THEFT-RESISTANT PRODUCT PACKAGING AND RELATED MANUFACTURING PROCESS

Abstract

Theft-resistant product package includes a front shell having a security pattern of thickened plastic areas or of cut-resistant strands on a plastic substrate and a back cover secured to and disposed relative to the front shell. An alternative theft-resistant product package includes an enclosed packaging structure having front and back surfaces spaced apart by at least one side wall around the perimeter of the front and back surfaces, and a plurality of indentations disposed in the at least one side wall. A process for manufacturing theft-resistant product packaging includes the steps of forming a theft-resistant security pattern of thickened plastic areas on a plastic substrate, shaping the plastic substrate to form a cavity, and securing the plastic substrate to a back cover.

Description

FIELD OF THE INVENTION

The present invention generally relates to packaging. More particularly, the present invention relates to tamper resistant product packaging.

BACKGROUND OF THE INVENTION

Product packaging is the science, art, and technology of enclosing or protecting products for distribution, storage, sale, and use. Product packaging can be described as a coordinated system of preparing goods for transport, warehousing, logistics, sale, and end use. Product packaging contains, protects, preserves, transports, informs, and helps sell the product it contains.

The first product packages used the natural materials available at the time including baskets of reeds, wooden boxes, pottery vases, ceramic amphorae, wooden barrels, and woven bags. Processed materials were used to form packages as they were developed. For example, early glass and bronze vessels. The earliest recorded use of paper for packaging dates back to 1035, when a Persian traveler visiting markets in Cairo noted that vegetables, spices and hardware were wrapped in paper for the customers after they were sold. Iron and tin plated steel were used to make cans in the early 19th century. Paperboard cartons and corrugated fiberboard boxes were first introduced in the late 19th century. Product packaging advancements in the early 20th century included Bakelite closures on bottles, transparent cellophane overwraps and panels on cartons, increased processing efficiency and improved food safety. As additional materials such as aluminum and several types of plastic were developed, they were incorporated into packages to improve performance and functionality. In-plant recycling has long been common for production of packaging materials. Now post-consumer recycling of aluminum and paper based products has been economical for many years. Since the 1980s, post-consumer recycling has increased due to curbside recycling, consumer awareness, and regulatory pressure.

As of 2003, the packaging sector accounted for about two percent of the gross national product in developed countries. About half of this market was related to food packaging. Product packaging serves a multitude of purposes today. First, product packaging is physical protection as the objects enclosed in the package may require protection from, among other things, mechanical shock, vibration, electrostatic discharge, compression, and temperature. Second, product packaging may provide a barrier protection from oxygen, water vapor, and dust. Permeation is a critical factor in design. Some packages contain desiccants or oxygen absorbers to help extend shelf life. Modified atmospheres or controlled atmospheres are also maintained in some food packages. Keeping the contents clean, fresh, sterile and safe for the intended shelf life is a primary function. Product packaging may also aid in containment or agglomeration when small objects are typically grouped together in one package for reasons of efficiency. For example, a single box of 1000 pencils requires less physical handling than 1000 single pencils. Liquids, powders, and granular materials also need containment. Product packaging is also used for information transmission as packages and labels communicate how to use, transport, recycle, or dispose of the package or product. With pharmaceuticals, food, medical, and chemical products, some types of information are required by governments. Some packages and labels also are used for track and trace purposes. Product packaging is used for marketing as the packaging and labels can be used by marketers to encourage potential buyers to purchase the product. Product package graphic design and physical design have been important and constantly evolving phenomenon for several decades. Marketing communications and graphic design are applied to the surface of the package and (in many cases) the point of sale display. Product packaging is also for convenience as packages can have features that add convenience in distribution, handling, stacking, display, sale, opening, reclosing, use, dispensing, and reuse. Also, product packaging can be used for portion control as a single serving or single dosage packaging has a precise amount of contents to control usage. Bulk commodities (such as salt) can be divided into packages that are a more suitable size for individual households and also aids the control of inventory.

One function of product packaging that most people don't realize is for security. Product packaging can play an important role in reducing the security risks of shipment. Packages can be made with improved tamper resistance to deter tampering and also can have tamper-evident features to help indicate tampering. Packages can be engineered to help reduce the risks of package pilferage. Some package constructions are more resistant to pilferage and some have pilfer-indicating seals. Packages may include authentication seals and use security printing to help indicate that the package and contents are not counterfeit. Packages also can include anti-theft devices, such as dye-packs, RFID tags, or electronic article surveillance tags that can be activated or detected by devices at exit points and require specialized tools to deactivate. Using product packaging in this way is a means of loss prevention.

Unfortunately, theft of goods is quite prominent today despite the advances in product packaging and theft prevention techniques. Two particular packaging types are quite susceptible to theft; the clamshell and blister pack product packaging. Clamshells are generally comprised of a housing and a chamber for storing products and may be reusable or permanently sealed. Permanently sealed clamshells are generally formed from a clear plastic housing that is sealed together through radio frequency (RF), sonic vibrations or electrical resistance. As the housing is generally made from clear plastic, inserts made of cardboard and other materials are often inserted into the clamshell packaging to describe or label the goods. Blister packs typically have two layers of cardboard or stiff paper with a clear plastic housing on the other side. Between the clear plastic housing and the cardboard is the product.

Many clamshell and blister packs have RFID tags embedded in the housing such that it is difficult to carry the product with the packaging out through the sensors at the entrance and exit of a storefront. Therefore, the thieves have simply removed the product from the packaging while still in the store. For instance, an area of high theft is in the knives department. With some retailers, they report to have stolen four knives for every one they legitimately sell. The thieves will grab the product off the shelves, relocate to a less noticeable spot and simply cut open the package to the remove the product. The thieves will literally use a knife, razor blade, or other cutting tool to slice open the clamshell and blister pack and then remove the product.

To help deter pilfering, the clamshell thickness has increased to make it harder to penetrate. This also means the cost of the product packaging itself has gone up and the overall product is now more costly. The cost of the thicker product packaging and the stolen product is passed on to the consumer. Additionally, such thick plastic packaging is typically slippery, whereby a knife being used to open the package by penetrating the plastic clamshell can bounce or slip off the package and cut or otherwise wound the user. Many stores want to reduce the amount of wasted material in their product packaging, yet want to prevent or reduce the amount of pilfered goods. Rising oil prices also drives the cost of plastic packaging up.

Accordingly, there is a need for a clamshell and blister pack design that reduces or eliminates the ability of a thief to quickly and easily slice open the product packaging to then steal the product located inside. The present invention fulfills these needs and provides other related advantages.

SUMMARY OF THE INVENTION

The present invention is directed to theft-resistant product packaging. In certain embodiments, the packaging comprises a front shell and a back cover secured to one another by folding, bonding, gluing and/or stapling edges of the cover shell and backing shell together. The front shell may comprise a matrix of cut-resistant strands disposed within or adjacent to a plastic substrate. Alternatively, the front shell may comprise a security pattern of thickened plastic areas on top of or integral with the plastic substrate. The cover shell may be preformed with a recess conforming to a shape of the product. The back cover is disposed relative to the front shell so as to form a cavity configured to contain a product. The cavity may be pre-formed in either the cover shell or the back cover. Alternatively, the cavity may be created simply by the cover shell and/or back cover bending or bulging around the product contained therein. The back cover may comprise cardboard, wood, metal, plastic or a matrix of cut-resistant strands disposed within or adjacent to a plastic substrate.

The cut-resistant strands may comprise metal, ceramic, glass, carbon fiber, fabric or fiber optic materials and may also include a hard, outer shell comprising a hardened adhesive, a powdered metal, or a ceramic material. The matrix may comprise a grid of cut-resistant strands overlayed, weaved, or twisted with respect to intersecting strands. The cut-resistant strands are disposed in the grid so as to form squares, rectangles, diamonds or parallelograms. The intersecting strands are welded, glued or bound at the points of intersection. The plastic substrate may comprise a laminate of thermoplastic or bio-film material formed around the matrix. The plastic substrate comprises first and second laminates of thermoplastic or bio-film material disposed on opposite sides of the matrix and formed around the matrix.

A method for manufacturing the theft-resistant product packaging comprises the step of providing a matrix of cut-resistant strands. The matrix is adhered to a plastic substrate to form a theft-resistant material. A front shell is formed from the theft-resistant material and may include a cavity for holding a product therein. The front shell is secured to a back cover so as to enclose the product therebetween.

The providing step includes orienting a first set of individual strands in a first direction and orienting a second set of individual strands in a second direction different from the first direction. A matrix is formed by overlaying, weaving, wefting and warping, or twisting the first and second sets of strands together. The first and second sets of wires are secured, welded, glued or bonded together. The first and second directions of the first and second sets of wires may be oriented perpendicularly to each other.

The method may also comprise the step of coating the strands with a hard, outer shell comprising a hardened adhesive, a powdered metal, or a ceramic material. The adhesive is initially applied as a liquid or other soft form and is hardened by the end of the process. The adhering step may include the steps of applying a first laminate of thermoplastic or bio-film material to one side of the matrix, and heating the matrix and first laminate such that the first laminate softens such that it becomes pliable. The applying step may include applying a second laminate of thermoplastic or bio-film material to another side of the matrix. Once heated the matrix and first/second laminate(s) are pressed such that the first/second laminate(s) becomes formed around and bonded to the matrix. The matrix and first/second laminate(s) may also be cooled to fix the matrix and first/second laminate(s) together.

The adhering step includes the steps of pulling the matrix across a surface, dispensing small pieces of thermoplastic or bio-film material over the matrix on the surface, heating the small pieces such that they soften or melt around the matrix, and rolling the matrix and heated small pieces such that they form the plastic substrate around the matrix. As above, the matrix and plastic substrate may be cooled to fix the matrix and plastic substrate together.

The forming step includes the steps of shaping the theft-resistant material into a clamshell or blister pack, and preforming a recess in the front shell conformed to a shape of the product. The forming step also includes the step of forming an unobstructed area in the front shell that is devoid of the matrix. The back cover comprises cardboard, wood, metal, plastic or theft-resistant material. The securing step comprises folding, bonding, gluing and/or stapling edges of the front shell and back cover together.

An alternative method of manufacturing theft-resistant product packaging comprises the steps of providing a plastic substrate, forming a theft-resistant material having a security pattern of thickened plastic areas on the plastic substrate, shaping a front shell from the theft-resistant material which may or may not include a cavity for holding a product therein, and securing the front shell to a back cover so as to enclose the product therebetween. The forming step may comprise the steps of dispensing pieces of thermoplastic or bio-film material over a surface of the plastic substrate. Those pieces of thermoplastic or bio-film material are then heated to their melting point. The heated pieces of thermoplastic or bio-film material on the plastic substrate are then impression rolled to form the security pattern of thickened plastic areas. The impression rolling may include feeding the plastic substrate and heated pieces of thermoplastic or bio-film material between a pair of impression rollers having at least one set of impression teeth with embossed or recessed portions. By these impression rollers, the security pattern is imprinted into the heated pieces of thermoplastic or bio-film material. The security pattern may also be created through extrusion, thermoforming or injection molding processes as described below.

The security pattern may comprise a plurality of ridges interspersed with recesses or grooves interspersed with plateaus. The ridges or plateaus are preferably configured in square, rectangular, diamond, trapezoidal, triangular, circular and/or ringed shapes. Alternatively, the ridges or grooves may comprise a repetitive pattern of a symbol, design or logo as in a company trademark or other trade identity. The plurality of ridges interspersed with recesses or grooves interspersed with plateaus or the repetitive pattern may be inline or offset. A symbol, design or logo such as a company name or trade identity may be embossed on the recesses or plateaus. After the step of creating the security pattern, e.g., by impression rolling, extrusion, thermoforming, or injection molding, the heated pieces of thermoplastic or bio-film material may be cooled to fix them together and to the plastic substrate. An interior portion devoid of thickened plastic areas may be impressed on the plastic substrate. In this case, the formed theft-resistant material has the security pattern of thickened plastic areas only in a perimeter area of the theft-resistant material.

Alternatively, a theft-resistant product package according to the present invention may include a front shell having a security pattern of cut-resistant strands disposed within or adjacent to a plastic substrate. In this embodiment, the cut-resistant strands are disposed generally side-by-side in a single plane and each strand is alternatingly, intermittently wound around adjacent strands. A back cover is secured to the front shell so as to form a cavity configured to contain a product. As before, the cavity may be pre-formed or may be created simply by the front shell and/or back cover bending or bulging around the product. The cut-resistant strands may comprise metal, ceramic, glass, carbon fiber or fabric materials. The cut-resistant strands preferably include a hard, outer shell comprising a hardened adhesive, a powdered metal, or a ceramic material.

The plastic substrate preferably comprises a laminate of thermoplastic or bio-film material formed around the security pattern. The plastic substrate may comprise first and second laminates of thermoplastic or bio-film material disposed on opposite sides of the security pattern and formed around the security pattern. The front shell may be preformed with a recess conforming to a shape of the product.

The back cover preferably comprises a cardboard, wood, metal, plastic, or a second security pattern of cut-resistant strands disposed within or adjacent to a second plastic substrate. The back cover may be secured to the front shell at its edges by a fold, a bond, glue or staples. A symbol, design or logo may be embossed on the plastic substrate in an open area of the security pattern. The front shell may have the security pattern along a perimeter area such that an interior portion of the front shell is devoid of the security pattern.

In an alternate embodiment, the theft-resistant product packaging may be manufactured by providing a plastic substrate, heating the plastic substrate such that it may be impression molded, impression rolling the heated plastic substrate so as to form a security pattern of thickened plastic areas on the plastic substrate, shaping a front shell from the theft-resistant material which may include a cavity for holding a product therein, and securing the front shell to a back cover so as to enclose the product therebetween. Instead of impression rolling the heated plastic substrate, the plastic substrate may be formed using an extrusion, thermoforming, or injection molding process that simultaneously creates the security pattern of thickened plastic areas integral with the plastic substrate. In an extrusion process, the security pattern has thickened plastic areas running only in one direction, e.g., in the direction of extrusion.

A theft-resistant product packaging may comprise an enclosed packaging structure made from thermoplastic material. The enclosed packaging structure has front and back surfaces spaced apart by at least one side wall around the perimeter of the front and back surfaces. A plurality of indentations are disposed in the at least one side wall, each of said plurality of indentations extending along the side wall from the front surface to the back surface. The enclosed packaging structure preferably has a generally round, square, rectangular, triangular or polygonal shape. The front surface of the enclosed packaging structure preferably has an open interior portion. In addition, the back surface of the enclosed packaging structure has an open interior portion having only thermoplastic material devoid of any blockages or obstructions. The enclosed packaging structure may be configured as two halves with a longitudinal line dividing the front and back surfaces in half.

Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate the invention. In such drawings:

FIG. 1 is a simplified perspective view of an exemplary manufacturing process of a wire grid of the present invention;

FIG. 1A is an illustration of an alternate wire/strand grid of the present invention;

FIG. 2A is a simplified perspective view of a portion of an exemplary manufacturing process of the present invention continued from FIG. 1;

FIG. 2B is a simplified perspective view of a portion of an alternate exemplary manufacturing process of the present invention continued from FIG. 1;

FIG. 3 is a simplified perspective view of a portion of an exemplary manufacturing process of the present invention continued from either FIG. 2A or 2B;

FIG. 4 is a simplified perspective view of a portion of an alternate exemplary manufacturing process of the present invention;

FIG. 4A is a simplified perspective view of a portion of an alternate exemplary manufacturing process of the present invention;

FIG. 4B is a simplified perspective view of a portion of an alternate exemplary manufacturing process of the present invention;

FIG. 4C is a close-up view of a portion of FIG. 4B designated by circle 4C;

FIG. 4D is a simplified perspective view of a portion of an alternate exemplary impression rolling manufacturing process of the present invention;

FIG. 4E is a simplified perspective view of a portion of an alternate exemplary thermoforming manufacturing process of the present invention;

FIG. 4F is a simplified perspective view of a portion of an alternate exemplary thermoforming manufacturing process of the present invention;

FIG. 4G is a simplified perspective view of a portion of an alternate exemplary injection molding manufacturing process of the present invention;

FIG. 4H is a simplified perspective view of a portion of an alternate exemplary spray fiber manufacturing process of the present invention;

FIG. 5 is a side view illustration of the structure of FIG. 2A taken along line 5-5;

FIG. 6 is a side view illustration of the structure of FIG. 2B taken along line 6-6;

FIG. 7 is an illustration of the wire grid before and after the processing steps illustrated in FIG. 2A or 2B;

FIG. 8 is a close-up view of the wire grid of FIG. 7 indicated by circle 8;

FIG. 9 is a top view of an exemplary embodiment of a wire mesh structure;

FIG. 10 is a top view of another exemplary embodiment of a wire mesh structure;

FIG. 11 is an enlarged sectional view of the structure of FIG. 9 indicated by circle 11 showing the wires welded;

FIG. 12 is an enlarged sectional view of the structure of FIG. 9 indicated by circle 12 showing the wires overlapping;

FIG. 13 is an enlarged sectional view of the structure of FIG. 10 indicated by circle 13 showing the wires welded;

FIG. 14 is an enlarged sectional view of the structure of FIG. 10 indicated by circle 14 showing adjacent wires twisted and connected;

FIG. 15 is a simplified perspective view of an exemplary manufacturing process of the present invention;

FIG. 16 is a simplified perspective view of an alternate exemplary manufacturing process of the present invention;

FIG. 17 is a simplified perspective view of another alternate exemplary manufacturing process of the present invention;

FIG. 18 is a sectional view of the manufacturing process of FIG. 15 taken along line 18-18;

FIG. 19 is a sectional view of the exemplary manufacturing process of FIG. 15 taken along line 19-19;

FIG. 20 is a sectional view of the exemplary manufacturing process of FIG. 16 taken along line 20-20;

FIG. 21 is a sectional view of the exemplary manufacturing process of FIG. 16 taken along line 21-21;

FIG. 22 is a sectional view of the exemplary manufacturing process of FIG. 17 taken along line 22-22;

FIG. 23 is a sectional view of the exemplary manufacturing process of FIG. 17 taken along line 23-23;

FIG. 24 is a perspective view of a clam pack embodying the present invention about to package a product;

FIG. 25 is a perspective view of the clam pack of FIG. 24 now packaging a product;

FIG. 26 is a perspective view of a clamshell mold embodying the present invention;

FIG. 27 is a perspective view of a clamshell embodying the present invention before it is folded;

FIG. 28 is a perspective view of the clamshell of FIG. 27 now folded about to package a product;

FIG. 29 is a perspective view of the clamshell of FIG. 27 now packaging a product;

FIG. 30 is a perspective view of the structure of FIG. 29 now resistant to cutting with a knife or razor;

FIG. 31 is a perspective view of a clam pack alternate embodiment of the present invention about to package a product;

FIG. 32 is a perspective view of the clam pack of FIG. 31 now packaging a product;

FIG. 33 is a simplified perspective view of another alternate exemplary manufacturing process of the present invention;

FIG. 34 is a perspective view of a blister pack embodying the present invention about to package a product;

FIG. 35 is a perspective view of the blister pack of FIG. 34 now packaging a product

FIG. 36 is a perspective view of an alternate embodiment of the clam pack of FIG. 24;

FIG. 37 is a perspective view of an alternate embodiment of the clam pack of FIG. 25;

FIG. 38 is a perspective view of an alternate embodiment of the clamshell of FIG. 28;

FIG. 39 is a perspective view of an alternate embodiment of the clamshell of FIG. 29;

FIG. 40 is a perspective view of a circular clam pack embodying the present invention;

FIG. 41 is a perspective view of an assembled circular clam pack embodying the present invention;

FIG. 42 is a cross-sectional view of the circular clam pack of FIG. 41 taken along line 42-42;

FIG. 43 is a cross-sectional view of the circular clam pack of FIG. 41 taken along line 43-43;

FIG. 44 is a top view of an alternate embodiment of the theft-proof product packaging material of the present invention;

FIG. 45 is a cross-sectional view of the theft-proof product packaging material of FIG. 44 taken along line 45-45;

FIG. 45A is a cross-sectional view of an alternate embodiment of the theft-proof product packaging material of FIG. 44 taken along line 45-45;

FIG. 46 is a cross-sectional view of the theft-proof product packaging material of FIG. 44 taken along line 46-46;

FIG. 46A is a cross-sectional view of an alternate embodiment of the theft-proof product packaging material of FIG. 44 taken along line 46-46;

FIG. 47 is a top view of another alternate embodiment of the theft-proof product packaging material of the present invention;

FIG. 47A is a cross-sectional view of the theft-proof product packaging material of FIG. 47 taken along line 47A-47A;

FIG. 48 is a top view of another alternate embodiment of the theft-proof product packaging material of the present invention;

FIG. 48A is a cross-sectional view of the theft-proof product packaging material of FIG. 48 taken along line 48A-48A;

FIG. 49 is a top view of an alternate embodiment of the theft-proof product packaging material having embossed rings;

FIG. 50 is a cross-sectional view of the theft-proof product packaging material of FIG. 49 taken along line 50-50;

FIG. 51 is a perspective view of wire/strand matrix folded about to package a product and card insert;

FIG. 52 is a perspective view of the wire/strand matrix of FIG. 51 folded around the product and card insert;

FIG. 53A is an exploded perspective view of an alternate embodiment of the wire/strand matrix with product and card insert about to be enclosed in a plastic clamshell;

FIG. 53B is a perspective view of the plastic clamshell enclosing the wire/strand matrix with product and card insert of FIG. 53A; and

FIG. 53C is a perspective view of the wire/strand matrix with product and card insert of FIG. 52 about to be enclosed in a plastic clamshell.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1-3 present simplified perspective views of an exemplary manufacturing process 10 for theft proof product packaging of the present invention. In FIG. 1, a grid or two-dimensional matrix 12 is formed first. The matrix 12 may be formed from a plurality of individual cut-resistant wires or strands 14. The cut-resistant wires or strands 14 may comprise metallic, ceramic, glass, or carbon-based materials. Preferably, the wires or strands 14 comprise aluminum, steel, nylon, or reinforced polymer. In a particularly preferred embodiment, the strands 14 are form from materials that are clear, transparent or translucent so as to not interfere with lines of sight or other viewing through packaging material containing the same, as described below. The strands 14 may also be impregnated with cut-resistant fibers, polypropylene pieces and/or ceramic scraps.

The following paragraphs describing the formation of the matrix 12 relate primarily to the use of metal wires 14, but a person skilled in the art will recognize that the same or similar methods can be used with the other materials. The term matrix 12 as used through the following written description is intended to and does refer to a matrix or security pattern of any type described herein. The matrix 12 is not intended to be limited to a wire grid or other configuration of cut-resistant strands 14.

The individual wires 14 come out of a machine called a creel 16. The creel 16 is able to store the rolls of individual wires 14. The creel 16 organizes the plurality of individual wires 14 into the correct location to thereafter form the matrix 12. A first set of individual wires 14 come out of the creel 16 and pass through a series of idle rollers 18. The idle rollers 18 help to align the individual wires 14 into their proper spacing.

The individual wires 14 then pass through a weft and warp insertion machine 20. The weft and warp insertion machine 20 introduces a perpendicular set of wires 22 to the previous individual wires 14 to form matrix 12. The perpendicular wires 22 are fed from a second creel or similar machine (not shown). The weft and warp insertion machine 20 may place a plurality of perpendicular individual wires 22 onto, i.e., overlaying, or weaved within the individual wires 14. The perpendicular wires 22 can be welded, weaved, glued, bound or temporarily held into place in relation to their spacing and position to the individual wires 14. The wires 14 and 22 may comprise metal, fiber, fabric or other cut-resistant material, as described elsewhere. The wires 14 and 22 may be coated with an adhesive material to increase cutting resistance. The adhesive material creates a hard shell with fiber or fabric through the core. The wires 14 and 22 may also comprise fiber or fabric coated with a powdered metal or ceramic material to provide a hard outer shell resistant to cutting.

FIG. 1A illustrates an alternate embodiment for the matrix 12. In this embodiment, the wire grid comprises a plurality of individual wires 14 arranged parallel to each other in a single plane and alternatingly, intermittently wound around adjacent wires to form a mesh such as chicken wire. Such a structure is known in the art and commonly available. This type of matrix 12 can be manufactured on an as-needed basis or purchased commercially. As with the wires 14 discussed above, this embodiment of the matrix 12 may be manufactured from strands 14 comprising metallic, ceramic, glass, or carbon-based materials such as aluminum, steel, nylon, or reinforced polymer.

In the next step, illustrated in FIGS. 2A and 2B, the matrix 12 is subjected to a process that adds an adhesive coating to the wire 14, 22. In FIG. 2A, the matrix 12 is passed through a vat or bath 80 of liquid or viscous adhesive material 82 that is caused to adhere to the wires 14, 22 by any known process. The adhesive material 82 may comprise a form of polymer which is caused to conform to the wires 14, 22 as by heating or other known process. FIG. 5 illustrates a partial side view of the process applying this adhesive material 82 to wires 22. FIG. 2B illustrates an alternate process for applying the adhesive material 82. In this alternate process, the adhesive material 82 is applied via spray guns 84 either above, below or on both sides of the matrix 12. In this method of application, the adhesive material 82 may comprise powder, flecks, or strands of metallic, ceramic, glass or carbon-based materials, such as aluminum oxide, nylon, fiber optic, or Kevlar. In the case of fiber optics, the material may be continuous strands or chopped pieces. Such materials may be subjected to an electromagnetic charge 86 as depicted in FIG. 6. It is worth noting that the process for applying the adhesive material 84 to the wires 14, 22 preferably does not involve sintering or a similar process. Both of these adhesive application processes are followed by a heating or curing process 87 to set the adhesive 82 as a hardened coating.

The next step in FIG. 3 is when the matrix 12 with the adhesive coating 82 is mated on one side to a first laminate 24 from a laminate reel 26a. The matrix 12 and first laminate 24 meet when they pass over another idle roller 18 or series of idle rollers 18. A second laminate 28 may then be introduced from another laminate reel 26b. The second laminate 28 can pass through a series of idle rollers 18 as it then mates to the matrix 12. Now, the matrix 12 has a first laminate 24 on one side and a second laminate 28 on the other side. Alternately, either laminate 24, 28 may be omitted so that the matrix 12 only has one laminate on one side. This is described more fully below.

A heat process 30 is applied to the matrix 12, laminate 24 and laminate 28 if present. The heat process 30 can be a multitude of designs and configurations used by one skilled in the art. For example, the heat process 30 can be accomplished through an oven, hot air, radiation, microwave/radio waves or other radiometric means. Here, it is shown simplistically as applied heat to the wire grid and forcing it between an idle roller 18 and a larger heated roller 32. Heat is absorbed into the laminates 24 and 28 which cause them to soften and become pliable so as to form around the matrix 12 and also bond together. Now the matrix 12 and laminates 24 and 28 are laminated together to act as a single material of theft proof product packing material 34. The material 34 is then rolled onto a storage reel 36 to be used later to create theft proof product packaging. As can be seen by one skilled in the art, there may exist a multitude of pathways and location of idle rollers 18 that accomplish the same end result, and this disclosure is not limited to the exact configuration shown and described herein.

The laminates 24 and 28 may be made from any common thermoplastic material. Alternatively, the laminates 24 and 28 may be made from a bio-film, such as corn-based material. Where bio-film on its own would tend to lose its shape and integrity in fairly low temperatures—125°-150°—the addition of the matrix 12 provides a support framework for the bio-film. With this support framework, the bio-film can retain its shape and integrity in higher temperatures.

FIG. 4 is another simplified perspective view of an alternate exemplary manufacturing process 10 for theft proof product packaging of the present invention. The matrix 12 can be formed as described in connection with FIGS. 1, 1 A, 2A and 2B with the creel 16 and weft and warp insertion 20, or can be taken from a premade wire grid reel 38. The matrix 12 is pulled onto a surface 38 where plastic feed 40 is combined and heated. The plastic feed 40 is small bits of plastic material. The plastic feed 40 is channeled into a plastic feed chute 42 such that is can be appropriately dispensed over the matrix 12.

As the plastic feed 40 is in the plastic feed chute 42, it is pre-heated at the pre-heat stage 44. When the plastic feed 40 is dispensed over the matrix 12, it is further heated in the final heat stage 46. The plastic feed 40 is distributed over and around the wire mesh. The heat stage 46 melts or softens the plastic feed 40 such that it flows around and bonds to the matrix 12. The plastic feed 40 and matrix 12 are then pulled through a blend and cover chamber where the heat is allowed to penetrate the plastic feed 40 as it forms around the matrix 12. Next, the matrix 12 and plastic feed 40 go through a series of leveling and thickness rollers 48. The rollers 48 level the amount of plastic in relation to the matrix 12 such that any inconsistencies are eliminated or reduced.

As illustrated in FIG. 4A, the matrix 12 and plastic feed 40 may be passed between top and bottom pocket impression rollers 98 designed to compress the plastic feed 40 through the openings on the matrix 12. At this point the plastic feed 40 has been heated to its impression rolling point as defined below. As illustrated in the close up of FIG. 4A, the pocket impression rollers 98 have abutting teeth 99 configured to create waffle-like impressions 100 in the plastic feed 40 that coincide with the shape of the matrix 12. In this method of manufacture, the pocket impression rollers 98 are necessary to compress the plastic such that the manufactured material 34 is not unnecessarily bulky or heavy by a uniformly thick layer of plastic.

FIG. 4B illustrates an alternate embodiment wherein the matrix 12 is replaced with laminate material 24 on its own. The laminate material 24 may be presented in any thickness and constructed of any material that is commonly used for product packaging as described herein. The laminate material 24 is pulled onto a surface 38 where a plastic feed 40 is combined and heated. The plastic feed 40 is small bits of plastic material as described above. The plastic feed 40 is channeled into a plastic feed chute 42 such that it can be appropriately dispensed over the laminate material 24 as described above in connection with FIG. 4A. The plastic feed 40 is similarly heated and applied, also as described above in connection with FIG. 4A. The laminate 24 with melted plastic feed 40 is fed through a series of leveling and thickness rollers 48 as described above.

In the embodiment of FIG. 4B, the impression rollers 98 are designed to compress the plastic feed 40 so as to form an embossed pattern in the plastic feed 40 and laminate 24. The embossed pattern will resemble those structures illustrated in FIGS. 44, 47, 48 and/or 49, all of which will be described more fully below. The embossed pattern represents a series of thickened areas of plastic material that present a hindrance to cutting or other inappropriate opening actions sought to be prevented through theft-proofing. The remainder of the process in FIG. 4B resembles the remainder of the process described in connection with FIG. 4A.

In alternate embodiments, as illustrated in FIG. 4C, the abutting teeth 99 on the pocket impression rollers 98 may include embossed or recessed portions 102 so as to imprint a pattern 104 into the surface of the plastic feed 40. The pattern 104 preferably comprises a repetition of a symbol or design in the configuration of the embossed or recessed portion 102. The repetition in the pattern 104 may be either continuous or discontinuous depending upon the proximity and number of abutting teeth 99 including an embossed or recessed portion 102. The symbol or design embodied in the configuration of the embossed or recessed portion 102 may comprise a generic symbol or a commercial logo or symbol, e.g., trademark. As described above, the abutting teeth 99 may be configured to create the impressions 100 that coincide with the shape of the matrix 12 such that the embossed or recessed portion 102 imprints the pattern in the openings on the interior of the wires or strands 14 forming the matrix 12. In alternate embodiments described herein, the impression rollers 98 may be configured with embossed or recessed portions 102 forming a continuous pattern of symbols or impressions forming areas of increased patterns of thickness throughout the plastic feed 40.

Returning to FIG. 4A, at this point the plastic feed 40 has melted or softened and been formed around the matrix 12 to create the theft proof product packaging material 34. The material 34 is quickly drawn through a cooling chamber 50 to stop any residual melting or movement of the plastic relative to the matrix 12. The material 34 is then passed through a series of idle rollers 18 as it is rolled onto a storage reel 36. As can be seen by one skilled in the art, the material 34 can be formed by combining one or two laminate sheets 24, 28 with a matrix 12 or by using a plastic feed 40 which is then melted to the wire grid, as this disclosure is not limited to the precise forms described and shown herein.

In either method of FIG. 3, 4 or 4A, the plastic laminates 24, 28 and/or plastic feed 40 may include powder, flecks or strands of the metallic, ceramic, glass or carbon materials described above in connection with the adhesive material 82 of FIGS. 2A and 2B. The powder, flecks or strands are preferably treated as described above. Such materials may be distributed in a random or predetermined set pattern and contribute to the cut-resistant properties.

In a variation on the process for manufacturing theft-resistant material 34 as described in FIG. 4C above, the plastic feed chute 42 and plastic feed 40 may be eliminated and a laminate 24a may be provided at the beginning of the process as illustrated in FIG. 4D. The laminate 24a is preferably heated to soften the same for impression rolling. The laminate is preferably heated to an impression forming point. In this context, the term impression forming point means a temperature at which the laminate is sufficiently soft so that it will accept and hold a shape when subject to impression rolling or other forming processes (as described below—see FIGS. 4E and 4F). For most materials, this impression forming point would be at or near the melting point of the material. Preferably, the impression forming point would be at some temperature less than the melting point such that the plastic material does not lose its cohesion or the polymer chains otherwise take on a different form, i.e., increased alignment or interlinking of polymer chains.

Impression rollers 98 compress the top and bottom surfaces of the thickened laminate 24a so as to form areas of thickened plastic integral with the laminate 24a forming a security pattern with any of the configurations and shapes provided by the impression rollers 98. The security pattern may comprise an ordered pattern or a random pattern, so long as the areas of thickened plastic provide the intended deterrence or hindrance to theft of the product contained within the packaging. The same ordered pattern or random pattern feature can also be applied to the matrix 12 of strands or wires 14 described above.

The plastic laminate may be formed using other processes known in the art. For example, extrusion, thermoforming or injection molding may be used to form a plastic substrate having a security pattern, e.g., areas of thickened plastic, resulting either from the impression rolling process of FIG. 4D or the initial extrusion, thermoforming, or injection molding processes. In the case of an extrusion process, the security pattern may only run in one direction, e.g., in the direction of the extrusion. The extrusion process does not lend itself to the formation of a security pattern having crossing areas of thickened plastic.

FIGS. 4E thru 4H illustrate other forming processes that can be used to form the security pattern. FIG. 4E illustrates an alternate manufacturing process in which the impression rollers 98 are replaced by a thermoforming machine 126. The thermoforming machine 126 accepts a softened laminate 24a from the heater 50a. A person of ordinary skill in the art will appreciate that the thermoforming machine can create the areas of thickened plastic integral with the laminate 24a as described elsewhere herein. The thermoforming machine 126 produces the theft-proof product packaging material 34 in sheets 36a which are stored in stacks instead of rolls. As with the other embodiments, the areas of thickened plastic form ribs or raised sections (see FIGS. 44-46) that present a hindrance to cutting or similar attempts at in-store product theft.

In FIG. 4F, another thermoforming machine 126 receives a matrix 12 of strands or wires 14 as described above. As the matrix 12 is fed into the thermoforming machine 126, it is sandwiched between laminates 24 provided by rolls 26a, 26b. The thermoforming machine 126 melts and presses the laminates 24 around the matrix 12 as described in connection with FIGS. 18-19. One of the laminates 24 may be eliminated so as to provide a laminate on only one side of the matrix 12 as described in connection with FIGS. 20-23. The thermoforming machine 126 again produces the theft-proof product packaging material 34 in sheets 36a which are stored in stacks.

FIG. 4G illustrates another alternate manufacturing process in which the impression rollers 98 are replaced by an injection molding machine 128. Instead of receiving a laminate 24a, the injection molding machine 128 receives an input of molten plastic or similar material from a hopper 130, as will be understood by a person of ordinary skill in the art. The injection molding machine 128 forms the molten plastic into theft-proof product packaging material 34 formed in a sheet 36a having a security pattern of areas of thickened plastic.

The alternate manufacturing process of FIG. 4H illustrates where a laminate 24a is fed into the thermoforming machine 126. Prior to entering the thermoforming machine 126, a quantity of strands, cables or wires 14 are dispersed from a hopper 132 across the surface of the laminate 24a in a random pattern. The intention here is to dispense a sufficient quantity of strands, cables or wires 14 such that a sufficient hindrance to unauthorized cutting of the product packaging is created. A second laminate 26a is preferably laid on top of the first laminate 24a to sandwich the strands, cables or wires 14. Once fed into the thermoforming machine 126, the laminates 24a, 26a are melted and formed around the strands, cables or wires 14. The thermoforming machine 126 again produces the theft-proof product packaging material 34 in sheets 36a which are stored in stacks.

Any of the above alternate manufacturing processes of FIGS. 4E thru 4H may be performed including or excluding a matrix 12, as described above, between layers of laminates or plastics described herein. Following the above alternate manufacturing processes of FIGS. 4E thru 4H, the process of manufacturing theft-proof product packaging material 34 continues as described herein. Due to the nature of the thermoforming machine 126 and/or injection molding machine 128, the material 34 may be formed into separate sheets 36a rather than a continuous sheet formed into a roll 36.

FIG. 7 illustrates the matrix 12 along different portions of the manufacturing process illustrated in FIGS. 1, 2A and 2B. In particular, the left side of FIG. 7 illustrates the matrix 12 before the application of the adhesive material 82 in either FIG. 2A or FIG. 2B. The right side of FIG. 7 illustrates the matrix 12 after application of the adhesive material 82 as illustrated in FIG. 2A or FIG. 2B. FIG. 8 illustrates a close-up view of the wire grid as indicted by circle 8 in FIG. 7. In this close-up view, the adhesive material 82 can be seen encasing each of the wires 14, 22 in the matrix 12.

A multitude of different wire grids or matrices 12 can be devised by one skilled the art. FIG. 9 is a top view of an exemplary embodiment of a matrix 12. The matrix 12 is made of perpendicular wires, including the individual wires 14 and perpendicular wires 22. FIG. 11 is an enlarged sectional view of the structure of FIG. 9 indicated by circle 11 showing the wires 14, 22 overlapping and welded 54. The wires 14, 22 can be welded every time they cross each other. The welding may be metallic welding if the wires are metallic, or may be bonded together using an adhesive or other means for attachment. Alternatively, the wires 14, 22 may be weaved together and bonded or attached every crossing or less frequently. FIG. 12 is an enlarged sectional view of the structure of FIG. 9 indicated by circle 12 showing the wires 14, 22 weaved 56 together. The weaving 56 can consist of placing one wire below another at one location and then above at another location. In this way the two wires 14 and 22 are woven and connected.

FIG. 10 is a top view of another exemplary embodiment of a wire mesh structure where two sets of parallel wires 14, 22 are combined at an angle relative to each other. The wires may form a diamond pattern, or a parallelogram shape. FIG. 13 is an enlarged sectional view of the structure of FIG. 10 indicated by circle 13 showing the wires 14, 22 welded and FIG. 14 is an enlarged sectional view of the structure of FIG. 10 indicated by circle 14 showing adjacent wires 14, 22 twisted and connected 58. FIGS. 11-14 also show the adhesive materials 82 on the wires 14, 22.

FIGS. 15-17 illustrate simplified perspective views of alternate embodiments of exemplary manufacturing processes already described above. FIG. 15 illustrates the wires 14 being fed from the creel 16 over idle rollers 18 and into the wefting and warping machine 20 where the perpendicular wires 22 are added. For clarity, the wefting and warping machine 20 is not illustrated in FIGS. 15-17, but is intended to be used as shown and described in FIG. 1. Subsequently the adhesive material 82 is applied by the device 80, 84 as shown and described in FIGS. 2A and 2B. For clarity, the application and curing processes are shown as box 94 in FIGS. 15-17. As illustrated previously in FIG. 3, laminate layers 24 and 28 are added to opposite sides of the matrix 12 and heated by roller 32 before being rolled onto storage reel 36. Notably different from the earlier embodiments, a portion 88 of the laminates 24, 28 extends beyond the width of the matrix 12 so as to create an unobstructed area 88 that is devoid of the matrix 12. The purpose for this will be explained in greater detail below.

FIG. 16 illustrates a simplified perspective view of yet another alternate embodiment of an exemplary manufacturing process similar to FIG. 15. However, in FIG. 16 the matrix 12 is attached to and bonded with a single laminate 24 as depicted. The second laminate 28 is omitted from this embodiment such that the matrix 12 only has laminate 24 on the underside as depicted in this drawing. FIG. 17 illustrates a perspective view of yet another alternate embodiment of an exemplary manufacturing process similar to FIG. 16. However, in this embodiment the laminate 24 on the underside of the matrix 12 is omitted and the laminate 28 on the upper side is included. This again results in a matrix 12 having a laminate 28 only on its upper surface as depicted in the drawing.

FIG. 18 is a side view of the structure manufactured in FIG. 15 taken along line 18-18. The first laminate 24 is on one side of the matrix 12 and the second laminate 28 is on the other side of the matrix 12. It can be seen in this stage that the two laminates 24 and 28 are not formed around the matrix 12, but have void spaces 52 in between. FIG. 19 is a side view of the structure manufactured in FIG. 15 taken along line 19-19. Heat has been applied to form or mold both laminates 24 and 28 around the matrix 12. The void spaces 52 have been eliminated.

FIGS. 20 and 22 illustrate side views of the structures manufactured in FIGS. 16 and 17 respectively taken along lines 20-20 and 22-22 therein. In FIG. 20, the first laminate 24 is on the underside of the matrix 12 and the second laminate 28 is omitted. In FIG. 22, the second laminate 28 is on the top side of the matrix 12 and the first laminate 24 is omitted. As in FIG. 18, the individual laminates 24 or 28 are not formed around the matrix 12, but have void spaces 52 in between the wires 14,22. FIGS. 21 and 23 are side views of the structure manufactured in FIGS. 16 and 17 respectively taken along lines 21-21 and 23-23 thereof. With heat having been applied to the single laminates 24 and 28, both respectively form or mold themselves to the matrix 12. The void spaces 52 have been eliminated. Where only a single laminate is used in either of these illustrated embodiments, the matrix 12 is exposed on the side of the laminate 24 or 28 that has been omitted.

The theft proof product packaging material 34 can then be formed into a multitude of packing designs. FIG. 24 is a perspective view of a clam pack 60 embodying the present invention about to package a product 62. The product 62 is placed between a backing 64 and the packaging material 34. The backing 64 can be cardboard, wood, metal, plastic or any other appropriate material. FIG. 25 is a perspective view of the clam pack 60 of FIG. 24 now packaging the product 62. The material 34 has been pressed over the product 62 and the ends of the material folded over the backing 64. The ends may then be bonded or glued in place such that it cannot be easily opened.

FIG. 26 is a perspective view of a clamshell mold 66 embodying the present invention. The clamshell mold 66 can be used to form the material 34 into a clamshell package 68. FIG. 27 is a perspective view of a clamshell package 68 before it is folded. The clamshell package 68 has a front side 74 and a back side 76. Once the clamshell package 68 has been formed, it can now package a product 62. FIG. 28 is a perspective view of the clamshell package 68 of FIG. 27 now folded about to package a product 62. FIG. 29 is a perspective view of the clamshell package 68 of FIG. 27 now packaging a product 62.

FIG. 30 is a perspective view of the structure of FIG. 29 now resistant to cutting with a knife or razor 70. The theft proof product package 72 securely contains the product 62. A razor 70 can easily cut the plastic, but it can't cut the matrix 12. The plastic laminates 24 and 28 hold the matrix 12 from being opened or moved aside. The matrix 12 and plastic laminates 24 and 28 work together to create a tamper and theft resistance package. A thief can no longer easily open a package within a store to remove the product from the packaging. When the consumer buys the product, the consumer may use a pair of scissors to open the package. The scissors create a shearing action that is needed to cut through the matrix 12. A knife or razor 70 cannot do this.

The cut-resistant wire-embedded plastic shell 72 allows the product to be seen underneath while presenting a visual deterrent to potential thieves. The theft proof product package 72 also would require a thief to spend a longer amount of time trying to remove the contents. Many thieves will be discouraged from theft due to the increased time it takes to steal a product.

FIG. 31 illustrates an alternate embodiment of the clam pack depicted in FIGS. 24 and 25. In this embodiment, the theft-proof packaging material 34 including the unobstructed area 88 is used. In this way, the backing 64 can include trade identity information 90 such as a logo or other product identification which is not obstructed by the matrix 12 or other theft-proof features of the packaging. FIG. 32 illustrates how the packaging material 34 including the unobstructed area 88 is attached to the backing 64 in such a way that the trade identity information 90 appears through the unobstructed area 88. The packaging material 34 and the backing material 64 are attached as described above in connection with FIG. 25.

The cut-resistant matrix 12 can be formed from a multitude of materials including metals such as copper or steel, and also from cut resistant fabrics, such as Kevlar. Alternatively, the matrix 12 can include a fabric core with a cut resistant coating such as a metallic or ceramic coating. As can be seen by one skilled in the art, various wires can be devised that are formable into a product package while being resistant to cutting with a knife or razor.

Because the matrix 12 does the bulk of the work to stop a razor blade 70, the plastic laminates 24 and 28 or plastic feed 40 used can be thinner. This means there is less waste used in making plastic containers as less plastic is needed. Typically, a laminate of plastic is about 20 thousands of an inch thick. With the present invention, that thickness can be reduced to 6-10 thousands of an inch. For example, two laminates 24 and 28 at 6 thousandths of an inch thickness would be a total thickness of 12 thousandths of an inch. This is substantially thinner than the standard 20 thousandths of an inch thickness used today.

FIG. 33 depicts a simplified perspective view of another exemplary manufacturing process of the present invention. The process depicted in FIG. 33 begins with a wire grid as is manufactured in FIG. 1 above. This wire grid is formed into one or more blister packs 60 through a machine process such as a tool and die 92. The tool and die 92 conforms the matrix 12 to a particular shape configured to accept a product 62. After the tool and die process 92, the formed wire grid is passed through an adhesive machine 94 to apply and cure the adhesive material 82 to the wire grid as described above in connection with FIGS. 2A and 2B. The blister pack 60 then moves to a plasticizing process 96 that applies plastic or laminate material 24,28 to the blister pack 60 using one of the methods described above, particularly those of FIGS. 3 and 4.

FIG. 34 is a perspective view of a blister pack 60 embodying the present invention about to package a product 62. The material 34 has been preformed to match the product 62. Alternatively, the product 62 may be packaged with filler such as cardboard or Styrofoam to conform to the blister pack 60. The backing 64 is formed to go around the material 34 and then fold over upon itself. The backing 64 is shown as one layer, but can be made from multiple layers of card stock or varying thicknesses and densities of cardboard. For instance, the backing 64 could be formed from two layers of card stock to give it sufficient stiffness and strength. The hole of the backing 64 contains one end of the material 34 and the backing 64 is then folded over one layer and adhered/sealed to itself. FIG. 35 is a perspective view of the blister pack of FIG. 34 now packaging a product.

The exemplary embodiments shown herein used two sets of wires 14 and 22 to form a matrix 12. However, it is possible by one skilled in the art that only one set of wires 14 are required to form the theft proof product packaging material 34, as this disclosure is not necessarily limiting it to the required use of two wires 14 and 22. For example, one set of wires 14 may be utilized where the wires 14 are laid along a wavy (non-straight) pattern such that they essentially perform the function of a matrix 12.

The theft proof product packaging material 34 can not only be used to make a blister pack and clamshell packages, but can be used to make other general packages such as boxes, tubes, shipping containers, envelopes and so forth. It is to be understood by one skilled in the art that the theft proof packaging material 34 can be used to a make a multitude of theft proof packages 72 beyond those specific embodiments shown and described herein.

FIGS. 36 and 37 illustrate an alternate embodiment of the clam pack previously discussed in FIGS. 24 and 25. In this embodiment, the theft-proof product packaging material 34 is formed into a clam pack 60 configured to package a product 62. The product 62 is placed between the backing material 64 and the packaging material 34. However, in this alternate embodiment the packaging material 34 includes an interior portion 106 that is comprised of plastic material resulting from one or both laminates 24, 28 or the formed plastic feed 40 described in earlier methods. This interior portion 106 is devoid of matrix 12, any other wires or strands 14 or any areas of thickened plastic 118 (see discussion of FIG. 4B above or FIGS. 44, 47, 48 and 49 below). The matrix 12, strands 14, or areas of thickened plastic 118 are confined to a perimeter portion 108 that folds over the edges of the backing 64. This configuration provides the theft-proof properties described above by preventing or hindering cutting around the perimeter of the packaging while displaying the product 62 without obstruction or other blockage by the matrix 12, strands 14 or areas of thickened plastic 118.

In a particular embodiment, the packaging material 34 including the interior portion 106 devoid of matrix 12 is manufactured using one of the methods described above. However, before application of the laminates 24, 28 or plastic feed 40, the matrix 12 is either manufactured with openings in the grid corresponding to the interior portion 106 or is cut to create the interior portion 106 prior to application of the laminates 24, 28 or plastic feed 40. Other variations using strands 14 or areas of thickened plastic 118 are similarly manufactured using the previously described processes. In the case of the process of FIG. 4B, the impression roller 98 would include large abutting teeth 100 configured to create interior portion 106.

FIGS. 38 and 39 show a similar alternate configuration for the clamshell packaging 68 illustrated in FIGS. 28 and 29. In this embodiment, the front side 74 includes an open interior portion 106 that is devoid of matrix 12 or similar structure while the perimeter portion 108 of the front side 74 contains the matrix 12 or similar structure. The back side 76 may also contain an interior portion 106 devoid of matrix 12, but is preferably constructed with a continuous matrix 12 or similar structure. As with the clam pack of FIGS. 36 and 37, this alternate embodiment of the clamshell displays the product 62 without blockage or obstruction by the matrix 12. The interior portion 106 of the front sides 74 is constructed in a manner similar to the interior portion 106 described above in connection with FIGS. 36 and 37.

FIGS. 40 and 41 illustrate an alternate embodiment of theft-proof packaging. In the illustrated embodiment, the theft-proof packaging comprises a circular-shaped packaging 110 comprising left and right halves 112, 114. Although the illustrated embodiment is circular, the packaging 110 may be configured in any shape, e.g., round, square, rectangular, triangular, polygonal, etc., so long as side walls are present as described below. Side walls of the left and right halves 112, 114 are constructed with ribs or indentations 116 that effectively increase the amount of material around the perimeter that one would need to cut through in order to open the package 110. The increased amount of material to cut through decreases the ease with which one may cut through the packaging 110 in order to open the product. This decrease in ease of opening has a resultant decrease in the amount of theft. This embodiment contains an open interior portion 106 on both the front and back sides so as to display the product contained therein without obstruction or blockage.

FIG. 42 presents a cross-sectional view of the package 110 taken along line 42-42 of FIG. 41. This cross-sectional view illustrates the two halves 112, 114 of the package 110 and the corresponding ribs or indentations 116 spaced around the side walls. This view also illustrates the open interior portion 106 on the back side of the package 110. FIG. 43 illustrates a cross-sectional view of the package 110 taken along line 43-43 of FIG. 41. This view illustrates the ribs or indentations 116 from the interior of the package 110.

FIGS. 44, 47 and 48 illustrate yet other alternate embodiments constructed according to a process described above in connection with FIG. 4B. A laminate or plastic sheet 24 passed through the process illustrated in FIG. 4B may result in a theft-proof product packaging material 34 comprising a plurality of embossed ridges or grooves 118 along with corresponding flat plateaus or depressions 120. The ridges or grooves 118 and plateaus or depressions 120 are formed according to a pattern contained on the impression rollers 98. The impression rollers 98 have a pattern of teeth 100 on their surface that imprint onto the softened plastic feed 40 and/or laminate material 24, 28. Because of the circular rotation of the impression rollers 98, they would imprint a repeating pattern of impressions having various shapes including square, rectangular, diamond, trapezoidal, triangular, circular, random lines, etc. The impression shapes may be aligned as illustrated in FIG. 44 or may be offset as illustrated in FIGS. 47 and 48. Packaging material 34 having similar patterns can also be made through the extrusion, thermoforming or injection molding processes described above.

The changes in thickness of the packaging material 34 across the ridges or grooves 118 and the plateaus or depressions 120 hinder the ability of one to easily cut the packaging material 34. The offset nature of the impressions in FIGS. 47 and 48 present an alternate obstruction pattern.

FIGS. 45 and 45A illustrate a cross-section of the ridges or grooves 118 and plateaus or depressions 120 of the packaging material 34 illustrated in FIG. 44, particularly along line 45-45. FIG. 45 illustrates where the ridges 118 and depressions 120 are only on the top surface of the packaging material 34. In this instance, only the top impression roller 98 has a pattern of teeth to create the ridges 118 and depressions 120.

The bottom impression roller 98 presents a smooth surface to create the flat underside of the cross-section of FIG. 45. FIG. 45A is manufactured using a similar process. However, the bottom impression roller 98 includes a pattern of teeth 100 configured to create the grooves 118 on the underside such that the ridges 118 on the top side have the hollow configuration as shown.

FIG. 46 illustrates a configuration in which both the top and bottom impression rollers 98 have a pattern of teeth 100 configured to generate the ridges 118 and depressions 120 shown. FIG. 46A illustrates an embodiment in which the ridges 118 are hollow or filled with a solid core such as in the case of the matrix 12.

FIG. 47A illustrates a cross-section of the packaging material 34 of FIG. 47 showing the alternating offset nature of the plateaus 120 that are circular in nature. FIG. 48A illustrates a similar cross-section of FIG. 48 showing the alternating offset pattern of plateaus 120 that are square in shape.

FIG. 49A illustrates a packaging material 34 having a pattern of embossed concentric rings 122. This pattern of rings 122 includes an interior portion 124 that is devoid of any embossing or other obstructions that would block the view through the packaging material 34. These rings 122 represent thickened plastic or other theft-proof material that hinders any attempt at theft. FIG. 50 is a cross-section of the packaging material 34 illustrated in FIG. 49.

FIGS. 51 thru 53C illustrate other alternate embodiments of the theft-proof product packaging. In one alternate embodiment (FIGS. 51 and 52), the matrix 12 without laminate or other plastic coating is provided. The product 62, with or without a packaging card 62a is sandwiched between the matrix 12 having a front portion 74a and a back portion 76a folded-over the product 62. The matrix 12 may be unmolded so as not to conform to the product 62. In this instance, the matrix 12 would bend or bulge around the product 62 (FIG. 53C). Alternatively, the folded-over matrix may include a spine 12a (FIG. 52) to facilitate widening of the folded-over matrix 12 and accommodate the product 62 therebetween. Such folded over matrix 12 including product 62 may then be sealed in standard clamshell-type packaging material 134, 136, as shown in FIG. 53C.

In another alternate embodiment (FIG. 53A), the matrix 12 is provided with only a front portion 74A and laminates 138, all of which are provided as individual sheets to enclose product 62 and packaging card 62A. The assembled matrix 12 is then enclosed in standard clamshell type packaging 134, 136, as illustrated in FIG. 53B. The final assembly of this theft-proof product packaging will resemble that of the alternate embodiment illustrated in FIG. 53C even though the assembly of the internal matrix 12 is performed in a different manner.

Although several embodiments have been described in detail for purposes of illustration, various modifications may be made to each without departing from the scope and spirit of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.

Claims

1. A process for manufacturing theft-resistant product packaging, comprising the steps of:

forming a theft-resistant security pattern of thickened plastic areas on a plastic substrate; and

securing the plastic substrate to a back cover so as to enclose a product therebetween.

2. The process of claim 1, wherein the forming step comprises the steps of:

heating the plastic substrate to its impression forming point; and

impression rolling the heated plastic substrate to form the security pattern of thickened plastic areas.

3. The process of claim 1, wherein the forming step comprises the steps of:

dispensing pieces of thermoplastic or bio-film material over a surface of the plastic substrate;

heating the pieces of thermoplastic or bio-film material to their impression forming point; and

impression rolling the heated pieces of thermoplastic or bio-film material on the plastic substrate to form the security pattern of thickened plastic areas.

4. The process of claim 2 or claim 3, wherein the impression rolling step comprises the steps of:

feeding the plastic substrate between a pair of impression rollers having at least one set of impression teeth with embossed or recessed portions; and

impressing the security pattern of thickened plastic areas.

5. The process of claim 2 or claim 3, further comprising the step of cooling the heated pieces of thermoplastic or bio-film material to fix them together.

6. The process of claim 1, wherein the security pattern comprises a plurality of ridges interspersed with recesses or grooves interspersed with plateaus, wherein the ridges or plateaus are configured in square, rectangular, diamond, trapezoidal, triangular, circular, and/or ringed shapes, or a repetitive pattern of a symbol, design or logo.

7. The process of claim 6, wherein the plurality of ridges interspersed with recesses or grooves interspersed with plateaus or the repetitive pattern, is inline or offset.

8. The process of claim 6, further comprising the step of embossing a symbol, design or logo on at least one of the recesses or plateaus.

9. The process of claim 1, wherein the security pattern comprises a repetitive pattern of a symbol, design or logo.

10. The process of claim 1, further comprising the step of impressing an interior portion devoid of thickened plastic areas on the plastic substrate, wherein the formed theft resistant material has the security pattern of thickened plastic areas along a perimeter area of the theft-resistant material.

11. The process of claim 1, further comprising the step of extruding, thermoforming, or injection molding the plastic substrate, wherein the forming step is performed simultaneously with the extruding, thermoforming, or injection molding step.

12. The process of claim 1, further comprising the step of shaping the plastic substrate to form a cavity configured to accept the product.

13. A theft-resistant product package, comprising:

an enclosed packaging structure made from thermoplastic material, the enclosed packaging structure having front and back surfaces spaced apart by at least one side wall around the perimeter of the front and back surfaces; and

a plurality of indentations disposed in the at least one side wall, wherein each of said plurality of indentations extends from the front surface to the back surface.

14. The theft-resistant product package of claim 13, wherein the enclosed packaging structure has a generally round, square, rectangular, triangular or polygonal shape.

15. The theft-resistant product package of claim 13, wherein the front surface of the enclosed packaging structure has an open interior portion having only thermoplastic material devoid of any blockages or obstructions.

16. The theft-resistant product package of claim 15, wherein the back surface of the enclosed packaging structure has an open interior portion having only thermoplastic material devoid of any blockages or obstructions.

17. The theft-resistant product package of claim 13, wherein the enclosed packaging structure comprises two halves with a longitudinal line dividing the front and back surfaces in half.

18. A theft-resistant product package, comprising;

a front shell comprising a formed plastic substrate having areas of thickened plastic, wherein the areas of thickened plastic form a security pattern on the plastic substrate; and

a back cover secured to the front shell so as to form a cavity configured to contain a product.

19. The theft-resistant product package of claim 18, wherein the areas of thickened plastic are integral with the plastic substrate and formed by extrusion, thermoforming, injection molding or impression rolling of the plastic substrate.

20. The theft-resistant product package of claim 18, wherein the security pattern comprises a plurality of ridges interspersed with recesses or grooves interspersed with plateaus, wherein the ridges or plateaus are configured in square, rectangular, diamond, trapezoidal, triangular, circular, and/or ringed shapes, or a repetitive pattern of a symbol, design or logo.

21. The theft-resistant product package of claim 20, wherein the plurality of ridges interspersed with recesses or grooves interspersed with plateaus or the repetitive pattern, is inline or offset.

22. The theft-resistant product package of claim 18, wherein the security pattern comprises a repetitive pattern of a symbol, design or logo.

23. A theft-resistant product package, comprising:

a front shell having a security pattern of cut-resistant strands disposed within or adjacent to a plastic substrate, wherein the cut-resistant strands are disposed generally side-by-side in a single plane and each strand is alternatingly, intermittently wound around adjacent strands; and

a back cover secured to the front shell so as to form a cavity configured to contain a product.

24. The theft-resistant product package of claim 23, wherein the cut-resistant strands comprise metal, ceramic, glass, carbon fiber, fabric or fiber optic materials.

25. The theft-resistant product package of claim 23, wherein the cut-resistant strands include a hard, outer shell comprising a hardened adhesive, a powdered metal, or a ceramic material.

26. The theft-resistant product package of claim 23, wherein the plastic substrate comprises a laminate of thermoplastic or bio-film material formed around the security pattern.

27. The theft-resistant product package of claim 26, wherein the plastic substrate comprises first and second laminates of thermoplastic or bio-film material disposed on opposite sides of the security pattern and formed around the security pattern.

28. The theft-resistant product package of claim 23, wherein the front shell is preformed with a recess conforming to a shape of the product.

29. The theft-resistant product package of claim 23, wherein the back cover comprises a cardboard, wood, metal, plastic or a second security pattern of cut-resistant strands disposed within or adjacent to a second plastic substrate.

30. The theft-resistant product package of claim 23 or claim 29, wherein the back cover is secured to the front shell at its edges by a fold, a bond, glue or staples.

31. The theft-resistant product package of claim 23, further comprising a symbol, design or logo embossed on the plastic substrate in an open area of the security pattern.

32. The theft-resistant product package of claim 23, wherein the front shell has the security pattern along a perimeter area such that an interior portion of the front shell is devoid of the security pattern.