Systems and methods for forming blister packages with support members for pharmaceutical product packaging

Abstract

Systems and methods are provided for forming both backing and support members of a solid pharmaceutical product package as well as the blister portions for the packages. The disclosed solid pharmaceutical product packaging solutions utilize fewer machines and processing steps in order to form an overall solid pharmaceutical product package. In accordance with the preferred exemplary embodiments of the present invention, the manufacturing processing steps associated with the formation of the blister members in the clear plastic sheets is integrated in line with manufacturing of the backing material.

We claim:  
     
         1 . A method of forming a product package comprising steps of: 
 forming holes in first and second portions of support board;    applying a sheet of plastic material to the cover the holes formed in the first portion of the support board;    applying a temporary covering material to holes formed in the second portion of the support board; and further wherein all the steps occur in a continuous process    
     
     
         2 . The method of  claim 1 , wherein the support board is formed of cardboard.  
     
     
         3 . The method of  claim 1 , further comprising a step of forming cavity members in the sheet of plastic material covering the holes in the first portion of the support board in the same in-line manufacturing process.  
     
     
         4 . The method of  claim 1 , wherein the support board is formed of plastic.  
     
     
         5 . The method of  claim 1 , wherein the temporary cover material is formed of foil.  
     
     
         6 . An in-line manufacturing machine for forming a product package comprising: 
 means for forming holes in first and second portions of support board;    means for applying a sheet of plastic material to cover the holes formed in the first portion of the support board; and    means for applying a temporary covering material to holes formed in the second portion of the support board.    
     
     
         7 . The machine of  claim 6 , wherein the support board is formed of cardboard.  
     
     
         8 . The machine of  claim 6 , further comprising a means for forming cavity members in the sheet of plastic material covering the holes in the first portion of the support board in the same in-line machine.  
     
     
         9 . The machine of  claim 6 , wherein the support board is formed of plastic.  
     
     
         10 . The machine of  claim 6 , wherein the temporary cover material is formed of foil.  
     
     
         11 . A method of forming a product package comprising steps of: 
 forming holes in first a support board;    applying a sheet of plastic material to the cover the holes formed in the support board;    and further wherein all the steps occur in a continuous process.    
     
     
         12 . The method of  claim 1   1 , further comprising a step of forming blister cavities in the plastic material at the locations of the holes.  
     
     
         13 . The method of  claim 12 , further comprising a step of filling the blister cavities with a product.  
     
     
         14 . The method of  claim 13 , further comprising a step of applying a backing material to seal the cavities.  
     
     
         15 . The method of  claim 14 , wherein the backing material is a foil material.  
     
     
         16 . The method of  claim 14 , wherein the backing material is a foil material that is secured to a cardboard support with holes formed therein.  
     
     
         17 . The method of  claim 12 , wherein the step of forming the blister cavities is performed at a forming station that is separated from a manufacturing machine which performs any preceding manufacturing steps.