RECLOSEABLE BLISTER PACKAGE AND METHOD OF USE

Abstract

A reclosable blister package for packaging one or more articles is provided with a blister that is capable of being closed against the face of backing so that the blister and the face of the backing can cooperatively form an article containing cavity. The blister includes a cavity portion, a flange, a hinge and a locking protrusion. The backing may include a panel having a blister slot and an interlocking opening. The blister slot may include a flange insertion portion and a hinge seat. The flange may be fitted through the blister slot and secured to the panel to hold the blister in place. The blister may be movable about the hinge to allow the package to be opened and closed. The locking protrusion may be configured to selectively snap-lock with the interlocking opening in the backing to hold the blister in the closed position.

Description

BACKGROUND OF THE INVENTION

The present invention relates to packaging, and more particularly to blister packages used as point-of-sale product packaging.

A wide variety of products intended for retail sale are packaged in packaging that includes plastic components. One of the most common forms of plastic point-of-sale packages is a blister package. A typical blister package includes a shaped plastic blister that forms the main cavity of the package and a backer panel that closes the cavity. The backer panel is often sealed to the blister, for example, by adhesive to enclose the product within the cavity. The backer panel may be formed from paperboard, plastic, aluminum or other similar materials. Because of the use of a paperboard backer panel, a blister package has the potential to be a relatively low cost packaging solution. The amount of plastic used to contain the product is relatively small and the backer panel can be sized to provide ample space for printed content.

Another common form of plastic point-of-sale package is a clamshell package. A typical clamshell package includes a pair of formed plastic parts (often “halves”) that are joined along an integrated, living hinge. The clamshell parts can be closed about the hinge to entrap the product to be packaged. Clamshell packages vary dramatically in design and configuration. For example, some clamshell packages are sealed shut to protect the contents of the package until it is opened by the end consumer. With sealed clamshell packages, it is often necessary to at least partially destroy the package to gain access to the contents. This can, among other things, prove inconvenient and frustrating to the end consumer. In other applications, the clamshell is not sealed in the finished package. In a reclosable configuration, the clamshell can be formed with contours that permit the two clamshell parts to be friction interfitted in a way that holds the parts together in a closed configuration about the packaged contents. It is not uncommon to incorporate paper or paperboard inserts into clamshell packages. For example, information and other content can be printed on an insert that is enclosed within the clamshell.

One particularly innovative clamshell composite package is shown in U.S. Pat. No. 7,931,148 to Hansen et al for DOUBLE HINGE DISPLAY PACKAGE AND METHOD OF USE, issued Apr. 26, 2011, which is incorporated herein by reference in its entirety. In one embodiment, U.S. Pat. No. 7,931,148 discloses a hybrid package that includes a reclosable plastic clamshell that is combined with a pair of paperboard panels. The clamshell may include front and rear parts that are joined by two hinges, including a manufacturing hinge and an operating hinge.

Another innovative composite package is shown in U.S. application Ser. No. 13/228,541 to Hansen et al for RECLOSABLE DISPLAY PACKAGE AND METHOD OF USE, filed Sep. 9, 2011, which is incorporated herein by reference in its entirety. In one embodiment, this application discloses a package having a thermoformed plastic component that cooperates with a tray to define an article containing space. The peripheral lip of the tray and the flange portion of the plastic component may be sandwiched between a pair of panels to hold them in place with respect to one another. The panels define a large opening that provides communication between the tray and the door portion of the plastic component. This embodiment reduces the amount of plastic used in the package by replacing one-half of a clamshell with a tray. The tray can be manufactured in whole or in part from a fibrous recycled material.

SUMMARY OF THE INVENTION

The present invention provides a reclosable blister package with a blister and a backing that are joined to cooperatively form and article containing space. The blister includes a flange that is fixed to the backing. The flange includes a hinge that allows the blister to open and closed with respect to the backing. The blister includes one or more snap-locks that are configured to interfit with openings in the backing to selectively hold the blister in the closed position.

In one embodiment, the backing is formed of two panels. In this embodiment, the flange may be sandwiched between the panels. For example, one panel may include a slot that allows the flange to be fitted through the slotted panel so that it can be trapped between the panels.

In one embodiment, the backing is a single panel. In this embodiment, the flange may be joined to a surface of the backing. For example, the panel may include a slot that allows the flange to pass through the panel so that it can be secured to the panel on the side opposite the blister.

In one embodiment, the hinge is narrower that the flange. In this embodiment, the slot may include a flange insertion portion and a hinge seat. The hinge seat may be configured to closely receive the hinge. During assembly, the flange may be fed through the insertion portion and the hinge may be fitted into the hinge seat. The hinge and hinge slot may be configured sot that the hinge is exposed in the assembled package.

In one embodiment, the blister includes one or more locking protrusions configured to snap-lock with corresponding openings in a panel. The number and location of locking protrusions and locking openings may vary. In one embodiment, the blister includes a hang hole extension. In the embodiment, the locking protrusion or protrusions may be disposed on the hang hole extension.

In one embodiment, the blister includes a peripheral flange configured to engage the face of the backing when the blister is closed. The flange may extend from the blister at a shoulder. In this embodiment, the locking protrusion or protrusions may be disposed on the shoulder and may be configured to be fitted into aligned locking slots in the backing. In one embodiment, the blister and flange are generally rectangular and a locking protrusion may be located in each corner of the blister.

In one embodiment, the backing includes an aperture and may also include a transparent film filling the aperture. The film may allow the contents of the package to be viewed without opening the blister.

In one embodiment, the panels may be joined by a cohesive, such as a rubber cement or a latex-based cohesive. The cohesive allows the package to be easily assembled without expensive sealing equipment. Alternatively, the panels may be joined by other adhesives, such as heat activated adhesives. In applications that incorporate a cohesive, the flange of the plastic component may be specially shaped to facilitate use with cohesive. In one embodiment the flange includes “wings” that extend outwardly to increase the strength of the connection between the plastic component and the panels while maintaining a bond between the panels. In one embodiment, the hinge extends in a transverse direction across the plastic component and the wings extend in a transverse direction beyond opposite transverse ends of the hinge. The wings may be spaced from the hinge a sufficient distance to allow the panels to be joined together by the cohesive in the region between the hinge and the wings to resist removal of the wings out from between the panels.

In one embodiment, the package may include a hang hole and the blister may include an extension configured to reinforce the hang hole. In this embodiment, the hang hole may be located toward the top of the package and the extension may be shaped to extend above the hang hole to reinforce the panels against tearing initiated at the hang hole. The extension may be shaped to extend completely around the hang hole, if desired.

In another aspect of the invention, a method is provided for forming a reclosable blister package. The blister is a one-piece plastic component having a blister portion and a flange. The flange may include a hinge. In one embodiment, the method includes the steps of: (a) forming a blister with a flange having a living hinge; (b) forming a backing with a slot configured to closely receive the flange of the blister; (c) fitting the flange through the slot so that the flange is disposed one side of the backing while the hinge and blister are exposed on the opposite side; and (d) securing the flange on the opposite side of the panel. In one embodiment, the backing includes two panels and the method includes sandwiching the flange between the two panels.

The present invention provides a simple and inexpensive blister that can be easily opened and closed, for example, by a consumer interested in gaining access to the packaged article(s). For example, the package allows a potential customer to inspect the packaged article(s) at the point of sale. It also allows a customer to more easily access article(s) once purchased. In this way, the present invention provides the benefits of a clamshell package while using only about one half as much plastic. The locking protrusion or protrusions provide a simple mechanism for snap-locking the blister into the closed position. In some embodiments, an extension of the blister is used to define a hang hole and to interlock with the backing. In some embodiments, the assembly slot includes a hinge seat that can facilitate assembly by providing a simply mechanism for registering the blister with respect to the backing. The hinge seat may also improve the overall strength of the package.

These and other objects, advantages and features of the invention will be more readily understood and appreciated by reference to the detailed description of the invention and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a package in accordance with an embodiment of the present invention.

FIG. 2 is a perspective view of the package in an open position.

FIG. 3 is a top plan view of the package.

FIG. 4 is a perspective view of the blister.

FIG. 5 is a top plan view of the blister.

FIG. 6 is a rear view of the blister package.

FIG. 7 is a front view of the blister.

FIG. 8 is a right side view of the blister.

FIG. 9A is a side view of the blister package with a portion shown in section.

FIG. 9B is enlarged view of Area A in FIG. 9A.

FIG. 10 is top plan view of a first alternative blister.

FIG. 11 is top plan view of a second alternative blister.

FIG. 12 is top plan view of a third alternative blister.

FIG. 13 is a top plan view of the backing.

FIG. 14 is a top plan view of an alternative backing.

FIG. 15 is a perspective view of a package in accordance with an alternative embodiment.

FIG. 16 is a perspective view of the alternative package in an open position.

FIG. 17 is a top plan view of the alternative package.

FIG. 18 is a perspective view of the alternative blister.

FIG. 19 is a top plan view of the alternative blister.

FIG. 20 is a rear view of the alternative blister package.

FIG. 21 is a front view of the alternative blister.

FIG. 22 is a right side view of the alternative blister.

FIG. 23A is a side view of the alternative blister package with a portion shown in section.

FIG. 23B is enlarged view of Area A in FIG. 23A.

FIG. 24 is a perspective view of a second alternative blister package.

FIG. 25 is a perspective view of the second alternative package in an open position.

FIG. 26 is a top plan view of the second alternative blister package.

FIG. 27 is a right side view of the second alternative blister package.

FIG. 28A is a back view of a portion the second alternative blister package.

FIG. 28B is an enlarged sectional view taken along line A-A of FIG. 28A.

FIG. 29 is a top plan view of the blister of the second alternative blister package.

FIG. 30 is a top plan view of the backing of the second alternative blister package.

DETAILED DESCRIPTION OF CURRENT EMBODIMENTS

A reclosable blister package in accordance with an embodiment of the invention is shown in FIGS. 1-3 and is generally designated 10. The blister package 10 is designed to hold and display articles, for example, at the point of sale. The blister package 10 of FIG. 1 generally includes a blister 12 and a backing 14. In this embodiment, the blister 12 is a thermoformed plastic component and the backing 14 is a pair of paper board panels 16, 18 (See FIGS. 13 and 14). In the illustrated embodiment, the blister 12 and the backing 14 cooperate to form a cavity 20 adapted to contain the packaged article(s) (not shown). The blister 12 includes a flange 22 that is fixedly secured to the backing 14. The flange 22 includes a hinge 24 that allows the blister 12 to pivot between open and closed positions to provide selective access to the packaged article(s). In this embodiment, the flange 22 is secured between the panels 16, 18 to hold the blister 12 in place with respect to the backing 14. The blister 12 includes one or more locking protrusions 38 that can be interfitted with one or more openings in the backing 14 to snap-lock the blister 12 in the closed position. The locking protrusions 38 may vary from application to application (See e.g. FIGS. 5, 10, 11 and 19). The backing 14 may be a single paperboard component that is divided into panels 16, 18 by a fold line 26. If desired, the panels 16, 18 may be sealed together using a cohesive (not shown) extending over the inner surfaces of the panels 16, 18. When used, cohesive permits simple manual assembly of the blister package 10 without sealing equipment.

The present invention is described in connection with various alternative embodiments configured to provide a generally rectangular reclosable blister package. These embodiments are merely exemplary and the present invention is not limited to rectangular reclosable blister packages. To the contrary, the size, shape and configuration of the blister and the backing may vary from application to application, as desired. For example, the size and shape of the blister and the backing may vary to accommodate articles of different sizes and shapes, or to provide packaging with unique and distinctive aesthetic appearance.

Directional terms, such as “front,” “rear,” “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inside,” “inner,” “inwardly,” “outside,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms is merely an expedient to facilitate disclosure with reference to the illustrations and should not be interpreted to limit the invention to packages of any specific orientation(s).

As noted above, the blister package 10 generally includes a blister 12 and a backing 13. The blister 12 is configured to be reclosable against the face of the backing 14. In this way, the blister 12 and the backing 14 cooperatively form an article receiving space. In the illustrated embodiment, the blister 12 is a thermoformed plastic component formed from one piece of plastic (See FIGS. 4-8). In the illustrated embodiment, the blister 12 includes a cavity portion 28 and a flange 22. The cavity portion 28 is shaped to form a pocket, which, when moved into the closed position, cooperates with the backing 14 to create an article containing cavity 20. In the illustrated embodiment, the blister 12 and the cavity portion 28 are generally rectangular. However, the blister 12 and the cavity portion 28 can be virtually any desired size and shape depending on the article(s) to be packaged or any other design or aesthetic considerations. For example, the blister 12 can alternatively be round, oval or essentially any other suitable shape. The cavity portion 28 can be shaped to snuggly receive the packaged article(s). For example, the cavity portion 28 may be formed to correspond with the interfacing contours of the packaged article(s) so that the article(s) can be seated within the blister 12. The number of cavity portions may also vary from application to application, as desired. For example, a single blister may be formed with a plurality of discrete cavity portions, where each portions is configured to package a separate article or a separate collection of articles.

The blister 12 may include a peripheral lip 32 configured to engage the face of the backing 14 when the blister 12 is in the closed position. In the illustrated embodiment, the peripheral lip 32 extends around the periphery of the cavity portion 28. The lip 32 of this embodiment is continuous and generally uniform in width, but may be discontinuous and may vary in width, if desired. In some applications, the lip 32 may be eliminated.

As noted above, the blister 12 is secured to the backing 14 by flange 22. The flange 22 extends from an edge of the cavity portion 28 and includes a hinge 24 that allows the cavity portion 28 to pivot freely with respect to the flange 22. In the illustrated embodiment, the cavity portion 28 is generally rectangular and the flange 22 extends from the bottom of the cavity portion 28. The size, shape and configuration of the flange 22 may vary from application to application. The flange 22 may be secured to the backing 14 in essentially any suitable matter. In the illustrated embodiment, the flange 22 is trapped between the panels 16, 18. In this embodiment, the panels 16 and 18 are joined face-to-face by a cohesive. Because the cohesive adheres predominantly only to itself, the flange 22 may be shaped to improve the cohesive interconnection of the various components. For example, in the illustrated embodiment, flange 22 includes extensions 30 that extend outwardly from opposite ends of the flange 22 to provide structure than can be entrapped between the cohesively adhered panels 16 and 18. In the illustrated embodiment, the overall width of the flange 22, including extensions 30, is narrower than the overall width of the backing 14 in the region of the flange 22 by an amount sufficient to provide adequate adhesion between the panels 16, 18 along the perimeter of the package 10. The amount of surface area in contact between panel 16 and panel 18 will affect the strength of the adhesion between the panels. By increasing the area of contact, the bond between the panels 16, 18 can be increased. This will not only help to hold the panels 16, 18 together, but if the area of contact is increased in the path along which the flange 22 must be moved to remove it from between the panels, then it will also help to retain the flange 22. In use, the size, shape and configuration of the flange 22 and the extensions 30 may vary from application to application to provide an appropriate balance between various factors, such as strength of the flange 22, retention of the flange 22 between the panels 16, 18, and adhesion between the panels 16, 18.

The flange 22 is adjoined to the cavity portion 28 by hinge 24. The hinge 24 can be essentially any structure that allows the cavity portion 28 to pivot with respect to the flange 22 between open and closed positions. In the illustrated embodiment, the hinge 24 is a living hinge formed integrally with blister 12. For example, the hinge 24 may be a square hinge (as shown) or other type of hinge form by shaping the plastic material. Despite the name, the square hinge 24 need not be “square”, but rather can be a ridge or bump or protrusion of essentially any cross-sectional shape (such as square, rectangular, round or triangular) formed in the plastic component. As a result of its shape, the square hinge 24 may reinforce the blister 12 in the transverse direction. More specifically, the square hinge 24 may be generally rigid in the traverse direction (e.g. along the length of the hinge), while still allowing the blister 12 to easily pivot between the open and closed positions. The square hinge may be facilitated by trim lines, die cuts, or other mechanisms generally know in the art. Alternatively, the hinge 24 can be a line of weakening extending transversely across the material of the plastic component, such that the cavity portion 28 and the flange 22 are capable of folding at the line of weakening. The line of weakening can include, for example, include a fold line, a score line, a line of reduced thickness or a line of perforations. In use, the hinge 24 may allow the cavity portion 28 to pivot away from the backing 14 as far as necessary to create an opening through which article(s) can be inserted into or removed from the package 10. As shown in FIG. 1, the hinge 24 may be exposed (e.g. not beneath the front panel 16 to allow the blister 12 to be opened and closed repeatedly without interference from the front panel 16. The hinge may alternatively be located between the panels 16, 18, if desired.

In the embodiment of FIGS. 1-3, the flange 22 and hinge 24 extend continuously across the blister 12. Alternatively, the flange and hinge may be discontinuous. For example, the blister 212 may include a flange that is divided into separate first and second flanges 222a-b, each with an integrated hinge 224a-b (See FIG. 12). As shown in FIG. 12, each flange 222a-b may include lateral extensions 230 to provide an improved connection with the panel or panels.

As noted above, the blister 12 is configured to selectively interlock with the backing 14 to hold the blister 12 in the closed position. The structure for interlocking the blister 12 and the backing 14 may vary from application to application. For example, in the embodiment of FIGS. 1-14, the blister 12 includes an upper extension 36 that includes locking protrusions 38 that snap-fit with an opening 40 in the backing 14 (See e.g. FIGS. 6, 9A and 9B). As another example, in the embodiment of FIGS. 15-23, the blister 12′ includes locking protrusions 38′ that extend from the periphery of the cavity portion 28′ and snap-fit with openings 40′ in the backing 14′ (See e.g. FIGS. 20, 23A and 23B).

Referring now to FIGS. 4, 5 and 8, the blister package 10 includes an upper extension 36 that extends from the top of the cavity portion 28 opposite the flange 22. In this embodiment, the upper extension 36 is centered on the cavity portion 28 and is substantially narrower the cavity portion 28. The illustrated upper extension 36 extends to the top of the backing 14 and defines a hang hole 42. The illustrated hang hole 42 is merely exemplary. The size, shape and configuration of the hang hole 42 may vary from application to application as desired. The extension 36 may include a tab 44 that provides a structure for grabbing the extension 36 to pull it open. In the illustrated embodiment, the tab 44 extends from the top center of the extension beyond the upper edge of the backing 14. However, the location of the tab 44 may vary from application to application. In some applications, the extension 36 and tab 44 may be configured to remain within the periphery of the backing 14. Although not shown, the tab 44 may be bent out of the plane of the extension 36 to extend at angle away from the backing 14, if desired. The tab 44 may be sized and shaped to provide sufficient gripping surface for a user to overcome the resistance to opening created by the interaction of the structure that interlocks the blister 12 and the backing 14. For example, the tab 44 can be sized so that it can be readily squeezed between a user's thumb and forefinger. As shown, the tab 44 may be positioned at the top center of the upper extension 36, but the tab 44 may be positioned at other locations, such as at essentially any desired location on the upper extension 36 or the lip 32.

In the embodiment of FIGS. 1-9, the locking protrusions 38 are disposed about the hang hole 42. Although the number and location of locking protrusions 38 may vary, in this embodiment, the extension 36 includes two semicircular locking protrusions 38 arranged on opposite sides of the hang hole 42. The locking protrusions 38 are formed with a reverse draft that allows them to snap-lock into engagement with the backing 14 (See FIGS. 9A and 9B). The size, shape and configuration of the locking protrusions 38 may vary from application to application. For example, in the alternative blister 312 of FIG. 10, the locking protrusions 338 may be disposed above and below the hang hole 342 rather than on opposite sides. As another example, in the alternative blister 412 of FIG. 11, the extension 436 may include a single locking protrusion 438 that forms a closed loop around the hang hole 442. In these embodiments, the backing defines a single opening 40 that is aligned with the locking protrusions 38 and the hang hole 42 (described in more detail below).

As noted above, the cavity portion 28 and the flange 22 can be integrally formed. The integrally formed blister 12 can be thermoformed or formed in any other suitable manufacturing process in one piece, such as from a single, one-sided die. Alternatively, the cavity portion 28 and the flange 22 may separately formed and joined by a component that forms the hinge 24. For example, the cavity portion 28 and the flange 22 may be separately formed and joined by a tape (not shown) or other form of flexible material. Although the cavity portion 28 of the illustrated embodiment is generally rectangular, the size, shape and configuration of the cavity portion 28 vary from application to application as desired. Similarly, the number of cavity portions may also vary from application to application, as desired. For example, a single blister may be formed with a plurality of discrete cavity portions, where each portions is configured to package a separate article or a separate collection of articles.

The blister 12 may be injection molded or thermoformed, and is typically constructed from polyvinyl chloride (PVC) or polyethylene terephthalate (PET) or some other polymer. Although the material is typically transparent, translucent or clear, the stock may also be opaque, clouded or tinted any suitable color in some applications. The blister 12 will vary in thickness from application to application. For standard applications, the blister 12 is likely to have a thickness ranging between 12 and 30 gauge (i.e., 12 to 30 thousands of an inch).

As noted above, the backing 14 of the illustrated embodiment includes two panels 16, 18 that are joined face-to-face to form a structure for closing the rear of the blister 12 and entrapping the flange 22 (See FIG. 13). The panels 16 and 18 also provide surface area that can receive printed material, such as text and images. In the illustrated embodiment, the backing 14 includes a front panel 16 and a rear panel 18. In the assembled package 10, the front and rear panels 16, 18 of this embodiment are joined together around the entire peripheral the flange 22. The front and rear panels 16, 18 may be secured together and/or to the flange 22 in any suitable manner, including adhesives known in the art. For example, the panels 16, 18 can be secured with a rubber or latex cohesive. As an alternative to cohesive, the panels 16, 18 may be joined face-to-face by any suitable adhesive, connector or fastener may (alone or in combination) be used to join the panels 16, 18 and the flange 22. The panels 16, 18 can be any desired size and shape depending on any number of relevant factors, such as desired aesthetics and the characteristics of the article(s) to be packaged (e.g. number, size, shape and weight). The backing 14 can be constructed out of paperboard material. However, other materials commonly known in the art, such as plastic, may also be used to form the door panel and tray panel. In the illustrated embodiment, the front and rear panels 16, 18 are integrally formed from a single piece of paperboard. For example, as shown in FIG. 13, the panels 16, 18 are joined together along a fold line 26 located along the top of each panel 16, 18. The fold line 26 may be a score line, a partial cut line, a row of perforations or the like. In the embodiment of FIG. 13, the fold line 26 forms the upper peripheral edge of the package 10 (FIG. 4), but could be along any edge of the package 10. As another example, shown in FIG. 14, the backing 114 includes panels 116, 118 that are joined together along a fold line 126 located along a side of the panels 116, 118. In another alternative embodiment (not shown), the panels may be manufactured separately from one another. Although the backing 14 of the illustrated embodiment includes front and rear panels 16, 18, the backing may alternatively include only a single panel (e.g. front panel 16). In embodiments with only a single panel, the flange 22 may be secured to the back side of the panel, for example, by cement, adhesive or mechanical fasteners.

In the illustrated embodiment, the front panel 16 defines a blister slot 48 configured to allow the flange 22 to be fitted though the front panel 16. In the illustrated embodiment, the blister slot 48 includes a flange insertion portion 60 and a hinge seat 62. The flange insertion portion 60 may extend transversely across the front panel 16 and may be of sufficient length and width to allow the flange 22 to pass through the front panel 16. As shown, the overall width of the flange insertion portion 60 may coincide with the width of the flange 22, including lateral extensions 30. In this embodiment, the hinge seat 62 is in communication with the flange insertion portion 60 so that, during assembly, the flange 22 can be fitted through the front panel 16 and then moved down until the hinge 24 is fitted into the hinge seat 62. In this embodiment, the width of the hinge seat 62 is slightly larger than the width of the hinge 24 and significantly narrower than the full width of the flange 22. In this way, the hinge seat 62 is configured to provide a seat capable of closely receiving the hinge 24 to locate the blister 12 with respect to the backing 14. The depth of the hinge seat 62 (e.g. the distance between the hinge seat 62 and the flange insertion slot 60) may vary from application to application. For example, the hinge seat 62 may be substantially deeper to provide additional spacing between the seated hinge 24 and the flange insertion portion 60. In one embodiment, this means moving the flange insertion slot 60 farther up the card away form the hinge seat 62. In some applications, this may reduce the likelihood of the flange 22 being pulled out from between the panels 16, 18.

In the embodiment of FIG. 14, the panels 16, 18 also include an opening 40 configured to receive the locking protrusions 38. The size, shape and configuration of the opening 40 are selected to correspond with the locking protrusions 38 so that the locking protrusions 38 can be snap-fitted into the opening 40. As shown, the opening 40 extends through both panels 16, 18, thereby allowing the locking protrusions 38 to be pushed entirely through the backing 14. In this embodiment, the opening 40 is generally oval in shape and is positioned to not only receive the locking protrusions 38, but also to provide a through hole coincident with the hang hole 42 in the blister 12. In the illustrated embodiment, the backing 14 includes a single opening that provides a through-hole for the hang hole 42 and is capable of receiving both locking protrusions 38. Alternatively, the backing 14 may include separate openings (not shown), for example, one opening for the hang hole 42 and a separate opening for each locking protrusion 38.

Although the panels 16, 18 of the illustrated embodiment are generally rectangular, they may vary from application to application as desired. For example, the general shape of the panels 16, 18 may vary depending on the shape of the article(s) to be packaged, the shape of the blister 12 and/or on the desired package aesthetics.

Assembly of the blister package 10 of FIG. 9 will now be described. In this embodiment, the blister 12 and panels 16, 18 are separately manufactured. These components may be manufactured using conventional techniques and apparatus. For example, the blister 12 can be thermoformed using a conventional negative mold, and the backing 14 can be die-cut from the desired paperboard stock. The backing 14 includes front panel 16 and rear panel 18 joined along fold line 26. The flange 22 of the blister 12 may be inserted through the blister slot 48. More specifically, the flange 22 may be inserted through the flange insertion portion 60 so that the flange 22 is primarily disposed on the inside of the front panel 16 and the hinge 23 and the cavity portion 28 are disposed on the outside of the front panel 16. The flange 22 is then moved down into the blister opening 48 to position the hinge 24 in the hinge seat 62. Because the hinge seat 62 coincides in width with the hinge 24. This action will properly locate the blister 12 with respect to the backing 14.

After the blister 12 is properly seated in the front panel 16, the panels 16, 18 may be closed to sandwich the flange 22. In the illustrated embodiment, the front panel 16 and rear panel 18 are joined along fold line 26 and the backing 14 is closed by pivoting the front panel 16 and rear panel 18 together about the fold line 26. The front panel 16 and rear panel 18 may be joined together by cement, adhesive or other mechanisms. In the illustrated embodiment, the entire inner surfaces of the front panel 16 and rear panel 18 are coated with a cohesive. When the inner surfaces of the two panels 16, 18 are brought into contact, they adhere to one another. The adhesion between the panels 16, 18 also holds the flange 22, including lateral extensions 30 to resist removal of the flange 22 from between the panels 16, 18. Alternatively, the panels 16, 18 may be joined by other cements or adhesives, such as heat activated adhesive, heat seal coating, standard glue, hot melt glue, single-sided tape, double-sided tape or an RF adhesive. If it is desirable to use single-sided tape, one method of doing so may be to tape the flange 22 to one of the panels 16, 18, and to tape the panels 16, 18 together with tape applied around the outside of the panels 16, 18. As another alternative (or in addition), the panels 16, 18 may be joined by mechanical structures, such as staples, rivets, grommets, push-lock pins or crimping. With embodiments that include a mechanical structure, the mechanical structure may extend through the flange 22 to mechanically secure the flange 22 with respect to one or both of the panels 16, 18. For example, the blister 12 may be secured by a staple extending through the flange 22 and one or both of the panels 16, 18. Additional methods for joining the panels 16, 18 may be available with specific panel materials. For example, if the panels 16, 18 are manufactured from plastic, they may be joined using ultrasonic or RF methods. Some alternative adhesives may adhere directly to the flange 22 and may therefore improve the bond between the panels 16, 18 and the flange portion 22. Although the entire inner surfaces of the panels 16, 18 are covered with adhesive in the illustrated embodiment, they may be partially coated in some applications. For example, in some applications, adhesive may be applied only along the peripheral edges of the panels 16, 18 or in select locations as desired to provide a suitable bond between the panels 16, 18 and flange 22.

After the panels 16, 18 have been joined together, the blister 12 may be moved into the closed position. In this embodiment, the blister 12 may be pivoted about hinge 24 until the cavity portion 28 engages the face of the front panel 16 and the locking protrusions 38 are fitted through opening 40 in the backing 14. More specifically, the cavity portion 28 can be pivoted into engagement with the front panel 16 and the extension 36 can be pressed toward the backing 14 until the locking protrusions 38 are snap-fitted into the opening 40. The interaction between the locking protrusions 38 and the opening 40 provides a snap lock that helps to hold the cavity portion 28 in the closed position (See FIGS. 6, 9A and 9B). In this embodiment, the peripheral lip 32 of the cavity portion 28 engages the outer surface of front panel 16 when the cavity portion 28 is snap-locked in the closed position (See e.g. FIG. 6).

A blister package 10′ in accordance with an alternative embodiment of the present invention is shown in FIGS. 15-23. This alternative blister package 10′ is essentially identical to blister package 10, except as expressly described. In this embodiment, the upper extension 36 is eliminated and the locking protrusions 38′ are disposed about the periphery of the cavity portion 28′. In this embodiment, the cavity portion 28′ includes a shoulder 70′ that provides a transition from the side wall 72′ to the peripheral lip 32′. The size, shape and configuration of the shoulder 70′ may vary from application to application. However, in the illustrated embodiment, the shoulder 70′ extends entirely around the cavity portion 28′ and is configured to engage the face of front panel 16′ when the blister 12′ is in the closed position. Although continuous in the illustrated embodiment, the shoulder 70′ may be discontinuous, if desired. In the illustrated embodiment, the shoulder 70′ includes four locking protrusions 38′ that snap fit with corresponding openings 40′ in the backing 14′ (described below) to hold the cavity portion 28 in the closed position. The locking protrusions 38′ of this embodiment are extensions from shoulder 70′ that have a reverse draft and are configured to snap-lock with the backing 14. In the illustrated embodiment, the locking protrusions 38′ include four protrusions generally positioned at the corners of the shoulder 70′. The number of locking protrusions 38′ may vary and they may be positioned in essentially any desired location on the shoulder 70′. The characteristics of the locking protrusions 38′, such as the number, location, shape and/or length of the snap elements, may be varied to provide the desired to characteristics in the snap-fit between the blister 12′ and the backing 14′. For example, longer or shorter snap elements 46 may vary the overall force required to snap-fit the blister 12′ into the closed position. Further, the leading and closing edges of the locking protrusions 38′ may be non-planar to provide some control over the interaction between the locking protrusions 38′ and the blister 12′. For example, the leading edge of the locking protrusions 38′ can be ramped to provide less resistance when snapping them into engagement with the backing 14′. As another example, the trailing edge of the locking protrusions 38′ can be squared to provide increased resistance to opening of the blister 12′. Alternatively, or additionally, the characteristics of the interfacing portions of the backing 14′, such as size or shape, may be varied to control the force required to operate the snap-fitting interaction of the blister 12 and backing 14. For example, the force required to open and close the blister 12′ may be varied by increasing or decreasing the closeness of the fit between the locking protrusions 38′ and the backing 14′, or by varying the thickness or characteristic of material of the panels 16, 18.

Optionally, the peripheral lip 32′ can include a tab 34′ extending outward from the peripheral lip 32′. The tab 34′ can be pulled by a user to swing the cavity portion 28′ away from the backing 14′ to open the package 10′. The tab 34′ may be sized and shaped to provide sufficient gripping surface for a user to overcome the resistance to opening created by the interaction of the structure that interlocks the blister 12′ and the backing 14′. For example, the tab 34′ can be sized so that it can be readily squeezed between a user's thumb and forefinger. As shown, the tab 34′ may be positioned at a corner of the lip 32′, but the tab 34′ may be positioned at any desired location on the lip 32′. As shown, the tab 34′ may be bent out of the plane of the lip 32′ to extend at angle away from the backing 14′, if desired. For example, in this embodiment, the tab 34′ includes a small nub 35′ that keeps the tab 34′ away from the front panel 16′.

In this embodiment, the panels 16′, 18′ are provided with openings 40′ configured to receive the locking protrusions 38′ on the shoulder 70′ of the cavity portion 28′. In this embodiment, the locking protrusions 38′ and openings 40′ may be configured so that the snap-lock occurs at the corners of the cavity portion 28′, which may provide a stiffer and more stable interaction between the cavity portion 28′ and backing 14′. As with blister package 10, the details of the locking protrusions 38′ and openings 40′ can be varied to adjust the characteristics of the interlock. For example, the number, size and/or location of locking protrusions 38′ and openings 40′ may be varied. As another example, the shape of the leading and trailing edges of the locking protrusion 38′ may be varied.

In this embodiment, the backing 14′ may include a hang hole 42′ that allows the package 10 to be easily hung, for example, from a display hook at the point of sale. The hang hole 42′ may vary in size, shape, configuration and location, or it may be eliminated when unnecessary. In this embodiment, the hang hole 42′ is defined by separate openings in the panels 16′, 18′. These openings align to form the hang hole 42′ when the backing 14′ is closed.

Another alternative blister 512 package is shown in FIGS. 24-30. In this embodiment, the blister package 510 generally includes a blister 512 and a backing 514, and is generally identical to blister package 10, except as otherwise described. As shown in FIGS. 24 and 25, the blister 512 is capable of being moved between open and closed positions. The blister 512 includes an upper extension 536 having a locking protrusion 538 that extends around the periphery of the hange hole 542. As with blister package 10, the locking protrusion 538 is interfitted with the backing 514 to selectively hold the blister 512 in the closed position (See FIGS. 27, 28A and 28B). As perhaps best shown in FIG. 26, the upper extension 536 may include a tab 534 extending beyond the upper edge of the backing 514 (as shown) or it may be fully contained within the periphery of the backing 514. Although shown as flat, the tab 534 may be bent away from the backing 514 to make it easier to grasp.

In this embodiment, the hang hole 542 may include a somewhat triangular shape to accommodate the peripheral locking protrusion 538. The size and shape of the hang hole 542 and the surrounding locking protrusion 538 may vary from application to application, as desired. As perhaps best shown in FIG. 28B, the locking protrusion 538 may include a reverse draft to create a snap-lock fit with the backing. In the illustrated embodiment, the reverse draft extends at about 87 degrees with respect to the face of the extension portion 536. The amount of reverse draft may, however, vary from application to application. If desired, the amount of reverse draft may vary along the locking protrusion. The reverse draft need not extend around the entire locking protrusion 538, but may instead extend through only one or more portions of the locking protrusion 538. For example, in the illustrated embodiment, the left side 537 and right side 539 of the locking protrusion 538 include reverse draft (See e.g. FIGS. 28A, 28B and 29). More specifically, in the illustrated embodiment, the reverse draft extends only through the curved regions on the left and right sides 537, 539 of the locking protrusion 538.

As perhaps best shown in FIG. 29, the blister 512 may include a flange 522 and a hinge 524. The flange 522 may includes lateral extensions 530 that extend from opposite ends beyond the hinge 524. The lateral extensions 530 may be rounded (as shown), but their size and shape may vary from application to application.

This alternative blister 512 may be used with a backing 514 having an opening 540 that corresponds in size and shape with the locking protrusion 538. In this embodiment, the backing 514 includes a front panel 516 and a rear panel 518 that are joined at a fold line 526 (See FIG. 30). The panels 514, 516 may be joined along different edges or may be separate components, if desired. As with blister package 10, the backing 514 defines a blister slot 548 with a flange insertion portion 560 and a hinge seat 562.

The blister packages 10, 10′ and 510 may be provided with other package features, as desired, such as functional and/or aesthetic features selected to tailor the package for specific applications. For example, the blister packages 10, 10′ and 510 may be provided with a foot to help it stand upright, a “touch and feel” hole that allows a user to touch and feel the packaged article(s) or any of a wide range of features that might be provided for branding purposes. As another example, a window may be formed through the backing to allow viewing of the package article(s). The window may be filled with a transparent film to allow viewing while protecting the article(s).

In another aspect, the present invention provides a method for forming a package, such as the blister package 10 described above. The method includes the steps of: (a) forming a blister 12 with a cavity portion 28, a flange 22 and a hinge 24; (b) forming a front panel 16 with a blister slot 48 having a flange insertion portion 60 and hinge seat 62; (c) forming a rear panel 18; (d) inserting the flange 22 into the blister slot 48 so that the flange 22 is disposed on the inside of the front panel 16 and the hinge 24 and cavity portion 28 are disposed on the outside of the front panel 16; (e) closing the front panel 16 and rear panel 18 about the flange 22; (f) closing the blister 12 the door portion 18 and tray 20 cooperatively defining an article containing cavity and (h) selectively pivoting the door portion 18 about the hinge 14 to open and close the package 10.

In one embodiment, the step of forming the plastic component 12 can include placing a piece of sheet stock in a mold and thermoforming the clamshell. The molding or thermoforming step can include forming cavity portion 28 and a flange 22 with a hinge 24. The flange 22 may be formed with lateral extensions 30 that extend beyond the hinge 24. In one embodiment, this step can also include (a) forming the blister 12 with an upper extension 60 that includes one or more locking protrusions 38 configured to snap into engagement within an opening in the backing 14. In an alternative embodiment, this step can also include (a) forming the cavity portion 28′ with a shoulder 70′ that includes locking protrusions 38′ configured to snap into engagement with openings 40′ in the backing 14′. The cavity portion 28′ may be rectangular and the shoulder 70′ may include four locking protrusions 38′ at or near the corners.

Optionally, the step of joining the front panel 16 and the rear panel 18 may include securing them together using a cohesive. A layer of cohesive may be applied to the inside surfaces of each of the front panel 16 and the rear panel 18. The inside surfaces of the two panels 16, 18 may be closed against each other to bring the layers of cohesive into contact, thereby joining the panels.

The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.

Claims

1. A reclosable blister package for packaging one or more articles comprising:

a backing having a panel with first and second major surfaces, said panel defining a blister slot and a panel hang hole having an interlocking opening; and

a blister having a cavity portion and a flange, said flange including a hinge, said flange extending through said blister slot, whereby said cavity portion is disposed on one side of said panel and said flange is disposed on an opposite side of said panel, said blister being selectively movable between an open position and a closed position by pivoting said cavity portion about said hinge, said cavity portion cooperating with said first major surface of said panel to define an article containing space when said blister is in said closed position, said blister including a snap-fit element configured to selectively interlock with said interlocking opening when said blister is in said closed position.

2. The blister package of claim 1 wherein said backing includes first and second panels, said first panel including said blister slot, said first panel and said second panel cooperatively defining said panel hang hole having said interlocking opening.

3. The blister package of claim 2 wherein said flange is sandwiched between said first panel and said second panel.

4. The blister package of claim 3 wherein said snap-fit element includes a reverse draft.

5. The blister package of claim 4 wherein said blister includes a plurality of snap-fit elements.

6. The blister package of claim 4 wherein said blister includes an extension, said snap-fit elements being defined in said extension.

7. The blister package of claim 6 wherein said extension extends upwardly from said cavity portion and defines a blister hang hole.

8. The blister package of claim 7 wherein said snap-fit element is located adjacent said blister hang hole.

9-12. (canceled)

13. A reclosable blister package comprising:

a one-piece plastic blister having a cavity portion and a flange, said flange including a hinge allowing said blister to pivot with respect to said flange, said flange being wider than said hinge, said blister including at least one snap-fit element;

a paperboard backing having first and second panels closed about said flange, said front panel defining a blister slot having a flange insertion portion and a hinge seat, said flange insertion portion being of sufficient width to allow said flange to be fitted through said flange insertion portion, said hinge seat being narrower than said flange insertion portion, said hinge seat being at least as wide as said hinge, said hinge being disposed within said hinge seat, said backing including at least one panel hang hole with an interlocking opening capable of selectively receiving said snap-fit element;

said blister being selectively movable between a closed position in which said cavity portion and said first panel cooperatively define an article containing space and an open position in which said blister is pivoted away from said first panel to provide access to said article containing space, said snap-fit element being configured to be snap-fitted into said interlocking opening when said blister is in said closed position, said snap-fitted engagement retaining said blister in said closed position.

14. The blister package of claim 13 wherein said blister includes an extension from said cavity portion, at least one snap-fit element being extended from said extension toward said first panel.

15. The blister package of claim 14 wherein said extension defines a blister hang hole.

16. The blister package of claim 15 wherein said extension includes at least two snap-fit elements located adjacent to said hang hole.

17. The blister package of claim 16 wherein said backing includes a single interlocking opening capable of receiving said at least two snap-fit elements, said interlocking opening configured to align with said blister hang hole when said blister is in said closed position.

18. The blister package of claim 15 wherein said interlocking opening is configured to receive said snap-fit element and to align with said blister hang hole when said blister is in said closed position.

19-21. (canceled)