Desiccant material included in a closed container.

(74) Agent: REYNOLDS, David, D. et al .; Novak Druce Reynolds Burt, King Street Station, Suite 750, 225 Reinekers Lañe, Alexandria. VA 22314 (US).

(81) Derignated Statea: AL. A.M. AT. AU. AZ. BB. BG, BR. BY.

CA, CH. CN, CZ, DE, DK. EE, ES. FI, GB, GE, HU. IS, KE, KG. KP, KR, KZ. LK, LR, LS, LT, LU. LV, MD. MG, MK, MN. MW. MX, NO, NZ. PL. PT, RO, RU, SD. SE, SG. SI, SK, TJ, TM, TR, TT, UA, UG, UZ, VN, ARDO patent (KE, LS, MW, SD, SZ, UG), Eunuian patent (AM, AZ, BY, KG, KZ, MD , RU, TJ, TM), European patent (AT. BE, CH, DE, DK, ES, FI, FR, GB, GR, IE, IT, LU, MC. NL, PT, SE). OAPI patent (BF, Bl, CF, CG, CI, CM. GA. GN, ML. MR, NE. SN. TD. TG).

PubUibed

With international search repon.

(54) Tille: DESICCANT MATERIAL INCLUDED IN A CLOSED CONTAINER

<img file="MX9708041A_D0001.tif" />

(57) Abetract

Shipping and storage container (01) having a body (12) and a cap (14) that together create an endosure that is constructed frotn thermoplastic and that inelude · at leait ooe iiuert (200) of high-ccncentration deaiccant integrally molded theiewith. The containerMay be injection molded about a pre-fonned iiuert la&gt; o that the iiuert is at least putially encased within the body of the container. Alternatively. the insert may be co-molded with the body of the container so that the two componeros are bonded together into one unitized and continuous body.

-1 DESICCANT MATERIAL INCLUDED IN A CLOSED CONTAINER

DESCRIPTION

TECHNICAL FIELD: The present invention relates to containers having desiccant capacities. More particularly, the present invention relates to thermoplastic containers.

PREVIOUS TECHNIQUE: There are many items that are preferably stored and / or shipped in an environment that is as free of moisture as possible. Therefore, it has been recognized that containers that have the ability to absorb excess moisture are suitable. One application in which moisture-wicking containers are desired is for shipping and storing medications whose efficacy is compromised by moisture. The initial placement of medicines in a sealed moisture-free container is usually controllable. Furthermore, the medicine container is selected such that it has low moisture permeability. Therefore, the medicine will normally be protected from moisture until it reaches the end user. However, once the consumer receives the medicine, the container must be opened and closed repeatedly to access the medicine. Every time the container is opened and is not sealed, moisture-containing air will likely be introduced into the container and sealed after closing. Unless moisture is somehow removed from the atmosphere or head space of the container, it can be detrimentally absorbed by the medication. For this reason, it is

-2a good known practice to include a desiccant unit together with the medicine in the container.

In other cases, moisture can be released from items that have been placed in shipping and / or storage containers. In the event that the containers are sealed and substantially impervious to moisture, the released moisture will remain within the container around the product. If not removed, this released moisture can have detrimental effects on every item that released the moisture. A substantial amount of moisture has been found to be released from certain food products within the first forty-eight (48) hours after manufacture and packaging. This released moisture will remain around the product until it is removed. If moisture is not removed shortly after release, it can cause food to degrade into one that cannot be sealed. In these cases, the desiccants can be included along with the contained items to continuously absorb the released moisture until the product is unpacked. In this way, a relatively dry environment is maintained around the stored item.

It was previously recognized that the need to remove moisture from inside sealed containers. Early attempts to achieve these goals included the provision of desiccant materials in cloth or similar bags that are placed in containers, together and mixed with the materials to be shipped or stored. However there is a problem

-3 consumer related when desiccant is lost and mixed together with consumable items. If not carefully and uniformly processed when unpacked, the desiccant cannot be separated from consumables and could harm a person if ingested in an unknown way

Another known way by which a desiccant can be provided within a container includes coating the inner surface of the container with a desiccant-containing material. Furthermore, it is known that desiccant properties are provided in a container through the use of layered structures in which a desiccant is "sandwiched" between the moisture permeable material that confines the desiccant. These layered structures are often in the form of flexible sheets that can be formed into bag-like containers in which the 15 items requiring a low humidity environment are placed.

Several of the known means by which desiccant-carrying containers are constructed require multiple steps and result in layered and more complex structures than desired. Furthermore, the provision of desiccant capsules 20 together with contained articles is not always satisfactory. As previously explained, mixing desiccants with food and

<td>medications is</td><td>convenient</td><td>since</td><td>point</td><td>of</td><td>view</td><td>of a</td>

<td colspan="2">consumer as to what</td><td colspan="2">the desiccant</td><td>I know</td><td>can</td><td>ingest</td>

<td>inadvertently.</td><td>Still further,</td><td>if he</td><td>desiccant</td><td>not</td><td colspan="2">is constituted</td>

<td>25 integrally with</td><td>the recipient,</td><td>or by</td><td>least</td><td>I know</td><td>unites the</td><td>same,</td>

It can be removed prematurely while still needed for continuous removal of moisture from inside the container. Therefore, a need has been recognized for containers that include a desiccant as an integral component of the container body. With respect to the included desiccant in the container, it is convenient to increase its moisture absorption capacities with respect to both the rate and quantity. Still further, as in all manufacturing processes, it is desirable to reduce the steps required to build the desiccant containers and simplify the resulting structures.

DESCRIPTION OF THE INVENTION: An embodiment of the present invention includes a container having desiccant capacities. The container includes a container body that forms at least a partial seal such that an interior space and an exterior space are created with respect to the container body. There is an insert formed from the desiccant retaining thermoplastic that is fixed relative to the body of the container. At least a portion of the insert is exposed to the interior space of the body of the container so that it can absorb moisture from it. The desiccant-retaining thermoplastic from which the insert is constructed has a high desiccant concentration of at least forty percent desiccant to thermoplastic by weight. The container body is comprised of substantially desiccant-free thermoplastic in one embodiment and low concentration desiccant thermoplastic having at most twenty percent desiccant to thermoplastic by weight in another embodiment. In a preferred embodiment, the body of the container is constructed of polypropylene. A lid that is seal-coupled to the body of the container and constructed of polyethylene can be optionally provided. It is contemplated that the insert can be sufficiently enclosed by the body of the container such that the insert is only exposed to the interior space of the container and not to the exterior of the container. In one embodiment, the insert is attached to the body of the container by a retaining edge 211 formed by the body of the container around the insert. In another, the insert is fixed to the container body by a shortened adaptation of the container body around the insert. It is contemplated that the insert and the container body can be molded into a used body. As an optional enhancement, the desiccant-retaining thermoplastic of which the insert is made can include a polar organic compound that increases the absorption capabilities of the desiccant. The insert may be in the form of a liner that covers at least a greater part of the interior body surface area of ​​the container.

An alternative embodiment is described, a container having desiccator capabilities. It includes a container body that forms at least a partial seal such that an internal space and an external space are created with respect to the container body. There is an insert constructed of thermoplastic that retains desiccant that is integrally bonded to the body of the container by a co-molding process that forms a single unified two-component body. After the molding process, at least a portion of the insert is exposed to the internal space of the body of the container to absorb moisture from it.

Also described is a method of co-molding the above container that has desiccant capabilities. Method steps include injecting a high concentration desiccant thermoplastic insert into a container mold. A container body is injected around the insert so that a single used body is formed from two components. When the mold of the container is formed, the insert is enclosed within the body of the container such that the insert is only exposed to one interior space of the container. The step of injecting the body of the container around the insert so that a single unified body of the two components is formed. When the container body is formed, the insert is enclosed within the container body such that the insert is only exposed to one interior space of the container. The step of injecting the body of the container around the insert is carried out contemporaneously with the step of injecting the insert such that the insert and the body fuse at an interface whereby the unified body is formed. Alternatively, the injection of the body of the container around the insert is carried out at a sufficiently high temperature so that the insert of the body fuses at an interface thus forming the unified body. Before the thermoplastic is injected into the mold, the different concentrations of the desiccant are prepared. During the injection process, the high desiccant concentrate thermoplastic is introduced into the mold through a first injection port 209 and the low desiccant or low desiccant concentrated thermoplastic is introduced into the mold through a second injection port 210. In one embodiment, the mold is moved from a first injection station to a second injection station. A preferred means of moving the mold between stations on a turntable.

The present invention provides a container and process for building the same that meets the need for more effective desiccant storage and shipping containers. These containers of the present invention provide superior desiccant capabilities, while at the same time allowing efficient construction of a container that has and maintains structural integrity. Furthermore, the present invention provides a means by which it can be formed having a substantially unified and continuous body.

BRIEF DESCRIPTION OF THE DRAWINGS.

Figure 1 is a cross-sectional view of a desiccant container with an insert in the form of a molded disc therein.

Figure 2 is a cross sectional view of a desiccant container with an insert in the form of a molded liner therein.

Figure 3 is a partial cross-sectional view of the container body showing an edge retainer.

Figure 4 is a side view of a partial section mold mounted on a turntable for transportation between injection stations and showing an insert container molded therein.

Figure 5 is a side view of a partially sectioned mold showing a container and insert molded therein in a single station configuration with two injection ports.

Figure 6 is a schematic view of the method by which the container is molded.

MODES FOR CARRYING OUT THE INVENTION: In one embodiment of the present invention, a relatively small container can be manufactured similar in construction to the asceptical vial and cap of US Patent 4,783,056 to Robert S. Abrams, the disclosure of which is expressly incorporated herein by reference. In the present application reference numbers similar to those of patent 4,783,056 are used to designate similar or similar apparatus or processes.

The present invention described includes and applies to the manufacture of similar containers. However, the containers 01 described herein are not limited to ampoules. It is contemplated that containers 01 constructed in accordance with the present invention may be larger or smaller than 4,783,056 ampoules and variably. Furthermore, the lids 14 can be integrally formed with the bodies 12 of the containers 01, or can be manufactured as separate units.

Furthermore, the present invention can be moralized exclusively within the body of a container 12 or a lid 14 for a container 01.

The material used in the construction of these containers 01 normally provides a barrier between the interior 201 and exterior 202 of the container 01 that is substantially impervious to moisture and more often thermoplastic. While it is contemplated that any thermoplastic can be used, polypropylene is preferred for the construction of body 12 of container 01. Polypropylene is suitable for its durability, stiffness and breaking strength after being molded into a container 01. Other examples of suitable thermoplastics can be selected from the following groups: polyolefin, polyethylene, polycarbonate, polyamide, ethylene vinyl acetate copolymer, ethylene methacrylate copolymer, polyvinyl chloride, polystyrene, polyester, polyester amide, polyacrylic ester, and polyvinylidene chloride, acrylic , polyurethane, polyacetal and polycarbonate. These and other thermoplastics can be used either singly or in combinations.

The present invention includes the manufacture of a container 01 in which the majority of the body of the container 12 is constructed of the base thermoplastic, eg, polypropylene due to its durability and resistance to rupture. To establish and / or increase a desiccant capacity it is integrally built

-1010 with body 12 of container 01. The concentration of desiccant retained within insert 200 may exceed seventy-five percent (75%). However, normally the concentration of desiccant in insert 200 will fall within a range of forty to seventy-five percent (40-75%) desiccant to thermoplastic by weight. This concentration is considered to be a high concentration for most thermoplastics. The maximum amounts of desiccant that can be carried will vary between different types of thermoplastics due to their different characteristics. However, in the case of polypropylene the maximum concentration of desiccant will be approximately seventy-five percent by weight (75%). As the concentrations of desiccants within thermoplastics increase, the performance of the material degenerates to unacceptable levels.

In one embodiment, insert 200 is located in the base or bottom 203 of container body 12 and is exposed to interior space 201 of container 01. The configuration of this embodiment is similar to a sample vial. Because durability and resistance to breakdown is reduced on the upper desiccant content scales, it is advantageous to have the polypropylene used in the construction of the container body 12 formed around the insert 200 except for those surfaces that will be exposed to the interior 201 of container 01. A container 01 of this configuration provides desired structural integrity while also providing

-1111 the higher desiccant capacity of the high desiccant loaded insert 200 that directly exposes the interior 201 of the container 01. It is also contemplated that the insert 200 may be included in the construction of the container lid 14. In this case, the insert will be integrally formed with the lid 14 so that the outer surface of the insert 200 is exposed to the inside 201 of the container 01 when installed on it.

As a further alternative embodiment, insert 200 may be less localized and extended to a high degree around a larger portion of container body interior surface 204 12. In this case, the high desiccant bearing thermoplastic forms more of a liner 205 on the inner surface 204 of the container 01. To provide maximum desiccant capacities liner 205 can completely cover the interior surface 204 of container 01; this may optionally include the internally exposed surfaces of the lid 14 of a closed container 01.

A contemplated method of manufacturing container 01 includes the provision of a preformed insert 200 around which the thermoplastic of the rest of body 12 of container 01 is injection molded. In this process, it is important that the insert 200 be attached to or within the body 12 of the container 01. This can be accomplished by merely molding the body 12 around the insert 200 so that the two components are mechanically connected to each other. The mechanical connection may take the form of a retaining edge 205 formed by the body of the

-1212 container 12 around the insert 200 that effectively fixes the insert 200 with respect to the rest of the body 01.

Alternatively, it is also contemplated that a "shortened fit" can be achieved by the body 12 by forming thermoplastic around the insert 200. A particular example of this shortened fit application could be the provision of a desiccant loaded insert 200 constructed of a base thermoplastic. made of polyethylene and a container body 12 molded around it from a polypropylene based thermoplastic. On cooling after injection molding, polyethylene shrinks less than polypropylene under similar circumstances. Therefore, if a polypropylene body is injection molded around the previously formed polyethylene insert 200, or contemporaneously injection molded with the container body 12, the polypropylene container body 12 will shrink around the insert. polyethylene 200. The shrink fit method can be implemented either if the insert 200 is relatively small and located with respect to the body of the container 12 or if the insert 200 is in the form of a previously described liner configuration 205. In any

<td>case the</td><td>body 12</td><td>of the</td><td>container</td><td colspan="2">formed</td><td>externally</td><td>can</td>

<td>shrink</td><td>around</td><td>of the</td><td>insert 200</td><td>yes</td><td>the</td><td>thermoplastic</td><td>of the</td>

<td>which is the</td><td>insert</td><td> 200</td><td colspan="2">and the body</td><td>of the</td><td>container 12</td><td>is it so</td>

selected approximately. The use of retaining edge 206 and the shrink adaptation method of fixing insert 200 or

-1313 liner 205 to the container body 12 is mainly used when the construction materials of the insert 200 and container body are not compatible. The two components will be considered incompatible if they do not automatically adhere to each other as a result of the manufacturing process.

Alternatively, insert 200 will be constructed of a material that attaches to body 12 of container 01 when body 12 is placed therein. Therefore, a preferred method of constructing insert 200 carrying container 01 of the present invention is being molded. That is, the primary body 12 of container 01 is molded, while the high desiccant insert 20 is also molded. The two portions are co-molded since they are either simultaneously or sequentially injection molded in a single process. The molding process

<td>give as</td><td colspan="2">Outcome</td><td colspan="5">building a body of</td><td>container</td>

<td>unified</td><td> 12</td><td>in</td><td>the</td><td>which</td><td>the insert</td><td> &gt; 200</td><td>this</td><td>combined</td>

<td colspan="2">seamlessly</td><td>with</td><td>the</td><td>Body</td><td>12, in the</td><td>most</td><td>of the</td><td>cases the</td>

Insert 200 and container body 12 adhere to each other as a result of a fusion of the base thermoplastics of which each is constructed at an interface between them. The melting action takes place when the insert 200 and the body of the container 12 are each injected into the mold 10 sufficiently narrow with respect to time so that each is at least in a semi-molten state while in contact with one another. . Alternatively, the heat from the thermoplastic of a body 12

-1414 injected around the insert 200 may cause the contacted portions of the insert 200 to slightly melt and fuse with the thermoplastic of the body 12 adjacent thereto. In each case, there will be a phase between the concentrated insert 5 with high desiccant content and the body of the container 12 in which the two building materials mix to some degree creating a seamless interface and therefore unifies the container e01 outside of the two components.

As explained, in a preferred embodiment, the high desiccant insert 200 is located at the bottom or bottom 203 of container 01. A surface of insert 200 can directly expose the interior 201 of container 01 or insert 200 can be fully encapsulated. by the primary body 12. Furthermore, it is contemplated that the bottom portion 203 of container 01 can be constructed exclusively of high desiccant thermoplastics if the reduced qualities of the material do not adversely affect the performance of container 01. This may be the case if container 01 will not be exposed to high pressure or rough handling. To produce said container 01, it is contemplated that the lower portion and the upper portion are formed of thermoplastic of different desiccant concentration, that is, thermoplastics of lower desiccant concentration will be injected into the upper portion of the mold 10 and higher desiccant concentration will be injected into the lower portion. The thermoplastic of the two 25 portions will mix in an interface and fusion in a body of

-1515 container used 12, as long as the base thermoplastics of each are compatible. Like the other injection processes, it is contemplated that each portion can be injected from separate injection ports 209 and 210 or the same port. As a result, the portions can be injected both sequentially or simultaneously. In each case, the proportion of the container body 12 formed by each portion will be controlled by the amount of thermoplastic injected into each one.

In either case, the thermoplastic in which the desiccant is retained is moisture permeable to the extent that the moisture inside 201 of container 01 can be transferred and stored in the desiccant. It is possible that the thermoplastic from which insert 200 is manufactured may have a higher moisture permeability than that from which the rest of body 12 of container 01 is constructed. In this case, insert 200 can be enclosed within container 01 by a lower moisture permeable thermoplastic in container body 12. In this way, moisture cannot be easily transferred from outside container 01 into the interior. In view of the possibility of desiring to defer moisture permeabilities in insert 200 and receiver body 12, it is contemplated that the two components 200, 12 can be constructed of different materials that are potentially incompatible.

The process of the present invention may vary in which the insert 200 is molded within the primary body 12 of the container

-1616

01. In a first embodiment of the molding process, it is contemplated that the mold 10 will move between two injection stations. An injection assembly which is generally designated by the differential rate 96 can be installed and removed from the casting frame 24. At one station, usually the first station, the insert 200 will be injection molded. In order to mold the insert 200, a ring-shaped barrier will be provided having a circumference that substantially equalizes the perimeter of a lower end of the die 48. The thickness of the insert 200 is desired to be approximately one eighth of an inch therefore the thickness or height of the barrier ring itself will be one eighth of an inch. As the injection assembly 96 is installed within the mold frame 24, the barrier ring is the main component. The ring is brought into contact with the bottom surface of the matrix 48 forming a barrier into which the thermoplastic can be injected. Then the thermoplastic with a high concentration of desiccant is injected into the interior of the ring thus forming the insert 200. The high desiccant concentration thermoplastic of the insert 200 can be injected at a temperature that is less than the temperature and that the thermoplastic of the body of the container 12 is injected. The reduced temperature may be required so that the desiccant contained therein does not degrade. The need for the reduced temperature can be made obvious by using different and / or high-grade desiccators that are not

-1717 susceptible to degradation within the normal temperature scales of the injection process.

When insert 200 has cooled sufficiently to a point that it will retain its shape after removal of the barrier ring, injection assembly 96 is removed from the mold frame

24, together with the barrier ring attached to it. Insert 200 adheres to the bottom surface of die 48 and remains within mold 10.

The mold 10 is moved to a second injection station similar to the one previously described, but configured to the desiccant-free thermoplastic, it is injected into the cavity 114 with which it forms the body of the container 12. The means to transport the mold frame 24 between the Stations it is preferred that it be a rotary table 207 that operates continuously between the two stations. During this second injection, the thermoplastic is injected to form the body of the container 01 and optionally the lid 14. During this same step, the thermoplastic is also injected around the insert 200 that has been previously formed. In this way, the portions of the insert 200 that could have been exposed to the exterior 202 of the container 01 are covered by the thermoplastic without desiccant.

The upper surface of the insert 200 is not covered by the desiccant-free thermoplastic as it remains in contact with the lower surface of the die 48. Through the insert 200 it is allowed to cool sufficiently to maintain its shape between station 25 one and two and during the second injection, the second injection of

Thermoplastic -1818 is made at a temperature sufficient to cause the two components 200, 112 to bond as described herein. Depending on the conditions, it is possible that the highly concentrated insert 200 will melt enough so that blood will flow into the body 12 of the container 01 located adjacent thereto. However, the amount of bleeding is not significant and does not degrade the performance of the outer thermoplastic that gives container 12 its strength and curability.

In an alternative embodiment of the molding process, only one injection station is used, but two injection ports 209 and 210 are provided thereto. Thermoplastic with high

The concentration of desiccant that forms insert 200 is injected through one of ports 109, while the desiccant-free thermoplastic that forms body 12 of container 01 is injected through 15 of other ports 210. In this process, The die 48 must move longitudinally away from the injection assembly 96 a distance equal to the thickness of the insert 200 to be formed. Like the two station processes, the insert 200 is formed first and the body 12 of the container 01 is formed between them. In 20 other respects, the two processes are similar.

It is anticipated that the rate of absorption in insert 200 can be controlled by the amount of surface area of ​​insert 200 exposed to interior 201 of the container. If higher absorption rates are desired, more insert surface area 25 200 should be exposed. If a longer absorption process is desired,

-1919 will expose less surface area. It is further contemplated that the rate of absorption by insert 200 can be controlled by encapsulation of insert 200. If lower rates of absorption are desired, then insert 200 can be enclosed to greater degrees by the thermoplastic that forms body 12 of container 01 and which it is less permeable to moisture. The absorption rate can also be controlled using different types of different moisture permeability rates. Still further, the rate of moisture absorption by insert 200 can be affected by other blends added to thermoplastic. In particular, it has been found that the addition of polar organic compounds such as "starch to the desiccant-filled thermoplastic will greatly increase the absorption rate. The addition of polyvinyl alcohol (PVOH) has similar incremental effects on the absorption rate of the charged desiccant thermoplastic. In a particular example, the addition of five percent (5%) by weight of starch to polypropylene having ten percent (10%) of desiccant and no starch.

The amount of moisture that can be absorbed by insert 200 can be controlled in many ways. It is contemplated that the amount of moisture absorbable by the insert 200 can be effected by changing the concentration of the desiccant within acceptable ranges; The higher the concentration, the greater the amount of moisture that can be captured.

-2020

In an alternative embodiment, the thermoplastic of which body 12 is constructed may also have desiccant retained and suspended therein. therein, but at concentrations less than insert 200. The concentration of desiccant in the thermoplastic has been found to affect performance characteristics. of molded container 01. As an example, it has been found that while the plastic will carry relatively high percentages of desiccant, desirable characteristics such as durability and break resistance can degrade at higher concentrations of desiccant. It has also been found that plastic can be combined with lower concentrations of desiccant without appreciably degrading the performance of the thermoplastic material in its molded and solid state. In a normal application, a relatively low concentration will fall within the range of five to fifteen percent (5-15%) of desiccant by weight to thermoplastic with a preferred concentration being approximately seven and a half percent (7.5%). Additionally, for the purposes of the description made herein, desiccant-free thermoplastics can also be considered low concentration thermoplastics.

Various concentrations of desiccant-containing thermoplastic are commercially available in pellet form. Usual concentrations can be achieved by dry mixing higher concentration desiccant pellets with lower concentration or thermoplastic desiccant pellets. When they mix in

-2121 appropriate proportions, any concentration of desiccant less than that of high concentration desiccant pellets can be achieved. After the dry mixing process, the resulting pellet mix can be injection molded in the 'normal way.

In a preferred embodiment of the present invention, it is contemplated that the thermoplastic source for the insert 200 and that of the container body 12 can be custom blended to achieve the respective desired desiccant concentrations of each. For the injection molding process, two supply hoppers can be provided; one having the thermoplastic with a high desiccant content from which the insert is formed and the other having a mixture of pellets of different concentrations that when melted in solution produce the thermoplastic with a lower quantity of desiccant from which the body 12 of the container 01 is formed . Insert 200 and container body 12 are injection molded according to the different methods described herein.

Although certain embodiments of the invention are illustrated, it will be appreciated that many modifications and variations of the present invention are possible in view of the above teachings and within the scope of the appended claims without departing from the spirit and intended scope of the invention.

-2222