Child-resistant blister package

Abstract

An improved child-resistant blister package is provided in which the lidding component includes a tear-resistant nonwoven layer and a barrier layer. The nonwoven layer can be a melt-spun continuous filament nonwoven web or a flash spun plexifilamentary sheet. The lidding component used in peel off-push through blister packages of the invention contains fewer layers and has improved puncture resistance compared to lidding components used in child-resistant packages known in the art. In addition, in peel off-push through and peel-open package designs of the present invention, the lidding peels more cleanly from the blister component compared to packages known in the art which have a tendency to tear during peeling.

1 . A blister package comprising a blister component having an inner surface and an outer surface and a multi-layer lidding component having an inner surface and an outer surface, wherein selected portions of the inner surfaces of the blister and lidding components are adhered together to form at least one cavity therebetween, the blister component comprising a first barrier layer selected from the group consisting of polymeric films, coated polymeric films, metal foils, and film-foil laminates, and the lidding component comprising a second barrier layer and a nonwoven layer comprising at least one melt-spun continuous filament nonwoven sheet.  
   
   
       2 . A blister package according to  claim 1  wherein the second barrier layer comprises a sheet layer selected from the group consisting of polymeric films, coated polymeric films, metalized polymeric films, and metal foils.  
   
   
       3 . A blister package according to  claim 2  wherein the lidding component further comprises an adhesive tie layer intermediate the second barrier layer and the nonwoven layer, and a heat-seal layer adhered to the side of the second barrier layer opposite the adhesive tie layer, such that the inner surface of the lidding component comprises the heat-seal layer and the outer surface of the lidding component comprises the nonwoven layer, and wherein the lidding and blister components are heat sealed to each other to form a seal therebetween.  
   
   
       4 . A blister package according to  claim 3  wherein the heat-seal layer comprises a heat-sealable sealant selected from the group consisting of poly(vinylidene chloride), vinyl/acrylic compositions, blends of polyolefin resins comprising ethylene vinyl acetate copolymers, blends of polyolefin resins comprising ethylene methyl acrylate copolymers, and polyester-based compositions.  
   
   
       5 . A blister package according to  claim 3  wherein the tie-layer comprises an adhesive composition selected from the group consisting of vinyl/acrylic compositions, blends of polyolefin resins comprising ethylene vinyl acetate copolymers, blends of polyolefin resins comprising ethylene methyl acrylate copolymers, ethylene vinyl acetate resins, ethylene methyl acrylate resins, and polyester-based polyurethanes.  
   
   
       6 . A blister package according to  claim 3  wherein the seal between the heat-seal layer and the blister component is peelable such that the blister package can be opened by peeling the lidding component from the blister component.  
   
   
       7 . A blister package according to  claim 6  wherein the heat-seal layer comprises a sealant selected from the group consisting of poly(vinylidene chloride), vinyl/acrylic compositions, blends of polyolefin resins comprising ethylene vinyl acetate copolymers, and blends of polyolefin resins comprising ethylene methyl acrylate copolymers.  
   
   
       8 . A blister package according to  claim 3  wherein the second barrier layer is frangible.  
   
   
       9 . A blister package according to  claim 8  wherein the adhesive tie layer is a peelable layer such that the combined nonwoven and adhesive tie layers can be peeled away from the second barrier layer and a material packaged in the blister package can be removed from the package after said peeling by pushing the packaged material through the frangible barrier layer.  
   
   
       10 . A blister package according to  claim 9  wherein the adhesive tie layer comprises an adhesive composition selected from the group consisting of vinyl/acrylic compositions, blends of polyolefin resins comprising ethylene vinyl acetate copolymers, and blends of polyolefin resins comprising ethylene methyl acrylate copolymers.  
   
   
       11 . A blister package according to  claim 9  wherein the second barrier layer comprises a frangible sheet layer selected from the group consisting of frangible polymeric films and frangible metal foils.  
   
   
       12 . A blister package according to  claim 3  wherein the second barrier layer comprises a metalized polymeric film that is metalized on one side thereof, and wherein the metalized side of the second barrier layer is adjacent the adhesive tie layer.  
   
   
       13 . A blister package according to  claim 3  wherein the second barrier layer comprises a polymeric film that is coated on one side thereof with a ceramic material, and wherein the coated side of the second barrier layer is adjacent the adhesive tie layer.  
   
   
       14 . A blister package according to  claim 12  wherein the metalized polymeric film comprises a metalized polyester film.  
   
   
       15 . A blister package according to  claim 14  wherein the metalized polyester film is a poly(ethylene terephthalate) film having a layer of aluminum metal deposited thereon.  
   
   
       16 . A blister package according to claims  1 ,  9  or  14  wherein the nonwoven layer comprises a full-surface bonded multiple component spunbond web.  
   
   
       17 . A blister package according to  claim 13  wherein the ceramic material is selected from the group consisting of oxides, nitrides, and carbides of silicon, aluminum, magnesium, chromium, lanthanum, titanium, boron, or zirconium, and mixtures thereof.  
   
   
       18 . A blister package according to claims  1  or  2  wherein the nonwoven layer comprises at least one meltblown web sandwiched between first and second melt-spun continuous filament nonwoven sheets.  
   
   
       19 . A blister package according to  claim 18  wherein the first and second melt-spun continuous filament nonwoven sheets are multiple component spunbond nonwoven webs.  
   
   
       20 . A blister package according to  claim 19  wherein the at least one meltblown web is a multiple component meltblown web.  
   
   
       21 . A blister package according to  claim 20  wherein the first and second spunbond nonwoven webs comprise bicomponent sheath-core spunbond fibers wherein the melting point of the sheath component is lower than the melting point of the core component by at least 10° C., and the at least one meltblown web comprises bicomponent side-by-side meltblown fibers.  
   
   
       22 . A blister package according to  claim 18  wherein the nonwoven layer comprises a plurality of meltblown webs sandwiched between the first and second melt-spun continuous filament nonwoven sheets.  
   
   
       23 . A blister package according to  claim 19  wherein the nonwoven layer is a thermally calendered nonwoven layer.  
   
   
       24 . A blister package according to  claim 23  wherein the nonwoven layer is a full-surface bonded nonwoven layer.  
   
   
       25 . A blister package according to  claim 24  wherein the first and second multiple component spunbond nonwoven webs comprise sheath-core spunbond fibers wherein the core component comprises a polyester and the sheath component comprises a polyester copolymer.  
   
   
       26 . A blister package according to claims  1  or  2  wherein the at least one melt-spun continuous filament nonwoven sheet comprises a spunbond nonwoven web.  
   
   
       27 . A blister package according to  claim 26  wherein the spunbond nonwoven web is a multiple component spunbond nonwoven web.  
   
   
       28 . A blister package according to  claim 27  wherein the multiple component spunbond nonwoven web comprises bicomponent spunbond fibers comprising a sheath component and a core component, wherein the melting point of the sheath component is lower than the melting point of the core component by at least 10° C.  
   
   
       29 . A blister package according to  claim 28  wherein the core component comprises a polyester and the sheath component comprises a polyester copolymer.  
   
   
       30 . A blister package according to  claim 29  wherein the core component comprises poly(ethylene terephthalate) and the polyester copolymer is selected from the group consisting of poly(ethylene terephthalate) copolymers that have been modified with 1,4-cyclohexanedimethanol and poly(ethylene terephthalate) copolymers that have been modified with di-methyl isophthalic acid.  
   
   
       31 . A blister package according to any of claims  27 - 30  wherein the multiple component spunbond nonwoven web is a thermally calendered multiple component spunbond nonwoven web.  
   
   
       32 . A blister package according to  claim 31  wherein the thermally calendered multiple component spunbond nonwoven web is a full-surface bonded spunbond nonwoven web.  
   
   
       33 . A blister package according to  claim 1  wherein the second barrier layer is a heat-sealable barrier layer adhered to the nonwoven layer, the inner surface of the lidding component comprises the heat-sealable barrier layer, and the lidding and blister components are heat sealed together to form a seal therebetween.  
   
   
       34 . A blister package according to  claim 33  wherein the seal is a peelable seal such that the blister package can be opened by peeling the lidding component from the blister component.  
   
   
       35 . A blister package according to  claim 33  where in the seal is a non-peelable seal and the blister package further comprises at least one notch located internal to the package or on an external edge of the package.  
   
   
       36 . A blister package according to  claim 34  or  35  wherein the heat-sealable barrier layer comprises poly(vinylidene chloride).  
   
   
       37 . A blister package according to  claim 34  or  35  wherein the at least one melt-spun continuous filament nonwoven sheet comprises a full-surface bonded multiple component spunbond nonwoven web.  
   
   
       38 . A blister package comprising a blister component having an inner surface and an outer surface and a multi-layer lidding component having an inner surface and an outer surface, wherein selected portions of the inner surfaces of the blister and lidding components are bonded together to form at least one cavity therebetween, the blister component comprising a first barrier layer selected from the group consisting of polymeric films, coated polymeric films, metal foils, and film-foil laminates, and the lidding component comprising a flash spun plexifilamentary sheet and a second barrier layer comprising a sheet layer selected from the group consisting of polymeric films, coated polymeric films, and metalized polymeric films.  
   
   
       39 . A blister package according to  claim 38  wherein the lidding component further comprises an adhesive tie layer intermediate the second barrier layer and the flash spun plexifilamentary sheet, and a heat-seal layer adhered to the side of the second barrier layer opposite the adhesive tie layer, such that the inner surface of the lidding component comprises the heat-seal layer and the outer surface of the lidding component comprises the flash spun plexifilamentary sheet, and wherein the lidding and blister components are heat sealed to each other to form a seal therebetween.  
   
   
       40 . A blister package according to  claim 39  wherein the heat-seal layer comprises a heat-sealable sealant selected from the group consisting of poly(vinylidene chloride), vinyl/acrylic compositions, blends of polyolefins comprising ethylene vinyl acetate copolymers, blends of polyolefin resins comprising ethylene methyl acrylate copolymers, and polyester-based compositions.  
   
   
       41 . A blister package according to  claim 39  wherein the tie-layer comprises an adhesive composition selected from the group consisting of vinyl/acrylic compositions, blends of polyolefin resins comprising ethylene vinyl acetate copolymers, blends of polyolefin resins comprising ethylene methyl acrylate copolymers, modified ethylene vinyl acetate resins, ethylene vinyl acetate resins, ethylene methyl acrylate resins, and polyester-based polyurethanes.  
   
   
       42 . A blister package according to  claim 39  wherein the seal between the heat-seal layer and the blister component is peelable such that the blister package can be opened by peeling the lidding component from the blister component.  
   
   
       43 . A blister package according to  claim 41  wherein the heat-seal layer comprises a heat-sealable sealant selected from the group consisting of poly(vinylidene chloride), vinyl/acrylic compositions, blends of polyolefin resins comprising ethylene vinyl acetate copolymers, and blends of polyolefin resins comprising ethylene methyl acrylate copolymers.  
   
   
       44 . A blister package according to  claim 39  wherein the second barrier layer is frangible.  
   
   
       45 . A blister package according to  claim 44  wherein the adhesive tie layer is a peelable layer such that the combined flash spun plexifilamentary sheet and adhesive tie layer can be peeled away from the second barrier layer and a material packaged in the blister package can be removed from the package after said peeling by pushing the packaged material through the frangible barrier layer.  
   
   
       46 . A blister package according to  claim 45  wherein the adhesive tie layer comprises an adhesive composition selected from the group consisting of vinyl/acrylic compositions, blends of polyolefin resins comprising ethylene vinyl acetate copolymers, and blends of polyolefin resins comprising ethylene methyl acrylate copolymers.  
   
   
       47 . A blister package according to  claim 45  wherein the second barrier layer comprises a metalized polymeric film that is metalized on one side thereof, and wherein the metalized side of the second barrier layer is adjacent the adhesive tie layer.  
   
   
       48 . A blister package according to  claim 45  wherein the second barrier layer comprises a polymeric film that is coated on one side thereof with a ceramic material, and wherein the coated side of the second barrier layer is adjacent the adhesive tie layer.  
   
   
       49 . A blister package according to  claim 47  wherein the metalized polymeric film comprises a metalized biaxially-oriented film.  
   
   
       50 . A blister package according to  claim 38  wherein the second barrier layer is heat sealable and is adhered to the flash spun plexifilamentary sheet, the inner surface of the lidding component comprises the heat-sealable barrier layer, and the lidding and blister components are heat sealed together to form a seal therebetween.  
   
   
       51 . A blister package according to  claim 50  wherein seal is a peelable seal such that the blister package can be opened by peeling the lidding component from the blister component.  
   
   
       52 . A blister package according to  claim 50  wherein the seal is a non-peelable seal and the blister package further comprises at least one notch located internal to the package or on an external edge of the package.  
   
   
       53 . A blister package according to  claim 51  or  52  wherein the heat-sealable barrier layer comprises poly(vinylidene chloride).  
   
   
       54 . A blister package according to  claim 38  or  39  wherein the flash spun plexifilamentary sheet is formed from at least one polymer selected from the group consisting of polyethylene, polypropylene, and poly(ethylene terephthalate).  
   
   
       55 . A blister package according to  claim 54  wherein the second barrier layer comprises a sheet layer selected from the group consisting of polyester films and polyester films having a coating of aluminum metal deposited on at least one side thereof.  
   
   
       56 . A blister package according to  claim 55  wherein the second barrier layer comprises a polyester film comprising poly(ethylene terephthalate).  
   
   
       57 . A blister package according to  claim 1  wherein the nonwoven layer has a Spencer Puncture measured according to ASTM D3420 with a {fraction (9/16)} inch diameter probe and a pendulum capacity of 5.4 Joules of at least 0.98 Joules, a tensile strength measured according to ASTM D5035 in both the machine direction and cross-direction of at least 35 N/cm, an elongation measured according to ASTM D5035 in both the machine direction and cross-direction of at least 15%, and an Elmendorf Tear measured according to ASTM D1424 in both the machine direction and the cross-direction of at least 0.33 N.  
   
   
       58 . A blister package according to  claim 57  wherein the nonwoven layer has a Spencer Puncture of at least 1.97 Joules, a tensile strength in both the machine and cross-direction of at least 43.8 N/cm, an elongation in both the machine direction and cross-direction of at least 20%, and an Elmendorf Tear of at least 0.89 N.  
   
   
       59 . A blister package according to  claim 57  or  58  wherein the nonwoven layer is a bicomponent spunbond web.