Abstract:
A method of packaging custom-printed business cards includes the steps of printing a quantity of business cards and dividing the quantity of business cards into a plurality subquantities of business cards. Each subquantity of business cards is inserted into an individual card chamber of an individual blister pack and substantially sealed. The blister pack is substantially sealed by applying a backing to the blister pack. The blister pack is self dispensing eliminating the need for a separate business card holder.

Description:
FIELD OF THE INVENTION  
       [0001]     The invention relates generally to the handling of printed materials. More particularly, the invention relates to the modularized packaging, storing and dispensing of printed materials such as business cards.  
       BACKGROUND OF THE INVENTION  
       [0002]     Business cards are often ordered, printed, and sold in large quantities, often exceeding five hundred or one thousand items at a time. Commonly, after printing, the business cards are packaged into cardboard boxes and shipped or delivered. Users often keep the business cards in the cardboard boxes, in or on their desks, and remove a selected number of cards before going to an event or on a business-related trip.  
         [0003]     Business card users often travel for business purposes to meetings, trade shows, and other events. Most of the time the user may exchange business cards with less than a dozen business contacts each day. However, at a trade show or convention, the user may distribute hundreds of cards to contacts in the course of a single day. Thus, it becomes important for the user to have an ample supply of business cards at hand. Carrying an entire box of business cards on long trips or to the floor of a trade show, is impractical. Business cards, out of their package, however, are easily susceptible to loss and damage. Loose cards are easily scattered, dog-eared and soiled. The more that business cards are handled prior to dispensing, the greater the likelihood that the card will lose integrity due to wear or soiling.  
         [0004]     Users can place a rubber band or paper clip to hold a larger number of cards for trips of long duration. However, clips and rubber bands can distort or damage the cards. In addition, once out of the box, the cards can be susceptible to being bent, torn, or otherwise damaged. The presentation of a damaged or dog-eared business card to a business prospect makes a poor impression on the prospect and may lead to the loss of a sale or valuable business contact.  
         [0005]     Business card holders can be used to protect a smaller quantity of cards in the interim between removal of the cards from their package and the handing out of the cards. The holders can contain a limited number of business cards, usually in the range of 5 to 20 cards. However, when a user is on a relatively long trip, or when a larger number of cards are needed, the holder&#39;s capacity to contain and protect cards can be insufficient.  
         [0006]     Current methods of packaging of business cards require that the business cards be packaged largely by hand, and that the lid to the business card box be applied manually. The process of preparing and printing business cards is largely accomplished by automation and can be done with high speed machinery. The requirement for manual packaging of the business cards at the end of the process dramatically limits the speed with which cards can be packaged and shipped.  
         [0007]     Blister style packaging has been successfully used to automate the packaging of items such as pharmaceuticals.  
         [0008]     U.S. Patent Publication No. 2002/0189964, U.S. Pat. No. 3,380,578, U.S. Pat. No. 4,588,090 and U.S. Patent Publication No. 2005/0056554 are representative disclosures of blister style packaging, but to date there have been no examples of blister style packaging that address the particular needs of packaging, storing and dispensing business cards.  
         [0009]     The business card production industry would benefit greatly from a different approach to packaging business cards that is amenable to automation. In addition, the users of business cards would benefit from business card packaging that allows users to transport and store business cards in smaller quantities than the typical lots of 500 to 1000 while still maintaining the cards in excellent condition so that the users can make a good impression on recipients of the cards.  
       SUMMARY OF THE INVENTION  
       [0010]     The problems outlined above are in large measure solved by the present invention. The invention gives users of business cards or other printed units access to bulk numbers of business cards stored in modular separable packets or modules. The modular separable packets are substantially sealed from the environment and protect the cards therein from wear and soiling until the cards are dispensed. The modular separable packets are structured to allow individual dispensing of the business cards while still providing substantial protection to the remaining business cards in the packet. The invention allows users to transport and store business cards in relatively small quantities, while still maintaining the cards in excellent condition and accommodating individual dispensing of the cards.  
         [0011]     The invention includes modules such as blister pack packaging adapted to store approximately 50-100 business cards in modularized packages. The modularized packages are positioned together in groups, with each modularized package individually separable from the group. A tear away strip on each modularized package can be selectively removed to provide for the dispensing of individual cards from the modularized package.  
         [0012]     The invention also includes a process of packaging business cards or other printed materials at the end of the printing process. The process of packaging the cards is readily adaptable to automation.  
         [0013]     The method includes the steps of printing a quantity of business cards, dividing that quantity of business cards into a plurality of sub-quantities and individually packaging each sub-quantity of business cards into a substantially sealed blister package containing approximately 10-250 business cards. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1  is a perspective view of a blister package in accordance with the present invention;  
         [0015]      FIG. 2  is an exploded perspective view of a blister package in accordance with the present invention;  
         [0016]      FIG. 3  is a perspective view of a series of three blister packs connected in a caravan fashion;  
         [0017]      FIG. 4  is a flow chart of a process in accordance with the present invention;  
         [0018]      FIG. 5  is a bottom perspective view of a blister pack including a tear off portion with the tear off portion intact;  
         [0019]      FIG. 6  is a bottom perspective view of a blister pack including a tear off portion with the tear off portion removed;  
         [0020]      FIG. 7  is a perspective view of an exemplary blister pack having features to increase its rigidity;  
         [0021]      FIG. 8  is a perspective view of an exemplary blister pack having features to increase its rigidity;  
         [0022]      FIG. 9  is a perspective view of an exemplary blister pack for packaging printed materials having an irregular shape and features to increase its rigidity; and  
         [0023]      FIG. 10  is a perspective view of another exemplary blister pack for packaging printed materials having an irregular shape and features to increase its rigidity. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0024]     Referring to  FIGS. 1 and 2 , the present invention generally includes a system for packaging and distributing business cards C, or the like, utilizing modules such as blister packs  10 . Blister pack  10  generally includes blister portion  12  and backing  14 . This application will generally discuss the invention in the context of business cards C however, it is to be understood that the invention may be used with other types of printed materials as well.  
         [0025]     Blister portion  12  generally includes flat portion  16  and card chamber  18 . Blister portion  12  may be formed of a transparent, opaque or translucent plastic or other synthetic material. Generally thermoplastics are used for the forming of the blister portion  12  but other materials may be used as well. Blister portion  12  of the present invention may be at least partially transparent.  
         [0026]     An exemplary card chamber  18  is substantially rectangular in shape and is dimensioned to receive business cards C or other printed materials. Card chamber  18  generally includes short sides  20 , long sides  22 , and display side  24 . Short sides  20  and long sides  22  are dimensioned to receive business cards C or other printed materials. Display side  24  may be substantially transparent to allow viewing of enclosed business cards C or other printed materials. Other chamber shapes may be used to accommodate variously shaped printed materials.  
         [0027]     The depth  26  of card chamber  18  is dimensioned to accommodate a conveniently preselected number of business cards C. For example, depth  26  may be selected so that card chamber  18  can accommodate 20 to 100 business cards C or other printed items.  
         [0028]     Referring now to  FIG. 2 , an exploded view of blister pack  10  is shown including a quantity  28  of business cards C. Backing  14  is a substantially planar thin sheet of material. Backing  14  may be formed of cardboard, plastic or other appropriate material. Desirably, backing  14  is pierced by a perforated opening  30 . Backing  14  may also be structured to have other uses. For example, backing  14  may be designed to be used as a business card holder or as a luggage tag. Either the business card holder or the luggage tag can hold one or more business cards C. The luggage tag can be attached to an item of luggage or other item for the purpose of identifying the owner of the item.  
         [0029]     Referring to  FIG. 2, 5 , and  6 , perforated opening  30  is dimensioned to have a length approximately equal to the length of short sides  20 . Perforated opening  30  is located at one end of card chamber  28 . Perforated opening  30  is dimensioned so that when perforated opening  30  is open a user may remove a small quantity of business cards C. For example, perforated opening  30  may be dimensioned so that a user may remove 1 to 10 business cards C therethrough. Perforated opening  30  is desirably arranged so as to be removable without tools by merely tearing off tear off portion  32  of backing  14 .  
         [0030]     Once tear off portion  32  is removed a user may access quantity  28  of business cards C. Placement of perforated opening  30 , is such that it allows ready removal of a small number of business cards by hand, while maintaining the rest of quantity  28  of business cards C in place inside card chamber  18 , where business cards C are protected from damage and soiling.  
         [0031]     Referring now to  FIG. 3 , in one embodiment of the invention, backing  14  may be configured as continuous backing  34 . Continuous backing  34  may be secured to multiple blister portions  12  caravan style. Optionally, separate backings  14  that make up continuous backing  34  are connected by perforated joints. For the purposes of this application, perforations or perforated joints are defined to be any localized weakening of the structure of backing  12  or blister portion  12  that allows adjacent backings  12  or blister portions  12  to be separated by tearing by hand without the need for scissors or other cutting tools. Perforations may include but are not limited to, actual perforations, thinning of the localized area or weakening of the localized area by heat. Continuous backing  34  allows for the packaging of multiple sub-quantities of business cards while still keeping the entire order connected together as a unit until it is separated by a user. Alternatively, continuous backing  34  may be marked for cutting with scissors or other tools.  
         [0032]     In another embodiment of the invention, multiple blister portions  12  may be joined by perforated joints  36  to create a caravan style package of multiple blister portions  12 . A benefit of the availability of multiple blister portions  12  connected together caravan style is that a user may select one or more sub-quantities of business cards in one or more blister portions  12  for removal to be taken along as needed.  
         [0033]     Referring now to  FIG. 4 , a block diagram of a series of steps in a method of packaging business cards or other printed materials is depicted. The production of a custom made order of business cards or other printed materials begins with printing step  38 . In this step, a quantity of custom made printed materials may be produced by conventional printing means. The custom business cards or other materials will typically include such information as business name, individuals name, address, phone number, and other contact information along with a business logo and related information.  
         [0034]     After the printing step  38  is complete dividing step  40  is performed. In dividing step  40 , the large quantity of custom made printed items such as business cards C are divided into a plurality of sub-quantities. The sub-quantities may be equal smaller quantities of printed materials such as 50-100 business cards. The sub-quantities may also be unequally divided so that a significant quantity of business cards, for example 300-500, are packaged together for placement in a fixed location such as a desk drawer and the remaining quantity of business cards are divided into smaller quantities of 50-100 for ease of transportation by the end user.  
         [0035]     Next comes inserting step  42 . In the inserting step  42  the various sub-quantities of business cards are placed into card chambers  18  of blister portions  12  of multiple blister packs  10  as described above. The blister packs  10  may be of substantially identical size or may vary in size depending upon the desired packaging arrangement.  
         [0036]     Next, backer application step  44  is performed. In the backer application step  44 , the backer  14  is applied to blister portions  12  to substantially seal blister packs  10 . When blister packs  10  are substantially sealed, individual sub-quantities of business cards C or other printed materials are protected from dirt or damage. In one embodiment of the invention the blister packs  10  are connected together caravan style, as described above.  
         [0037]     Next, the multiple blister packs  10 , whether attached together caravan style or individually are placed into a common package  46 . Thus, multiple blister packs  10  containing business cards C are joined together in a common unit. In the final step, shipping  48 , the package of business cards or other printed materials is shipped to the end user.  
         [0038]     In another embodiment of the invention, blister packs  10  of different sizes or configurations may be used together to package a variety of different printed materials. The blister packs  10  or other modules may, for example, contain business cards, stationery and envelopes for a particular individual. In another example, business cards and marketing materials for a particular product or marketing campaign may be supplied in blister packs  10  or other modules that are joined together for a representative&#39;s convenience. The blister packs  10  containing varying types of printed materials may be joined or separate and packaged together in a common package. The blister packs  10  may be sized and shaped differently from one another to accommodate the various printed materials.  
         [0039]     It may be necessary to coordinate the printing and packaging processes so that the various printed materials are grouped together appropriately. For example, if business cards, envelopes and stationary are all printed on different manufacturing lines, the lines would need to be coordinated so that the three different items would converge for packaging.  
         [0040]     Referring to  FIGS. 1-3  and  5 - 6  an exemplary reinforced blister pack  50  is depicted. Reinforced blister pack  50  includes short sides  20 , long sides  22 , display side  24  and corner beads  52 . Short sides  20  and long sides  22  are dimensioned to receive business cards C or other printed materials. Corner beads  52  are formed at the junctures of short sides  20  and long sides  22  in this example. Comer beads  52  may also be formed at the edges  54  where short sides  20  and long sides  22  meet display side  24 . Comer beads  52  can be formed at some or all of the eight edges of blister pack  50 .  
         [0041]     Referring to  FIG. 7 , another embodiment of reinforced blister pack  50  is depicted. In this embodiment, reinforced blister pack  50  includes raised perimeter  54 . Raised perimeter  54  extends substantially along edges  56 . Raised perimeter  54  surrounds sunken plateau  58 . This embodiment may also include corner beads  52 .  
         [0042]     Referring to  FIG. 8 , reinforced blister pack  50  may also include a dome  60 . One or more dome  60  may include a steeper portion  62  and a flattened portion  64 . As depicted in  FIG. 8 , corner beads  52  may used in combination with dome  60 . Domes  56  may include but are not limited to circular, oval or quadrilateral in shape.  
         [0043]     Referring to  FIG. 9 , another embodiment of reinforced blister pack  50  is depicted. This embodiment is formed to accept irregularly shaped printed items. This embodiment also includes corner beads  52  and domes  60 , Referring to  FIG. 10 , another embodiment of reinforced blister packs  50  is depicted. This embodiment is formed to accept irregularly shaped printed items and includes domes  60 .  
         [0044]     In operation, an end user may select one or more sub-quantities of business cards C in blister pack  10  for use at a time. This allows an end user to maintain the business cards or other printed materials in pristine condition until it is desired to remove them for distribution. Thus the business cards or other printed materials remain in excellent condition, allowing a user to make a positive impression upon business contacts to which printed materials are distributed.  
         [0045]     The present invention may be embodied in other specific forms without departing from the central attributes thereof, therefore, the illustrated embodiments should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than the foregoing description to indicate the scope of the invention.