U.S. patent application number 14/171465 was filed with the patent office on 2015-08-06 for cohesive sealed package with anti-theft feature and method of making the same.
This patent application is currently assigned to Quality Packaging, Inc.. The applicant listed for this patent is Quality Packaging, Inc.. Invention is credited to Paul Chistman, Scott Farkas, Joe Madron, Paul Schreifels.
Application Number | 20150217920 14/171465 |
Document ID | / |
Family ID | 53754203 |
Filed Date | 2015-08-06 |
United States Patent
Application |
20150217920 |
Kind Code |
A1 |
Madron; Joe ; et
al. |
August 6, 2015 |
COHESIVE SEALED PACKAGE WITH ANTI-THEFT FEATURE AND METHOD OF
MAKING THE SAME
Abstract
A multi-piece package is provided. The package includes a
plastic component configured to hold a product. The plastic
component includes a product compartment sized to receive the
product, an outer portion at least partially surrounding the
product compartment and a post extending outward from the outer
portion. The package includes a non-plastic component. The
non-plastic component includes a first segment having an outer
surface and an inner surface, a second segment having an outer
surface and an inner surface, a product opening formed through the
non-plastic component and a post opening cut through the
non-plastic component. The outer portion of the plastic component
is captured between opposing portions of the first segment of the
non-plastic component and of the second segment of the non-plastic
component following assembly. The product compartment extends
through the product opening and the post extends through the post
opening following assembly.
Inventors: |
Madron; Joe; (Madison,
WI) ; Farkas; Scott; (Fremont, WI) ;
Schreifels; Paul; (Fond du Lac, WI) ; Chistman;
Paul; (Slinger, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Quality Packaging, Inc. |
Fond du Lac |
WI |
US |
|
|
Assignee: |
Quality Packaging, Inc.
Fond du Lac
WI
|
Family ID: |
53754203 |
Appl. No.: |
14/171465 |
Filed: |
February 3, 2014 |
Current U.S.
Class: |
53/467 ;
206/485 |
Current CPC
Class: |
B65D 25/22 20130101;
B65D 75/22 20130101; B65D 75/566 20130101; B65D 75/30 20130101;
B65D 25/10 20130101 |
International
Class: |
B65D 75/30 20060101
B65D075/30; B65D 25/10 20060101 B65D025/10; B65D 25/22 20060101
B65D025/22; B65B 5/04 20060101 B65B005/04; B65B 7/26 20060101
B65B007/26 |
Claims
1. A theft-resistant multi-piece package comprising: an integral,
molded, plastic shell configured to hold a product, the plastic
shell comprising: a product compartment sized to receive the
product; a flange extending from an edge of the product
compartment, the flange at least partially surrounding the product
compartment, the flange defining a planar outer surface; and an
anchor extending outwardly from and substantially perpendicular to
the planar outer surface of the flange; a fibrous board comprising:
a first segment having an outer surface and an inner surface; a
second segment having an outer surface and an inner surface; a
hinge coupling the first segment to the second segment; a product
opening cut through the fibrous board; and an anchor port formed
through the fibrous board; a first cohesive layer formed on the
inner surface of the first segment of the fibrous board; and a
second cohesive layer formed on the inner surface of the second
segment of the fibrous board; wherein the fibrous board is folded
along the hinge such that the first cohesive layer engages the
second cohesive layer sealing the first segment of the fibrous
board to the second segment of the fibrous board; wherein the
flange of the plastic shell is captured between opposing portions
of the first segment of the fibrous board and the second segment of
the fibrous board and the product compartment extends through the
product opening; and wherein the anchor extends through the anchor
port such that engagement between an outer surface of the anchor
and an inner edge of the anchor port, upon deflection of the
product shell, resists movement of the plastic shell relative to
the fibrous board.
2. The theft-resistant multi-piece package of claim 1 wherein a gap
is located between the outer surface of the anchor and the inner
edge of the anchor port.
3. The theft-resistant multi-piece package of claim 2 wherein the
gap is between 1/100 inches and 1/10 inches.
4. The theft-resistant multi-piece package of claim 2 wherein the
first cohesive layer and the second cohesive layer does not bond to
the plastic shell such that the portions of the fibrous board
adjacent to the anchor port are not bonded to the portion of the
plastic shell adjacent to the anchor.
5. The theft-resistant multi-piece package of claim 1 wherein the
anchor port is an opening separate from the product opening such
that a portion of the fibrous board is located between the anchor
port and the product opening.
6. The theft-resistant multi-piece package of claim 1 wherein the
plastic shell further comprises a second anchor, wherein the
fibrous board comprises a second anchor port, wherein the second
anchor extends through the second anchor port such that engagement
between an outer surface of the second anchor and an inner edge of
the second anchor port, upon deflection of the product shell,
resists movement of the plastic shell relative to the fibrous
board.
7. The theft-resistant multi-piece package of claim 6 wherein the
anchor and the second anchor are positioned on the flange such that
both the anchor and the second anchor are located between a
peripheral edge of the flange and the product compartment of the
plastic shell.
8. The theft-resistant multi-piece package of claim 6 wherein the
anchor port and the second anchor port are positioned on the flange
such that a line intersecting the centers of the anchor port and
the second anchor port is substantially parallel to the hinge.
9. The theft-resistant multi-piece package of claim 6 wherein the
anchor port and the second anchor port are positioned on the flange
such that a line intersecting the centers of the anchor port and
the second anchor port is substantially parallel to a lateral edge
of the fibrous board.
10. The theft-resistant multi-piece package of claim 6 wherein the
anchor and the second anchor are positioned such that less than 1/8
inches is between the center of the anchors and the nearest lateral
outer edge of the product shell.
11. The theft-resistant multi-piece package of claim 6 wherein the
fibrous board includes a hanger opening configured to support the
package on a display rack.
12. The theft-resistant multi-piece package of claim 6 wherein
product compartment of the plastic shell is located between the
anchor and the second anchor.
13. The theft-resistant multi-piece package of claim 12 wherein the
plastic shell further comprises a third anchor and a fourth anchor,
wherein the fibrous board comprises a third anchor port and a
fourth anchor port, wherein the third anchor extends through the
third anchor port and the fourth anchor extends through the fourth
anchor port, wherein the product compartment is located between the
third anchor and the fourth anchor.
14. The theft-resistant multi-piece package of claim 1 further
comprising a product within the product compartment of the plastic
shell, wherein a gap between an outer surface of the product and an
inner surface of the product compartment adjacent the anchor is
greater than 1/4 inch.
15. A multi-piece package comprising: a plastic component
configured to hold a product, the plastic component comprising: a
product compartment sized to receive the product; an outer portion
at least partially surrounding the product compartment; and a post
extending outward from the outer portion; a non-plastic component
comprising: a first segment having an outer surface and an inner
surface; a second segment having an outer surface and an inner
surface; a product opening located through the non-plastic
component; and a post opening located through the non-plastic
component; wherein the outer portion of the plastic component is
captured between opposing portions of the first segment of the
non-plastic component and of the second segment of the non-plastic
component following assembly; and wherein the product compartment
extends through the product opening and the post extends through
the post opening following assembly.
16. The multi-piece package of claim 15 wherein a gap is located
between the outer surface of the post and the inner edge of the
post opening, wherein the gap is between 1/100 and 1/10 inches,
wherein the post is positioned such that less than 1/8 inches is
between the center of the post and the nearest lateral, outer edge
of the plastic component.
17. The multi-piece package of claim 15 further comprising a
cohesive material located on the inner surfaces of the first
segment and the second segment of the non-plastic component,
wherein the post opening is an opening separate from the product
opening such that a planar portion of the non-plastic component is
located between the post opening and the product opening.
18. The multi-piece package of claim 17 wherein the non-plastic
component further includes a hanger opening configured to support
the package from a display rack, wherein the post opening is an
opening separate from the hanger opening such that a planar portion
of the non-plastic component is located between the post opening
and the hanger opening.
19. A method of assembling a multi-piece package comprising:
providing a plastic component configured to hold a product, the
plastic component comprising: a product compartment sized to
receive the product; a planar outer portion at least partially
surrounding the product compartment; and a post extending outward
from the planar outer portion; providing a non-plastic component,
the non-plastic component comprising: a first segment having an
outer surface and an inner surface; a second segment having an
outer surface and an inner surface; a hinge coupling the first
segment to the second segment; a product opening formed through the
non-plastic component; and a post opening located through the
non-plastic component; placing a product within the product
compartment of the plastic component; and closing the non-plastic
component around the plastic component such that the planar outer
portion of the plastic component is captured between opposing
portions of the first segment and the second segment of the
non-plastic component, the product compartment extends through the
product opening and the post extends through the post opening.
20. The method of assembling a multi-piece package of claim 19
wherein a cohesive material is located on opposing portions of the
inner surface of the first segment of the non-plastic component and
the inner surface of the second segment of the non-plastic
component.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to the field of
product packaging. The present invention relates specifically to a
multi-piece package including anti-theft features.
SUMMARY OF THE INVENTION
[0002] One embodiment of the invention relates to theft-resistant
multi-piece package. The package includes an integral, molded,
plastic shell configured to hold a product. The plastic shell
includes a product compartment sized to receive the product and a
flange extending from an edge of the product compartment. The
flange at least partially surrounds the product compartment and the
flange defines a planar outer surface. The plastic shell includes
an anchor extending outwardly from and substantially perpendicular
to the planar outer surface of the flange. The package includes a
fibrous board. The fibrous board includes a first segment having an
outer surface and an inner surface, a second segment having an
outer surface and an inner surface, a hinge coupling the first
segment to the second segment, a product opening formed through the
fibrous board and an anchor port cut through the fibrous board. The
package includes a first cohesive layer formed on the inner surface
of the first segment of the fibrous board and a second cohesive
layer formed on the inner surface of the second segment of the
fibrous board. The fibrous board is folded along the hinge such
that the first cohesive layer engages the second cohesive layer
sealing the first segment of the fibrous board to the second
segment of the fibrous board. The flange of the plastic shell is
captured between opposing portions of the first segment of the
fibrous board and the second segment of the fibrous board and the
product compartment extends through the product opening. The anchor
extends through the anchor port such that engagement between an
outer surface of the anchor and the inner edge of the anchor port,
upon deflection of the product shell, resists movement of the
plastic shell relative to the fibrous board.
[0003] Another embodiment of the invention relates to multi-piece
package. The package includes a plastic component configured to
hold a product. The plastic component includes a product
compartment sized to receive the product, an outer portion at least
partially surrounding the product compartment and a post extending
outward from the outer portion. The package includes a non-plastic
component. The non-plastic component includes a first segment
having an outer surface and an inner surface, a second segment
having an outer surface and an inner surface, a product opening
formed through the non-plastic component and a post opening located
through the non-plastic component. The outer portion of the plastic
component is captured between opposing portions of the first
segment of the non-plastic component and of the second segment of
the non-plastic component following assembly. The product
compartment extends through the product opening and the post
extends through the post opening following assembly.
[0004] Another embodiment of the invention relates to a method of
assembling a multi-piece package. The method includes the step of
providing a plastic component configured to hold a product. The
plastic component includes a product compartment sized to receive
the product, a planar outer portion at least partially surrounding
the product compartment and a post extending outward from the
planar outer portion. The method includes the step of providing a
non-plastic component. The non-plastic component includes a first
segment having an outer surface and an inner surface, a second
segment having an outer surface and an inner surface, a hinge
coupling the first segment to the second segment, a product opening
formed through the non-plastic component and a post opening located
through the non-plastic component. The method includes the step of
placing a product within the product compartment of the plastic
component. The method includes the step of closing the non-plastic
component around the plastic component such that the planar outer
portion of the plastic component is captured between opposing
portions of the first segment and the second segment of the
non-plastic component, the product compartment extends through the
product opening and the post extends through the post opening.
[0005] Alternative exemplary embodiments relate to other features
and combinations of features as may be generally recited in the
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] This application will become more fully understood from the
following detailed description, taken in conjunction with the
accompanying figures, wherein like reference numerals refer to like
elements in which:
[0007] FIG. 1 is a perspective view of a package according to an
exemplary embodiment.
[0008] FIG. 2 is a perspective view of a board component of the
package of FIG. 1 according to an exemplary embodiment.
[0009] FIG. 3 is a perspective view of a product shell of the
package of FIG. 1 according to an exemplary embodiment.
[0010] FIG. 4 is a cross-sectional view of an anchoring structure
of the package of FIG. 1 taken along line 4-4 according to an
exemplary embodiment.
[0011] FIG. 5 is cross-sectional view of an anchoring structure of
the package of FIG. 1 taken along line 5-5 according to another
exemplary embodiment.
[0012] FIG. 6 is a perspective view of a package according to
another exemplary embodiment.
[0013] FIG. 7 is a second perspective view of the package of FIG. 6
according to another exemplary embodiment.
[0014] FIG. 8 is a perspective view of a board component of the
package of FIG. 6 according to an exemplary embodiment.
[0015] FIG. 9 is a perspective view of a first product shell
component of the package of FIG. 6 according to an exemplary
embodiment.
[0016] FIG. 10 is a perspective view of a second product shell
component of the package of FIG. 6 according to an exemplary
embodiment.
[0017] FIG. 11 is a cross-sectional view of an anchoring structure
of the package of FIG. 6 taken along line 11-11 according to an
exemplary embodiment.
DETAILED DESCRIPTION
[0018] Referring generally to the figures, various embodiments of a
multi-piece product package are shown. In the various embodiments
shown, the multi-piece product package includes a non-plastic
component (e.g., a board made of fibrous material, such as
corrugate, chipboard, paper etc.) and a plastic product shell. To
seal the package, the non-plastic component is folded around the
plastic product shell capturing a peripheral area or flange of the
product shell between opposing portions of the non-plastic
component and thus sealing the product within the package.
[0019] In contrast to many conventional packages, various
embodiments of the package discussed herein include a layer of a
cohesive material that is located on the inner surface of the
non-plastic component. In general, a cohesive material is a
material that forms a strong bond to itself but forms no or very
weak bonds to the other materials of the package. Thus, when the
non-plastic component is folded around the plastic product shell,
opposing sections of the cohesive layer located on the inside of
the non-plastic component form strong bonds with each other, and
thus, acts to hold the package in the sealed configuration. In
contrast to many conventional packages that uses a conventional
adhesive (e.g., hot-melt adhesive, a high-pressure adhesive, etc.),
various embodiments of the multi-piece package of the present
applications can be sealed with very low pressures without heat,
and in fact, in various embodiments, can be sealed using manual
pressure. Thus, in various embodiments, expensive and complicated
equipment, such as heat-seal machinery or high-pressure sealing
presses, are not need to assemble the multi-piece package of the
present application.
[0020] In addition, following sealing the cohesive does not
substantially bond to the plastic material of the product shell.
Because of the lack of bonding between the product shell and the
cohesive layer, little or no cohesive residue or residue from the
non-plastic component remains on the plastic product shell which,
in at least some instances, facilitates recyclability of the
multi-piece package of the present application. In addition, in
various embodiments, the cohesive layer is applied to the inner
surface of the non-plastic component in an aqueous state allowing
the cohesive material to penetrate a top layer of the material of
the non-plastic component. As the water is removed (e.g., by
evaporation), the cohesive layer is left intermeshed with the
material of the top layer of the material of the non-plastic
component. When the package is sealed, this intermeshing of the
cohesive causes the sealing bond with the opposing layer of
cohesive to be very strong such that separation of the non-plastic
component following sealing is likely to cause tears or other easy
to identify marks showing that the package was opened, thus
providing a tamper indicating property.
[0021] In addition to the tamper evident features provided by the
cohesive, the multi-piece package of the present application
provides for increased theft resistance through an innovative
structure that locks the plastic product shell within the
non-plastic component. In various embodiments, the locking or
anchor feature includes an anchor protrusion or post formed in the
portion of the plastic shell trapped between opposing portions of
the non-plastic component. The anchor post is received through an
anchor port or opening located in the non-plastic component.
Engagement between the outer surface of the anchor post and the rim
of the opening limits or prevents relative movement and/or bending
of the plastic shell relative to the none plastic component. This
resistance limits or prevents the ability of a thief to bend,
crumple or otherwise move the plastic shell from the non-plastic
component to access the product with in the product shell without
tearing or separating the non-plastic component.
[0022] In various embodiments, the package may include one or more
anchors located at areas around the periphery of the product shell
where access may be likely. For example, the anchors may be
positioned in areas where there is a significant gap between the
outer surface of the product and the plastic shell that may allow
the plastic shell to be deformed enough to fit out of the opening
in the non-plastic component in the absence of the anchor. In
various embodiments, the anchor structures discussed herein have
been found to be particularly useful in conjunction with a
multi-piece package using a cohesive. As noted above, the cohesive
does not substantially bond to the plastic product shell such that
in certain packaging configurations, the shell may be removed from
the non-plastic component by squeezing or deformation. As discussed
in more detail below the anchor arrangement discussed herein limits
or prevents such removal. In contrast to the packaging of the
present application, package designs in which substantial bonding
occurs between the non-plastic component and the product shell
(e.g., packages that use adhesives, such as hot melt or pressure
adhesives) typically would not benefit from or need an anchor
structure, as discussed herein, because of the high level of
bonding between the plastic shell and the non-plastic
component.
[0023] Referring to FIG. 1, a multi-piece package, shown as package
10, is shown according to an exemplary embodiment. Package 10
includes a plastic component, shown as product shell 12, and a
non-plastic component, shown as fibrous board 14. In FIG. 1,
package 10 is shown in the assembled configuration. In the
assembled configuration, an exemplary product 16 shown in
ghost-lines is located within a product compartment 18 of product
shell 12. In one embodiment, the face of package 10 shown in FIG. 1
is a front face of package 10, and in another embodiment, the face
of package 10 shown in FIG. 1 is a rear face of package 10.
[0024] In the assembled configuration of FIG. 1, product shell 12
is trapped or captured between a front and a back section of board
14. As discussed in more detail below, package 10 includes posts,
shown as anchors 20, that extend from product shell 12 and that
extend through anchor openings 22 formed through board 14. The
engagement between the outer surface of anchors 20 and the inner
edge or rim of anchor openings 22 limits or prevents product shell
12 from being removed from board 14 by squeezing or deforming
product shell 12. In various embodiments, openings 22 are die cut
holes created through board 14.
[0025] In the assembled configuration, board 14 has an outer
surface 24 that faces outward. Outer surface 24 may include various
printing (e.g., labels, graphics, logos, stickers, etc.) related to
package 10 and/or product 16. Package 10 may include one or more
additional openings, such as hanger opening 26. Hanger opening 26
is located near the upper edge of package 10 and is configured to
support package 10 from a hanger of a shelf, display rack, etc.
[0026] Referring to FIG. 2, board 14 is shown prior to assembly
with product shell 12. Board 14 includes a first segment or
portion, shown as upper section 30, and a second segment or
portion, shown as lower section 32, in the orientation of FIG. 2. A
hinge, shown as fold line 34, is located between upper section 30
and lower section 32. Upper section 30 includes a product opening
36. In other embodiments, upper section 30 and lower section 32 may
be separate board components that are not physically joined by a
hinge, and in such embodiments, upper section 30 and lower section
32 are aligned around product shell 12 prior to engagement of the
opposing cohesive layers.
[0027] As shown in FIG. 2, anchor openings 22 are openings through
board 14 that are distinct from both product opening 36 and the
openings that form the hanger opening. Thus, as shown in the
embodiment of FIG. 2, a substantially planar section of board 14 is
located between each anchor hole 22 and product opening 36.
[0028] In the embodiment shown, anchor openings 22 are located on
either side of product opening 36. Specifically, board 14 includes
four anchor openings. In this embodiment, two anchor openings 22
are located on the left side of product opening 36, and two anchor
openings 22 are located on the right side of product opening 36.
Further in this embodiment, anchor openings 22 on the left side of
product opening are aligned with each other such that a line
bisecting the centers of each anchor opening 22 is substantially
parallel to left lateral edge 38. In addition, anchor openings 22
on the right side of product opening are aligned with each other
such that a line bisecting the centers of each anchor opening 22 is
substantially parallel to right lateral edge 40.
[0029] As shown in the exemplary embodiment of FIG. 2, fold line 34
substantially bisects board 14 such that the length of the
perimeter and the shape of upper section 30 and lower section 32
are substantially the same. In other embodiments, fold line 34 may
be located at other positions relative to upper section 30 and
lower section 32 such that the size and shape of upper section 30
and lower section 32 are not equal. In another embodiment, board 14
may not include a fold line 34 such that upper section 30 and lower
section 32 are separate pieces of material that are aligned with
each other during assembly. Upper section 30 includes a first
hanger opening 42, and lower section 32 includes a second hanger
opening 44. Following assembly, first hanger opening 42
substantially aligns with second hanger opening 44 to form hanger
opening 26 (shown in FIG. 1).
[0030] FIG. 2 shows the inner surfaces of the two sections of board
14. In this embodiment, upper section 30 includes an inner surface
46, and lower section 32 includes an inner surface 48. In various
embodiments, inner surface 46 and inner surface 48 are coated with
a cohesive material. In one such embodiment, the entire inner
surface 46 and the entire inner surface 48 are coated with the
cohesive, and in such embodiments, the coating of cohesive may be
substantially uniform (e.g., substantially the same amount of
cohesive applied per unit area). In another embodiment, the coating
of cohesive may be non-uniform, where higher quantities of cohesive
are applied at locations requiring strong bonding (e.g., toward
lateral and upper edges of board 14, around anchor openings 22,
etc.). In another embodiment, the coating of cohesive may be
applied only in select areas of inner surface 46 and inner surface
48. However, in such embodiments, the select areas of cohesive on
inner surface 46 opposes the select areas of cohesive on inner
surface 48, such that the opposing layers of cohesive contact each
other to form the bond that holds package 10 together.
[0031] The cohesive of package 10 may be any material that can be
applied to board 14 and that forms a bond with itself and that does
not form a bond with product shell 12. In various embodiments, the
cohesive is applied to board 14 in liquid form, and the cohesive
material then dries to form a dry-tack cohesive layer. In various
embodiments, the cohesive on board 14 is an aqueous cohesive
material. In a specific embodiment, the cohesive on board 14 is an
aqueous latex cohesive.
[0032] In various embodiments, the application of the liquid
cohesive to the inner surfaces of board 14 allows the cohesive
material to soak a portion of the distance into board 14 below
inner surfaces 46 and 48. When the cohesive material dries, the
cohesive material coats inner surfaces 46 and 48 and is also
intermeshed with the fibers of board 14. The intermeshing of the
cohesive material with the material of board 14 assists the
cohesive layer to provide a strong bond to hold package 10 together
following assembly. In various embodiments, the cohesive needs
relatively lower pressure to form the bond that holds package 10
together. In one embodiment, the bond between opposing layers of
cohesive can be formed via use of manual pressure. In a specific
embodiment, the bond between opposing layers of cohesive can be
formed by use of less than 50 lbs of forces, specifically less than
20 lbs of force and more specifically less than 5 lbs of force.
[0033] Referring to FIG. 3, product shell 12 is shown prior to
assembly with board 14 to form package 10. Product shell 12
includes a product compartment 18 and a peripheral area, shown as
flange 50. As shown in FIG. 3, product compartment 18 is a raised
area that extends outward from and perpendicular to flange 50 to
create the space or cavity within product compartment 18 sized to
receive product 16. In the embodiment shown, flange 50 is a
substantially planar area that extends around at least a portion of
product compartment 18. Specifically, flange 50 extends around the
lateral sides and upper side of product compartment 18. Product
shell 12 is a formed or molded, integral plastic component such
that flange 50 and product compartment 18 are integrally formed
from a single piece of material.
[0034] Product shell 12 includes anchors 20 extending outward from
and substantially perpendicular to flange 50 (e.g., such the
longitudinal axis of anchor 20 forms an 80 to 90 degree angle
relative to the outer surface of flange 50). In the embodiment
shown, both anchors 20 and the portion of the shell forming product
compartment 18 extend outward in the same direction and from the
same side of product shell 12. In another embodiment, anchors 20
and the portion of the shell forming product compartment 18 extend
outward in opposite directions and on opposite sides of product
shell 12. Product shell 12 includes a plurality of anchors 20 and
specifically includes four anchors 20. In this embodiment, a pair
of anchors 20 are located to one lateral side (i.e., the left side
in the orientation of FIG. 3) of product compartment 18, and a
second pair anchors 20 are located to the other lateral side (i.e.,
the right side in the orientation of FIG. 3) of product compartment
18.
[0035] In the embodiment, shown anchors 20 are substantially
cylindrical posts. However, in other embodiments, anchors 20 may
have other cross-sectional shapes. In specific embodiments, anchors
20 may be rectangular prism shaped such that the cross-section of
anchors 20 are substantially rectangular, square, parallelogram,
etc. In other embodiments the cross-sectional shape of anchors 20
may be oval, elliptical, non-rectangular polygons, or irregular
shapes.
[0036] Product shell 12 includes an upper edge 52 defined by the
upper edge of flange 50, a lateral edge 54 defined by the left
lateral edge of flange 50, and a lateral edge 56 defined by the
right lateral edge of flange 50. In this embodiment, the pair of
anchors 20 on the left side of product compartment 18 are aligned
with each other such that a line that bisects the center of each
anchor is substantially parallel to edge 54, and the pair of
anchors 20 on the right side of product compartment 18 are aligned
with each other such that a line that bisects the center of each
anchor is substantially parallel to edge 56. However, it should be
understood that in other embodiments, product shell 12 may include
different numbers (e.g., 2, 3, 5, 6, etc.) or different positioning
(e.g., positioning non-parallel to the edges of flange 50) of
anchors 20.
[0037] In the embodiment of FIG. 3, anchors 20 of product shell 12
are positioned relative to the lateral edges of flange 50 such that
the lateral outermost surface of each anchor 20 extends laterally
outward beyond the portions of the lateral edges of flange 50
adjacent anchors 20. In various embodiments, anchors 20 of product
shell 12 are positioned adjacent to the lateral edges of flange 50
such that a relatively small distance is located between the
outermost surface of anchors 20 and the nearest adjacent lateral
edge. For example, in various embodiments, anchors 20 are located
adjacent to the nearest lateral edge of flange 50 such that less
than one inch, specifically less and 1/2 inch, and more
specifically less than a 1/8 inch is located between the nearest
lateral edge and the center of anchor 20. In a one embodiment, the
shortest distance between the center of each anchor 20 and the
nearest lateral edge of flange 50 is between 1/32 inch and 1/8
inch. Further, product shell 12 includes anchor flanges 58 that
extend laterally outward from flange 50 at the location of each
anchor. In the embodiment shown, anchor flanges 58 are
semi-circular extensions of flange 50 that are substantially
coplanar with flange 50. Thus, the lateral outer most edge of
anchor flanges 58 define laterally extending curved portions of
lateral edges 54 and 56 located adjacent to anchors 20. In various
embodiments, anchor flanges 58 act to support anchors 20 located
adjacent to the lateral edges of flange 50. The positioning of
anchors 20 adjacent the edges of flange 50 and the presence of
anchor flanges 58 facilitate the anchoring or locking of product
shell 12 within board 14 in various embodiments.
[0038] In various embodiments, anchors 20 are spaced along the
respective edge of product shell 12 such that anchors 20 are able
to secure product shell 12 within board 14. In various embodiments,
as shown in FIG. 3, anchors 20 are spaced such that more than half
of the length of edges 54 and 56 are located between the respective
anchors 20. In another embodiment, anchors 20 are spaced such that
more than 75% of the length of edges 54 and 56 are located between
the respective anchors 20. In another embodiment, product shell 12
also includes anchors 20 along the upper edge and/or the lower edge
of product shell 12.
[0039] Referring back to FIG. 1, package 10 is show following
assembly. As shown, product shell 12 is enclosed or trapped within
board 14. In this embodiment, upper section 30 and/or lower section
32 of board 14 are rotated about fold line 34 bringing the inner
surfaces of board 14 toward each other. As the inner surfaces of
board 14 come into contact with each, product compartment 18
extends through product opening 36 formed in upper section 30 of
board 14, and lower section 32 of board 14 seals the open rear side
of product shell 12. In addition, flange 50 of product shell 12 is
captured between the inner surfaces of the opposing sections of
board 14, and opposing portions of the cohesive layer located on
the inner surface of board 14 bond to each other sealing package 10
in the closed configuration shown in FIG. 1. By this arrangement, a
product may be sealed within product compartment 18 of package
10.
[0040] In addition, following sealing, anchors 20 extend through
and/or protrude from openings 22. In this arrangement, anchors 20
extends a distance beyond outer surface 24 of board. In another
embodiment, the height of anchors 20 are less than depth of anchor
holes 22 such that the upper surface of anchors 20 are recessed
below outer surface 24. Because of the bonding between the cohesive
on the opposing surfaces of board 14, board 14 is bonded in place
around anchors 20 at positions where portions of product shell 12
are not interposed between sections of board 14.
[0041] As noted above, the interaction between the outer surfaces
of anchors 20 and the inner edge of anchor openings 22 acts to
further secure and to limit movement of product shell 12 within
board 14. Specifically, in various embodiments, the interaction
between the outer surfaces of anchors 20 and the inner edge of
anchor openings 22 acts to limit the ability of one (e.g., a thief)
to deform product shell 12 enough to remove product shell 12
through product opening 36 without tearing or separating board 14.
In other words, if one attempts to deform product shell 12 in an
attempt to disengage product shell 12 from board 14, the outer
surface of anchor 20 will engage the inner edge of anchor hole 22
limiting or preventing further movement of the exterior edge of
product shell 12 toward the product opening of board 14. In
addition, anchors 20 are received within openings 22 of board 14
during assembly via the same sealing or closing action that traps
product shell 12 within board 14.
[0042] In various embodiments, anchors 20 and anchor holes 22 are
positioned at locations where product shell 12 may be particularly
susceptible to deformation. For example, in various embodiments,
anchors 20 and anchor holes 22 are positioned at locations where
the clearance between the outer surface of product 16 and the inner
surface of product shell 12 is great enough that it may be possible
to deform product shell 12 to allow access to product 16 without
tearing or separating board 14. In various embodiments, anchors 20
and anchor openings 22 are located around product compartment 18
adjacent to (e.g., within 2 inches of, within 1 inch of, within a
1/2 inch of) areas where the clearance between the outer surface of
product 16 and the inner surface of product shell 12 in assembled
package 10 is greater than a 1/4 inch. In various embodiments, the
width of flange 50 (i.e., the distance from the outer edge of the
flange to the nearest point of the product compartment) is less
than or equal to 1/2 inch.
[0043] Referring to FIG. 4 and FIG. 5, detailed cross-sectional
views of an anchor 20 received within an anchor hole 22 are shown
according to an exemplary embodiment. Referring to FIG. 4, anchor
20 extends through anchor hole 22 such that anchor 20 extends a
distance from outer surface 24. In various embodiments, anchor 20
extends a distance D1, from outer surface 24 that is sufficient to
limit or prevent one from disengaging anchor 20 by pushing or
crushing anchor 20 back through anchor hole 22. In various
embodiments, D1 is between 1/32 of an inch and one inch and more
specifically, is between 1/16 of an inch and a 1/2 inch. Anchor 20
has height above the outer surface of flange 50, shown as D3. In
various embodiments, D3 is between 1/32 of an inch and one inch,
specifically, is between 1/16 of an inch and 1/4 inch and in a
specific embodiment is about 1/8 of an inch. However, in other
embodiments, anchor 20 may be recessed below outer surface 24 of
board 14.
[0044] Referring to FIG. 4 and FIG. 5, in various embodiments there
is a relatively small clearance between the inner surface 60 of
anchor hole 22 and lateral outer surface 62 of anchor 20. The
clearance between inner surface 60 and lateral outer surface 62 is
large enough to allow easy alignment of anchor 20 with anchor hole
22 during package assembly but also small enough to provide an
effective limitation on the ability to remove product shell 12 from
board 14 without tearing or separating board 14. FIG. 5 shows the
distance between the inner surface 60 of anchor hole 22 and lateral
outer surface 62 of anchor 20 as distance D2. In various
embodiments, the clearance between inner surface 60 of anchor hole
22 and lateral outer surface 62 of anchor 20 is expressed as the
difference between the diameter of hole 22 and the outer diameter
of anchor 20, and in such embodiments, D2 is understood as one half
of the difference between the diameter of hole 22 and the outer
diameter of anchor 20. This expression of clearance is useful in
understanding the relationship between hole 22 and anchor 20
because anchor 20 may not be centered within hole 22 each time the
package is sealed. In various embodiments, D2 is between 1/1000
inch and 1/8 of an inch and more specifically, is between 1/100
inch and 1/10 inch. In a specific embodiment, D2 is about 1/64 of
an inch (e.g., 1/64 of an inch plus or minus 5%), and in such
embodiments, the difference between the diameter of hole 22 and the
outer diameter of anchor 20 is about 1/32 of an inch (e.g., 1/32 of
an inch plus or minus 5%).
[0045] Further, referring generally to FIG. 4 and FIG. 5, the two
cohesive layers located on opposing inner surfaces of board 14 are
shown as cohesive layers 64 and 66. As shown in FIG. 4, cohesive
layers 64 and 66 contact the upper and lower surfaces,
respectively, of flange 50. However, because the cohesive material
does not form a bond with the material of flange 50, there is no
direct attachment, bond or coupling that maintains the contact
between cohesive layers 64 and 66 and flange 50. In contrast, as
shown in FIG. 5, to the exterior of edge 56 of flange 50, cohesive
layers 64 and 66 contact each other forming a bond in bond area 68.
In general (as shown in FIG. 1), bond area 68 extends around and to
the exterior of flange 50. As shown in FIG. 5, bond area 68 extends
more than half of the distance inward from outer edge 40 toward
edge 56 of flange 50. The bond formed between cohesive layers 64
and 66 within bond area 68 acts to trap product shell 12 within
board 14.
[0046] In various embodiments, product shell 12 is made from a wide
variety of plastic materials. In some embodiments, product shell 12
is made from a translucent or transparent plastic material. Product
shell 12 may be formed from polyethylene, polypropylene,
polyethylene terephthalate, polyvinylchloride or any other suitable
packaging polymer material. In various embodiments, product shell
12 may be formed from a post-consumer recycled plastic material or
an in-house (e.g., scrap) recycled plastic material. Product shell
12 may be formed from any suitable molding or formation processes,
including thermoforming, injection molding, compression molding,
extrusion, blow molding, etc.
[0047] In various embodiments, board 14 is formed from a wide
variety of non-plastic materials. Board 14 may be formed from a
fibrous material, such as corrugate, chip board, paper, etc. In
various embodiments, the non-plastic or fibrous material of board
14 may include a layer of fibrous material and one or more layers
of non-fibrous materials (e.g., plastics, laminates, foils, etc.).
In addition, the outer and/or inner surfaces of board 14 may
include various layers of ink, graphics, labels, stickers,
printing, etc. related to the contents of package 10.
[0048] Referring to FIGS. 6-10, a package 100 is shown according to
an exemplary embodiment. Package 100 is substantially similar to
package 10 except for the differences discussed herein. Package 100
includes a product shell 102 and a board 104. As discussed above,
product shell 102 is trapped between opposing portions of board
104. Product shell 102 includes anchors 106 that extend through
anchor openings 108 to facilitate coupling of product shell 102
within board 104 as discussed above. In addition, package 100 is
held together via a bond formed between opposing layers of cohesive
material located on opposing inner surfaces of board 104.
[0049] FIG. 6 shows one side (e.g., a rear side) of package 100,
and FIG. 7 shows another side (e.g., a front side) of package 100.
Product shell 102 includes a product compartment 110. Product
compartment 110 includes a first portion 112 that extends out from
one of the outer surfaces (e.g., the rear outer surface 116) of
board 104. Product compartment 110 includes a second portion 114
that extends out from one of the outer surfaces (e.g., the front
outer surface 118) of board 104.
[0050] As shown in FIG. 8, board 104 includes two product openings
that allow for product shell 102 to extend out of both the front
and rear side of board 104 following assembly of package 100.
Specifically, board 104 includes an upper section 120 that includes
a first product opening 122 and a lower section 124 that includes a
second product opening 126. Board 104 includes a hinge, shown as
fold line 128 that allows upper section 120 and lower section 124
to be pivoted toward each other to capture product shell 102
between the inner surfaces of upper section 120 and lower section
124, as shown in FIG. 6 and FIG. 7.
[0051] In the embodiment shown in FIG. 8, anchor holes 108 are
located adjacent fold line 128. In this embodiment, anchor holes
108 are located along what will become the lower lateral edge 130
of package 100, as shown in FIG. 6. Further, anchor openings 108
are aligned with each other such that a line bisecting the centers
of each anchor opening 108 is substantially parallel to fold line
128.
[0052] Referring to FIG. 9 and FIG. 10, the two separate pieces
that form product shell 102 are shown. Referring to FIG. 9, a first
section 132 of product shell 102 that defines portion 114 of the
product compartment is shown. First section 132 includes a
peripheral flange 136 that extends around portion 114 of the
product compartment and that defines the outer most edge 138 of
first section 132. Flange 136 includes an expanded section 140 that
has a greater width than the portions of flange 136 on either side
of expanded section 140.
[0053] First section 132 of product shell 102 includes a pair of
anchor posts 142 that extend from outward from and perpendicular to
the plane defined by expanded section 140 As shown, anchor posts
142 are substantially cylindrical and are spaced apart such that
each post 142 is located adjacent opposing corners of expanded
section 140. In various embodiments, more than half of the length
of expanded section 140 is located between anchor posts 142, and
more specifically, more than 75% of the length of expanded section
140 is located between anchor posts 142. In various embodiments,
this spacing provides spaced anchor points to support product shell
102 within board 104.
[0054] Referring to FIG. 10, a second section 150 of product shell
102 that defines portion 112 of the product compartment is shown.
Second section 150 includes a peripheral flange 152 that extends
around portion 112 of the product compartment and that defines the
outer most edge 154 of second section 150. Flange 152 includes an
expanded section 156 that has a greater width than the portions of
flange 152 on either side of expanded section 156.
[0055] Second section 150 of product shell 102 includes a pair of
anchor posts 158 that extend outward from and perpendicular to the
plane defined by expanded section 156 As shown, anchor posts 158
are substantially cylindrical and are spaced apart such that each
post 158 is located adjacent opposing corners of expanded section
156. In various embodiments, more than half of the length of
expanded section 156 is located between anchor posts 158, and more
specifically, more than 75% of the length of expanded section 156
is located between anchor posts 158. In various embodiments, this
spacing provides spaced anchor points to support product shell 102
within board 104.
[0056] In general, each anchor 142 is friction fit within the
corresponding anchor 158 to couple first section 132 to second
section 150. This coupling between first section 132 and second
section 150 of product shell 12 acts to maintain the relative
positioning of first section 132 to second section 150 following
assembly of product shell 102 around the product. Following
assembly of product shell 102, board 104 is folded around product
shell such that flange 136 and flange 152 are trapped within board
104. As discussed above, opposing layers of a cohesive material
located on the inner surface of board 104 bonds tightly to the
opposing cohesive layer following assembly to maintain the package
100 in the closed configuration shown in FIG. 6 and FIG. 7.
[0057] Referring to FIG. 11, a cross-sectional view of assembled
anchor 106 located within anchor hole 108 is shown according to an
exemplary embodiment. Both anchors 142 and anchors 158 are hollow
generally cylindrical structures. The inner cavity of anchor 158
receives anchor 148. Further, the inner cavity of anchor 158 is
sized such that he inner surface of anchor 158 engages and forms an
interference or friction fit with the outer surface of anchor 146.
Thus, anchors 106 include an outer wall formed from anchor 158 and
an inner wall formed from anchor 146. In addition, package 100
includes a layer of cohesive 160 located on the inner surface of
lower board section 124 and an opposing layer of cohesive 162
located on the inner surface of upper board section 120. In one
embodiment, instead of being separate pieces, first section 132 and
second section 150 may include a foldable hinge structure joining
the two sections together, and in this embodiment, assembled anchor
106 acts to hold the shell in the closed, folded position.
[0058] As shown in the embodiment of FIG. 11, the material of
second section 150 may have a thickness less than the thickness of
the material of first section 132. In another embodiment, the
material of second section 150 may have a thickness greater than
the thickness of the material of first section 132. In another
embodiment, the material of second section 150 may have a thickness
substantially the same as the thickness of the material of first
section 132.
[0059] In various embodiments, the present application relates to a
method of making a and assembling a product package, such as
packages 10 and 100, discussed above. In various embodiments a
method of assembling a multi-piece package is provided. In such
embodiments the method includes providing a plastic component
configured to hold a product. In such embodiments, the plastic
component includes a product compartment sized to receive the
product, a planar outer portion at least partially surrounding the
product compartment and a post extending outward from the planar
outer portion. The method includes providing a non-plastic
component. The non-plastic component includes a first segment
having an outer surface and an inner surface, a second segment
having an outer surface and an inner surface, a hinge coupling the
first segment to the second segment, a product opening formed
through the non-plastic component and a post opening cut or created
through the non-plastic component. The method includes placing a
product within the product compartment of the plastic component.
The method includes closing the non-plastic component around the
plastic component such that the planar outer portion of the plastic
component is captured between opposing portions of the first
segment and the second segment of the non-plastic component, such
that the product compartment extends through the product opening
and such that the post extends through the post opening. In various
embodiments, the method includes applying a cohesive material, as
discussed above, on opposing portions of the inner surface of the
first segment of the non-plastic component and the inner surface of
the second segment of the non-plastic component.
[0060] It should be understood that the figures illustrate the
exemplary embodiments in detail, and it should be understood that
the present application is not limited to the details or
methodology set forth in the description or illustrated in the
figures. It should also be understood that the terminology is for
the purpose of description only and should not be regarded as
limiting.
[0061] Further modifications and alternative embodiments of various
aspects of the invention will be apparent to those skilled in the
art in view of this description. Accordingly, this description is
to be construed as illustrative only. The construction and
arrangements, shown in the various exemplary embodiments, are
illustrative only. Although only a few embodiments have been
described in detail in this disclosure, many modifications are
possible (e.g., variations in sizes, dimensions, structures, shapes
and proportions of the various elements, values of parameters,
mounting arrangements, use of materials, colors, orientations,
etc.) without materially departing from the inventive teachings and
advantages of the subject matter described herein.
[0062] For purposes of this disclosure, the term "coupled" means
the joining of two components directly or indirectly to one
another. Such joining may be stationary in nature or movable in
nature. Such joining may be achieved with the two members and any
additional intermediate members being integrally formed as a single
unitary body with one another or with the two members or the two
members and any additional member being attached to one another.
Such joining may be permanent in nature or alternatively may be
removable or releasable in nature.
[0063] While the current application recites particular
combinations of features in the claims appended hereto, various
embodiments of the invention relate to any combination of any of
the features described herein whether or not such combination is
currently claimed, and any such combination of features may be
claimed in this or future applications. Any of the features,
elements, or components of any of the exemplary embodiments
discussed above may be used alone or in combination with any of the
features, elements, or components of any of the other embodiments
discussed above.
* * * * *