U.S. patent application number 10/596290 was filed with the patent office on 2010-06-03 for package with pilfer proof assembly.
Invention is credited to Richard Thibault.
Application Number | 20100133123 10/596290 |
Document ID | / |
Family ID | 34676811 |
Filed Date | 2010-06-03 |
United States Patent
Application |
20100133123 |
Kind Code |
A1 |
Thibault; Richard |
June 3, 2010 |
PACKAGE WITH PILFER PROOF ASSEMBLY
Abstract
A product package and method for product packaging including an
internal product container (14) having an external mating surface
(118,326) and an external sleeve (12) configured to substantially
enclose the product container (14) and having an opposing internal
mating surface (112,347) and in which the package is assembled by
sliding the product container (14) into the external sleeve (12)
until the external mating surface (118,326) on the product
container 14 and the internal mating surface (112,347) on the
sleeve (12) matingly engage to lock the product container (14) in
place within the external sleeve (12) to prevent pilferage of and
tampering with the product.
Inventors: |
Thibault; Richard;
(Broomall, PA) |
Correspondence
Address: |
MEADWESTVACO CORPORATION;ATTN: IP LEGAL DEPARTMENT
1021 Main Campus Drive
Raleigh
NC
27606
US
|
Family ID: |
34676811 |
Appl. No.: |
10/596290 |
Filed: |
December 8, 2004 |
PCT Filed: |
December 8, 2004 |
PCT NO: |
PCT/US04/40970 |
371 Date: |
July 26, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60528043 |
Dec 8, 2003 |
|
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|
Current U.S.
Class: |
206/1.5 ;
53/467 |
Current CPC
Class: |
B65D 77/0406
20130101 |
Class at
Publication: |
206/1.5 ;
53/467 |
International
Class: |
B65D 85/00 20060101
B65D085/00; B65B 1/04 20060101 B65B001/04 |
Claims
1. A product package, comprising: a product container having an
external mating surface; and an outer sleeve retaining said product
container, said outer sleeve also including an internal opposing
mating surface engaging said external mating surface of said
product container, wherein a portion of the outer sleeve provides a
barrier preventing access to the internal opposing mating
surface.
2. A product package as claimed in claim 1, wherein said external
mating surface is a tab and said internal opposing mating surface
is a recess.
3. A product package as claimed in claim 2, wherein said tab is
resilient.
4. A product package as claimed in claim 2 wherein said outer
sleeve is resilient.
5. A product package as claimed in claim 2, wherein said tab and
said outer sleeve are resilient.
6. A product package as claimed in claim 1, wherein said external
mating surface is a recess and said internal opposing mating
surface is a tab.
7. A product package as claimed in claim 6, wherein said tab is
resilient.
8. A product package as claimed in claim 6, wherein said outer
sleeve is resilient.
9. A product package as claimed in claim 6, wherein said tab and
said outer sleeve are resilient.
10. A product package, comprising: a product container having at
least one external tab; and a resilient outer sleeve retaining and
substantially enclosing said product container, said resilient
outer sleeve further including at least one corresponding tab
receiving recess matingly engaging said at least one external tab,
wherein a portion of the resilient outer sleeve provides a barrier
preventing access to the tab receiving recess.
11. A product package as claimed in claim 10, wherein said tab is
resilient.
12. A product package, comprising: a product container having at
least one resilient external tab; and an outer sleeve retaining and
substantially enclosing said product container, said outer sleeve
further including at least one corresponding tab receiving recess
matingly engaging said at least one external tab, wherein a portion
of the outer sleeve provides a barrier preventing access to the tab
receiving recess.
13. A product package as claimed in claim 12 wherein said outer
sleeve is resilient.
14. A product package, comprising: a product container having at
least one resilient external tab; and an outer sleeve having at
least one opening configured to enable said outer sleeve to slide
over said product container to retain and substantially enclose
said product container and having at least one corresponding
internal recess matingly engaged with said at least one resilient
external tab, wherein a portion of the outer sleeve provides a
barrier preventing access to the internal recess.
15. A product package as claimed in claim 12 wherein said outer
sleeve is resilient.
16. A product package, comprising: a product container having at
least one recess in its outer surface; and an outer sleeve having
at least one opening configured to enable said outer sleeve to
slide over said product container to retain and substantially
enclose said product container and having at least one
corresponding resilient internal tab matingly engaged with said at
least one recess in the outer surface of said product container,
wherein a portion of the outer sleeve provides a barrier preventing
access to the resilient internal tab.
17. A product package as claimed in claim 16 wherein said outer
sleeve is resilient.
18. A method for packaging a product in a product container,
comprising the following steps: placing the product in the product
container having at least one external mating surface; inserting
the product container into a product packaging enclosure of a shape
suitable for retaining and substantially enclosing said product
container, said product packaging enclosure having at least one
corresponding opposing mating surface; and engaging said at least
one external mating surface and said at least one corresponding
opposing mating surface to lock the product container in position
within said product packaging enclosure, wherein a portion of the
outer sleeve provides a barrier preventing access to the opposing
mating surface.
19. A method for packaging a product as claimed in claim 18,
wherein said external mating surface is a tab and said internal
opposing mating surface is a recess, and said step of engaging said
at least one external mating surface and said at least one
corresponding opposing mating surface to lock the enclosure in
position includes inserting said tab into said recess.
20. A method for packaging a product as claimed in claim 19,
wherein said tab is resilient, and said step of inserting said
product container into said product packaging enclosure includes
deflecting said tab as the product container is inserted into the
product packaging enclosure and allowing said tab to spring back
upon insertion into said recess.
21. A method for packaging a product as claimed in claim 19 wherein
said outer sleeve is resilient, and said step of inserting said
product container into said product packaging enclosure includes
deflecting said product packaging enclosure to pass over said tab
as the product container is inserted into the product packaging
enclosure and substantially restoring said product packaging
enclosure to its intended shape in order to enable said tab to
lockingly engage said recess.
22. A method for packaging a product as claimed in claim 19,
wherein said tab and said outer sleeve are resilient, and said step
of inserting said product container into said product packaging
enclosure includes deflecting said tab and deflecting said product
packaging enclosure as the product container is inserted into the
product packaging enclosure and allowing said tab to spring back
upon insertion into said recess and substantially restoring said
product packaging enclosure to its intended shape in order to
enable said tab to lockingly engage said recess.
23. A method for packaging a product claimed in claim 18, wherein
said external mating surface is a recess and said internal opposing
mating surface is a tab.
24. A method for packaging a product as claimed in claim 23,
wherein said tab is resilient, and said step of inserting said
product container into said product packaging enclosure includes
deflecting said tab as the product container is inserted into the
product packaging enclosure and allowing said tab to spring back
upon insertion into said recess.
25. A method for packaging a product as claimed in claim 23,
wherein said outer sleeve is resilient, and said step of inserting
said product container into said product packaging enclosure
includes deflecting said tab and deflecting said product packaging
enclosure as the product container is inserted into the product
packaging enclosure and allowing said tab to spring back upon
insertion into said recess and substantially restoring said product
packaging enclosure to its intended shape in order to enable said
tab to lockingly engage said recess.
26. A method for packaging a product as claimed in claim 23,
wherein said tab and said outer sleeve are resilient, and said step
of inserting said product container into said product packaging
enclosure includes deflecting said tab and deflecting said product
packaging enclosure as the product container is inserted into the
product packaging enclosure and allowing said tab to spring back
upon insertion into said recess and substantially restoring said
product packaging enclosure to its intended shape in order to
enable said tab to lockingly engage said recess.
27. A product packaging assembly to prevent product pilfering,
comprising: a molded tray shaped to contain a specified product and
having at least one indentation disposed along at least one edge to
function as part of a locking mechanism; and a sleeve retaining
said molded tray having at least one extended tab disposed along an
internal edge matingly interlocking with said at least one
indention, wherein a portion of the sleeve provides a barrier
preventing access to the extended tab.
28. The assembly as claimed in claim 27 wherein said molded tray
has at least one depression disposed along one end of the molded
tray to prevent access to the contents while said molded tray is
locked within said sleeve.
29. The assembly as claimed in claim 27 wherein said molded tray is
comprised of halves, each of which incorporates at least one shaped
receiving cavity in order to substantially surround the specific
contents when the halves are folded together.
30. The assembly as claimed in claim 27 wherein said external
sleeve is formed by a single piece of material folded over itself
and secured at the external edge.
31. A packaging assembly to prevent product pilfering comprising: a
molded tray shaped to contain a specified product and having at
least one tab disposed along an edge to function as part of a
locking mechanism; and a sleeve retaining said molded tray having
at least one corresponding indention disposed along an internal
edge of said sleeve matingly interlocking with said at least one
tab, wherein a portion of the outer sleeve provides a barrier
preventing access to the indentation.
32. The assembly as claimed in claim 31 wherein said molded tray
has a plurality of shaped receiving cavities to hold specific
contents.
33. The assembly as claimed in claim 31 wherein said molded tray
has at least one depression disposed along at least one end of the
molded tray and at least one depression disposed along at least one
end of the molded tray to prevent access to the contents while said
molded tray is locked within said sleeve.
34. The assembly as claimed in claim 31 wherein said molded tray is
comprised of halves, each of which incorporates at least one shaped
receiving cavity in order to substantially surround the specific
contents when the halves are folded together.
35. The assembly as claimed in claim 31 wherein said external
sleeve is formed by a single piece of material folded over and
secured at the external edge.
36. A packaging assembly to prevent product pilfering comprising:
an outer sleeve of tapered shape configured so that the openings of
the sleeve are different sizes and containing at least one notched
internal edge; and a clamshell molded tray configured to fully
enclose a specific product and to be partially inserted within said
outer sleeve, said tray having at least one extended tab matingly
engaging with said at least one notched internal edge of said outer
sleeve, wherein a portion of the outer sleeve provides a barrier
preventing access to the notched internal edge.
37. The assembly as claimed in claim 36 wherein said outer sleeve
is comprised of a single piece of material folded over and secured
at the external edge.
38. A product package comprising a complementary locking mechanism,
wherein the package comprises a product container having a first
part of a complementary locking mechanism and an outer sleeve
comprising a second part of a complementary locking mechanism such
that the complementary locking mechanism prevents the product
container from being slidably moved within the outer sleeve wherein
a portion of the outer sleeve provides a barrier to prevent access
to the complementary locking mechanism to prevent tampering with
the complementary locking mechanism.
39. A product package according to claim 38 wherein the outer
sleeve is formed from a single unitary blank wherein the single
unitary blank comprises the second.
40. A product package according to either of claims 38 or 39 where
the first part of the complementary locking mechanism is a
recess.
41. A product package according to either of claims 38 or 39 where
the first part of the complementary locking mechanism is a
protrusion.
42. A product package according to either of claims 38 or 39 where
the second part of the complementary locking mechanism is a
recess.
43. A product package according to either of claims 38 or 39 where
the second part of the complementary locking mechanism is a
protrusion.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to co-pending U.S.
Provisional application 60/528,043, filed on Dec. 8, 2003. The
entire disclosure of that prior filed application is hereby
incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of
product packaging, and in particular to product containers having
an internal locking mechanism and pilfer proof assembly.
BACKGROUND OF THE INVENTION
[0003] Product packaging serves a number of important functions,
including: protecting the packaged product from damage,
attractively displaying the packaged product, preventing theft or
tampering, and providing the purchasing consumer easy post-purchase
access. In addition, it is desirable for a package to be as
inexpensive as possible to manufacture.
SUMMARY OF THE INVENTION
[0004] The present invention fulfills the needs identified above by
providing packaging comprising a product container for protecting
the product from damage and attractively displaying the product,
retained within an outer sleeve to prevent theft or tampering. The
present invention includes an interior product container having a
mating surface on the exterior of the product container and an
outer sleeve having a corresponding opposing mating surface on the
interior of the outer sleeve for locking the outer sleeve in
position around the product container to prevent theft or
tampering.
[0005] In exemplary embodiments, the mating surfaces include
panels, tabs, ribs, catches, abutments, edges, cutouts, apertures,
and like elements, integral to or attached to either a card or
tray, configured to connect with similar complimentary elements
associated with an outer sleeve, and referred to herein as the
mating surfaces.
[0006] An embodiment of the present invention comprises a tray with
an engaging tab and a sleeve with a tray receiving area. At least
one pre-formed tray, configured with a receiving cavity to receive
and hold at least one portable item, may be locked into the tray
receiving area. An outer sleeve configured to receive the tray into
a tray receiving area has disposed along it a locking edge
configured to engage a tab at a locking position. A tray may be
fully or partially inserted within the void defined by the outer
sleeve.
[0007] Another embodiment comprises a tray with a recess to receive
a locking tab and a sleeve with a locking tab. This tray has
disposed along an edge an indention to receive a locking tab. The
outer sleeve defines a void configured to receive the tray, and has
a locking tab to engage the indention in the tray.
[0008] Other embodiments of the present invention include improved
components, such as a monolithically fabricated tray. Here, a tray
may be fabricated from any forming technique or process known to
those skilled in the art, including but not limited to
thermoforming, vacuum forming, and injection molding. The tray
comprises at least one recessed cavity configured to receive and
hold a product. The tray may also be formed by two hinged halves to
fully enclose the product.
[0009] In practice, the embodiments of the present invention are
configured to resist access to an item by securing the item in a
locking package. A method for resisting access to an item secured
in an embodiment of the present invention comprises the following
steps, presented in the following order for the purposes of
teaching and not limitation. Provide a tray container with a means
for engagement. Provide an outer sleeve with open ends to form an
accessible void, and opposing mating surfaces to interlockingly
secure the tray. Align the tray with the open end and orientate the
corresponding opposing mating surfaces. Insert the card fully into
the void to cause the corresponding opposing mating surfaces to
couple or connect. The tray may also have depressions that may be
folded and oriented to fill the end of the void and prevent access
to the product.
[0010] Embodiments according to this invention offer at least the
following advantages: lightness in weight, resistance to tampering,
excellent durability, ease of assembly, product protection, ease of
storage, ease of disposal, the ability to present devices of
different and unusual shapes, and excellent economy.
[0011] It is also contemplated that the present invention is not
limited to specific goods, but is applicable to a plethora of
goods. Other advantages of the present invention will be apparent
from the following description, the accompanying drawings, and the
appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a perspective view of a product package
according to an aspect of the invention.
[0013] FIGS. 2 and 3 show front and rear views of the package shown
in FIG. 1.
[0014] FIGS. 4 and 5 show left and right side views, respectively,
of the package shown in FIG. 1.
[0015] FIGS. 6 and 7 show top and bottom views, respectively, of
the package shown in FIG. 1.
[0016] FIG. 8 shows a plan view of a blank for fabricating a sleeve
according to an aspect of the invention.
[0017] FIG. 9 shows a plan view of the blank shown in FIG. 8,
partially assembled into a sleeve.
[0018] FIG. 10 shows a plan view of the blank shown in FIG. 8,
fully assembled into a sleeve.
[0019] FIG. 11 shows an end view of the sleeve shown in FIG.
10.
[0020] FIG. 12 shows a plan view of a blank for fabricating an
internal tray according to an aspect of the invention.
[0021] FIG. 13 shows a perspective view of an internal tray,
according to an aspect of the invention.
[0022] FIG. 14 shows a perspective view of an alternative internal
tray, according to an aspect of the invention.
[0023] FIG. 15 shows a perspective view of an internal tray,
according to an aspect of the invention.
[0024] FIG. 16 shows a plan view of a blank for fabricating an
internal tray according to an aspect of the invention.
[0025] FIG. 17 shows a plan view of a blank for fabricating a
sleeve according to an aspect of the invention.
[0026] FIG. 18 shows a plan view of a blank for fabricating a
sleeve according to an aspect of the invention.
[0027] FIG. 19 shows a shows a perspective view of an open internal
product container, according to an aspect of the invention.
[0028] FIG. 20 shows a perspective view of a closed internal
product container, according to an aspect of the invention.
[0029] FIG. 21 shows a perspective view of the method of assembly
of the internal tray within the sleeve of one embodiment of the
invention.
DETAILED DESCRIPTION
[0030] As required, detailed embodiments of the present invention
are disclosed herein. It will be understood that the disclosed
embodiments are merely exemplary of the invention that may be
embodied in various and alternative forms. The figures are not
necessarily to scale, and some features may be exaggerated or
minimized to show details of particular components. In other
instances, well-known materials or methods have not been described
in detail in order to avoid obscuring the present invention.
Therefore, specific structural and functional details disclosed
herein are not to be interpreted as limiting, but as a basis for
the claims and for teaching one skilled in the art to variously
employ the present invention.
[0031] Generally speaking, FIG. 1 shows a perspective view of an
exemplary product package 10 according to the present invention.
The package 10 includes a tri-fold sleeve 12 having an upper
opening at an upper end and lower opening at a distal end. The
package 10 also includes a monolithic internal tray 14, which, as
assembled and illustrated, comprises a combination of formed
depressions 16a-c and a product receiving cavity 18. Generally
describing the assembled product package from the point of view of
FIG. 1, the upper opening is partially-blocked by a first formed
depression 16a, the product (not shown) rests in the receiving
cavity 18, and the lower opening is substantially-blocked by a
combined second depression 16b and third depression 16c matingly
folded to form a rigid base.
[0032] Further and as will be described in detail, the sleeve 12
includes a locking tab, best shown in FIG. 8, and the tray 14
includes a locking tab receiving channel, best shown in FIGS. 12
and 13. Alternatively, and best shown in FIG. 17, the sleeve
includes a locking tab receiving channel and, as shown in FIGS. 15
and 16, the tray includes a locking tab. Returning to FIG. 1, when
assembled, the locking tab and receiving channel matingly engage to
prevent the fully inserted tray 14 from being removed from the
sleeve 12. In practice, with the product resting in the receiving
cavity 18 of the assembled product package, the product is
inaccessible without permanently destroying the sleeve 12 or tray
14.
[0033] In other words, in practice the product is attractively
displayed but is inaccessible from the upper partially-blocked
opening because of the opposing configuration of depression 16a and
receiving cavity 18, and is inaccessible from the lower
substantially-blocked opening because of the matingly folded
depressions 16b and 16c. For the benefit of the purchasing consumer
a perforated line 20, substantially the height of the sleeve 12, is
provided so that after purchasing the packaged product 10 the
consumer may easily open the package and access the product.
[0034] In the illustrated embodiment, the package 10 cannot be
resealed after the perforation 20 is breached. Accordingly, the
breached perforation stands as evidence of tampering or theft of
the product. It is contemplated that the package may be designed to
be opened and refastened, with or without breaching a perforation.
Those skilled in the art will appreciate that a means for opening
the sleeve 12 may be provided for the purpose of accessing the
product, together with a means for closing the sleeve 12. By way of
illustration and not limitation, the sleeve 12 may be opened or
refastened with locking tabs, tape, Velcro.RTM., string, buttons,
bands, or other well-known approaches for opening and refastening
lapped flaps.
[0035] As further shown in FIG. 1, the receiving cavity 18 is
shaped to receive a product to be held in the package 10. For the
reasons presented below, it will be appreciated that receiving
cavity 18 may be fully modified to accommodate any shaped product.
In addition, the depressions 16a-c as illustrated are half-oval
shaped. It will likewise be appreciated that depressions 16a-c may
be freely modified to accommodate any shape that prevents
unauthorized access to the product from the upper or lower
ends.
[0036] FIGS. 2-7 show additional views of the package 10 shown in
FIG. 1. FIGS. 2 and 3, respectively, illustrate the front and rear
views of the package 10. In FIG. 2, depression 16a is viewed from
its concave side while receiving cavity 18 is viewed from its
convex side. In FIG. 3, the opposite hand is shown. FIGS. 4 and 5
show left and ride side views of the package 10, and better
illustrate the concave/convex orientations of depression 16a and
cavity 18. FIG. 6 shows the partially-blocked upper opening formed
by depression 16a, while FIG. 7 shows the substantially-blocked
lower base formed by mated depressions 16b-c.
[0037] The operation of the locking mechanism and pilfer proof
assembly will now be described with respect to several exemplary
embodiments and an exemplary fabrication technique, and it will be
apparent that the described container and fabrication technique may
be modified without departing from the spirit of the invention.
FIG. 8 shows a plan view of a blank 100 for forming a sleeve 12
according to one embodiment of the invention. FIG. 17 shows a plan
view of a blank 340 for forming a sleeve 12 according to another
embodiment of the invention. The thickness of the sheet is selected
based on a number of factors, including price and strength. The
sheet should be thick enough to provide structural support, but
thin enough to allow the sheet to be flexed and folded, as
described herein.
[0038] The blank 100, 340 is die cut from a sheet of suitable
material, such as PVC, APET, or PETG. By way of example and not
limitation, the illustrated blank 100, 340 is 0.025'' thick PVC.
Other materials including paperboard may be used if desired, and
textual or graphic matter may be printed directly onto the blank
using a high-speed printing process.
[0039] With regard to choice of materials, the blank 100, 340 may
comprise paper, paperboard, cardboard, plastic, or combinations
thereof. Where the blank 100, 340 comprises paperboard, bleached
sulphate, solid unbleached sulphate, or clay-coated newsback are
well-known design choices. Typically the paperboard coating is a
fluid blend of materials, such as coating clay, calcium carbonate,
and/or titanium dioxide with starch or adhesive smoothly applied to
the traveling surface. Successive densification and polishing
finish the mineral-coated surface to a superior, graphic-print
surface. When the blank and/or tray is paper, fabrication
techniques well known to those skilled in the art, including vacuum
forming, are contemplated. When the blank and/or tray is plastic,
fabrication techniques well known to those skilled in the art,
including thermo-forming, injection molding, and the like, are
contemplated.
[0040] Returning now to FIGS. 8 and 17, a series of score lines
102, 341 is fabricated into the blank 100, 340 to divide the blank
into a number of panels and tabs. In addition, a perforated line
103, 342 is added in order for the purchasing consumer to access
the product. The blank 100, 340 includes a first panel 104, 343, a
second panel 106, 344, and a third panel 108, 345, which are folded
and lapped to form the finished sleeve 12. An attachment edge 110,
346 is defined by the outside edge of the third panel 108, 345,
opposite the outside edge of the first panel 104, 333.
[0041] Continuing to refer to FIGS. 8 and 17, extending from the
outside edge of the first panel 104 is a single non-releasable
locking tab 112. According to one aspect of the invention, the
locking tab 112 is rectangular in shape. The locking tab 112
includes a first locking edge 114 and a second locking edge 116
that, as described below, engage a receiving channel 118, best
illustrated in FIGS. 12 and 13, and described further below.
Alternatively, as shown in FIG. 17, a tab section 350 extends
outward from the first panel 343. Disposed between tab section 350
and the first panel, midway along the length of the sleeve, is a
cutout 347 to function as a locking tab receiving channel. The
cutout 347 is open to receive a locking tab 326, shown in FIGS. 15
and 16, and the cutout has edges 348 and 349.
[0042] In fabricating a finished sleeve 12 from the blank 100, the
locking tab 112 is folded inward toward the interior of first panel
104. Alternatively, in fabricating a finished sleeve from blank
330, the tab section 350 is folded inward toward the interior of
the first panel 343, creating locking tab receiving channel 347
from the cutout. First panel 104, 343 is then folded over second
panel 106, 344. The partially folded blank 100 is shown in FIG. 9.
Third panel 108, 345 is then folded over first panel 104, 343. A
suitable technique is employed to affix the attachment edge 110,
346 to the first panel 104, 343 along the cross-hatch regions 122.
By way of illustration and not limitation, the cross-hatch regions
122 may be affixed by chemical, thermal, or mechanical bonding
methods well known to those skilled in the art.
[0043] As best illustrated in FIGS. 10 and 11, it will be seen that
the bonding of the attachment edge 110, 346 to the first panel 104,
343 creates a sleeve 12 with openings at the left and right of the
blank 100, 340. As shown in FIG. 11, locking tab 112 is captured
between first panel 104 and second panel 106. Alternatively, the
folded tab section 350 folded against the first panel 343 will
create a locking tab receiving channel 347 between the first panel
343 and second panel 344. The void 124 created by the folded panels
104, 344, 106, 344, and 108, 345 will be filled by internal tray
14, 325, as described in detail further below.
[0044] FIGS. 12 and 13 illustrate an exemplary embodiment of the
internal tray 14. FIGS. 15 and 16 illustrate another exemplary
embodiment of the internal tray 325. In a preferred embodiment the
internal tray 14, 325 is a plastic thermoformed tray. More
specifically, the tray includes a receiving cavity 18, 328, upper
depression 16a, 327a, lower depressions 16b-c, 327b-c, and locking
tab receiving channel 118. Alternatively, and best shown in FIGS.
15 and 16, the tray may include a locking tab 326 in place of a
locking tab receiving channel 118. As with the sleeve blank 100,
330, the tray 14, 325 may be made of any suitable material.
[0045] With regard to an exemplary method of manufacturing, the
tray 14, 325 may begin as a blank 200, 330, best illustrated in
FIGS. 12 and 16, used in a thermoform moulding process. A score
line 102, 332 is provided, and a length along one edge of the blank
is removed to form a locking tab receiving channel 118.
Alternatively, one edge of the blank may be cut in at least one
location along its length to form a locking tab 326. In a preferred
embodiment, the locking tab receiving channel 118, 347 is no longer
in length than is necessary to securely engage locking tab 112,
326. Receiving channel 118 includes a first locking edge 202 and a
second locking edge 204. In practice, the locking edges 114, 116 of
the locking tab 112 matingly engage the locking edges 202, 204 of
the tray 14 when the tray 14 is fully inserted into the receiving
void 124 of the sleeve 12. Alternatively, in practice locking edges
336, 334 of locking tab 325 on the tray 325 matingly engage locking
edges 348, 349 of locking tab receiving channel 347 within the
sleeve 340 when the tray 325 is fully inserted into the receiving
void 124 of the sleeve 340.
[0046] The blank 200, 330 is of sufficient size to receive the
product to be packaged, represented here by the shape 206, 338. It
will be appreciated by those skilled in the art that the receiving
cavity 18, 328, best shown in FIGS. 13 and 15, can be of any shape
conceivable. Accordingly, shape 206, 328 is shown here is for
purposes of illustration and not limitation.
[0047] The thermoform moulding process creates, in the exemplary
tray 14, 326, a receiving cavity 18, 328 and depressions 16a-c,
327a-c. Although only one receiving cavity 18, 328 is shown, it is
contemplated that multiple receiving cavities may be provided. In
addition, although only one depression 16a, 327a is shown at one
end, it is contemplated that two depressions may be provided at
this end, thereby creating a substantially-blocked end on both
sides of the assembled product package 10.
[0048] Alternative exemplary embodiments of both the sleeve 12 and
tray 14, 325 are contemplated. For example, with regard to the
sleeve 12, rather than utilizing a tri-fold blank 100, 340 it is
contemplated to use a bi-fold blank to form a pillowed sleeve with
internal lock. Conceptually, and in practice, the bi-fold blank is
identical to the tri-fold blank 100, 340 except the bi-fold blank
does not include the second panel 106, 344. Otherwise, the bi-fold
blank is folded and attached in the same manner as described above,
including the locking tab 112, or locking tab receiving channel
347, and perforated line 103, 342.
[0049] With regard to an alternative exemplary embodiment of the
tray 14, reference is now made to FIG. 14. Here the tray 300
includes a fully encapsulating receiving cavity formed by mating
cavity depressions 304 and 306, mating upper depressions 310 and
312, mating lower depressions 314 and 316, mating receiving
channels 318 and 320, and score lines 322. When folded along score
line 322, a fully encapsulating receiving cavity is formed that
performs according to inventive concepts described herein.
[0050] The assembly of the product package 10 will now be
described. With reference to FIG. 11, depending on the size of the
finished sleeve 12, it would be possible for a worker to hold the
sleeve 12 in one hand, using the thumb and fingers to apply
pressure to the side edges 130. The worker can then pop the sleeve
12 open, expanding the receiving void 124 sufficiently to insert
the internal tray 14. As described above in reference to the first
embodiment illustrated by FIG. 8, first panel 104 includes locking
tab 112. As best illustrated by FIG. 11, after the panels are
folded the locking tab 112 extends inwardly to engage the receiving
channel 118. In the alternative embodiment illustrated by FIG. 17,
first panel 343 includes receiving channel 347 exposed inwardly to
receive the locking tab 326.
[0051] In the foregoing exemplary embodiments, the end of the tray
14, 325 which comprises depression 16a, 327a is the leading end
inserted into the receiving void 124. If an alternative embodiment
includes two depressions 16a-a', 327a-a' identical to 16b-c,
327b-c, then depression 16a', 327a' is folded along a score line
such that the depressions 16a-a', 327a-a' form a three-dimensional
top identical to the base best shown in FIG. 1, before inserting
the tray into the receiving void 124.
[0052] However, before inserting the internal tray 14, the worker
would look and confirm the tray 14 is oriented so that the
receiving channel 118, 347 is aligned with the locking tab 112,
326. When fully inserted, the receiving channel 118, 347 engages
the locking tab 112, 326 so both must be aligned to matingly
engage. Prior to fully inserting the tray 14 into the sleeve 12,
the product is loaded into the receiving cavity 18. Depression 16c,
327c is folded along the score line 102 provided, such that
depressions 16b, 327b, and 16c, 327c form the three-dimensional
base best illustrated in FIG. 1.
[0053] Because of the resilience of the material used to fabricate
the sleeve 12 and locking tab 112, the locking tab has a tendency
to fold and unfold slightly. The slight folding of the tab 112 is
beneficial as the tray passes by the tab 112, pushing the tab 112
back against the first panel 104 or second panel 106. The slight
unfolding of the tab 112 is beneficial in ensuring a firm locking
mechanism--when receiving channel 118 is immediately adjacent to
the tab 112, the tab 112 springs back from the panel 104, 106 to
fill the void that is the receiving channel 118. It will be clear
to one skilled in the art that after the locking tab 326 is folded
is folded inwardly to allow the tray 325 to be inserted into the
sleeve 12, the resilience of the locking tab 326 causes the locking
tab 326 to unfold slightly when it comes into contact with the
receiving channel 347, thereby likewise ensuring a firm locking
mechanism between said locking tab 326 and said receiving channel
347.
[0054] Completing the assembly of product package 10, as shown in
FIG. 20, the base formed by 16b-c is fully inserted into the sleeve
12. Substantially simultaneous with the full insertion of the tray
14, 325 into the sleeve 12, locking tab 112, 326 springs from its
compressed position to matingly engage receiving channel 118, 347.
When engaged and as illustrated, the tab's first locking edge 336
abuts the locking tab receiving channel's first locking edge 348
while the tab's second locking edge 334 abuts the locking tab
receiving channel's second locking edge 349. With the respective
locking edges 336, 348; 114, 202 and 334, 349; 116, 204 abutting
each other, the tray 14 and sleeve are fully engaged. It is
contemplated, and easily understood, that because of the
versatility of the present invention, when fully inserted and
engaged the locking edges 114, 202; 116, 204; 336, 349; 334, 348;
114, 204 and 116, 202 may abut to create the internal locking
mechanism. The above described manual operations may also be
performed by machine.
[0055] It will be understood that while the exemplary embodiment
illustrates a single locking tab 112 and a single receiving channel
118, multiple locking tabs 112 and receiving channels 118 are
contemplated, the number and arrangement being merely a design
choice.
[0056] The exemplary product package configuration of FIGS. 1-13 is
oval shaped. It is contemplated that the present invention is well
suited for all package shapes including square, rectangular,
circular, sextagonal, octagonal, and variations thereof. The
product package configuration is merely a design choice in response
to the type and number of products contained in the one or more
receiving cavities.
[0057] The depressions 16a-c, 327a-c are hollow as illustrated, but
as one skilled in the art will understand, ribs may be provided
within the depression or enclosure to improve the structural
integrity or related performance characteristics of the product
package 10. In addition, one or more depressions 16a-c, 327a-c may
be formed on the blank 100, 340 rather than the blank 200, 330.
[0058] A further alternative exemplary embodiment of the invention
is best shown in FIGS. 18-20. A blank 400, best shown by FIG. 18,
is used to create an asymmetrically shaped sleeve 12. As described
in the above embodiments, the sleeve will be constructed from a
thermoformed blank 400, or other flexible or resilient material.
Blank 400 includes scored lines 401 and first panel 402, second
panel 403, and third panel 404. Blank 400 will fold along 401 so
that first panel 403 and second panel 404 will form the front and
back of the sleeve. One side 405 joining 403 and 404 will be formed
by the scored fold lines 401. A second side 406 will be formed by
the folds between first panel 403 and adhesive panel 402. The
sleeve will be fully closed by folding adhesive panel 402 onto the
edge of second panel 404. A perforation 407 along the length of the
blank 400 will allow the consumer access to the product. Protruding
cavities 408 may be included to allow the consumer to view the
product inside. Indentions 409 will be cut into blank 400 and will
be disposed in sides 405, 406 to engage a locking mechanism.
[0059] A clamshell product container 455 is best shown in FIG. 19.
As described in the above embodiments, the container will be
constructed from a thermoformed blank. A number of recessed
cavities 450 will be disposed along the blank to fully enclose the
product being packaged. As will be understood by one skilled in the
art, there may be any number of cavities 450 comprised of any shape
required to enclose the product. One side 451 would function as the
front of the container as another side 452 would function as the
rear of the container. The container may be hinged 453 along its
top edge. When folded along the hinge 453, side one 451 and side
two 452 will close with the cavities 450 aligned to fully enclose
the product. The resulting product container 455 will be narrow at
the top hinge 453 but thicker toward the bottom to form a
trapezoidal shape. Extending from side 451 and side 452 are two
protruding tabs 454. When folded along the hinge 453, the
protruding tabs 454 along side one and the protruding tabs 454
along side two will align to form the portion of the locking
mechanism on the product container. The two sides will be closed
together by adhesive or other means known by those skilled in the
art as indicated in the above embodiments. The protruding tabs 454
may be flexible or rigid, however, if the sleeve is rigid, then the
protruding tabs 454 of the product container must be a resilient
material to be folded inwardly and then released to matingly engage
the indentations 409 in the sleeve 12 during the assembly of the
final package.
[0060] Once assembly is accomplished, the final package will be
best shown by FIG. 20. The sleeve 12 will be shaped so as to slide
over the product container 455 to a certain point where it may not
progress further due to the thickness at the bottom of the
container 455. The locking mechanism is engaged if the sleeve is
flexible as the sleeve 12 moves over the protruding tabs 454 until
they are matingly engaged with the notches 409 cut into the sides
405, 406 of the sleeve 12. At that point, the flexible sleeve is
expanded by the increased thickness of the lower part of the
product container so that it cannot be flexed to slide the flexible
sleeve back over the protruding tabs 454. Alternatively if the
sleeve 12 is rigid or if the product container is not of increasing
thickness, the protruding tabs 454 should be resilient and should
be folded inwardly to allow the sleeve to pass over them until they
are matingly engaged with the notches 409 cut into the sides 405,
406 of the sleeve 12, and the protruding tabs 454 spring back into
a protruding position in the notches 409. Once the notches 409 are
matingly engaged with the protruding tabs 454, the only access to
the product will be through the perforation 407 along the length of
the sleeve 12.
[0061] It should be emphasized that the above-described embodiments
of the present invention, particularly, any "preferred"
embodiments, are merely possible examples of implementations,
merely set forth for a clear understanding of the principles of the
invention. Many variations and modifications may be made to the
above-described embodiment(s) of the invention without departing
substantially from the spirit and principles of the invention.
Further, it will be understood that variations, modifications, and
enhancements can be made to the disclosed apparatus and methods
without departing from the scope of the present invention as
defined in the following claims. All such modifications and
variations are intended to be included herein within the scope of
this disclosure and the present invention and protected by the
following claims.
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