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EP-4739502-A1 - MECHANICALLY STRENGTHENED MULTILAYER, MULTIBARRIER, DESICCANT INTERLACED COLD FORMABLE BLISTER LAMINATES, OPTIONALLY PVC-FREE

EP4739502A1EP 4739502 A1EP4739502 A1EP 4739502A1EP-4739502-A1

Abstract

The present disclosure relates to multilayer, multibarrier, cold formable blister laminate. The present disclosure further relates to a compact blister pack made by cold forming of the multilayer, multibarrier, cold formable blister laminate. The laminate of the present disclosure incorporates or interlace mechanical cum impact strength enhancing materials, desiccant materials or both mechanical cum impact strength enhancing and desiccant materials. The laminate of the present disclosure has enhanced deep draw formability as well as is capable of yielding cold formed blisters of compact size along with improved mechanical and impact strength for cavities with large dimensions without any rupture after forming and at the same time providing requisite ultra high barrier with use of desiccant interlacing when required, against adverse environmental impact. The laminate of the present disclosure can be used for packaging of various products having large dimensions and which are fragile as well as sensitive or highly sensitive to moisture, temperature, and light.

Inventors

  • Bhandari, Shreyans Mohan
  • BHANDARI, MOHAN HARAKCHAND
  • NAIK, PRAFUL RAMACHANDRA
  • Mukherjee, Somenath Sailen
  • BHARADIA, RAHUL GOPIKISAN
  • NEMMANIWAR, Suhas Udhavrao
  • UMARANI, Mahendra Mukund

Assignees

  • Bilcare Limited

Dates

Publication Date
20260513
Application Date
20240708

Claims (20)

  1. 1. A multilayer, multibarrier, cold formable blister laminate comprising: (a) at least one first polymer layer having thickness in the range of 10 microns to 300 microns; wherein said first polymer layer is selected from the group consisting of polyethylene (PE) layer, modified polyethylene (m-PE) layer, polypropylene (PP) layer, modified polypropylene (m-PP) layer, oriented polyamide (OP A) layer, modified oriented polyamide (m-OPA) layer, polyvinyl chloride (PVC) layer, modified polyvinyl chloride (m-PVC) layer, cyclic olefin co-polymer (COC) layer, and modified cyclic olefin copolymer (m-COC) layer; (b) at least one intermediate metal layer having thickness in the range of 10 microns to 200 microns having a first operative surface and a second operative surface; and (c) at least one second polymer layer having thickness in the range of 10 microns to 300 microns; wherein said second polymer layer is selected from the group consisting of polyethylene (o-PE) layer, modified polyethylene (m-PE) layer, polypropylene (o-PP) layer, modified polypropylene (m-PP) layer, oriented polyamide (OPA) layer, modified oriented polyamide (m-OPA) layer, polyvinyl chloride (PVC) layer, modified polyvinyl chloride (m-PVC) layer, cyclic olefin co-polymer (COC) layer, modified cyclic olefin copolymer (m-COC) layer, polyethylene terephthalate layer (PET), and modified polyethylene terephthalate (m-PET) layer; wherein said at least one first polymer layer is disposed on said first operative surface and said at least one second polymer layer is disposed on said second operative surface; and wherein the water vapour transmission rate (WVTR) of said laminate is in the range of 0.00009 gm/pkg/day to 0.02 gm/pkg/day at 40°C and 75% RH.
  2. 2. The laminate as claimed in claim 1, wherein said at least one first polymer layer, said at least one intermediate layer and said at least one second polymer layer are adhered to each other by a method selected from extrusion lamination and adhesive lamination.
  3. 3. The laminate as claimed in claim 2, wherein said adhesive lamination is performed by forming an adhesive layer on the layers selected from said first polymer layer, said intermediate metal layer and said second polymer layer, having thickness in the range of 1 gsm to 10 gsm; said adhesive layer is selected from the group consisting of polyester based adhesive layer, polyurethane based adhesive layer, and polyacrylic based adhesive layer.
  4. 4. The laminate as claimed in claim 1, wherein said intermediate metal layer comprises at least one metal selected from the group consisting of aluminum (Al), palladium (Pd), platinum (Pt), copper (Cu), nickel (Ni), gold (Au) and silver (Ag).
  5. 5. The laminate as claimed in claim 1, wherein said first polymer layer and/or said second polymer layer is a polyethylene layer, and said polyethylene layer being at least one selected from the group consisting of high density polyethylene (HDPE) polymer layer, medium density polyethylene polymer layer, low density polyethylene (LDPE) polymer layer, linear low-density polyethylene (LLDPE) polymer layer, linear polyethylene polymer layer, chlorinated polyethylene polymer layer, crosslinked polyethylene polymer layer, ultra-high molecular weight polyethylene (UHMWPE) polymer layer and polyethylene copolymer with styrene-butadiene layer.
  6. 6. The laminate as claimed in claim 1, wherein said first polymer layer and/or said second polymer layer is a modified polyethylene layer; said modified polyethylene layer being selected from a metal oxide coated polyethylene layer, a barrier polymer coated polyethylene layer, a metallized polyethylene layer, a metallocene modified polyethylene polymer layer and a desiccant modified polyethylene polymer layer; said modified polyethylene layer being obtained by a method selected from (a) coating a metal oxide on a polyethylene sheet to obtain said metal oxide coated polyethylene layer, wherein said metal oxide is selected from AlOx, SiOx, CuOx, NiOx, and CoOx; (b) coating a barrier polymer on a polyethylene sheet to obtain said barrier polymer coated polyethylene layer having thickness of said polymer coating is in the range of 1 gsm to 10 gsm; wherein said barrier polymer being selected from poly vinylidene chloride (PVdC), polyvinyl acetate (PVAc), polyvinyl alcohol (PVOH) and Heat seal lacquer (HSL); (c) depositing a metal on a polyethylene sheet to obtain said metallized polyethylene layer having an optical density in the range of 0.5 to 2.5; wherein said metal is selected from aluminum (Al), palladium (Pd), platinum (Pt), copper (Cu), nickel (Ni), gold (Au) and silver (Ag); (d) adding metallocene to a polyethylene polymer in an amount in the range of 1 mass% to 90 mass% followed by extruding or laminating to obtain said metallocene modified polyethylene polymer layer; and (e) adding desiccant to a polyethylene polymer in an amount in the range of 1 mass% to 70 mass% followed by extruding or laminating to obtain said desiccant modified polyethylene polymer layer; said desiccant being at least one selected from the group consisting of silica, calcium chloride, calcium carbonate, calcium oxide, magnesium oxide, magnesium chloride, sodium sulphate, dry aluminum chloride, aluminum oxide, molecular sieves, and activated charcoal.
  7. 7. The laminate as claimed in claim 1, wherein said first polymer layer and/or said second polymer layer is a polypropylene layer, said polypropylene layer being at least one selected from the group consisting of polypropylene homopolymer layer, polypropylene random copolymer layer and polypropylene impact copolymer layer.
  8. 8. The laminate as claimed in claim 1, wherein said first polymer layer and/or said second polymer layer is a modified polypropylene layer; said modified polypropylene layer being selected from a metal oxide coated polypropylene layer, a polymer coated polypropylene layer, a metallized polypropylene layer, a metallocene modified polypropylene polymer, and desiccant modified polypropylene polymer; said modified polypropylene layer being obtained by a method selected from (a) coating a metal oxide on a polypropylene sheet to obtain said metal oxide coated polypropylene layer, wherein said metal oxide is selected from AlOx, SiOx, CuOx, NiOx, and CoOx; (b) coating a barrier polymer on a polypropylene sheet to obtain said barrier polymer coated polypropylene layer having thickness of said polymer coating is in the range of 1 gsm to 10 gsm; wherein said barrier polymer is selected from poly vinylidene chloride (PVdC), polyvinyl acetate (PVAc) polyvinyl alcohol (PVOH) and heat seal lacquer (HSL); (c) depositing a metal on a polypropylene sheet to obtain said metallized polypropylene layer having an optical density in the range of 0.5 to 2.5; wherein said metal is selected from aluminum (Al), palladium (Pd), platinum (Pt), copper (Cu), nickel (Ni), gold (Au) and silver (Ag); (d) adding metallocene to a polypropylene polymer in an amount in the range of 1 mass% to 90 mass% followed by extruding or laminating to obtain said metallocene modified polypropylene polymer layer; and (e) adding desiccant to a polypropylene polymer in an amount in the range of 1 mass% to 70 mass% followed by extruding or laminating to obtain said desiccant modified polypropylene polymer layer; said desiccant being at least one selected from the group consisting of silica, calcium chloride, calcium carbonate, calcium oxide, magnesium oxide, magnesium chloride, sodium sulphate, dry aluminum chloride, aluminum oxide, molecular sieves, and activated charcoal.
  9. 9. The laminate as claimed in claim 1, wherein said first polymer layer and/or said second polymer layer is selected from a modified polyethylene layer and a modified polypropylene layer, wherein (a) said modified polyethylene layer has a plurality of strata selected from the group consisting of virgin polyethylene stratum, desiccant modified polyethylene stratum, metallocene modified polyethylene stratum, metal oxide coated polyethylene stratum, polymer coated polyethylene stratum, and metallized polyethylene stratum; and (b) said modified polypropylene layer has a plurality of strata selected from the group consisting of virgin polypropylene stratum, desiccant modified polypropylene stratum, metallocene modified polypropylene stratum, metal oxide coated polypropylene stratum, polymer coated polypropylene stratum, and metallized polypropylene stratum.
  10. 10. The laminate as claimed in claim 1, wherein said first polymer layer and/or said second polymer layer is an oriented polyamide layer, said oriented polyamide layer being selected from semi-crystalline polyamide layer, amorphous polyamide layer, and a copolymer thereof; said semi-crystalline polyamide is at least one selected from the group consisting of Nylon 6, Nylon 6,6, Nylon 6,9, Nylon 6,12, Nylon 12,12, and a copolymer thereof.
  11. 11. The laminate as claimed in claim 1 , wherein said first polymer layer and/or said second polymer layer is a modified oriented polyamide (OP A) layer; said modified oriented polyamide (OP A) layer being selected from a metallized oriented polyamide layer, a metal oxide coated oriented polyamide layer, and a barrier polymer coated oriented polyamide layer; said modified oriented polyamide (OP A) layer being obtained by a method selected from (a) depositing a metal on an oriented polyamide (OPA) sheet to obtain said metallized oriented polyamide layer having an optical density in the range of 0.5 to 2.5; wherein said metal is selected from aluminum (Al), palladium (Pd), platinum (Pt), copper (Cu), nickel (Ni), gold (Au) and silver (Ag); (b) coating of a metal oxide on an oriented polyamide (OPA) sheet to obtain said metal oxide coated oriented polyamide layer, wherein said metal oxide is selected from AlOx, SiOx, CuOx, NiOx, and CoOx; and (c) coating a barrier polymer on an oriented polyamide (OPA) sheet to obtain said barrier polymer coated oriented polyamide layer having thickness of said polymer coating is in the range of 1 gsm to 10 gsm; wherein said barrier polymer being selected from poly vinylidene chloride (PVdC), polyvinyl acetate (PVAc), polyvinyl alcohol (PVOH) and Heat seal lacquer (HSL).
  12. 12. The laminate as claimed in claim 1, wherein said second polymer layer is a polyethylene terephthalate (PET) layer, and said polyethylene terephthalate (PET) layer is at least one selected from group comprising of amorphous polyethylene terephthalate (APET) layer, polyethylene terephthalate (PET) layer, glycol modified PET (PETg) layer, poly (1,3- propylene) terephthalate layer, poly (1,4- butylenes) terephthalate layer, elastomeric polyester comprising poly (1,4-butylene) terephthalate layer and poly (tetramethylene ether) glycol layer.
  13. 13. The laminate as claimed in claim 1, wherein said second polymer layer is a modified polyethylene terephthalate (o-PET) layer; said modified polyethylene terephthalate (o-PET) layer being selected from a metallized polyethylene terephthalate layer, a metal oxide coated polyethylene terephthalate layer and a barrier polymer coated polyethylene terephthalate layer; said modified polyethylene terephthalate (o-PET) layer being obtained by a method selected from (a) depositing a metal on a polyethylene terephthalate (o-PET) sheet to obtain said metallized polyethylene terephthalate layer having an optical density in the range of 0.5 to 2.5; wherein said metal is selected from aluminum (Al), palladium (Pd), platinum (Pt), copper (Cu), nickel (Ni), gold (Au) and silver (Ag); (b) coating of a metal oxide on a polyethylene terephthalate (o-PET) sheet to obtain said metal oxide coated polyethylene terephthalate layer, wherein said metal oxide is selected from AlOx, SiOx, CuOx, NiOx, and CoOx; and (c) coating a barrier polymer on a polyethylene terephthalate (o-PET) sheet to obtain said barrier polymer coated polyethylene terephthalate layer having thickness of said polymer coating is in the range of 1 gsm to 10 gsm; wherein said barrier polymer is selected from polyvinylidene chloride (PVdC), polyvinyl acetate (PVAc), and polyvinyl alcohol (PVOH), and heat seal lacquer (HSL).
  14. 14. The laminate as claimed in claim 1, wherein said first polymer layer and/or said second polymer layer is a modified cyclic olefin co-polymer layer; said modified cyclic olefin co-polymer layer being selected from a metal oxide coated cyclic olefin co-polymer layer, a barrier polymer coated cyclic olefin co-polymer layer and a metallized cyclic olefin co-polymer layer; said modified cyclic olefin co-polymer layer being obtained by a method selected from (a) coating a metal oxide on a cyclic olefin co-polymer sheet to obtain said metal oxide coated cyclic olefin co-polymer layer, wherein said metal oxide is selected from AlOx, SiOx, CuOx, NiOx, and CoOx; (b) coating a barrier polymer on a cyclic olefin co-polymer sheet to obtain said barrier polymer coated cyclic olefin co-polymer layer having thickness of said polymer coating is in the range of 1 gsm to 10 gsm; wherein said barrier polymer is selected from poly vinylidene chloride (PVdC), polyvinyl acetate (PVAc), polyvinyl alcohol (PVOH) and Heat seal lacquer (HSL); and (c) depositing a metal on a cyclic olefin co-polymer sheet to obtain said metallized cyclic olefin co-polymer layer having an optical density in the range of 0.5 to 2.5; wherein said metal is selected from aluminum (Al), palladium (Pd), platinum (Pt), copper (Cu), nickel (Ni), gold (Au) and silver (Ag).
  15. 15. The laminate as claimed in claim 1, wherein said first polymer layer and/or said second polymer layer is a polyvinyl chloride (PVC) polymer layer, and said polyvinyl chloride (PVC) polymer layer is selected from flexible PVC layer, rigid PVC layer, chlorinated PVC layer, and oriented PVC layer r.
  16. 16. The laminate as claimed in claim 1, wherein said first polymer layer and/or said second polymer layer is a modified polyvinyl chloride layer; said modified polyvinyl chloride layer being selected from a metal oxide coated polyvinyl chloride layer, a barrier polymer coated polyvinyl chloride layer, and metallized polyvinyl chloride layer; said modified polyvinyl chloride layer being obtained by a method selected from (d) coating a metal oxide on a polyvinyl chloride sheet to obtain said metal oxide coated polyvinyl chloride layer, wherein said metal oxide is selected from AlOx, SiOx, CuOx, NiOx, and CoOx; (e) coating a barrier polymer on a polyvinyl chloride sheet to obtain said barrier polymer coated polyvinyl chloride layer having thickness of said polymer coating is in the range of 1 gsm to 10 gsm; wherein said barrier polymer is selected from polyvinylidene chloride (PVdC), polyvinyl acetate (PVAc), polyvinyl alcohol (PVOH) and Heat seal lacquer (HSL); and (f) depositing a metal on a polyvinyl chloride sheet to obtain said metallized polyvinyl chloride layer having an optical density in the range of 0.5 to 2.5; wherein said metal is selected from aluminum (Al), palladium (Pd), platinum (Pt), copper (Cu), nickel (Ni), gold (Au) and silver (Ag).
  17. 17. The laminate as claimed in claim 1, wherein (a) said at least one first polymer layer is prepared by a method selected from cast extrusion and blow extrusion; and (b) said at least one second polymer layer is prepared by a method selected from cast extrusion and blow extrusion.
  18. 18. The laminate as claimed in claim 1, wherein a primer layer having thickness in the range of 1 gsm to 3 gsm is applied on the first operative surface or the second operative surface OR the surface of the first polymer layer or the second polymer layer in contact with the first operative surface or the second operative surface; and wherein said primer layer is at least one selected from the group consisting of acrylic based primer layer, polyurethane based primer layer and polyester based primer layer.
  19. 19. The laminate as claimed in claim 1, wherein (a) said first polymer layer comprises (i) a polypropylene layer having thickness of 60 microns; and (ii) a metallocene modified polyethylene layer having thickness of 100 microns, wherein said polypropylene layer and said metallocene modified polyethylene layer are bonded together, (b) said intermediate metal layer is an aluminum layer having thickness of 50 microns; and (c) said second polymer layer comprises (i) a modified oriented polyamide layer having a thickness of 25 microns; (ii) a layer of a combination of a metallocene modified polyethylene and a desiccant modified polyethylene having thickness of 60 microns, wherein said modified oriented polyamide layer and said layer of said combination of said metallocene modified polyethylene and said desiccant modified polyethylene, are bonded together.
  20. 20. The laminate as claimed in claim 1, wherein (a) said first polymer layer is a polypropylene having thickness of 60 microns; (b) said intermediate metal layer is an aluminum layer having thickness of 50 microns; and (c) said second polymer layer comprises (i) a metallized oriented polyamide layer having a thickness of 25 microns; and (ii) a PVC layer having thickness of 60 microns, wherein said metallized oriented polyamide layer and said PVC layer are bonded together.

Description

MECHANICALLY STRENGTHENED MULTILAYER, MULTIBARRIER, DESICCANT INTERLACED COLD FORMABLE BLISTER LAMINATES, OPTIONALLY PYC-FREE FIELD The present disclosure relates to a multilayer, multibarrier, mechanically strengthened desiccant interlaced, optionally PVC free cold formable blister laminate. The present disclosure further relates to a compact blister pack made of the multilayer, multibarrier, mechanically strengthened desiccant interlaced, optionally PVC free cold formable blister laminate. DEFINITIONS As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used, indicate otherwise. The term “Multilayer laminate” refers to a laminate comprising at least two layers made from different combinations of polymer films such as PVC, PP, PE, COC, PET, nylon, other polymeric films and foils, more particularly foils made from metals like aluminum or other metals juxtaposed in layer formation and infused with specialty materials having moisture barrier/adsorption, desiccant properties and/or having mechanical strengthening properties; wherein layers were adhesively laminated or extrusion laminated to meet special requirements of moisture barrier and mechanical properties like stiffness, stretchability, drawability, impact strength, tensile strength, peak elongation. The term “Mechanically strengthened” refers to enhancement and improvement in key mechanical properties like stretchability, drawability, stiffness, tensile strength, impact strength and peak elongation of the individual polymer film layer and/or foil layer by infusion, introduction, inclusion or adhesion of specialty material in the polymer resin during film formation or during the lamination process of the polymer film/foil layer over an existing film, foil or laminate leading to the making of the multilayer laminate. The term “Impact strength” is the measure of ability of a multilayer laminate to resist cracking, fracturing, or deformation under impact or shock loads. It is a critical property that determines the multilayer laminate’s ability to withstand external forces. The term “Drawability” refers to the ability of a multilayer laminate in formation of a cavity of desired depth without having any micro cracks, pinholes and retaining desired barrier and mechanical properties when subjected to the blister formation process using cold forming process. The term “Stretchability” refers to the ability of some polymer films to improve the stretching property of a multilayer laminate such that the multilayer laminate does not break or fracture during the blister cavity formation process. The term “Tensile strength at peak” is defined as the maximum stress that a multilayer laminate can bear before breaking or fracturing when it is allowed to be stretched or pulled. The term “Percent Elongation at peak” is defined as a measurement of the amount in percentage a multilayer laminate will plastically and elastically deform upto its breaking or fracturing. The term “Stiffness” refers to a measured value which is directly proportional to increase in the tensile strength of multilayer laminates which is accomplished by incorporation of additional polymer layers in the laminates. The term “Cold forming process” refers to the stamping of the solid material or multi-layer laminates to force it into a form and impart a desired shape and size at or near room temperature. In the case of blister packaging, it is achieved by the application of force on a multilayer laminate in a perpendicular direction to its parting line. The laminate stretches and retains the imparted shape and form after the stamp has been removed. The term “blister pack” or package (pkg) refers to a formable web/multilayer laminate into which blisters or cavities are formed, wherein after placing the product into these blisters or cavities, a lid or a sealing layer, is employed as a seal/ cover/ support. It is thus a pre-formed package used for packaging of consumer goods, foods, and for pharmaceuticals. The terms “blister cups” or “blisters” or “cavities” refer to a recess or a pocket in a laminate made by thermoforming or cold forming process to accommodate a product. The term “product” refers to a product comprising but not limited to pharmaceuticals, nutraceuticals, healthcare, medical devices, medical diagnostics, electronic components, electronic products, consumable products in either unit, multi or aggregated formats The term “support” refers to a layer of a film, paper, metal foil or laminate comprising a polymer film, paper, aluminium foil or a laminate which is used for covering/ protecting the blister pockets or cavities and the term “base” refers to the plane surface of the laminate sheet from where the stretching takes place to form the cavity or a recess. A recess is thus formed within the laminate, and with a shoulder defining the base material in between the recess