BLISTER DISPLAY PACK USING MOLDED PULP AS BACKING MATERIAL

Abstract

A blister display pack includes two generally flat backing sheets joined together by an adhesive, and a clear plastic contained having a flat insertion portion held between the two backing sheets. A produce is housed in a protruding portion of the plastic container. The two backing sheets are made of a molded pulp material. Raised and/or recessed features are formed in the backing sheets to provide enhanced strength and rigidity.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to product packaging, and in particular, it relates to packaging for products suitable for store merchandising.

2. Description of the Related Art

A conventional blister pack for product packaging and display typically has a clear plastic container with a flat insertion portion held between two flat sheets and a chamber portion protruding from a cut in one or both of the flat sheets for holding the product being sold or displayed. The flat sheets are typically made of corrugated cardboard, SBS board and/or other materials, and at least one sheet provides structural support for the display pack. The flat sheets are of a size that makes the package suitable for store display. The product may be removed by separating the two flat sheets or by cutting open the flat sheet or the plastic container.

SUMMARY OF THE INVENTION

The present invention is directed to an improved blister display pack.

An object of the present invention is to provide a blister display pack that uses a molded pulp backing material.

Additional features and advantages of the invention will be set forth in the descriptions that follow and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims thereof as well as the appended drawings.

To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, the present invention provides a display pack for a product, which includes a first and a second backing sheet made of a molded pulp material, at least one backing sheet defining at least one cutout, the first and the second backing sheets being join together by an adhesive material; and at least one container having a flat insertion portion and a chamber portion for holding the product, the insertion portion being held between the two backing sheets and the chamber portion protruding from one of the backing sheets via the cutout. One or both of the backing sheets may have raised or recessed features formed thereon to enhance strength and rigidity.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a display pack according to an embodiment of the present invention.

FIG. 2 is a schematic cross-sectional view of the display pack of FIG. 1 taken along the direction A-A.

FIGS. 3A and 3B show the display pack of FIG. 1 in an unassembled state.

FIGS. 4A-4C schematically illustrate the cross-sectional shape of the raised or recessed features on the display pack.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiments of the present invention provide a blister display pack that uses molded pulp as the backing material. FIG. 1 is a perspective view of a display pack according to an embodiment of the present invention. FIG. 2 is a schematic cross-sectional view of the display pack of FIG. 1 taken along the direction A-A (In FIG. 1B, the gaps between the various parts are exaggerated for clarity). FIGS. 3A and 3B show the display pack of FIG. 1 in an unassembled state. As shown in FIGS. 1-3B, the display pack 10 includes two generally flat backing sheets 11 and 12 adhered to each other to form a support panel. Each backing sheets 11, 12 has a cutout portion 11a, 12a (backing sheet 11 is shown in FIG. 3A and 3B). The display pack also includes two containers 13 and 14 each having a flat insertion portion 13a, 14a held between the two backing sheets 11 and 12 and a chamber portion 13b, 14b protruding from the cutout portion 11a, 12a, respectively, to form a space to house the product 20. Although FIGS. 1A and 1B show two containers 13 and 14 forming one space to house the product, the display pack 10 may alternatively have only one container protruding from one of the two backing sheets 11 and 12, in with case the other backing sheet does not have a cutout. As another alternative, the display pack 10 may have more than two containers protruding from a corresponding number of cutouts on one or both backing sheets. The number of containers and their arrangements on the backing sheets depend on the product being packaged.

The containers 13, 14 are preferably made of a clear plastic material. In one preferred embodiment, the clear plastic material is vacuum formed plastic made of recycled water bottle flakes.

The backing sheets 11 and 12 are made of molded pulp. Molded pulp, also referred to as molded fiber, is a packaging material typically made from 100% recycled corrugated board and/or newspaper. The recycled corrugated board or newspaper is soaked and formed into a paper pulp, and molded into a desired shape. Molded pulp is widely used for protective packaging and for food service trays and beverage carriers. Preferably, due to environmental concerns, the pulp used in this application is unbleached. The molded pulp backing sheets 11 and 12 may have any suitable thickness, depending on the size of the display pack 10. In one particular example, each molded pulp backing sheet is about 1/16 inches thick for a display pack of about 6 by 10 inches in size.

The molded pulp backing sheets 11 and 12 are formed into desired shapes to provide enhanced strength and rigidity for the display pack 10. Preferably, raised or recessed features 11b and 12b are formed in the backing sheets 11 and 12. Viewed from a direction perpendicular to the backing sheets, these raised or recessed features 11b and 12b preferably have elongated shapes extending across a substantial portion of the backing sheets. In the example shown in FIG. 1A, a raised feature 11b is shown as extending along and near the four edges of the display pack 10. In one particular example, the backing sheets are about 10 by 6⅜ inches in size, and the raised feature around the edges is about ½ inches wide and about ⅜ inches from the edges. The arrangement of the raised or recessed features will depend on the shape of the backing sheets 11 and 12 and the sizes and locations of the outputs 11a and 12a.

The cross-sectional shape of the raised or recessed features, viewed along the plane of the backing sheets, may be a variety of shapes, some of which are schematically illustrated in FIGS. 4A-4C. FIG. 4A shows a portion of the two backing sheets 11 and 12 having respective raised features 11b1 and 12b1, which correspond to each other in locations and are indented (protrude) in opposite directions in the assembled display pack, forming a hollow channel therebetween. The cross-sectional shape of the raised features shown in FIG. 4A is rounded, but it may also be triangular or rectangular, or any other suitable shape. FIG. 4B shows a portion of the two backing sheets 11 and 12 having respective raised features 11b2 and 12b2, which correspond to each other in locations but are indented in the same directions so that one is nested in the other in the. As a result, the assembled display pack has a raised feature on one surface and a corresponding recessed feature on the opposite surface. FIG. 4C shows a portion of the two backing sheets 11 and 12 having respective raised features 11b3 and 12b3, where the raised feature 11b3 corresponds to a flat area of the backing sheet 12 and the raised feature 12b3 corresponds to a flat area of the backing sheet 11. In FIGS. 4B and 4C, the cross-sectional shapes of the raised and recessed features are rounded, but they may also be triangular, rectangular, or any other suitable shape. In this respect, although the backing sheets are described as being generally flat, they may have many non-flat features or areas.

In the assembled display pack, the backing sheets 11 and 12 are adhered together by an adhesive material. In a preferred embodiment, the adhesive is a heat sensitive water based adhesive. One example is an adhesive made by Coating and Adhesive Corporation, product No. 207-C-Enviroshell. A heat sealer device may be used to activate the adhesive and seal the two backing sheets 11 and 12 together. Other suitable adhesives may be used. The adhesive material is applied to at least a peripheral area of the backing sheets near the edges of the display pack. It may additionally be applied to other (interior) areas of the backing sheets, or over the entire area of the backing sheets.

Preferably, the edge portions of the backing sheets are treated to increase their tear resistance of the display pack. In one embodiment, the adhesive material used to seal the two backing sheets is selected such that it increases the tear resistance of the display pack. The water based adhesive mentioned above achieves such a result. In another embodiment, polyethylene (PE) or polylactic acid (PLA) is applied (e.g. sprayed) around the edges of the backing sheets or over the entire backing sheets. It may be applied on the inside or the outside surface of the backing sheets and on either or both sides of the display pack. The material may be applied before or after sealing. As mentioned above, the PE or PLA materials can be used to increase tear resistance, but they should be used as little as possible so that the display pack is more environmentally friendly.

Optionally, for a better appeal, printed sheets such as paper may be adhered to the backing sheet on one or both sides of the display pack, preferably in the flat areas of the backing sheets. The molded pulp backing sheets can also be directly printed on. The display pack may be pegged for retail sale or be insert in trays for club stores. As another option, small plant seeds may be embedded in the molded pulp backing sheets so that the backing sheets can be planted after use. There have been products such as greeting cards where small plant seeds are embedded in the paper, making it suitable for planting.

As compared to conventional blister packs, blister packs using molded pulp backing sheets according to embodiments of the present invention use more recycled materials and are more environmentally friendly.

It will be apparent to those skilled in the art that various modification and variations can be made in the display packs of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover modifications and variations that come within the scope of the appended claims and their equivalents.

Claims

1. A display pack for a product, comprising:

a first and a second backing sheet made of a molded pulp material, at least one backing sheet defining at least one cutout, the first and the second backing sheets being join together by an adhesive material; and

at least one container having a flat insertion portion and a chamber portion for holding the product, the insertion portion being held between the two backing sheets and the chamber portion protruding from one of the backing sheets via the cutout.

2. The display pack of claim 1, wherein one or both of the first and second backing sheets have raised or recessed features formed thereon.

3. The display pack of claim 1, wherein the first and second backing sheets each have a raised feature extending along all edges of the backing sheets.

4. The display pack of claim 1, wherein the container is made of a clear plastic material.

5. The display pack of claim 1, wherein the adhesive material is a heat-sensitive water based adhesive material.

6. The display pack of claim 1, wherein the adhesive material is applied between the first and second backing sheets in at least a peripheral area of the backing sheets.

7. The display pack of claim 1, further comprising a polyethylene (PE) or polylactic acid (PLA) material applied to at least a peripheral area of the first and second backing sheets.

8. The display pack of claim 1, further comprising a coating applied to at least a peripheral area of the first and second backing sheets.

9. The display pack of claim 1, further comprising a print sheet adhered to the first or the second backing sheet.

10. The display pack of claim 1, wherein the backing sheets contains plant seeds embedded in the molded pulp material.