Patent Document

CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]    This application claims priority under 35 U.S.C. 119(e) on U.S. provisional patent application No. 60/292,356 entitled “DISPLAY CARD HAVING REINFORCED HANGER HOLE,” filed on May 21, 2001, the entire disclosure of which is incorporated herein by reference. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The present invention generally relates to display cards for displaying products for sale and, more particularly, to a hanging display card package having a combined display card and container for retaining product for display to consumers.  
           [0003]    A common practice for packaging and displaying small retail items, such as cylindrical alkaline batteries, is to package the items in thermoformed blister packages and place the packages on shelves or hang the packages on hooks on various display racks. Conventional battery packages are generally composed of a display card which provides a generally stiff supportive backing, usually composed of paperboard, and a thermoformed polymeric blister that is bonded or otherwise attached to the display card. The display card provides support for displaying the merchandise for sale and usually contains print with suitable indicia, such as advertising, trademarks, and instructions.  
           [0004]    With battery display packages, batteries of the same size are commonly made available to consumers for purchase in a package containing a predetermined number of batteries. The batteries are displayed and sold in blister-type packages which usually contain two, four, or eight batteries commonly packaged in each display package. In accordance with one battery packaging approach, the thermoformed blister generally comprises a piece of transparent polymeric material, e.g., plastic, heat-sealed to the front side of the display card. According to another approach, a clam-type thermoformed polymeric blister, generally having a shape to fit over and cover the batteries, is supported on the paperboard display card. The clam-type polymeric blister typically has two pieces, each having a peripheral flange disposed between the two layers of the paperboard of the display card. The blister isolates the product from the surrounding environment and prevents inadvertent damage to the product that can result from repeated handling prior to sale. Additionally, the blister allows for the orderly display of products for sale to purchasers.  
           [0005]    Hanging display packages generally include a closed loop hanger hole formed in the display card near the upper edge. The hanger hole enables the package to be hung on a hanger, such as a hook, on a display stand for display to consumers in a retail store. The hanger hole is formed by cutting (e.g., stamping) away a piece of card material from the paperboard display card in a shape sufficient to receive the hanger. It is generally preferred that the hanger hole be located as close to the upper edge as possible, so as not to interfere with the surface area available on the display card for displaying print indicia and retaining product. However, a sufficient amount of the card material must be present between the hanger hole and the upper edge of the display card to provide adequate strength to support the package on the hanger and prevent tearing of the display card. A tear in the display card may render the display package unhangable on the display stand and torn display cards are generally unattractive to consumers, thus rendering the package less desirable. The potential for torn display cards increases with heavier packages, shortened distance between the hanger hole and upper edge, and misuse by retail customers or store clerks.  
           [0006]    Accordingly, there is a need, heretofore unfulfilled, for a hanging product display package for displaying product for sale to consumers having a display card that provides a hanger hole of sufficient strength to hold the product on a display stand without tearing the display card. In particular, it is desirable to provide for such a hanging product display package that retains batteries for display and sale to consumers in retail stores.  
         SUMMARY OF THE INVENTION  
         [0007]    The present invention provides for a display card and product display package having a reinforced hanger hole that is resistant to tearing. To achieve this and other advantages, and in accordance with the purpose of the present invention as embodied and described herein, one aspect of the present invention provides for a display card for retaining product. The display card includes a main body including a front surface, a rear surface, and an edge. The main body has a first layer of material attached to a second layer of material. The display card has a closed loop hanger hole formed in the main body that is adapted to receive a hanger to hang the display card for display. The display card also has a tape reinforcement layer adhered to the main body in a region adjacent to the hanger hole to enhance the strength of the display card between the hanger hole and the edge of the main body.  
           [0008]    According to another aspect of the present invention, a display package for retaining product is provided. The display package comprises a container having a housing defining a compartment adapted to house product. The display package also has a display card having a main body and supporting the container. The main body has a first layer of material attached to a second layer of material. The display card has a front surface, a rear surface, and an edge. The display package further has a closed loop hanger hole formed in the display card for allowing the display package to be hung from a hanger for display. A tape reinforcement layer is disposed between the first and second layers of material and adhered to the display card in a region adjacent to the hanger hole to provide reinforced strength between the hanger hole and the edge of the display card.  
           [0009]    Accordingly, the tape reinforcement layer advantageously enhances the strength of the region adjacent to the hanger hole. The enhanced strength region adjacent to the hanger hole prevents tearing of the display card, particularly during abusive handling of the display package. Accordingly, a more attractive product display package is maintained, which is particularly useful for displaying small items, such as batteries, for display to consumers in retail stores.  
           [0010]    These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    In the drawings:  
         [0012]    [0012]FIG. 1 is a front view of a battery display package having a reinforced hanger hole according to one embodiment of the present invention;  
         [0013]    [0013]FIG. 2 is an exploded view of the battery display package shown in FIG. 1;  
         [0014]    [0014]FIG. 3 is a rear view of the front layer of the display card;  
         [0015]    [0015]FIG. 4 is an enlarged cross-sectional view taken through lines IV-IV of FIG. 1;  
         [0016]    [0016]FIG. 5 is a front perspective view of a battery display package having a reinforced hanger hole shown in a partial exploded view; and  
         [0017]    [0017]FIG. 6 is a rear view of the display package shown in FIG. 5.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0018]    For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal” and derivatives thereof shall relate to the invention as oriented in FIGS. 1 and 5. However, it is to be understood that the invention may assume various alternative orientations and step sequences except where expressly specified to the contrary. It is also to be understood that the specific packages illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.  
         [0019]    Referring to FIGS. 1 and 2, a hanging product display package  10  is shown for packaging a plurality of cylindrical batteries, such as AA-sized alkaline batteries for display and sale to consumers in a retail store, according to a first embodiment. The product display package  10  houses four cylindrical AA-size batteries, according to one example, in a combination display card and merchandise container. While a battery display package  10  is shown and described herein, it should be appreciated that the present invention provides a product display package that may house products of various sizes, shapes, and numbers, which may include batteries or other types of products, without departing from the spirit of the present invention.  
         [0020]    The product display package  10  generally includes a display card  12  have a substantially planar main body, and a polymeric blister merchandise container  30  supported by the display card  12 . The display card  12  is shown made up of two layers of materials, including a front layer of paperboard  14  attached to a rear layer of paperboard  16 . Paperboard layers  14  and  16  may include two separate sheets of paperboard substantially similarly shaped and bonded together via glue. Alternately, layers  14  and  16  may be formed from a single sheet of paperboard that is folded along one edge, such as the lower edge, and pressed and bonded together. Display card  12  generally includes an upper edge  20 , two vertical side edges  24  and  26  on the left and right sides, respectively, and a lower edge  22 . The upper edge  20  of display card  12  is shown having an asymmetric shape relative to a central vertical axis in that the upper edge  20  extends to a position that is lower on the right vertical edge  26  as compared to the left vertical edge  24 .  
         [0021]    Provided near the upper edge  20  of display card  12  is a closed loop hanger hole (aperture)  18  which allows the display card  12  to be hung from a hanger, such as a hook, on a display stand. The hanger hole  18  is spaced below the upper edge  20 , but is preferably formed as close as possible to the upper edge  20  so as to maximize the amount of surface area available therebelow on the display card  12  that may be used to retain product and contain print indicia such as advertising, trademarks, and instructions. The closed loop hanger hole  18  is completely surrounded by and defined by the display card  12  such that the hole is spaced apart the upper edge  20 . While the hanger hole  18  is shown having a horizontal slot with an enlarged circular region in the center, it should be appreciated that the hanger hole  18  may be configured in various shapes and sizes.  
         [0022]    The merchandise container  30  that is shown in the first embodiment is a reclosable and reusable transparent thermoformed blister container that houses four cylindrical batteries  32 . The merchandise container  30  has a peripheral flange  34  formed around the perimeter of the compartment containing product and extending radially outward. The peripheral flange  34  is sandwiched between the front and rear layers  14  and  16 , respectively, of display card  12 . Merchandise container  30  extends through a cut out (e.g., aperture) formed in the front layer of display card  12 . The merchandise container  30  is preferably bonded or trapped in place between the front and rear layers  14  and  16  of display card  12  prior to the display card  12  being torn open.  
         [0023]    The display card  12  of the present invention includes a tape reinforcement layer  40  adhered via adhesive  42  to the display card  12  in a local region adjacent to the hanger hole  18  to provide enhanced strength between the hanger hole  18  and the upper edge  20  of the display card  12 . As is shown in FIG. 3, the tape reinforcement layer  40  is adhered to a rear surface of the front layer  14  of the display card  12 . Accordingly, the tape reinforcement layer  40  is sandwiched between the front and rear layers  14  and  16  of display card  12 . According to this embodiment, the tape reinforcement layer  40  is hidden from view of consumers and does not interfere with external viewable space on the display card  12  that may otherwise be employed to contain print indicia. The tape reinforcement layer  40  is preferably adhered to a surface of the display card  12  by any suitable adhesive  42 , such as conventional glue and heat activated adhesives. While the tape reinforcement layer  40  is shown adhered to a rear surface of the front layer  14  of display card  12 , it should be appreciated that the tape reinforcement layer  40  may instead be adhered to the front surface of the rear layer  16  of display card  12 , or may be adhered to both the rear surface of the front layer  14  and the front surface of the rear layer  16  of display card  12 . Alternately, the tape reinforcement layer  40  may be adhered to the rear surface of the rear layer  16  or the front surface of the front layer  14  of display card  12 .  
         [0024]    The tape reinforcement layer  40  may include a polypropylene film tape, such as 230 polypropylene, adhered via an adhesive  42  such as emulsion acrylic. According to one example, the polypropylene film has a thickness of 1.9 mils and the emulsion acrylic has a thickness of 1.0 mil. Another example of tape reinforcement layer  40  includes polyester film, such as Mylar® which is commercially made available by E. I. duPont De Nemours and Company. The tape reinforcement layer  40  may alternately employ a fiber reinforced strip of material. If desired, the thickness of the tape may be increased to 5 mils to compensate for decreases in the thickness of the paperboard and/or increases in the weight of the article housed in the package. The thickness of the display card  12  is substantially greater than the thickness of the tape reinforcement layer  40 . Preferably, the tape reinforcement layer  40  has a thickness of no greater than fifty percent (50%) of the thickness of the display card  12 . More preferably, the tape reinforcement layer  40  has a thickness of no greater than twenty-five (25%) percent of the thickness of the display card  12 .  
         [0025]    According to one embodiment, the battery display package  10  is manufactured by starting with a sheet of paperboard material. Prior to cutting out the individual display cards from the starting sheet, a strip of reinforcement tape is adhered across the sheet of paperboard material. The front layer  14  of display card  12  is then cut from the sheet with a punch to form the shape of the upper and lower edges and the left and right edges. At the same time, the strip of reinforcement tape is also cut to the shape as shown which is located so as to surround the closed loop hanger hole  18  and be between, and preferably adjacent to, the hanger hole  18  and the upper edge  20 , as well as upper portions of the left and right edges of display card  12 . The rear layer  16  of display card  12  is also cut from a sheet of paperboard material. The merchandise container  30 , containing product, is sandwiched between front and rear layers  14  and  16 , and layers  14  and  16  are glued or otherwise adhered together. The hanger hole  18  is formed by cutting out a piece of card material from each of front and rear layers  14  and  16  and tape reinforcement layer  40 .  
         [0026]    Referring to FIG. 4, the tape reinforcement layer  40  is shown adhered to both the front and rear layers  14  and  16  of display card  12 . It should be appreciated that the front and rear layers  14  and  16  of display card  12  are adhered together via adhesive layer  42 , which may include a heat activated adhesive. In addition, adhesive  42  is disposed between the rear surface of front layer  14  and tape reinforcement layer  40 , as well as between the front surface of rear layer  16  and tape reinforcement layer  40 . The tape reinforcement layer  40  may be first adhered to the rear surface of the front layer  14 , and thereafter the front surface of the rear card  16  is adhered, via a heat activated adhesive, to the rear surface of the front card  14 .  
         [0027]    Accordingly, the product display package  10  of the first embodiment employs a tape reinforcement layer  40  disposed between front and rear layers  14  and  16  of display card  12 , which advantageously makes the tape reinforcement layer  40  hidden from view of consumers. As a consequence, more external viewable surface space is made available for print indicia.  
         [0028]    Referring to FIGS. 5 and 6, a battery display package  10 ′ is shown. The battery display package  10 ′ employs a single layer display card  12 ′ having a thermoformed blister merchandise container  30 ′ heat-sealed or otherwise bonded to the front surface of display card  12 ′. As a consequence, the merchandise container  30 ′ traps product(s), such as cylindrical alkaline batteries  32 , between the merchandise container  30 ′ and the front surface of the display card  12 ′. Accordingly, the merchandise container  30 ′ forms a compartment for holding product(s), and the container  30 ′ and product(s) are retained by the display card  12 ′.  
         [0029]    The battery display package  10 ′ further includes a closed loop hanger hole  18  displaced below the upper edge  20  of display card  12 ′ for receiving a hanger, such as a hook, for hanging the battery display package  10 ′ from a display stand. A tape reinforcement layer  40  is adhered to the rear surface of the display card  12 ′. The hanger hole  18  and tape reinforcement layer  40  may include the hanger hole and tape reinforcement layer as discussed in connection with the first embodiment. The tape reinforcement layer  40  remains visible to consumers on the back surface of the single layer display card  12 ′. The tape reinforcement layer  40  is provided in a region adjacent to the hanger hole  18  and between the hanger hole  18  and upper edge  20  of display card  12 ′ so as to provide enhanced strength to the region surrounding the hanger hole  18  and prevent tearing between the upper edge  20  and hanger hole  18 . Consequently, the battery package  10 ′ is less susceptible to tearing which may otherwise occur due to abusive handling of the package  10 ′.  
         [0030]    According to one example, the merchandise container  30  of package  10  according to the first embodiment is preferably made of a polymeric thermoformed blister. The individual front and rear layers  14  and  16  of display card  12  each have a thickness of approximately 16-24 mils. The tape reinforcement layer  40  preferably has a thickness of about 2 mils for a polypropylene film, and each adhesive layer has a thickness of about 1 mil. According to another example, the display card  12 ′ of package  10 ′ has a thickness in the range of approximately 16-32 mils, the tape reinforcement layer  40  preferably has a thickness of about 2 mils for a polypropylene film, and the adhesive layer has a thickness of about 1 mil.  
         [0031]    It will be understood by those who practice the invention and those skilled in the art, that various modifications and improvements may be made to the invention without departing from the spirit of the disclosed concept. The scope of protection afforded is to be determined by the claims and by the breadth of interpretation allowed by law.

Technology Category: 3