Abstract:
A product package system is provided comprising a blister pack having a cavity and an overwrap. The system enables a product to be packaged and easily removed by opening the overwrap. The overwrap can include tear strips to facilitate easy opening. The blister pack can embody a clamshell pack having a living hinge.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This is a national phase application under 35 U.S.C. §371 of PCT Application No. PCT/US2010/056022 filed Nov. 9, 2010, which claims the benefit of U.S. Provisional Application No. 61/259,467, filed Nov. 9, 2009, the contents of each of which are expressly incorporated herein by reference. 
     
    
     FIELD OF ART 
       [0002]    Product packages for consumer goods, such as blister packs for toys, glasses, consumer electronics, videos, games, etc., are generally discussed herein with particular discussions on blister packs having easy to remove security overwrap covers. 
       BACKGROUND 
       [0003]    Prior art blister packs for packaging toys and consumer components, such as electronics, toys, and accessories, among others, are typically heat sealed for shipping, displaying, and providing security. They have a clam-shell configuration made from a thermoforming process in which one-half of the clamshell is formed with a cavity and the other half either as a flat lidding or with a second cavity to increase the overall cavity dimension of the clam-shell. The two sections are typically sealed along a common perimeter, using frequency sealing, ultrasonic sealing, or simple heat seal. An optional paper insert may be provided for art work and other ad space, such as product information and product name. 
         [0004]    Although prior art blister packs serve their intended needs, they pose issues for consumers and the environment. Among other things, blister packs are made of durable plastics, such as polyvinyl chloride (PVC), which make them hard to open. Among small circles of consumers, the difficult-to-open packages have given rise to “wrap rage”. Furthermore, the all plastic configuration goes against recent environmental push for plastic reduction to reduce carbon footprint. 
         [0005]    Accordingly, there is a need for a better or at least an alternative package usable for various applications, such as consumers, aerospace, medical, and energy. 
       SUMMARY 
       [0006]    The present apparatus, device, and method may be practiced by providing a product package system comprising a blister pack. The blister pack can comprise a cavity placed inside an overwrap comprising an opening; wherein the cavity projects, at least in part, out the opening of the overwrap; and wherein a flap on the overwrap is folded over a package opening and is fixed to a surface near the package opening by adhesive. 
         [0007]    In yet another aspect of the present apparatus, device, and method, there is provided a method for assembling a product package system comprising placing a consumer product into a cavity of a blister pack; placing a lidding against the blister pack so as to cover the cavity; placing the blister pack and lidding into a package opening of an overwrap; aligning the cavity so that the cavity projects outwardly of at least one window incorporated in the overwrap; and applying an adhesive to close the packaging opening. 
         [0008]    In still yet aspect of the present method is a method for using a product package system. The method of using the product package system comprising causing a side of an overwrap of the product package to open to expose an interior cavity of the overwrap. The method further comprising the steps of extracting a blister pack from the interior cavity of the overwrap and separating a cover on the blister pack to expose a cavity on the blister pack without cutting the cover or the blister pack. Finally, the method includes the step of extracting a product from the cavity of the blister pack. 
         [0009]    Other aspects and variations of the glove assemblies summarized above are also contemplated and will be more fully understood when considered with respect to the following disclosure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    These and other features and advantages of the present apparatus, system, and method will become appreciated as the same become better understood with reference to the specification, claims and appended drawings wherein: 
           [0011]      FIG. 1  is an exemplary semi-schematic perspective view of a lidding of a blister pack provided in accordance with aspects of the present disclosure, 
           [0012]      FIG. 2  is an exemplary perspective view of a blister pack provided in accordance with aspects of the present disclosure, 
           [0013]      FIG. 2A  is an exploded top view of an upper left corner of the blister pack of  FIG. 2 ; 
           [0014]      FIG. 3  is an exemplary perspective view of a blister pack assembly provided in accordance with aspects of the present disclosure; 
           [0015]      FIG. 4  is an exemplary schematic perspective view of an overwrap configured for receiving the blister pack assembly of  FIG. 3  provided in accordance with aspects of the present disclosure; 
           [0016]      FIG. 5  is an exemplary perspective view of a product package system provided in accordance with aspects of the present disclosure; 
           [0017]      FIG. 6  is an exemplary front view of the product package system of  FIG. 5 ; and 
           [0018]      FIG. 7  is an exemplary rear view of the product package system of  FIG. 5 . 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    The detailed description set forth below in connection with the appended drawings is intended as a description of the presently preferred embodiments of product packages and systems (herein “package or package assembly”) provided in accordance with aspects of the present disclosure and is not intended to represent the only forms in which the present disclosure may be constructed or utilized. The description sets forth the features and the steps for constructing and using the package assembly of the present disclosure in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and structures may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the disclosure. As denoted elsewhere herein, like element numbers are intended to indicate like or similar elements or features. 
         [0020]      FIG. 1  is a schematic view of a lidding  10  provided in accordance with aspects of one embodiment. The lidding  10  has a first surface  12 , an opposed second surface  14 , a length L and a width W. The lidding  10  can be made from any suitable natural, synthetic, composite, and laminate materials, including but not limited to paper and board materials; metals and foils; or plastics. In a preferred embodiment, the lidding  10  is made from a paperboard material. In one embodiment, the lidding  10  may be made from a prior art material having acceptable thickness or weight, including from paperboard material and from recyclable material. The first surface  12 , the second surface  14 , or both may have printing or art work, such as for describing the contents of the package and/or for providing manufacturer information, among others. 
         [0021]      FIG. 2  is a schematic view of a blister pack  16  provided in accordance with aspects of one embodiment. The blister pack  16  may be made from a transparent or opaque plastic or other rigid or semi-rigid materials. The blister pack  16  can be made from any suitable natural, synthetic, composite, and laminate materials, including, without limitation, plastics such as cellulose acetate butyrate (CAB), polystyrene, polyethylene terephthalate (PETG); polycarbonate; polyethylene, including PET, PVC, HDPE, and LDPE; polytetrafloralethylene; acetal, acrylic and combinations thereof. 
         [0022]    In some embodiments, the blister pack  16  may be made from a thermoforming process using suitable plastic materials, such as from PET or PVC or other known plastics for thermoforming a blister pack for packaging consumer goods. The plastic material is preferably transparent. However, an opaque or a semi-opaque material may be used without deviating from the spirit and scope of the present disclosure. In another embodiment, the blister pack  16  is made from a vacuum forming process. In yet other embodiments, the blister pack  16  may be formed by injection molding. In alternative embodiments, the blister pack  16  may be formed by other suitable plastic manufacturing processes, including but not limited to blow molding or rotational molding. 
         [0023]    As shown in  FIG. 2 , the blister pack  16  comprises a cavity  18  having a defined volumetric capacity. The cavity  18  can have a rectangular, a square, a cylindrical or any other appropriately shaped container configuration for storing consumer goods with rectangular and square configurations being more preferred. For example, the cavity can have an irregular shape for accommodating an irregular shaped toy. 
         [0024]    In other embodiments, the cavity  18  is made of several individual cavities. The individual cavities can have different configurations, including but not limited to irregular shape, rectangular shape, square, cylindrical, elliptical or combinations thereof. In some embodiments, the individual cavities are separately formed and assembled into the cavity  18  to form multiple sub-cavities. In one embodiment, the separately formed individual cavities are stacked vertically one on top of another, horizontally one adjacent to another, or combinations thereof. In alternative embodiments, the individual cavities are created by dividing the space within the cavity  18  using, for example, panels or partitions. In some embodiments, the individual cavities are identically sized and shaped. In alternative embodiments, the individual cavities are configured for housing objects of varying sizes and shapes. In some embodiments, the cavity  18  comprises multiple individual cavities, such as cavities  18   a,    18   b.  and  18   c  for separately housing glasses. In alternatives embodiments, the cavity  18  may comprise a plurality of individual cavities, such as two to ten, or more than ten, configured for housing different consumer goods. 
         [0025]    The cavity  18  is positioned on the blister pack  16  such that a first gap or distance D 1  is formed between the upper edge of the blister pack and the upper sidewall surface of the cavity  18 ; a second gap or distance D 2  is formed between the lower edge of the blister pack  16  and the lower sidewall surface of the cavity  18 ; and two side gaps or distances D 3  and D 4  are formed between the side edges of the blister pack  16  and the left and right sidewalls of the cavity  18 , respectively. In one example, D 1  equals to D 2  and D 3  equals to D 4 . In other embodiments. D 1  equals to D 2 , which is equal to D 3 , and which is equal to D 4 . In another example, D 1  is not equal to D 2 . As further discussed below, the gaps D 1 -D 4  are sized so that the cavity  18  can project out of a window of an overwrap and fits securely and snugly within the window of the overwrap, as further discussed below. Because of the location of the cavity  18  and relative dimensions of the cavity and the window of the overwrap, the blister pack  16  cannot be removed from the overwrap without tempering with the overwrap, such as by cutting the window or opening the tear strip. 
         [0026]    The blister pack  16  comprises two or more spaced apart channels  20  configured to receive the lidding  10  of  FIG. 1 . The channels  20  may be formed by folding the left and right edges of the material used to make the blister pack  16 .  FIG. 2A  is an exploded view of an upper left corner of the blister pack  16  of  FIG. 2  showing one of the two or more receiving channels  20 . 
         [0027]    Thus, aspect of the present apparatus, assembly, and method is understood to include a blister pack comprising a cavity for receiving a consumer product, such as a toy, an accessory, an electronic component, cards, a video chip, a DVD, etc., and two spaced apart channels configured for receiving a lidding. In one specific example, the two spaced apart channels are formed by folding two edges of a body of material for forming the blister pack. In another example, the folds are formed along a longer dimension of the body but can be formed along the shorter dimension of the body. If the body of material for forming the blister pack is generally rectangular, then the folds may be formed along any two spaced-apart edges. 
         [0028]      FIG. 3  is a schematic view of a blister pack assembly  22 , which comprises the lidding  10  of  FIG. 1 , the blister pack  16  of  FIG. 2 , and one or more consumer products (not shown) placed in the cavity  18  of the blister pack. In practice, after the cavity  18  is occupied with one or more consumer products, the lidding  10  is slid into the two spaced apart channels  20  to form the blister pack assembly  22 . In some embodiments, the lidding  10  is held within the two receiving channels  20  by friction or by a third channel formed along the lower width section of the blister pack  16  (not shown) between the two spaced apart channels  20 . In alternative embodiments, the lidding  10  may be retained within the two receiving channels  20  by a retainer means, such as a latch, fastener or the like. Alternatively or in addition thereto, the lidding  10  may be secured to the blister pack  16  using staples, tapes or combinations thereof. For example, the lidding may be placed against the blister pack and stapled thereto without the channels  20 , although the channels may also be incorporated. In still another example, the lidding and the blister pack may incorporate corresponding snap-fit engagement means, such as detents, tongue and groove, etc. In this example, the lidding may be made from similar material as the blister pack. 
         [0029]    Thus, aspect of the present embodiment is understood to include a method for forming a blister pack assembly, comprising providing a blister pack comprising a cavity for receiving one or more consumer product, and two or more spaced apart channels configured for receiving a lidding; placing the one or more consumer product within the cavity; and engaging the lidding into the two or more spaced apart channels to close the blister pack. 
         [0030]    In an alternative embodiment, a clamshell having a foldable hinge and one or more cavities may be used instead of the disclosed blister pack  16 . If the alternative clamshell is used, then the lidding may be omitted. However, the common edges of the clamshell does not have to be heat sealed before placing the clamshell into an overwrap. Leaving the two sections merely touching or using a simple snap-fit arrangement or staples are possible options. 
         [0031]      FIG. 4  is a schematic view of an overwrap  24  provided in accordance with aspects of the present apparatus, assembly, and method. In one embodiment, the overwrap  24  is made from a chip board, a fiberboard, a film, TYVEK® synthetic material (e.g., high-density polyethylene fibers), a multi-laminate film, other suitable materials, or combinations thereof. The overwrap is preferably made from a difficult to tear or temper material. The overwrap  24  has a front layer  32 , a back layer  34 , which are attached to one another along one or more common peripheral edge, and a package opening  36  that opens up into an interior cavity of the overwrap. In some embodiments, the overwrap  24  comprises an adhesive closure system  26  for closing the package opening  36  after a product has been placed inside. In other embodiments, the package opening  36  may be closed using staples, tapes or combinations thereof. In some embodiments, the opening  36  is sized to receive the blister pack and the overwrap  24  is sized to accommodate the blister pack  16  with the cavity  18  projecting out of the window  30 . In a specific embodiment, the overwrap  24  embodies a similar configuration as a mailer, such as an Express Mail envelope from the US Postal Office or a FedEx envelope. In another embodiment, the overwrap has a tear strip  28  for removing the blister pack and the contents. In one embodiment, the adhesive closure system  26  and tear strip  28 , when both are incorporated, are located along one lengthwise edge of the overwrap  24 . In another embodiment, the adhesive closure system and tear strip are located along one widthwise edge of the overwrap. The overwrap can be viewed broadly as having an opening and a mechanism for closing the opening after the blister pack has been placed therein. In still other embodiments, the adhesive closure system and tear strip are located along two or more edges of the overwrap, such as along the two lengthwise edges or along one lengthwise edge and one widthwise edge. The overwrap  24  may have printing or indicia identified thereon, such as a logo, product information, product code, bar code, instructions, etc., for facilitating sales and marketing. 
         [0032]    As shown, an opening or window  30  is incorporated on the front layer  32 . The window may be die cut to size before securing the front layer  32  to the back layer  34 . For example, the window may be cut with a size sufficient to accommodate the cavity  18  of the blister pack assembly  22  and allow the cavity  18  to project outwardly therefrom, as further discussed below. In an alternative embodiment, a second window (not shown) is incorporated on the second layer  34  of the overwrap for accommodating a two-cavity clamshell blister pack. In another example, the window  30  is formed with ribs or spacers so as to form multiple windows for separately accommodating the different cavities on a multi-cavity blister pack, such as that shown in  FIG. 3 . 
         [0033]    In still yet another embodiment, pleats may be incorporated along one or more of the edges of the overwrap  24 , such as along all the edges of the overwrap. The pleats (not shown), when incorporated, allow the package opening  36  to be opened sufficiently wider than a comparable overwrap without pleats to receive the blister pack assembly  22 , as further discussed below. Also although not shown, a hanging bore or opening (not shown) may be incorporated for hanging the overwrap on a hook for displaying, such as on a store shelf. 
         [0034]      FIG. 5  is a schematic view of a product package system  38  of the present embodiment. The system  38  is formed by placing the blister pack assembly  22  of  FIG. 3  through the package opening  36  of the overwrap  24  of  FIG. 4  and aligning the two so that the cavity  18  projects out the window  30 . The gaps D 1 , D 2 , D 3  and D 4  surrounding the cavity  18  ( FIGS. 2 and 3 ) are thus retained within the upper wall, the lower wall and the two side walls around the window  30 , respectively. The corresponding surfaces of the overwrap and the blister back secure the blister pack assembly  22  within the overwrap  24 . As configured, the blister pack assembly  22  cannot be removed from the overwrap  24  without tempering with the overwrap, such as by cutting the window  30  or opening the tear strip  28 . Among other things, once the closure system is closed, the size of the blister pack assembly  22  is physically too large for the only remaining opening  30  to extract the blister pack. Where multiple windows are provided, alignment is required to place each rib between each adjacent sub-cavity, such as between cavities  18   a  and  18   b.  The closure system  26  is then used to enclose the blister pack assembly  22  within the overwrap  24 . 
         [0035]      FIGS. 6 and 7  are front and rear views of the product package system  38  of  FIG. 5 , respectively. The blister pack assembly  22  may be removed from the overwrap  24  by pulling on the tear strip  28  to open the package opening  36  and remove the blister pack assembly  22 . Once removed, the blister pack assembly  22  can be fully opened by separating the lidding  10  from the blister pack  16 . The lidding  10  can easily be separated from the blister pack  16  by sliding the lidding  10  out of the receiving channels  20 . As described, the consumer product placed within the cavity  18  of the blister pack assembly  22  is accessible without having to cut open the blister pack assembly  22 . Furthermore, the ability to fully open the blister pack assembly  22  and to completely remove the lidding  10  from the blister pack  16  facilitates recycling of the various components of the blister pack assembly  22  in that paper and plastic components can easily be sorted and placed in appropriate recycling bins. 
         [0036]    As understood, an aspect of the present disclosure is a product package system comprising a thermoformed blister pack placed inside an overwrap comprising an adhesive closure system. In another embodiment, a tear strip is provided on the overwrap for removing the blister pack. 
         [0037]    The present disclosure is further understood to include a lidding for sliding between two spaced apart channels formed on the blister pack before placing the blister pack into the overwrap. In a specific embodiment, a cavity on the blister pack projects out a window incorporated on a front layer, a back layer, or both layers of the overwrap. 
         [0038]    A still further feature of the present disclosure is a method for making a product package system comprising a clamshell blister pack and for assembling one or more consumer products within the clamshell blister pack without having to heat seal the clamshell blister pack. By not heat sealing the clamshell blister pack, the product package system is less costly and less labor intensive to produce due to the fewer steps. Furthermore, the product package system is easier to package and open. Still furthermore, recycling is made easier due to the ability to fully open the blister pack and sort between plastic and paper. 
         [0039]    Although limited embodiments of the product package system and its components have been specifically described and illustrated herein, many modifications and variations will be apparent to those skilled in the art. For example, the various components may be made from different materials, different art may be used for product placement and information, such as incorporating different colors, and different sizes may be used for packaging different contents. Furthermore, it is understood and contemplated that features specifically discussed for one package and system may be adopted for inclusion with another provided the functions are compatible. Accordingly, it is to be understood that the illustrated embodiments have been set forth only for the purposes of examples, and that the embodiments should not be taken as limiting the disclosure as defined by the following claims. The following claims are, therefore, to be read to include not only the combination of elements which are literally set forth, but all equivalent elements for performing substantially the same function in substantially the same way to obtain substantially the same result. The claims are thus to be understood to include those that have been illustrated and described above, those that are conceptually equivalent, and those that incorporate the ideas of the present disclosure.