Abstract:
An apparatus and method for configuring product packaging and removal of the packaging from a product is disclosed. The labeled product packaging includes a shrink wrap packaging adapted for sealing around a product. A predefined point of failure is configured in the packaging and includes a failure mode for when pulled in at least one direction. A label is sealed to the packaging and adhered to the predefined point of failure in covering relation over the predefined point of failure. Lifting the label from the packaging tears open the packaging starting at the predefined point of failure so the product can be removed from the packaging.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    This invention relates generally to an apparatus and method for configuring and opening product packaging and more particularly to an apparatus and method for labeled packaging and an easy method for removal of the labeled packaging from the product. 
         [0003]    2. Description of the Prior Art 
         [0004]    Product packaging can be difficult to apply and remove depending upon the type of packaging that is preferred for use with the product. Packaging that seals the product can be both onerous and complicated to remove or separate it from the product. Peel wrap, for example, is applied to shrink wrap packaging and functions as an opening feature for the customer or end-user to use to remove the product packaging. This and many other current features used to assist in opening shrink wrapped product are widely viewed as unnecessarily complicated and unreliable. 
         [0005]    It is therefore desirable to provide a cost efficient and effective way to configure the packaging and labeling on a product to aid in the removal of packaging from the product. 
         [0006]    It is further desirable to provide reliable packaging that is easily removed. 
         [0007]    It is further desirable to provide product packaging for pressed solid products that is configured for easy removal and separation from the pressed solid product. 
       SUMMARY OF THE INVENTION 
       [0008]    In one embodiment, the invention is a method for removing packaging from a product. The method includes providing a product in a packaging having a label covering a predefined failure point in the packaging. The steps include lifting the label from the packaging to tear open the packaging starting at the predefined failure point and separating the packaging from the product. In a preferred form, the lifting step includes separating a portion of the label from packaging around a portion of the predefined failure point without tearing open the packaging. For example, lifting in one direction prevents tearing of the predefined failure point in the packaging thereby permitting reapplication of the label and preservation of the packaging while lifting in another direction tears open the packaging. 
         [0009]    In another embodiment, the invention is labeled product packaging. The packaging is shrink wrap packaging that is adapted for sealing around a product. A predefined point of failure is configured in the packaging. The predefined point of failure has a failure mode for when pulled in at least one direction away from the packaging. A label is secured to the packaging in covering relation over the predefined point of failure. The label is also sealed to the packaging and adhered to the predefined failure point. In a preferred form of the invention, the product is a block of solid detergent, and the predefined point of failure is a cut through the packaging in the shape of an “X”, a crescent or a “V”. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1A  front elevation view of a product with labeled packaging according to one aspect of the invention. 
           [0011]      FIG. 1B  is a top view of a product with labeled packaging according to another aspect of the invention. 
           [0012]      FIG. 2A  is a front elevation view of a design for a predefined point of failure in the packaging according to one embodiment of the invention. 
           [0013]      FIG. 2B  is a front elevation view of another design for a predefined point of failure in the packaging. 
           [0014]      FIG. 2C  is a front elevation view of another design for a predefined point of failure in the packaging. 
           [0015]      FIG. 3  is an enlarged view taken along line  3 - 3  in  FIG. 2B  of one embodiment of a predefined point of failure. 
           [0016]      FIG. 4A  is a perspective view of a process for cutting the predefined point of failure in the product packaging according to one embodiment of the present invention. 
           [0017]      FIG. 4B  is an end view of the process shown in  FIG. 4A . 
           [0018]      FIG. 5A  is a front elevation view illustrating opening of the product packaging for the predefined point of failure shown in  FIG. 2A . 
           [0019]      FIG. 5B  is a front elevation view illustrating opening of the product packaging for the predefined point of failure shown in  FIG. 2B . 
           [0020]      FIG. 5C  is a front elevation view illustrating opening of the product packaging for the predefined point of failure shown in  FIG. 2C . 
           [0021]      FIG. 6A  is a front elevation view illustrating removal of a label from the predefined point of failure shown in  FIG. 2B  without removing the packaging. 
           [0022]      FIG. 6B  is a front elevation view illustrating removal of a label from the predefined point of failure shown in  FIG. 2C  without removing the packaging. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0023]    Product packaging can encompass use of numerous types of packaging enclosing various types of product. In one aspect of the present invention, shrink wrap is used as a product packaging  10  as illustrated in  FIGS. 1A-B  for enclosing a product such as a pressed solid or cast block of detergent. The product packaging  10  can include one or more labels  12  positioned on one or more surfaces of the product packaging  10 . For example, label  12  could be positioned on a top or bottom face of the product packaging  10  as illustrated in  FIG. 1B  or on a front or back face of the product packaging  10  as illustrated in  FIG. 1A . Labeling could also be printed directly onto the product packaging  10 . The product packaging  10  generally assumes the shape of the enclosed product. For example, as illustrated in  FIGS. 1A-B , the product packaging  10  has a peanut shape as a result of the enclosed product being peanut-shaped. Thus, labeling such as label  12  illustrated in  FIGS. 1A-B  may be positioned on a surface of the product packaging  10  that is generally planar or non-planar. Because the product packaging  10 , such as shrink wrap, follows closely the contour or outer surface of the enclosed product, removal of the product packaging  10  can be complicated and difficult. Furthermore, it is important that the product packaging  10  remain sealed until the product is used. What follows is a description of the invention which allows for easy removal of the product packaging  10  and access to the enclosed, sealed product. 
         [0024]    In one aspect of the invention, the product packaging  10  includes a label  12  applied to the packaging after it is sealed around an enclosed product. For example, in the case of the product packaging being shrink wrap, the shrink wrap and enclosed product are run through a heat tunnel prior to label application. The label  12  may include various forms of information, artwork, company marks, branding, product ingredients and use suggestions, source or manufacture of the product, and instructions for removing the packaging  10  or reapplying the label  12 . The label  12  is adhered to the surface of the underlying product packaging  10  using a light or medium grade adhesive as is further defined below. 
         [0025]    In one aspect of the present invention, after the product packaging is applied so as to enclose the product and before the label  12  is adhered to the product packaging  10 , a predefined point of failure  14 ,  16  or  18  as illustrated in  FIGS. 2A-C  is configured in the product packaging  10 . For example, in the case where the product packaging  10  is shrink wrap, the shrink wrap and the enclosed product are run through a heat tunnel before the predefined point of failure is formed in the product packaging  10 . Making the predefined point of failure after heat tunneling minimizes label  12  alignment and cutting issues relating to formation of the predefined point of failure. 
         [0026]      FIGS. 2A-C  illustrate exemplary embodiments of a predefined point of failure  14 ,  16  and  18  of the present invention. For example, as illustrated in  FIG. 2A , the predefined point of failure  14  is generally an “X” shape. The predefined point of failure  14  may be formed by cutting the product packaging  10  in the desired shape, perforating the product packaging  10  in the desired shape or generally weakening the material of the product packaging  10  in a desired shape. In  FIG. 2B , the predefined point of failure  16  is formed in a crescent shape and in  FIG. 2C  the predefined point of failure  18  is formed in a horizontal “V” shape. In each instance, the predefined point of failure may be formed by a cut passing through the entirety of the product packaging  10 , a perforation of the product packaging  10  or a weakening of the product packaging  10 .  FIGS. 2A-C  illustrate some exemplary shapes and geometries of a predefined point of failure. The present invention contemplates that other shapes and/or geometries may be used to form a predefined point of failure in the product packaging  10 . For example, the predefined point of failure could be an oval, “U”, or rectangular shape. Depending upon the desired functionality, certain shapes may achieve the objections of the present invention better than others as described below. 
         [0027]    As shown in  FIGS. 2A-C , label  12  is positioned and adhered to the product packaging in covering relation over the predefined point of failure  14 ,  16  and  18 . By encompassing the entire predefined point of failure, the label  12  acts as a protective mechanism that prevents dirt, moisture, or other contaminates from contacting the enclosed product through the predefined point of failure. Thus, the label  12  adheres to the product packaging  10  and the predefined point of failure to seal the packaging to protect and preserve the enclosed product. 
         [0028]    As indicated, the predefined point of failure may be formed in the product packaging  10  by a cut passing through the entirety of the product packaging  10 , a perforation in the product packaging  10  or intermittent cuts in the product packaging  10  formed in the shape of the predefined point of failure. The predefined point of failure may also include a weakening of the product packaging  10  in the shape of the predefined point of failure.  FIG. 3  illustrates one example taken from the predefined point of failure  16  illustrated in  FIG. 2B . In  FIG. 3 , the predefined point of failure  16  is cut into the product packaging  10  and forms a crescent shape. The crescent shape is used here as an example since the following configuration could be applied to the other shapes discussed and considered above. The cut extends through the product packaging  10  to form the shape of the predefined point of failure  16  with the exception of a portion of the product packaging that forms tabs  20  and  22 . Here, the product packaging  10  within the crescent shape remains attached to the product packaging  10  without outside the crescent shape via tabs  20  and  22 . The tabs  20  and  22  keep the product packaging  10  within the predefined point of failure  16  generally on the same plane as the product packaging  10  outside of the predefined point of failure  16 . The tabs  20  and  22  also allow the material within the predefined point of failure  16  to remain taut without creating an unattended separation or gap between the product packaging  10  within the predefined point of failure  16  and the product packaging  10  outside of the predefined point of failure  16 . This is particularly useful in the instance where the enclosed product has one or more non-planar surfaces such as illustrated in  FIGS. 1B and 4A . The tabs  20  and  22  help prevent the predefined point of failure  16  from adhering to a surface of the enclosed product, such as by static electricity, thereby residing in a plane or position than the product packaging  10  around the predefined point of failure  16 . Keeping the product packaging  10  around the predefined point of failure  16  generally in the same plane allows the label  12  to adhere to the surface of the product packaging  10  and the predefined point of failure thereby ensuring that when the label  12  is applied to the product packaging  10 , the label  12  adheres to the entire of the product packaging  10  beneath the label  12  and not just the surface of the packaging around the predefined point of failure. 
         [0029]      FIGS. 4A-B  illustrate one aspect of the invention for forming a predefined point of failure in product packaging  10 . For example, a laser cutting system  24  may be used to configure a predefined point of failure in product packaging  10 . In this manner, the product is enclosed within shrink wrap packaging as previously discussed and moved along a conveyor  26 . A positioner  32  moves and holds the product packaging  10  in a fixed distance away from the laser  28 . The laser beam  30  emitted from the laser  28  is then used to create a predefined point of failure  14  in the product packaging  10 . The predefined point of failure, as previously described, may include a continuous cut, a partial cut, a perforated cut, or a weakening of the product packaging  10 . Positioning the product packaging  10  a fixed distance from the laser  28  permits a fixed power setting to be used for the laser  28  so as to not affect the enclosed product, particularly when cutting a predefined point of failure on a non-planar surface of the product packaging  10  as illustrated in  FIG. 4A . In one aspect of the invention, a laser from a laser manufacturer/provider such as Preco, Inc. or LasX may be used to form a predefined point of failure in the product packaging  10 . In another aspect of the invention, a heating element shaped in the form of a predefined point of failure may be used to cut or form a predefined point of failure in the product packaging  10 . This could include a heating element having a “X”, crescent or horizontal “V” shape. The temperature of the heating element could be controlled so as to control the cut or weakening of the product packaging  10  in order to form a desired predefined point of failure. With each of these methods, the predefined point of failure is created in the product packaging  10  before the label  12  is applied or adhered to the product packaging  10  in covering relation over the predefined point of failure. In another aspect of the present invention, a foil may be included or incorporated into a label  12  and formed in the shape of a predefined point of failure such as an “X” shape, crescent shape or generally horizontal “V” shape. The label  12  having the foil is then adhered to product packaging  10  onto a desired surface of the product packaging  10 . Here, the product packaging  10  does not include a predefined point of failure before application of the label  12 . To form the predefined point of failure in the shape of foil, the label  12  is exposed to magnetic energy which thereby heats the foil creating a predefined point of failure in the product packaging  10  beneath the label  12  and in the shape of the foil. Thus, the predefined point of failure is created in the product packaging  10  while the label  12  is adhered to the product packaging  10 . In this manner, the product packaging  10  remains sealed at all times even while the predefined point of failure is being formed in the product packaging  10 . 
         [0030]      FIGS. 5A-C  illustrate exemplary aspects of the invention for removing product packaging  10  from product enclosed in the packaging. As previously indicated, the label  12  is adhered to the product packaging  10 . In one aspect of the invention, a light or medium grade adhesive  34  is applied to the backside of a label  12 . A stronger adhesive  36  such as illustrated in  FIGS. 6A-6B  may be applied to the portion of label  12  in contact with the predefined point of failure to permit separation between the label  12  and the product packaging  10  while maintaining adherence of the label  12  to the predefined point of failure. In  FIG. 5A , the predefined point of failure  14  is formed in the shape of an “X”. A corner or edge of the label  12  is lifted and separated from the product packaging  10 . As the label  12  is torn from the product packaging  10 , the label  12  remains adhered to the predefined point of failure  14  thereby forming tears  38  and  40  in the product packaging  10  which continue to propagate through the product packaging  10  while the label  12  is further lifted and torn from the product packaging  10 . Continuing to pull the label  12  from product packaging  10  tears the product packaging  10  to allow the product enclosed in the product packaging  10  to be separated from the product packaging  10  with ease.  FIGS. 5B-C  illustrate how the product packaging  10  is opened using the crescent shape predefined point of failure  16  and the horizontal “V” shape predefined point of failure  18 . Like  FIG. 5A , the label  12  is lifted from the product packaging  10 . The predefined point of failure  16  and  18  remain adhered to the label  12  thereby forming tears  38  and  40  in the product packaging  10  which propagate through the product packaging  10  as the label  12  is further torn from the product packaging  10 . As previously indicated, the label  12  may include various types of indicia such as instructions on how to remove the label  12  and thereby tear open the product packaging  10 . 
         [0031]      FIGS. 6A-B  illustrate the dual functionality of certain shapes of predefined points of failure of the present invention. In certain instances, depending upon the shape of the predefined point of failure, the label  12  may be removed and reapplied without opening the product packaging  10 . Also, the label may be replaced with another label without opening the product packaging  10 . For example, in instances where the label  12  needs reapplied, replaced or adjusted because it was applied incorrectly, is the wrong label or is misaligned, the label  12  may be removed from the product packaging  10  without tearing the product packaging  10 . In  FIG. 6A , the predefined point of failure  16  is in the shape of a crescent as illustrated in  FIGS. 2B and 5B . Lifting the label  12  in one direction as illustrated in  FIG. 5B  tears open the product packaging  10 ; however, lifting the label  12  in the opposite direction permits the label  12  to be separated from the product packaging  10  without tearing the product packaging  10  as illustrated in  FIG. 6A . Thus, in the case where the predefined point of failure is formed in the direction in which the label  12  is peeled, the label  12  is permitted to separate from the product packaging  10  without tearing the product packaging  10 . The label  12  then may be reapplied and used to subsequently tear open the product packaging  10  as illustrated in  FIG. 5B . Similarly, in  FIG. 6B , to remove label  12  without tearing product packaging  10 , the label  12  is peeled off in the direction of the predefined point of failure  18 . One or more tabs, such as tabs  20  and  22  illustrated in  FIG. 3  may be included in the predefined point of failure  16  and  18  in  FIGS. 6A-B  to further prevent unintentional tearing of the product packaging  10  when the label  12  is peeled in the direction of the predefined point of failure. As previously indicated, the label  12  may include one or more types of adhesive. For example, a light adhesive  34  may be used for generally adhering to the surface of the product packaging  10  around the predefined point of failure whereas a stronger adhesive  36  may be used to adhere the label  12  to the predefined point of failure itself. The bonding strength of the adhesive  36  is sufficient to maintain adherence to the predefined point of failure when the label  12  is lifted from the product packaging  10  as illustrated in  FIGS. 5A-C , but still permits the label  12  to be removed and reapplied as shown in  FIGS. 6A-B . 
         [0032]    In another aspect of the present invention, the product packaging may be without a label. In this manner the predefined point of failure configured in the product packaging is left uncovered. As discussed above, the predefined point of failure may include tabs to keep it from unintentionally opening thereby keeping the product packaging generally sealed until opened. The predefined point of failure could be also be configured as a perforation or by intermittent cuts passing through the packaging. The packaging remains generally sealed until the user grips the predefined point of failure and begins to separate it from the packaging. The packaging separates along the predefined point of failure first and then forms one or more tears that propagate into the packaging to open it. Indicia may be printed directly on the packaging indicating to the user how to open it. 
         [0033]    The above Specification, examples, and data provide a complete description of the manufacturing and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.