Abstract:
A multi-layered blister package and assembling method include a blister sheet having a blisters for containing a product therein and an opposing cover surface adjacent to blister openings. The package also includes a front sheet having apertures configured to receive the blisters and a back sheet coupled to at least a portion of the front sheet. The back sheet includes an inner back panel foldably connected to an outer back panel. The inner and outer back panels each include removable tabs each covering an access slot. The tabs and access slots of the inner and outer back panels are in alignment when the inner back panel is folded adjacent to the outer back panel. The cover surface of the blister sheet is positioned adjacent to the inner back panel such that each blister opening is in alignment with the tabs and access slots of the inner and outer back panels.

Description:
BACKGROUND OF THE INVENTION 
   This invention relates generally to a blister card package for packaging a product and more particularly, to a multi-layered blister card package and method of making the same. 
   At least some known packages used for packaging products such as, but not limited to, tablets, capsules, and other similar products include blister cards to facilitate retaining, dispensing, concealing, transporting, and/or securing the products contained therein. At least some known push-through type blister card packages appear to include child-resistant, senior friendly, and tamperproof features. Although the known blister card packages may appear to share all of the above features, there often exits at least some negative tradeoff between such features. 
   For example, at least some known blister card packages may require greater human dexterity and strength to dispense the products. As a result, such known blister card packages may be more tamperproof and/or may provide greater safety for children by inhibiting access to the products contained therein. Therefore, accidental ingesting of the products by children may be restricted. Further, the products contained in such know blister card packages may be more easily dispensable by adults. However, such products may also be difficult to access by a senior citizen because of a lack of strength required to dispense the product. 
   Alternatively, at least some known blister card packages may require less strength to dispense the products. As a result, such known blister card packages may provide greater simplicity for adults and seniors by allowing easier dispensing of the products contained therein. Further, the products provided in such known blister card packages may be more easily dispensed by seniors. However, such products may be less tamperproof and/or easily accessed by children that have the strength required to dispense the product. Therefore, such known blister card packages provide less safety for children. 
   BRIEF DESCRIPTION OF THE INVENTION 
   In one aspect, a multi-layered blister package is provided. The multi-layered blister package includes a blister sheet having a plurality of blisters for containing a product therein and an opposing cover surface. Each blister includes an opening adjacent to the cover surface. The multi-layered blister package also includes a front sheet having a plurality of apertures configured to receive the plurality of blisters on the blister sheet. Further, the multi-layered package includes a back sheet coupled to at least a portion of the front sheet. The back sheet includes an inner back panel foldably connected to an outer back panel. The inner and outer back panels each include a plurality of removable tabs each covering an access slot. The tabs and access slots of the inner back panel are in alignment with the tabs and access slots of the outer back panel when the inner back panel is folded adjacent to the outer back panel. The cover surface of the blister sheet is positioned adjacent to the inner back panel such that each blister opening is in alignment with the tabs and access slots of the inner back panel and the tabs and access slots of the outer back panel. 
   In another aspect, a back sheet is provided. The back sheet includes an outer back panel and an inner back panel foldably connected to the outer back panel. The inner and outer back panels each include a plurality of removable tabs each covering an access slot. The tabs and access slots of the inner back panel are in alignment with the tabs and access slots of the outer back panel when the inner back panel is folded adjacent to the outer back panel. 
   In another aspect, a method for assembling a multi-layered blister package is provided. The method includes providing a blister sheet having a plurality of blisters for containing a product therein and an opposing cover surface. Each blister includes an opening adjacent to the cover surface. The method also includes providing a front sheet having a plurality of apertures and receiving the plurality of blisters on the blister sheet in the apertures. Further, the method includes coupling a back sheet to at least a portion of the front sheet. The back sheet including an inner back panel foldably connected to an outer back panel. Further, the method includes providing each of the inner and outer back panels with a plurality of removable tabs each covering an access slot, folding the inner back panel adjacent to the outer back panel to align the tabs and access slots of the inner back panel with the tabs and access slots of the outer back panel, and positioning the cover surface of the blister sheet adjacent to the inner back panel such that each blister opening is in alignment with the tabs and access slots of the inner back panel and the tabs and access slots of the outer back panel. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of an exemplary embodiment of a multi-layered blister package in a partially opened position; 
       FIG. 2  is a plan view of an exemplary embodiment of a front sheet of the exemplary multi-layered blister package shown in  FIG. 1 ; 
       FIG. 3  is a plan view of a first exemplary embodiment of a back sheet of the exemplary multi-layered blister package shown in  FIG. 1 ; and 
       FIG. 4  is a plan view of an alternative exemplary embodiment of a back sheet of the exemplary multi-layered blister package shown in  FIG. 1 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The exemplary systems and methods described herein overcome the structural disadvantages of known blister packages by facilitating a balancing of child-resistant, senior friendly and tamperproof features. 
   Various exemplary details are described herein, with reference to the  FIGS. 1-4 , wherein like numerals refer to like parts. 
   It should be appreciated that “horizontal” and “horizontally” is used throughout this application to refer to directions and orientations extending from the left to the right of the page, and vice versa, for the ease of understanding. 
   It should be appreciated that “vertical” and “vertically” is used throughout the application to refer to directions and orientations extending from the bottom to the top of the page, and vice versa, for the ease of understanding. It should also be appreciated that “vertical” and “vertically” is used to reference directions and orientations substantially perpendicular to the “horizontal” and “horizontally” disposed features. 
     FIG. 1  illustrates a perspective view of an exemplary multi-layered blister package  1  in a partially opened position. As shown in  FIG. 1 , the blister package  1  includes at least the following layers: a blister sheet  20 , a front sheet  100 , and a back sheet  190  having a flap  195 . Each layer of the blister package  1  is described in greater detail hereinafter. 
   The blister sheet  20  may be fabricated from a substantially transparent plastic material. The blister sheet  20  includes a plurality of protruding blisters  24  including a closed end and an opened end (not shown). The blisters  24  are linearly aligned in a vertical column. Each blister  24  is a receptacle such as, but not limited to, a cup and a pocket that may receive a product therein. The opened end of the blister  24  may be sealed off by a reinforcing layer such as, but not limited to, a foil layer (not shown). As a result, the product may be retained and subsequently dispensed from the blister package  1  by depressing the respective blister  24  of the blister sheet  20  so that the product may puncture through the foil layer. In a fully assembled position of the blister package  1 , the blister sheet  20  is positioned between the front sheet  100  and the back sheet  190 . 
   In one exemplary embodiment, the blister sheet  20  is fabricated from a substantially transparent depressible plastic material. However, it should be appreciated that the blister sheet  20  may also be fabricated from any suitable material known to those skilled in the art and guided by the provided teachings, and therefore is not limited to a specific type of material. 
     FIG. 2  illustrates a plan view of an exemplary front sheet  100  of blister package  1  (shown in  FIG. 1 ). As shown in  FIG. 2 , the front sheet  100  may be fabricated from a substantially planar blank of a substantially paperboard material. The front sheet  100  may include a plurality of panels connected to each other and aligned in a horizontal direction with a plurality of fold lines dividing the panels. 
   The panels include a first panel  110 , a central second panel  120 , and a third panel  130 . Each of the panels  110 ,  120 ,  130  of the front sheet  100  is separated from another panel by at least one substantially vertical fold line  140 . The first and third panels  110 ,  130  are positioned adjacent to opposing end portions of the second panel  120 . 
   The second panel  120  includes a plurality of spaced apertures  124  that are linearly aligned in a vertical column. Each aperture  124  is sized to receive a respective blister  24 . Providing the blister receiving apertures  124  in the central second panel  120  is preferable because such panel is centrally positioned to help facilitate protecting the blisters  24  from being tampered with and/or accidentally depressed. Also, the central placement of the blisters  24  helps to restrict children from accessing the product contained therein as compared to edge placed blisters that may be more easily accessed by children. 
   Although the second panel  120  is described as including the blister receiving apertures  124 , it should be appreciated that a plurality of blister receiving apertures may alternatively or additionally be provided in the first and/or the third panels  110 ,  130 . 
   In one exemplary embodiment, the front sheet of the blister package is fabricated from a substantially paperboard material. However, it should be appreciated that the front sheet may be fabricated from any suitable material such as, but not limited to cardboard, corrugated board, plastic and/or any suitable material known to those skilled in the art and guided by the provided teachings. Therefore, the front sheet is not limited to a specific type of material provided that the material facilitates folding along the fold lines where such folding has been described. 
     FIG. 3  illustrates a plan view of a first embodiment of a back sheet  200  of blister package  1  (shown in  FIG. 1 ). As shown in  FIG. 3 , the back sheet  200  may be fabricated from a substantially planar blank made substantially of paperboard material. The back sheet  200  may include a plurality of panels connected to one another and a plurality of fold lines dividing the panels. 
   The back sheet  200  includes a plurality of panels  210 ,  220 ,  230  linearly aligned in a horizontal direction and a vertically extending flap  250 . The panels include a first panel  210 , a central second panel  220 , and a third panel  230 . Each of the panels  210 ,  220 ,  230  of the back sheet  200  is separated from another panel by at least one substantially vertical fold line  240 . The first and third panels  210 ,  230  are positioned adjacent to opposing end portions of the second panel  220 . 
   The second panel  220  includes a plurality of connecting tabs  222 , a plurality of spaced tabs  224 , and a plurality of notches  226 . The connecting tabs  222  are linearly aligned in a first vertical column. The spaced tabs  224  are linearly aligned in an adjacent second vertical column. 
   Each connecting tab  222  is a perforated tear away area that is defined by a respective partially surrounding perforation  223 . Each connecting tab  222  includes a protruding top end  222   a  and a recessed bottom end  222   b . The connecting tabs  222  are disposed so that the top end  222   a  of one connecting tab  222  may be removably coupled to the bottom end  222   b  of an adjacent connecting tab  222 . Therefore, adjacent connecting tabs  222  contact and border each other at coinciding perforations  223 . As a result, each of the connecting tabs  222  form a linearly aligned first vertical column of the continuously disposed connecting tabs in which each connecting tab  222  may be individually removed. 
   The top end  222   a  of a topmost connecting tab  222  is not removably coupled to another connecting tab  222 . Instead, a plurality of notches  226  is provided adjacent to such top end  222   a  to facilitate individual removal of the topmost tab  222  from the back sheet  200 . The bottom end  222   b  of each tab  222  is removably coupled to an adjacent spaced tab  224  that is located in the second vertical column. 
   Each spaced tab  224  is a perforated tear away area that is defined by a respective surrounding perforation  225 . Each spaced tabs  224  is substantially a same size as the blister respective receiving aperture  124 . Each spaced tab  224  includes a side end  224   a  and an opposing side end  224   b . The spaced tabs  224  are disposed so that the side end  224   a  of each respective spaced tab  224  is removably coupled to the bottom end  222   b  of an adjacent tab  222 . Therefore, the side end  224   a  of a single spaced tab  224  contacts and borders the bottom end  222   b  of a single adjacent tab  222  at coinciding perforations  223 ,  225 . 
   A single spaced tab  224  and a single adjacent tab  222  contact each other to form a horizontally aligned row of tabs. However, each of the spaced tabs  224  are spaced from or do not contact an adjacent spaced tab  224 . Although the spaced tabs  224  are not connected with respect to each other, the spaced tabs  224  are aligned and register with a plurality of spaced tabs provided on the vertically extending flap  250 . 
   The vertically extending flap  250  vertically extends and is separated from the second panel  220  by a horizontal fold line  260 . The vertically extending flap  250  includes a plurality of spaced reinforcing tabs  254  that are vertically aligned and register with the spaced tabs  224  provided on the second panel  220 . 
   Each reinforcing tab  254  is a perforated tear away area that is defined by a respective surrounding perforation  255 . Each reinforcing tab  254  includes a body  256  and an engagement portion  257  that each borders a tab fold line  258 . The reinforcing tabs  254  are substantially a same size as the spaced tabs  224 . Therefore, the reinforcing tabs  254  provide an additional tear away tab sandwiched between the back sheet  200  and the blister sheet  20  with the foil layer. 
   As a result, the vertically extending flap  250  may facilitate mounting and alignment of the blister sheet  20  and the foil layer during assembly. Additionally, the reinforcing tabs  254  provide additional product dispensing barriers that are child-resistant, senior friendly, and tamperproof. Further, the vertically extending flap  250  and the reinforcing tabs  254  facilitate prevention of an accidental depression of the blisters  24  causing accidental dispensing of a product contained therein. 
   In one exemplary embodiment, the back sheet of the blister package is fabricated from a substantially paperboard material. However, it should be appreciated that the back sheet may be fabricated from any suitable material such as, but not limited to cardboard, corrugated board, plastic and/or any suitable material known to those skilled in the art and guided by the provided teachings. Therefore, the back sheet is not limited to a specific type of material provided that the material facilitates folding along the fold lines where such folding has been described. 
     FIG. 4  illustrates a plan view of an alternative embodiment of a back sheet  300  of blister package  1  (shown in  FIG. 1 ). As shown in  FIG. 4 , the back sheet  300  may be fabricated from a substantially planar blank made substantially of paperboard material. The back sheet  300  may include a plurality of panels connected to one another and a plurality of fold lines dividing the panels 
   The back sheet  300  includes a plurality of panels  310 ,  320 ,  330  linearly aligned in a horizontal direction and a vertically extending flap  350 . The panels include a first panel  310 , a central second panel  320 , and a third panel  330 . Each of the panels  310 ,  320 ,  330  of the back sheet  300  is separated from another panel by at least one substantially vertical fold line  340 . The first and third panels  310 ,  330  are positioned adjacent to opposing end portions of the second panel  320 . 
   The second panel  320  includes a plurality of connecting tabs  322 , a plurality of spaced tabs  324 , and a plurality of notches  326 . The connecting tabs  322  are linearly aligned in a first vertical column. The spaced tabs  324  are linearly aligned in an adjacent second vertical column. 
   Each connecting tab  322  is a perforated tear away area that is defined by a respective surrounding perforation  323 . Each connecting tab  322  includes a protruding top end  322   a  and a recessed bottom end  322   b . The connecting tabs  322  are disposed so that the top end  322   a  of one connecting tab  322  may be removably coupled to the bottom end  322   b  of an adjacent tab  322 . Therefore, adjacent tabs  322  contact and border each other at coinciding perforations  323 . As a result, each of the connecting tabs  322  forms a linearly aligned first vertical column of the continuously disposed connecting tabs in which each connecting tab  322  may be individually removed. 
   The top end  322   a  of a topmost tab  322  is not removably coupled to another tab  322 . Instead, a plurality of notches  326  is provided adjacent to such top end  322   a  to facilitate individual removal of the topmost tab  322  from the back sheet  300 . The bottom ends  322   b  of each tab  322  is removably coupled to an adjacent spaced tab  324  that is located in the second vertical column. 
   Each spaced tab  324  is a perforated tear away area that is defined by a respective surrounding perforation  325 . Each spaced tabs  324  is substantially a same size as the respective blister receiving aperture  124 . Each spaced tab  324  includes a side end  324   a  and an opposing side end  324   b . The spaced tabs  324  are also disposed so that the side end  324   a  of each respective spaced tab  324  is removably coupled to the bottom end  322   b  of an adjacent tab  322 . Therefore, the side end  324   a  of a single spaced tab  324  contacts and borders the bottom end  322   b  of a single adjacent tab  322  at coinciding perforations  323 ,  325 . 
   A single spaced tab  324  and a single adjacent tab  322  contact each other to form a horizontally aligned row of tabs. However, each of the spaced tabs  324  are spaced from or do not contact an adjacent spaced tab  324 . Although the spaced tabs  324  are not connected with respect to each other, the spaced tabs  324  are aligned and register with a plurality of spaced tabs provided on the vertically extending flap  350 . 
   The vertically extending flap  350  vertically extends and is separated from the second panel  320  by a horizontal fold line  360 . The vertically extending flap  350  includes a plurality of spaced reinforcing tabs  354  that are vertically aligned and register with the spaced tabs  324  provided on the second panel  320 . Each reinforcing tab  354  is a perforated tear away area that is defined by a respective bordering perforation  355 . 
   Similar to the exemplary embodiment shown in  FIG. 3 , each reinforcing tab  354  includes a body  356  having opposing side edge  354   a ,  354   b . However, instead of a grip edge, each reinforcing tab  354  is also defined by a continuous elongated access aperture  358  having a length L that spans the side edges  354   b  of all reinforcing tabs  354 . Therefore, the reinforcing tabs  354  provide an additional tear away tab sandwiched between the back sheet  300  and the blister sheet  20  with the foil layer. 
   As a result, the vertically extending flap  350  may facilitate mounting and alignment of the blister sheet  20  and the foil layer during assembly. Additionally, the reinforcing tabs  354  provide additional product dispensing barriers that are child-resistant, senior friendly, and tamperproof. an additional tear away tab sandwiched between the back sheet  300  and the blister sheet  20  with the foil layer. Further, the vertically extending flap  350  and the reinforcing tabs  354  facilitate prevention of an accidental depression of the blisters  24  causing accidental dispensing of a product contained therein. 
   In one exemplary embodiment, the back sheet of the blister package is fabricated from a substantially paperboard material. However, it should be appreciated that the back sheet may be fabricated from any suitable material such as, but not limited to cardboard, corrugated board, plastic and/or any suitable material known to those skilled in the art and guided by the provided teachings. Therefore, the back sheet is not limited to a specific type of material provided that the material facilitates folding along the fold lines where such folding has been described. 
   An exemplary method of assembling the blister package and an exemplary method of removing a product from an assembled blister package are described below. 
   To assemble the blister package  1 , the spaced blisters  24  of the blister sheet  20  may be aligned with and positioned in the apertures  124  that are provided in the second panel  120  of the front sheet  100 . The blister sheet  20  may be fixed to the second panel  120  in such an aligned position. Prior to or after the blisters  24  are positioned in the respective apertures  124 , products may be placed in the blisters  24 . Subsequently, the foil layer may be fixed to the blister sheet  20  to cover the opened ends of the blisters  24  to seal the products within the blisters  24 . The front sheet  100  and the blister sheet  20  may then be fixed to the back sheet  200 ,  300 . 
   Prior to fixing the back sheet  200 ,  300 , the vertically extending flap  250 ,  350  is folded about a horizontal fold line  260 ,  360  onto the second panel  220 ,  320  of the back sheet  200 ,  300 . As a result, the spaced reinforcing tabs  254 ,  354  of the vertically extending flap  250 ,  350  are aligned and registered with the spaced tabs  224 ,  324  of the second panel  220 ,  320  of the back sheet  200 ,  300 . In this folded flap position, the back sheet  200 ,  300  is fixed to the blister sheet  20  and the front sheet  100  so that the reinforcing tabs  254 ,  354  and the spaced tabs  224 ,  324  register with the respective aperture  124  of the second panel  220 ,  320  of the front sheet  100 . The first and third panels  110 ,  130  may then be folded onto the second panel  120  along the vertical fold line  140  in a fully folded position to protect the centrally located second panel  120 . 
   To remove a product from the blister package  1 , respective tabs are removed to facilitate access to a cavity of the blister  24 . For example, the protruding top end  222   a ,  322   a  of the topmost tab  222 ,  322  may be engaged by accessing the notches  226 ,  326  to tear away the topmost tab  222 ,  322  along the perforations  223 ,  323 . After the topmost tab  222 ,  322  is removed, an access slot is provided to facilitate access to the respective adjacent spaced tab  224 ,  324 . The side end portion  224   a ,  324   a  of the spaced tab  224 ,  324  may then be engaged by accessing the opening to tear away the spaced tab  224 ,  324 . After the adjacent spaced tab  224 ,  324  is removed, a second access slot is provided to facilitate access to the respective registered/aligned reinforcing tab  254 ,  354 . 
   If the reinforcing tab  254  includes the body  256  and the engagement portion  257 , then the engagement portion  257  of the reinforcing tab  254  may be engaged by accessing the second opening to tear away the reinforcing tab  254  along the perforations  255 . If the reinforcing tab  354  is adjacent to the connecting elongated access aperture  358 , then the side edge  354   b  of the body  356  of the reinforcing tab  354  may be engaged by accessing the second opening to tear away the reinforcing tab  354  along the perforations  355 . 
   Once the respective tabs are removed, the closed ends of the blisters  24  are depressed. As a result of removal of the tabs and a pressing force, the product may puncture through the foil layer to release the product from the blister package  1 . 
   Although the blisters  24  described above have not been specifically described, it should be appreciated that any type of size, shape, and/or material such as, but limited to a small oval transparent plastic blister, may be used provided that the blister facilitates retaining and dispensing of a contained product where such retaining and dispensing has been described. 
   It should also be appreciated that the front sheet  100 , the blister sheet  20 , the underlying foil layer, the flap  250 ,  350 , and the horizontal panels of the back sheet  200 ,  300  may be fixedly joined together by any suitable means such as, but limited to, an adhesive. 
   It should also be appreciated that the vertical and horizontal fold lines discussed above may be any weakened line such as, but not limited to, a score line and a perforated line, that may be formed by any conventional technique. 
   While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.