Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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STICK PACK DESIGN
Cross Referenced to Related Applications
[0001] This
application claims the benefit of U.S. Provisional Patent Application Serial
No. 62/259,808, filed on November 25, 2015 and entitled "Stick Pack Design",
the entire
disclosure of which is incorporated herein by reference.
Field of the Invention
[0002] The present disclosure is directed to a stick pack pouch or packaging
for dispensing a
compound.
Back2round
100031 Stick packs, also called stickpacks, stick pack pouches, uni-sticks,
and sachets, are
long, flexible pouches used to hold a single-serving or single-dose amount of
liquid and/or
powder. Shaped like a traditional pack of gum, stick packs are sealed on their
two short ends
and have a single seal down the back. Stick packs are used to hold a variety
of food-based
compounds, including single-serve drink mixes, real and artificial sweeteners.
Stick packs are
also used to hold pharmaceutical agents for both adults and children,
including in liquid or
powder form. The convenient size and shape minimizes packaging and alleviates
problems
that can arise when users are forced to measure out a dose of a pharmaceutical
agent. Rather
than requiring a separate dispenser or measuring device, stick packs are
quickly opened by
the user and the proper dosage is immediately ready for consumption. The stick
packs are
often opened by ripping the packaging along a factory-scored perforation.
However, these
perforations are often inadequately or incorrectly scored, or can otherwise be
difficult to
open.
100041 Further, for most pharmaceutical uses, stick packs are designed with
one or more
child-resistant features that prevent children from accessing the liquid or
powder inside the
stick pack. For example, a multi-step process might be required for opening
the stick pack.
However, many of these child resistant features also make the stick packs
difficult for adults,
especially seniors or those with limited mobility or dexterity, from opening
the package.
[0005] Another problem with conventional stick packs is that the contents can
be difficult to
administer to another person such a child or senior. In order to pour the
powder or liquid into
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the other person's mouth, typically the length of the stick pack is grasped.
However, using
too little force can accidentally trap some of the contents, while using too
much force can
result in spilling off the stick pack during the administration.
[0006] Accordingly, there is a continued need in the art for stick packs that
are easy to open
and dispense by adults, but retain child-resistant features that prevent
children from accessing
the contents of the stick pack. There is also a continued need in the art for
stick packs that
facilitate administration of the contents to another person.
Summary of the Invention
[0007] The present disclosure is directed to stick pack packaging and methods
of
manufacture. According to embodiments described or otherwise envisioned
herein, the
methods and systems are directed to a stick pack with an upper sealed edge, a
lower sealed
edge, and a longitudinal edge. The upper region has a notch and a horizontal
perforation line
parallel with the top edge, and a spout formed at least partially in the upper
region but not
extending past the upper sealed edge. The stick pack is configured to be
folded along its
longitudinal axis to fold the notch, and when the notch is folded a user can
easily tear the top
sealed edge along the horizontal perforation line to expose the spout.
[0008] According to an aspect is a stick pack design. The stick pack includes:
(i) a top sealed
portion with a top edge, a horizontal notch parallel with the top edge and
passing through the
stick pack, and a horizontal perforation line parallel with the top edge; (ii)
a bottom edge
portion with an elongated sealed portion proximate to a central compartment of
the stick
pack; (iii) a longitudinal seal extending from the top sealed edge to the
bottom edge; and (iv)
a spout formed at least partially in the top sealed portion but not extending
past the top sealed
edge; (v) where the stick pack is configured to be folded along its
longitudinal axis to fold the
notch, where only when the notch is folded can a user easily tear the top
sealed edge along
the horizontal perforation line to expose the spout.
[0009] According to an embodiment, the stick pack packaging is made of a foil
laminate.
[0010] According to an embodiment, the horizontal perforation line is a laser-
scored
perforation line.
100111 According to an embodiment, the horizontal perforation line can be
intermittent.
[0012] According to an embodiment, the central compartment comprises an insert
gas.
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[0013] According to an embodiment, the stick pack packaging comprises a
polyethylene
terephthalate layer.
[0014] According to an embodiment, the stick pack further comprises a security
feature.
[0015] According to an embodiment, the stick pack further includes a plurality
of central
sealed portions formed in the central compartment, where the plurality of
central sealed
portions are configured to impart a complex flow pattern on the contents
within the central
compartment when a user squeezes the central compartment.
[0016] According to an embodiment, the spout comprises a plurality of
channels.
[0017] According to an embodiment, the spout is bifurcated along at least a
portion of its
length, the bifurcation defined at least in part by a central sealed region.
[0018] According to an aspect is a stick pack design. The stick pack includes:
(i) a central
compartment; (ii) a top sealed portion with a top edge, a horizontal notch
parallel with the
top edge and passing through the foil laminate, and further including a
horizontal perforation
line parallel with the top edge; (iii) a bottom sealed portion with a bottom
sealed edge; (iv) a
spout extending from the central compartment and formed at least partially in
the top sealed
portion; (v) a plurality of central sealed portions formed in the central
compartment, where
the plurality of central sealed portions are configured to impart a complex
flow pattern on the
contents within the central compartment when a user squeezes the central
compartment; (v)
where the stick pack is configured to be folded along its longitudinal axis to
fold the notch,
such that only when the notch is folded can a user easily tear the top sealed
edge along the
horizontal perforation line to expose the spout.
100191 According to an embodiment, the bottom sealed edge is proximate the
central
compartment of the stick pack, and includes an outer wall that extends
downwardly from the
sealed portion to a bottom edge to define a central cylindrical space
configured to receive at
least a portion of a user's finger.
100201 According to an aspect is a stick pack design. The stick pack includes:
(i) a central
compartment; (ii) a top sealed portion with a top edge, a horizontal notch
parallel with the top
edge and passing through the foil laminate, and further including a horizontal
perforation line
parallel with the top edge; (iii) a bottom sealed portion comprising a bottom
sealed edge; and
(iv) a spout extending from the central compartment and formed at least
partially in the top
sealed portion, where the spout is bifurcated along at least a portion of its
length, the
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bifurcation defined at least in part by a central sealed region; (v) where the
stick pack is
configured to be folded along its longitudinal axis to fold the notch, such
that only when the
notch is folded can a user easily tear the top sealed edge along the
horizontal perforation line
to expose the spout.
[0021] According to an embodiment, the stick pack further includes a plurality
of central
sealed portions formed in the central compartment, where the plurality of
central sealed
portions are configured to impart a complex flow pattern on the contents
within the central
compartment when a user squeezes the central compartment.
[0022] According to an embodiment, the bottom sealed edge is proximate the
central
compartment of the stick pack, and includes an outer wall that extends dow-
nwardly from the
sealed portion to a bottom edge to define a central cylindrical space
configured to receive at
least a portion of a user's finger.
[0023] According to an aspect is a method of manufacturing a stick pack. The
method
includes the steps of: (i) cutting a stick pack out of a laminate material,
where the stick pack
comprises a top edge, a bottom edge, and two opposing longitudinal edges; (ii)
scoring, using
a laser, a horizontal perforation line into the outermost layer of the
laminate material from
one longitudinal edge to the other longitudinal edge; (iii) creating a
horizontal notch through
the laminate material near the top edge, where the horizontal notch is aligned
along the
horizontal perforation line; (iv) sealing the two opposing longitudinal edges
together to form
a longitudinal sealed edge; (v) sealing the bottom edge of the stick pack to
form a central
compartment which is open at the top edge; (vi) filling, through the top edge,
the central
compartment at least partially with a content; and (vii) sealing the top edge
to enclose the
contents within the central compartment, wherein a spout is formed in the top
region near the
top edge.
[0024] According to an embodiment, the method includes the step of filling
through the top
edge, the central compartment at least partially with an inert gas.
[0025] According to an embodiment, the method further includes the step of
forming a
plurality of central sealed elements in the central compartment, where the
plurality of central
sealed portions are configured to impart a complex flow pattern on the
contents within the
central compartment when a user squeezes the central compartment.
[0026] According to an embodiment, where the bottom edge of the stick pack is
sealed to
comprise a sealed portion proximate to a central compartment of the stick
pack, and to further
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comprise an outer wall that extends downwardly from the sealed portion to a
bottom edge to
define a central cylindrical space configured to receive at least a portion of
a user's finger.
[0027] These and other aspects of the invention will bd apparent from the
embodiments
described below.
Brief Description of the Drawines
[0028] The present invention will be more fully understood and appreciated by
reading the
Following Detailed description of the invention in conjunction with the
accompanying
drawings, in which:
[0029] Figure 1 is a schematic representation of a front view and a reverse
view of stick
pack, in accordance with an embodiment.
[0030] Figure 2 is a schematic representation of a stick pack with a
longitudinal axis, in
accordance with an embodiment.
100311 Figure 3 is a schematic representation of a folded stick pack, in
accordance with an
embodiment.
100321 Figure 4 is a schematic representation of a stick pack which has been
opened to
expose the spout, in accordance with an embodiment.
[0033] Figure 5 is a schematic representation of a stick pack prior to folding
or sealing, in
accordance with an embodiment.
[0034] Figure 6 is a schematic representation of a stick pack with an
administration tab, in
accordance with an embodiment.
100351 Figure 7 is a schematic representation of a stick pack with a
bifurcated spout, in
accordance with an embodiment.
[0036] Figure 8 is multiple schematic representations of stick packs with
central sealed
elements, in accordance with an embodiment.
[0037] Figure 9 is a flowchart of a method for manufacturing a stick pack, in
accordance with
an embodiment.
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Detailed Description
100381 The present disclosure describes various embodiments of stick pack
packaging. The
stick packs include an upper sealed edge, a lower sealed edge, and a
longitudinal edge. The
upper region has a notch and a horizontal perforation line parallel with the
top edge, and a
spout formed at least partially in the upper region but not extending past the
upper sealed
edge. The stick pack is configured to be folded along its longitudinal axis to
fold the notch,
and when the notch is folded a user can easily tear the top sealed edge along
the horizontal
perforation line to expose the spout. The stick pack can also include an
administration tab or
region that facilitates administration of the contents by one person to
another person. The
stick pack can also include a plurality of central sealed elements that impart
a complex flow
pattern on the contents within the central compartment when a user squeezes
the central
compartment.
100391 Referring now to the drawings, wherein like reference numerals indicate
identical or
corresponding parts throughout the several views, there is shown in FIG. 1 a
FRONT and
REVERSE view of stick pack 10. Stick pack 10 has top edge 12, bottom edge 14,
and side
edges 16 and 18. Stick pack 10 also has a sealed edge 20 extending outwardly
from the
reverse side 22 of the pack, and extending longitudinally along the length of
the stick pack.
100401 Stick pack 10 is sealed at three different regions to keep the contents
within the closed
packaging. The stick pack is sealed at the top region 24, at bottom region 26,
and all along
sealed edge 20, also called a fin. When the stick pack is filled with a
predetermined amount
of liquid or powder ¨ shown by dashed fill line 30, although the amount can
vary
significantly from the shown amount ¨ the contents and the top region seal 24
results in a
headspace 28 which contains air or an inert gas. Headspace 28 also prevents
spilling or loss
of the contents during opening of the stick pack. Headspace 28 allows for
resuspension of an
oral suspension, such as when the user shakes or kneads the stick pack. The
headspace also
allows mixing or kneading of the stick pack for gels and solutions, including
but not limited
to thixotropic gels and solutions.
100411 According to an embodiment, the stick pack contains variable amounts of
the
contents. A stick pack containing a liquid or gel can comprise, for example,
anywhere from 1
ml to 20 mls of liquid or gel, or more. For example, the size of the stick
pack 10 can vary
depending on the amount of liquid, gel, or powder intended to be stored inside
the packaging.
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Accordingly, smaller stick packs may comprise less than 1 ml, while larger
stick packs may
comprise more than 20 mls. Common dosages are 2.5, 5, 10, and 20 mls, among
many others.
[0042] Stick pack 10 comprises a multi-step child-resistant opening mechanism
that balances
safety with ease of opening. To open the stick pack 10, a user first folds the
stick pack 10
longitudinally along axis A-A, shown in FIG. 2. Folding the stick pack along
axis A-A
exposes a notch 32, as shown in FIG. 3, which is pre-formed all the way
through the stick
pack. Prior to folding the stick pack along axis A-A, however notch 32 is
inaccessible to the
user. When notch 32 is accessible, the user can utilize the notch to rip the
top of the stick
pack along a pre-scored perforation line 34 to expose the spout 36, as shown
in FIG. 4.
[0043] According to an embodiment, the scored perforation line 34 is created
in the film
prior to formation of the stick pack, or before sealing of any of the edges.
The perforation line
34 can be formed, for example, by laser ablation of only the outermost layer
of the stick pack,
by mechanical knife, or by other methods. According to an embodiment,
therefore,
perforation line 34 is formed by laser ablation of an outermost aluminum layer
of a multi-
layer film laminate. A laser-scored perforation line 34 allows for thicker
films for the stick
pack 10 without significantly increasing the force required to tear along the
perforation and
open the stick pack. Additionally, according to an embodiment the perforation
is formed
along both sides of fin 20, which allows the user to easily rip through the
fin when opening
the stick pack.
[0044] Referring to FIG. 5, in one embodiment, is a stick pack 10 prior to
sealing at the top
region 24, at bottom region 26, and along sealed edge 20. The stick pack is
approximately
rectangular and can be cut or punched out of a larger piece of material during
manufacturing.
To form the stick pack, the two sides of longitudinal seal 20 are placed next
to each other and
sealed to form a single fin 20. Top region 24 can be sealed, except for the
spout region 36,
and bottom region 26 can be sealed. Sealing can be accomplished, for example,
by heating
the region to be sealed. At a point during the manufacturing and/or sealing
process, the stick
pack 10 is scored and notch 34 is formed.
[0045] Stick pack 10 can be made of any suitable material, and can comprise
one or a
plurality of layers. For example, the innermost layer of the stick pack is
preferably made of a
material that does not interact with the contents of the stick pack, and does
not absorb or
otherwise let the contents stick to or diffuse through the material. Examples
of suitable layer
materials include paper, aluminum, polyethylene (PE), and polyethylene
terephthalate (PET),
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among many others. According to one embodiment, the outermost layer of the
stick pack is a
paper or aluminum layer upon which logos, instructions, and other labeling
materials can be
printed. The next layer may be a PET layer, and the innermost layer may be a
PE layer.
Accordingly, the layers may be aluminum/adhesive/PET/adhesive/PE, in one
embodiment.
[0046] Referring to FIG. 6 is a FRONT view of an embodiment of stick pack 10.
The stick
pack has a top edge 12, bottom edge 14, and side edges 16 and 18. Stick pack
10 also has a
sealed edge 20 extending outwardly from the reverse side 22 of the pack, and
extending
longitudinally along the length of the stick pack. Stick pack 10 is sealed at
top region 24,
bottom region 26, and sealed edge 20. When the stick pack is filled with a
predetermined
amount of liquid or powder ¨ shown by dashed fill line 30, although the amount
can vary
significantly from the shown amount ¨ the contents and the top region seal 24
results in a
headspace 28 which contains air or an inert gas. For some pharmaceutical
products, for
example, an inert gas can help prevent oxidation or degradation of the
product. Inert gasses
can include, for example, nitrogen and/or argon, among others.
[0047] Bottom region or tab 26 of this embodiment provides additional material
for gripping
during administration. Bottom tab 26 can be completely sealed, or can define a
hollow central
gripping region. For example, instead of being completely sealed, bottom
region 26 of this
embodiment can be only sealed at two places; along seal 20 (not shown in the
FRONT view
of FIG. 6), and at sealed portion 38. The walls of stick pack 10 therefore
define an
administration tab or space 40 into which a user can insert a finger to assist
with
administration of the contents of the stick pack to another individual. For
example, a user can
insert a first finger into the empty space of administration tab 40 and grip
one or more sides
of the tab, thereby providing a way to grip stick pack 10 without the risk of
spilling or
blocking the contents of the stick pack. A user can alternatively insert a
thumb or other finger
into the space of administration tab 40 to grip the stick pack.
[0048] Referring again to FIG. 6, in one embodiment, the spout 36 is narrow
and elongated,
while in FIG. 4 the spout 36 is much wider. The length and width of spout 36
controls the
rate at which the contents of stick pack 10 are dispensed to the user. A
narrow and/or
elongated spout, for example, slows the dispensing speed, which can increase
the residence
time of the product in the mouth and/or esophagus for some products and
therapies.
100491 Referring to FIG. 7 in one embodiment, is an alternative spout design
for stick pack
10. In the figure, for example, the spout 36 is bifurcated by a sealed region
36a. The
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bifurcated spout not only controls the flow rate of the content, but also
helps mix or re-
suspend the contents. Trifurcated spouts are also possible, as are other
designs. In most cases,
the spout is created by controlling the sealing of the top region 24. When top
region 24 is
sealed, for example, the portion of the top region that will be the spout is
not heated and
therefore does not seal. To accomplish this, according to another embodiment,
the cross-seal
jaws of a sealing mechanism can be designed or patterned such that there is no
pressure or
sealing applied in the area of the spout. Although heat will be applied to the
entire jaw, the
film will not be pressed together in the area of the spout, and thus the
opposed layers of the
film will not form a seal in that area.
100501 Referring to FIG. 8, in various embodiments, is a stick pack 10 with a
plurality of
central sealed elements 44. The plurality of central sealed elements 44
provides a mechanism
for mixing contents, such as re-suspending liquid suspensions, and/or to shear
the contents of,
for example, thixotropic pharmaceuticals. Often, mixing a suspension prior to
dosing can be
important to the efficacy and proper dosage or the content. For some contents,
if the viscosity
of the content is low enough, the stick pack can be shaken by the user and the
headspace will
allow for mixing of products. For other contents, shearing can be vital to
liquefy a thixotropic
drug product or to re-suspend a suspension prior to dosing. The plurality of
central sealed
elements 44 provides a mechanism for lowering the viscosity of the content
and/or re-
suspending by imparting a complex flow pattern on the contents when a user
squeezes the
central compartment of the stick pack. For example, the stick pack 10 can be
kneaded by a
user prior to dosage. Kneading will move the contents inside the stick pack,
forcing the
contents to interact with the plurality of central sealed elements. Both sharp
edges and curved
portions of the central sealed elements will facilitate the mixing of the
contents. For example,
FIG. 8 depicts a variety of central sealed elements 44, including elongated
diamond shapes,
rectangles, and teardrops, although many other shapes are possible. In several
of these
designs, neighboring sealed elements create narrow passageways that facilitate
mixing and
shearing. The plurality of central sealed elements 44 can be formed during or
after the initial
sealing process.
[0051] According to an embodiment, stick pack 10 can comprise one or more
security
features. For example, stick packs can be serialized for tracking and
identification. Serializing
can comprise, for example, labeling with a unique bar code, QR code, or other
code that
allows for specific identification of the stick pack. All stick packs can be
serialized with a
similar code format, while some stick packs may be labeled with a specific
code format for
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an individual manufacturer, date, and/or content. As another security feature,
the stick pack
can be labeled using a specialty or anti-counterfeiting ink. One or more
security features
allow for increased tracking and identification of pharmaceuticals. For
example, a stick pack
sold illegally to another individual can be tracked back to the manufacturer,
seller, and/or
intended user of the stick pack. Using the bar code, QR code, or other unique
code. As
another example, suspect stick pack can be authenticated by examining the
presence or
authenticity of anti-counterfeiting ink or other anti-counterfeiting feature.
[0052] Referring to FIG. 9, in accordance with an embodiment, is a method 200
of
manufacturing a stick pack 10. At a first step 210, the stick pack material is
provided and the
stick pack is cut out of the stick pack material. The material can be any of
the materials
described or otherwise envisioned herein. At step 220, a perforation line is
formed in the stick
pack material from one longitudinal edge to the other longitudinal edge.
Additionally, a notch
is formed in the stick pack. According to a preferred embodiment, the
perforation line is
formed only in the outermost layer of a foil laminate using laser scoring.
Step 220 can be
performed prior to cutting the stick pack out of the stick pack material.
[0053] At step 230, the stick pack is folded to align the two longitudinal
edges which are
sealed to form the longitudinal sealed edge 20. At step 240, the bottom edge
of the stick pack
is sealed, forming a central compartment that is open at the top.
[0054] At step 250 of the method, the contents are introduced to the central
compartment. At
step 260 of the method, the top edge of the stick pack is sealed. According to
an embodiment,
a spout is formed in the top edge as it is sealed. The spout can be any of the
shapes and sizes
disclosed or otherwise envisioned herein.
[0055] At optional step 245 of the method, a plurality of central sealed
portions is formed in
the central compartment. As described above, the plurality of central sealed
portions imparts
a complex flow pattern on the contents the central compartment when a user
squeezes the
central compartment. The plurality of central sealed portions can be formed,
for example, by
heating specific patterns or shapes into the folded stick pack, which causes
the opposing
internal sides of the central compartment to adhere in the shape or pattern.
100561 While various embodiments have been described and illustrated herein,
those of
ordinary skill in the art will readily envision a variety of other means
and/or structures for
performing the function and/or obtaining the results and/or one or more of the
advantages
described herein, and each of such variations and/or modifications is deemed
to be within the
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scope of the embodiments described herein. More generally, those skilled in
the art will
readily appreciate that all parameters, dimensions, materials, and
configurations described
herein are meant to be exemplary and that the actual parameters, dimensions,
materials,
and/or configurations will depend upon the specific application or
applications for which the
teachings is/are used. Those skilled in the art will recognize, or be able to
ascertain using no
more than routine experimentation, many equivalents to the specific
embodiments described
herein. It is, therefore, to be understood that the foregoing embodiments are
presented by way
of example only and that, within the scope of the appended claims and
equivalents thereto,
embodiments may be practiced otherwise than as specifically described and
claimed.
Embodiments of the present disclosure are directed to each individual feature,
system, article,
material, kit, and/or method described herein. In addition, any combination of
two or more
such features, systems, articles, materials, kits, and/or methods, if such
features, systems,
articles, materials, kits, and/or methods are not mutually inconsistent, is
included within the
scope of the present disclosure.
