U.S. patent application number 11/033702 was filed with the patent office on 2006-07-13 for printed plastic packaging.
Invention is credited to Christopher R. Tilton.
Application Number | 20060151350 11/033702 |
Document ID | / |
Family ID | 36177866 |
Filed Date | 2006-07-13 |
United States Patent
Application |
20060151350 |
Kind Code |
A1 |
Tilton; Christopher R. |
July 13, 2006 |
Printed plastic packaging
Abstract
A premium plastic package is provided as well as a method for
producing such a package. Printing on multiple surfaces of a
package to obtain appealing visual effects is described. Methods of
sealing plastic packages are described, including some that use
ultraviolet light to activate an adhesive. Plastic materials that
can be used include recycled and/or recyclable polyurethane.
Inventors: |
Tilton; Christopher R.;
(Laguna Niguel, CA) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
2040 MAIN STREET
FOURTEENTH FLOOR
IRVINE
CA
92614
US
|
Family ID: |
36177866 |
Appl. No.: |
11/033702 |
Filed: |
January 12, 2005 |
Current U.S.
Class: |
206/461 |
Current CPC
Class: |
B65D 2203/00 20130101;
B65D 73/0092 20130101; B65D 2401/55 20200501; B65D 2211/00
20130101 |
Class at
Publication: |
206/461 |
International
Class: |
B65D 73/00 20060101
B65D073/00 |
Claims
1. An enclosure to deter theft of a product in the enclosure
comprising: a first plastic portion having first and second
surfaces, said first plastic portion having printing upon at least
one of said first and second surfaces; a second plastic portion
having third and fourth surfaces, said second plastic portion
having printing upon at least one of said third and fourth
surfaces; and wherein said first and second plastic portions are
secured to enclose a product.
2. The theft-deterrent enclosure of claim 1, wherein first and
second plastic portions are secured using ultraviolet light to
activate an adhesive.
3. The theft-deterrent plastic enclosure of claim 1, wherein the
plastic clamshell package is formed from recycled polyurethane.
4. The theft-deterrent plastic enclosure of claim 1, wherein the
plastic portions are clear.
5. The theft-deterrent plastic enclosure of claim 1, wherein at
least three of the plastic surfaces have printing.
6. A theft-deterrent plastic enclosure for a product comprising: a
front plastic portion and a back plastic portion; at least two
inner surfaces, at least one of which is printed; at least two
outer surfaces, at least one of which is printed; wherein the
plastic portions are formed from recycled material.
7. The theft-deterrent plastic enclosure of claim 6, wherein said
front and back plastic portions are sealed together using
ultraviolet light to activate an adhesive.
8. The theft-deterrent plastic enclosure of claim 6, wherein the
recycled material is recycled polyurethane.
9. The theft-deterrent plastic enclosure of claim 6, wherein the
plastic portions are clear.
10. The theft-deterrent plastic enclosure as in claim 6, wherein
the at least two printed surfaces comprise opposite sides of the
same plastic portion.
11. The theft-deterrent plastic enclosure of claim 6, wherein the
plastic enclosure is a clamshell.
12. A method of forming a theft-deterrent plastic clamshell package
for a product, comprising: extruding a plastic material into a
plastic sheet; printing on one surface of the plastic sheet;
printing on the other surface of the plastic sheet; forming the
plastic sheet into a package; placing a product into the package;
and closing said package.
13. The method of claim 12, wherein the closing step comprises
sealing the package using ultraviolet light to activate an
adhesive.
14. The method of claim 12, wherein the plastic material is
recycled polyurethane.
15. The method of claim 12, wherein the plastic material is
clear.
16. The method of claim 12, wherein the steps of forming, placing,
and closing are performed in the same machine, fully
automatically.
17. The method of claim 12, wherein the step of closing the package
further comprises die cutting the package to separate the
package.
18. A theft-deterrent printed plastic package for a product
comprising: a first plastic portion having first and second
surfaces, said first portion having printing upon at least one of
said first and second surfaces; a second plastic portion having
third and fourth surfaces, said second portion having printing upon
at least one of said third and fourth surfaces, said second portion
secured to said first portion at multiple seal points around the
product; said package is at least 13 inches long in a first
dimension.
19. The package of claim 18, wherein said first and second plastic
portions are formed from at least thirty-gauge plastic.
20. The package of claim 18, wherein said first and second plastic
portions are formed from plastic having a minimum caliper of 16
mil.
21. The package of claim 18, wherein said plastic portions are
formed from recycled polyurethane.
22. The package of claim 19, wherein said first and second plastic
portions are secured using ultraviolet light to activate an
adhesive.
23. The package of claim 18, wherein said first and second portions
are secured at two seal points around the product.
24. The package of claim 18, wherein said package is at least 15
inches long in a second dimension.
Description
BACKGROUND OF THE INVENTIONS
[0001] 1. Field of the Inventions
[0002] The inventions disclosed herein relate to product packaging.
More specifically, some embodiments provide for a retail product
display package that is not only resistant to theft and tampering,
but also highly attractive and formed from recycled materials.
[0003] 2. Description of the Related Art
[0004] Retail establishments commonly attempt to make their
products more attractive to customers. However, some of the same
techniques that attract buyers can also attract thieves. Theft is a
problem that has long plagued retail establishments, especially
theft of compact, high-margin goods-personal electronic devices,
for example which are attractive to thieves because they can be
easy to pocket and have a high resale value. Often, retail stores
make these items less accessible to customers, placing them behind
or inside of a glass counter, for example. That way, store
personnel do not have to spend as much time watching over patrons
to make sure they are not pilfering goods.
[0005] This solution is effective at preventing theft, but can have
the undesirable side effect of lowering sales. For a variety of
reasons, many customers are uncomfortable asking a sales clerk to
help them. For example, some customers are simply too impatient to
wait for a busy clerk to get to them. No matter what the reason, if
a customer cannot quickly and easily select an item for purchase
without the aid of a store clerk, a customer is less likely to
purchase it.
[0006] As an alternative to placing the goods behind a counter or
in a protective case, many stores instead prefer to display
high-margin items inside oversized packaging that is unlikely to
fit in the pocket of a potential thief. Tamper-resistant packaging
can also help foil the would-be larcenist by deterring any attempts
to tear, puncture, cut, or fold the packaging to make it easier to
conceal.
[0007] In addition to concerns relating to potential theft, retail
establishments generally have a preference for packaging that
improves the appearance of the products inside. However, currently
used plastic packaging and the techniques for creating it leave
much to be desired. For example, low cost skin packs use shrink
wrap surrounding printed cardboard, but these packages are not
sufficiently tamper resistant to package high-priced items.
Likewise, blister packs are not sufficiently secure, due to
readily-tom cardboard portions. Clamshell packaging can be more
tamper-resistant than blister packs, but in current forms, it has
drawbacks as well, because generally a cardboard insert must be
separately printed and then positioned within the packaging by
human hands. Indeed, many of the complex folds and features
employed to make clamshell packaging more tamper resistant make
such packaging expensive to manufacture. For example, the thick
plastic often used is relatively expensive, and assembly steps are
difficult to automate. Furthermore, many of the packaging genres
described above do not make use of recycled materials, leading to
increased manufacturing costs. Finally, current methods do not
provide for printing on more than one surface of plastic packaging
material.
[0008] Therefore, a theft-deterring package that is capable of
displaying informative product information, can be cheaply
manufactured, and can comprise a highly attractive design would be
of great benefit to the retail sales industry. Indeed, low cost
theft prevention packaging that also provides a very high quality
presentation while using recycled materials has not been available
in the past.
SUMMARY OF THE INVENTIONS
[0009] The inventions described herein have several features, no
single one of which is solely responsible for their desirable
attributes. Without limiting the scope of the inventions as
expressed by the claims that follow, some of the prominent features
will now be discussed briefly. Embodiments disclosed in this
application provide for packaging that solves many of the problems
encountered in the past. For example, some embodiments are not only
resistant to theft and tampering, they are also inexpensive to
manufacture and highly attractive. Furthermore, some embodiments
provide high impact point-of-sale marketing through use of
specialty printing directly on multiple surfaces of plastic
materials. Various plastic materials can be used in accordance with
the disclosed embodiments, including recycled or virgin plastics.
The disclosed inventions provide for superior quality and
environmentally favorable packaging with unique visual appeal and
theft-resistant properties.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Preferred embodiments will now be discussed in detail. The
embodiments depict novel and non-obvious aspects of printed
packaging that has great advantages over the prior art. The
embodiments shown in the drawings are for illustrative purposes
only, and the claimed inventions should not be deemed limited by
the exemplary embodiments illustrated by the following figures:
[0011] FIG. 1 shows a perspective view of a folded clamshell
package.
[0012] FIG. 2 shows an exploded view of a two-part clamshell
package.
[0013] FIG. 2A shows a plan view of the two-part clamshell package
of FIG. 2 in an assembled state.
[0014] FIG. 3 depicts overlying patterns.
[0015] FIG. 4 shows two overlapping patterns.
[0016] FIG. 5 illustrates a cross-sectional view of a plastic
package.
[0017] FIG. 6 shows a flow chart for the steps in a plastic
packaging production method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Product information printed directly on a product's
packaging enhances convenience for potential buyers. A buyer can
study the package at the point of sale and compare various products
according to the data printed on the package. This can save time
for a consumer and provide access to useful information, reducing
the risk that the product will later be returned or that the
consumer will not be happy with the purchase. Furthermore, such
information on packaging increases the chances that a customer will
buy the product by informing him or her of its novel features and
advantages over other products. Information provided on product
packaging can also have a persuasive role from a purely advertising
perspective by conveying a positive brand message and encouraging
purchase through enumerating the merits and utility of the
product.
[0019] But providing product data to the diligent comparative
shopper is not the only reason to print directly on product
packaging; the packaging can in fact attract buyers that would
otherwise not be interested in the product. For example, the
packaging may prominently display a trademark or brand name that
does not or cannot appear so prominently on the product itself. A
package may further display colors that are more eye-catching than
would be desirable for the product itself. Furthermore, a product
package can serve the purpose of calling attention to the product
or group of products, drawing the consumer closer to the product or
products. Indeed, product packaging can be part of an overall
visual effect caused by a display in a retail location. For
example, the product packaging can have colors that harmonize or
clash with display colors to create a visual effect. Such
attractive packaging and/or brightly colored advertising increases
the product's visibility on the shelf.
[0020] Another way a product packaging can add value is by
associating a product with an entity from popular culture such as a
movie personality or a broader advertising campaign. This can be
accomplished by portraying commonly recognized images or words on
the packaging. A product's packaging can thus capitalize on the
popularity or status of any entity or fad. Recognizing the multiple
ways product packaging can be used in a retail setting, various
improvements can further enhance current packages and the methods
and systems that lead to their creation and use.
Clamshell Packaging
[0021] One type of product packaging that can have good
theft-deterrent properties is clamshell packaging (clamshell). As
its name suggests, clamshell packaging can comprise two
complementary plastic portions that may be linked along one side in
order to fold together like the two complementary shells that form
the exoskeleton of the well-known marine crustacean.
[0022] FIG. 1 illustrates an embodiment of such a folded clamshell
configuration 110. As illustrated, a folded clamshell 110 can have
a first portion 111 and a second portion 115, joined together at a
crease 136. The two portions can in fact be integrally formed in
earlier manufacturing steps and folded to create crease 136 in a
later step. First portion 111 can have a first surface 112 and a
second surface 114. Similarly, second portion 115 can have a third
surface 116 and a fourth surface 118.
[0023] Either of first portion 111 and second portion 115 can
comprise a molded portion, such as molded portion 132 in FIG. 1. A
molded portion such as molded portion 132 can be generally
contoured to the shape of a product to be packaged (not shown).
Such a molded portion 132 can be in first portion 111, second
portion 115, and/or both portions. A product can be sandwiched
between the two portions of the packaging, fitting, for example,
within the contours of the molded portion.
[0024] To assemble a clamshell package the product is placed
between the two halves, which are then brought together. Once the
package is closed, the edges can be advantageously secured to each
other with glue, heat or other means suitable to prevent the edges
from being easily separated.
[0025] Alternatively, the two portions of a clamshell package need
not be hingedly linked before being sealed together. Thus,
clamshells can consist of two molded pieces of transparent plastic,
PVC, or other material that is difficult for human hands to tear.
The pieces are sometimes mirror images of one another, with the
edges of one half designed to mate or fit within the edges of the
other. Some embodiments may have one plastic portion that includes
a raised lip about its perimeter. The path traced by the lip about
the perimeter of that portion is preferably the same shape as, but
of slightly larger dimension than, the edges of the complementary
portion. The lip can provide a seat for the complementary portion,
facilitating automated manufacturing of the package by providing
accurate relative positioning of the two portions. The lip can also
advantageously block access to the edges of the complementary
portion. Because a thief cannot grasp the edges of the
complementary portion, he or she cannot attempt to easily peel the
two portions apart in order to remove the product.
[0026] A slightly different type of clamshell can be a self-service
package for containing small parts. Such a package can include a
bottom part having a perimeter wall, thereby forming a cup shape. A
lid, also having a perimeter wall that forms a cup shape, can
overlap the perimeter wall of the bottom part to close the
container. An adhesive label can span the boundary between the two
halves to seal them together.
[0027] Another type of clamshell can have a rigid back panel with a
product holding area and a separate larger graphics area. The panel
can have a flange that carries product information and the panel
can also seat against part of the product. The rigid back panel and
product cassette can be packaged with a further external thin film
shrink wrap.
Theft Deterrence
[0028] Some clamshells, such as those described above, can be
effective at deterring theft because they are difficult to fold,
nearly impossible to tear open, and difficult to cut open without
attracting attention. Some clamshells can be, however, quite
expensive to manufacture due to expensive materials and high labor
costs if non-plastic inserts are used to provide a place for
printing words or designs. Embodiments disclosed herein overcome
this dilemma by providing for printing directly on the plastic
clamshell packaging material.
[0029] Certain embodiments comply with theft deterrent standards
published by various retail companies. For example, some retail
establishments require that a theft resistant package have a
minimum size. Some advantageous embodiments meet such requirements
by being at least 15 inches wide by at least 13 inches tall. Other
sizes can also be adequately theft resistant. Retail establishments
also sometimes require plastic packaging materials to be of a
minimum hardness or thickness. Some advantageous embodiments meet
such requirements by being formed from a minimum of thirty-gauge
plastic. Some embodiments meet such requirements by using plastic
having a minimum caliper of 16 mil. Other thicknesses and
properties can also be adequately theft resistant. Retail companies
sometimes require that theft resistant packaging meet certain
minimum closure requirements. Some advantageous embodiments meet
these requirements by having multiple seal points in the plastic
packaging around the product. Some preferred embodiments
additionally have metal locking inserts and/or wire hooks that
attach the product to the plastic. Some preferred embodiments meet
these requirements by being "fully sealed," for example by using
heat sealing or a water-based urethane on the interference fit
edges. Some preferred embodiments are sealed so as to leave no
openings or holes larger than 1/8 inch in diameter.
[0030] The plastic packaging can include a raised ridge or indented
portion that projects outwardly from or protrudes inwardly from the
surface of the plastic package. Such a ridge or indented portion
can provide the package with greater rigidity, thereby increasing
the package's ability to resist bending. The ridge can thus prevent
a would-be larcenist from easily folding the package in order to
more easily conceal it under his or her clothing or inside a purse
or shopping bag. In addition, raised ridges can assist in the
vertical display of multiple packages in a box (not shown). Rather
than including such a ridge, the plastic packaging may
alternatively be constructed of plastic that is thick enough to
resist bending.
[0031] Some types of packaging are not necessarily designed to
prevent theft, but still include at least two plastic portions
sealed to one another. For example, a package can comprise a box
having one open side made of rigid plastic having a flexible
plastic cover adhered to a rim of the box spanning the opening. A
tab on the corner of the cover can enable a consumer to easily tear
off the cover in order to access the product inside. Another type
of plastic packaging can comprise a rigid plastic shell shaped
either as a hollow cylinder with one open end, or as a U. The open
end of the shell can be covered with a flexible plastic seal that
can be easily peeled away to access the product inside.
Printing
[0032] As illustrated in FIG. 2, in some embodiments, the plastic
portions of clamshell packaging can be printed upon. For example,
if a clamshell package has two complementary plastic portions, each
portion can have generally two surfaces. Each of the four surfaces
can receive printed material in the form of words, designs, colors,
layers of ink, etching, chemical effects, etc. In some embodiments,
printing on multiple surfaces of plastic materials allows for
special effects graphics, creation of transparent and/or
translucent surfaces, and even three-dimensional effects. These and
many other special graphical effects are possible by combining
printing on plastics with printing on multiple surfaces of a
package. Indeed, the quality of such graphics can be superior to
graphics printed on a paperboard insert card.
[0033] FIG. 2 illustrates one embodiment of a plastic clamshell
package 210 having printing on multiple plastic surfaces. In
contrast to FIG. 1, FIG. 2 illustrates a two-part clamshell without
a connecting crease such as crease 136 of FIG. 1. Clamshell 210
does, however, have multiple plastic portions. As shown, a
clamshell package 210 can have a first portion 211 and a second
portion 215. First portion 211 can have a first surface 212 and a
second surface 214. Similarly, second portion 215 can have a third
surface 216 and a fourth surface 218. As illustrated, each plastic
surface can be printed upon. For example, first surface 212 can
have printing 222 on it as illustrated by the numeral "1." Second
surface 214 can have printing 224 on it as illustrated by the
printed numeral "2." Printing 224 is visible through the plastic
portion 215. When viewed from the front, the numerals 1 and 2 seem
to partially overlap, even though the respective inks used to print
the two numerals do contact each other. This visual overlapping
effect is made possible by printing on both surfaces of the plastic
portion 215. Similarly, third surface 216 can have printing 226 on
it as illustrated by the numeral "3," and fourth surface 218 can
have printing 228 on it as illustrated by the numeral "4," as seen
through the plastic portion 215.
[0034] FIG. 2A illustrates how the plastic portions 211 and 215 of
FIG. 2 can come together, with product 234 sandwiched in between
them. As shown, printed portions 222, 224, 226, and 228 (numerals
1-4) seem to overlap, even though only one numeral is printed on
each of the four surfaces 212, 214, 216, and 218. The printing on
the back surfaces of the two plastic portions 211 and 215 (surfaces
214 and 218) is indicated with vertical lines. The printing on the
front surfaces (surfaces 212 and 216) of the two plastic portions
211 and 215 is indicated with horizontal lines. Thus, in the
illustrated configuration, the numerals are visible to the observer
despite the fact that some of them are farther removed from the
viewer, being separated from the viewer by successive plastic
portions. As shown, the numeral 1 is located closest to the viewer,
followed by numerals 2 and 3, separated from the viewer by plastic
portion 211, and finally by numeral 4, separated from the viewer by
both plastic portions 211 and 215.
[0035] Multiple layers of printing can have many desirable
benefits. Spectacular visual effects can be achieved by using
combinations of four colors on multiple superimposed plastic
surfaces. The color combinations used and the relative positioning
of the patterns can be chosen to depict any number of unique
designs. Multiple surface printing has the advantage of allowing
visual depth and spatial effects to be more convincing and
realistic. Printing in an overlapping manner also allows for a wide
variety of design options.
[0036] FIG. 3 illustrates one way in which layered printing can
comprise complementary layers that are configured to create a
visual effect when positioned one over another. In one embodiment,
the illustrated layers do not represent separate plastic portions,
but instead represent regions or surfaces that can accept printing.
For example, the layers can represent the four surfaces of two
plastic portions, such as surfaces 212, 214, 216, and 218 in FIG.
2. In some embodiments, a first layer 312 can have a printed
pattern 322. A second layer 314 can have a second pattern 324, a
third layer 316 can have a third pattern 326, and a fourth layer
318 can have a fourth pattern 328. Each pattern can be printed on a
surface of transparent plastic, thus allowing light to pass through
each layer to some extent. This allows underlying layers to be
partially visible through overlying layers. Furthermore, each
pattern can have some portions that are opaque and some that are
transparent, according to the lines and spaces in the printed
patterns. Thus, as patterns overlay one another, visual effects are
created that are unique to each pattern combination. The effect
created by any pattern combination can also change according to the
relative orientations of the two patterns to each other, either in
a parallel plane or in a more complex spatial relationship. As FIG.
3 illustrates, combinations of overlying patterns can result in
numerous new patterns and/or visual effects.
[0037] FIG. 4 illustrates another way in which multiple-layer
printing can achieve visual effects. Masking pattern 422 can
generally obscure anything that is located behind pattern 422.
However, if masking patter 422 is partially removed or is not
printed on a portion of a transparent surface, a second pattern
such as pattern 424 can be visible through the opening. This
negative printing technique has great potential for striking visual
effects, as can be seen in FIG. 4. Similar visual combinations can
also be advantageous, such as a "peek-a-boo" printing effect,
inverse, and or cutaway printing. Packaging materials can also be
printed or sized to allow a portion of the product inside to be
accessible to the sight or touch of a potential buyer.
[0038] Another embodiment capitalizes on principles of artistic
perspective. In some embodiments, for example, a design printed on
an inferior surface positioned behind a superior surface can appear
to be contained deep within or far behind the design of the
superior surface: This appearance of perspective can be enhanced
when printing appears on more than two surfaces of overlaid plastic
material. Thus, appropriately printed images can create an enhanced
sense of depth in a plastic packaging material with an otherwise
more shallow appearance. In some embodiments, a printing process
using combinations of multiple colors can lead to spectacular
visual effects. For example, a four color process has many
advantages. Some embodiments create translucent and lenticular
effects. Some embodiments use spot color processes.
[0039] FIG. 5 illustrates a cross-section of various layers that
can comprise a packaging configuration 510. Layer 522 represents
printing on a surface 512 of plastic portion 511. Printing 524 can
also be located on surface 514 of plastic portion 511. Opening 530
can contain the product to be packaged, or it can be a gap,
depending on where the cross-section of the package 510 is taken.
On the other side of opening 530 is another plastic portion 515,
having a surface 516 with a printed layer 526. Similarly, surface
518 can have a printed layer 528. As illustrated by eye 542, a
viewer can see a combination of patterns comprising the various
layers of printing and plastics in the line of sight 544 of the
viewer.
[0040] Plastic portions 511 and 515 can be adapted to receive
print. Printing layers 522, 524, 526 and 528 can be adapted to
adhere to plastic surfaces, including, in some embodiments,
recycled PET, recycled PVC, and/or other recycled and/or recyclable
plastics. When the plastic surfaces and/or printing materials are
adapted to adhere, the ability of the plastic material to receive
print eliminates the need to place a cardboard insert within the
package, as with some prior art packages. Eliminating the cardboard
insert can lower both the cost of producing the package itself, and
the cost of assembling the product and package together. The cost
of producing the package can be lowered because fewer materials are
needed. The cost of assembling the product and package together can
be reduced because the labor step of placing the cardboard insert
within the package is eliminated.
[0041] Although FIG. 5 illustrates a printing layer adhered to each
of the four plastic surfaces, some embodiments only have printing
on one of the surfaces. Other embodiments have printing on only two
of the surfaces. Other embodiments have printing on only three of
the surfaces. More surfaces can also be included, and various other
combinations of layered surfaces and printing configurations are
contemplated.
[0042] Other ways in which the appearance of plastic packaging can
be enhanced include using translucent and/or iridescent materials.
For example, metallic, shimmering, highly reflective, and/or
glittering effects can be created with some chemical substances.
These substances can be used on one or multiple layers of the
plastic packaging. Multiple layers of ink can also be printed onto
a single plastic surface. Design and marketing potential increases
drastically when printing can be accomplished on multiple surfaces
of plastic packaging.
Materials
[0043] Many retail establishments prefer to use clear plastic for
at least a portion of the packaging that is used to enclose and
display products. This allows consumers to see the product inside.
Traditionally, clear plastic has also been used to permit the
consumer to see through the plastic material to a printed insert or
printed cardboard backing. However, printing directly on clear
plastic has many advantages. Such an approach can avoid extra costs
associated with extra inserts, for example. Furthermore, printing
on clear plastic allows for a wide array of impressive visual
effects.
[0044] Plastic materials that can be used for these purposes
include thermoplastic materials. Preferred embodiments are formed
from plastic materials that resist tearing, puncturing, and/or
ripping. Preferred materials include polyvinyl chloride (PVC),
polyethylene (PET), recycled PET, recycled PVC, polypropylene, PVC
styrene, APET, recyclable PET, recyclable PVC, and other materials
having similar tamper-resistant properties. Preferred materials
also include those materials that can be sealed using RF, sonic,
heat, or ultraviolet sealing technology. Various embodiments are
formed from a wide variety of virgin, recycled, or recyclable
materials, providing a unique appearance that is both superior in
quality and also environmentally favorable. The plastic material
can be completely transparent, partially transparent, or fully
impervious to light. Varying levels of opacity can be accomplished
by printing ink layers on the surfaces of the plastic material or
by including opaque materials in the mixture of chemicals that is
used to form the original plastic material, for example. A plastic
package can comprise a transparent cover and a non-transparent
backing, or a transparent backing and a non-transparent cover.
Various other combinations of transparency and/or opacity are also
possible.
[0045] The innovations described herein permit a relatively
inexpensive assembly process. By allowing premium printing on the
plastic packaging material itself, the process saves the cost of an
additional package insert, as well as the assembly costs of
inserting the package insert. Indeed, many of the steps described
above can be effectively automated. Cost savings also occur by
allowing such printing to occur on recycled materials. Recycled
plastics can be obtained cheaply, reducing the costs of the
necessary raw materials. Furthermore, by using recyclable
materials, some costs can be recovered by reusing scraps or
off-fall materials left over after the manufacturing process.
Moreover, post-consumer recycling can be a source of raw materials,
further reducing costs.
Manufacturing
[0046] FIG. 6 illustrates a method of manufacturing a plastic
package. An extruding step 620 can comprise extruding plastic
material and gathering the resulting sheets onto rolls.
[0047] A printing step 63.0 can comprise feeding the plastic sheet
through a printer. The printer can print on one or multiple
surfaces of the plastic sheet concurrently. In some embodiments, a
second printing step 640 can comprise sending the same plastic
sheet through the same or a subsequent printer.
[0048] A cutting step 650 can comprise die-cutting portions of the
plastic sheet or cutting portions of the sheet with a rolling
blade, for example. The cutting step can form smaller portions for
one or multiple packages. Cutting step 650 can also comprise
folding portions of plastic if the resulting package is to have a
crease such as crease 136, for example. In some embodiments, the
cutting step can comprise molding or stamping the plastic portions
to form contours intended to house the product or other items to be
contained within the packaging. Such contours can be formed at the
same time the plastic sheet is cut if the cutting die also
comprises a stamping mold. Such molding can also comprise heating
or cooling the plastic material. In some embodiments, the plastic
material can be vacuum molded. This technique employs a vacuum to
force the plastic material against a mold so that the plastic
subsequently retains the shape of the mold.
[0049] Filling step 660 can comprise placing the product within the
plastic packaging. Other items can also be placed within the
plastic packaging, such as instructions, batteries, printed
materials, companion items, other products, storage cases, refill
containers, spare parts, assembly hardware, etc.
[0050] Closing step 670 can include a method of closing the plastic
packaging. For example, staples, rivets, pins, or glue can be used.
In some embodiments, complementary features are formed in the two
portions of a plastic package that mate together. For example,
tongue features can fit into groove features formed in the
respective portions of a plastic package. Alternatively, tabs can
be formed in one portion to fold over or protrude through a slot in
the other portion. Some embodiments employ plastic lips, locks, or
snaps that can be formed by shaping the plastic. For sufficient
theft or tamper resistance, however, often these methods require
additional sealing measures to be taken. Some potential additional
measures include heat sealing, RF welding, UV welding, and
ultrasonic welding.
Closure
[0051] Ultraviolet, or UV welding, has many advantages. For
example, UV welding can achieve sufficient strength to provide
theft resistance. UV welding can also be accomplished cheaply and
efficiently, with relatively few steps. In some embodiments, an
adhesive substance such as thermoset glue can be applied. After the
two plastic portions have been placed in contact with the thermoset
glue, ultraviolet light can be shined on the glue and plastic. The
ultraviolet light activates the adhesive properties of the glue.
One advantage of UV welding is its adhesive strength. Using this
approach, sufficient tamper-resistance can be achieved even though
the two flat plastic portions may not have features such as lips,
locks, or snaps in addition to the adhesive material. Two flat,
featureless surfaces can thus be strongly adhered to each other
simply and effectively.
[0052] Another advantage of UV welding is that such techniques can
seal a much wider array of materials than those that can be sealed
by conventional techniques. This provides for even greater latitude
in design for visual effects in packaging. For example, UV welding
techniques can be used to bond recycled polyurethane (RPET), a
material that is difficult to seal with conventional techniques.
Another material that can be bonded using UV welding is APET.
[0053] In some embodiments, the two plastic portions of the
packaging can be closed together using a method such as stamping or
heating. For example, a stamp can be used to exert pressure on the
two plastic layers while they are in apposition. The pressure can
seal the two portions together at or near the place where the stamp
contacts the plastic. Another example uses heat to meld the two
plastic portions together. This can be accomplished using a hot
implement that contacts the packaging at various places around the
perimeter while the two portions are in apposition, for example.
Sonic heat and RF welding methods can be used to fuse the two
portions, for example. Alternatively, non-UV wavelengths of
radiation can also be used to activate adhesives. An adhesive can
be activated by microwave, infrared, radio frequency, or gamma ray
radiation, for example. In one exemplary RF welding approach, two
electrodes can be placed in close proximity to each other, but not
in direct contact with each other. The electrodes can be permitted,
however, to contact one or both of the plastic portions of the
packaging. The plastic material can act as a dielectric that
permits some electrical current to flow, but with some resistance.
As the plastic resists current flow, electrical energy is converted
into thermal energy and the heat melds a portion of the plastic
packaging. This approach advantageously permits the two electrodes
to not be independently heated. The heating effect can be reserved
for the material to be heated such as the plastic, for example.
[0054] In some advantageous embodiments, adhesive substances can be
used to chemically attach the two or more portions of a package
together. For example, glue that cures over time as it dries can be
used. Multiple-component glues can also be used, where one
component is applied and another component activates the adhesive
effect. In some embodiments, the packaging can be closed using a
water-based urethane sealant. Advantageously, the adhesive may be
applied only in areas where adhesion is to take place.
Alternatively, the adhesive may be applied to an entire surface of
one of the plastic portions. If glue is applied to an entire
surface, the glue is preferably of the type that will not adhere
permanently to the product. The glue may, for example, be applied
to one portion of the packaging and then allowed to dry before the
package is assembled. The glue in the adhesion areas is then
activated by heat, RF waves, ultrasonic waves or another sealing
method. Preferably, any adhesive used is transparent so as not to
interfere with consumers reading the printing on either of the
plastic portions.
[0055] In some embodiments, plastic features can be formed that
complement other welding techniques. For example, abutting plastic
portions can include raised ridges, narrow exposed channels, etc.
These features can allow welding to occur in conjunction with a
roller or other mechanisms that can urge the corresponding plastic
portions into proper contact. These features and mechanisms can
cause an effective and strong plastic-to-plastic seal. They can
allow the two plastic portions to mechanically interlock
together.
[0056] In some embodiments, the adhesion only occurs in discrete
areas of the package, and preferably in areas where the adhesion
makes it very difficult to separate the two plastic portions. For
example, adhering the two plastic portions together near the edges
makes it difficult for a thief to effectively grasp the edges of
both pieces in order to pull them apart. Furthermore, many of the
fusion techniques described above, including RF welding, ultrasonic
welding and UV welding, produce such a strong bond between the two
plastic portions that it is virtually impossible for a thief to
separate the two. Even if a thief could separate the two portions
by peeling, the process would likely require a substantial amount
of effort, and would produce an exceptional amount of noise,
attracting the attention of other store patrons and/or store
personnel, thereby effectively foiling the attempted larceny.
[0057] One example of preferred packaging equipment that can be
used to accomplish the methods described above is a Multivac
machine, manufactured by Multivac, Inc., of Kansas City, Missourri.
Other form, fill, and seal equipment can also be used. Preferred
machines function in-line, fully automatically, and have a
high-volume output. In a preferred form, fill and seal machine, a
bed is tooled with molds that heat and form plastic material to
contours of the molds. The plastic material can be fed in to one
end of the machine from a roll of plastic. The machine then orients
the plastic correctly with respect to the molds and forms the
plastic into the shape of the mold. After the plastic is formed by
the molds and cooled, if necessary, the product(s) is/are placed
into the molded plastic. Then, the plastic backing (in the form of
flat plastic film off a roll, for example) that preferably has been
printed on one or both surfaces is fed into the machine, which
seals the plastic backing to the molded portion, thus securely
enclosing the product inside. The printed plastic backing can be
formed from rigid or flexible plastic material. Moreover, the steps
described above can be performed in a different order.
[0058] Because the form, fill and seal machine can have multiple
molds for multiple product packages, the machine can advantageously
separate the individual packages from each other by a die cutting
step. Advantageously, the sealing and cutting steps can be combined
into a single die-cut seal step, where part of the die exerts
pressure on the package to urge the portions together in a secure
seal, while another part of the die is sharper and shaped to cut
through the plastic adjacent to the sealed portion. The form, fill
and seal equipment can be oriented horizontally or vertically with
respect to the floor.
[0059] The specifications of any given machine can be described in
terms of the machine's "web," measured perpendicularly to the
machine's length. Machines with wider webs have more capacity to
form packaging at any given position along the machine's length.
Accordingly, even though machines with wider webs index--or move
the packaging through--at slower absolute speeds than narrower web
machines, the overall efficiency of the wider webbed machines is
greater. Thus, the larger the web, the more units per cycle can be
formed at the same time.
[0060] The foregoing description sets forth various preferred
embodiments and other exemplary but non-limiting embodiments of the
inventions disclosed herein. The description gives some details
regarding combinations and modes of the disclosed inventions. Other
variations, combinations, modifications, modes, and/or applications
of the disclosed features and aspects of the embodiments are also
within the scope of this disclosure, including those that become
apparent to those of skill in the art upon reading this
specification. Thus, the scope of the inventions claimed herein
should be determined only by a fair reading of the claims that
follow.
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