Methods for dispensing and adhering hot melt entrained polymers to substrates

Abstract

Disclosed are an entrained polymer or an entrained polymer composition, and a method for forming and adhering an entrained polymer structure to a substrate using the entrained polymer or an entrained polymer composition. The method includes providing a substrate configured to receive application of a molten entrained polymer. A particulate entrained polymer in molten form is applied in a predetermined shape, to a surface of the substrate, to form a solidified entrained polymer structure on the substrate. The entrained polymer includes a monolithic material formed of at least abase polymer and a particulate active agent. The surface of the substrate is compatible with the molten entrained polymer so as to thermally bond with it. In this way, the entrained polymer bonds to the substrate and solidifies upon sufficient cooling of the entrained polymer.

What is claimed is: 
     
         1 - 30 . (canceled) 
     
     
         31 . A method for forming and adhering an entrained polymer strip to a substrate, comprising the steps of:
 a. extruding an entrained polymer composition in molten form, wherein the entrained polymer composition comprises a mixture of a base polymer and a particulate active agent, the particulate active agent being from 20% to 80% by weight with respect to the total weight of the entrained polymer;   b. providing a substrate having a surface for receiving application of the entrained polymer composition, and   c. applying the entrained polymer composition in molten form in the shape of a strip to a part of the surface of the substrate to form thereon a solidified entrained polymer strip, wherein the entrained polymer composition adheres to the part of the surface of the substrate by thermal bonding, wherein the entrained polymer structure is formed upon cooling and solidification of the entrained polymer composition,   
       wherein the method is carried out using a hot melt dispensing apparatus comprising:
 i. an extruder for blending and melting the entrained polymer composition and for providing a flow of the entrained polymer composition in molten form through the apparatus; 
 ii. a hose having an internal lumen in fluid communication with an exit of the extruder to receive the flow of the entrained polymer composition in molten form; and 
 iii. an applicator in fluid communication with the hose, the applicator comprising a dispenser for dispensing the molten entrained polymer composition, 
 wherein the lumen terminates at the applicator to which the entrained polymer composition in molten form is conveyed through the hose, and wherein the dispenser applies the entrained polymer composition in molten form to the surface of the substrate. 
 
     
     
         32 . The method of  claim 31 , wherein the particulate active agent comprises an antimicrobial agent. 
     
     
         33 . The method  claim 31 , wherein the particulate active agent comprises a desiccant. 
     
     
         34 . The method of  claim 33 , wherein the particulate active agent comprises a starch desiccant. 
     
     
         35 . The method of  claim 31 , wherein the particulate active agent comprises molecular sieve. 
     
     
         36 . The method of  claim 31 , wherein the particulate active agent comprises silica gel. 
     
     
         37 . The method of  claim 36 , wherein the particulate active agent further comprises an antimicrobial agent. 
     
     
         38 . The method of  claim 37 , wherein the entrained polymer composition comprises a channeling agent that forms passages that penetrate through the base polymer in the solidified entrained polymer. 
     
     
         39 . The method of  claim 31 , wherein the entrained polymer composition comprises a channeling agent that forms passages that penetrate through the base polymer in the solidified entrained polymer. 
     
     
         40 . The method of  claim 31 , wherein the substrate is a foil and the surface of the substrate comprises a polymer sealing layer on the foil. 
     
     
         41 . The method of  claim 40 , wherein the particulate active agent is a molecular sieve and the substrate and solidified entrained polymer adhered thereto form a composite, the composite forming a portion of a pouch or blister pack. 
     
     
         42 . A method for forming and adhering entrained polymer structures to substrates in an automated package production line using a hot melt dispensing apparatus, the method comprising the steps of:
 a. providing a hot melt dispensing apparatus comprising:
 (i) an extruder for blending and melting entrained polymer composition and providing a flow of the entrained polymer composition in molten form through the extruder and from an exit of the extruder; and 
 (ii) a manifold operatively connected to and in fluid communication with the exit of the extruder, the manifold being configured to convey the entrained polymer composition in molten form to a plurality of hoses operatively connected to and in fluid communication with the manifold, each hose having an internal lumen configured to receive flow of the entrained polymer composition in molten form, each hose leading to a dispenser for dispensing the molten entrained polymer composition; 
   b. extruding through the extruder the entrained polymer composition in molten form, the entrained polymer composition comprising a mixture of a base polymer and a particulate active agent;   c. conveying the entrained polymer composition in molten form from the extruder, through the manifold, through each hose and through the dispenser of each respective hose;   d. providing a substrate, which is in solid form, having a surface for receiving application of the entrained polymer composition, and   e. dispensing from each dispenser the entrained polymer composition in molten form and applying the entrained polymer composition in a predetermined shape to the surface of the substrate to form thereon a solidified entrained polymer structure, wherein the entrained polymer composition adheres to the surface of the substrate by thermal bonding, wherein the entrained polymer structure is formed upon cooling and solidification of the entrained polymer composition, the solidified entrained polymer structure comprising an outer boundary, the surface of the substrate extending outwardly beyond the outer boundary.   
     
     
         43 . The method of  claim 42 , wherein the particulate active agent comprises a desiccant. 
     
     
         44 . The method of  claim 42 , wherein the particulate active agent comprises silica gel and an antimicrobial agent. 
     
     
         45 . The method of  claim 44 , wherein the entrained polymer composition comprises a channeling agent that forms passages that penetrate through the base polymer in the solidified entrained polymer. 
     
     
         46 . The method of  claim 42 , wherein the particulate active agent comprises molecular sieve. 
     
     
         47 . A method for forming and adhering entrained polymer composition in a repeated predetermined pattern to a substrate in an automated package production line, the method comprising the steps of:
 a. extruding an entrained polymer composition in molten form, wherein the entrained polymer composition comprises a mixture of a base polymer and a particulate active agent, the particulate active agent being from 20% to 80% by weight with respect to the total weight of the entrained polymer;   b. providing a substrate having a surface for receiving application of the entrained polymer composition;   c. applying the entrained polymer composition in molten form in the shape of a predetermined pattern to a part of the surface of the substrate to form thereon a solidified entrained polymer pattern, wherein the entrained polymer composition adheres to the part of the surface of the substrate by thermal bonding, wherein the entrained polymer composition in the predetermined pattern is formed upon cooling and solidification of the entrained polymer composition; and   d. repeating steps (b) and (c) so as to form and adhere the repeated predetermined pattern to the substrate in the automated package production line,   
       wherein the method is carried out using a hot melt dispensing apparatus comprising:
 i. an extruder for blending and melting the entrained polymer composition and providing a flow of the entrained polymer composition in molten form through the apparatus; 
 ii. a hose having an internal lumen in fluid communication with an exit of the extruder to receive the flow of the entrained polymer composition in molten form; and 
 iii. an applicator in fluid communication with the hose, the applicator comprising a dispenser for dispensing the molten entrained polymer composition, 
 
       wherein the lumen terminates at the applicator to which the entrained polymer composition in molten form is conveyed through the hose, and wherein the dispenser applies the entrained polymer composition in molten form to the surface of the substrate in the predetermined pattern, wherein the lumen is heated as the entrained polymer composition is conveyed through the hose to the dispenser to maintain the molten form of the entrained polymer composition, wherein the dispenser is heated to maintain the molten form of the entrained polymer composition for applying to the surface of the substrate and to facilitate precise formation of the entrained polymer composition into the repeated predetermined pattern. 
     
     
         48 . The method of  claim 47 , wherein the particulate active agent comprises a desiccant. 
     
     
         49 . The method of  claim 47 , wherein the particulate active agent comprises silica gel and an antimicrobial agent, the entrained polymer composition further comprising a channeling agent that forms passages that penetrate through the base polymer in the solidified entrained polymer. 
     
     
         50 . The method of  claim 47 , wherein the particulate active agent comprises molecular sieve.