PROTECTIVE RAZOR PACKAGE

A package includes a first member and a second member. The second member and the first member define a first cavity. A periphery of the first member is joined to a periphery of the second member to define a sealed portion, such that respective perimeters of the first member and the second member cooperate to define an outer edge of the sealed portion. The second member includes a ridge at least partially circumscribing the first cavity while remaining inward of the outer edge. The ridge includes an inner wall, an outer wall, and a rim. Both the inner wall and the outer wall extend rearward from and substantially perpendicularly relative to the first member and are connected by the rim. At least a portion of the rim, over a length of the ridge, is substantially parallel to the first member.

FIELD OF INVENTION

The present disclosure generally relates to packaging for personal care products with enhanced structural support for providing an improved product display.

BACKGROUND OF INVENTION

Personal care articles such as shaving razors and tooth brushes are typically sold in clear plastic product packages containing one or a plurality of product units. These plastic packages are commonly referred to as blister packages and conventionally include a transparent plastic blister with a sheet or card material inside the package or as an outer seal which may add rigidity to the package and facilitate suspension of the package from a hanger of a point-of-sale display. The sheet or card material will usually be printed with appropriate data concerning the product within the pack. The pack is typically configured so that on the point-of-sale display the blister is at the front so that the contents within the blister are clearly visible to the customer, and the card is usually provided with tear perforations to provide access to the contents within the package.

Typically, individual product packages are received from a manufacturer in shipping containers where several individual product packages are contained loosely therein and/or where individual product packages are stacked upon one another. These product packages must then be removed from the shipping container by a retail employee and mounted to the hanger of a point-of-sale display. Subsequently, consumers may remove the product packages from the hanger and remount thereto upon considering the product for purchase. Thus, the product package is typically jostled during its shipment, mounting to the point-of-sale display, and consumer handling which may affect the orientation of the product within the package.

What is desired is a product package that can provide protection against drops, load compression, vibration, and other types of jostling that can lead to package failure. What is further desired is a product package that can provide such protection while providing design elements that can improve consumer recognition of products and/or product features contained therein.

SUMMARY OF THE INVENTION

In accordance with one embodiment, a package includes a first member and a second member. The first member includes a front surface and a rear surface, and the first member is substantially planar. The second member includes an inner surface and an outer surface. The inner surface and the rear surface of the first member define a first cavity. A periphery of the inner surface of the second member is joined to a periphery of the rear surface of the first member to define a sealed portion. Respective perimeters of the first member and the second member cooperate to define an outer edge of the sealed portion. The second member includes a ridge at least partially circumscribing the first cavity while remaining inward of the outer edge. The ridge includes an inner wall, an outer wall, and a rim. The rim connects at least a portion of the inner wall and outer wall. Both the inner wall and the outer wall extend rearward from and substantially perpendicularly relative to the first member. At least a portion of the rim, over a length of the ridge, is substantially parallel to the first member.

In accordance with another embodiment, a razor package includes a first member, a second member, and a razor. The first member includes a front surface and a rear surface, and the first member being substantially planar. The second member includes an inner surface and an outer surface. The inner surface and the rear surface of the first member define a first cavity. A periphery of the inner surface of the second member is joined to a periphery of the rear surface of the first member to define a sealed portion. Respective perimeters of the first member and the second member cooperate to define an outer edge of the sealed portion. At least a portion of the razor is contained within the first cavity. The second member includes a ridge at least partially circumscribing the first cavity while remaining inward of the outer edge. The ridge includes an inner wall, an outer wall, and a rim. The rim connects the inner wall to the outer wall. Both the inner wall and the outer wall extend rearward from and substantially perpendicularly relative to the first member. At least a portion of the rim, over a length of the ridge, is substantially parallel to the first member.

In accordance with yet another embodiment, a razor package includes a card, a thermoplastic member, and a razor. The card includes a front surface and a rear surface. The card is substantially planar and substantially rectangular. The thermoplastic member includes an inner surface and an outer surface. The inner surface and the rear surface of the card define a first cavity and a second cavity. A periphery of the inner surface is joined to a periphery of the rear surface of the card to define a sealed portion. Respective perimeters of the card and the thermoplastic member cooperate to define an outer edge of the sealed portion. The sealed portion includes an inner edge. The inner edge defines an aperture fully circumscribed within a portion of the sealed portion. At least a portion of the razor is contained within the first cavity. The thermoplastic member includes a continuous, multi-level ridge at least partially circumscribing the first cavity and the second cavity while remaining inward of the sealed portion. The ridge includes an inner wall, an outer wall, and a rim. The rim connects at least a portion of the inner wall and outer wall. Both the inner wall and the outer wall extend rearward from and substantially perpendicularly relative to the card. At least a portion of the rim, over a length of the ridge, is substantially parallel to the card.

DETAILED DESCRIPTION OF THE DRAWINGS

The following text sets forth a broad description of numerous different embodiments. The description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible, and it will be understood that any feature, characteristic, component, composition, ingredient, product, step or methodology described herein can be deleted, combined with or substituted for, in whole or part, any other feature, characteristic, component, composition, ingredient, product, step or methodology described herein. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims.

Protective razor packages described herein, which may include types of blister packages, may provide desirable benefits for vendors and consumers alike. For example, while conventional blister packages may include rigid elements that facilitate suspension of the package from a hanger, the protective razor packages described herein may include a ridge to provide improved stability. Protective razor packages may further include one or more cavities that contribute to improved stability. Such additional stability and protection may benefit vendors by decreasing the likelihood that package contents will become damaged or that damaged packing will discourage potential consumers from purchasing the product contained therein. Likewise, consumers may benefit from having improved stability and protection of the packages from the point-of-sale display until actual use of the product contained therein.

Further, the protective razor packages, as described herein, may employ a transparent blister on a rear of the package to provide for additional space on the front of the package to communicate product information. That is, with the display of package contents being limited to a rearward-facing blister, for example, the front of the package may offer greater flexibility for brand management and engaging consumers. As such, a vendor may experience an improved ability to communicate a desired message to a consumer, while a consumer may experience an improved recognition of products and/or product features contained within the package.

Referring toFIG. 1, a package10is shown. As shown inFIG. 1, a package10includes a first member12having a front surface14. In certain embodiments, the front surface14of the first member12may display product graphics and/or information15thereon, including but not limited to branding, product title, advertising, product instructions, advertising claims, product claims, product comparisons, and/or any other graphics, information, text, etc., as desired. The product graphics and/or information15, shown schematically inFIG. 1, may be positioned anywhere on the front surface14and cover any portion of this surface. In such embodiments, the front surface14of the first member12may be a portion of the package10that is immediately visible to a consumer, for example, from a hanging display. In certain embodiments, the first member12can be substantially planar. While the first member12is shown inFIG. 1to be substantially rectangular, it will be appreciated that a first member may take the form of any of a variety of suitable shapes, including, for example, the shape of the product contained within the package. Furthermore, it will be appreciated that a first member may be a card formed of cardboard, paper, or any of a variety of suitable materials. In certain embodiments, a thickness of the first member12may be from about 0.012 inches to about 0.030 inches; from about 0.014 inches to about 0.022 inches; or in some examples, about 0.016 inches.

The package10may further include a second member18. The second member18may be a thermoformed plastic blister, and in certain embodiments, the second member may be transparent to display package contents. However, like the first member12, a second member may be formed of any of a variety of suitable materials. For example, the second member may be formed of polyethylene terephthalate (PETG), glycol-modified polyethylene terephthalate (PET-GAG), recycled polyethylene terephthalate (RPET), layered PETG and RPET, and other combinations thereof. In such embodiments where the second member is formed from layered PETG and RPET, the second member may include from about 10% to about 20% of PETG, by weight of the second member, and from about 80% to about 90%, by weight of the second member, of RPET. The second member18may include an inner surface20and an outer surface22, and in certain embodiments, a thickness of the second member18may be from about 0.012 inches to about 0.030 inches; from about 0.015 inches to about 0.022 inches; or in some examples, about 0.0175 inches.

In certain embodiments, and as suggested by the exploded view ofFIG. 2, for example, a periphery of the inner surface20of the second member18may be joined to a periphery of a rear surface16of the first member12. The joined peripheries of each of the inner surface20of the second member18and the rear surface16of the first member12define a sealed portion24, which is best shown inFIGS. 3, 4, and 5. In certain embodiments, the sealed portion24may provide the only contact between the first member12and the second member18. Respective perimeters of the first member12and the second member18may cooperate to define an outer edge26of the sealed portion24. As shown in the embodiment depicted inFIGS. 2 and 3, the outer edge26may be substantially rectangular. It will be appreciated that in certain embodiments, a process for manufacturing such packages can include joining multiple first members to second members to form an array of connected packages prior to an edge cut. In such embodiments, an edge cut may ensure a “clean” outer edge, such that respective perimeters of a first member and a second member substantially align with each other.

In certain embodiments, the sealed portion24may further include an inner edge42. The inner edge42may define an aperture44, as shown inFIGS. 1-3, where the aperture44may be fully circumscribed within a portion of the sealed portion24. In some embodiments, the aperture44may be disposed in the seal portion along an upper portion of the package. In such embodiments, the aperture44may be common to both the first member12and the second member18. As described above for an outer edge, it will be appreciated that a “clean” inner edge may be provided by cutting or stamping a sealed portion such that respective edges of a first member and a second member substantially align with each other. In some embodiments, the aperture44can facilitate mounting of the package to a hanging display.

Referring toFIGS. 2 and 3, the rear surface16of the first member12and the inner surface20of the second member18may cooperate to define a first cavity28. In certain embodiments, the first cavity28can be configured to receive a personal care article (e.g., razor, toothbrush). In certain embodiments, and as best shown inFIGS. 2 and 3, the rear surface16of the first member12and the inner surface20of the second member18may cooperate to define a second cavity30and a third cavity32. In certain embodiments, and as shown inFIGS. 2 and 3, the first cavity28may be contiguous with the second cavity30. Furthermore, in certain embodiments, and as shown inFIGS. 2 and 3, the first cavity28may be contiguous with the third cavity32. However, while the embodiment ofFIG. 3is shown to include the first cavity28, the second cavity30, and the third cavity32in the above-described configuration, it will be appreciated that a package can include any suitable number of cavities in any of a variety of suitable configurations.

As shown inFIG. 3, for example, the second member18may include a ridge34. In certain embodiments, and as shown inFIG. 3, the ridge34may at least partially circumscribe the first cavity28, the second cavity30, and the third cavity32while remaining inward of the outer edge26, with “inward” referring to a direction inbound from the outer edge26and, generally, toward a center of the package10. In certain embodiments, the ridge34may be continuous and extend substantially along and/or adjacent to the outer edge26of the package10, just inward of the sealed portion24. In certain embodiments, the ridge34may be substantially parallel to the outer edge26. And as shown inFIGS. 2 and 3, extension of the ridge34along the outer edge26may be interrupted only by the aperture44. In such embodiments, the ridge34may extend from a first side60of the inner edge42to a second side62of the inner edge42. However, it will be appreciated that in some embodiments, the ridge may extend fully along an outer edge of a package, fully circumscribing one or more of the cavities (e.g., the first, second, and/or third cavities). In some embodiments, the ridge may comprise a plurality of ridges extending partially or fully along an outer edge of a package to partially or fully circumscribe one or more of the cavities (e.g., the first, second, and/or third cavities).

In some embodiments, the ridge34extends generally away from and substantially perpendicularly to a surface of the first member18. Also, in this example, the ridge34extends rearward from and substantially perpendicularly to a surface, opposite the inner surface20, of the first member18. In some embodiments, the ridge may provide several benefits to the package. For example, the ridge may provide increased stability of the package by increasing a force required to bend or flex the package. Such additional stability may, for example, provide resistance to, for example, rotational or lateral forces applied to the package. Secondly, the ridge may, for example, act as a dampening spring. That is, the ridge may absorb compression forces, such as those resulting from package drops, load compressions, and vibrations, any of which could otherwise lead to package failure.

In certain embodiments, and as best shown inFIGS. 3-5, the ridge34may include a multi-level depth over the length thereof. In such embodiments, the ridge34may include an inner wall36, an outer wall38, and a rim40, as best shown inFIGS. 4 and 5. In certain embodiments, both of the inner wall36and the outer wall38extend rearward from and substantially perpendicularly relative to the first member12. In such embodiments, the inner wall36and the outer wall38are connected by the rim40, and over a length of the ridge34, at least a portion of the rim40is substantially parallel to the first member12. As shown inFIGS. 4 and 5, at least a portion of the outer wall38may substantially abut the sealed portion24. In certain embodiments, and as best shown inFIG. 4, at least a portion of the rim40, over the length of the ridge34, may connect a rear portion46of the outer wall38to a rear portion48of the inner wall36. In certain embodiments, and as best shown inFIG. 5, at least a portion of the rim40, over the length of the ridge34, may connect a rear portion46of the outer wall38to a front portion50of the inner wall36. And as shown inFIG. 5, for example, at least a portion of the inner wall36may define at least a portion of the second cavity30. While the rim40is shown inFIGS. 4 and 5to be substantially flat, it will be appreciated that at least a portion of the rim can be rounded or any of a variety of suitable configurations.

As shown inFIG. 6, a razor package110may include a razor152, which may be contained within a first cavity128. In certain embodiments, and as shown inFIG. 6, the razor152may include a head unit154and a handle156, which is attachable to the head unit154. The first cavity128may be shaped to receive the head unit154and at least a portion of the handle156. In such embodiments, a second cavity130may also contain at least a portion of the handle156. In alternative embodiments, however, the first cavity128may be shaped to receive the razor152in its entirety. In certain embodiments, additional devices (e.g., blades or blade cartridges, or other cartridges) may be contained in a third cavity132, as shown inFIG. 6. The second cavity130may further contain a display card (not shown), which may include additional product information thereon. In certain embodiments, a height of the second cavity130may be about one-third of a height of the package110, and the second cavity may be included in a lower portion of the second member118. While the second cavity (30,130) shown in the embodiments ofFIGS. 3, 5, and 6is shown to have a substantially rectangular-prismatic shape, it will be appreciated that a second cavity, or any other cavity, may take the form of any of a variety of suitable shapes.

Additionally, in certain embodiments, the outer surface222of the second member218of the package210may include stacking and denesting lugs264,266. InFIG. 7, for example, the ridge234is shown to include male stacking and denesting lugs264, which may be integrated into and extend from the inner wall236, and female stacking and denesting lugs266, which may be integrated into and defined by the outer wall238. In certain embodiments, and as shown inFIG. 7, at least a portion of a male stacking and denesting lug264may extend from the rim240. In certain embodiments, the ridge234may include two or more stacking and denesting lugs264,266on each of three sides. However, whileFIG. 7depicts one exemplary embodiment, it will be appreciated that male stacking and denesting lugs may be included on an outer wall, female stacking and denesting lugs may be included on an inner wall, and either type of stacking and denesting lugs may be integrated into a ridge in any of a variety of suitable configurations, such as any configuration to permit stacked parts from nesting (i.e., denesting).

Stacking and denesting lugs may facilitate creation of a platform to allow functional stacking such that purchased parts (e.g., second members) may be used with high reliability in manufacturing. For example, positioning of the stacking and denesting lugs may be changed from part to part to substantially prevent stacked parts from nesting. In certain embodiments, nesting may be substantially prevented where a wall depth is greater than an interference point of two or more stacked parts. In such embodiments, the interference point may be determined by geometry, draft angle, and/or material thickness. In certain embodiments, for example, the interference point may be from about 6 mm to about 7 mm.

Inventive Examples 1-4 and Comparative Examples 1-4 were prepared and subsequently tested using an INSTRON® force and measurement test stand according to the procedure described below. Each of Inventive Examples 1-4 were prepared with a ridge and at least a first cavity and a second cavity, with the second cavity included in a lower portion of a second member, as described above. Each of the Comparative Examples 1-4 was a blister package currently in use with existing products, with none of the Comparative Examples including a ridge as described above. Results for the testing are shown in Table 1 below.

TABLE 1Testing of Force Required for Blister FailureForce Required to Flex toExampleFailure (N)Inventive Example 112.75Inventive Example 211.06Inventive Example 311.63Inventive Example 413.24Average12.17Comparative Example 14.76Comparative Example 23.48Comparative Example 33.72Comparative Example 42.94Average3.73

Referring to the results in Table 1, each of Inventive Examples 1-4 outperformed each of Comparative Examples 1-4, at least with respect to structural stability. Based on the averages calculated above, the Inventive Examples required more than three times the force to flex the blister to failure than that required for the Comparative Examples.

Procedure for Test of Force Required to Flex Razor Package Blister to Failure

Secure a first blister sample in a clamping stand that has been affixed to the same surface (e.g., table) as the INSTRON® force and measurement test stand. The clamping stand must be secured to the surface such that the stand may withstand forces to be applied to the blister samples. Tooling of the clamping stand may be fitted to receive the blister sample at an end of the sample opposite to an end having a hanghole disposed therein. For example, the tooling of the clamping stand may be configured to provide a negative image of the blister sample to receive the same. The tooling of the clamping stand should secure about one-third of the length of the blister sample, leaving about two-thirds of the length, including the end with the hanghole, exposed to testing.

Once the clamping stand and blister sample have been adjusted to correspond to the height of the INSTRON® force and measurement test stand, the hanghole may be clamped to the INSTRON® test stand. While a downward force is applied to the hanghole in the present testing, the test may also be performed by applying an upward force. The same method should be used for each blister sample.

The INSTRON® PC software may be set up by arranging for a new experiment and using the appropriate fields. Next, the INSTRON® device may be activated. Ideally, the rate of pull should be adjusted to a relatively slow setting so that the blister sample may be observed to effectively identify a failure point. The failure point is the point at which any portion of the non-clamped portion of the blister sample moves from a “flex” to a “break.” That is, the non-clamped portion of the blister sample may be considered “failed” when the non-clamped portion defines an angle instead of a curve. Subsequently, a force value can be recorded as the “force to flex to failure.” The procedure may then be repeated for the remaining blister samples.

Examples

A. A package, comprising:a. a first member having a front surface and a rear surface, the first member being substantially planar; andb. a second member having an inner surface and an outer surface, the inner surface and the rear surface of the first member defining a first cavity, a periphery of the inner surface of the second member being joined to a periphery of the rear surface of the first member to define a sealed portion, and respective perimeters of the first member and the second member cooperating to define an outer edge of the sealed portion;c. wherein the second member comprises a ridge at least partially circumscribing the first cavity while remaining inward of the outer edge, the ridge comprising:i. an inner wall;ii. an outer wall; andiii. a rim connecting at least a portion of the inner wall and outer wall, both the inner wall and the outer wall extending rearward from and substantially perpendicularly relative to the first member, wherein at least a portion of the rim, over a length of the ridge, is substantially parallel to the first member.
B. A package according to paragraph A, wherein the rear surface of the first member and the inner surface of the second member further define a second cavity, and wherein the second cavity is at least partially circumscribed by the ridge.
C. A package according to paragraph B, wherein the rear surface of the first member and the inner surface of the second member further define a third cavity, and wherein the third cavity is at least partially circumscribed by the ridge.
D. A package according to any one of paragraphs B-C, wherein the first cavity is contiguous with the second cavity.
E. A package according to any one of paragraphs B-D, wherein at least a portion of the inner wall of the ridge defines at least a portion of the second cavity.
F. A package according to any one of paragraphs B-E, wherein a height of the second cavity is about one-third of a height of the package.
G. A package according to any one of paragraphs A-F, wherein the sealed portion comprises an inner edge, the inner edge defining an aperture fully circumscribed within a portion of the sealed portion disposed along an upper portion of the package.
H. A package according to paragraphs G, wherein the outer wall of the ridge substantially abuts the sealed portion, over the length of the ridge.
I. A package according to paragraphs H, wherein the ridge extends about the package from a first side of the inner edge to a second side of the inner edge.
J. A package according to any one of paragraphs A-I, wherein the outer edge is substantially rectangular.
K. A package according to any one of paragraphs A-J, wherein at least a portion of the rim, over the length of the ridge, connects a rear portion of the outer wall to a rear portion of the inner wall.
L. A package according to any one of paragraphs A-K, wherein at least a portion of the rim, over the length of the ridge, connects a rear portion of the outer wall to a front portion of the inner wall.
M. A razor package, comprising:a. a first member having a front surface and a rear surface, the first member being substantially planar;b. a second member having an inner surface and an outer surface, the inner surface and the rear surface of the first member defining a first cavity, a periphery of the inner surface of the second member being joined to a periphery of the rear surface of the first member to define a sealed portion, and respective perimeters of the first member and the second member cooperating to define an outer edge of the sealed portion; andc. a razor, at least a portion of the razor being contained within the first cavity;d. wherein the second member comprises a ridge at least partially circumscribing the first cavity while remaining inward of the outer edge, the ridge comprising:i. an inner wall;ii. an outer wall; andiii. a rim connecting the inner wall to the outer wall, both the inner wall and the outer wall extending rearward from and substantially perpendicularly relative to the first member, wherein at least a portion of the rim, over a length of the ridge, is substantially parallel to the first member.
N. A package according to paragraphs M, wherein the razor comprises a head unit and a handle, and wherein the first cavity is shaped to receive the head unit and at least a portion of the handle.
O. A package according to paragraph N, wherein the rear surface of the first member and the inner surface of the second member further define a second cavity, the second cavity having a substantially rectangular-prismatic shape.
P. A package according to paragraph O, wherein the first cavity is contiguous with the second cavity, the second cavity containing at least a portion of the handle of the razor.
Q. A package according to any one of paragraphs M-P, wherein the sealed portion comprises an inner edge, the inner edge defining an aperture fully circumscribed within a portion of the sealed portion.
R. A package according to paragraph Q, wherein the outer wall of the ridge substantially abuts the sealed portion, over the length of the ridge.
S. A package according to paragraph R, wherein the ridge extends from a first side of the inner edge to a second side of the inner edge.
T. A razor package, comprising:a. a card having a front surface and a rear surface, the card being substantially planar and substantially rectangular;b. a thermoplastic member having an inner surface and an outer surface, the inner surface and the rear surface of the card defining a first cavity and a second cavity, a periphery of the inner surface being joined to a periphery of the rear surface of the card to define a sealed portion, respective perimeters of the card and the thermoplastic member cooperating to define an outer edge of the sealed portion, and the sealed portion comprising an inner edge, the inner edge defining an aperture fully circumscribed within a portion of the sealed portion; andc. a razor, at least a portion of the razor being contained within the first cavity;d. wherein the thermoplastic member comprises a continuous, multi-level ridge at least partially circumscribing the first cavity and the second cavity while remaining inward of the sealed portion, the ridge comprising:i. an inner wall;ii. an outer wall; andiii. a rim connecting at least a portion of the inner wall and outer wall, both the inner wall and the outer wall extending rearward from and substantially perpendicularly relative to the card, wherein at least a portion of the rim, over a length of the ridge, is substantially parallel to the card.

The foregoing description of embodiments and examples has been presented for purposes of description. It is not intended to be exhaustive or limiting to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed and others will be understood by those skilled in the art.

It should be understood that any feature and/or element of any one of the embodiments and/or examples shown and described above herein may be removed from the embodiment and/or example, replaced with a feature or element from another embodiment or example herein or replaced with an equivalent feature or element. The embodiments were chosen and described for illustration of various embodiments. The scope is, of course, not limited to the examples or embodiments set forth herein, but may be employed in any number of applications and equivalent articles by those of ordinary skill in the art. Rather it is hereby intended the scope be define by the claims appended hereto.