Abstract:
A blister pack ( 10 ) includes a blister segment ( 12 ) and a tool (T 1 , T 2 ), both integrally formed with a tray (Y). The blister segment ( 12 ) has a blister bubble ( 14 ) at least partially surrounded by a blister flange (F). Substrate ( 16 ) serving as a gate ( 18 ) covers the opening of the blister bubble ( 14 ). The tool (T 1 , T 2 ) is adapted for puncturing the substrate gate ( 16/18 ) to gain access to the interior of the blister bubble ( 14 ). A blister segment ( 12 ) is configured and has reinforcing features ( 40, 34 ) so that it may serve as the tool (T 1 , T 2 ).

Description:
TECHNICAL FIELD 
       [0001]    This invention relates generally to blister packs and, more specifically, to blister packs including a tool for accessing an interior of a blister. 
       BACKGROUND OF THE INVENTION 
       [0002]    A blister pack is a type of package that protects one or more items or articles, by sealing the articles between a substantially planar substrate and a concave compartment structure. The concave compartment structure is typically referred to as a blister or a bubble. Blisters are typically formed of a plastic or foil type material and the substrate is frequently paper, foil, plastic, paperboard or a laminate of one or more of these materials. The encased article is typically accessed by pushing the article, from the bubble side of the blister pack, until the article breaks through the substrate. Frequently, the blister pack includes lines of demarcation that define each segment having an individual blister. Each line of demarcation may be a frangible line, such as a perforated line, that facilitates separation of a segment of a blister from the blister pack. 
         [0003]    A problem with blisters is that it is often difficult to push the product encased in the blister through the blister substrate. This problem can exist because the substrate is made particularly durable to maintain the freshness and efficacy of the encased product, or to inhibit removal of the encased product in order to increase the child-resistance rating. Thus, a need exists for a means for facilitating removal of an encased item or article from a blister. 
         [0004]    One solution has entailed using a tool, which is not packaged with the blister pack, to puncture or cut the substrate of a blister. However, a tool such as this is not always available in every environment. Further, the tool may have a cutting blade that is a hazard to users. Another solution is to include a cutting apparatus in, or as part of, the package that includes the blister pack. However, these cutting apparatuses are manufactured separately from the blister packs and the rest of the package, thereby adding to material and manufacturing costs. 
         [0005]    Although prior attempts to solve the problem of removing an encased article from its protective seal are known, there remains a need for a convenient and cost effective means for safely and efficiently penetrating the substrate or protective seal of a blister. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention overcomes the shortcomings of the prior art by providing a blister pack that includes at least one blister segment with substrate covering a blister bubble opening and at least one integral tool for penetrating the substrate of the blister segment. 
         [0007]    According to one aspect of the invention the tool is at least partially formed from a flanged portion of the blister pack. The blister pack includes a tray and a substrate. The flanged portion of the blister pack includes a substantially planar portion of the tray to which the substrate is attached. Lines of demarcation, including frangible lines and perforated lines, define the tool in the blister pack and facilitate detachment of the tool from the blister pack. 
         [0008]    According to another aspect of the invention, the tool comprises a reinforced region and a blade region for cutting and/or puncturing substrate material. The reinforced region reinforces the blade region such that the blade region can penetrate, puncture or cut the substrate of a blister without undue deformation that might limit the tool&#39;s effectiveness. In one facet of this aspect, the reinforced region is in the form of a raised member. In another facet of this aspect the raised member is offset from an edge of the tool. In an additional facet of this aspect, the raised member is proximate a cutting edge of the tool. 
         [0009]    According to still another aspect of the invention, the tool is at least partially formed from a flanged portion of the blister pack and reinforcement is provided by a folded-over tab structure. The reinforced region of the tool is formed by folding the tab structure of the flanged portion along a fold line. 
         [0010]    According to an additional aspect of the invention, the tool includes a blister bubble that defines the reinforced region. 
         [0011]    According to yet another aspect of the invention, a system is provided including a blister pack and a package. The blister pack includes at least one blister. A tool for penetrating the substrate of a blister of the blister pack is integral to the package. 
         [0012]    According to further aspect of the invention, a method for accessing an article in a blister in a blister pack is provided. The blister pack includes at least one blister and at least one tool. The method includes detaching a tool from the blister pack and using the tool to penetrate the substrate of a blister. 
         [0013]    Other systems, methods, features, and advantages of the present invention will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. All such additional systems, methods, features, and advantages are included within the scope of the present teaching and are protected by the accompanying claims. 
         [0014]    The foregoing has broadly outlined some of the aspects and features of the present invention, which should be construed to be merely illustrative of various potential applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by combining various aspects of the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIG. 1  is a perspective view of an exemplary embodiment of blister pack, according to the present invention. 
           [0016]      FIG. 2  is a plan view showing the blister pack of  FIG. 1 , according to the present invention. 
           [0017]      FIG. 3  is a perspective view showing the blister pack of  FIG. 1 , wherein an exemplary embodiment of a blister segment is being detached from the blister pack, according to the present invention. 
           [0018]      FIG. 4  is an elevation view showing the blister pack of  FIG. 1 , with an exemplary embodiment of a detached blister segment poised for use as an exemplary embodiment of a tool to puncture substrate over an opening of a selected blister bubble, according to the present invention. 
           [0019]      FIG. 5  is an elevation view similar to  FIG. 4 , showing the exemplary embodiment of the tool being used to puncture substrate over an opening of a selected blister bubble, according to the present invention. 
           [0020]      FIG. 6  is a perspective view of the blister pack of  FIG. 1  and tool in use as shown in  FIG. 5 , according to the present invention. 
           [0021]      FIG. 7  is a perspective view that is essentially the same view as  FIG. 6  but with a reinforcing tab corner folded in reverse of its position in  FIG. 6  and disposed on the side of the blister segment opposite the blister bubble, according to the present invention. 
           [0022]      FIGS. 8 and 9 , are related perspective views showing two steps (pre-puncturing and puncturing, respectively) in the use of an exemplary embodiment of a detached tool to open a detached blister segment, according to the present invention. 
           [0023]      FIG. 10  is a perspective view of an exemplary embodiment of a tool disposed beside an opened blister segment, according to the present invention. 
           [0024]      FIG. 11  is a perspective view of an exemplary embodiment of a tool using a blade portion that is proximate a reinforcing raised member to puncture substrate over a blister bubble opening of a blister segment, according to the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0025]    As required, detailed embodiments of the present invention are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms, and combinations thereof. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as an illustration, specimen, model, or pattern. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known components, systems, materials, or methods have not been described in detail in order to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. 
         [0026]    Referring now to the drawings, wherein like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of exemplary embodiments of a blister pack that includes at least one blister and at least one tool for penetrating the substrate of a selected blister. The tool includes a strengthening element that provides structural rigidity to the tool in general and to a penetrating corner of the tool in particular. 
         [0027]    To help distinguish the various elements of the invention, the term “blister bubble” will be used to refer to the cavity, blister, bubble or compartment to which access is sought through use of the tool. The term “blister segment” will be used to refer to the segment of the blister pack tray that may be separated from the tray itself. The blister segment comprises a blister bubble at least partially surrounded by a flange and having substrate covering the opening to the interior of the blister bubble. 
         [0028]    Referring first to  FIGS. 1 and 2 , an exemplary blister pack  10  is illustrated that includes multiple individual blister segments  12  (best shown in  FIG. 3 ). The blister pack  10  includes a tray Y that can be formed from a plastic type sheet to include cavities or bubbles  14 . The tray Y of the exemplary embodiment is a substantially planar structure having blister bubbles  14 . The size and shape of the bubbles  14  are design choices that are made such that one or more of an article can be disposed within a blister bubble  14 . The blister pack  10  also includes a planar substrate  16  (shown in  FIG. 7 ) that is formed from one or more layers of material. The substrate  16  may be paper, foil, plastic, paperboard or a laminate of one or more of these materials. The substrate  16  is attached to a substantially planar portion of the tray Y to cover the openings of the blister bubbles  14  and thereby enclose or seal articles within the blister bubbles  14 . 
         [0029]    The planar portion of the tray Y and the corresponding attached portion of the substrate  16  define a flanged portion F of the blister pack  10 , and of each blister segment  12 . Each portion of the substrate  16  that is disposed over the open end of a blister bubble  14  defines a gate  18  (shown in  FIG. 7 ). Each blister segment  12  is defined in the blister pack  10  by lines of demarcation  20 . 
         [0030]    Referring to  FIGS. 1 ,  2  and  3  simultaneously, the lines of demarcation  20  facilitate detachment of a single blister segment  12  from the blister pack  10 . For example, the lines of demarcation  20  may be frangible lines or perforated lines. In general, the lines of demarcation  20  may be typical weakened lines of severance. 
         [0031]    Referring now to  FIG. 3 , in an exemplary embodiment, the flanged portion F of each blister segment  12  includes a penetrating corner  32  and a folding corner  34 . The folding corner  34  is a tab at a corner of the blister segment  12  that is defined in part by a fold line  30 . The penetrating corner  32  and the folding corner  34  are defined in part by a common first edge E 1  and are further defined by an opposite edge E 2 , E 3 , respectively. 
         [0032]    An end of the fold line  30  that is adjacent to the penetrating corner  32 , or is otherwise adjacent to the first edge E 1 , is offset from the edge E 2  by a distance L 1 . Opposite ends of the fold line  30  are offset a distance L 2 , L 3  from the edges E 3 , E 1 , respectively. In the exemplary embodiment, the distances L 2 , L 3  are substantially the same. 
         [0033]    Referring to  FIGS. 5 and 6 , the folding corner  34  of the blister segment  12  is folded along fold line  30  and toward the blister bubble  14 . Alternatively, the folding corner  34  may be folded away from the blister bubble  14 , as shown in  FIGS. 7-10 . The folded corner  34  and the flanged portion F, which the folding corner  34  substantially overlaps, define a reinforced region R 1 . A blade region B 1  of the flanged portion F is defined between the reinforced region R 1  and the edges E 1 , E 2 . The blade region B 1  includes the penetrating corner  32 . 
         [0034]    The reinforced region R 1  increases the structural rigidity of the adjacent blade region B 1 , including the penetrating corner  32 , such that the blade region B 1  can withstand an increased applied force before substantially bending, buckling or otherwise deforming. Accordingly, the exemplary blister segment  12  can be used as a tool T 1  for penetrating the gate  18  of a selected blister segment  12 ′. The selected blister segment  12 ′ to be opened may be attached to the blister pack  10 , as shown in  FIGS. 4-7 , or may be detached from the blister pack  10 , as shown in  FIGS. 8 and 9 . 
         [0035]    To access articles that are sealed in a selected blister segment  12 ′, the penetrating corner  32  of the tool T 1  is forced through the gate  18  of the selected blister segment  12 ′, as shown in  FIG. 5 , thereby penetrating, or puncturing, the selected blister segment  12 ′. The edges E 1 , E 2  of the tool T 1  can be used to make and enlarge a cut C, as shown in  FIG. 7 , in order to facilitate access to the article. To access the encased article, the cut C may be made to facilitate tearing of the gate  18  as the article is pushed through it, to facilitate tearing gate  18  with a finger, or to create an opening that is large enough to allow a user to remove the article. 
         [0036]    Referring again to  FIGS. 1-4 , in an exemplary embodiment, each blister segment  12  (shown in  FIG. 3 ) includes a reinforcing bubble  40  that is disposed in a penetrating corner  42  of the flanged portion F. In this embodiment, reinforcing bubbles  40  are formed in the tray Y along with bubbles  14 . Each reinforcing bubble  40  can be any suitable size or shape such that it increases the effective thickness of the flanged portion F to provide a reinforced region. 
         [0037]    The reinforcing bubble  40  may be disposed such that it is offset from the edges E 2 , E 4 . A blade region B 2  (shown in  FIG. 3 ) of the flanged portion F is defined between the reinforcing bubble  40  and edges E 2 , E 4 . The reinforcing bubble  40  increases the structural rigidity of the blade region B 2 , including the penetrating corner  42 , such that the blister segment  12  can be used as a tool T 2  for penetrating the gate  18  of a selected blister segment  12 ′. 
         [0038]    Referring to now  FIG. 11 , the penetrating corner  42  of the tool T 2  is forced through the gate  18  of a selected blister segment  12 ′ thereby penetrating the selected blister segment  12 ′. Once the tool T 2  has punctured the blister to form a cut C, the tool T 2  can be used to propagate the cut C to facilitate access to the article. 
         [0039]    It should be noted that the reinforcing or structural element that provides the reinforced region is not limited to a reinforcing bubble  40  formed from the tray Y. Rather, the structural element may be a protuberance in the form of a rib, a raised element, or an element that is attached to the tray Y or substrate  16  to provide the same functionality. 
         [0040]    It should also be noted that the tools T 1 , T 2  do not have to be integral to a blister segment  12 , as described above. For example, the tool can be a flanged portion F of the blister pack  10 , defined by lines of demarcation  20 , or attached by a perforated edge. 
         [0041]    In additional alternative embodiments, the blister pack  10  is packaged in a carton (not shown). The carton includes a flap with a reinforcing or structural element, such as a fold line, such that the flap can be used as a tool for accessing a selected blister segment  12 ′. 
         [0042]    The law does not require and it is economically prohibitive to illustrate and teach every possible embodiment of the present claims. Hence, the above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims.