Abstract:
The present invention generally relates to a bubble package which allows a product to be displayed independently standing alone or hanging from a bracket/shelf, and also provides the ability to separate the paper and plastic portions of the package into at least two separate environmentally recycled portions. The paper based portion of the package operates as a display card and/or as a stiffener. The sides of the one or more display cards are bonded to one another to enclose the product within the plastic and prevent tampering with the product. The plastic portion, in addition to containing and displaying the product therein, optionally incorporates a base near the bottom of the package. The base protrudes from the bottom of the package and secures back onto the plastic portion via a securing mechanism. This arrangement allows the package to stand independent. Optionally, a corrugated plastic insert can be used to provide additional support to the unit. In a typical arrangement, the plastic portions and paper portions avoid being bonded or directly adhered to one another, allowing the card to be entirely separable and allowing for complete environmental recyclability.

Description:
RELATED APPLICATION DATA 
       [0001]    This application claims priority to previously filed U.S. Provisional Patent Application No. 60/906,104, entitled “Environmentally Separable Hinged Clam-Shell Packaging Device with Corrugated Insert”, and filed Mar. 9, 2007, which is hereby incorporated in its entirety by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention generally relates to a package which allows a product to be displayed. In one embodiment, the package of the present invention can stand alone independently or can be hanged from a bracket or shelf. In another embodiment, the package of the present invention is able to be separated into its component parts so that such parts can be, if so required, independently recycled. In still another embodiment, due to its ability to be separated the package of the present invention can comprise various components formed from dissimilar materials (e.g., paper and plastic). 
       BACKGROUND OF INVENTION 
       [0003]    Blister or clam shell packages have long been used for packaging a wide variety of products and for displaying these products for sale in retail stores. The package is typically designed to conform to the configuration of the article contained therein. Such blisters/calm-shells, after filling, are bonded to supporting paper cards and can either be hung from a rack or if a stand-up type mechanism is utilized can be displayed on a shelf or table. Current stand up displays pose environmental recycling problems as typically the package is not completely separable/deconstructable. Typically, the bonding of the plastic to the card results in a plastic which is contaminated with paper/cardboard. 
         [0004]    In recent years, the number and variety of products packaged and displayed in blister-type and clam shell type packaging has greatly increased. Part of this increase is due to the popularity of warehouse shopping centers. Such blister and clam-shell packages have found wide use in retail stores and warehouse centers as they display each item and also protect the product inside from tampering. As such, the displays should be pilfer-resistant, meaning one cannot easily shoplift, or steal, the product contained therein without first removing the item from the package or in the alternate by shoplifting the entire bulky package. 
         [0005]    The hanging display, once predominantly used in the industry, has yielded portions of the market to alternative types of displays. The proliferation of warehouse stores/centers has required the use of a variety of standup displays. U.S. Pat. No. 4,784,268 details a standalone device which discloses a standard blister card on a shelf, eliminating the need for hanging the package. The patent discloses a stand-alone device which bonds plastic to a cardstock. The drawback to this setup is that this bonding/adhering between plastic and cardstock contaminates the plastic and thereby renders it unsuitable for a recycling process. 
         [0006]    In recent years, several major warehouse centers and retail outlets have undertaken environmentally friendly and/or green programs regarding recycling. These programs promote the use of environmentally friendly packaging and has necessitated the need for more environmentally friendly packaging designs. Thus, there is a need in the art for a package that not only has the ability stand independently, but also one that is more readily recycled. 
       SUMMARY OF INVENTION 
       [0007]    The present invention generally relates to a package which allows a product to be displayed. In one embodiment, the package of the present invention can stand alone independently or can be hanged from a bracket or shelf. In another embodiment, the package of the present invention is able to be separated into its component parts so that such parts can be, if so required, independently recycled. In still another embodiment, due to its ability to be separated the package of the present invention can comprise various components formed from dissimilar materials (e.g., paper and plastic). 
         [0008]    In one embodiment the present invention relates to a de-constructable package comprising: a front, a back, a base, and at least one insert, wherein the at least one insert has a top edge, a bottom edge, and at least one cavity, wherein the front, the back, the base and the at least one insert together form a de-constructable package, and wherein the combination of the base and the at least one insert permit the de-constructable package to stand independently. 
         [0009]    In another embodiment the present invention relates to a de-constructable package comprising: a front, a back, a base, and at least one clamshell insert, wherein the at least one insert has a top edge, a bottom edge, and at least one cavity, wherein the front, the back, the base and the at least one insert together form a de-constructable package, and wherein the combination of the base and the at least one insert are integrally formed and permit the de-constructable package to stand independently. 
         [0010]    In another embodiment the present invention relates to a method for forming a de-constructable package comprising: providing a front, providing a back, providing a base, providing at least one insert, wherein the at least one insert has a top edge, a bottom edge, and at least one cavity, and securing the front, the back, the base and the at least one insert together to form a de-constructable package, wherein the combination of the base and the at least one insert permit the de-constructable package to stand independently. 
         [0011]    In another embodiment the present invention relates to a display package formed from cardstock and a plastic type material, the package being able to be hung or displayed on a shelf or other suitable means wherein the package can be completely recycled. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is an exploded view of a package according to one embodiment of the present invention; 
           [0013]      FIG. 2  is a front view of the package of  FIG. 1 ; 
           [0014]      FIG. 3  is a cross-sectional view of the package of  FIG. 1 ; 
           [0015]      FIG. 4  is a close-up view of a portion of the package of  FIG. 3 ; 
           [0016]      FIG. 5  is a close-up view of another portion of the package of  FIG. 3 ; 
           [0017]      FIG. 6  is a front view of an alternative insert for use in a package in accordance with an embodiment of the present invention; 
           [0018]      FIG. 7  is a front view of a corrugated plastic insert for use in conjunction with the a package in accordance with an embodiment of the present invention; and 
           [0019]      FIG. 8  is a front view of still another alternative insert for use in a package in accordance with an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]    The present invention generally relates to a package which allows a product to be displayed. In one embodiment, the package of the present invention can stand alone independently or can be hanged from a bracket or shelf. In another embodiment, the package of the present invention is able to be separated into its component parts so that such parts can be, if so required, independently recycled. In still another embodiment, due to its ability to be separated the package of the present invention can comprise various components formed from dissimilar materials (e.g., paper and plastic). 
         [0021]    In one embodiment, the present invention provides a display package which can stand alone on a shelf, or table, or can be hung via a suitable bracket or holder. In another embodiment, the plastic and paper portions can be separated for recycling. In one embodiment the plastic and paper portions are not directly bonded to one another, thereby permitting easy separation of the two portions. In another embodiment the plastic and paper portions are compressed together, again allowing for separation of the two portions. Another embodiment of a package in accordance with the present invention includes a plastic insert located between at least two paper-based pieces such that the combination of the at least three pieces forms a package that can stand independently and is easily recyclable. In one instance, the plastic insert is designed to contain hinged base located at the bottom of the package that permits the plastic insert to wrap around one or more portions of at least one of the paper-based pieces. Such a design can include a continuous piece of plastic formed around a bottom strip of at least one of the paper-based pieces of the package thereby permitting the package to stand, without requiring the plastic shell portion to directly attach, adhere or be glue to the aforementioned paper-based piece. In this instance, the avoidance of a direct seal between the plastic and the one or more paper-based pieces allows for greater flexibility in recycling. This embodiment allows for a design that avoids paper/fiber contamination as the sealing mechanism occurs between the paper cards and not between the plastic and the card. 
         [0022]    As used in the specification and claims, de-constructable is defined as a package that can be separated into suitable paper and plastic portions and then optionally be recycled via normal waste collection means. Recycleable is defined as a package recycled via normal waste collection means. Clamshell is a type of packaging design that is known to those of skill in the art. As used in conjunction with the present invention, suitable paper-based materials include, but are not limited to, paper, cardboard, cardstock, fluted card stock, fluted cardboard, corrugated card stock, fluted cardboard or any other product formed using paper/wood product as the starting material. Plastic or plastic-based materials suitable for use in conjunction with the present invention include, but are not limited to, products made from polymers. Examples of suitable plastic polymers include, but are not limited to, polypropylenes (PP), polystyrenes (PS), high impact polystyrenes (HIPS), polyethylene terephthalates (PET), poly(vinyl chlorides) (PVC), polyurethanes (PU), polycarbonates (PC), polyvinylidene chlorides (PVDC) and polyethylenes (PE). Due to the nature of product display, most embodiments will employ a transparent or translucent plastic. 
         [0023]    An additional stiffening card can be employed via the use of corrugated plastic, or even paper-based, insert. In one embodiment, a corrugated plastic insert is included in addition the plastic shell or inner portion. In another embodiment the profile or the blister flange itself is corrugated. This corrugated plastic allows for a substantially stiffer package and improves tamper resistance, appearance and stability. 
         [0024]    Examples of one embodiment of a hinged package are detailed in  FIGS. 1 through 6 .  FIG. 1  details a front exploded view of one embodiment used to display a product. While the embodiment of the drawing details light bulbs as the product, the present invention is not limited to just packaging for light bulbs, Rather any type item, or number of items, can be placed within the confines of the package. In one embodiment, package  2  is comprised of a front  6 , a middle  20 , and a back  10 . In one embodiment, front  2  and back  10  are formed from a paper-based material, while middle  20  is formed from a plastic-based material. As can be seen from  FIG. 1 , middle  20  contains a one or more product portions  4  that are formed to conform to and/or hold any suitable number of objects  8  (see  FIG. 3 ). 
         [0025]    Regarding front  6 , in one embodiment front  6  has formed therein at least one opening that is designed to permit, if so desired, a portion, or portions, of middle  20  to protrude there through. In this case, middle  20  can also be referred to as an insert in package  2  because middle  20  can be “inserted” between front  6  and back  10 . 
         [0026]    Typically the material chosen for middle  20  permits a user to visually observe product  8  contained therein. Accordingly, in one embodiment if visibility is desirable middle  20  is formed from a clear plastic, or plastic-based, material. However, middle  20  of the present invention does not always need to be formed from a translucent, clear, or optically clear plastic material. In addition, the plastic used is of an adequate thickness to prevent tampering and/or pilfering of product  8 . It is understood that the particular design of product portions  4  depends upon the contents destined to be contained, or cradled therein. 
         [0027]      FIG. 1  also details front  6 . In one embodiment front  6  (also defined as the front) may be decorative and used as a way of advertising, or providing information about, product  8  contained therein. This concept is not limited to any one single advertising embodiment as an unlimited number of embodiments are possible to produce any number of packaging end designs. Front  6  can be made from any of the paper-based materials detailed above. In one embodiment, front  6  is formed from paper, cardboard, or even a plastic or plastic-based material. In still another embodiment, the paper-based materials used in the packaging of the present invention contain at least some amount of recycled paper material. 
         [0028]    Additionally, front  6  can be made from a material which seals to one or more cards on at least one side (i.e card front can be made from several layers of cardstock, with an advertisement typically being on the outermost or top layer). The side for this adhesion/sealing of front  6  is not shown in  FIG. 1 . The non-advertisement containing side is typically used for sealing and is, in this example, the back (or second surface) of front  6 . Front  6  may contain one or more optional holes or voids at or near the top of the package to allow the package to be hung from a display. 
         [0029]      FIG. 2  provides an assembled view of package  2 . As such,  FIG. 2  details the typical final product a consumer in a retail setting would view package  2 . In this view base  14  is secured to middle  20  (also defined herein as the middle portion). 
         [0030]      FIG. 3  provides a cutaway side profile of package  2 . In order to show the various layers involved,  FIG. 3  details front  6 , back  10 , and blister flange  12  and details the layered aspects. In a standard use such as in a retail store, these three layers are adhered/affixed/bonded to one another. In one embodiment, front  6  is secured directly to back  10  via a securing means such as, but not limited to glue, adhesive, heat activated adhesive, pressure activated adhesive, releaseable adhesive, or pressure. Releaseable adhesive is defined as an adhesive means which releases, leaving behind minimal traces of the adhesive upon one surface. 
         [0031]    In one embodiment, the outermost edges of front  6  and back  10  are approximately the same size and shape to allow package  2  to maintain a neat and professional appearance. Front  6  and back  10  are both slightly larger than the outermost edges of blister flange  12 . This setup allowing a proper seal between front  6  and back  10  and adequately securing blister flange  12 . In such an embodiment front  6  and back  10  adhere to one another at the edges, essentially securing blister flange  12  in between front  6  and back  10  and ultimately securing middle  20  into place. 
         [0032]      FIG. 3  also provides a profile view of one embodiment of base  14  of package  2 . Base  14  providing adequate support for vertically displaying package  2  on a shelf, table or in a sleeved box. Base  14  providing a stable support and allowing package  2  to stand independently. One problem frequently encountered in the art involves the use of an undercut. An undercut is usually needed to facilitate release of the plastic portion from the forming mold. Such a procedure produces an unstable package which falls over as the product must lean at an angle. The base in those examples not being at a 90 degree angle to the supporting card or the base being undersized/unstable. 
         [0033]    In one embodiment base  14  becomes a two portion continuous piece with base  14  securing or locking to the bottom of product portions  4 . The size of the base  14  varies due to the product  8  used and the product portions  4  desired. In various embodiments, packages  2  displaying products  8  requiring various width bases, various height bases or various depth bases. As stated previous, base  14  being dependent on package  2  and product  8  requirements. Finally, while a circular base  14  is detailed in  FIG. 2 , the exact shape of base  14  may vary. The shape of base  14  may be altered due to aesthetic or functional factors. 
         [0034]    In one embodiment back  10  contains a series of cutouts. Such a series of cutouts can be, but are not limited to perforations in the cardboard to allow a complete or partial detachment of the cutout portion of the cardboard. Such a cutout allowing for removal of one or more of the products contained therein. In another embodiment product portions  4  or middle  20  may include perforations in the plastic to allow a complete or partial detachment of the cutout portion of the plastic. 
         [0035]      FIGS. 1 and 2  detail the locking or securing aspect described previous via a female portion  16  of base  14  and a male portion  18  of product portions  4 . The exact location of female portion  16  and male portion  18  can be altered, reversed or moved according the product  8  being displayed/sold. In one embodiment a sloping surface is used to secure female portion  16  and male portion  18 . Base  14  attaches or locks itself onto the bottom edge of product portions  4 . Various embodiment are possible which utilize different locking mechanisms that allow a securing of the two portions. Examples include, but are not limited to, a raised cylinder and a recessed cylinder, a rectangular block with a corresponding recessed block, and any number of varying shapes and corresponding recessed areas. The locking mechanism may vary and take different forms based on the needs and requirements of the individual user. The ultimate purpose of the locking mechanism being to secure or close the package to allow display in a vertical manner.  FIGS. 2 and 3  detail the package with base  14  secured to bottom edge of plastic profile  4  and allowing the package to stand independently. 
         [0036]    As shown in  FIG. 4  and as stated previous, package  2  contains two significant parts, the card stock referred to as front  6  and back  10  and the middle  20 . Middle  20  including both the blister flange  12  and the product portions  4 .  FIG. 4  details the arrangement at the top edge of product portions  4 . In this embodiment front  6  is directly bonded to back  10 . This arrangement essentially locks in or secures blister flange  12 . 
         [0037]      FIG. 5  details one embodiment of the bottom of package  2 . At or near the bottom of package  2 , the area between base  14  and product portions  4  contains card strip  22  and plastic strip  24 . Card strip  22  being a continuous narrow strip connected to front  6 . Card strip  22  able to seal at one or more points to back  10 . This sealing being a glue, an adhesive, a heat activated adhesive, a pressure activated adhesive, pressure or any other suitable adhering means. As shown in  FIG. 6 , in one embodiment plastic strip  24  is continuous with base  14 , blister flange  12  and product portions  4 . Plastic strip  24  in one embodiment containing one or more void spaces  26  to facilitate the securing of front  6  to back  10  via card strip  22 . The continuity in this embodiment between plastic strip  24 , base  14  and blister flange  12  only being broken by the optional use of void spaces or opening  26 . Opening  26  in essence being a hole or void in middle  20  which allows the adequate securing of card strip  22  to back  10 . In one embodiment, opening  26  also allowing base  14  to bend at the angle needed for securing. 
         [0038]    As detailed in  FIG. 6 , middle  20  can be removed from the mold as one continuous piece. The entire middle  20  being designed in one plane as one flat piece. Once placed between front  6  and back  10 , middle  20  can bend into the second plane needed to effect the base features of package  2 . Base  14  rotates about plastic strip  24  and can be aided in this rotation via the optional plastic strip pass through  26 . In one embodiment base  14  rotates from the original orientation in middle  20  plane to a 90-degree angle from its original orientation. This allows base  14  to provide support to package  2  and stand in an upright manner. Additional embodiments may employ a variety of angles and may employ various starting dimensions which provide a lateral base  14  to display package  2  in a vertical plane. 
         [0039]    In order to increase the stiffness of package  2  a corrugated plastic insert  28  may be used (see  FIG. 7 ). Corrugated plastic insert  28  providing substantial strength/stiffening to front  6  and back  10 . The corrugated plastic insert  28  also providing additional tamper and pilfer resistance aspects to package  2 . The corrugated aspects of corrugated plastic insert  28  can be, but are not limited to a series of ribs  30  which are semi-circular, a triangular aspect, a rectangular aspect, a cross hatched pattern, a fluted aspect, or any other suitable arrangement which adds stiffness/strength to this area. In one embodiment, the corrugated portion runs to plastic insert  28  edges. Corrugated plastic insert  28  can be included as a separate insert as shown in  FIG. 7  or can incorporate the corrugated aspects into blister flange  12  as shown in  FIG. 8 . Such a one piece corrugated plastic insert  32  being incorporated into the molding process of middle  20 , including specifically blister flange  12  to provide a one piece plastic product providing the beneficial aspects of both corrugated plastic insert  28  and blister flange  12 . 
         [0040]    Embodiments needing additional vertical support benefit from the strength corrugated plastic inserts  28 ,  32  provide, this being especially important for allowing additional support to allow a product to stand adequately. Embodiments needing additional tamper or pilfer resistance may also benefit from the tear resistance aspects corrugated plastic insert  28 ,  32  provide. In one embodiment, corrugated plastic insert  32  being slightly smaller than the dimension of front  6  and back  10 , allowing for proper sealing between card front  6  and card back  10 . As stated previous the use of void spaces is also possible to effectuate proper adhesion. Finally the use of corrugated plastic inserts  28 ,  32  allowing for complete recycling of the paper portions and plastic portions of package  2 . 
         [0041]    The size aspects of the middle  20  and/or the corrugated plastic insert  28  or any combination thereof are important. In order to properly place product  8  these inserts/portions must be properly sized. One such embodiment involves using a middle  20  and/or corrugated plastic insert  28  which is nearly the same size as front  6  and back  10 , with middle  20  and/or corrugated plastic insert  28  being slightly smaller to allow a seal between front  6  and back  10 . Using a middle  20  and/or a corrugated plastic insert  28  nearly the same size as front  6  and back  10  allows for optimal product  8  placement as product  8  has less ability to move around as product portions  4  are properly positioned between the at least two cards. Middle  20  and/or corrugated plastic insert  28  providing additional tamper resistance and reducing potential pilfering of the package. 
         [0042]    One advantage to using middle  20  and/or the corrugated plastic insert  28  involves the elimination of a cardboard stiffener. In instances where a cardboard stiffener is used, one can now utilize these stiffening aspects into either middle  20  or by using corrugated plastic insert  28 , and thereby one or more components is removed from processing. 
         [0043]    Although some of the features and concepts of the invention have been described in detail with particular reference to certain embodiments detailed herein, other embodiments which are within the scope of the invention can achieve the same results. Variations and modifications of the present invention which may be made by those skilled in the art are within the scope of the invention as defined by the claims and equivalents thereof.