Abstract:
A display card ( 200 ) including a front layer ( 230 ) and a back layer ( 210 ), wherein at least a portion of the front layer ( 230 ) is connected to at least a portion of the back layer ( 210 ), a blister ( 220 ) supported by at least one of the front layer ( 230 ) and the back layer ( 210 ), and at least one support tube ( 240 ) defined by the front layer ( 230 ) and the back layer ( 210 ), wherein the support tube is formed by folding the front layer ( 230 ) relative to the back layer ( 210 ).

Description:
[0001]    The present application claims priority from U.S. Ser. No. 60/864,815 filed on Nov. 8, 2006, the entire contents of which are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    Display cards are often used to show merchandise in a store environment. Display cards are typically made from sheet material such as paperboard where the card thickness may range from about 0.012 to 0.037 inches, as compared with greater thicknesses typically characterized by corrugated packaging materials. To provide structural support or stability or stacking strength, display cards may be placed in an outer shipping case or tray. Another way to provide stacking strength is to enclose a display card, product, or carded product, within a plastic clamshell that is designed to support a load. 
       SUMMARY 
       [0003]    In one aspect, the disclosed card structure may include a front layer and a back layer, wherein at least a portion of the front layer is connected to at least a portion of the back layer, a blister supported by at least one of the front layer and the back layer, and at least one support tube defined by the front layer and the back layer, wherein the support tube is formed by folding the front layer relative to the back layer. 
         [0004]    In another aspect, the disclosed card structure may include a front panel having an inner surface and an outer surface, a back panel having an inner surface and an outer surface, wherein at least a portion of the inner surface of the front panel is connected to at least a portion of the inner surface of the back panel, a blister supported by the front panel and/or the back panel, and at least one support tube defined by folding the front panel relative to the back panel, wherein the inner surface of the front panel is spaced apart from the inner surface of the back panel at the support tube. 
         [0005]    Other aspects of the disclosed card structures for enhanced stacking strength will become apparent from the following description, the accompanying drawings and the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  shows in perspective view an unassembled display card; 
           [0007]      FIG. 2  shows in perspective view the assembled display card of  FIG. 1 ; 
           [0008]      FIG. 3  shows in perspective view a display card having support tubes; 
           [0009]      FIG. 4  shows a partial front view of unassembled panels of another display card; 
           [0010]      FIG. 5  shows a top view of the assembled display card of  FIG. 4 ; 
           [0011]      FIG. 6  shows a partial front view of unassembled panels of another display card; 
           [0012]      FIG. 7  shows a perspective view from the upper left of the assembled display card of  FIG. 6 ; 
           [0013]      FIG. 8  shows a partial front view of unassembled panels of another display card; 
           [0014]      FIG. 9  shows a perspective view from the upper left of the assembled display card of  FIG. 8 ; 
           [0015]      FIG. 10  shows a perspective view of an assembled display card having means for retaining support tubes in an open configuration; 
           [0016]      FIG. 11  shows a plan view of a blank from which another display card may be formed; 
           [0017]      FIG. 12  shows a perspective view of the partially assembled display card formed from the blank of  FIG. 11 , having means for retaining support tubes in an open configuration; and 
           [0018]      FIGS. 13 to 15  show perspective views of additional structure shapes that may be incorporated. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    Display card structures are disclosed that provide stacking strength and stability. In certain embodiments, the display card structures are made using sheet materials such as paperboard, for example in thickness ranges between about 0.012 to 0.037 inches. In some embodiments, the display card structures may incorporate theft resistance, for example through use of tear-resistant paperboard such as MeadWestvaco&#39;s ENDURANCE® brand paperboard. 
         [0020]      FIG. 1  is a perspective view of a display card  100 , shown in an unassembled state. A back panel  110  is shown, for example a rectangular piece of paperboard. A blister  120  is provided, for example a formed piece of transparent plastic, forming a cavity in which to hold an object, and also having peripheral edges  125 . A front panel  130  is shown, for example a rectangular piece of paperboard, also having a cutout area  135  through which the cavity portion of blister  120  may protrude. The cavity portion of blister  120  may also protrude through an optional cutout area  115  in the back panel  110 . 
         [0021]      FIG. 2  is a perspective view of the display card  100 , shown in an assembled state. Typically this assembled state is achieved by placing an object in the blister  120 , then sandwiching the blister  120  between the back panel  110  and front panel  130 , with the periphery  125  of the blister captured between the two panels. The panels may be sealed together by any one of a variety of methods, for example by adhesive or heat sealing or by RF sealing. The back panel  110  and front panel  130  may be separate pieces, or they may be formed from one piece, joined at an edge. 
         [0022]    Display card  100  as shown in  FIG. 2  will not easily stand upright on a display shelf. Instead, several of the display cards may typically be placed in an outer package such as a corrugated carton, with at least one of its sides or top open for access to the display cards. If the outer package is to be stacked, then the front of the outer package may have an opening from which to remove the display cards. 
         [0023]    Even when held in an outer carton, display card  100  may fall from an upright orientation as the outer carton becomes empty. This may be undesirable as the product becomes harder to see. Further, display card  100  does not provide much vertical strength for support when several outer cartons are stacked on top of one another. 
         [0024]    Display cards are disclosed here with additional features added to improve the stacking strength of the card. The stacking features can be made using variety of methods that ultimately result in the creation of a tube or hollow beam, which is capable of supporting a load that is greater than what the card could support on its own. In one embodiment, where a substrate such as MeadWestvaco ENDURANCE® brand paperboard is used, these structural tubes may be created during the heat sealing process at same time that the product is being sealed into the card. In cases where the card does not include a heat sealable coating, like standard solid bleached sulfate (SBS), coated natural kraft (CNK), and laminates including VALERON® brand laminate (Illinois Tool Works, Inc.), the cards can be glued using a variety of hot and cold adhesives, epoxies, tapes, etc. 
         [0025]    In its basic form, the card may be constructed using two panels, either connected at any one edge or detached. The front panel and/or back panel may be made to hold a blister, typically by means of an aperture. The front card and back card may be scored such that when sealed together, a tube or beam may be erected on or near one or both vertical edges of the card. 
         [0026]      FIG. 3  shows a display card  200  in an embodiment according to the present disclosure. Support tubes  240  are provided by the design of display card  200 , for example, by folding back panel  210  and front panel  230 . In the embodiment shown in  FIG. 3 , side portions  212  of the back panel may be folded forward along score or fold line  211 . The front panel  230  may have several folds, creating subpanels  232 ,  234 , and  236  by means of score or fold lines  231 ,  233 , and  235 . At least some areas of the central portions of back panel  210  and front panel  230  may be attached to one another by, for example, adhesive or heat sealing. This helps to give some strength to the display card, and serves to contain the blister  220 . Also, the subpanels  236  of the front panel may be attached to the side portions  212  of the back panel, thus forming the support tubes  240 . However, subpanels  232  and  234  need not be provided with any adhesive or heat seal material, since they do not attach to the back panel. 
         [0027]    In another embodiment, a blister may be attached to the front or back panel without the use of an aperture in the panel. 
         [0028]    A reinforcement brace  245 , such as a strip of paperboard, is shown partly inserted into support tube  240 , to help retain the channel in an optional configuration. The reinforcement brace may be retained by adhesive or other suitable means. Typically. the support tubes may exhibit a certain amount of spring back to their starting positions—this spring back will create a force that will hold the reinforcement brace in place; however, tabs, slots, and other devices may be added to the reinforcement brace with corresponding features added to the cards, to help keep the reinforcement brace more permanently in place. For example, one or more tabs in the reinforcement brace may fit into one or more slots in the card or panels proximate to the support tube. 
         [0029]    Display card  200  may be formed from a separate back panel  210  and front panel  230 , or these panels may be formed from one piece, joined at an edge.  FIGS. 4 and 5  further illustrate the construction of display card  200 , in an embodiment where back panel  210  and front panel  230  start as separate pieces.  FIG. 4  is a frontal, partial view of each panel as flat blanks while separated, and  FIG. 5  is a top view of the two panels joined together in a folded configuration. The blister  220  is not shown in these FIGS. but is understood that the finished display card may comprise a blister. 
         [0030]    At least a portion of the central part of front panel  230  is attached to the central part of back panel  210 . Also front subpanels  236  are attached to the outer parts of side portions  212 . Attachment may be for example by an adhesive or melt seal. It will be noted that some areas of the center of back panel  210 , and some areas of side portions  212 , need not have any adhesive or melt seal material. Also front subpanels  232  and  234  need not have any adhesive or melt seal material. By appropriately folding along lines  211 ,  231 ,  233 , and  235 , the completed display card  200  may be formed, as earlier shown in  FIG. 3 . Support tubes  240  are incorporated into the display card, and the support tubes may contain reinforcement braces  245 . 
         [0031]    It can thus be seen that the embodiment in  FIGS. 3 to 5  represents an example of a display card that easily converts from a generally flat assembly into a standing structure with additional stacking strength. The flat assembly may be converted to the standing structure by bending the vertical edges forward. 
         [0032]      FIGS. 6 and 7  show another embodiment as display card  300 , formed in this example from a separate back panel  310  and front panel  330 , although these panels may be formed from one piece, joined at an edge.  FIG. 6  is a frontal, partial view of each panel as flat blanks while separated, and  FIG. 7  is a high-angle top view perspective view of the two panels joined together in a folded configuration. A blister is not shown in these FIGS. but is understood that at least one of the front panel  330  and back panel  310  may be formed with an aperture and the finished display card may comprise a blister. In another embodiment, a blister may be attached to the front or back panel without use of an aperture. 
         [0033]    At least a portion of the central part of front panel  330  is attached to the central part of back panel  310 . Also front subpanels  336  are attached to rear subpanels  316 . Attachment may be for example by an adhesive or melt seal. It will be noted that center of back panel  310 , and center of front panel  330 , need not be sealed together over their entire area, although they may be sealed together over at least a portion of their area. Front subpanels  332 ,  334  and rear subpanels  312 ,  314  need not have any adhesive or melt seal material. By appropriately folding along lines  311 ,  313 ,  315 ,  331 ,  333 , and  335 , the completed display card  300  may be formed, as shown in  FIG. 7 . For example, the flat assembly may be converted into a standing assembly by pressing inward on the vertical edges of the card. Support tubes  340  are incorporated into the display card, and the support tubes may contain reinforcement braces  345 . 
         [0034]      FIGS. 8 and 9  show yet another embodiment as display card  400 , formed in this example from a separate back panel  410  and front panel  430 , although these panels may be formed from one piece, joined at an edge.  FIG. 8  is a frontal, partial view of each panel as flat blanks while separated, and  FIG. 9  is a high-angle top view perspective view of the two panels joined together in a folded configuration. A blister is not shown in these FIGS. but is understood that at least one of the front panel  430  and back panel  410  may be formed with an aperture and the finished display card may comprise a blister. In another embodiment, a blister may be attached to the front or back panel without use of an aperture. 
         [0035]    At least a portion of the central part of front panel  430  is attached to the central part of back panel  410 . Also front subpanels  436  are attached to rear subpanels  416 . Attachment may be for example by an adhesive or melt seal. It will be noted that center of back panel  410 , and center of front panel  430 , need not be sealed together over their entire area, although they may be sealed together over at least a portion of their area. Front subpanels  432 ,  434  and rear subpanels  412 ,  414  need not have any adhesive or melt seal material. By appropriately folding along lines  411 ,  413 ,  415 ,  431 ,  433 , and  435 , the completed display card  400  may be formed, as shown in  FIG. 9 . For example, the flat assembly may be converted into a standing assembly by pressing inward on the vertical edges of the card. Support tubes  440  are incorporated into the display card, and the support tubes may contain reinforcement braces  445 . 
         [0036]      FIG. 10  shows a display card  500  in an embodiment according to the present disclosure. This display card is in some respects similar to display card  200  of  FIG. 3 , and therefore not all details will be described. Support tubes  550  are provided by the design of display card  500 . Portions of support tubes  550  may be provided with cut lines and fold lines, for example cut line  552  and fold line  554 , which in this example define areas x and y in the support tube. Here, in the lower part of the support tube, cut line  552  is shown separated slightly as would occur when an inward force is directed against areas x and y. In the upper part of the support tube, the areas x and y are shown having been pushed into the support tube, to act as braces to prevent the support tube from flattening. A reinforcement  560  such as a piece of paperboard may also be used to help keep areas x and y in a bracing position. 
         [0037]      FIG. 11  shows a plan view of front blank  610  and back blank  620  suitable for making a display card  600  shown in  FIG. 12 . Front blank  610  comprises a center panel  605 , with side panels  601 ,  602 ,  603 , and  604  to one side, and corresponding side panels  606 ,  607 ,  608 , and  609  to the other side. The center panel  605  may have an aperture  615  to receive a blister. Hanging apertures  618 ,  628  may likewise be provided. 
         [0038]    Within certain of the side panels, cut lines  632  may be provided to form a vee-shaped cut defining one or more triangular shaped flaps  640 . A catch tab  634  may be provided in the cut line  632 . A slot  630  may also be provided as shown. 
         [0039]      FIG. 12  shows a back view of a display card  600  partially constructed from the front blank  610  and back blank  620 . As a step in this process, the side panels  607 ,  608 ,  609  may be folded over upon side panel  606  and center panel  605 , with side panel  609  being attached to center panel  605 , for example by adhesive. Side panels  601 ,  602 ,  603  may likewise be folded over upon side panel  604  and center panel  605 , with side panel  601  attached to center panel  605 . The partly assembled structure at this stage (not shown) may be a flat structure. At this point a blister may be placed in aperture  615 , and back blank  620  then attached to center panel  605 . 
         [0040]    By exerting an inward-directed force on side panels  603 ,  604 , the structure shown in  FIG. 12  may be obtained, with a support tube  650  formed in a triangular shape. Triangular shaped flap  640  may then be pushed into support tube  650 , and the catch tab  634  may engage slot  630 . The triangular shaped flap  640  may thus hold support tube  650  in an open configuration. 
         [0041]    In the example display card  600 , the blister (not shown) faces to the front and the support tubes face to the back of the structure. However, several different arrangements may be designed, with the blister facing either forward or backward, and the support tubes facing either forward or backward. The use of an aperture may be advantageous to capture the blister within the display structure. However, the display card may also be made without an aperture. 
         [0042]    Display cards  200 ,  300 ,  400 ,  500  and  600  are only examples of some possible embodiments. The display card may have other shapes or structures, such as are shown in  FIGS. 13 ,  14 , and  15 , with sketches of trays  700 ,  701 ,  702 ,  703 ,  704 ,  705 ,  706 ,  707 ,  708 ,  709 ,  710  as taken from “Paperboard Packaging: Ideas and Innovation, 2 nd  Edition”, by the Paperboard Packaging Council. It can be easily seen that the embodiments already described may also be realized in the shapes shown in  FIGS. 13 to 15 , which, whether glued, heat sealed, or otherwise assembled, ultimately create a support tube structure as described above. 
         [0043]    The card structures disclosed herein are able to stand, and to provide additional stacking strength above that of a standard flat card. In many distribution and sales environments, such as club stores, the ability to stack and display products without additional support structures, such as shelves, is highly desirable and in some cases mandated. A number of these structures also work well with existing fulfillment operations, allowing the additional support features to be incorporated at the time the product is packaged and adhered to the card. 
         [0044]    The shape, size, number, orientation, and location of the support tubes may be chosen to provide the desired amount of strength and stability. For example, the number and cross sectional area of a support tube or tube may be made large enough, and distributed appropriately, to support any expected stacking forces. The orientation, location, and size of support tubes may be chosen to enhance the standing stability of a display card; for example, if a blister of a certain size protrudes through the front of a display card, then it may be desired to have support tubes located to the left and right sides of the card, oriented generally on the front side of the card, and with a size and shape of sufficient cross sectional area to cause the display card containing the blister to be free-standing. For example, these characteristics may be met by the design of the display card  200  of  FIG. 3 . 
         [0045]    Methods of making and using the display card structures in accordance with the present disclosure should be readily apparent from the mere description as provided herein. No further discussion or illustration of such products or methods, therefore, is deemed necessary. 
         [0046]    While certain embodiments of the present disclosure have been described and illustrated, it should be apparent that many modifications to the disclosed embodiments and implementations may be made. The present application includes such modifications and is limited only by the scope of the claims. 
         [0047]    Although the disclosed embodiments illustrated herein have been described with reference to MeadWestvaco ENDURANCE® brand paperboard as a component of a theft resistant package, such as a MeadWestvaco NATRALOCK™ brand package, these embodiments may easily be implemented with the use of other materials, and are contemplated for use in packaging a wide variety of products including, but not limited to, pharmaceuticals, electronics, software, and other high value products for which theft resistance is required and product visibility is preferred.