Elongated tool hang tag package with bridge strap

A hang tag package in one embodiment includes a base portion including an upper mounting portion, a first display portion located beneath the mounting portion and including a first window through which a tip portion of an elongated tool is viewable from the front of the base portion, and a body portion located beneath the display portion, the body portion including at least one integrally formed first welding pad. The hang tag package further includes a bridge strap including at least one integrally formed second welding pad ultrasonically welded to the integrally formed first welding pad whereby the elongated tool is entrapped between the body portion and the bridge strap.

FIELD

This disclosure relates generally to product display packages and, more particularly, to a hang tag for elongated tools such as drill bits.

BACKGROUND

Unless otherwise indicated herein, the materials described in this section are not prior art to the claims in this application and are not admitted as prior art by inclusion in this section.

There are a variety of display packages designed for presenting relatively small products that are sold at retail as well as other stores, where the products are conveniently placed on rods or hooks that extend from a wall or display case. These display packages are commonly known as clip or hang tags which are designed to hold the product and provide a surface for an information label while providing an aperture which allows the hang tag to be hung on the outwardly extending rod or hook.

Drill bits and other elongated tools have been displayed using hang tags. In order to maximize the amount of drill bits that can be displayed in a given volume, it is desirable to reduce the size of the hang tags. Accordingly, relatively thin, elongated hang tags have been designed which have a mounting aperture at the upper end, an intermediate area on which labels can be placed, and a lower portion adapted to receive and hold the product, such as a drill bit, screwdriver and other tools.

A significant concern, particularly with drill bits which can be expensive relative to other similarly sized products, is shoplifting by customers who simply walk out of a retail establishment with the product. In response to this issue, security tags are often placed on the hang tags. Another concern with regard to drill bits is that customers have been known to switch the hang tag of an expensive drill bit with the hang tag of a less expensive drill bit.

Accordingly, it would be beneficial if a hang tag package could protect a tool such as a drill bit and provide for informational display and mounting while reducing the overall size of the package and product. It would be further beneficial if a hang tag were more difficult to disassemble the hang tag package from known hang tag packages to prevent removal of the product prior to sale and/or to hinder switching of hang tags.

SUMMARY

In accordance with one embodiment, a hang tag package includes a base portion including an upper mounting portion, a first display portion located beneath the mounting portion and including a first window through which a tip portion of an elongated tool is viewable from the front of the base portion, and a body portion located beneath the display portion, the body portion including at least one integrally formed first welding pad. The hang tag package further includes a bridge strap including at least one integrally formed second welding pad ultrasonically welded to the integrally formed first welding pad whereby the elongated tool is entrapped between the body portion and the bridge strap.

In one or more embodiments, the hang tag package further includes an adhesive adhered to at least one anchoring structure of the base portion and to the elongated tool thereby adhering the elongated tool to the base portion.

In one or more embodiments, the body portion further includes a second window and the elongated tool is aligned with the second window such that a portion of the elongated tool is visible through the body portion from the front of the body portion.

In one or more embodiments the bridge strap includes at least one neck extending partially about the elongated tool.

In one or more embodiments the at least one neck is shaped complementary to a facing portion of the elongated tool.

In one or more embodiments the body portion includes side panels extending along the sides of the second window. Each side panel includes one of the first welding pads to which the second welding pads are ultrasonically welded.

In one or more embodiments, the body portion includes an anti-walking ridge associated with each welding pad, wherein the anti-walking ridges are configured to restrict movement of the bridge strap with respect to the body portion during an ultrasonic welding operation.

In one or more embodiments the two side panels are not co-planar.

In one or more embodiments the bridge strap includes an upper neck extending partially about the elongated tool and a lower neck extending partially about the elongated tool. A backing extends between the upper neck and the lower neck and is aligned with the second window.

In one or more embodiments, the bridge strap further includes a rib extending alongside the backing and spaced apart from the backing. The hang tag package further includes a label including a first end portion attached to the rib, the label extending from the first rib, around a front side of the body portion, over the backing, and to the rib whereat a second end portion of the label is attached to the first end portion of the label.

In one or more embodiments at least one of the upper neck and the lower neck is configured to closely conform to the elongated tool such that rotation of the elongated tool with respect to the at least one of the upper neck and the lower neck is inhibited.

In accordance with one embodiment, a method of forming a hang tag package includes providing a base portion including an upper mounting portion, a first display portion located beneath the mounting portion and including a first window, and a body portion located beneath the display portion, the body portion including at least one integrally formed first welding pad. The method includes positioning an elongated tool on a backside of the base portion such that a tip portion of the elongated tool is viewable from the front of the base portion through the first window. Then a bridge strap is ultrasonically welded to the body portion by ultrasonically welding at least one integrally formed second welding pad of the bridge strap to the at least one integrally formed first welding pad thereby entrapping the elongated tool between the body portion and the bridge strap.

In one or more embodiments, the method includes adhering at least one anchoring structure of the base portion to the elongated tool with an adhesive thereby adhering the elongated tool to the base portion.

In one or more embodiments of the method positioning the elongated tool on the backside of the base portion further includes aligning the elongated tool with a second window of the base portion such that a portion of the elongated tool is visible through the body portion from the front of the body portion.

In one or more embodiments the method includes positioning at least one neck of the bridge strap partially about the elongated tool prior to ultrasonically welding the bridge strap to the body portion.

In one or more embodiments of the method positioning the at least one neck of the bridge strap partially about the elongated tool includes positioning at least one neck of the bridge strap partially about a complementarily shaped facing portion of the elongated tool.

In one or more embodiments of the method providing the base portion includes providing a body portion which includes a first side panel extending along a first side of the second window, and a second side panel extending along a second side of the second window. The at least one integrally formed first welding pad includes a first side welding pad integrally formed with the first side panel and the at least one integrally formed first welding pad includes a second side welding pad integrally formed with the second side panel. Additionally, the at least one integrally formed second welding pad includes a third welding pad integrally formed with the bridge strap and the at least one integrally formed second welding pad includes a fourth welding pad integrally formed with the bridge strap. Accordingly, ultrasonically welding the bridge strap to the body portion includes ultrasonically welding the third welding pad to the first side welding pad and ultrasonically welding the fourth welding pad to the second side welding pad.

In one or more embodiments of the method the first side panel is not co-planar with the second side panel.

In one or more embodiments the method includes positioning an upper neck of the bridge strap partially about the elongated tool prior to ultrasonically welding the bridge strap to the body portion, positioning a lower neck of the bridge strap partially about the elongated tool prior to ultrasonically welding the bridge strap to the body portion, and aligning a backing of the bridge strap with the second window, the backing extending between the upper neck and the lower neck.

In one or more embodiments of the method at least one of the upper neck and the lower neck is configured to closely conform to the elongated tool such that rotation of the elongated tool with respect to the at least one of the upper neck and the lower neck is inhibited.

DETAILED DESCRIPTION

The following description is presented to enable any person skilled in the art to make and use the described embodiments, and is provided in the context of a particular application and its requirements. Various modifications to the described embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the described embodiments. Thus, the described embodiments are not limited to the embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein.

FIG. 1depicts a product display package100which in this embodiment is a hang tag package including a drill bit102. In other embodiments, other elongated products are displayed by the hang tag package100such as screw drivers, chisels, etc. The hang tag package100includes a base portion104, a label105, and a bridge strap106shown inFIG. 2. The base portion104includes an upper mounting portion108, a display portion110, and a body portion112.

The upper mounting portion108includes a mounting window114which in the embodiment ofFIG. 1is fully encircled but in other embodiments is open to one side. The mounting window114is configured to be used when mounting the hang tag package100for display using, for example, a peg, clip, or other device whereby the hang tag package100hangs from the upper mounting portion108. The position of the mounting portion108allows an elongated tool such as the drill bit102to be mounted with its tip facing upwardly for ease of inspection by a customer without requiring removal of the hang tag package from the display.

The display portion110is located immediately below the upper mounting portion108and includes a display window116and a backwardly extending lip118. The lip118includes a mouth120through which a tip122of the drill bit102extends. The display window116, which in this embodiment is fully encircled but in other embodiments is open to one of the sides of the hang tag package100, allows a customer to see the tip122of the drill102.

The body portion112is located immediately beneath the display portion110and includes two side panels124and126. As shown more clearly inFIG. 3, the side panels124and126are angled with respect to one another so that they are not coplanar. This provides additional rigidity to the hang tag package. Since the label105is affixed to the side panels, the angled configuration provides greater visibility for a wider label viewing angle.

The angled configuration further provides for centering of the drill bit102on the body portion112and aligns the drill bit102with both the display window116and a display window130in the body portion112in embodiments including the display window130. Accordingly, since the mouth120allows the drill bit102to be positioned directly against the backside128(seeFIG. 3) of the body portion112, the side panels cover a portion of the drill bit102when the hang tag package is viewed from the side.

Returning toFIG. 1, the display window130allows a customer to see the fluted portion132of the drill bit102from the front of the hang tag package100in embodiments including the display window130. In some embodiments, the display window130is omitted. The body portion112is sized so that when the hang tag package100is hung, the handle of the elongated tool, or in the case of the drill bit102, the shank134, extends beneath the body portion112. Accordingly, a customer can see all of the relevant portions of the drill bit102. Moreover, the customer can test fit the shank of the drill bit102, or other elongated tool, into another tool without removing the elongated tool from the rest of the hang tag package.

FIG. 4shows the backside128of the base portion104. In this embodiment, the body portion112includes a depression140which has a flat surface, along with a number of anchoring structures142. The anchoring structures142, which in various embodiments are boss structures or debossed structures, in this embodiment are circular and are used with an adhesive144shown inFIG. 2to inhibit removal of the drill bit102from the hang tag. Anchoring structures in some embodiments are provided additionally or alternatively on the elongated tool.

In some embodiments, the anchoring structures provide increased surface areas for the adhesive144. The adhesive144engages the anchoring structures142and the drill bit102to inhibit rotation and/or removal of the elongated product from the hang tag package100. In some embodiments, the elongated tool is provided with a debossed area which, along with the debossed structures142, provides enhanced securement for the adhesive. When provided on the drill bit the debossed area in some embodiments is located beneath a flute.

In one embodiment, the adhesive is selected to act in a manner similar to a rubber cement. To wit, the adhesive acts substantially like a gasket which increases friction by remaining at least somewhat tacky rather than by providing an unbreakable connection with the elongated tool. The adhesive thereby resists rotation of the elongated tool while being easily removed from the elongated tool when the elongated tool is removed from the hang tag package. In one embodiment such an adhesive is commercially available from DHM Adhesives Inc. of Calhoun, Ga under the trade name DHM-798 which is a hot melt polyolefin based glue with excellent adhesion to plastics, fiberglass, metal, and most substrates.

Returning toFIG. 4, the backside of the base portion104further includes four welding pads150,152,154, and156. In one embodiment, the welding pads150,152,154, and156are integrally formed with the body portion112. The welding pads150,152,154, and156are used to connect the base portion104to the bridge strap106which is shown in further detail inFIG. 5.

The bridge strap106includes four integrally formed welding pads158,160,162, and164which, as discussed in further detail below, are welded to the welding pads150,152,154, and156, respectively.

The bridge strap106further includes a backing portion166and two support ribs168and170. The backing portion166traps the drill102and the underling adhesive144against the body portion112. The welding pads150,152,154, and156of the body portion112are configured such that when welded to the welding pads158,160,162, and164, the bridge strap106is aligned with the body portion112. Hence, the backing portion166is aligned with the display window130in embodiments including the second window130.

The support ribs168and170and the backing portion166are used to support the label105as described with reference toFIG. 6. The label105includes a first end portion174, a front label portion176, a window178, a rear label portion180, and a second end portion182. The label105is attached to the base portion104and the bridge strap106by adhering the first end portion174to the support rib170, wrapping the label105around the front of the base portion104and then over the support rib168and the backing portion166, and adhering the second end portion182to the first end portion174at the rib170.

The label105is configured such that when attached to the base portion104and the bridge strap106, the window178is aligned with the display window130with the front label portion176centered about the display window130in embodiments including the display window130. In any event, the front label portion176extends over at least a portion of each of the side panels124/126. Additionally, the rear label portion180is centered on the backing portion166. Accordingly, the front label portion176is clearly visible to provide detailed information regarding the elongated tool to a consumer while the hang tag package100is on display, and the rear label portion is available for additional information such as warning information and coding labels.

Since the label105is overlapped at the rib170, none of the writing or illustrations on the label will mismatch in a critical area. Moreover, the label105conceals the security tag184positioned within the depression140. Because of the ribbed structure of the bridge strap106, a lesser amount of materials is required thereby lowering costs and weight of the hang tag package100. The material used for the label is selected to provide puncture resistance so that consumers do not puncture the label105when handling the hang tag100. To this end, in one embodiment, the label105is formed using 60 # bi-orientated polypropylene (BOPP).

Also shown inFIG. 6are upper anti-walking ridges186and188and lower anti-walking ridges190and192. The anti-walking ridges186/188/190/192are integrally formed with the base portion104and positioned immediately above (anti-walking ridges186/188) or below (anti-walking ridges190/192) an associated welding pad150/152/154/156. The anti-walking ridges186/188/190/192extend away from the base portion104to a greater degree than the associated welding pad150/152/154/156. While any desired shape can provide the function of the anti-walking ridges186/188/190/192which is discussed in more detail below, in one embodiment the anti-walking ridges186/188/190/192are identically shaped and sized and have the same shape and size as associated guide surfaces on the bridge strap106.

Referring again toFIG. 5, two of the associated guide surfaces194are shown (the two associated with the welding pads160/164are not shown). Each guide surface194extends outwardly from the associated welding pad.

Continuing withFIG. 5, the bridge strap106further includes a neck196and a neck198. The neck196and the neck198, which in some embodiments are differently sized and/or shaped, are sized and shaped to allow the drill bit102to be positioned within the upper neck196and the lower neck198when the drill bit102is held against the body portion112by the bridge strap166.

One or both of the neck196and the neck198is/are sized and shaped to conform to the size and shape of the drill bit102or other elongated tool to provide additional stability to the hang tag package. By way of example,FIG. 7depicts a bridge strap106′ that is used with the base portion104ofFIG. 1which includes a neck196′ which is sized to provide three points of contact for the facing portion of a circularly shaped portion of an elongated tool102′.

FIG. 8depicts a bridge strap106″ that is used with the base portion104ofFIG. 1which includes a neck196″ which is sized to closely conform to the shape of the facing portion of an elongated tool102″. When an elongated tool has a non-circular shape, a closely conformed neck such as the neck196″ inhibits rotation of the elongated tool. This configuration is particularly advantageous when the elongated tool does not include an increased diameter portion which can be used to inhibit pulling the elongated tool out of the hang tag package.

The bridge strap196″ in some embodiments is incorporated with a base portion which includes a protuberance. By way of example, in embodiments wherein one or more of the anchoring structures142(seeFIG. 4) is a bossed anchoring structure, and the elongated tool102″ is a drill bit, or tool including a groove or flute which extends axially and radially about the tool, the anchoring structure is configured to align with the flute. Accordingly, the anchoring structure142precludes simply pulling the elongated tool102″ out of the hang tag, while the neck196″ precludes rotation of the elongated tool to preclude “unscrewing” the elongated tool from the hang tag. Accordingly, the adhesive in some of these embodiments is omitted without enabling removal of the elongated tool. The flute thus acts as a debossed anchoring structure.

In some embodiments, the elongated tool is provided with a debossed anchoring structure/opening into which a bossed anchoring structure of the body portion112extends to inhibit or prevent relative movement between the elongated tool and the body portion112. In some embodiments, the debossed anchoring structure and bossed anchoring structure only prevent pulling the elongated tool out of the hang tag, e.g., when the debossed anchoring structure is a flute. In other embodiments the debossed anchoring structure and bossed anchoring structure prevent pulling the elongated tool out of the hang tag and further prevent rotation of the elongated tool with respect to the body portion, e.g., when the debossed area does not extend axially along the shaft for a distance which allows pulling the elongated tool out of the hang tag.

The hang tag package100is assembled in one embodiment according to the method200ofFIG. 9. While discussed with reference to the hang tag package ofFIG. 1, the process is also used with the other embodiments described herein with such modifications as appropriate for the differences of the various embodiments. Moreover, in different embodiments one or more steps of the method200are omitted and or replaced, and the order of the steps modified. At block202the base portion104is provided. In one embodiment, the base portion104is made from a rigid plastic material, such as a thermoplastic polymer. In one embodiment, the base portion104includes high-density polyethylene (HDPE). Typically, the base portion104is manufactured via an injection molding process.

At block204the security tag184is affixed in the depression140in some embodiments. An adhesive is applied to the base portion104at block206. In some embodiments, the adhesive is applied in depression140and the security tag is affixed in the depression140in a following step. Once the adhesive is applied, the elongated tool is inserted onto the body portion (and the adhesive). The angled side panels124and126help to align the elongated tool on the body portion112. In embodiments including flutes or openings and protruding (bossed) anchoring structures142, the anchoring structures142further assist in aligning the elongated tool on the body portion112. Alignment of the elongated tool in some embodiments includes alignment of the elongated tool with one or more of the display windows116and130.

The bridge strap106is then positioned on the body portion112(block210). In particular, the bridge strap106is aligned with the body portion112by positioning the welding pads158,160,162, and164of the bridge strap106on the welding pads150,152,154, and156of the body portion112. The anti-walking ridges186/188/190/192assist in aligning the bridge strap106as each of the guide surfaces194are positioned immediately adjacent an associated anti-walking ridge.

In order to achieve contact between the respective welding pads, the bridge strap106in some embodiments is flexed by forcing the welding pads of the bridge strap against the welding pads of the body portion thereby pressing the elongated tool against the body portion112with the backing portion166.

At block212the bridge strap106is welded to the body portion112. To this end one or more of the body portion welding pads and the bridge strap welding pads are provided in some embodiments with features, e.g., ridges, to assist in the welding process which in some embodiments is an ultrasonic welding process. The anti-walking ridges186/188/190/192interacting with the guide surface194prevent the bridge strap welding pads from moving off of the base portion welding pads during the welding process. The process ends at block214when a label105is attached to the welded bridge strap and body in the manner discussed above.

WhileFIG. 2shows the base portion104and the bridge strap106as separately formed components, in some embodiments the base portion and the bridge strap are integrally formed. By way of example,FIG. 10shows the base portion104′ and the bridge strap106′ which have been formed as a single molding with a joiner strip220. In some embodiments, the joiner strip220is severed prior to the process200. In other embodiments, the bridge strap106′ is simply folded over the body portion104′ along the joiner strip220and then welded to the body104′ in the manner described above.

FIG. 11shows another embodiment of a hang tag package230. The hang tag package230includes an elongated tool232, a base portion234and two bridge straps236. The bridge straps236include two welding pads238which are welded to the base portion234.

The base portion234is similar to the base portion104. Rather than a display window130, however, the base portion234includes a rib240which is configured to be inserted within a flute (not shown) or opening (not shown) of the elongated tool232. The rib240prevents the elongated tool232from being pulled out of the hang tag package230. The base portion234further includes two pairs of alignment guides242. The alignment guides242align the elongated tool232on the base portion234in preparation for ultrasonic welding of the bridge straps236to the base portion234. In some embodiments, an adhesive is applied between the elongated tool and the alignment guides242to resist rotation. In some embodiments, one or more of the bridge straps236, rib240, and alignment guides242are incorporated into the base portion104.

In the above embodiments, the hang tag package provides a number of advantages. The angled body portions provide enhanced strength and customer viewing. The hang tag package provides for viewing of both ends of the elongated tool and to the central portion of the elongated tool. The hang tag package further provides access to the shank of the elongated tool so a customer can verify compatibility of the elongated tool with other tools while preventing removal of the elongated tool prior within a retail facility. The hang tag package is easily assembled and does not incorporate small fasteners which can be difficult to control during assembly.