers; polyacrylic acid, acrylic acid copolymers, and polyacrylates; polyacrylamide and acrylamide copolymers; water-soluble polyamides; water-soluble polyurethanes, and/or any other water-soluble material suitable for serving the principles described herein.

As mentioned, with such non-edible films, the product 118, 218 can comprise non-edible products. For example, the products 118, 218 can include personal care products such as shampoo, conditioner, hair styling gels, liquid or granular soaps/sanitizers, bath oils, and/or any other such product—especially in unit dose and travel-pack sizes, e.g., 1 g/1 ml to 20 g/20 ml. One advantage of using the blister pack concept described herein for such personal care products is that a user may retrieve one or more primary packages 116, 216 of the product 118, 218 without wetting the remaining, unused, primary packages 116, 216. For example, in an embodiment wherein the primary packages 116, 216 contain shampoo, a user may carry the entire blister pack 100, 200 into the shower and retrieve the desired amount of product. The remaining packages 116, 216, however, would remain dry and protected by the blister card 102, 202 and backing material 108, 208. Thus, the concept disclosed herein provides a convenient unit-dose dispensing system without raising the concern of a user with wet hands damaging the unused product. Alternatively, for non-edible products, the backing material 108, 208 can be optionally omitted, to reduce costs and/or packaging waste, for example.

In still other alternative embodiments, the non-edible product can include unit doses of solid formulated product (e.g., hygroscopic and adsorptive) including horticultural products, e.g., plant foods, potent low-dose pesticides such as larvicides and sulfonylurea herbicides, household products, e.g., low-dose usually eco-friendly formulations of automatic dishwasher and laundry detergent products, agricultural products, and/or any other product. With such solid formulated non-edible products, the water-soluble primary packaging 116, 216 advantageously reduces vibrations and helps prevent “cold cracking” in a manner similar to that described above with regard to the edible embodiments of the packages 116, 216.

Finally, any of the features and advantages described above with respect to the edible use embodiments equally apply to the non-edible use embodiments. That is, the non-edible use embodiments can be constructed in accordance with any of the details described herein, just as the edible use embodiments can be constructed in accordance with any of the details described herein.

It should be appreciated that the foregoing description merely provides examples and embodiments of the present invention and the present invention is not intended to be limited thereby. Rather, the present invention is intended to include subject matter falling within the spirit and scope of the description, as well as equivalents thereof, as would be understood by a person having ordinary skill in the art.

Claims

1. A package, comprising

a primary package formed within a secondary package, the primary package comprising a water-soluble film container and the secondary package comprising a blister card having at least one blister defining a cavity.

2. The package of claim 1, wherein the primary package is edible.

3. The package of claim 2, wherein the edible primary package comprises a polysaccharide polymer.

4. The package of claim 3, wherein the polysaccharide polymer is selected from the group consisting of pullulan, carboxymethyl-cellulose, hydroxypropylmethylcellulose, and combinations thereof.

5. The package of claim 3, wherein the primary package further comprises one or more additives selected from the group consisting of gelatin, sorbitol, glycerol, propylene glycol, lecithin, polysorbate 80, and sodium lauryl sulfate, and combinations thereof.

6. The package of claim 1, wherein the primary package is inedible.

7. The package of claim 6, wherein the inedible primary package comprises a material selected from the group consisting of polyvinyl alcohols, polyvinyl alcohol copolymers, polyalkylene oxides, polyacrylamides and acrylamide copolymers, water-soluble polyamides, water-soluble polyurethanes, and combinations thereof.

8. The package of claim 1, wherein at least a portion of the water-soluble film container is removably adhered to the blister.

9. The package of claim 1, wherein the water-soluble film container comprises a first water-soluble film layer and a second water-soluble film layer formed adjacent to the first water-soluble film layer to define a container cavity between the first and second water-soluble film layers.

10. The package of claim 9, wherein the first and second water-soluble film layers are formed only within the cavity of the at least one blister on the blister card.

11. The package of claim 9, wherein the first water-soluble film layer substantially conforms to a shape of the blister card.

12. The package of claim 9, further comprising a backing removably adhered to the second water-soluble film layer.

13. The package of claim 9, wherein the first water-soluble film layer is formed of a first water-soluble material and the second film layer is formed of a second water-soluble material, different from the first water-soluble material.

14. The package of claim 13, wherein the second water-soluble material comprises one or more properties including increased hardness, decreased elasticity, increased brittleness, and decreased ductility as compared to the first water-soluble material.

15. The package of claim 9, wherein the first and second water-soluble films comprise substantially the same material.

16. The package of claim 1, wherein the blister card is formed of a material selected from the group consisting of polyethylene terephthalate (PET), polystyrene, a blend of polystyrene, polypropylene, and polylactic acid.

17. The package of claim 1, wherein one or more of the blister card and the backing have a permeability coefficient greater than or equal to 2 cm3·mil/100 in2/day·atm, at 25° C., 75% RH.

18. The package of claim 12, wherein the backing is a foil backing or a paper backing coated with a moisture proof substance.

19. The package of claim 1, further comprising one or more water-soluble barriers disposed in the water-soluble film container and dividing the water-soluble film container into two or more volumes.

20. A method of making a packaged product, the method comprising:

disposing a blister card material on a forming block having at least one recess;

disposing a first water-soluble film on the blister card material, adjacent to a surface of the blister card material opposite the forming block;

working the blister card material into the at least one recess to form a blister having a blister cavity;

working the first water-soluble film into the blister cavity to form a cavity within the first water-soluble film;

filing the cavity formed by the first water-soluble film with a product; and

adhering a second water-soluble film to a portion of a surface of the first water-soluble film opposite the blister card material to seal the product in the cavity formed by the first water-soluble film.

21. The method of claim 20, further comprising adhering the first water-soluble film to the blister card material.

22. The method of claim 20, wherein the first and second water-soluble films comprise a polysaccharide polymer.

23. The method of claim 20, comprising working the first water-soluble film into the at least one recess such that a contour of the first water-soluble film substantially corresponds to a contour of the blister card material.

24. The method of claim 20, comprising simultaneously working the blister card material and the first water-soluble film into the at least one recess.

25. The method of claim 20, comprising working the blister card material and the first water-soluble film into the at least on recess using a process selected from the group consisting of suction, blowing the blister card material and first water-soluble film into the at least one recess, pouring the blister card material and first water-soluble film into the at least one recess, and combinations thereof.

26. The method of claim 20, further comprising:

removing a portion of the first water-soluble film disposed outside the blister cavity to form a first water-soluble film portion only within the blister cavity before filing the cavity formed by the first water-soluble film with the product; and

removing a portion of the second water-soluble film disposed outside the blister cavity to form a second water-soluble film portion only within the blister cavity.

27. The method of claim 20, further comprising adhering a backing to a surface of the second water-soluble film opposite the first water-soluble film.

28. The method of claim 27, comprising removably adhering the backing to the surface of the second water-soluble film opposite the first water-soluble film.

29. The method of claim 20, further comprising disposing one or more water-soluble barriers within the cavity formed by the first water-soluble film to divide the cavity into two or more cavity portions before filling the cavity with the product.

30. The method of claim 29, further comprising filling each of the two or more cavity portions with different products.

31. The method of claim 20, further comprising perforating seams in the package to define a unit dose comprising a blister.