Abstract:
A packaging apparatus for packaging OTC drugs, prescription medications (e.g., “starter packs” given to patients by their physicians), or any other suitable object or substance (e.g., tablets, button cell batteries or other small parts or components) is provided. The packaging apparatus combines two thermoforming packaging techniques: clam shell packaging and blister packaging into a single package.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This claims priority to U.S. Provisional Patent Application No. 60/809,090, filed May 26, 2006, which is hereby incorporated by reference herein in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to packaging and, more specifically, to clamshell packaging with an integrated blister pack. 
       BACKGROUND OF THE INVENTION 
       [0003]    A typical apparatus for packaging over-the-counter (“OTC”) drugs (e.g., flu or allergy tablets) includes a conventional blister pack for enclosing the drugs and a paper carton for housing the blister pack: This configuration has several drawbacks. For example, often times the blister pack and the paper carton become separated and one or the other lost since the items are entirely separate pieces. Thus, the important drug labeling and warnings that are often printed on the paper carton may not be seen by a person who takes the OTC drugs. Also, the party who has the paper carton may find that the blister pack is missing when that party needs the medication. Further, many times a retailer must return the product to the supplier because the paper carton has worn over time. Paper cartons are also typically bulky and therefore require significant real estate in retail establishments. 
         [0004]    In view of the foregoing, it would be desirable to provide an improved apparatus and method for packaging OTC drugs, medications or any other suitable object or substance to overcome the above stated drawbacks. The present invention minimizes, and in some aspects eliminates, the above-mentioned failures, and other problems, by utilizing the methods and structural features described herein. 
         [0005]    Features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by the practice of the invention without undue experimentation. Features and advantages of the invention may be realized and obtained via the instruments and combinations particularly pointed out in the drawings, subsequent detailed description and appended claims. 
       SUMMARY OF THE INVENTION 
       [0006]    The above and other objects and advantages of the present invention are provided in accordance with the principles of the present invention described herein. Embodiments of the present invention relate to a packaging apparatus for packaging OTC drugs, prescription medications (e.g., “starter packs” given to patients by their physicians), or any other suitable object or substance (e.g., tablets, button cell batteries or other small parts or components). 
         [0007]    In an embodiment of the present invention, a packaging apparatus is provided. The packaging apparatus includes a first element hingedly connected to a second element. The second element has at least one cavity for an object and the first element is selectively matable with the second element. The hinge may enable movement of the first element relative to the second element such that the packaging apparatus may be positioned in an open position or a closed position. The packaging apparatus also includes a membrane fixed to the second element for sealing the cavity. The membrane is capable of being ruptured which permits passage of an object through the membrane when force is applied against the membrane by the object. 
         [0008]    In an embodiment, the packaging apparatus also includes an additional membrane fixed to the second element to form a second barrier sealing the cavity within the second element. 
         [0009]    Other objectives and advantages of the present invention will become apparent to the reader and it is intended that these objectives and advantages are within the scope of the present invention. 
         [0010]    To accomplish the above and related objectives, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    For a better understanding of the present invention, reference is made to the following description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which: 
           [0012]      FIG. 1  is an above perspective of a packaging apparatus in accordance with the present invention in a closed position. 
           [0013]      FIG. 2  is an above perspective of the packaging apparatus of  FIG. 1  in an open position. 
           [0014]      FIG. 3  is an angled-side perspective of the packaging apparatus of  FIG. 1  in an open position. 
           [0015]      FIG. 4  is an angled-above perspective of a packaging apparatus in accordance with the present invention in an open position. 
           [0016]      FIG. 5  is a side-peripheral view of a packaging apparatus in accordance with the present invention in an open position. 
           [0017]      FIG. 6  is a side-peripheral view of a packaging apparatus in accordance with the present invention in a closed position. 
           [0018]      FIG. 7  is an above perspective of a packaging apparatus in accordance with the present invention in an open position. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    The foregoing and other features, aspects, and advantages of the present invention will be more apparent from the following detailed description, which illustrates exemplary embodiments of the present invention. 
         [0020]    It is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways where particular configurations, process steps, and materials disclosed herein as such configurations, process steps, and materials may vary somewhat. In addition, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting. Furthermore, as will be apparent to those skilled in the art, the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. 
         [0021]    For purposes of the description of the drawings and the embodiments of the present invention, as mentioned for each drawing, each figure may not be drawn to scale. Some areas may be drawn bigger and/or simpler in order to clearly portray the improvement to what has already been established. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention claimed. It is also to be understood that the terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting since the scope of the present invention will be limited only by the appended claims and equivalents thereof. 
         [0022]    In an embodiment, the package combines two thermoforming packaging techniques: clam shell packaging and blister packaging to make possible the “Clamshell-Blister Pack” shown in  FIGS. 1-7 . Generally, a clamshell package includes a rigid thermoformed plastic container that features a hinged lid with, for example, a positive snap closure so the package can be opened and resealed. The lid may be printed with, for example, the product name and/or instructions for use. Alternatively or additionally, an insert card may be included within the clamshell package to explain the uses and features of the product. A blister package includes one or more cavities preformed in a material (typically plastic), where the material is backed by another material (e.g., paper or metal foil) to keep the product within the cavity. 
         [0023]      FIG. 1  is an above perspective of a packaging apparatus  100  in a closed position displaying the hinged lid  102 , also referred to as the top or first element, of the packaging apparatus  100 . The packaging apparatus  100 , also referred to as a clamshell package, includes a rigid thermoformed plastic container featuring the hinged lid  102 . Those skilled in the art will recognize that the packaging apparatus  100  could be formed of a semi-rigid material, or possibly a flexible material, and still fit within the scope of the present invention. The hinged lid  102  may entail a positive snap closure so the clamshell package  100  can be opened and resealed. The lid  102  which has an interior may be printed with, for example, the product name and/or instructions for use, as described below. The printed material may be on the inside, outside or both of the lid  102 . Alternatively or additionally, an insert card, sticker or other appended label (not shown) may be included within the clamshell package  100  to explain the uses and features of the product. 
         [0024]      FIG. 2  is an above perspective of the packaging apparatus  100  in an open position. The hinged lid  102  of  FIG. 1  is fixed upon a base  106  by a hinge  104 . The base  106 , also referred to as the second element, includes at least one cavity  114 ( n ) for receiving an object (e.g., flu or allergy tablets or gelcaps). Those skilled in the art will recognize that the cavity  114 ( n ) may be configured to accommodate multiple objects and typically it will include multiple cavities  114 (1−n). The packaging apparatus  100  also includes a membrane  108  fixed to the base  106  for maintaining the object in the at least one cavity  114 ( n ). The membrane  108  may seal all of the cavities  114 (1−n), only some of the cavities  114 (1−n) or only one of the cavities  114 (1−n). The membrane  108  is capable of being ruptured and thus permitting passage of an object through the membrane  108  upon an application of force against the membrane  108 . It may also be possible to rupture the membrane  108  via force applied to the base  106 , which applies force to the object within the cavity, which in turn applies force to the membrane  108 , thus rupturing the membrane  108  and permitting passage of the object through the membrane  108 . The lid  102  and base  106  may be formed in a single and continuous form, fill, and seal process from two or more flexible films. Alternatively, other methods for forming the packaging apparatus  100  may be employed. Those skilled in the art will recognize that any combination of the lid  102  and base  106  affixed to one-another via a hinge  104  may be utilized (e.g., the lid  102 , base  106  and hinge  104  as separate parts; the hinge  104  formed integral with only the lid  102  or only the base  106 ). Further, while the hinge has been illustrated as a single hinge running along the full length of the clamshell package  100 , those skilled in the art will recognize that one or more smaller hinges could be employed without departing from the scope of the invention. 
         [0025]    The Clamshell-Blister Pack  100  may be formed in a single and continuous form, fill, and seal process. A clear thermoplastic film such as polyvinyl chloride or a polyolefin may be printed with trademarks, labeling requirements and graphic design and then thermoformed to provide in a single piece: 
         [0026]    1. a lid (cover)  102 ; 
         [0027]    2. a base  106  containing at least one cavity  114 ( n ) and having shoulders  110  to receive the lid  102 ; and 
         [0028]    3. a living hinge  104  connecting the base  106  to the lid  102 . 
         [0000]    A second film or membrane  108  such as paper, metal foil, a laminate of paper and/or metal foil having a surface coated with a film of a thermoplastic material such as polyethylene, polystyrene, or the like, is sealed to the base  106  to seal the blister cavities  114 (1−n). This process may be achieved through the conventional application of heat and pressure or in any other suitable fashion. The blister package portion  114  may contain products  115 (1−n) within the blister cavities  114 (1−n). These products  115 (1−n) may be identical, different, grouped etc. 
         [0029]    The base  106  may be covered by a third film  116  which also may be a rupturable membrane made of paper, foil, or a laminate of paper and foil. The third film  116  may be sealed to the bottom of the base  106  to act as a second barrier between the real world and the product  115 (1−n). The third film  116  may also extend beyond the perimeter of the packaging apparatus and be used as a hang tag so the packaging apparatus  100  may be hung in a hanging display rather than stored on a shelf. 
         [0030]      FIG. 3  is an angled-side perspective of a packaging apparatus  100  as described above in relation to  FIG. 2 . 
         [0031]      FIG. 4  is an angled-above perspective of a packaging apparatus  100  as described above in relation to  FIG. 2 . 
         [0032]      FIGS. 5-7  are perspective views of a packaging apparatus in accordance with embodiments of the present invention.  FIG. 5  is a side-peripheral view of the packaging apparatus  100  in an open position as described above in relation to  FIG. 2 .  FIG. 5  shows the location of the third film  116 .  FIG. 6  is a side-peripheral view of the packaging apparatus  100  in a closed position as described in relation to  FIG. 1 , in which the lid  102  and base  106  are illustrated.  FIG. 7  is an above perspective of the packaging apparatus  100  in an open position, as described in  FIG. 2 . 
       INDUSTRIAL EMBODIMENTS 
       [0033]    Illustrative advantages of the Clamshell Blister Pack will now be described. Economical: The Clamshell Blister Pack eliminates the need for, and the expense of the printed paper carton required for a conventional blister pack. It also eliminates the complex and highly regulated inventory requirements for the printed paper carton. With a conventional blister package, the blister is one component of the package and the printed paper carton is the second component. In contrast, the Clamshell Blister Pack forms the blister pack within its own integral “carton”, as stated above in reference to  FIG. 2 . The blister package  114  is formed within the cavity  114 ( n ) of the base  106  of the clamshell apparatus  100 . An assortment of configurations may occur between the cavity  114 ( n ) and the blister package  114 , which could include, among others, that the cavity  114 ( n ) may be separated into multiple blister packages  114  for different products  115 (1−n). 
         [0034]    Safe: The Clamshell Blister Pack provides a tamper evident package that may permanently maintain the integrity of important drug labeling and warnings (as compared with typical paper cartons that are discarded or deteriorate). 
         [0035]    Efficient: The Clamshell Blister Pack can be manufactured by a fully automated form, fill, and seal operation that produces a completed FDA-compliant package ready for use. 
         [0036]    Convenient: The Clamshell Blister Pack has an extremely thin profile (up to 80% thinner than conventional packages) that allows patients to easily slip the package into a pocket to carry with them. 
         [0037]    Patient Compliance: Each blister cavity of the Clamshell Blister Pack may be labeled or numbered to enable the patient to know if they have taken, or need to take their medication. 
         [0038]    Maintains Quality Appearance: The Clamshell Blister Pack will not easily scuff, smear, crush, rip, or stain. It preserves a clean quality product appearance at retail and significantly reduces returns for shopworn merchandise. 
         [0039]    Better Merchandising: The Clamshell Blister Pack is up to 80% thinner than conventional packages permitting many more packages per facing at retail and more efficient use of space for retail displays. 
         [0040]    Space Saving and Elegant Package for Physicians&#39; Samples: The Clamshell Blister Pack provides the perfect format for physicians&#39; samples or “patient starter packs”. 
         [0041]    Other features and advantages of embodiments of the present invention will be apparent from the drawings and claims. 
         [0042]    Thus it is seen that a clamshell package with integrated blister pack and method of its manufacture are provided. Although particular embodiments have been disclosed herein in detail, this has been done by way of example for purposes of illustration only, and is not intended to be limiting with respect to the scope of the appended claims, which follow. It is contemplated by the inventor that various substitutions, alterations, and modifications may be made without departing from the spirit and scope of the invention as defined by the claims. Other aspects, advantages, and modifications are considered to be within the scope of the following claims. The claims presented are representative of the inventions disclosed herein. Other, unclaimed inventions are also contemplated. The inventor reserves the right to pursue such inventions in later claims.