Recyclable blister pack and process of making

Abstract

A recyclable blister pack system is provided, including a substrate having a dry tack cohesive adhesive layer deposited on one of its surfaces and a blister layer for receiving a product. The properties of the dry tack cohesive are selected so the blister layer is separable from the substrate without leaving substantial substrate residue on the blister layer. This improves the recyclability of the blister layer.

1 . A method for making a multi-piece package comprising:
 providing a planar fibrous substrate including:
 an unprinted surface; 
 a first region; 
 a second region; 
 a line dividing the fibrous substrate into the first region and the second region and configured to facilitate folding along the line; and 
 an opening passing through the second region; 
   applying an aqueous coadhesive to opposing sections of the unprinted surface of the first region and the second region;   drying the aqueous coadhesive to form a dry-tack coadhesive layer located on the opposing sections of the unprinted surface of the first region and the second region;   providing a blister layer configured accept a product;   positioning the blister layer between the first and second regions of the substrate such that a portion of the blister layer extends through the opening;   folding the substrate along the line bringing the opposing sections of the dry-tack coadhesive layer into contact with each other; and   applying pressure to adhere the opposing sections of the dry-tack coadhesive layer to each other to capture the blister layer within the substrate.   
     
     
         2 . The method of  claim 1  wherein the aqueous coadhesive is a latex rubber coadhesive. 
     
     
         3 . The method of  claim 1  wherein applying the aqueous coadhesive comprises:
 dispensing the aqueous coadhesive onto the unprinted surface of the substrate; and 
 spreading the dispensed aqueous coadhesive uniformly via a roller. 
 
     
     
         4 . The method of  claim 3  wherein the spreading step includes linearly moving the substrate between the roller and an opposing second roller. 
     
     
         5 . The method of  claim 3  wherein the drying step follows the applying step. 
     
     
         6 . The method of  claim 1  further comprising storing the substrate, after the drying step, in an area maintained between 40-100 degrees Fahrenheit. 
     
     
         7 . The method of  claim 1  wherein the applying step occurs at a first location and the folding step and the applying pressure step occur a second location different from the first location. 
     
     
         8 . The method of  claim 7  further comprising shipping the substrate to the second location after the drying step and before the folding step. 
     
     
         9 . The method of  claim 1  wherein the blister layer includes a peripheral section, wherein the peripheral section of the blister layer is located between opposing sections of the dry-tack coadhesive layer following folding, wherein the dry-tack coadhesive only adheres to itself and does not adhere to the blister layer, wherein the blister layer is made of recycled polyethylene terephthalate. 
     
     
         10 . The method of  claim 1  further comprising scoring the substrate to form the line configured to facilitate folding. 
     
     
         11 . The method of  claim 1  wherein the substrate is at least one of a corrugated material and a chipboard material. 
     
     
         12 . The method of  claim 1  wherein the substrate includes a printed surface opposite the unprinted surface. 
     
     
         13 . A process for making a multi-piece package comprising:
 providing a planar fibrous substrate comprising:
 an unprinted surface; 
 a printed surface opposite the unprinted surface; 
 a first region; 
 a second region; 
 a line configured to facilitate folding, the line dividing the fibrous substrate into the first region and the second region; 
   applying an aqueous coadhesive to opposing sections of the unprinted surface of the first region and the second region; and   drying the aqueous coadhesive located on the unprinted surface of the substrate to form a dry-tack coadhesive layer.   
     
     
         14 . The method of  claim 13  wherein the aqueous coadhesive is a latex rubber coadhesive. 
     
     
         15 . The method of  claim 13  wherein the drying step is at least one of air-drying and heat-drying. 
     
     
         16 . The method of  claim 13  wherein applying the aqueous coadhesive comprises:
 dispensing the aqueous coadhesive onto the unprinted surface of the substrate; and 
 spreading the dispensed aqueous coadhesive uniformly by linearly moving the substrate between a first roller and an opposing second roller. 
 
     
     
         17 . The method of  claim 13  further comprising scoring the substrate to form the line configured to facilitate folding. 
     
     
         18 . The method of  claim 13  wherein the applying step occurs at a first location and further comprising shipping the substrate after the drying step to a second location different from the first location. 
     
     
         19 . The method of  claim 13  further comprising storing the substrate, after the drying step, in an area maintained between 40-100 degrees Fahrenheit. 
     
     
         20 . A process for making a multi-piece package comprising:
 providing a planar fibrous substrate comprising:
 an unprinted surface; 
 a printed surface opposite the unprinted surface; 
 a first region; 
 a second region; 
 a centerline dividing the fibrous substrate into the first region and the second region, the centerline configured to facilitate folding of the planar fibrous substrate along the centerline; 
   dispensing an aqueous latex coadhesive onto opposing sections of the unprinted surface of the first region and the second region while; and   spreading the dispensed aqueous coadhesive uniformly by linearly moving the substrate between a first roller and an opposing second roller;   drying the aqueous coadhesive located on the unprinted surface of the substrate to form a dry-tack coadhesive layer; and   storing the substrate, after the drying step, in an area maintained between 40-100 degrees Fahrenheit.