U.S. patent application number 14/155503 was filed with the patent office on 2014-07-17 for electronic circuits for product packaging and game pieces.
This patent application is currently assigned to The C.W. Zumbiel Company. The applicant listed for this patent is The C.W. Zumbiel Company. Invention is credited to Steven J. Block, Alexander M. Kronk, Brian W. McKee, Ryan Ramer, Joseph P. Yock.
Application Number | 20140197052 14/155503 |
Document ID | / |
Family ID | 51164362 |
Filed Date | 2014-07-17 |
United States Patent
Application |
20140197052 |
Kind Code |
A1 |
Block; Steven J. ; et
al. |
July 17, 2014 |
ELECTRONIC CIRCUITS FOR PRODUCT PACKAGING AND GAME PIECES
Abstract
Product packages and methods of making same, and unpowered
conductive circuits for use, for example, as game pieces and
methods of making the same. The product package includes a
paperboard blank configured to be formed into a box. An electrical
circuit is printed with conductive ink pattern onto a surface of
the blank. A user may interact with the electrical circuit by, for
example, pressing tabs cut into the box. The tabs may include
conductive contacts that activate sections of the electrical
circuit, thereby producing one or more desirable effects in
response to various combinations of tabs being pressed by the user.
The electrical circuit may be powered by a battery inserted into a
battery compartment of the product package. The blank may include a
removable section with a printed electrical circuit, or a portion
thereof, that may be separated from the blank and used separately
from the product package.
Inventors: |
Block; Steven J.; (Amelia,
OH) ; Kronk; Alexander M.; (Plain City, OH) ;
McKee; Brian W.; (Columbus, OH) ; Ramer; Ryan;
(Loveland, OH) ; Yock; Joseph P.; (Cincinnati,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The C.W. Zumbiel Company |
Hebron |
KY |
US |
|
|
Assignee: |
The C.W. Zumbiel Company
Hebron
KY
|
Family ID: |
51164362 |
Appl. No.: |
14/155503 |
Filed: |
January 15, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61822613 |
May 13, 2013 |
|
|
|
61753253 |
Jan 16, 2013 |
|
|
|
Current U.S.
Class: |
206/216 ;
427/97.3; 427/98.4 |
Current CPC
Class: |
A63F 3/00643 20130101;
A63F 9/001 20130101; B65D 81/36 20130101; A63F 2009/2454 20130101;
B65D 5/4216 20130101; A63F 2003/00712 20130101; A63F 2009/0012
20130101; A63F 2250/265 20130101; A63F 2250/505 20130101; A63F
2009/241 20130101 |
Class at
Publication: |
206/216 ;
427/98.4; 427/97.3 |
International
Class: |
B65D 25/34 20060101
B65D025/34 |
Claims
1. A product package comprising: a paperboard blank including a
first surface, the paperboard blank being configured to define the
product package; and a first conductive ink pattern printed on the
first surface of the paperboard blank, the first conductive ink
pattern defining at least part of an electrical circuit integrated
with the product package.
2. The product package of claim 1 wherein the paperboard blank is
configured so that the first surface forms an interior surface or
an exterior surface of the product package.
3. The product package of claim 1 further comprising: a dielectric
pattern applied to the first surface of the paperboard blank; and a
second conductive ink pattern printed on the first surface of the
paperboard blank, wherein the dielectric pattern electrically
isolates a portion of the first conductive ink pattern from a
portion of the second conductive ink pattern.
4. The product package of claim 1 further comprising: an electronic
component coupled to the conductive ink pattern.
5. The product package of claim 1 wherein the first ink pattern
includes a first contact pad, a second contact pad separated by a
gap from the first contact pad, and a third contact pad configured
to selectively couple the first and second contact pads in response
to being pressed into contact with the first and second contact
pads.
6. The product package of claim 5 wherein the paperboard blank
includes a cut line and a fold line configured to define a tab, the
tab including the third contact pad and being located so that the
third contact pad is pressed into contact with the first and second
contact pads in response to the tab being folded along the fold
line.
7. The product package of claim 5 wherein gap has a length, the
first contact pad has a width and includes a first projection, the
second contact pad has a width and includes a second projection,
and the projections are configured to define the gap so that the
length of the gap exceeds the width of the first contact pad and
the width of the second contact pad.
8. The product package of claim 7 wherein the first projection is
one of a first plurality of projections, the second projection is
one of a second plurality of projections, and the first and second
pluralities of projections are configured to define the gap so that
the gap has a winding characteristic.
9. The product package of claim 1 wherein the paperboard blank
includes a plurality of cut lines and a plurality of fold lines
configured to define a battery compartment, the battery compartment
including a chock defined by a section of the paperboard blank
defined by two non-intersecting cut lines and three
non-intersecting fold lines.
10. The product package of claim 9 wherein the fold lines defining
the chock are intersected by the cut lines defining the chock.
11. The product package of claim 1 wherein the electrical circuit
is printed on a section of the paperboard blank defined by one or
more cut lines so that the section is removable from the paperboard
blank, the conductive ink pattern includes a first set of one or
more contact pads, and the first set of contact pads include a
shape, a number, or an arrangement that is recognizable by a touch
sensitive device.
12. The product package of claim 11 wherein the section of
paperboard blank is configured to be formed into a game piece.
13. The product package of claim 12 wherein the electrical circuit
includes a second set of one or more contact pads configured to
electrically couple the first set of one or more contact pads to a
user holding the game piece.
14. The product package of claim 12 wherein the game piece is
configured to be used with an application executing on the touch
sensitive device and visible on a screen of the touch sensitive
device.
15. The product package of claim 11 wherein the paperboard blank
includes a boss at the location of each contact pad, and a portion
of each contact pad is raised by the boss to define a contact
surface.
16. The product package of claim 1 wherein the paperboard blank
includes a score line, the printed circuit includes a trace
crossing the score line and having a width-to-thickness aspect
ratio, wherein the width-to-thickness aspect ratio is selected so
that a conductive ink comprising the first conductive ink pattern
does not fracture maintained when flexed by bending of the
paperboard blank at the score line.
17. A method of making a product package including an integrated
electrical circuit, the method comprising: printing a conductive
pattern on a first surface of a paperboard blank, the first
conductive ink pattern defining at least part of an electrical
circuit integrated with the product package.
18. The method of claim 17 further comprising: applying a
dielectric pattern applied to the first surface of the paperboard
blank; and printing a second conductive ink pattern on the first
surface of the paperboard blank, wherein the dielectric pattern
electrically isolates a portion of the first conductive ink pattern
from a portion of the second conductive ink pattern.
19. The method of claim 17 further comprising: coupling an
electronic component to the conductive ink pattern.
20. The method of claim 17 wherein the conductive ink pattern
includes one or more contact pads, and the contact pads include a
shape, a number, or an arrangement that is recognizable by a touch
sensitive device.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of Provisional
Application No. 61/822,613, filed May 13, 2013, and Provisional
Application No. 61/753,253, filed Jan. 16, 2013, which are each
hereby incorporated by reference herein in its entirety.
BACKGROUND
[0002] The invention relates generally to packaging for consumer
products that incorporates electrical circuitry and, more
particularly, to paperboard boxes that include electrical circuitry
that is integrated with the box, and methods of making the same, as
well as unpowered conductive circuits for use, for example, as game
pieces and methods of making the same.
[0003] Point-of-sale product marketing is a highly competitive
process. When shopping for consumer goods in a retail environment,
consumers often make choices based largely on the appearance of the
product packaging. Customers of commodities, such as breakfast
cereals, tend to be especially receptive to being influenced by
product packaging. In particular, children may be attracted to
products that are packaged in interesting ways, or that include a
stimulating toy or prize, and may attempt to persuade their parents
to buy the product based primarily on the appearance of the product
package or the inclusion of the toy in the product package.
Consequently, there is a need for cost-effective, new, and improved
product packages that entice customers to buy the product, and
methods for making these cost-effective, new, and improved product
packages.
SUMMARY
[0004] In one embodiment, a product package includes a paperboard
blank having a surface and a conductive ink pattern printed on the
surface of the paperboard blank. The blank is configured to define
the product package (e.g., upon uprighting or erecting). The
conductive ink pattern defines at least part of an electrical
circuit that is integrated with the product package.
[0005] In another embodiment, a method of making a product package
includes printing a conductive pattern on a surface of a paperboard
blank. The conductive ink pattern defines at least part of an
electrical circuit that is integrated with the product package.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate various
embodiments of the invention and, together with the general
description of the invention given above, and the detailed
description of the embodiments given below, serve to explain the
principles of the invention.
[0007] FIG. 1 is a diagrammatic view of an exemplary game
application.
[0008] FIG. 2 is a schematic view of a circuit that implements the
game application of FIG. 1.
[0009] FIG. 3 is a top view of a blank of packaging material
configured to be formed into a box that includes a printed
conductive ink pattern which defines a lower level of printed
electrical circuitry for implementing the circuit of FIG. 2.
[0010] FIG. 4 is a top view of the blank of FIG. 3 illustrating a
dielectric layer pattern for isolating the lower level of printed
electrical circuitry from an upper level of printed electrical
circuitry.
[0011] FIG. 5 is a top view of the blank of FIG. 4 that includes a
printed conductive ink pattern that defines the upper level of
printed electrical circuitry.
[0012] FIG. 6 is a top view of the blank of FIG. 5 illustrating a
dielectric over-layer pattern for protecting the underlying
electrical circuitry.
[0013] FIG. 7 is a top view of the blank of FIG. 6 illustrating the
layers defined in FIGS. 3-6.
[0014] FIG. 8 is a cross-sectional view of a multi-level portion of
a printed circuit showing a vertical structure for the conducting
and insulating layers.
[0015] FIG. 9 is a top view of a blank of packaging material
configured to be formed into a box that includes a printed
conductive ink pattern which defines a lower level of printed
electrical circuitry for an alternative implementation of the
circuit in FIG. 3.
[0016] FIGS. 10 and 11 are diagrammatic views showing additional
detail of contact pads comprising a switch of the circuitry in FIG.
2 in accordance with embodiments of the invention.
[0017] FIG. 12 is a top view of the blank of FIG. 9 illustrating a
dielectric layer pattern for isolating the lower level of printed
electrical circuitry from an upper level of printed electrical
circuitry.
[0018] FIG. 13 is a top view of the blank of FIG. 12 that includes
a printed conductive ink pattern that defines the upper level of
printed electrical circuitry.
[0019] FIG. 14 is a top view of the blank of FIG. 13 illustrating a
dielectric over-layer pattern for protecting the underlying
electrical circuitry.
[0020] FIG. 15 is a top view of the blank of FIG. 14 illustrating
the layers defined in FIGS. 9 and 12-14.
[0021] FIG. 16 is diagrammatic view of a side of a box formed from
the blank in FIG. 7 showing tabs and a cavity configured to receive
a battery.
[0022] FIG. 17 is diagrammatic view of the side of the box in FIG.
16 showing the tabs in a folded position.
[0023] FIG. 18 is a perspective view of a product package in the
form of a cereal box.
[0024] FIG. 19 is diagrammatic view of an image that may be printed
on a side of the box in FIG. 18 consistent with an embodiment of
the invention.
[0025] FIG. 20 is a schematic view of a circuit that implements an
electronic feature on a package.
[0026] FIG. 21 is a top view of a blank of packaging material
configured to be formed into a box that includes a printed
conductive ink pattern which defines a level of printed electrical
circuitry for the circuit in FIG. 20.
[0027] FIG. 22 is a top view of the blank of FIG. 21 illustrating a
dielectric over-layer pattern for protecting the underlying
electrical circuitry.
[0028] FIG. 23 is a top view of the blank of FIG. 22 illustrating
the layers defined in FIGS. 21 and 22.
[0029] FIG. 24 is diagrammatic view of an image that may be printed
on a side of a box formed from the blank in FIG. 23 consistent with
an alternative embodiment of the invention.
[0030] FIG. 25 is a schematic view of a circuit in accordance with
an alternative embodiment of the invention.
[0031] FIG. 26 is a top view of a blank of packaging material
configured to be formed into a box that includes a printed
conductive ink pattern which defines a lower level of printed
electrical circuitry for the circuit in FIG. 25.
[0032] FIG. 27A includes a top view of a section of the blank in
FIG. 26 that may be formed into a game piece for use with a touch
sensitive device, and a perspective view of the assembled game
piece.
[0033] FIG. 27B is a top view of the section of the blank in FIG.
27A including a printed image.
[0034] FIG. 27C is a perspective view of the game piece of FIG.
27B.
[0035] FIG. 27D is a perspective view of a section of the blank in
accordance with an alternative embodiment in which the contact pads
have been embossed to provide raised contact surfaces.
[0036] FIG. 27E is a cross-sectional view taken generally along
line 27E-27E in FIG. 27D.
[0037] FIG. 28 is a top view of the blank of FIG. 26 illustrating a
dielectric layer pattern for isolating the lower level of printed
electrical circuitry from an upper level of printed electrical
circuitry.
[0038] FIG. 29 is a top view of the blank of FIG. 28 that includes
a printed conductive ink pattern that defines the upper level of
printed electrical circuitry.
[0039] FIG. 30 is a top view of the blank of FIG. 29 illustrating a
dielectric over-layer pattern for protecting the underlying
electrical circuitry.
[0040] FIG. 31 is a top view of the blank of FIG. 30 illustrating
the layers defined in FIGS. 26, and 28-30.
[0041] FIG. 32 is a top view of a game that may be printed on the
blank in FIG. 31.
[0042] FIG. 33 is a perspective view of the game in FIG. 32 showing
a user activating a switch with a game stylus.
[0043] FIG. 34 is a top view of a game in accordance with an
alternative embodiment of the invention.
[0044] FIG. 35 is a perspective view of the game in FIG. 34 showing
a user activating a switch with a game stylus.
DETAILED DESCRIPTION
[0045] Embodiments of the invention are directed primarily to
product packaging that incorporates printed electrical circuitry
applied to one or more interior or exterior surfaces of the
package. The printed electrical circuitry may be configured to
provide the consumer with a variety of applications, such as a game
or other sensory stimulating apparatus. To this end, applications
provided by embodiments of the invention may provide a plurality of
sensory stimulations, such as light and sound.
[0046] For example, the product package may be a cereal box
configured to provide an interactive game or other electronic
entertainment once the goods have been removed from the product
package. The product package may also be configured so that the
electrical circuit draws attention to the product or otherwise
enhances the appeal of the product when displayed in a retail
environment. To this end, embodiments of the invention may include
a variety of printed electrical circuits and electrical components,
including lines, switches, and terminals. These circuits may be
operatively coupled with light-emitting diodes, power sources,
programmable chips, audio transducers, and electronic displays to
provide a desired application or effect. Power sources may include
an internal power source (e.g., a battery integrated into the
product package) or an external power source (e.g., an alkaline
battery that is coupled to the product package externally and/or
provided by the user).
[0047] The printed electrical circuitry may be printed either
directly on a surface of the product package, or on a secondary
carrier substrate, such as a flexible film, that can then be
attached to the product package. The inks used to print the
circuitry may include any suitable printable material, such as
metallic (e.g., silver) ink, conductive carbon ink, silver chloride
ink, or any other suitable ink. In addition, dielectric ink, such
as an acrylic, may be deposited over a lower layer of conductive
ink so that another layer of conductive ink may be deposited over
the lower conductive ink layer to form electrical circuits having
multiple layers. Additional dielectric layers may be printed
between the conductive layers to increase the isolation between the
conductive layers. These additional dielectric layers may include
layers having dissimilar materials. The conductive ink may be
printed on the product package material using a conventional
printing technique, such as screen print, flexo, gravure,
photo-pattern, pad printing, and jet printing to form traces and
other components of the printed electrical circuitry. Carriers for
the ink (known as film formers) may be based on acrylics,
urethanes, water, latex, and/or any other suitable carrier.
[0048] The ink may typically comprise carbon in a water-based
carrier so that the resulting product satisfies the Coalition of
Northeastern Governors (CONEG) model legislation regarding
allowable levels of heavy metals in solid municipal waste. These
materials may also prevent contamination of food products contained
in the product package, and may contribute to bio-degradable and/or
recyclable features of the package. The application of sustainable
environmental stewardship in the recyclability of the package and
printed circuits sharply contrasts with normal printed circuits
that include metallic content.
[0049] After the traces defining the electrical circuit are printed
on a blank comprised of a packaging material, the blank may be cut
to define openings for discrete electronic components, e.g., light
emitting diodes (LEDs), battery contact pads, or other features of
the desired application. The discrete electronic components may be
coupled to the traces using a suitable conductive material, such as
a conductive tape (e.g., copper tape) or a conductive adhesive
(e.g., a conductive epoxy). In an embodiment of the invention,
holes may be cut in the packaging material so that the product
package is configured to receive LEDs, which may be coupled to
traces printed on an interior surface of the product package. The
openings may allow the LEDs to be visible from outside of the
product package. In an alternative embodiment, the LEDs may be
attached to an outside surface of the package, in which case the
holes for the LEDs may be omitted. The packaging material may also
be cut to define a receptacle configured to receive a battery, such
as a 9-volt battery, for powering the electrical circuitry. Further
cuts may define detachable game components configured to interact
with a game board portion of the box, or other external devices
such as a touch screen of a tablet computer or smart phone.
Embodiments of the invention may also include other electrical
circuits, such as a processor, that are coupled to the traces.
These additional circuits may be coupled to the interior surface of
the product package so that they are not visible from the exterior
of the product package. Embodiments of the invention may thereby
bring added value in a post-use application to consumer product
package at a reasonable cost.
[0050] Referring now to FIG. 1, an exemplary embodiment of the
product packaging provides an electronic version of a
"rock-paper-scissors" game 10. In rock-paper-scissors, each of two
players simultaneously indicates the selection of one of a rock 12,
a sheet of paper 14, or a pair of scissors 16 with a respective
hand gesture 18, 20, 22. If one of the players selects a rock and
the other paper, the player selecting paper wins. If one of the
players selects paper and the other scissors, the player selecting
scissors wins. If one of the players selects scissors and the other
rock, the player selecting rock wins. If both players select the
same object, the game is a push, and there is no winner.
[0051] The embodiments of the invention are not limited to the
"rock-paper-scissors" game 10. Generally, other types of
multi-player or single player games may be provided by the
inventive product packaging and printed electrical circuitry. The
games may possess educational value appropriate for a self-guided
teaching session, may be geared toward amusement purposes, or a
combination of these objectives.
[0052] FIG. 2 illustrates a circuit 30 for implementing the
electronic version of rock-paper-scissors of FIG. 1. The circuit 30
includes LEDs 38, 40 and a plurality of double-pole switches 32-37
that selectively couple LEDs 38, 40 to a power source 42 (e.g., a
battery). The power source may be coupled to the circuit 30 through
a resistor 44 to control the amount of current that flows through
the LEDs 38, 40. The switches 32-37 are coupled by conductive
traces 46 so that the switches 32-37 define a logic circuit that
illuminates an appropriate LED 38, 40 in response to the game
players each activating one pair of the switches 32-37. In an
embodiment of the invention, switches 32 and 37 are labeled as
representing scissors, switches 33 and 35 are labeled as
representing paper, and switches 34 and 36 are labeled as
representing rock.
[0053] To play the game, one player (player "A") activates one of
switches 32-34, and another player (player "B") activates one of
switches 35-37. If both players activate switches representing the
same type of object, a circuit is not completed through either of
the LEDs 38, 40, and neither of the LEDs is illuminated (or
optionally both LEDs 38, 40 can be simultaneously illuminated). If
player A activates switch 32 (scissors) and player B activates
switch 35 (paper), a circuit is completed that couples LED 38 to
power source 42. In response to being connected to power source 42,
LED 38 illuminates, indicating player A is the winner. If player A
activates switch 32 (scissors) and player B activates switch 36
(rock), a circuit is completed that couples LED 40 to power source
42. In response to being connected to power source 42, LED 40
illuminates, indicating player B is the winner. In a similar
manner, if player A activates switch 33 (paper) and player B
activates switch 36 (rock), LED 38 illuminates indicating player A
is the winner. If player A activates switch 33 (paper) and player B
activates switch 37 (scissors), LED 40 is illuminated indicating
player B is the winner. If player A activates switch 34 (rock) and
player B activates switch 37 (scissors), LED 38 is illuminated
indicating player A is the winner. Finally, if player A activates
switch 34 (rock) and player B activates switch 35 (paper), LED 40
is illuminated indicating player B is the winner.
[0054] LEDs 38, 40 represent one type of discrete electronic
component that can be integrated into the circuit 30. Other types
of discrete electronic components, such as sound chips and memory
chips, may also be integrated into the circuit 30. The discrete
electronic components may be coupled to the traces using a suitable
conductive material, such as a conductive tape (e.g., copper tape)
or a conductive adhesive (e.g., a conductive epoxy). Alternatively,
the electronic component may be mounted to a thin, flexible board
(e.g., an FR-4 printed circuit board), which includes conductive
material (e.g., amounts of the conductive ink) applied at the
contact points with the traces of the circuit 30. The board (and
the attached electronic component) may be positioned in a
pick-and-place operation, and then the board may be adhesively
bonded (e.g., tacked) to the paperboard blank using, for example, a
hot melt adhesive.
[0055] Referring now to FIGS. 3-7, in an embodiment of the
invention, the circuit 30 may be implemented on a substrate or
blank 50 of packaging material having a surface 51. The blank 50
may be comprised of a substrate of a cellulose-based material
commonly referred to as paperboard or cardboard, which has a
thickness (e.g., 0.022 inches) suitable for a product package. The
blank 50 may include score or fold lines 52 and cut lines 54
configured so that the blank 50 may be formed into a carton or box,
such as a cereal box 200, 230 (FIGS. 16-18), having one or more
tabs 56 and openings 57.
[0056] As best shown in FIG. 3, a conductive ink pattern 58 may be
deposited on the surface 51 of the blank 50, which may correspond
to an interior surface of the product package, to form a printed
circuit. The conductive ink pattern may be comprised of a plurality
of traces 62 printed on the surface 51, with each trace 62 having a
width W, a length L, and a thickness T (FIG. 8). The traces 62 may
be configured so that there are gaps 63 between exposed sections,
or contact pads 65 of selected traces 62 that comprise the
double-pole switches 32-37, as will be described in more detail
below. Selected traces 62 may also include regions that provide
contact pads 65 configured to interact with other sections of the
conductive ink pattern 58 and/or external circuit components, such
the power source 42. For example, contact pads 65a and 65b (FIG. 5)
may be configured to engage terminals of a battery.
[0057] The conductive ink pattern 58 may be printed the front side
of the blank 50, the back side of the blank 50, or both sides of
the blank 50. The conductive ink pattern 58 may appear on the
inside of the package, the outside of the package, or on both sides
of the package after the blank 50 is uprighted or erected to form
the package.
[0058] The width W, length L, and thickness T of the traces 62 may
be controlled by adjusting the amount of ink, and the pattern in
which the ink is applied to the surface 51. By adjusting the
dimensions of the traces 62, the resistances of the circuit 30 may
be controlled. In one embodiment, the resistor 44 of circuit 30 may
be provided by the resistance of the traces 62 so that the need for
a discrete electrical component is negated. In addition, the width
W and/or thickness T of each trace 62 may be adjusted independently
of the other to balance resistances between different sections of
the conductive ink pattern 58 and/or to compensate for varying
lengths L of the traces 62. The trace thickness may be measured
relative to the plane of the surface 51 on which the traces 62 are
printed.
[0059] The fold lines 52 and cut lines 54 may be configured so that
the blank 50 can be formed into a box suitable for containing a
consumer product, such as a breakfast cereal. Additional fold lines
52 and cut lines 54 may also be included in the blank 50 to define
features of the product package that facilitate operation of the
circuit 30. For example, the fold lines 52 and cut lines 54 may be
configured in a pattern 67 configured to define a battery cavity or
compartment 204 (FIG. 16) in the finished product package 200 (FIG.
16). Electrical power may be supplied from a battery held in the
battery compartment 204 to a printed circuit configuration on the
top side, the back side, or both sides of the blank 50 which
allows, in certain embodiments, for the mounting of devices or the
implementation of circuitry inside, outside, or both (i.e., on the
interior and/or the exterior) of a package formed from the folded
and uprighted blank 50.
[0060] The carton formed from the blank 50 defines a
three-dimensional platform characterized by a height, a width, and
a depth with folding about the scores (e.g., fold lines 52) for
erection/set-up. On the platform, a myriad of end-use applications
are achievable through design and placement of a customized circuit
configuration.
[0061] The integrity of the printed circuit defined by the
conductive ink pattern 58 may be maintained regardless of whether
the surface 51 is the back side (which is porous) of the substrate
selected as the blank 50 or the top side of the selected substrate
(which may be less porous than the backside) when the printed
circuit is flexed over structural score lines 52. The ability to
maintain the integrity may depend, among other factors, upon the
width-to-thickness aspect ratio of the traces 62.
[0062] It has been observed that, if the thickness T of the traces
62 is greater than a few microns, the traces 62 tend to fracture
(i.e., crack) and/or flake off in areas where the traces 62 cross
score or fold lines 52 when the blank 50 is folded (e.g., folding
by 90.degree. at the fold line 52). It has also been determined
that traces 62 having an insufficient thickness T tend to be
unreliable conductors when printed on interior surfaces of
paperboard blanks 50. This unreliability may be due, at least in
part, to the roughness of the interior surfaces of the paperboard
blanks 50 typically used in product packaging. These conflicting
requirements for fabricating traces 62 with conductive ink have
discouraged persons having ordinary skill in the art of package
engineering from using conductive ink to form circuits on cardboard
blanks. However, it has been discovered that by increasing the
width W of the traces 62 so that the traces have a large
width-to-thickness aspect ratio, printed conductive ink traces may
be formed that provide reliable circuits on interior surfaces of
folded cardboard blanks 50. The resistance of the traces is
proportional to the length, width and height of the traces 62, in
addition to the resistivity of the material comprising the
conductive ink. Depending on the appropriate print technique and
circuit configuration different dimensioning specifications are
applied. For example, in an embodiment of the invention, a gravure
plate may have an etch effect described as BCM (billion cubic
microns) and, in this application, may reach a 100 Billion Cubic
Microns (BCM) of ink per cm.sup.2 in the gravure pattern in
combination with a trace width W of between 0.375 and 0.750 inches.
In another embodiment of the invention, rotogravure printing may
use a 60 Lines per Inch (LPI) screen and a volume application for
the conductive ink of 60 Billion Cubic Micron (BCM) to provide a
sheet resistance value of about 100 ohms per square. Circuit
resistors, such as resistor 44, may be integrated into the
conductive ink pattern 58 by adjusting the width (i.e., the
resistance) of the traces 62.
[0063] Moreover, by adjusting the width of the traces 62, the
resistance of the traces 62 may be adjusted to a desired level, and
circuit resistances may be balanced while maintaining an optimum
trace thickness T to resist cracking. The LEDs 38, 40 may thereby
be illuminated equally (i.e., nominally equal intensities of output
visible light) by the circuit 30 regardless of the collective
length of the traces 62 that are coupling the LEDs 38, 40 to the
power source 42. In certain circuit configurations, circuit design
requires the application of "Sheet Resistivity" (ohms per square)
calculations to create matching resistance levels in balancing
luminosity between the mutually-illuminated LEDs 38, 40. As an
example, if a circuit is interacting with a device such as a LED, a
two (2) volt forward voltage and rated at 20 mA and powered in a
circuit with a nine (9) volt battery, the circuit must provide a
performance of no more than 350 ohms as provided by the thickness
and width of the conductive material in the traces 62 from a
printing application.
[0064] As best shown in FIG. 4, a dielectric pattern 64 may be
deposited over one or more regions of the conductive ink pattern 58
to isolate selected traces 62 from later deposited conductive ink
patterns. The dielectric pattern 64 may be comprised of a plurality
of dielectric regions 66 defined using a conventional printing
technique, such as the aforementioned screen print, flexo, gravure,
photo-pattern, pad printing, and jet printing to deposit an acrylic
or other suitable material on the surface 51 of blank 50. The
dielectric regions 66 may be configured to cover sections of the
traces 62 of conductive ink pattern 58 so that additional
conductive ink traces may be applied in a crossing pattern without
undesired shorting to the conductive ink pattern 58. The insulating
cross-over points providing for circuit-over-circuit
configurations, and may permit the use of one or more switches,
such as switches 32-37, in a portion or portions of a circuit. In
an alternative embodiment of the invention, the dielectric regions
66 may be defined by applying tape, a decal, or other suitable
dielectric film to the surface 51.
[0065] FIG. 5 illustrates a conductive ink pattern 68 that includes
a plurality of traces 70 and plurality of contact pads 72. The
contact pads 72 may be defined on the tabs 56 so that when the
blank 50 is formed into a box and the tabs 56 are folded along
their respective fold lines 52, the contact pads 72 of tabs 56 are
aligned with corresponding gaps 63 to form the double-pole switches
32-37 of circuit 30. The tabs 56, traces 62, 70, and contact pads
65, 72 are thereby configured so that each of the double-pole
switches 32-37 may be closed by pressing a corresponding tab 56
into contact with a respective set of contact pads 65. Pressing the
selected tab 56 into contact with the respective contact pads 65
may cause the contact pads 72 of the selected tab 56 to bridge the
respective gaps 63. A set of contact pads 65 comprising one of the
double-pole switches 32-37 may thereby be electrically coupled by
the contact pads 72 to close the selected double-pole switch
32-37.
[0066] FIG. 6 illustrates a dielectric pattern 80, which may be
deposited over sections of the conductive ink patterns 58, 68 to
define a protective layer over regions of the traces 62, 70. The
dielectric pattern 80 may be comprised of a plurality of dielectric
regions 82 defined in a similar manner as describe with respect to
dielectric pattern 64. The dielectric regions 82 may be configured
to cover sections of the conductive ink patterns 58, 68 while
leaving contact pads 65, 72 exposed to allow operation of the
circuit 30, and to facilitate coupling of additional circuit
components, such as the LEDs 38, 40 and power source 42 to the
circuit 30.
[0067] FIG. 7 is a top view of the surface 51 of blank 50 before
the blank 50 is formed into the product package, and includes the
conductive ink patterns 58, 68 and the dielectric patterns 64, 80.
The illustrated blank 50 is configured so that the tabs 56 are
arranged into two rows 84, 86 of tabs 56. The blank 50 may be
further configured so that when the blank 50 is formed into the
product package, row 84 of tabs 56 aligns with two rows 88, 90 of
contact pads 65, and row 86 of tabs 56 aligns with two rows 92, 94
of contact pads 65. In response to pressure on one of the tabs 56,
the cut lines 54 defining edges of the tab 56 may give way,
allowing the tab 56 to pivot on a hinge formed by the fold line 52
connecting the tab 56 to the blank 50. As tab 56 pivots, each
contact pad 72 of tab 56 may contact one pad 65 in each of rows 90
and 92, or rows 94 and 96 of contact pads 65, which are separated
by the gap 63. Two sets of opposing contact pads 65 in opposing
rows (e.g., rows 88 and 90, or rows 92 and 94) may thereby be
electrically coupled through the contact pads 72 of the tab 56.
Each tab 56 may thereby engage a corresponding set of contacts 65
to provide one of the double-pole switches 32-37 of circuit 30.
[0068] Through the printing of conductive ink patterns 58, 68
and/or the dielectric patterns 64, 80, circuits may be created of
non-connected, connected, and circuit-over-circuit configurations.
The conductive ink pattern 58 and the dielectric pattern 64 may be
comprised of non-metallic materials. The development of printing
techniques and the use of conductive non-metallic material
facilitates the successful creation of the circuit 30 on either
side of the folding carton material, which may be coated or
uncoated, as well as crossing through folding or scoring lines for
box or carton erection/set up. In particular, the printing
techniques and the use of conductive non-metallic material in the
embodiments disclosed herein promote the printing of the circuit 30
on the uncoated backside of uncoated paperboard, which is
porous.
[0069] Referring now to FIG. 8 a cross-sectional view of a portion
of circuit 30 is depicted showing a plurality of layers including
the lower conductive trace 62, the dielectric region 66 isolating
the lower conductive trace 62 from the upper conductive trace 70,
and the top dielectric region 82, which forms an over-layer or "rub
layer" that protects the lower layers. The dielectric region 66 may
be comprised of a plurality of vertically stacked layers, including
barrier layers 93, 95, and a plurality of insulating layers 97-99.
The barrier layers 93, 95 may be deposited as a water-based ink
containing cationic polymer particles to form a barrier between the
trace 62 and subsequently deposited layers. The barrier layers 93,
95 may reduce unwanted interactions between the traces 62, 70 and
insulating layers 97-99, as well as fill voids in the underlying
layers to provide a smooth surface for receiving subsequently
deposited layers. The barrier layers 93, 95 may thereby provide
improved adhesion and ink holdout as compared to dielectric regions
66 lacking the barrier layers 93, 95. The insulating layers 97-99
may be formed by depositing a suitable insulating ink, such a
ceramic ink including alumina and/or barium titanate (BaTiO.sub.3).
In a specific embodiment of the invention, three insulating layers
are deposited using barium titanate ink at a rate of about 60
Billion Cubic Microns per square centimeter (BCM/cm.sup.2) using a
gravure, silk screen, or other suitable process. The resulting ink
layers may be air dried, or energy cured using heat and/or
ultraviolet light.
[0070] Referring now to FIGS. 9-11, an alternative embodiment of
the circuit 30 is depicted as being implemented on a blank 100 of
packaging material. The blank may include fold lines 52 and cut
lines 54 configured so that blank 100 may be formed into a box in a
similar manner as described above with respect to blank 50. FIG. 9
illustrates a conductive ink pattern 102 deposited on a surface 104
of blank 100. The surface 104 of blank 100 may correspond to an
interior surface of the product package. The conductive ink pattern
102 may be comprised of a plurality of traces 106 printed on the
surface 104. The traces 106 may be configured to have interlocking
features that define a winding gap 108 between exposed sections of
selected traces 106 that comprise contact pads 110 of double-pole
switches 32-37. The gap 108 is marked by repeated turns along its
length.
[0071] FIGS. 10 and 11 present detailed views of two exemplary
embodiments of the contact pads 110, which include a plurality of
interlocking projections 112. The projections 112 may be configured
so that they extend outward from a respective base line 114 toward
an adjacent trace 106, which has projections 112 similarly
extending from the respective baseline 114 in an opposing
direction. The projections 112 of the adjacent traces 106 may
thereby form the interlocking projections 112 that define the
winding gap 108 between the contact pads 110 of opposing traces 106
and thereby comprise a switch.
[0072] The projections 112 may be configured to define the gap 108
as including a plurality of interconnected linear segments, as
shown in FIG. 10. The gap 108 may have a width defined by a
distance separating opposing projections 112, and a length defined
by the distance required to traverse from one end 109 of the gap
108 to another end 111 of the gap 108. By defining the gap 108 to
have a winding shape, the length of the gap 108 may be increased as
compared to gaps having a parallel configuration of opposing
contact pads 65, such as gap 63. The gaps 108 shown in FIGS. 9 and
10 are generally depicted as being defined by a plurality of
straight segments joined at right angles. Alternatively, the
projections 112 may be configured to define a plurality of straight
gap segments joined at angles other than right angles. The
projections 112 may also be configured to define one or more curved
segments such as shown in FIG. 11. Hence, a person having ordinary
skill in the art would understand that embodiments of the invention
are not limited to the exemplary configurations of the gap 108
shown in FIGS. 10 and 11. This person would further understand that
other shapes may be used to provide the interlocking features that
define the winding gap 108. Thus, embodiments of the invention may
include gaps 108 defined using projections 112 having numerous
shapes that increase the length of the gap 108. The configuration
of the gap 108 is therefore not limited to the exemplary
embodiments shown and described herein. In any case, the gaps 108
formed by contact pads 110 having interlocking projections 112 may
provide an increased length across which the contact pads 110 may
be coupled as compared to gaps between contact pads lacking the
interlocking feature.
[0073] Similarly as described above with respect to FIG. 5, the
contact pads 72 may be defined on the tabs 56 so that, when the
blank 100 is formed into a box and the tabs 56 are folded along
their respective fold lines 52, the contact pads 72 of tabs 56 are
aligned with corresponding gaps 108 to form the double-pole
switches 32-37 of circuit 30. The contact pads 72 may be defined by
the same process used to define the traces 106.
[0074] Referring now to FIG. 12, the dielectric pattern 64 may be
deposited over one or more regions of the conductive ink pattern
102 to isolate selected traces 106 from later deposited conductive
ink patterns as described above with respect to FIG. 4. The
dielectric regions 66 may be configured to cover sections of the
traces 106 of conductive ink pattern 102 so that additional
conductive ink traces may be applied in a crossing pattern without
undesired shorting to the conductive ink pattern 102.
[0075] FIG. 13 illustrates a conductive ink pattern 116 that
includes a plurality of traces 118 and the plurality of contact
pads 72. The contact pads 72 may thereby include an additional
conductive layer deposited during the process that defines the
traces 118. The tabs 56, traces 106, 118, and contact pads 110 are
thereby configured so that each of the double-pole switches 32-37
may be closed by pressing a corresponding tab 56 into contact with
respective contact pads 110. Pressing the selected tab 56 into
contact with the respective contact pads 110 may cause the contact
pads 72 of the selected tab 56 to bridge the respective gap 108. A
set of contact pads 110 comprising one of the double-pole switches
32-37 may thereby be electrically coupled by the contact pads 72 to
close the selected double-pole switch 32-37.
[0076] FIG. 14 illustrates a dielectric pattern 120, which may be
deposited over sections of the conductive ink patterns 102, 116 to
define a protective over-layer over regions of the traces 106, 118.
The dielectric pattern 120 may be comprised of a single dielectric
layer, or a plurality of dielectric layers defined in a similar
manner as describe above with respect to dielectric pattern 80. The
dielectric regions 122 may be configured to cover sections of the
conductive ink patterns 102, 116 while leaving the contact pads 72,
110 exposed to allow operation of the circuit 30. The dielectric
pattern 120 may also be configured to leave regions of the traces
106 exposed to facilitate coupling of additional circuit components
such as the LEDs 38, 40 and power source 42 to the circuit 30.
[0077] FIG. 15 is a top view of the surface 104 of blank 100 before
the blank 100 is formed into the product package, and includes the
conductive ink patterns 102, 116 and the dielectric patterns 64,
120. The blank 100 may be configured so that the surface 104 of
blank 100 faces the interior of the assembled product package.
Similarly to the blank 50, the blank 100 is configured so that the
tabs 56 are arranged into two rows 124, 126 of tabs 56. The blank
100 may be further configured so that when the blank 100 is formed
into the product package, row 124 of tabs 56 aligns with a row 128
of contact pads 110, and row 126 of tabs 56 aligns with a row 130
of contact pads 110. In response to pressure on one of the tabs 56,
the cut lines 54 defining edges of the tab 56 may yield, thereby
allowing the tab 56 to pivot on a hinge formed by the fold line 52
connecting the tab 56 to the blank 100. As tab 56 pivots, each
contact pad 72 of tab 56 may contact a set of contact pads 110 of
row 128, or contact pads 110 of row 130, thereby bridging the
respective gaps 108. Two sets of opposing projections 112 of the
respective contact pads 110 may thereby be electrically coupled
through the contact pads 72 of the tab 56. Each tab 56 may thereby
engage a set of corresponding contact pads 110 to provide one of
the double-pole switches 32-37 of circuit 30.
[0078] FIGS. 16 and 17 illustrate a side view of an exemplary
embodiment of the product package 200 showing a side 202 of the
product package 200 that includes the row of tabs 56 corresponding
to switches 35-37 of circuit 30. The product package 200 may
include the battery compartment 204 formed from the battery
compartment pattern 67 of blank 50, 100. The battery compartment
204 may include a chock 206 formed by pressing on a section 208 of
a corner 210 of product package 200 so that the section 208 extends
into the battery compartment 204. The chock 206 may be configured
to provide pressure or tension on a battery 212, thereby urging
terminals (not shown) of battery 212 into contact with contacts
65a, 65b. The tabs 56 may include indicia such as images 214-216
and/or text 220-222 identifying each tab as being associated with
one of paper (214, 220), rock (215, 221), or scissors (216, 222).
In FIG. 16, the tabs 56 are shown in a position that is essentially
coplanar with the side 202 of product package 200. In FIG. 17, the
tabs 56 are shown pressed inward so that they extend into the
interior of the product package 200.
[0079] FIG. 18 illustrates a perspective view of a product package
230 consistent with an embodiment of the invention. The product
package includes one side 232 having the openings 57 configured to
accept LEDs, and another side 238 having tabs 56. Similarly to the
product package 200 in FIGS. 16 and 17, the product package 230
includes a battery compartment 240 and battery 242.
[0080] Referring now to FIG. 19 an exemplary image 244 that may be
printed or otherwise applied to side 232 of product package 230 is
illustrated. Image 244 may be associated with the
rock-paper-scissors game electrical circuit 30 described in detail
above. To this end, each opening 57 may include one of the LEDs 38,
40, which are configured to illuminate in response to a player
activating a tab 56 corresponding to the switch 32-37 for a winning
selection of rock, paper, or scissors. The LED 38, 40 may thereby
indicate that the player identified by one of arrows 248, 250 is
the winner for a particular round of rock-paper-scissors.
[0081] Referring now to FIGS. 20 and 21, an alternative embodiment
of the invention including a circuit 254 comprising a switch 255, a
power source 256, a resistor 257 and one or more LEDs 258, 259 is
presented. The circuit 254 may be realized as a conductive ink
pattern 260 deposited on a surface 262 of a blank 264 (which is
similar to blank 50), which may correspond to an interior surface
of a product package. The conductive ink pattern 262 may be
comprised of a plurality of traces 266 printed on the surface 262.
The traces 266 may be configured so that contact pads 268 define a
winding gap 270 between exposed sections of selected traces 266
that comprise a portion of the switch 255. Portions of the traces
266 crossing fold lines 52 may be configured with an increased
width to provide improved robustness in those areas. The blank 264
may also include a tab 272 having a contact pad 274 that provides
another portion of the switch 255, and contact pads 276-281
configured to couple the conductive ink pattern 262 to external
components of the circuit 254, such as a power source 256 and LEDs
258, 259. For example, contacts 276 and 277 may be configured to
engage terminals of a battery. The resistor 257 of circuit 254 may
be provided by the resistance of the traces 266. The value of the
resistor 257 may be defined by adjusting the width, length, and
thickness of the traces 266 as described above with respect to
circuit 30.
[0082] Referring now to FIG. 22, a dielectric pattern 290 may be
deposited over sections of the conductive ink pattern 260 to define
a protective over-layer over regions of the traces 266. The
dielectric pattern 290 may be comprised of a plurality of
dielectric regions 292 defined in a similar manner as describe with
respect to dielectric pattern 80. The dielectric regions 292 may be
configured to cover sections of the conductive ink pattern 260
while leaving contact pads 268, 274, 276-281 exposed to allow
operation of the circuit 254, and to facilitate coupling of
additional circuit components, such as the LEDs 258, 259 and power
source 256.
[0083] FIG. 23 is a top view of the surface 262 of blank 264 before
the blank 264 is formed into the product package, and includes the
conductive ink pattern 260 and the dielectric pattern 290.
Similarly to blanks 50, 100, blank 264 may be configured so that
when the blank 264 is formed into the product package, the surface
262 of blank 264 faces the interior of the package, and the tab 272
aligns with the contact pads 268. In response to pressure on the
tab 272, the cut lines 54 defining the edges of the tab 272 may
give way, allowing the tab 272 to pivot on a hinge formed by the
fold line 52 connecting the tab 272 to the blank 264. As the tab
272 pivots, the contact pad 274 may come into contact with contact
pads 268, thereby bridging the respective gap 270. The opposing
contact pads 268 may thereby be electrically coupled through the
contact pad 274 of the tab 272 to close the switch 255 of circuit
254.
[0084] FIG. 24 presents an exemplary image 294 that may be printed
or otherwise applied to an exterior side of a product package
formed from the blank 264. The image 294 may include a feature 296
(e.g., eyes) aligned with the openings 57 so that the product
package is configured to attract attention to the feature 296 in
response to a user activating the tab 272. To this end, each
opening 57 may include one of the LEDs 258, 259, which are
configured to illuminate in response to a user activating the tab
272 corresponding to the switch 255. The LEDs 258, 259 may be
energized one at a time or multiple illuminations to create special
effects. End uses that utilize switched illumination may include,
but are not limited to, annunciation of a game winner, a response
to a challenge (e.g., a question), or adding special effects to a
graphic design, such as "glowing eyes" on the graphic design of a
face. In another embodiment, one of the LEDs 258, 259 may be
omitted such that a single LED is illuminated when the tab 272 is
activated.
[0085] Referring now to FIG. 25, a circuit 300 for a game according
to an alternative embodiment of the invention may include a power
source 302, a resistor 304, a plurality of LED's 306-309, and a
plurality of switches 314-327. The circuit 300 may be configured so
that the switches 314-327 selectively couple one or more of the
LED's 306-309 to the power source 302 through the resistor 304 in
response to activation by a user. Activation of the switches
314-327 may thereby illuminate one or more LED's in a predetermined
manner. The circuit 300 may further be configured to provide an
indication of a game result based on the user's activation of a
selected switch 314-327.
[0086] Referring now to FIG. 26, the circuit 300 may be implemented
on a blank 330 in a similar manner as described above with respect
to blanks 50, 100, and 264. To this end, a conductive ink pattern
332 may be deposited on a surface 334 of blank 330. The surface 334
of blank 330 may correspond to an exterior surface of a product
package. The conductive ink pattern 332 may be comprised of a
plurality of traces 336 printed on the surface 334. The traces 336
may be configured to define a gap 338 (illustrated in this
exemplary embodiment as a winding gap) between exposed sections of
selected traces 336 to define contact pads 340 of switches 314-327.
Fold lines 52 and cut lines 54 may be configured to allow the blank
330 to be formed into a product package. The fold lines 52 and cut
lines 54 may also define a portion 341 of the blank 330 configured
to form a compartment for receiving the power source 302, which may
be a battery (not shown). The compartment may include various
features, e.g., terminals and tabs, for mating with the battery
terminals.
[0087] The blank 330 may also include a section 342 defined by one
or more cut lines 54. The section 342 may include a contact pad
344, and may be configured to be punched out of the product package
by the user and assembled into a game stylus. The game stylus may
be used to activate a selected switch by pressing the contact pad
344 against the contact pads 340 comprising one of the switches
314-327 so that the contact pad 344 of the stylus bridges the gap
338 separating the selected contact pads 340. The user may thereby
selectively activate one of the switches 314-327. The stylus acts
as a switch device by closing certain circuit points, thus
illuminating LED's, or powering additional add-on devices.
[0088] The blank 330 may also include a section 346 having a
plurality of contact pads 348-352 electrically coupled through one
or more traces 354. The section 346 may also be defined by one or
more cut lines 54. The section 346 may be in a portion of the blank
330 that is separate from the portion used to form the product
package, and may be removed prior to forming the product package
for inclusion inside the product package as a toy or prize. As best
shown in FIG. 27A, the section 346 may also include fold lines 52
configured so that when the section 346 is removed from the product
package and folded along the fold lines, the section 346 provides a
game piece 357 suitable for use with a touch-sensitive device, such
as a tablet computer or a smart phone having a touch screen. To
this end, the section 346 of blank 330 may be configured so that
the fold lines 52 define a bottom portion 356 including contact
pads 349-351 and side portions 358, 360 including contact pads 348
and 352, respectively. Each of the contact pads 348-352 may be
electrically coupled to the other contact pads 348-352 by the
traces 354.
[0089] When folded along the fold lines 52, the side portions 358,
360 may form a gripping portion 362 of the game piece 357 that
extends from the bottom portion 356 so that the contact pads
349-351 of bottom portion 356 are on an outer surface of the game
piece 357. One or more of the traces 354 may be located along the
length of the fold lines 52 to provide robust coupling (i.e.,
coupling that is resistant to damage caused by folding) between the
traces 356 on the bottom portion 356 of game piece 357 and the
traces 356 on the side portions 358, 360 of game piece 357. The
game piece 357 may be further configured so that the contact pads
346, 352 of side portions 358, 360 face outward. The game piece 357
may thereby be configured so that when the user grips the gripping
portion 362 of game piece 357, the user's fingers are in contact
with contact pads 346, 352. The user may thereby be electrically
coupled to the contact pads 349-351 on the bottom portion 356 of
game piece 357 so that the touch screen may sense a change in
electrical loading of areas of the touch screen that come into
contact with the contact pads 349-351.
[0090] The contact pads 349-351 may be configured to form a unique
footprint that is recognized by an application running on the touch
sensitive device, such as a game running on a tablet computer.
Generally, games can be purchased or downloaded for free directly
onto a touch sensitive device, such as a mobile computing device,
from an online application store, commonly known as an "app store"
or "app market". The use of game pieces with touch sensitive
devices is described in detail in U.S. Application Publication No
2012/0007808, entitled "GAME PIECES FOR USE WITH TOUCH SCREEN
DEVICES AND RELATED METHODS", the disclosure of which is
incorporated herein by reference in its entirety.
[0091] The number, size, shape, and positions of the contact pads
349-351 of game piece 357 may be varied from one product package to
another so that multiple such different structurally-created game
pieces may be defined that are each individually recognizable by
the application. In operation, the user may grip the gripping
portion 362 of game piece 357, and press the bottom portion 356
against the touch screen. In response, the application may sense a
change in capacitance, impedance, or loading in regions of the
touch screen that are in contact with the contact pads 349-351. The
application may then provide a response to the user based on the
configuration of the contact pads 349-351. For example, the
application may display a particular image or cartoon character
based on the sensed configuration of the contact pads 349-351, or
may take the user to a specific portion of a game.
[0092] FIGS. 27B and 27C present an exemplary embodiment of the
invention in which the game piece 357 includes an image of a car
363. This exemplary embodiment of the game piece 357 may be used,
for example, in a game involving a car moving along a track
displayed on a touch sensitive device 355 (e.g., a capacitance
touch screen). In use, the user may place the game piece 357
between their thumb and index finger as shown in FIG. 27C. The game
piece 357 may then be placed in contact with the touch screen,
which may determine the type of game piece 357 based on the size,
shape, position, and number of contact pads 349-351 on the bottom
portion 356 of the game piece 357. In this way, the application may
be made to respond differently to different game pieces 357.
Different game pieces 357 could be provided in the product
container over a period of time, thereby providing an incentive to
purchase the same product multiple times so as to collect each
variation of the game piece 357.
[0093] With reference to FIGS. 27D, 27E in which like reference
numerals refer to like features in FIGS. 27A-C, the contact pads
349-351 of game piece 357 may embossed so that each includes a
respective contact surface 349a-351a that is raised relative to the
background defined by the top surface 330a of the section 346 of
the blank 330. The configuration of the contact pads 349-351 may
provide a relatively high relief avoid inappropriate contact
(signal noise) to the screen of the touch sensitive device 355 with
the connecting circuit runs. The relief provided by the embossing
increase the signal-to-noise (S/N) ratio by elevating or raising
the traces 354 away from the surface of the screen of the touch
sensitive device 355, when the game piece 357 is in use, so traces
354 do not interrupt the contact surfaces 349a-351a themselves
and/or contact the surface of the screen of the touch sensitive
device 355.
[0094] Each of the contact pads 349-351 includes a surface
349c-351c that is a plane parallel to the plane of the surface 330a
of the blank 330 and an inclined connecting surface 349b-351b. The
surfaces 349a-351a and 349b-351b of the contact pads 349-251
reflect the contour of the bosses formed in the underlying and
supporting material of the blank 330. For example, the surfaces
349a, 349b reproduce the contour of the surfaces 347a, 347b of a
boss 347 impressed by an embossing die in the blank 330 at the
location of the contact pad 349. The embossing die includes a
protruding feature that applies pressure to the board 330 at the
location of the boss 347. The board 300 plastically deforms to form
the boss 347 when pressure is applied by the embossing die. Only a
portion of the contact pad 349 is embossed (i.e., displaced from
the plane of the board 330 by the boss 347) such that, for example,
the conductive material of the contact pad 349 is present on each
of the surfaces 347a, 347b, and 330a, as well as on surfaces
349a-351a.
[0095] Characteristics of the boss 347, such as the included angle,
.theta., of the surface 347b relative to a bottom surface 330b of
the blank 330, the height of the surface 347a relative to the top
surface 330a of the blank 330, dimensions or area of the surface
347a (e.g., diameter if the surfaces 347a is round), and the
relative size of the contact pad 349 to the surface 347a, may be
selected to avoid fracturing the continuity of the circuit by
cracking the conductive material of the contact pad 349. In one
embodiment, the surface 347b may be characterized by an included
angle, .theta., of 30.degree. and the surface 347a may be flat or
planar.
[0096] In one embodiment, the height of the top surface 347a at the
boss 347 relative to the top surface 330a is less than or equal to
about 80% of the thickness, t, of the blank 330. Limiting the
height of the top surface 347a (i.e., the depth of the boss 347) to
this extent may reduce the risk of fracturing the conductive
material comprising the contact pad 347. In another embodiment, the
height of the top surface 347a relative to surface 330a is less
than or equal to the thickness, t, of the blank 330. Limiting the
level of the relief to this extent may reduce the risk of
fracturing the board comprising the blank 330 in addition to
fracturing the conductive material comprising the contact pad 347.
In yet another embodiment, the height of the top surface 347a at
the boss 347 relative to the top surface 330a is less than or equal
to about 80% of the thickness, t, of the blank 330 and greater than
or equal to about 45% of the thickness, t, of the blank 330.
Limiting the lower limit on the height of the top surface 347a may
provide a threshold for preventing the surface 347c and the traces
354 from contacting the surface of the screen of the touch
sensitive device 355.
[0097] The contact surfaces 350a and 351a are formed by bosses
similar or identical to boss 347 and, in each instance, each of the
contact pads 350, 351 is only partially embossed similar to contact
pad 349. The selection of the relative size of the contact pads
349-351 to the dimensions of their bosses may be used to account
for inaccuracies in feature registration during the printing and
embossing processes. As the size of the contact pads 349-351
increases, the level of embossing can be increased. Nearby score or
fold lines 52 may be debossed into the section 346 of the blank 330
due to their proximity to the contact pads 349-351.
[0098] Referring now to FIG. 28, a dielectric pattern 364
comprising one or more dielectric regions 366 deposited over one or
more regions of the conductive ink pattern 332 may be used to
isolate selected traces 336 from later deposited conductive ink
patterns in a similar fashion as described above with respect to
FIG. 4. The dielectric regions 366 may be configured to cover
sections of the traces 336 of conductive ink pattern 332 so that
additional conductive ink traces may be applied in a crossing
pattern without undesired shorting to the conductive ink pattern
332.
[0099] FIG. 29 illustrates a conductive ink pattern 368 that
includes a plurality of traces 370 as well as the contact pad 344
of section 342, the plurality of contact pads 348-352 and traces
354 of section 346. The contact pads 344, 348-352 and traces 354
may thereby include an additional conductive layer deposited during
the process that defines the conductive ink pattern 368. The traces
336, 370 and contact pads 340, 344 may be configured so that each
of the switches 314-327 may be selectively closed by pressing a
conductive member, such as the contact pad 344 of section 342, into
contact with a respective set of contact pads 340. Pressing the
conductive member into contact with the contact pads 340 of a
switch 314-327 may cause the contact pad 344 to bridge the
respective gap 338. A set of contact pads 340 comprising one of the
switches 314-327 may thereby be electrically coupled by the contact
pad 344 to close the selected switch 314-327.
[0100] FIG. 30 illustrates a dielectric pattern 380, which may be
deposited over sections of the conductive ink patterns 332, 368 to
define a protective over-layer over regions of the traces 336, 354,
370. The dielectric pattern 380 may be comprised of a plurality of
dielectric regions 382 defined in a similar manner as described
with respect to dielectric pattern 80. The dielectric regions 382
may be configured to cover sections of the conductive ink patterns
336, 368 while leaving contact pads 340, 344, 348-352 exposed to
allow operation of the circuit 300, and to facilitate coupling of
additional circuit components, such as the LEDs 306-309 and power
source 302. FIG. 31 provides a top view of the blank 330 before the
blank 330 is formed into the product package, and includes the
conductive ink patterns 336, 368 and the dielectric patterns 364,
380.
[0101] FIG. 32 is a top view of the blank 330 after an exterior
printing process. The resulting printed exterior surface includes
an exemplary game board printed over the circuit 300. The printed
game board may include openings (i.e., areas in which ink is not
deposited) over the LED's 306-309 and contact pads 340
corresponding to the switches 314-327. The game may include a path
384, a plurality of questions 386-390, and instructions 392 on how
to play the game. A plurality of switches (e.g., two) may be
associated with each question. For example, switches 326 and 327
may be associated with question 386 (e.g., "2+2+?"), with
activation of switch 326 indicating one answer (e.g., "1"), and
activation of switch 327 indicating another answer (e.g., "4"). In
response to activating switch 326, LED 306 may illuminate,
indicating that the user should turn left to continue up the path
384 in one direction. Similarly, in response to activating switch
327, LED 309 may illuminate, indicating that the user should
proceed up the path 384 by turning right. In the illustrated
exemplary embodiment, providing a sufficient number of correct
answers may lead the user to switch 317. In response to activating
switch 317, LED 307 may be illuminated indicating that the user has
won the game. In contrast, incorrect answers may lead the user to
one of switches 314-316, activation of which may illuminate LED 308
indicating that the user should go back and try again. FIG. 33
presents a detailed perspective view of a user playing the game by
activating switch 318 using the stylus to answer question 389,
which would illuminate LED 306 and indicate that the user should
proceed up the path to the left.
[0102] Referring now to FIGS. 34 and 35, a blank 400 including an
exemplary game is depicted in accordance with an alternative
embodiment of the invention. The game may include a plurality of
switches 402-406 and a plurality of LED's 410, 412 configured so
that one LED of the plurality of LED's 410, 412 illuminates in
response to activation of one of the switches 402-406. In the
illustrated game, a printed ink circuit (not shown) may be
configured so that activation of one of the switches 402-406 causes
LED 410 to be illuminated to indicate the user has selected the
correct answer (e.g., the correct location of a pot of gold). The
remaining switches 402-406 may be configured so that activation
causes LED 412 to be illuminated to indicate that the user has
selected an incorrect answer (e.g., an incorrect location for the
pot of gold). As best shown in FIG. 35, the user may activate a
switch 402-406 by pressing the contact pad 344 of the game stylus
against the contact pads of the switch in question. Games may
thereby be configured so that the user is required to select from
multiple (e.g., more than two) choices or answers.
[0103] The circuits of the various embodiments of the invention may
be printed directly on the package and, as a consequence, is not
laminated or inserted. In one embodiment, the circuit may be
printed on the backside of the package, which is the side opposite
to the frontside that is typically displayed on a product shelf.
The circuit may be comprised of materials that conform to CONEG
regulations for landfill that are intended to reduce the sum
concentration levels of incidentally-introduced heavy metals, such
as lead, mercury, cadmium, and hexavalent chromium, present in
package or packaging components. The circuit may be a multi-level
construction formed by overprinting the discrete functional layers
over one another. The circuit may be comprised dielectric
(insulating) layers between adjacent conductive layers of the
circuit. The circuit may be comprised of alternating layers of
chemical formulations to achieve dielectric (insulating)
effectiveness and qualities. The package may include a battery
compartment, which may be accessible to a consumer from the
exterior of the package for inserting a battery (e.g., a nine-volt
battery) to functionally energize the circuit for operation. The
package may include a plurality of integrated switch gates printed
directly on the package, which are printed directly on the backside
of the package in one embodiment.
[0104] The circuit may be printed by a rotogravure print process,
which involves engraving an image of a level of the circuit pattern
onto an image carrier, such as a cylinder, and using a rotary
printing press to print the circuit. Cylinder engravings are known
as an abnormal configuration for direct print in packaging
applications. A different engraving configuration may be used for
each circuit level printed with the rotogravure print process. The
engravings may include cross-hatched (i.e., intersecting) channels
for carrying ink. This is in contrast to conventional intaglio
printing, which includes isolated incisions into the surface of the
image carrier.
[0105] The circuit design may incorporate a specific line width and
ink film deposits sufficient to cause a light emitting diode to
emit light of a given brightness without the utilization of an
in-line resistor. The on-package printed circuit may be operational
within itself (i.e., self-contained) in that no external input is
required to, for example, play the game embodied in the circuit or
to otherwise utilize the package.
[0106] The circuit may be printed from roll form to sheet. The
package may be die cut and/or scored with scoring (i.e., score
lines) going through or across the multiple circuits without
rendering the circuits inoperative. The package may be first
printed on the backside of a paperboard substrate, and then
inverted and re-printed on the coated/top side of the
substrate.
[0107] The package is multi-use in that not only is the actual
product protected, but a secondary use is achieved in providing
additional consumer value, such as a functional game or an enhanced
visual presence, for amusement and/or education. Because of the
addition of the circuit, the package may be offered to consumers as
an incentive to buy a particular foodstuff contained inside the
package, such as breakfast cereal. The package may be offered as an
in-store or point-of-sale prize that is immediately received by the
customer with the purchase of the foodstuff, and with no apparent
increase in the price of the foodstuff. Moreover, because the
amusing/educational features are part of the package, the package
may continue to circulate after the product has been consumed so
that persons other than the original purchaser may be exposed to
product marketing included on the package.
[0108] The integrity of the printed circuit may be maintained when
printed on either the backside (porous interior) of the selected
substrate or the top side of the selected substrate (which may be
less porous than the backside), and flexed over structural score
lines. Circuits may be bent at 90 degrees or more crossing over
score lines singularly or multiple times in "X", "Y" and "Z"
coordinate directions, and the bending may be achieved without loss
of conductivity.
[0109] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof.
Moreover, references herein to terms such as "vertical",
"horizontal", etc. are made by way of example, and not by way of
limitation, to establish an absolute frame of reference.
[0110] It will be understood that when an element is described as
being "connected" or "coupled" to or with another element, it can
be directly connected or coupled to the other element or, instead,
one or more intervening elements may be present. In contrast, when
an element is described as being "directly connected" or "directly
coupled" to another element, there are no intervening elements
present. When an element is described as being "indirectly
connected" or "indirectly coupled" to another element, there is at
least one intervening element present.
[0111] As used herein, the term "in response to" means "in reaction
to" and/or "after" a first event. Thus, a second event occurring
"in response to" a first event may occur immediately after the
first event, or may include a time lag that occurs between the
first event and the second event. In addition, the second event may
be caused by the first event, or may merely occur after the first
event without any causal connection.
[0112] While the invention has been illustrated by the description
of one or more embodiments thereof, and while the embodiments have
been described in considerable detail, they are not intended to
restrict or in any way limit the scope of the appended claims to
such detail. Additional advantages and modifications will readily
appear to those skilled in the art. The invention in its broader
aspects is therefore not limited to the specific details,
representative apparatus and methods and illustrative examples
shown and described. Accordingly, departures may be made from such
details without departing from the scope or spirit of Applicant's
general inventive concept.
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