U.S. patent application number 10/320953 was filed with the patent office on 2003-04-10 for article-embedded folding container and method for producing same.
Invention is credited to Lux, Gerard Paul JR., Moore, Melanie A..
Application Number | 20030066270 10/320953 |
Document ID | / |
Family ID | 25109618 |
Filed Date | 2003-04-10 |
United States Patent
Application |
20030066270 |
Kind Code |
A1 |
Lux, Gerard Paul JR. ; et
al. |
April 10, 2003 |
Article-embedded folding container and method for producing
same
Abstract
A packaging blank capable of forming a container having at least
two internal compartments comprises in one embodiment a
substantially rectangular bottom panel having opposing first and
second side panels, a substantially rectangular top panel connected
to the bottom panel by the second side panel, and an internal panel
connected to the top panel by a first glue flap, wherein the bottom
panel typically includes at least one display window. Upon
construction the packaging blank provides a container having
multiple internal compartments that may be viewable through a
plurality of display windows. A method of packaging a product and
an associated article comprises in one embodiment the steps of
providing a blank, folding the internal panel over the top panel,
positioning the article on the internal panel, folding the bottom
panel over the internal panel, and securing the container formed by
the blank.
Inventors: |
Lux, Gerard Paul JR.;
(Charlotte, NC) ; Moore, Melanie A.; (Charlotte,
NC) |
Correspondence
Address: |
SUMMA & ALLAN, P.A.
11610 NORTH COMMUNITY HOUSE ROAD
SUITE 200
CHARLOTTE
NC
28277
US
|
Family ID: |
25109618 |
Appl. No.: |
10/320953 |
Filed: |
December 16, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10320953 |
Dec 16, 2002 |
|
|
|
09777219 |
Feb 5, 2001 |
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Current U.S.
Class: |
53/462 |
Current CPC
Class: |
B65D 5/0254 20130101;
B65D 77/02 20130101; B65D 2203/06 20130101; B65D 2585/56 20130101;
B65D 5/4237 20130101; B65D 5/54 20130101; B65D 5/48014
20130101 |
Class at
Publication: |
53/462 |
International
Class: |
B65B 011/00 |
Claims
That which is claimed is:
1. A method of packaging articles, said method comprising:
providing a flexible blank having an internal planar side and an
external planar side, said blank comprising a bottom panel having a
first and second side panel, a top panel connected to the bottom
panel by the second side panel, and an internal panel that is
connected to the top panel by a first glue flap, opposite the top
panel; folding the internal panel over the top panel upon which at
least one article is positioned; positioning at least one article
to be packaged on the external planar side of the internal panel;
and folding the bottom panel over the internal panel.
2. A packaging method according to claim 1, wherein the blank
provided includes a second glue flap connected to the internal
panel, opposite the first glue flap; and the step of folding the
internal panel comprises: folding the internal panel to a position
substantially adjacent the top panel; and adhering the second glue
flap to the second side panel.
3. A packaging method according to claim 1, wherein the step of
positioning at least one article comprises adhering the article to
be packaged to the internal panel.
4. A packaging method according to claim 1, wherein the step of
folding the bottom panel comprises adhering a portion of the bottom
panel to the internal panel, thereby forming a substantially flat
container.
5. A packaging method according to claim 4, wherein the step of
adhering a portion of the bottom panel further comprises adhering
the first side panel to the first glue flap.
6. A packaging method according to claim 4, wherein the step of
folding the bottom panel further comprises folding the bottom panel
over the internal panel such that at least one article is viewable
through at least one display window formed in the bottom panel.
7. A packaging method according to claim 1, further comprising:
placing a product to be packaged on an internal planar side of the
flexible blank; and securing the container after the step of
folding the bottom panel.
8. A method of packaging articles, said method comprising:
providing a one-piece flexible blank having an internal planar side
and an external planar side, said blank comprising a bottom panel
having a first and second side panel, a top panel connected to the
bottom panel by the second side panel, and an internal panel that
is connected to the top panel by a first glue flap, opposite the
top panel; providing a product to be packaged; placing the product
on the internal planar side of the flexible blank; folding the
internal panel over the top panel; positioning at least one article
to be packaged on the external planar side of the internal panel;
and folding the bottom panel over the internal panel.
9. A packaging method according to claim 8, wherein the one-piece
flexible blank further comprises a second glue flap connected to
the internal panel, opposite the first glue flap; and wherein the
step of placing the product comprises adhering the product to the
internal planar side of the one-piece flexible blank.
10. A packaging method according to claim 8, wherein the step of
folding the internal panel comprises folding the internal panel to
a position substantially adjacent the top panel, and adhering the
second glue flap to the second side panel.
11. A packaging method according to claim 8, wherein the step of
positioning at least one article comprises adhering the article to
be packaged to the internal panel.
12. A packaging method according to claim 8, wherein the step of
folding the bottom panel comprises adhering a portion of the bottom
panel to the internal panel, thereby forming a substantially flat
container.
13. A packaging method according to claim 12, wherein the step of
adhering a portion of the bottom panel further comprises adhering
the first side panel to the first glue flap.
14. A packaging method according to claim 12, wherein the step of
folding the bottom panel further comprises folding the bottom panel
over the internal panel such that at least one article is viewable
through at least one display window formed in the bottom panel.
15. A method of packaging articles, said method comprising:
providing a flexible blank having an internal planar side and an
external planar side, wherein the external planar side of the blank
is finished, said blank comprising a bottom panel having a first
and second side panel, a top panel connected to the bottom panel by
the second side panel, an internal panel that is connected to the
top panel by a first glue flap, opposite the top panel, and a
second glue flap connected to the internal panel, opposite the
first glue flap; providing a product to be packaged; providing one
informational insert to be packaged; placing the product on the
internal planar side of the flexible blank; folding the internal
panel over the top panel; positioning the informational insert on
the external planar side of the internal panel; and folding the
bottom panel over the internal panel.
16. A packaging method according to claim 15, wherein the step of
placing the product comprises adhering the product to the internal
planar side of the top panel.
17. A packaging method according to claim 15, wherein the step of
folding the internal panel comprises folding the internal panel to
a position substantially adjacent the top panel, and adhering the
second glue flap to the second side panel.
18. A packaging method according to claim 15, wherein the step of
positioning at least one article comprises adhering the article to
be packaged to the internal panel.
19. A packaging method according to claim 15, wherein the step of
folding the bottom panel comprises adhering a portion of the bottom
panel to the internal panel, thereby forming a substantially flat
container.
20. A packaging method according to claim 19, wherein the step of
folding the bottom panel further comprises folding the bottom panel
over the internal panel such that at least one article is viewable
through at least one display window formed in the bottom panel.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuing application of copending U.S.
application Ser. No. 09/777,219, filed Feb. 5, 2001, for
Article-Embedded Folding Container and Method for Producing Same.
This copending application is commonly assigned with this
application and is hereby incorporated entirely herein by
reference.
FIELD OF THE INVENTION
[0002] The invention relates to a packaging blank. In particular,
the invention relates to a packaging blank capable of forming a
container having multiple internal compartments. The invention
further relates to a container formed from the blank that includes
multiple internal compartments and one or more display windows that
provide a view of the internal compartments. Still further, the
invention relates to a method of packaging articles in the
container wherein the container is formed around the articles. The
articles to be positioned can include a variety of components,
including informational inserts, coupons, warranty cards, warning
cards, pouches, sachets, or similar substantially flat
articles.
BACKGROUND OF THE INVENTION
[0003] Conventional packaging includes top walls, bottom walls,
side walls, and closure panels for containing various products. As
known to those skilled in the art, packaging is typically formed
from packaging blanks, or blanks for short. It will be understood
that as used herein the term "blank" may include cardboard, rigid
paper, flexible plastic, or similar products made of paperboard or
plastic. In particular, the packaging industry favors the use of
one-piece flexible blanks, which are readily incorporated into
automated processes for forming packaging containers.
[0004] As used herein, the term "article" will refer primarily to
an informational insert or insert for short. Typical inserts are
large sheets of printed paper that are folded to a smaller size for
inclusion into a packaging container. Generally, the inserts are
inserted into the interior of the containers alongside the primary
product.
[0005] Today, the packaging of inserts, in concert with an
associated product, is managed in the product manufacturers'
facilities. Actual insertion into the container is accomplished by
either manual or automated processes. As an example, pharmaceutical
manufacturers are often required to include one or more
informational inserts along with their primary products (e.g.,
typically blister cards or plastic bottles of tablets). Manual
insertion of inserts is slow and labor intensive. Although
typically more efficient than manual insertion, automated insertion
systems may result in increased waste, slower production speeds,
and may also require additional labor on the line. By supplying an
insert-embedded folding container, the need for manual or in-line
insertion of inserts at the product manufacturer's site is
eliminated, thus creating significant efficiencies in their
production processes.
[0006] Product manufacturers in selected industries, such as the
pharmaceutical industry, are required to incorporate Good
Manufacturing Practices to ensure that the correct informational
insert is married with the appropriate product being housed in the
container. However, most containers lack windows that permit a view
of the inserts and any identifying code (e.g., bar code) printed on
the insert. Thus, once sealed, it is necessary to actually destroy
the package in order to verify the process. Therefore, it is
desirable to provide a packaging blank capable of forming a
container that includes one or more display windows that permit
viewing of one or more informational inserts contained therein. It
will be understood that as used herein, the term "viewing" may
include reading with the human eye or scanning with a bar code
scanner.
[0007] Most current processes employed create packaging on one
apparatus and then insert products and associated inserts on a
separate apparatus after the container is formed. The method of
packaging pharmaceuticals and inserts as described above typically
uses a belt-driven conveyor for advancing a blank along a
production line. In production, the blank is folded along fold
lines and portions of the blank are secured to one another (e.g.,
by adhesive) to form a container. This process is typically
completed by a packaging supplier who then ships the finished
package to the product manufacturer. Subsequently, the product
manufacturer mechanically inserts the primary product into the
packaging. The insert can then either be manually or mechanically
placed into the container.
[0008] Unfortunately, this method creates "dual inventories" at the
product manufacturers' facilities. The product manufacturer is
required to independently stock and track the primary product, the
package, and the inserts up until the point of manufacture. Thus
there is a need for a method for providing an insert-embedded
folding container that simplifies the product manufacturer's
inventory requirements.
OBJECT AND SUMMARY OF THE INVENTION
[0009] It is therefore an object of the present invention to
provide for the packaging of a product and an associated insert
suitable for use in automated processing.
[0010] Another object of the invention is the provision of a
container formed from a blank that provides visual verification
that the primary product is properly matched with its associated
insert.
[0011] A further object of the invention is to increase the
manufacturing efficiencies associated with placing informational
inserts or other articles.
[0012] Yet another object of the invention is to improve inventory
management by eliminating the necessity for manufacturers to track
separate inventories for containers and inserts.
[0013] The invention meets these objectives with a packaging blank
capable of forming a container having multiple internal
compartments. In particular, the invention is a packaging blank
having multiple display windows that provide a view of the internal
compartments of the container upon construction. In another aspect,
the invention is a method for packaging an article (e.g., insert)
that incorporates the blank wherein the container is formed around
the insert.
[0014] The foregoing and other objects and advantages of the
invention and the manner in which the same are accomplished will
become clearer based on the following detailed description taken in
conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of a preferred embodiment of
the container illustrating the display windows that permit viewing
of indicia printed on article (e.g., informational inserts) that
are positioned in an internal compartment.
[0016] FIG. 2 is a top planar view of a preferred embodiment of the
packaging blank depicting the top panel, bottom panel, internal
panel, and display windows.
[0017] FIG. 3 is a cross-sectional view taken generally along lines
3-3 on FIG. 1 depicting a product (e.g., blister pack) positioned
in one internal compartment and articles (e.g., multiple inserts)
positioned in another internal compartment of the preferred
embodiment.
[0018] FIG. 4 is a perspective view of the container illustrating a
user pulling the pull-flap upwardly, thereby detaching the sides of
the pull flap from the bottom wall to gain access to the internal
compartment containing the insert.
[0019] FIG. 5 is a perspective view of the container showing the
user removing the insert from an internal compartment.
[0020] FIG. 6 is a perspective view of the container depicting the
user removing a packaged product from an internal compartment.
[0021] FIG. 7 is a perspective view of a second embodiment of the
container illustrating a single display window.
[0022] FIG. 8 is a top planar view of the second embodiment of the
packaging blank.
[0023] FIG. 9 is a cross-sectional view of the second embodiment of
the container taken generally along lines 9-9 on FIG. 7 depicting a
blister pack positioned in one internal compartment and an insert
positioned in another internal compartment.
[0024] FIG. 10 is a perspective view of the packaging blank
displaying an insert placed on the internal panel of the second
embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present invention will now be described more fully
hereinafter with reference to the accompanying drawings, in which a
preferred embodiment of the invention is shown. This invention may,
however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein. Rather,
these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the
invention to those skilled in the art. Like numbers refer to like
elements throughout.
[0026] An overall view of a container 16 formed from a preferred
embodiment of a packaging blank 10 which incorporates features of
the present invention is set forth in FIG. 1. As used herein, the
term "panel" is used in conjunction with the packaging blank of the
present invention and refers to sections of the blank. Further, the
term "wall" is used in conjunction with the container of the
present invention and refers to structures forming the
container.
[0027] As depicted in FIG. 2, the packaging blank 10 includes a top
panel 11, a bottom panel 12, and an internal panel 13. It will be
understood by those of skill in the art that the terms top panel
and bottom panel, and top wall and bottom wall, are also referred
to as front panel and rear panel in the packaging industry.
[0028] With reference to the orientation of the blank in FIG. 2, it
will be understood that the term "width" refers to a distance
measured from the lowermost portion of a side panel 14, 15 or glue
flap 21, 22 to the uppermost portion of a side panel or glue flap.
It will be further appreciated by those of ordinary skill in the
art that, as used herein, the concept of a panel or wall being
"between" two other panels or walls does not necessarily imply that
the three panels or walls are contiguous (i.e., in intimate
contact). Rather, as used herein, the concept of one panel or wall
being between two other panels or walls is meant to describe the
relative positions of the panels or walls within the blank or
container structure, respectively. Similarly, as used herein, the
concept of a first panel being connected to a second panel by a
third panel, "opposite" the second panel, merely describes the
relative positions of the first and second panels within the blank
structure.
[0029] The bottom panel 12 of the preferred blank 10 as shown in
FIG. 2 includes opposing first and second side panels 14, 15, and
at least two display windows 20. An alternative embodiment of the
preferred blank 10 may include a single window (not shown). The
bottom panel 12 is connected to the top panel 11 by the second side
panel 15. Upon constructing the blank 10 into a container 16, the
window 20 facilitates bar code verification as discussed
herein.
[0030] The internal panel 13 of the preferred embodiment is
connected to the top panel 11 by a first glue flap 21. As depicted,
the top panel 11 is positioned between the bottom panel 12 and the
internal panel 13. The internal panel 13 includes a second glue
flap 22 positioned opposite the first glue flap 21. The width of
the second glue flap 22 is preferably less than the width of the
first glue flap 21.
[0031] Advantageously, the blank 10 is capable of being folded such
that the internal panel 13 divides the interior space defined by
the top panel 11 and the bottom panel 12 in order to form more than
one internal packaging compartment 23. See FIG. 3. Thus, the blank
10 is capable of forming a container 16 that has at least two
internal compartments 23 for separately receiving a product 71 and
an article 34 (e.g., insert).
[0032] In the preferred embodiment, the top panel 11, bottom panel
12, and internal panel 13 are substantially rectangular.
Nevertheless, it will be understood that the top and bottom panels
11, 12 and internal panel 13 are not limited to a rectangular shape
and may be oval, polygonal, or elliptical in shape.
[0033] As illustrated in the preferred embodiment of FIG. 2, the
packaging blank 10 may be a one-piece flexible blank formed from
paperboard or plastic. The blank 10 includes an external planar
side 24 and an internal planar side 25. The external planar side 24
is preferably finished. As used herein, it will be understood that
the term "finished" means coated with a material to produce an
attractive glossy finish. The term "finished" will also be
understood to mean the inclusion of printed material or other
identifying indicia (e.g., a company's logo).
[0034] In order to facilitate the formation of a substantially
rectangular container 16, the widths of the first and second side
panels 14, 15 of the preferred embodiment are about equal to one
another.
[0035] As depicted in FIG. 2, two pairs of dust flaps 30 are
provided at opposing ends of the first side panel 14 and the second
side panel 15. Each pair of dust flaps 30 extend beyond the ends of
the first and second side panels 14, 15, and are foldable along
fold lines formed in the blank 10. The dust flaps 30 form part of
end closures for securing the container 16 as described herein. In
the preferred embodiment, a pair of closure panels 31 is also
provided at opposing ends of the bottom panel 12. Alternatively,
the pair of closure panels 31 may be attached to opposing ends of
the top panel 11. In yet another embodiment, a pair of closure
panels 31 may be formed at opposing ends of both the bottom and top
panel 12, 11 so that the opposing closure panels may be folded
inwardly against one another in an overlapping fashion and adhered
to one another. As known to those skilled in the art, this latter
embodiment forms what is known as a "sealed end" carton or
container.
[0036] The outermost opposing ends of each closure panel 31 may
include an outermost tuck flap 32 for insertion into the interior
of the container 16 upon construction. Accordingly, the dust flaps
30, closure panels 31, and tuck flaps 32 form the end closures for
securing the container 16 formed from the blank 10.
[0037] As shown in FIG. 2, the preferred embodiment of the present
invention provides a pull-flap 33 that is formed by perforations 26
in the bottom panel 12. The pull-flap 33 is positioned on the
bottom panel 12 adjacent to one of the display windows 20 and
defines at least one side of a first window. As configured, the
pull-flap 33 of the preferred embodiment defines the entire
perimeter of a second window.
[0038] In this configuration, the pull-flap 33 formed in the blank
10 provides a consumer with easy access to an insert 34 that may be
placed in one of the internal compartments 23. Specifically, the
pull-flap 33 permits the consumer to grasp the edge of the
pull-flap adjacent a window, lift the flap away from the container
16 to tear the perforations 26 in the bottom panel 12, thereby
separating the pull-flap from the bottom panel and providing access
to the insert 34 contained within an adjacent internal compartment
23. See FIGS. 4, 5, and 6. Accordingly, the product 71 is
preferably positioned in a first internal compartment 70 and the
insert 34 is positioned in a second internal compartment 72. See
FIG. 3.
[0039] As configured, the display windows 20 are positioned on the
bottom panel 12 such that the external planar side 24 of the
internal panel 13 is viewable through the display windows upon
construction of the container 16. The display windows 20 thereby
provide a view of at least two different positions on the external
planar side 24 of the internal panel 13. Accordingly, two windows
would provide a view of two separate inserts 34 and any indicia
(e.g., bar code) printed thereon.
[0040] A perspective view of a second embodiment of the present
invention is depicted in FIG. 7. As illustrated in FIG. 8, the
second embodiment of the invention includes a packaging blank 35
having a top panel 36, bottom panel 37, and an internal panel 38.
The bottom panel 37 is connected to the top panel 36 by a first
side panel 39, and includes at least one display window 40. The
internal panel 38 of the second embodiment is connected to the top
panel 36 by a second side panel 41. As depicted, the top panel 36
is positioned between the bottom panel 37 and the internal panel
38.
[0041] The internal panel 38 includes a glue flap 42 positioned
opposite the second side panel 41. The glue flap 42 has a width
that is less than the width of the first side panel 39. As shown in
FIG. 9, the second embodiment of the packaging blank 35 is likewise
foldable such that the internal panel 38 (illustrated as an
internal wall 67) divides the interior space of a container 43
defined by the top and bottom panels 36, 37 (illustrated as a top
wall 65 and a bottom wall 66), thereby forming a
multi-compartmented container.
[0042] With reference to FIG. 8, the second embodiment likewise
consists essentially of a one-piece flexible paperboard blank 35
that includes a finished external planar side 44 and an internal
planar side 45. In order for the second embodiment to facilitate
the formation of the substantially rectangular container 43, the
width of the first side panel 39 and the width of the second side
panel 41 are about equal.
[0043] The end closures of the second embodiment depicted in FIG. 8
also include dust flaps 46, closure panels 47, and tuck flaps 48
similar to the first embodiment of FIG. 2. In other words, the
first and second side panels 39, 41 each include a pair of dust
flaps 46 formed at respective opposing ends. In addition, a pair of
closure panels 47 and associated tuck flaps 48 is likewise provided
at opposing ends of either the bottom panel 37 or top panel 36 to
secure the container 43. In another embodiment, a pair of closure
panels 47 may be formed at opposing ends of both the bottom and top
panel 37, 36 so that the opposing panels may be folded against one
another (i.e., overlapping) and adhered to form a sealed end
carton.
[0044] The second embodiment also provides a pull-flap 49 formed by
perforations 50 in the bottom panel 37. As illustrated in FIG. 8,
the edge of the pull flap 49 is positioned adjacent the display
window 40. As configured, at least one display window 40 is
positioned on the bottom panel 37 such that the external planar
side 44 of the internal panel 38 is viewable through the display
window upon construction of the container 43.
[0045] The multiple windows of the preferred embodiment and the
single window of the second embodiment are similar with respect to
their positioning. Stated differently, each window 20, 40 of the
first and second embodiments is positioned on the bottom panels 12,
37 such that a portion of the external planar sides 24,44 of the
internal panels 13, 38 is viewable through each window when the
packaging blanks 10, 35 are formed into containers 16, 43.
[0046] Another aspect of the present invention, as illustrated in
FIG. 1, includes a container 16 formed from the packaging blank 10
that has multiple internal compartments 23. As described above, the
term "wall" is used in conjunction with the container of the
present invention--as opposed to the previously described blank.
Further, the term wall refers to structures forming the container
as opposed to the sections of the blank. With reference to the
orientation of the container in FIG. 1, it will be understood that
the term "width" refers to a distance measured from the base of the
container to the top of the container.
[0047] A preferred embodiment of the container includes a top wall
55, a bottom wall 56, and an internal wall 57. In the preferred
embodiment the top wall 55, bottom wall 56, and internal wall 57
are substantially rectangular in shape, but may be oval, polygonal,
or any similar shape supporting the construction of a container.
The bottom wall 56 is connected to the top wall 55 by a first and
second side wall 58, 59. At least one display window 20 is provided
in the bottom wall 56 for viewing the internal wall 57 that is
positioned between the top and bottom walls. See FIG. 3.
Alternatively, it will be understood that a preferred embodiment of
the container 16 may include a single window. The internal wall 57
is connected at each end to the first and second side walls 58, 59.
The positioning of the internal wall 57 thereby defines multiple
internal packaging compartments 23, that is to say, a first
internal compartment 70 and a second internal compartment 72,
within the container 16, as illustrated in FIG. 3.
[0048] The internal wall 57 of the preferred embodiment of the
container 16 includes a first glue flap 61 that connects the
internal wall to the first side wall 58. The internal wall 57 also
includes a second glue flap 62 attached to the second side wall 59.
The width of the second glue flap 62 is preferably less than the
width of the second side wall 59. The container 16 is preferably
formed from a one-piece flexible paperboard blank 10 that includes
an external planar side 18 and an internal planar side 25. The
container 16 may also be formed from a one-piece flexible plastic
blank. A preferred embodiment of the container 16 includes a
finished external planar side that may include printed matter or
similar indicia. In this configuration, the top wall 55, bottom
wall 56, and internal wall 57 form substantially parallel planes.
See FIG. 3.
[0049] The width of the first and second side walls 58, 59 are
about equal to facilitate the formation of a substantially
rectangular container 16. The first and second side walls 58, 59
each include a pair of dust flaps 30 formed at opposing ends of the
respective side walls. In the preferred embodiment, the bottom wall
56 includes a pair of closure panels 31 formed at opposing ends of
the bottom wall. It will be understood that the pair of closure
panels 31 may, alternatively, be positioned at opposing ends of the
top wall 55.
[0050] Each of the closure panels 31 may include a tuck flap 32
formed at opposing ends of the closure panels for insertion into
the interior of the container 16. In an alternative embodiment
lacking tuck flaps 32, an end closure may be formed from a pair of
closure panels formed at opposing ends of both the bottom and top
panel. In this configuration, the opposing panels may be folded
inwardly against one another (i.e., overlapping) and adhered to one
another, thus forming sealed end carton. It will be understood that
an end of the container 16 may be secured in any number of ways
consistent with standard packaging practices.
[0051] The preferred embodiment of the container 16 may also
include a pull-flap 33 for providing access to the interior of the
container. Specifically, perforations 26 in the bottom wall 56
define the pull-flap 33 that is positioned adjacent the display
windows 20. As discussed, the pull-flap 33 provides easy access to
multiple inserts 34 positioned on the internal wall 57 without
destroying the sealed and secured package. As configured, at least
one display window 20 is positioned on the bottom wall 56 such that
a portion of internal wall 57 is viewable through display windows
20.
[0052] As shown in FIG. 3, the preferred embodiment includes any
number of informational inserts 34 positioned on the internal wall
57. In this fashion, the inserts are viewable through the display
windows 20.
[0053] An alternative embodiment of the container 43 also includes
a top wall 65, a bottom wall 66, and an internal wall 67. See FIG.
9. The bottom wall 66 is likewise connected to the top wall 65 by a
first and second side wall 68, 69. The bottom wall 66, however,
includes a single display window 40. The internal wall 67 is
similarly connected to the first and second side walls 68, 69. The
internal wall 67 is also positioned between the top and bottom
walls 65, 66, thereby forming more than one internal packaging
compartment 23. The internal wall 67 also includes a single glue
flap 42. In the second embodiment of the container 51, however, the
glue flap 42 is attached to the first side wall 68. In this
configuration, the top wall 65, bottom wall 66, and internal wall
67 form substantially parallel planes.
[0054] The second embodiment of the container 43 likewise may be
formed from a one-piece flexible paperboard or plastic blank 35
that has an external planar side 44 and an internal planar side 45.
Preferably, the external planar side is finished.
[0055] In regards to end closures, the first side wall 68 includes
a pair of dust flaps 46 formed at opposing ends of the first side
wall. The second side wall 69 likewise includes a pair of dust
flaps 46 formed at opposing ends of the second side wall. The
bottom wall 66 includes a pair of closure panels 47 formed at
opposing ends of the bottom wall. Alternatively, the top wall 65
may include a pair of opposing closure panels 47. It will be
understood that a pair of closure panels 47 may also be provided at
opposing ends of both the top and bottom walls 65, 66 for forming a
sealed end. Each closure panel 47 may also include a tuck flap 48
formed at the outermost opposing ends of the closure panels.
[0056] A pull-flap 49 is also provided in the second embodiment of
the container 43. The pull-flap is similarly formed by perforations
50 in the bottom wall 66, and positioned adjacent to the display
window 40. As described, the display window 40 is positioned on the
bottom wall 66 such that a portion of the internal wall 67 is
viewable through the display window.
[0057] Another aspect of the invention includes the use of the
packaging blanks 10, 35 of the present invention in conjunction
with a method for packaging articles (e.g., an informational
insert). This method is preferably accomplished at a packaging
supplier's facility, thereby eliminating the requirement for a
product manufacturer to package the product and its associated
article (e.g., an informational insert) in separate insertion
steps. Stated differently, the product manufacturer is not required
to independently stock and track the primary product, the
associated inserts, and the package. As depicted, a flexible blank
that includes an internal planar side and an external planar side
is provided on a work station.
[0058] In a preferred method, a blank 10 is provided that includes
a bottom panel 12 having first and second side panels 14, 15, and a
top panel 11 connected to the bottom panel by the second side
panel. The preferred method further provides a blank 10 having an
internal panel 13 that is connected to the top panel 11 by a first
glue flap 21 positioned opposite the top panel.
[0059] The internal panel 13 is then folded over the top panel 11
to form, upon construction, a first internal compartment 70 in
which a product 71 to be packaged is positioned, for example, at a
product manufacturer's facility during the final stages of
packaging. See FIG. 3. Alternatively, a packaging manufacturer may
incorporate the step of placing a product associated with the
article on an internal planar side 25 of the flexible blank 10. It
will be understood that the product may be placed on the top panel
11, the second side panel 15, or the internal panel 13 in this
alternative method.
[0060] Upon folding the internal panel 13 over the top panel 11,
the external planar side 24 of the blank 10 is presented for
receiving at least one article 34 as described herein. In a
preferred method, the internal panel 13 is folded along a fold line
connecting the first glue flap 21 to the top panel 11 such that the
internal panel is substantially parallel and adjacent to the top
panel. In a preferred method, the blank provided includes a second
glue flap 22 that is connected to the internal panel 13, and
positioned opposite the first glue flap 21. As provided, the
external planar side 24 of the second glue flap 22 is then adhered
to the internal planar side 25 of the second side panel 15. In the
preferred method, the internal panel 13 is folded over the top
panel 11 such that the folded blank 10 is substantially flat.
[0061] After folding the internal panel 13 over the top panel 11
and adhering the second glue flap 22 to the second side panel 15,
at least one article 34 is positioned on the external planar side
24 of the internal panel. It will be understood, that upon
construction of the container, a second internal compartment 72 is
formed in which the article is positioned. A preferred method of
positioning the article 34 includes adhering the article to the
external planar side 24 of the internal panel with adhesive or
static charge.
[0062] The step of positioning an article may incorporate a
conventional device that includes an arm having a suction means
which retrieves an article and then positions the same on a panel
of the blank. For example, an article 34 may be retrieved and then
selectively placed on the blank 10 such that a bar code 63 on the
article is viewable through a display window 20 upon construction
of the container 16. Accordingly, a bar code scanner positioned
along an automated production line may scan the bar code 63 on the
article 34, thereby expediting pharmaceutical compliance. In other
words, the product manufacturer can ensure that the appropriate
article-embedded container is married with the appropriate product
71 (e.g., pharmaceutical) to be packaged in the container 16.
[0063] Subsequently, the bottom panel 12 is folded over the
internal panel 13. In a preferred method, the bottom panel 12 is
folded over the top panel 11 and the internal planar side of the
first side panel 14 is adhered to the external planar side of the
first glue flap 21, thereby forming a substantially flat container
suitable for shipment and capable of being constructed into a
substantially rectangular container 16.
[0064] Accordingly, the bottom panel 12 is folded over the internal
panel 13 such that one or more articles 34 positioned on the
internal panel are viewable though multiple display windows 20
formed in the bottom panel. The substantially flat container having
an article 34 embedded therein, may subsequently be shipped to a
product manufacturer where a product 71 can be married with its
respective article-embedded container 16. Specifically, the
substantially flat container can be constructed in a rectangular
container 16 and the product 71 associated with the article 34 can
be positioned in the first internal compartment 70.
[0065] Subsequently, the container may be secured by folding a pair
of dust flaps 30 formed at opposing ends of the first and second
side panels 14, 15 against the internal panel 13. A pair of tuck
flaps 32 formed at the outermost opposing end of the bottom panel
12 is then inserted into the first internal compartment 70.
Consequently, a pair of closure panels 31 formed at opposing ends
of either the top panel 11 or the bottom panel 12 are positioned
adjacent each pair of dust flaps 30 and the container 16 is
secured. Nevertheless, it will be understood that an end closure
may be formed from closure panels 31 formed at opposing ends of the
top and bottom panels 11, 12 that do not include tuck flaps 32,
such that an end of the container 16 may be secured by overlapping
and adhering the closure panels to form a sealed end, thus securing
the container.
[0066] Accordingly, the present method whereby an article is
positioned on the blank, and the container is subsequently formed
around the article, promotes substantially higher assembly speeds
and lower waste than existing methods, whereby the container is
formed and then the article is inserted into the finished
container. Stated differently, the present method positions an
article during the formation of the container, as opposed to
inserting the article after construction of the container.
Accordingly, upon construction of the container, the finished
package includes an article and is ready to accept an associated
product. Moreover, the present method is capable of incorporating a
wide variety of products into the present container. For example,
cosmetics, gifts, small toys, and the like may be packaged along
with an associated insert in accordance with the present invention.
In addition, multiple products can be placed in the same package.
In cases where the container forming equipment allows faster
construction speeds than the capability of one retrieval arm
device, additional retrieval units can be placed along the
production line and synchronized to deliver the finished product at
a faster rate than previously achieved.
[0067] In the drawings and specification, there have been disclosed
typical embodiments on the invention and, although specific terms
have been employed, they have been used in a generic and
descriptive sense only and not for purposes of limitation, the
scope of the invention being set forth in the following claims.
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