Abstract:
A tamper-resistant plastic package having a plastic sleeve with at least one open end into which a product carrier tray, also made of plastic, can be inserted into sliding and interlocking engagement with the sleeve. The sleeve desirably comprises a continuous side wall having sufficient length and cross-sectional area to receive the product carrier tray into sliding engagement therewith. The product carrier tray is preferably thermoformed from another plastic sheet made of the same or a different plastic material. The plastic sheets used to make the sleeve and product carrier tray each preferably further comprise one or more structural elements, as described in greater detail below, that cooperate to provide a mechanical interlock when the product carrier tray is fully inserted into the sleeve.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    This invention relates to plastic packages and, more particularly, to plastic display packages having a sleeve formed from a die-cut plastic sheet, and a thermoformed product carrier tray that is insertable into sliding and interlocking engagement with the sleeve. 
         [0003]    2. Description of Related Art 
         [0004]    In recent years, tamper-resistant clamshell display packages have become widely used in the retail marketing of consumer goods. So-called “big box” retailers favor use of the packages because they facilitate display in tray-packs or case-packs and significantly reduce shrinkage attributable to shoplifting, pilfering and employee theft. Conventional clamshell packages are typically thermoformed from transparent PVC resin and have two halves that are hinged and can be folded together and sealed after inserting one or more products into recesses formed in one or both sides of the clamshell. Display cards with appropriate graphics or instructions are typically inserted into the packages before they are sealed. Because the PVC is tough and durable, and because the edge closures are typically bonded together by an RF seal, clamshell packages are extremely difficult to open without destroying the package. 
         [0005]    Disadvantages of the conventional clamshell packages to manufacturers include the facts that they are expensive to make, are relatively heavy, are not recyclable, and making the RF seal needed to produce the “destruction bond” consumes time and energy. Consumers, particularly children and senior citizens, are frustrated by conventional clamshell packages because they are extremely difficult, if not impossible, to open following purchase, invite injury from accidental use of sharp or pointed tools needed to access the products, present a disposal problem in that they are neither easily handled nor recyclable. Because clamshell packages typically have irregular thicknesses and tend to have relatively sharp edges, they are also difficult to gift-wrap when the subject products are purchased as gifts. 
         [0006]    More recently, applicant has disclosed in a co-pending application fully recyclable, tamper-resistant packaging in which a product is displayed inside a full-thickness recess in a folded inner box that is insertable into a substantially transparent, plastic outer box, which outer box is then sealed with a destruction bond seal. The use of a transparent, thermoformed tray to support the product within a recess in the inner box is also disclosed. 
         [0007]    Notwithstanding the advantages and benefits achievable through use of such prior art packages, however, there remains a need for rigid, tamper-resistant packages that can be easily and inexpensively fabricated from die-cut plastic sheet material in which products can be attractively and visibly displayed, and that are resistant to theft or pilfering of the contained products without the need for a destruction bond seal. 
       SUMMARY OF THE INVENTION 
       [0008]    According to a preferred embodiment of the invention, plastic packages for displaying products are disclosed that comprise a plastic sleeve having at least one open end into which a product carrier tray, also made of plastic, can be inserted into sliding and interlocking engagement with the sleeve. The sleeve is preferably formed by folding and joining opposed side portions of a single rigid plastic sheet to create a continuous side wall having sufficient length and cross-sectional area to receive the product carrier tray into sliding engagement therewith. The product carrier tray is preferably thermoformed (sometimes referred to as vacuum-formed) from another rigid plastic sheet made of the same or a different rigid plastic material. The plastic sheets used to make the sleeve and product carrier tray, respectively, each preferably further comprise one or more structural elements, as described in greater detail below, that cooperate to provide a mechanical interlock when the product carrier tray is fully inserted into the sleeve. 
         [0009]    As used herein, the terms “rigid plastic” or “rigid sheet” refers to plastic sheet material, typically cut from rolls formed from extruded webs of thermoplastic resin, that can be die-cut, scored, folded, thermoformed, and taped or glued, for example, to make packaging components such as the sleeve and product carrier tray identified above. Although said to be “rigid,” the sleeves and product carrier trays disclosed herein are understood to be flexible when subjected to manually applied pressure. Such “rigid plastics” or “rigid sheets” are to be distinguished and differentiated, however, from web rolls of flexible, thin-film plastics such as those commonly used to make products like stretch wrap, shrink wrap or over-wrap, even when made from the same polymeric resins as the “rigid sheets,” and also from injection molded plastic packages such as CD and DVD cases. Plastic resins that can be used in making the packages of the invention include, for example, polyethylene terephthalate (PET), amorphous polyethylene terephthalate (APET), polyvinyl chloride (PVC), polylactic acid (PLA), polypropylene (PP), polystyrene (PS) and high density polyethylene (HDPE), all of which are well known to those of skill in the art. 
         [0010]    According to a particularly preferred embodiment of the invention, the product carrier tray further comprises at least one end portion adapted to close each open end of the sleeve when the product carrier tray is fully inserted into interlocking engagement with the sleeve. The product carrier tray can also be made with at least one hinge member that enables a portion of the tray to be folded back against itself prior to insertion into the sleeve to form the package of the invention. Preferred structures for use as mechanical interlocks between the sleeves and product carrier trays in the packages of the invention include, for example, 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The apparatus of the invention is further described and explained in relation to the following drawings wherein: 
           [0012]      FIG. 1  is a front perspective view of a preferred embodiment of the tamper-resistant display package of the invention; 
           [0013]      FIG. 2  is an exploded front perspective view showing the tamper-resistant package of  FIG. 1  prior to insertion of the product carrier tray into the sleeve; 
           [0014]      FIG. 3  is a top plan view of the die-cut sheet used to make the sleeve of  FIG. 2 ; 
           [0015]      FIG. 4  is a simplified end view in which the die-cut sheet of  FIG. 3  is partially assembled; 
           [0016]      FIG. 5  is a simplified end view of the sleeve of  FIG. 2 ; 
           [0017]      FIG. 6  is an enlarged front view of the product carrier tray as in  FIG. 2 ; 
           [0018]      FIG. 7  is an enlarged, cross-sectional elevation view of the product carrier tray, taken along line  7 - 7  of  FIG. 6 ; 
           [0019]      FIG. 8  is a front perspective view of another preferred embodiment of the tamper-resistant package of the invention; 
           [0020]      FIG. 9  is an exploded front perspective view showing the tamper-resistant package of  FIG. 8  prior to insertion of the product carrier tray into the sleeve; 
           [0021]      FIG. 10  is a top plan view of the die-cut sheet used to make the sleeve of  FIG. 9 ; 
           [0022]      FIG. 11  is a simplified end view in which the die-cut sheet of  FIG. 10  is partially assembled; 
           [0023]      FIG. 12  is a simplified end view of the sleeve of  FIG. 9 ; 
           [0024]      FIG. 13  is a front perspective view of the product carrier tray as in  FIG. 9 ; 
           [0025]      FIG. 14  is an enlarged, cross-sectional side elevation view of the product carrier tray, taken along line  14 - 14  of  FIG. 13 ; 
           [0026]      FIG. 15  is a front perspective view of another preferred embodiment of the tamper-resistant package of the invention; 
           [0027]      FIG. 16  is an exploded front perspective view showing the tamper-resistant package of  FIG. 15  prior to insertion of the product carrier tray into the sleeve; 
           [0028]      FIG. 17  is a top plan view of the die-cut sheet used to make the sleeve of  FIG. 16 ; 
           [0029]      FIG. 18  is a simplified end view in which the die-cut sheet of  FIG. 17  is partially assembled; 
           [0030]      FIG. 19  is a simplified end view of the sleeve of  FIG. 16 ; 
           [0031]      FIG. 20  is a right side elevation view of the product carrier tray as in  FIG. 16 ; 
           [0032]      FIG. 21  is a rear perspective view of the product carrier tray of  FIG. 16 ; and 
           [0033]      FIG. 22  is a rear perspective view of the product carrier tray as in  FIG. 21  but showing the two halves unfolded around the longitudinally extending hinge disposed between them. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0034]    Three different principal embodiments of the invention are further described and explained below, although it should be appreciated that these three embodiments are merely illustrative, and not limiting, as to the many package configurations that can be made within the scope of the invention. The subject packages are preferably transparent, either clear or tinted, to facilitate viewing of a product contained inside, although will be apparent to those of skill in the art upon reading this disclosure that such packages can also comprise printed images and graphics, holographic images, opaque wall sections, and the like. 
         [0035]    One preferred embodiment of the package of the invention is further described and explained in relation to  FIGS. 1-7 . Referring to  FIGS. 1 and 2 , package  10  comprises sleeve  12  and at least one product carrier tray  14 . The length, thickness and cross-sectional configuration of sleeve  12  and product carrier tray  14  are preferably such that product carrier tray  14  is slidably insertable into sleeve  12 . Sleeve  12  and product carrier tray  14  are each preferably made from a rigid, die-cut sheet of the same or a different plastic. Plastic resins useful for making either sleeve  12  or product carrier tray  14  include polyethylene terephthalate (PET), amorphous polyethylene terephthalate (APET), polyvinyl chloride (PVC), polylactic acid (PLA), polypropylene (PP), polystyrene (PS) and high density polyethylene (HDPE), and other similarly effective polymeric materials that are well known to those of skill in the art. Sleeve  12  and product carrier tray  14  preferably each comprise at least one structural element that is useful for establishing a mechanical interlock between the two parts whenever product carrier tray  14  is fully seated inside sleeve  12 . 
         [0036]    As used herein, the term “mechanical interlock” refers to a structural relationship in which at least one structural element of either sleeve  12  or product carrier tray  14  abuts against or is blocked by at least one cooperating structural element of the other part to prevent the product carrier tray  14  from being easily disengaged from sleeve  12  without the use of tools or without otherwise deforming package  10 . The nature of the mechanical interlock is preferably such that product carrier tray  14  can be easily inserted inside sleeve  12 , and, when fully inserted, a portion of the sleeve or tray is biased into an engagement with the other that cannot thereafter be disengaged or defeated simply by reversing the direction of travel of the tray relative to the sleeve. In the embodiment of  FIGS. 1-7 , the mechanical interlock occurs between projection  34   
         [0037]      FIGS. 3-5  disclose how sleeve  12  is formed from a die-cut plastic sheet. Referring to  FIG. 3 , the sheet used to form sleeve  12  preferably comprises sidewall panel sections  20 ,  22  that, when folded about fold line  28 , cooperate to form a substantially continuous sidewall for package  10  of  FIG. 1 . Flap  18 , connected to sidewall panel section  20  at fold line  26 , preferably comprises window  16  that cooperates with a projecting structure on the product carrier tray  14 , as discussed below, to form a mechanical interlock with product carrier tray  14 . Tabs  17 ,  19  opposite slot  21  and indention  23 , respectively, are preferably provided to allow clearance around the end portions without causing window  16  of flap  18  to disengage from projection  34  as disclosed below. Flap  24 , provided for use in securing sleeve  12  in a closed position, is connected to sidewall panel section  22  at fold line  30 .  FIG. 4  depicts an intermediate stage in the assembly of sleeve  12 , wherein sidewall panel sections  20 ,  22  have been flexed around fold line  28 , and wherein flap  18  has been folded inwardly around fold line  26 . Flap  24  is preferably folded inwardly toward sidewall panel section  22  around fold line  30 .  FIG. 5  depicts an end view of sleeve  12  when fully assembled, with flap  24  being secured in facing engagement to that portion of inwardly folded flap  18  that is adjacent to fold line  26 . Flap  24  is preferably secured to flap  18  by any commercially available adhesive well known to those of skill in the art to be suitable for use in permanently securing two facing and contacting surfaces made of the particular polymeric resin selected for use as sleeve  12 . 
         [0038]    It should be appreciated that the cross-section depicted in  FIG. 5  is simply one of many different configurations in which packages  10  of the invention can be made. One advantage of this particular configuration is that the curvature of sidewall panel sections  20 ,  22  serve as guides to position the free end of flap  18  just inwardly of the apex formed by fold line  28 , thereby adding more rigidity to sleeve  12 . By holding flap  18  in position relative to sidewall panel sections  20 ,  22  in this manner, sleeve  12  causes window  16  as shown in  FIG. 3  to be biased into engagement with cooperating projection  34  of product carrier tray, as shown in  FIG. 7 . 
         [0039]    Product carrier tray  14  and the mechanical interlock between sleeve  12  and product carrier tray  14  are further described and explained in relation to  FIGS. 6  and  7 . Product carrier tray  14  is preferably thermoformed from a rigid plastic sheet  33 , and further comprises a product cavity  32 , projection  34 , and end portions  36 ,  38  and  40 . End portion  40  is preferably connected to end portion  38  by hinge  42  and is foldable around hinge  42  as indicated by arrow  44  to provide a closer fit inside sleeve  12 . As will be apparent from  FIG. 7 , product cavity  32  desirably has sufficient depth and an appropriate configuration to enable a product to be held in a preferred alignment within package  10  during shipment and display. Cavity  32  does not, however, have to be sufficiently deep to hold the entire product, as clearance between cavity  32  and the surrounding sleeve  12  is also provided by the projection of end portions  36 ,  38  beyond sheet  33 . As shown in  FIGS. 6 and 7 , cavity  32  has a configuration that conforms to a product in the form of tube. It is understood, however, that cavity  32  can be similarly made to conform to other products having an infinite number of other configurations and sizes as desired. As product carrier tray  14  is inserted into sleeve  12 , as described above, projection  34  of the tray is biased into engagement with window  16  of sleeve  12 , thereby preventing tray  14  from being easily removed from sleeve  12 . Although it is not shown in  FIGS. 1-7 , a tear strip such as tear strip  60  described in relation to the embodiment of  FIGS. 9 and 10  below can also be provided in sleeve  12  of this embodiment to facilitate entry into package  10  by the consumer following purchase. 
         [0040]    Another preferred package  50  of the invention is described and explained in relation to  FIGS. 8-14 . Package  50  preferably comprises plastic sleeve  52  and product carrier tray  54 , both of which are preferably fabricated using methods and materials as disclosed above for sleeve  12  and product carrier tray  14  of package  10 . Product carrier tray  54  is slidably insertable into sleeve  52  to form package  50 , and, when fully seated inside sleeve  52 , is held in place by a mechanical interlock formed between die-cut tab  56  on product carrier tray  54  and elongate slot  58  inside sleeve  52 . Referring particularly to  FIGS. 9 and 10 , sleeve  52  further comprises a tear strip  60  that can be easily removed by a purchaser to disengage tab  56  from slot  58  and thereby facilitate removal of a product from package  50  prior to use. 
         [0041]      FIGS. 10-12  disclose how sleeve  52  is formed from a die-cut plastic sheet. Referring to  FIG. 10 , the sheet used to form sleeve  52  preferably comprises sidewall panel sections  62 ,  64  that, when folded about fold line  72 , cooperate to form a substantially continuous sidewall for package  50  of  FIG. 8 . Flaps  66 ,  68 ,  70 , connected to sidewall panel section  64  by fold lines  74 ,  76 ,  78 , respectively, are provided to facilitate sealing sidewall panel sections  62 ,  64  together on the side opposite fold line  72 . Elongate slot  58  is desirably formed along fold line  78 , and cooperates with projecting tab  56  on product carrier tray  52  (as shown in  FIGS. 8 and 9 ) to form a mechanical interlock similar to that previously discussed in relation to window  16  and projection  34  of package  10 . 
         [0042]      FIG. 11  depicts an intermediate stage in the assembly of sleeve  52  wherein sidewall panel sections  62 ,  64  are flexed around fold line  72 , and wherein flaps  66 ,  68 ,  70  have been sequentially folded in alternating directions around fold lines  74 ,  76  and  78 , respectively. When flap  68  is folded downwardly from the position shown in  FIG. 11  into facing engagement against flap  66 , as shown in  FIG. 12 , flap  70  is drawn into facing engagement with the inside surface of sidewall panel  64 , where it can be adhered to panel  64  by means of tape, adhesive, heat sealing or any other conventional attachment means suitable for use with such materials and package configurations. When the outwardly facing side of flap  66  is then pressed into facing engagement with the inside surface of the free end portion of sidewall panel section  62  and adhered thereto by the same or similarly effective means, flaps  66 ,  68  and  70  cooperate to form a bracket attaching the otherwise open ends of side panels  62 ,  64  in close proximity while simultaneously positioning elongate slot  58  in such manner that it can receive tab  56  when product carrier tray  54  is inserted into and fully seated inside sleeve  52  as shown in  FIG. 8 .  FIG. 12  depicts an end view of sleeve  52  when fully assembled. 
         [0043]    Product carrier tray  54  and the mechanical interlock between sleeve  52  and product carrier tray  54  are further described and explained in relation to  FIGS. 13 and 14 . Product carrier tray  54  is preferably thermoformed from a rigid plastic sheet  80 , and further comprises a product cavity defined by recess  82 , and end portions  84 ,  86 ,  88  and  90 . End portion  88  is preferably connected to end portion  84  by hinge  92  and is foldable around hinge  92  as indicated by arrow  96  to provide a closer fit when inserted into sleeve  52 . As will be apparent from  FIG. 14 , product cavity  32  desirably has sufficient depth and an appropriate configuration to enable a product to be held in a preferred alignment within package  50  during shipment and display. The product cavity does not, however, have to be sufficiently deep to hold the entire product, as clearance between the product cavity and the surrounding sleeve  54  is also provided by the outward projection of paired end portions  84 ,  88  and  86 ,  90 , respectively, beyond sheet  80 . As with cavity  32  shown in  FIGS. 6 and 7 , it is understood that the product cavity in product carrier tray  54  of package  50  can be similarly made to conform to other products having an infinite number of other configurations and sizes as desired. As product carrier tray  54  is inserted into sleeve  52 , as described above, projection  56  of the tray is biased into engagement with elongate slot  58  of sleeve  52 , thereby preventing tray  54  from being easily removed from sleeve  52 . 
         [0044]    Another preferred package  100  of the invention is described and explained in relation to  FIGS. 15-22 . Package  100  preferably comprises plastic sleeve  102  and product carrier tray  104 , both of which are preferably fabricated using methods and materials as disclosed above for sleeves  12 ,  52  and product carrier trays  14 ,  54  of packages  10 ,  50 . Product carrier tray  104  is slidably insertable into sleeve  102  to form package  100 , and, when fully seated inside sleeve  102 , is held in place by a mechanical interlock formed between die-cut flap  112  of sleeve  102  and end portions  130 ,  132  of product carrier tray  104  when tray  104  is fully seated inside sleeve  102 . Referring particularly to  FIGS. 9 and 10 , sleeve  102  can further comprises a tear strip  60  that can be easily removed by a purchaser to expand sleeve  102  and thereby disengage flap  112  from between end portions  130 ,  132  to facilitate removal of a product from package  100  prior to use. 
         [0045]      FIGS. 17-19  disclose how sleeve  102  is formed from a die-cut plastic sheet. Referring to  FIG. 17 , the sheet used to form sleeve  102  preferably comprises sidewall panel sections  106 ,  108  that, when folded about fold line  116 , cooperate to form a substantially continuous sidewall for package  100  of  FIG. 15 . Flap  105 , connected to sidewall panel  106  at fold line  114 , and flap  110 , connected to sidewall panel  108  at fold line  118 , are provided to facilitate sealing sidewall panels  106 ,  108  together on the side opposite fold line  116 . Flap  112 , connected to flap  110  at fold line  120 , is provided for use in achieving a mechanical interlock with product carrier tray  104 . 
         [0046]      FIG. 18  depicts an intermediate stage in the assembly of sleeve  102  wherein sidewall panel sections  106 ,  108  are flexed around fold line  116  and wherein flaps  110 ,  112  are folded around fold line  118 .  FIG. 19  depicts an end view of sleeve  102  when fully assembled, with flap  105  being secured in facing engagement to that portion of inwardly folded flap  110  that is adjacent to fold line  118 . Flap  24  is preferably secured to flap  18  by any commercially available adhesive well known to those of skill in the art to be suitable for use in permanently securing two facing and contacting surfaces made of the particular polymeric resin selected for use as sleeve  12 . 
         [0047]    Product carrier tray  104  is further described and explained in relation to  FIGS. 20-22 . Product carrier tray  104  is preferably thermoformed from a rigid plastic sheet, and is similar to product carrier trays  14 ,  54  described above except that tray  104  comprises two thermoformed sheet portions  126 ,  128  joined by longitudinal hinge  146 . The two sheet portions each further comprise centrally disposed product cavity sections  158 ,  160 , respectively, that cooperate to form an enclosure for the packaged product. Each sheet portion also comprises longitudinally spaced, laterally projecting end portions  130 ,  132  and  134 ,  136 , respectively. When a product is inserted into one of the two product cavities  158 ,  160 , sheet portions  126 ,  128  are folded together at hinge  146 , causing projecting bosses  138 ,  140  to enter and frictionally engage receptacles  142 ,  144 , thereby holding the two sheet portions in facing and contacting engagement to confine a product inside the space defined by combined cavities  158 ,  160 . Package  100  ( FIG. 15 ) is then assembled by inserting product carrier tray  104  into sleeve  102 . Flap  112  is pressed against an inside wall of sleeve  102  as the end portions on the leading end of product carrier tray  14  are inserted into the sleeve. When product carrier tray  104  is fully seated inside sleeve  102 , flap  112  of sleeve  102  drops into position between the longitudinally spaced end portions on one side of tray  104 , thereby creating a mechanical interlock that prevents tray  104  from being conveniently removed from sleeve  102  by moving tray  104  in a direction opposite to the direction of insertion. 
         [0048]    Other alterations and modifications of the invention will likewise become apparent to those of ordinary skill in the art upon reading this specification in view of the accompanying drawings, and it is intended that the scope of the invention disclosed herein be limited only by the broadest interpretation of the appended claims to which the inventors are legally entitled.