Reusable blister package

An improved reusable blister package is provided which consists of a base member, a top member and a label sheet. The top member mateably engages the opening of the base member. The label sheet seals the package shut after manufacture and prior to purchase. The package is opened by pulling the label sheet and the top member out and away from the base member thereby tearing the label sheet along the upper and side portions of the top member. The label sheet located along the lower end of the top member remains untorn and provides a hinge mechanism connecting the lower end of the top member to the lower end of peripheral flange of the base member. The improved package provides an outwardly facing label sheet that is entirely available for graphic presentations of logos and other product indicia.

This invention relates generally to blister packages for the retail display 
of small items, and more particularly, to such blister packages which are 
reclosable and therefore reusable by the consumer. 
BACKGROUND OF THE INVENTION 
Retailers and manufacturers of small items, such as small hardware items, 
are constantly presented with the problem of properly displaying their 
goods on the shelf to the consumer. Because items such as picture hangers, 
screws and tacks are no longer sold in bulk or by weight, such items must 
be packaged in manageable quantities for sale to the consumer. Such 
packages are normally of a rectangular shape with a hole through the top 
and are displayed on a wire-type carrier, or display hook, that extends 
horizontally outward from a rear shelf wall. 
Conventionally, the goods are contained within a clear plastic portion, 
known as the blister. The blister is mounted on a flat piece of cardboard 
or is bordered by a wide peripheral flange. Because the blister portion 
cannot be used for the display of trademarks and product information, the 
cardboard or flange bordering the blister must be large enough to display 
this information. Thus, much of the shelf space consumed by a blister 
package is attributable to the display of trademarks and other product 
information, not containing the products themselves. This is an 
inefficient use of shelf-space; retailers sell products, not packages and 
packaging information. 
Because packaging small items in these blister-type packages is a 
relatively inefficient use of shelf space or area in today's highly 
competitive retail environment, retailers will crowd the horizontally 
extending display hooks together thereby creating a crowded shelf 
appearance and making it difficult for the consumer to discern one product 
from another. A manufacturer's products can be lost in the "sea" of 
competing products hanging on the numerous display hooks. 
Thus, two competing concerns are present. Retailers are concerned with 
making the best use of their available shelf space and floor space; 
manufacturers are concerned with product appearance and product identity. 
Both retailers and manufacturers desire the entire shelf areas containing 
blister-type packages to have an attractive appearance. The present 
invention makes significant contributions to all of the above concerns. To 
appreciate the contributions made by the present invention to the blister 
package art, an understanding of the available blister packages and their 
shortcomings is necessary. 
One conventional embodiment of a blister package includes a clear blister 
or product containing portion that is glued over a piece of cardboard. The 
product is contained within the space or chamber between the blister and 
the stiff cardboard backing. While these types of blister packages are the 
least expensive to manufacture, they are the most inefficient in terms of 
shelf space. Cardboard mounted blister packages take up too much shelf 
space because the blister portion containing the product is not available 
for labeling or product identification; it is too difficult and too 
expensive to put a label on the blister itself. Therefore, the stiff 
cardboard backing must extend significantly beyond the outer periphery of 
the blister portion to adequately identify the manufacturer, the product 
specifications and display any logos. 
Other blister-type packages that are reclosable or reusable are also known. 
These types of blister packages are normally manufactured out of a single 
piece of clear plastic. The blister or product containing portion is 
integrally connected to the top or back member by a "living hinge" that 
joins the two parts. The package may be opened and closed repeatedly 
because at least one nesting surface on the product containing portion 
mates with a cooperating surface on the top portion allowing the package 
to close and open repeatedly. Because the top is not permanently sealed or 
glued to the product containing portion, the package may be reopened and 
reclosed. Thus, the consumer can use the package as a container for the 
small products at home without the need for transferring the products to a 
different container such as a cup or a jar. The reusable blister concept 
has been received very favorably and is used for a variety of products. 
However, current reclosable blister packages do not satisfy the product 
presentation and shelf space concerns of manufacturers and retailers alike 
addressed above. Namely, the product is still contained in a clear blister 
bubble which dominates the appearance of the package. In order for a 
manufacturer to properly identify the product and display its logo, a 
large outer periphery must extend substantially beyond the blister 
portion. This large outer periphery wastes valuable shelf space. Thus, 
while the consumer has gained the benefits of a reusable package, the 
retailer's concern regarding wasted shelf space is largely unaddressed and 
the manufacturer still has little space on which to properly identify the 
product and display its logo. 
Thus, there is a need for a new, improved reusable blister package that 
makes economical use of the retailer's limited shelf space and still 
provides the manufacturer adequate space to identify its product. This 
problem has been solved by the present invention. 
BRIEF DESCRIPTION OF THE INVENTION 
An improved reusable blister package that efficiently uses shelf space 
while enabling a manufacturer to prominently display its logo, graphics 
and other indicia is provided as follows. The container is manufactured 
from three separate parts: a base member, which includes the blister 
portion; a top member which serves as a lid; and a label sheet, or 
adhesive front sheet. This assemblage being described from rear to front 
as the consumer would view the container hanging on a support hook. 
The base member includes a product containing portion which is commonly 
referred to as the blister. The opening of the product containing portion 
is shaped so that it can mateably engage with the top member. A peripheral 
flange extends outward from and around the opening and beyond the outer 
periphery of the top member when the package is closed. At least one 
nesting surface for engaging the top member is provided inside the product 
containing portion just inside of the opening. 
The top member is of the same general geometrical shape as the base member, 
only the outer periphery of the top member is smaller than the outer 
boundaries of the peripheral flange of the base member. The top member is 
sized to mateably engage the base member when the two are folded together. 
The top member includes an outwardly extending wall which engages the 
nesting surface of the base member. The engagement of the wall and the 
nesting surface provide the mechanism which enables the container to be 
opened and reclosed repeatedly. 
Finally, the label sheet covers the top member and the outer portion of the 
peripheral flange of the base member when the product is sealed by the 
manufacturer. Hence, the outer periphery of the top member must be inside 
of the outer periphery of the peripheral flange of the base member to 
ensure an adequate seal by the adhesive label sheet. The label sheet 
includes a line of perforations that are in matching registry with the 
upper end and opposing sides of the outer periphery of the top member. The 
label sheet is not perforated along the lower end of the top member. 
In the preferred embodiment, a pull tab consisting of the upper perforation 
of the label sheet and the upper end of the top member is accessible to 
being gripped and pulled by the consumer. The container is opened by 
pulling the pull tab outward and downward. A hinge mechanism is provided 
at the lower ends of the top member and the base member by the 
unperforated portion of the label sheet which remains in contact with 
lower outer peripheral flange of the base member. 
The package is displayed by the retailer with the label sheet facing 
outward toward the consumer and the product containing portion of the base 
member facing inward toward the back of the shelf. Thus, the largest flat 
surface area of the package, which is bounded by the outer periphery of 
the peripheral flange of the base member, is available to the manufacturer 
for graphics such as logos and product specifications. The "blister 
portion" or the product containing portion of the base member, which 
cannot effectively be used for labeling purposes, projects inward toward 
the rear of the shelf. Therefore, no portion of the flat surface area 
which can be effectively used to display graphics is wasted. The package 
makes as efficient use of shelf space as possible while enabling the 
manufacturer to have more surface area for graphics in a smaller package. 
Thus, the present invention discloses a reusable blister package with an 
effective hinge provided by the lower end of the label sheet that is 
attractive to both retailers and manufacturers alike. The large, flat 
surface area facing the consumer enables the manufacture to display 
improved graphics and create a dramatic merchandizing effect. Because the 
label sheet, which faces outward toward the consumer, is a label, the 
graphics and/or color scheme may be easily changed by the manufacturer. 
Retailers can now demand color coordinated or color coded groups of 
products from a manufacturer. 
The package is also attractive to consumers because it provides the 
benefits of prior reclosable blister packages. Namely, the consumer can 
still see the products before purchase and the package is a useful 
container for home use.

DETAILED DESCRIPTION OF THE INVENTION 
Like reference numerals will be used to refer to like or similar parts from 
Figure to Figure in the following description of the drawing. 
FIG. 1 is a perspective view of the reusable blister package 10 made in 
accordance with the present invention. The package consists essentially of 
three layers or plies of generally overlapping sheet material, two of 
which are formed into three dimensional structures. 
The first layer or ply, as viewed in FIG. 2 and looking toward the left, is 
the flat label sheet 11 whose generally rectangular contour is best seen 
in FIG. 1 and whose thickness is best appreciated in FIG. 2. The label 
sheet 11 faces outward toward the consumer and serves as a flat surface 
for the display of graphics and other product information. The label sheet 
11 covers the large surface area bordered by the outer periphery 12 of the 
base member 13 (see FIG. 3). The label sheet entirely covers the generally 
pentagonal contour of the top member 14 (see FIGS. 1 and 4) when the top 
member 14 is in the closed position or is mateably engaged with the base 
member 13 (see FIG. 3). As discussed in detail below, the label sheet 11 
includes perforations 17 along the upper ends 19, 20 and two opposing 
sides 21, 22 of the top member 14 and remains unperforated along the lower 
end 24 of the top member 14. The lower, unperforated portion of the label 
sheet 11 provides a hinge mechanism 23 which pivotally joins the top 
member 14 to the base member 13. 
The second of the three layers is the top member 14. The top member 14 is 
disposed between the flat label sheet 11 and the base member 13. The outer 
periphery of the top member 14 is of a general pentagonal shape (see FIGS. 
1 and, especially, 4) but the protruding wall 26, which mateably engages 
the opening 18 (see FIG. 2) of the base member 13, has a generally 
rectangular contour. As best seen in FIG. 2, the top member 14, in 
conjunction with label sheet 11, serves as a pivoting lid to the base 
member 13. As discussed below, the top member 14 may be reopened and 
reclosed so the consumer can use the package 10 as a container at home 
without transferring the goods to a different container such as a cup or a 
jar. 
The third of the three layers is the base member 14. As best seen in FIGS. 
2 and 3 the base member includes the blister, or product containing 
portion 30. The see-through product containing portion 30 faces the away 
from the consumer when the package is hung from a display rack (not 
shown). In the preferred method of display, the label sheet 11, which 
includes logos and other graphic presentations, faces toward the consumer. 
While the clear product containing portion 30 faces inward away from the 
consumer, it still enables the consumer to view the products before 
purchase. 
Referring to FIG. 1, the hole 15 which is formed in all three layers, 
provides a means for hanging the package 10 on a horizontally extending 
display rack or hook (not shown). 
To open the package 10, the consumer grasps the pull-tab 16 provided near 
the uppermost point of the perforation 17 in label sheet 11. The portion 
of the label sheet 11 which is co-extensive with the outer boundaries of 
the top member 14, and the top member 14 itself, are both pulled outward 
and downward from the base member 13 thereby tearing the perforation 17 
along a path overlying the upper ends 19, 20 and opposing sides 21, 22 of 
the top member 14. The label sheet 11 remains untorn along the hinge line 
indicated at 23 (see FIG. 1). This portion of the label sheet along the 
lower end 24 of the top member 14 provides a hinge mechanism 23 enabling 
the top member 14 to remain pivotally connected to the base member 13 
after the initial opening along the perforation 17. If the manufacturer 
does not require a significant amount of space for graphics, a window 29 
may be included in the label sheet 11 which would enable the consumer to 
view the products without removing the package 10 from the shelf. 
FIG. 2 illustrates the hinge, indicated at 23. The top member 14 and the 
portion of the label sheet 11 adhering to the top member 14 are 
simultaneously pulled away from the base member 13. As discussed above, 
the label sheet 11 is torn along the upper ends 19, 20 and opposing sides 
21, 22 of the top member 14 (19 and 22 are not shown in FIG. 2) but 
remains untorn along the lower end 24 of the top member 14 thereby 
providing the hinge 23. The top member 14 mateably engages the opening 18 
(see FIG. 2) of the base member 13 upon reclosure when the top surface 25 
of the protruding wall 26 engages the nesting surface 27 (see FIGS. 2 and 
3) located just inside the product containing portion 30 of the base 
member 13. 
The base member 13 and the top member 14 engage one another by a closure 
mechanism. The specific location of the closure mechanism is not 
important. The closure mechanism of the preferred embodiment, which is 
best seen in FIG. 2, is located at the nesting surface 27 of the upper end 
31 of the product containing portion 30 of the base member 13, see FIG. 2. 
However, other closure mechanisms may be provided along the sides 32, 33 
of the product containing portion 30 and the opposing side walls 34, 35 of 
the top member 14. Further, the depth, indicated at 28, of the product 
containing portion 30 of the base member 13 can be varied according to the 
quantity and size of the items to be contained therein. 
FIG. 3 is a rear elevation view of the base member 13. The nesting surface 
27 positively engages the top surface 25 of the protruding wall 26 of the 
top member 14 (see FIG. 4). The nesting surface 27 extends slightly upward 
and outward (see FIG. 6) from the body of base member 13 thereby creating 
a stacking surface 36. To provide level stacking for several base members 
13 after manufacture, additional stacking surfaces 37, 40 are provided at 
the lower end of the base member 13. The alignment ribs 47-52 also make it 
easier to stack a series of base members 13 after manufacture. The 
upwardly extending ribs 41, 42 and downwardly extending ribs 43, 44 
provide additional strength to the outwardly extending flange 45 of the 
base member 13. 
FIG. 4 is a rear side view of the top member 14. The outwardly extending 
wall, shown generally at 26, mateably engages with the opening 18 (see 
FIG. 2) of the product containing portion 30 of the base member 13. The 
upper surface 25 of the outwardly extending wall 26 positively engages the 
nesting surface 27 (see FIGS. 2, 3 and 6) to snap the top member 14 shut 
when the reusable container 10 is closed. The perforation 17 of the label 
sheet 11 (see FIG. 1) is in matching registry with the upper ends 19, 20 
and opposing sides 21, 22 of the outer periphery of the top member 14. The 
upper ends 19, 20 of the top member 14 form an upwardly extending flange 
which forms part of the pull-tab mechanism 16. 
FIG. 5 is a bottom view of the base member 13 shown in FIG. 3. As shown 
above, the stacking surfaces 37, 40 provide a level stacking surface to 
complement the stacking surface 36 adjacent to the nesting surface 27 (see 
FIG. 6). The size of the peripheral flange 45 can be varied according to 
the amount of graphic space desired, but need extend only slightly beyond 
the outer periphery 46 of the top member 14. 
FIG. 6 further illustrates the closure mechanism located at the upper ends 
19, 20 of the top member 14 and the upper end 31 of the base member 13. 
The top outwardly protruding wall 25 positively engages the nesting 
surface 27. Because the material comprising the base member 13 and top 
member 14 is preferably a resilient material like polystyrene, the top 
wall 25 simply snaps into place as shown upon the application of manual 
pressure. 
FIG. 7 illustrates the precise location of the hinge 23. The hinge 23 
connects the lower end 24 of the top member 14 to the peripheral flange 45 
of the base member 13. The bottom outwardly extending wall 54 of the top 
member 14 is free to pivot upward and outward out of the lower nesting 
surface 55 of the base member 13. 
Thus, a reclosable blister package 10 is provided which includes a hinge 23 
consisting of the untorn portion of the label sheet 11. The hinge 23 
flexibly connects the lower end 24 of the top member 14 to the lower end 
(see FIG. 3) of the peripheral flange 45 of the base member 13. The result 
is a reclosable blister package 10 that provides ample room for enhanced 
graphics on the label sheet 11. The chamber formed between base member 13 
and top member 14 in closed condition is no smaller than the chamber of 
conventional blister packages. The entire surface area of the label sheet 
11 is available for the display of logos, product specifications and other 
advertising information. No flat surface space that faces the consumer as 
the packages hang on a display rack is wasted. 
Retailers are extremely pleased because the packages use shelf space 
economically. Oversized cardboard backing or wide flanges are no longer 
necessary for blister-type packages. Manufacturers favor this invention 
because of the increased surface area provided on label sheet 11 that is 
now available for graphics. Given the increased area for graphics, 
manufacturers are able to create a more aesthetically pleasing package 
which, of course, is also attractive to consumers and retailers. 
The preferred material of construction is polystyrene for all three 
components, the base member 13, the top member 14 and the label sheet 11. 
The label sheet 11 is thinner than both the top member 14 and the base 
member 13 thereby enabling it to be peeled back and torn along the 
perforation 17 easily. Because all three components may be made of the 
same material, recycling is simplified. No separation of certain 
components from others is required. 
Although the preferred embodiment of the present invention has been 
illustrated and described, it will at once be apparent to those skilled in 
the art that variations may be made within the spirit and scope of the 
invention. Accordingly, it is intended that the scope of the invention be 
limited solely by the scope of the hereafter appended claims and not by 
the specific wording in the foregoing description.