Abstract:
A hangable package structure for use with small, heavy products that are sold in blister card packages is disclosed. The package can be suspended from a peg or displayed on a shelf without using a tray or other holder. The package prevents the occurrence of a problem known as “hanger hole tear-through” of the blister card and provides for partial portability of the purchased product.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention is directed to hangable packages typically employed in a self-serve retail environment where consumers can select individual packages from a shelf or rack. In particular, this invention is directed to packages that include a card which is hung from a peg that passes through an opening in the top of the card.  
         [0002]     Package structures used to display articles for sale come in a wide array of designs. The ideal package is inexpensive to manufacture using well known manufacturing equipment and has several features that are important to the consumer and/or the retail store&#39;s personnel. For example, in order to maximize the merchant&#39;s flexibility for displaying a package at various locations throughout the store, the package should be both peggable as well as able to stand without needing a holder or tray. Peggable packages are packages that can be suspended from a generally horizontal rod that passes through an opening in the package. Another desirable feature is partial portability which means that a portion of the package&#39;s contents, including a portion of the packaging itself, can be removed from the initial package structure without destroying the integrity and usefulness of the initial package. Another desirable feature is that the consumer can easily and reliably verify the package&#39;s contents before making the purchase. A feature that is important to store owners is that the package enables a sufficiently high level of product density which means that the amount of wasted space within a single package or between packages on a display rack is minimized. To counteract the problem of some consumers stealing a portion of the product from a package and then returning the partially depleted package to the store shelf, the package should be sufficiently robust to minimize pilferage while also providing easy access to the product by consumers who legally purchase the package. Finally, the ideal package will provide adequate space on the package&#39;s exterior surface for advertising, logo placement, instructions regarding the product, etc.  
         [0003]     One of the most popular package structures is generally referred to as a “blister card.” The basic components of the blister card are a rectangularly shaped card member having a thickness of approximately 6.6 mm and a thermally formed cup shaped container made of a transparent plastic material that surrounds the merchandise to be displayed and sold. The container is secured to the card member which is hung from a peg that is attached on one end to a vertical surface such as a display stand. The card is hung by inserting one end of the peg through an opening in the card that is located near an edge of the card. Conventional blister cards perform satisfactorily when the merchandise in the container is not too heavy. For example, products such as pencils or small quantities of paper clips are well suited for sale in blister cards.  
         [0004]     Unfortunately, the use of a blister card package structure to display and sell heavy products can cause problems for the retail store owners, customers, and manufacturers of the goods for sale. Examples of heavy products that are conventionally sold in blister card package structures include cylindrically shaped standard alkaline batteries that are used by consumers to power digital cameras, flashlights, toys, etc. When several batteries, such as twelve or more AA size batteries or at least six C size or D size batteries, are housed in a single blister card package, the weight can exceed three hundred grams. When the merchandise to be sold is too heavy, some of the blister card packages suffer from a problem known as “hanger hold tear-through.” A blister card with a torn hanger hole is shown in  FIG. 1 . This problem occurs when section  21 , located between the hanger hole opening  25  in the card member and the closest edge  27  of card member  23 , tears away thereby allowing the card to fall from the peg. Because the card has been torn, store personnel cannot return the blister card to the peg so that the merchandise can be displayed and sold.  
         [0005]     Another cause of the hanger hole tear-through problem is rough handling of the blister card package by consumers. When a blister card package is removed from a peg, the consumer may inadvertently pull down on the package causing the peg to tear the card above the hangar hole. If the consumer should then decide not to purchase that package, it cannot be rehung on the peg because the card was accidentally torn.  
         [0006]     In addition to occurring within a retail store, the hanger hole tear through problem can occur during shipment of the blister carded product from the manufacturer of the merchandise to the store. This problem is particularly noticeable when a merchandiser containing blister cards is shipped preloaded. In this situation, a merchandiser containing pegs, on which blister card packages have been hung, is shipped from the manufacturer to the retailer. The retailer can then unpack and use the fully loaded merchandiser without needing to hang peggable packages on the pegs. During shipment, which typically takes place via truck, the packages may be frequently jostled or vibrated on the peg for hours or days. Because the card is suspended from the peg, the peg works to weaken the card so that the card tears between the hanger hold and the edge of the card thereby allowing the package to fall. Despite knowing that the merchandise contained within the package is not damaged, most customers elect not to purchase a package with a torn hanger hole. The torn packages are then returned to the manufacturer where the product must be repackaged before it can be sold. This step needlessly increases the manufacturer&#39;s cost.  
         [0007]     Another problem with using blister card package structures is that the package cannot stand by itself in a vertical position. As shown in  FIG. 2 , this problem is caused by a lower edge  29  of the card member  23  projecting beyond the cavity  31  that contains the merchandise so that the package tilts when allowed to stand by itself on a horizontal surface. This problem is caused by the extension of the cavity&#39;s lower flange  33  that must be secured to the card member in order to seal the merchandise into the cavity. Manufacturers of the product contained in the blister card, as well as retail store personnel, would benefit from a package that is capable of hanging from a peg or standing in a vertical position without the support of a tray or other holder.  
         [0008]     Previous attempts to solve the hanger hole tear-through problem have included the following concepts. First, as disclosed in U.S. Patent Application Publication No. 2002/0170218A1, a piece of tape may be applied to the top of the card member between the hanger hole and the edge of the card. The tape reinforces the card above the hanger hole, thereby strengthening the card so that the tear-through problem is significantly reduced or eliminated. Second, as disclosed in U.S. Design Pat. No. 427,523, the top of the card may be folded over to create a double thickness of card between the hanger hole and the edge of the card. However, neither the application of tape to the card nor the folding over at the top of the card resolve both the hanger hold tear-through problem and enable the package to stand by itself on a horizontal surface.  
       BRIEF SUMMARY OF THE INVENTION  
       [0009]     The present invention solves problems associated with the use of conventional blister card package structures that may be displayed by hanging the package or by standing it on a horizontal surface. The present invention is capable of holding small heavy items without the card tearing above the hanger hole and the same package may be used in a free standing vertical orientation.  
         [0010]     The present invention is a hangable package structure having a partially enclosed interior region that houses at least one compartment. The structure includes a folded strip shaped base member having a planar surface, a first end that defines a first opening through the base member, and a second end that defines a second opening through the base member. The base member&#39;s midsection is located between and separates the first end from the second end. The first opening in the base member aligns with the second opening in the base member to provide an unobstructed path through a partially enclosed interior region which is defined on three sides by the first end, the second end, and the midsection. A first compartment is secured to the planar surface of the base member&#39;s first end and is located within the partially enclosed interior region.  
         [0011]     In another embodiment, the present invention is a process for manufacturing a package structure. The process includes the following steps. Providing a strip shaped base member having a planar surface, a first end that defines a first opening through the base member, a second end that defines a second opening through the base member, and a midsection that is located between and separates the first end from the second end. The first end abuts the midsection at a first axis and the second end abuts the midsection at a second axis. Providing a first compartment having an opening. Securing the planar surface of the base member&#39;s first end over the opening in the compartment. Folding the base member to align the first opening with the second opening to provide an unobstructed path through the partially enclosed interior region which is defined on three sides by the first end, the second end, and the midsection. The compartment is housed within the partially enclosed region. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]      FIG. 1  is a perspective view of a conventional peggable package with a torn hanger hole;  
         [0013]      FIG. 2  is a side view of a conventional peggable package resting on a horizontal surface;  
         [0014]      FIG. 3  is a perspective view of a base member that is useful in a package structure of this invention;  
         [0015]      FIG. 4  is a perspective view of a first compartment suitable for use in a package structure of this invention;  
         [0016]      FIG. 5  is a side view of the first compartment shown in  FIG. 4 ;  
         [0017]      FIG. 6  is a perspective view of a second compartment suitable for use in a package structure of this invention;  
         [0018]      FIG. 7  is a side view of the second compartment shown in  FIG. 6 ;  
         [0019]      FIG. 8A  is a side view of the first compartment shown in  FIG. 5  with items loaded into the compartment&#39;s cavity;  
         [0020]      FIG. 8B  is a side view of the second compartment shown in  FIG. 7  with articles being loaded into the compartment&#39;s cavities;  
         [0021]      FIG. 9  shows the base member being sealed over the openings in the cavities of the first and second compartments;  
         [0022]      FIG. 10  is a perspective view of a partially folded package structure of this invention;  
         [0023]      FIG. 11  is a side view of a completely folded package structure of this invention;  
         [0024]      FIG. 12  is a perspective view of a package structure of this invention hung on a peg;  
         [0025]      FIG. 13  is a cross sectional view of a folded package structure of this invention; and  
         [0026]      FIG. 14  is a side view of a folded package structure of this invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0027]     Referring now to the drawings and more particularly to  FIG. 3 , there is shown a base member  20 . The base member has a first end  22 , a second end  24 , and a midsection  26 . The first end defines first opening  28  through base member  20 . The second end defines second opening  30  through base member  20 . First opening  28  and second opening  30  are sometimes referred to as hanger holes. First end  22  abuts midsection  26  at first axis  32 . Second end  24  abuts midsection  26  at second axis  34 . First axis  32  and second axis  34  are parallel to one another and function as flexible connections. One or both of the axes may be perforated to facilitate separating the base member into two or more sections by tearing the base member at the perforations. Base member  20  is a rectangularly shaped strip of paperboard material. The base member includes a planar surface  36 .  
         [0028]     Indicia, such as logos and advertising, may be printed on the side of the base member opposite the planar surface. Abutting one edge of first end  22  is an optional first locking tab  38 . Abutting one edge of second end  24  is an optional second locking tab  40 . Base member  20  has a longitudinal axis  42 .  
         [0029]      FIG. 4  shows one embodiment of first compartment  50 , which includes a first cavity  52  and two anti-bowing ribs  54  and  56 . Formed along two sides of first cavity  52  are protrusions  58  and  60 . Flange area  62  encircles the perimeter of first compartment  50 .  FIG. 5  is a side view of first compartment  50 .  
         [0030]      FIG. 6  is a perspective view of a second compartment  70  having a first cavity  72  and a second cavity  74 . Second compartment  70  includes anti-bowing ribs  76  and  78 . Locking protrusions  80  and  82  are located on cavities  72  and  74 , respectively. Flange area  84  defines the perimeter of second compartment  70 .  FIG. 7  is a side view of second compartment  70 .  
         [0031]     As shown in  FIGS. 4 and 6 , first compartment  50  and second compartment  70  may be formed as separate components which are individually attached to the base member. However, if desired, both compartments could be formed from a single strip of material so that a portion of the material bridges the midsection of the base member. If both compartments are formed from a single strip, then openings must be created in the strip to align with openings  28  and  30  in base member  20 .  
         [0032]      FIG. 8A  is a side view of first compartment  50  with four articles  90  stored in first cavity  52 .  FIG. 8B  is a side view of a second compartment  70  with a plurality of articles  90  loaded into first cavity  72 . Four additional articles are flowing into cavity  74 .  
         [0033]      FIG. 9  shows base member  20  as it is secured over the cavities in first compartment  50  and second compartment  70 . The distance between the first compartment and the second compartment is approximately equal to the width of the base member&#39;s midsection  26 . The base member may be sealed to the compartments using conventional technologies such as an adhesive, tape, the application of heat, or various welding techniques such as the use of ultrasonic energy.  
         [0034]      FIG. 10  shows a partially folded package, wherein second end  24  has been rotated about axis  34 . To completely fold the package as shown in  FIG. 11 , first end  22  (in  FIG. 10 ) is rotated about axis  32  so that ends  22  and  24  are parallel with one another. The folding process causes cavity  52  to be inserted between cavities  72  and  74 . Protrusions  58  and  60  on cavity  52  are forced past protrusions  80  and  82  on cavities  72  and  74 . The protrusions prevent the cavities from freely disengaging from one another, thereby requiring the consumer to exert some force on the free ends of the compartments in order to force them apart so that the articles stored therein can be accessed.  
         [0035]     In addition to the protrusions previously described, other designs can be used to create a means for securing the cavities, and thus the compartments and ends of the base, into a single unitary package. In an alternate embodiment, protrusions  58  and  60  on cavity  52  could be made to engage recesses (not shown) instead of protrusions in cavities  72  and  74 . Alternatively, one or more protrusions on the base of a cavity could be made to engage a recess in the surface of the opposing compartment. Yet another alternative is to use protrusions and recesses on the ribs and the cavities to create a means for interlocking the cavities formed in one compartment to the ribs formed in the opposing compartment.  
         [0036]     The present invention may also comprise a base member having more than two ends. For example, a base member in the shape of a cross, rather than a strip, would have four ends that could be folded upon one another to create a rectangularly shaped package.  
         [0037]     Anti-bowing ribs  54 ,  56 ,  76  and  78 , shown in  FIG. 10 , are designed to prevent outward bowing of the package&#39;s sides when folded packages, such as the one shown in  FIG. 11 , are stacked on top of each other in a vertical orientation. For example, during shipment of the folded packages from the manufacturer to the retailer, the packages may be stacked on top of each other in a master shipping container. If the packages are stacked so that midsection  26  of the package at the bottom of the container abuts locking tab  40  of an adjoining package, then the package at the bottom of the stack must be able to support the weight of two packages without bowing and suffering a structural failure. The anti-bowing ribs are intended to provide sufficient structural support to prevent bowing of the package that would occur if the anti-bowing ribs were not present. To be most effective, the anti-bowing ribs must cross the longitudinal midpoints of the first end  22  and second end  24  of base member  20 . The ribs may be formed as an integral part of first compartment  50  or second compartment  70 . Alternatively, the ribs could be formed as separate elongated components that are then secured to a compartment.  
         [0038]     The distance between two ribs, such as ribs  76  and  78  in  FIG. 6 , should be equal to or slightly greater than the width of base  53  of cavity  52 . Similarly, the distance between ribs  54  and  56  in  FIG. 4  should be equal to or slightly greater than the width of base  73  of cavity  72  and the width of base  75  or cavity  74 . Preferably, the distance between two ribs formed on the same compartment creates a slight interference fit with the base of the opposing compartment&#39;s cavity thereby enabling the ribs to prevent undesirable side-to-side movement of the cavities when the package is folded as in  FIG. 11 .  
         [0039]     As shown in  FIG. 11 , the base member&#39;s locking tabs  38  and  40  can be secured to one another to create a fourth side which functions as an optional means for locking the folded base strip and compartments into a unitary package. In one embodiment, the tabs may be glued to one another. In another embodiment, the tabs may be configured so that a portion of tab  38  fits through a slot in tab  40  thereby enabling the first and second ends of the base member to be releasably secured to one another.  
         [0040]     Shown in  FIG. 12  is a merchandiser having a folded package structure hung from a support means. The folded package structure is hung from an elongated horizontal support member  101 , such as a peg, that is secured on its proximate end  106  to a vertical surface  108  such as a wall. The distal end  110  of support member  101  is inserted through the first opening  28  in first end  22 , the unobstructed path  102  in the partially enclosed region  104  and then through the second opening  30  in second end  24 . The package structure  100  shown in  FIG. 12  is a preferred embodiment of the claimed invention. Package  100  can be used to display small heavy objects, such as twelve AA size alkaline batteries, by hanging the package from a peg or by placing the package on a horizontal surface in an upright position. Base member  20  includes four panels, previously identified as first end  22 , midsection  26 , second end  24 , and locking tabs  38  and  40 , that cooperate to define a partially enclosed region  104  that houses and protects the merchandise contained in cavities  52 ,  72  and  74 . Because the package is not enclosed on two sides, a consumer can visually inspect the merchandise before purchasing the package. However, the four panels that define the exterior surface of the package provide a substantial barrier to pilferage of some or all of the merchandise when the package is on display in the store. Midsection  26  of base member  20  reinforces the area above hanger hole openings  28  and  30  thereby preventing hanger hole tear through. As described earlier, the base member&#39;s axes may be perforated between cavities  52 ,  72  and  74 , thereby allowing individual cavities to be removed from the package without destroying the remaining portion of the package and the unused batteries are kept within the original package until they are needed. Alternatively, perforations  92 , as shown in  FIGS. 4 and 6 , may be positioned around each cavity to facilitate removal of the cavity from the compartment after the package has been purchased and unfolded by the consumer. Perforations  92  need to extend through both base member  20  and the compartment in which the cavity is formed. Protrusions  58  and  60  on cavities  52 ,  72  and  74  provide a means for releasably securing the cavities to one another thereby enabling the package to resist racking during shipment and/or storage by the consumer.  
         [0041]     A cross sectional view of another embodiment of a package of this invention is shown in  FIG. 13  wherein a single compartment  94  is secured to base member  20 . A side view of yet another embodiment of a package of this invention is shown in  FIG. 14  wherein a single strip  86  of material is used to form both compartments,  96  and  98 , as well as a middle portion  88  that abuts midsection  26  of strip  20 .  
         [0042]     The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and are not intended to limit the scope of the invention which is defined by the following claims as interpreted according to the principles of patent law.