Abstract:
A security packaging that provides a multi-panel packaging structure that displays a visual indication if package tampering has occurred.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to tamper evident security packaging, and more specifically to a security packaging which provides a sealed polymeric structure which may be patterned that displays a visual indication if package tampering has occurred. 
       BACKGROUND OF THE INVENTION 
       [0002]    In the retail sector and elsewhere, there has been an ongoing and growing need for improved tamper evident packaging. Foods, consumer products, medications, mail and other goods continue to be the object of tampering, whether to taint contents, alter freshness assurances, to gain valuable private and/or confidential information, or for some other purpose. In particular, product packaging is often damaged or compromised. One type of packaging that is particularly susceptible to tampering is that associated with pre-paid gift cards. As an example, it is a common practice in the pre-paid card sector to encode or otherwise load a card e.g., a generally rectangular plastic “wallet-sized” card, akin to a credit card) with a predetermined cash equivalent value. Upon payment by a consumer for the value on the card, the card can then be used to pay for transactions until the value on the card has been depleted. The cards may not necessarily be registered in the identity of a particular individual, and thus resemble cash, in the sense that it is difficult to trace transactions and correlate them with particular users of the cards. The relative anonymity of the resulting transactions thus makes pre-paid cards attractive theft targets. 
         [0003]    Security features are often employed in the packaging industry in an effort to deter theft and protect legitimate consumers. Unfortunately, many existing security features have been circumvented by individuals involved in retail theft. While many tamper-evident and theft-proof features have been developed, most are cost prohibitive given the low cost requirement for packaging, as the packaging must be provided to a consumer for essentially no cost as an enticement to seek goods or services from a particular retailer or service provider. In pre-paid card packaging, assuming that a consumer is going to purchase a card with a value of $25, the consumer will only expect to pay $25 for the card, with no additional charges. As a result, it has proven particularly challenging to develop security features that effectively prevent and deter theft at a very low cost point. 
         [0004]    A common theft issue with particular relevance to the pre-paid card industry includes the ability to remove a pre-paid card from a retail outlet without activating or purchasing the card. The account information can then be accessed and recorded and the card repackaged either in its original packaging or new packaging which can then be placed back onto a retail outlet shelf. Once the card is activated by a legitimate paying customer, the account information can be used to make purchases without the knowledge of the paying customer. For example, a wrongdoer may have taken a pre-paid card from a retail location, removed the card from its packaging, obtained the code associated with the card, and then carefully re-packaged the card so it appears unused, as if new. The wrongdoer will then enter into a transaction (e.g., on the internet, via mail order, or otherwise) in which the wrongdoer supplies the card code as means of payment. If and when the card is activated by the legitimate user, the transaction of the wrongdoer will be processed. The sophistication of the techniques of the wrongdoers has become so refined in recent years that re-packaging of cards into their original packaging commonly results in little or no evidence to a reasonably observant cashier that the card has been removed from the packing and subsequently repackaged. 
         [0005]    U.S. Pat. No. 5,777,305 discloses a packaging assembly that permits remote activation and deactivation of a pre-paid card without removing the card from the packaging. However, the teachings do not appear to address the difficulties in preventing an individual from stealing an unactivated card, removing the unactivated card from the packaging to record any necessary account numbers or codes from the card and placing the unactivated card back into the packaging and subsequently back on a store shelf. 
         [0006]    U.S. Pat. No. 5,667,247 discloses a card package assembly that includes an adhesive placed on an inner wall of the packaging to hold a card in place. However, the packaging does not appear to afford a simple and straightforward approach to determining whether tampering has occurred. 
         [0007]    U.S. Pat. No. 7,000,844 discloses a display packaging for gift cards that includes a personal identification number or “PIN” obscured by a removable covering. However, one of the problems sought to be addressed by the present teachings does not appear to be solved by teachings of that patent, inasmuch as the disclosure of the patent makes it possible to re-cover the PIN to create the appearance that no tampering has occurred. 
         [0008]    U.S. Patent Application Publication No. 2009/0107862 discloses a card and carrier system that shows damage to the carrier when the enclosed card is accessed. However, the card itself shows no indication of tampering and there is no means disclosed to prevent the carrier from being repaired with no indication of tampering. 
         [0009]    Notwithstanding the above, there remains a need for improved packaging that indicates tampering on a carrier so that the carrier cannot be repaired or reproduced with no tamper indication. There is a further need for packaging that includes substrates that are treated to seal about packaging contents so that the packaging cannot be easily recreated. There is a further need for packaging that includes substrates that are formed so that once the packaging is opened, a permanent indication of such opening is formed on the exterior of the packaging. More particularly, there continues to be a need for low-cost tamper-evident packaging that includes an external visual indicator of package damage and does not allow individuals to re-package and re-seal a pre-paid card after accessing and recording the necessary account information from the pre-paid card. 
       SUMMARY OF THE INVENTION 
       [0010]    The present invention addresses one or more of the above needs by providing improved tamper evident packaging and associated methods, in which a package encloses an object in a manner in which the object cannot be removed without substantially irreversibly disrupting an indicator of tampering. For example, the packaging may be formed by a method for forming a tamper evident packaging comprising providing one or more panel structures and one or more stretch film layers. The packaging may be formed by a multi-layer patterned structure. 
         [0011]    The present teachings contemplate a method including providing a first panel having an opening therein, the panel including a first surface and a second surface and locating a first stretch film layer onto the first surface of the first panel so that at least a portion of the first stretch film layer lies in direct planar contact with the first surface and at least a portion of the first stretch film layer covers the opening. The method may further include locating an item within the opening and onto the first stretch film layer so that at least a portion of the item lies in direct planar contact with the first stretch film layer. The method may then include locating a second stretch film layer onto the item so that at least a portion of the second stretch film layer lies in direct planar contact with the item and at least a portion of the second stretch film layer lies in direct planar contact with the first stretch film layer. A heat source may then be applied to the packaging to shrink and seal the first and second stretch film layers about the item. 
         [0012]    The teachings herein further provide for a method including providing a first panel having an opening therein, with the opening optionally extending onto at least a second panel, these panels including a first surface and a second surface, and locating at least a portion of a first stretch film layer onto the first surface of at least one panel so that at least a portion of the first stretch film layer lies in direct planar contact with the first surface and at least a portion of the first stretch film layer covers the opening. The first stretch film layer can also extend onto at least a second panel. Additional stretch film layers may also be used for each panel. The method may further include locating an item within the opening and onto the first stretch film layer so that at least a portion of the item lies in direct planar contact with the first stretch film layer and locating a second stretch film layer or the portion of the first stretch film layer extending onto the second panel onto the item so that the portion of the second stretch film layer or first stretch film layer extending onto the second panel lies in direct planar contact with the item. A heat source may then be applied to the packaging to shrink and seal the stretch film layers about the item. 
         [0013]    The method for forming the packaging may include applying an adhesive layer located between one or more panels and the first or second stretch film layer. An opening may be formed in the second panel so that the item can be viewed within the packaging. After heating, the first and second stretch film layers may not extend beyond any edge of the first and second panel. The item may be located so that it cannot be removed from an assembled packaging without rupturing a surface of the first or second stretch film layer. A third panel may be formed in the packaging. A magnetic stripe may be applied onto the second surface of the first panel. A magnetic stripe may be applied onto the second surface of the second panel. A magnetic stripe may be applied onto the second surface of the third panel. 
         [0014]    The teachings herein further contemplate a packaging comprising a first panel having an opening therein, the panel including a first surface and an opposing second surface. The packaging further includes a first stretch film layer applied onto the first surface of the first panel so that at least a portion of the first stretch film layer lies in direct planar contact with the first surface and at least a portion of the first stretch film layer covers the opening. The packaging may also include an item located within the opening and onto the first stretch film layer so that at least a portion of the item lies in direct planar contact with the first stretch film layer. A second stretch film layer may be applied onto the item so that at least a portion of the second stretch film layer lies in direct planar contact with the item and at least a portion of the second stretch film layer lies in direct planar contact with the first stretch film layer. A second panel may be located onto the second stretch film layer such that the second panel is in direct opposing relationship with the first panel but is not in direct contact with the first panel. 
         [0015]    The teachings herein also contemplate a method for forming a tamper evident packaging comprising die-cutting a first inner layer of a first panel of a packaging, wherein a second outer layer of the first panel remains uncut and die-cutting a first inner layer of a second panel of a packaging, wherein a second outer layer of the second panel remains uncut. An item may be located onto one of the first panel or second panel. The first panel and second panel may be adhered to one another so that the item is located in between the first panel and second panel. The die-cutting of the first inner layers may form a plurality of patterned cuts into the first inner layers. The die-cutting of the first inner layers may form a plurality of patterned cuts that extend to one or more terminal edges of the first layers. The first panel and second panel may be adhered to one another by an adhesive located along one or more terminal edges of the first panel, the second panel, or both. Upon opening an adhered packaging, an imprint of the die-cutting of the first inner layers may be visible upon one or more of the second outer layer. 
         [0016]    Among the various features of the teachings herein are that the layered structure may include at least two panels and at least one stretch film layer bonded to retain an item therein. An opening (e.g., a cut-out window) may be formed in one or more of the panels and the opening may be covered by the one or more stretch film layers. 
         [0017]    Advantageously, the packaging may be formed as a layered structure having one or more panel layers, one or more stretch film layers and one or more adhesive layers. The adhesion layer may be located between the one or more stretch film layers and one or more of the panels. The openings and the stretch film layer located across the openings may be free of any adhesive layer. 
         [0018]    Also contemplated within the scope of the teachings herein is a heating step that shrinks and seals the one or more stretch film layers. Thereafter, any removal of the item from the packaging will require rupture of one or more of the stretch film layers 
         [0019]    Among the various features of the teachings herein are that the layered structure may include at least two panels and each panel may be die-cut so that the panel is only partially cut (e.g., at least 30%, at least 40%, at least 50% or at least 60% through the panel) so that the cuts do not extend through to any external surface of each panel. The cuts extend deep enough into the panel so that the cuts are visible through the external surface of each panel once a previously sealed packaging has been opened. 
         [0020]    Advantageously, the packaging may be formed as a layered structure having one or more panel layers, each panel layer including an inner layer having a die-cut pattern formed thereon and an outer layer that lies in direct planar contact with the inner layer but is substantially free of any cuts. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]      FIG. 1  is a top down schematic view of an illustrative packaging in accordance with the present teachings. 
           [0022]      FIG. 2  is a perspective view of an illustrative packaging in accordance with the present teachings. 
           [0023]      FIG. 3  is a top down schematic view of an illustrative packaging in accordance with the present teachings. 
           [0024]      FIG. 4  is a perspective view of an illustrative packaging in accordance with the present teachings. 
           [0025]      FIG. 5  is a top down view of four illustrative packagings in accordance with the present teachings. 
       
    
    
     DETAILED DESCRIPTION 
       [0026]    The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present invention as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description. 
         [0027]    This application is related to and claims the benefit of the priority date of U.S. Provisional Application Ser. Nos.: 61/665,551 filed on Jun. 28, 2012; 61/618,273 filed Mar. 30, 2012; and 61/613,662 filed Mar. 21, 2011. The entirety of these applications are hereby incorporated by reference for all purposes. 
         [0028]    In general, the teachings herein provide for a packaging that includes at least one panel, one or more stretch film layers and an adhesive layer. The packaging may include at least two panels. One or more of the at least one panels may include an opening therein. The film layers may have first and second surfaces and may be at least partially transparent and overlaying the opening in the at least one panel so that a first surface of the film layer opposes the one or more panels. The teachings herein further provide for a packaging that includes at least two panels, each having a die-cut layer and an uncut layer. Each of the layers may include a first surface and, a second surface such that the second surfaces of each of the die-cut layer and the uncut layer may lie in direct planar contact with one another. 
         [0029]    As shown for example in  FIGS. 1 and 2 , the packaging  10  may include a first panel  12 , a second panel  14 , a first stretch film layer  16  and a second stretch film layer  18 . The first panel  12  and second panel  14  may include a first opening  20  and a second opening  22 , respectively. An adhesive layer  24  may be located between each stretch film layer and panel. However, the adhesive layer may extend only to the edges  26  of the panels. Thus, the first opening  20  and second opening  22  may be substantially free of any adhesive layer. As depicted in  FIG. 2 , an item  28  may be located in between the first stretch film layer  16  and second stretch film layer (not visible in  FIG. 2 ). 
         [0030]    As shown for example in  FIGS. 3 and 4 , the packaging  10  may include a first panel  12 , a second panel  14 , and a third panel  30 . It is contemplated that at least one stretch film layer may cover at least a portion of at least one panel. In this illustrative packaging  10 , there is a first stretch film layer  16  that covers at least a portion of all three panels. The first panel  12  and a second panel  14  may include a first opening  20  that extends over both the first panel  12  and the second panel  14 . An adhesive layer  24  may be located between each stretch film layer and panel. However, the adhesive layer  24  may extend only to the edges  26  of the panels. Thus, the first opening  20  may be substantially free of any adhesive layer. As depicted in  FIG. 4 , an item  28  may be located in between the first stretch film layer  16 . As shown in  FIG. 3 , a third panel  30  may have an attached magnetic stripe  32  for use with a credit card reader. 
         [0031]    As shown for example in  FIG. 5 , the packaging  34  may include a first panel  38 , and a second panel  40 . Each of the first and second panel may include a first inner layer  36  having a plurality of die-cut patterns  42  formed thereon. Each panel may also include a second outer layer (not shown) that opposes and lies in direct planar contact with each of the first inner layers  36 . The die-cut patterns  42  are cut only through each of the first inner layers  36  as shown, but do not extend through the second outer layer (not shown). An item (not shown) may be located onto one of the first inner layers  36  and the opposing panel  38  or  40  may be located over the item so that the openings  44  of each of the first panel  38  and second panel  40  are substantially aligned with one another. The first panel  38  and second panel  40  may then be adhered to one another along one or more terminal edges  46  of one or both of the first and second panels. 
         [0032]    The packaging may be assembled by providing a first planar panel having a first inner layer and a second outer layer, the first inner layer having a die-cut pattern formed thereon. An adhesive or other means of attachment may then be placed in contact with the first inner layer of the first panel and may preferably be located only along one or more edge portions so that an adhesive-free area exists within the first inner layer of the first panel for locating an item for packaging thereon. The item for packaging may then be located onto the first inner layer of the first panel. A second panel having a first inner layer and a second outer layer may then be located onto and covering at least a portion of the item and the first inner layer of the first panel. The second panel may also include a plurality of die-cut patterns formed onto the first inner layer of the second panel. However, the second panel may also be free of any die-cut portions. When located onto the first panel, at least a portion of the first inner layer of the second panel may be located in direct planar contact with at least a portion of the first inner layer of the first panel. 
         [0033]    One embodiment of the packaging may be assembled by providing a first planar panel having an opening. A first adhesion layer may then be placed in contact with the first panel. The adhesion layer may include a film or adhesive deadener so that only the portion of the first panel that is adjacent to the opening (as opposed to the opening itself) is contacted by a material that causes adherence. A first stretch film layer may then be placed in contact with the first adhesion layer so that the film layer covers the opening and adheres to the portion of the first panel adjacent the opening. An item may be then be located in contact with the first stretch film layer and a second stretch film layer may be located over the item and opposing the first stretch film layer, such that a portion of the first and second stretch film layers may be in direct planar contact with one another. A second adhesion layer may then be deposited onto the second stretch film layer. (e.g., on the surface of the second stretch film layer opposite the surface that contacts the first stretch film layer). A second planar panel may then be placed in planar contact with the second adhesion layer and/or second stretch film layer. 
         [0034]    Another embodiment of the packaging may be assembled by providing a first planar panel connected with a second planar panel having an opening extending over both panels. An adhesion layer may then be placed in contact with the first and second panels. The adhesion layer may include a film or adhesive deadener so that only the portions of the first and second panels adjacent to the opening (as opposed to the opening itself) are contacted by a material that causes adherence. A stretch film layer may then be placed in contact with the adhesion layer so that the stretch film layer covers the opening and adheres to the portion of the first and second panels adjacent the opening. An item may then be located in contact with the stretch film layer adhered to the first panel. The stretch film layer adhered to the second panel and the second panel can be located over the item, opposing the stretch film layer adhered to the first panel (e.g., by folding the second panel over the first panel), such that the item is in direct contact with the stretch film layer on at least two sides. The first and second panels and the stretch film layer adhered to each may be in direct planar contact with one another. A third planar panel may then be placed in planar contact with the second planar panel for additional support. 
         [0035]    A magnetic stripe may be applied to an outer side of the packaging. One or more panels of the packaging may have a portion cut away (e.g., at the bottom of the panel) to reduce the thickness of the packaging so the magnetic stripe can fit within a credit card reader. 
         [0036]    The item located within the packaging may be a planar retail item. As an example, the item may be pre-paid card such as a gift card, ATM card, phone card or the like. The item may be substantially free of any contact with an adhesive layer. The item may be located in direct planar contact with both the first and second stretch film layers. During a heat-shrinking process, the item is preferably sealed in between the first and second stretch film layers. Thus, any attempt to remove the item from between the stretch film layers will require tearing or some disruption of the continuity of one or more of the stretch film layers. It is this disruption of the stretch film layers that may be indicative of tampering with the packaging. 
         [0037]    The stretch film layers may be any material that provides sufficient transparency to view the item, while functioning to seal about an item located within the packaging during application of heat or another sealing stimulus. The film layer may be a plastic (e.g., a thermoplastic) film and preferably comprises polyvinyl chloride. Other suitable plastic films that may be used include nylon, polypropylene, high-density polyethylene, low-density polyethylene, linear low-density polyethylene, polyvinylidene chloride and combinations thereof. The film layers may be any material with sufficient transparency for viewing packaging contents through an opening in a panel of the packaging. 
         [0038]    The adhesion layers may also include one or more adhesives for adhering at least a portion of the panels and film layers to one another. The adhesive may be capable of adhering to multiple types of substrates, including suitable substrates used for the panels and film layers. The adhesives may form a strong enough bond between one or more layers so that the layers are maintained within or attached to the packaging. Suitable adhesives may include synthetic adhesives such as polymeric (e.g., thermoplastic, elastomeric, emulsion or thermosetting) adhesives. The adhesive may also include a bioadhesive such as starch, casein or albumin based adhesives. The adhesive may also include a UV curing adhesive. The adhesive may be a pressure sensitive adhesive such as a fugitive adhesive. 
         [0039]    The panels discussed herein may be any packaging material pliable enough to be scored and folded but strong enough to provide sufficient support for containing an item thereon or within. A particular feature of the material may be that it is durable enough to resist tearing during attempts to remove any packaging contents from within the panels (e.g., to separate the packaging contents from the film layer that is adhered to the panel). The panels may be formed of paper materials including but not limited to paperboard, chipboard, cardboard, fiberboard, natural fibers, mineral fibers or any combination thereof. The panel material may be a virgin material, a post-consumer recycled material, or both. The panel material may be a recyclable material and/or a biodegradable material. If the panel material includes paperboard, the paperboard may be a bleached or unbleached paperboard. For example it may be a solid bleached sulfate (SBS) paperboard. The panel material may contain a major portion that can be recycled. The panels may be formed of a polymeric material including but not limited to thermoplastics, thermoset plastics, elastomeric containing materials or any combination thereof. Examples of polymeric materials that may be employed include polyamide, polyester, polystyrene, polyethylene (including polyethylene terephthlate, high density polyethylene and low density polyethylene), polypropylene, polyvinyl chloride, bio-based plastics/biopolymers (e.g., poly lactic acid), silicone, acrylonitrile butadiene styrene (ABS), or any combination thereof. 
         [0040]    The gauge of the panel material may vary depending on the size of the packaging or the desired strength of the packaging. As an example, if the panel material includes paperboard, the gauge of the paperboard may be greater than about 6 point paperboard. The gauge of the paperboard may be less than about 22 point paperboard. 
         [0041]    The item located within the packaging may include at least one generally planar surface. In the case of the pre-paid card example, the item may generally be a polymeric material as is common with pre-paid cards. The item may be composed of materials similar to those disclosed for use in the panels such as paperboard materials. 
         [0042]    Though not necessarily drawn to scale, geometries, relative proportions and dimensions shown in the drawings are also part of the teachings herein, even if not explicitly recited. However, unless otherwise stated, nothing shall limit the teachings herein to the geometries, relative proportions and dimensions shown in the drawing. 
         [0043]    Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. Plural structural components can be provided by a single integrated structure. Alternatively, a single integrated structure might be divided into separate plural components. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. 
         [0044]    The preferred embodiment of the present invention has been disclosed. A person of ordinary skill in the art would realize however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention. 
         [0045]    The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present invention as set forth are not intended as being exhaustive or limiting of the invention. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.