COHESIVE SEALED PACKAGE WITH ANTI-THEFT FEATURE AND METHOD OF MAKING THE SAME

Abstract

A multi-piece package is provided. The package includes a plastic component configured to hold a product. The plastic component includes a product compartment sized to receive the product, an outer portion at least partially surrounding the product compartment and a post extending outward from the outer portion. The package includes a non-plastic component. The non-plastic component includes a first segment having an outer surface and an inner surface, a second segment having an outer surface and an inner surface, a product opening formed through the non-plastic component and a post opening cut through the non-plastic component. The outer portion of the plastic component is captured between opposing portions of the first segment of the non-plastic component and of the second segment of the non-plastic component following assembly. The product compartment extends through the product opening and the post extends through the post opening following assembly.

Description

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of product packaging. The present invention relates specifically to a multi-piece package including anti-theft features.

SUMMARY OF THE INVENTION

One embodiment of the invention relates to theft-resistant multi-piece package. The package includes an integral, molded, plastic shell configured to hold a product. The plastic shell includes a product compartment sized to receive the product and a flange extending from an edge of the product compartment. The flange at least partially surrounds the product compartment and the flange defines a planar outer surface. The plastic shell includes an anchor extending outwardly from and substantially perpendicular to the planar outer surface of the flange. The package includes a fibrous board. The fibrous board includes a first segment having an outer surface and an inner surface, a second segment having an outer surface and an inner surface, a hinge coupling the first segment to the second segment, a product opening formed through the fibrous board and an anchor port cut through the fibrous board. The package includes a first cohesive layer formed on the inner surface of the first segment of the fibrous board and a second cohesive layer formed on the inner surface of the second segment of the fibrous board. The fibrous board is folded along the hinge such that the first cohesive layer engages the second cohesive layer sealing the first segment of the fibrous board to the second segment of the fibrous board. The flange of the plastic shell is captured between opposing portions of the first segment of the fibrous board and the second segment of the fibrous board and the product compartment extends through the product opening. The anchor extends through the anchor port such that engagement between an outer surface of the anchor and the inner edge of the anchor port, upon deflection of the product shell, resists movement of the plastic shell relative to the fibrous board.

Another embodiment of the invention relates to multi-piece package. The package includes a plastic component configured to hold a product. The plastic component includes a product compartment sized to receive the product, an outer portion at least partially surrounding the product compartment and a post extending outward from the outer portion. The package includes a non-plastic component. The non-plastic component includes a first segment having an outer surface and an inner surface, a second segment having an outer surface and an inner surface, a product opening formed through the non-plastic component and a post opening located through the non-plastic component. The outer portion of the plastic component is captured between opposing portions of the first segment of the non-plastic component and of the second segment of the non-plastic component following assembly. The product compartment extends through the product opening and the post extends through the post opening following assembly.

Another embodiment of the invention relates to a method of assembling a multi-piece package. The method includes the step of providing a plastic component configured to hold a product. The plastic component includes a product compartment sized to receive the product, a planar outer portion at least partially surrounding the product compartment and a post extending outward from the planar outer portion. The method includes the step of providing a non-plastic component. The non-plastic component includes a first segment having an outer surface and an inner surface, a second segment having an outer surface and an inner surface, a hinge coupling the first segment to the second segment, a product opening formed through the non-plastic component and a post opening located through the non-plastic component. The method includes the step of placing a product within the product compartment of the plastic component. The method includes the step of closing the non-plastic component around the plastic component such that the planar outer portion of the plastic component is captured between opposing portions of the first segment and the second segment of the non-plastic component, the product compartment extends through the product opening and the post extends through the post opening.

Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:

FIG. 1 is a perspective view of a package according to an exemplary embodiment.

FIG. 2 is a perspective view of a board component of the package of FIG. 1 according to an exemplary embodiment.

FIG. 3 is a perspective view of a product shell of the package of FIG. 1 according to an exemplary embodiment.

FIG. 4 is a cross-sectional view of an anchoring structure of the package of FIG. 1 taken along line 4-4 according to an exemplary embodiment.

FIG. 5 is cross-sectional view of an anchoring structure of the package of FIG. 1 taken along line 5-5 according to another exemplary embodiment.

FIG. 6 is a perspective view of a package according to another exemplary embodiment.

FIG. 7 is a second perspective view of the package of FIG. 6 according to another exemplary embodiment.

FIG. 8 is a perspective view of a board component of the package of FIG. 6 according to an exemplary embodiment.

FIG. 9 is a perspective view of a first product shell component of the package of FIG. 6 according to an exemplary embodiment.

FIG. 10 is a perspective view of a second product shell component of the package of FIG. 6 according to an exemplary embodiment.

FIG. 11 is a cross-sectional view of an anchoring structure of the package of FIG. 6 taken along line 11-11 according to an exemplary embodiment.

DETAILED DESCRIPTION

Referring generally to the figures, various embodiments of a multi-piece product package are shown. In the various embodiments shown, the multi-piece product package includes a non-plastic component (e.g., a board made of fibrous material, such as corrugate, chipboard, paper etc.) and a plastic product shell. To seal the package, the non-plastic component is folded around the plastic product shell capturing a peripheral area or flange of the product shell between opposing portions of the non-plastic component and thus sealing the product within the package.

In contrast to many conventional packages, various embodiments of the package discussed herein include a layer of a cohesive material that is located on the inner surface of the non-plastic component. In general, a cohesive material is a material that forms a strong bond to itself but forms no or very weak bonds to the other materials of the package. Thus, when the non-plastic component is folded around the plastic product shell, opposing sections of the cohesive layer located on the inside of the non-plastic component form strong bonds with each other, and thus, acts to hold the package in the sealed configuration. In contrast to many conventional packages that uses a conventional adhesive (e.g., hot-melt adhesive, a high-pressure adhesive, etc.), various embodiments of the multi-piece package of the present applications can be sealed with very low pressures without heat, and in fact, in various embodiments, can be sealed using manual pressure. Thus, in various embodiments, expensive and complicated equipment, such as heat-seal machinery or high-pressure sealing presses, are not need to assemble the multi-piece package of the present application.

In addition, following sealing the cohesive does not substantially bond to the plastic material of the product shell. Because of the lack of bonding between the product shell and the cohesive layer, little or no cohesive residue or residue from the non-plastic component remains on the plastic product shell which, in at least some instances, facilitates recyclability of the multi-piece package of the present application. In addition, in various embodiments, the cohesive layer is applied to the inner surface of the non-plastic component in an aqueous state allowing the cohesive material to penetrate a top layer of the material of the non-plastic component. As the water is removed (e.g., by evaporation), the cohesive layer is left intermeshed with the material of the top layer of the material of the non-plastic component. When the package is sealed, this intermeshing of the cohesive causes the sealing bond with the opposing layer of cohesive to be very strong such that separation of the non-plastic component following sealing is likely to cause tears or other easy to identify marks showing that the package was opened, thus providing a tamper indicating property.

In addition to the tamper evident features provided by the cohesive, the multi-piece package of the present application provides for increased theft resistance through an innovative structure that locks the plastic product shell within the non-plastic component. In various embodiments, the locking or anchor feature includes an anchor protrusion or post formed in the portion of the plastic shell trapped between opposing portions of the non-plastic component. The anchor post is received through an anchor port or opening located in the non-plastic component. Engagement between the outer surface of the anchor post and the rim of the opening limits or prevents relative movement and/or bending of the plastic shell relative to the none plastic component. This resistance limits or prevents the ability of a thief to bend, crumple or otherwise move the plastic shell from the non-plastic component to access the product with in the product shell without tearing or separating the non-plastic component.

In various embodiments, the package may include one or more anchors located at areas around the periphery of the product shell where access may be likely. For example, the anchors may be positioned in areas where there is a significant gap between the outer surface of the product and the plastic shell that may allow the plastic shell to be deformed enough to fit out of the opening in the non-plastic component in the absence of the anchor. In various embodiments, the anchor structures discussed herein have been found to be particularly useful in conjunction with a multi-piece package using a cohesive. As noted above, the cohesive does not substantially bond to the plastic product shell such that in certain packaging configurations, the shell may be removed from the non-plastic component by squeezing or deformation. As discussed in more detail below the anchor arrangement discussed herein limits or prevents such removal. In contrast to the packaging of the present application, package designs in which substantial bonding occurs between the non-plastic component and the product shell (e.g., packages that use adhesives, such as hot melt or pressure adhesives) typically would not benefit from or need an anchor structure, as discussed herein, because of the high level of bonding between the plastic shell and the non-plastic component.

Referring to FIG. 1, a multi-piece package, shown as package 10, is shown according to an exemplary embodiment. Package 10 includes a plastic component, shown as product shell 12, and a non-plastic component, shown as fibrous board 14. In FIG. 1, package 10 is shown in the assembled configuration. In the assembled configuration, an exemplary product 16 shown in ghost-lines is located within a product compartment 18 of product shell 12. In one embodiment, the face of package 10 shown in FIG. 1 is a front face of package 10, and in another embodiment, the face of package 10 shown in FIG. 1 is a rear face of package 10.

In the assembled configuration of FIG. 1, product shell 12 is trapped or captured between a front and a back section of board 14. As discussed in more detail below, package 10 includes posts, shown as anchors 20, that extend from product shell 12 and that extend through anchor openings 22 formed through board 14. The engagement between the outer surface of anchors 20 and the inner edge or rim of anchor openings 22 limits or prevents product shell 12 from being removed from board 14 by squeezing or deforming product shell 12. In various embodiments, openings 22 are die cut holes created through board 14.

In the assembled configuration, board 14 has an outer surface 24 that faces outward. Outer surface 24 may include various printing (e.g., labels, graphics, logos, stickers, etc.) related to package 10 and/or product 16. Package 10 may include one or more additional openings, such as hanger opening 26. Hanger opening 26 is located near the upper edge of package 10 and is configured to support package 10 from a hanger of a shelf, display rack, etc.

Referring to FIG. 2, board 14 is shown prior to assembly with product shell 12. Board 14 includes a first segment or portion, shown as upper section 30, and a second segment or portion, shown as lower section 32, in the orientation of FIG. 2. A hinge, shown as fold line 34, is located between upper section 30 and lower section 32. Upper section 30 includes a product opening 36. In other embodiments, upper section 30 and lower section 32 may be separate board components that are not physically joined by a hinge, and in such embodiments, upper section 30 and lower section 32 are aligned around product shell 12 prior to engagement of the opposing cohesive layers.

As shown in FIG. 2, anchor openings 22 are openings through board 14 that are distinct from both product opening 36 and the openings that form the hanger opening. Thus, as shown in the embodiment of FIG. 2, a substantially planar section of board 14 is located between each anchor hole 22 and product opening 36.

In the embodiment shown, anchor openings 22 are located on either side of product opening 36. Specifically, board 14 includes four anchor openings. In this embodiment, two anchor openings 22 are located on the left side of product opening 36, and two anchor openings 22 are located on the right side of product opening 36. Further in this embodiment, anchor openings 22 on the left side of product opening are aligned with each other such that a line bisecting the centers of each anchor opening 22 is substantially parallel to left lateral edge 38. In addition, anchor openings 22 on the right side of product opening are aligned with each other such that a line bisecting the centers of each anchor opening 22 is substantially parallel to right lateral edge 40.

As shown in the exemplary embodiment of FIG. 2, fold line 34 substantially bisects board 14 such that the length of the perimeter and the shape of upper section 30 and lower section 32 are substantially the same. In other embodiments, fold line 34 may be located at other positions relative to upper section 30 and lower section 32 such that the size and shape of upper section 30 and lower section 32 are not equal. In another embodiment, board 14 may not include a fold line 34 such that upper section 30 and lower section 32 are separate pieces of material that are aligned with each other during assembly. Upper section 30 includes a first hanger opening 42, and lower section 32 includes a second hanger opening 44. Following assembly, first hanger opening 42 substantially aligns with second hanger opening 44 to form hanger opening 26 (shown in FIG. 1).

FIG. 2 shows the inner surfaces of the two sections of board 14. In this embodiment, upper section 30 includes an inner surface 46, and lower section 32 includes an inner surface 48. In various embodiments, inner surface 46 and inner surface 48 are coated with a cohesive material. In one such embodiment, the entire inner surface 46 and the entire inner surface 48 are coated with the cohesive, and in such embodiments, the coating of cohesive may be substantially uniform (e.g., substantially the same amount of cohesive applied per unit area). In another embodiment, the coating of cohesive may be non-uniform, where higher quantities of cohesive are applied at locations requiring strong bonding (e.g., toward lateral and upper edges of board 14, around anchor openings 22, etc.). In another embodiment, the coating of cohesive may be applied only in select areas of inner surface 46 and inner surface 48. However, in such embodiments, the select areas of cohesive on inner surface 46 opposes the select areas of cohesive on inner surface 48, such that the opposing layers of cohesive contact each other to form the bond that holds package 10 together.

The cohesive of package 10 may be any material that can be applied to board 14 and that forms a bond with itself and that does not form a bond with product shell 12. In various embodiments, the cohesive is applied to board 14 in liquid form, and the cohesive material then dries to form a dry-tack cohesive layer. In various embodiments, the cohesive on board 14 is an aqueous cohesive material. In a specific embodiment, the cohesive on board 14 is an aqueous latex cohesive.

In various embodiments, the application of the liquid cohesive to the inner surfaces of board 14 allows the cohesive material to soak a portion of the distance into board 14 below inner surfaces 46 and 48. When the cohesive material dries, the cohesive material coats inner surfaces 46 and 48 and is also intermeshed with the fibers of board 14. The intermeshing of the cohesive material with the material of board 14 assists the cohesive layer to provide a strong bond to hold package 10 together following assembly. In various embodiments, the cohesive needs relatively lower pressure to form the bond that holds package 10 together. In one embodiment, the bond between opposing layers of cohesive can be formed via use of manual pressure. In a specific embodiment, the bond between opposing layers of cohesive can be formed by use of less than 50 lbs of forces, specifically less than 20 lbs of force and more specifically less than 5 lbs of force.

Referring to FIG. 3, product shell 12 is shown prior to assembly with board 14 to form package 10. Product shell 12 includes a product compartment 18 and a peripheral area, shown as flange 50. As shown in FIG. 3, product compartment 18 is a raised area that extends outward from and perpendicular to flange 50 to create the space or cavity within product compartment 18 sized to receive product 16. In the embodiment shown, flange 50 is a substantially planar area that extends around at least a portion of product compartment 18. Specifically, flange 50 extends around the lateral sides and upper side of product compartment 18. Product shell 12 is a formed or molded, integral plastic component such that flange 50 and product compartment 18 are integrally formed from a single piece of material.

Product shell 12 includes anchors 20 extending outward from and substantially perpendicular to flange 50 (e.g., such the longitudinal axis of anchor 20 forms an 80 to 90 degree angle relative to the outer surface of flange 50). In the embodiment shown, both anchors 20 and the portion of the shell forming product compartment 18 extend outward in the same direction and from the same side of product shell 12. In another embodiment, anchors 20 and the portion of the shell forming product compartment 18 extend outward in opposite directions and on opposite sides of product shell 12. Product shell 12 includes a plurality of anchors 20 and specifically includes four anchors 20. In this embodiment, a pair of anchors 20 are located to one lateral side (i.e., the left side in the orientation of FIG. 3) of product compartment 18, and a second pair anchors 20 are located to the other lateral side (i.e., the right side in the orientation of FIG. 3) of product compartment 18.

In the embodiment, shown anchors 20 are substantially cylindrical posts. However, in other embodiments, anchors 20 may have other cross-sectional shapes. In specific embodiments, anchors 20 may be rectangular prism shaped such that the cross-section of anchors 20 are substantially rectangular, square, parallelogram, etc. In other embodiments the cross-sectional shape of anchors 20 may be oval, elliptical, non-rectangular polygons, or irregular shapes.

Product shell 12 includes an upper edge 52 defined by the upper edge of flange 50, a lateral edge 54 defined by the left lateral edge of flange 50, and a lateral edge 56 defined by the right lateral edge of flange 50. In this embodiment, the pair of anchors 20 on the left side of product compartment 18 are aligned with each other such that a line that bisects the center of each anchor is substantially parallel to edge 54, and the pair of anchors 20 on the right side of product compartment 18 are aligned with each other such that a line that bisects the center of each anchor is substantially parallel to edge 56. However, it should be understood that in other embodiments, product shell 12 may include different numbers (e.g., 2, 3, 5, 6, etc.) or different positioning (e.g., positioning non-parallel to the edges of flange 50) of anchors 20.

In the embodiment of FIG. 3, anchors 20 of product shell 12 are positioned relative to the lateral edges of flange 50 such that the lateral outermost surface of each anchor 20 extends laterally outward beyond the portions of the lateral edges of flange 50 adjacent anchors 20. In various embodiments, anchors 20 of product shell 12 are positioned adjacent to the lateral edges of flange 50 such that a relatively small distance is located between the outermost surface of anchors 20 and the nearest adjacent lateral edge. For example, in various embodiments, anchors 20 are located adjacent to the nearest lateral edge of flange 50 such that less than one inch, specifically less and ½ inch, and more specifically less than a ⅛ inch is located between the nearest lateral edge and the center of anchor 20. In a one embodiment, the shortest distance between the center of each anchor 20 and the nearest lateral edge of flange 50 is between 1/32 inch and ⅛ inch. Further, product shell 12 includes anchor flanges 58 that extend laterally outward from flange 50 at the location of each anchor. In the embodiment shown, anchor flanges 58 are semi-circular extensions of flange 50 that are substantially coplanar with flange 50. Thus, the lateral outer most edge of anchor flanges 58 define laterally extending curved portions of lateral edges 54 and 56 located adjacent to anchors 20. In various embodiments, anchor flanges 58 act to support anchors 20 located adjacent to the lateral edges of flange 50. The positioning of anchors 20 adjacent the edges of flange 50 and the presence of anchor flanges 58 facilitate the anchoring or locking of product shell 12 within board 14 in various embodiments.

In various embodiments, anchors 20 are spaced along the respective edge of product shell 12 such that anchors 20 are able to secure product shell 12 within board 14. In various embodiments, as shown in FIG. 3, anchors 20 are spaced such that more than half of the length of edges 54 and 56 are located between the respective anchors 20. In another embodiment, anchors 20 are spaced such that more than 75% of the length of edges 54 and 56 are located between the respective anchors 20. In another embodiment, product shell 12 also includes anchors 20 along the upper edge and/or the lower edge of product shell 12.

Referring back to FIG. 1, package 10 is show following assembly. As shown, product shell 12 is enclosed or trapped within board 14. In this embodiment, upper section 30 and/or lower section 32 of board 14 are rotated about fold line 34 bringing the inner surfaces of board 14 toward each other. As the inner surfaces of board 14 come into contact with each, product compartment 18 extends through product opening 36 formed in upper section 30 of board 14, and lower section 32 of board 14 seals the open rear side of product shell 12. In addition, flange 50 of product shell 12 is captured between the inner surfaces of the opposing sections of board 14, and opposing portions of the cohesive layer located on the inner surface of board 14 bond to each other sealing package 10 in the closed configuration shown in FIG. 1. By this arrangement, a product may be sealed within product compartment 18 of package 10.

In addition, following sealing, anchors 20 extend through and/or protrude from openings 22. In this arrangement, anchors 20 extends a distance beyond outer surface 24 of board. In another embodiment, the height of anchors 20 are less than depth of anchor holes 22 such that the upper surface of anchors 20 are recessed below outer surface 24. Because of the bonding between the cohesive on the opposing surfaces of board 14, board 14 is bonded in place around anchors 20 at positions where portions of product shell 12 are not interposed between sections of board 14.

As noted above, the interaction between the outer surfaces of anchors 20 and the inner edge of anchor openings 22 acts to further secure and to limit movement of product shell 12 within board 14. Specifically, in various embodiments, the interaction between the outer surfaces of anchors 20 and the inner edge of anchor openings 22 acts to limit the ability of one (e.g., a thief) to deform product shell 12 enough to remove product shell 12 through product opening 36 without tearing or separating board 14. In other words, if one attempts to deform product shell 12 in an attempt to disengage product shell 12 from board 14, the outer surface of anchor 20 will engage the inner edge of anchor hole 22 limiting or preventing further movement of the exterior edge of product shell 12 toward the product opening of board 14. In addition, anchors 20 are received within openings 22 of board 14 during assembly via the same sealing or closing action that traps product shell 12 within board 14.

In various embodiments, anchors 20 and anchor holes 22 are positioned at locations where product shell 12 may be particularly susceptible to deformation. For example, in various embodiments, anchors 20 and anchor holes 22 are positioned at locations where the clearance between the outer surface of product 16 and the inner surface of product shell 12 is great enough that it may be possible to deform product shell 12 to allow access to product 16 without tearing or separating board 14. In various embodiments, anchors 20 and anchor openings 22 are located around product compartment 18 adjacent to (e.g., within 2 inches of, within 1 inch of, within a ½ inch of) areas where the clearance between the outer surface of product 16 and the inner surface of product shell 12 in assembled package 10 is greater than a ¼ inch. In various embodiments, the width of flange 50 (i.e., the distance from the outer edge of the flange to the nearest point of the product compartment) is less than or equal to ½ inch.

Referring to FIG. 4 and FIG. 5, detailed cross-sectional views of an anchor 20 received within an anchor hole 22 are shown according to an exemplary embodiment. Referring to FIG. 4, anchor 20 extends through anchor hole 22 such that anchor 20 extends a distance from outer surface 24. In various embodiments, anchor 20 extends a distance D1, from outer surface 24 that is sufficient to limit or prevent one from disengaging anchor 20 by pushing or crushing anchor 20 back through anchor hole 22. In various embodiments, D1 is between 1/32 of an inch and one inch and more specifically, is between 1/16 of an inch and a ½ inch. Anchor 20 has height above the outer surface of flange 50, shown as D3. In various embodiments, D3 is between 1/32 of an inch and one inch, specifically, is between 1/16 of an inch and ¼ inch and in a specific embodiment is about ⅛ of an inch. However, in other embodiments, anchor 20 may be recessed below outer surface 24 of board 14.

Referring to FIG. 4 and FIG. 5, in various embodiments there is a relatively small clearance between the inner surface 60 of anchor hole 22 and lateral outer surface 62 of anchor 20. The clearance between inner surface 60 and lateral outer surface 62 is large enough to allow easy alignment of anchor 20 with anchor hole 22 during package assembly but also small enough to provide an effective limitation on the ability to remove product shell 12 from board 14 without tearing or separating board 14. FIG. 5 shows the distance between the inner surface 60 of anchor hole 22 and lateral outer surface 62 of anchor 20 as distance D2. In various embodiments, the clearance between inner surface 60 of anchor hole 22 and lateral outer surface 62 of anchor 20 is expressed as the difference between the diameter of hole 22 and the outer diameter of anchor 20, and in such embodiments, D2 is understood as one half of the difference between the diameter of hole 22 and the outer diameter of anchor 20. This expression of clearance is useful in understanding the relationship between hole 22 and anchor 20 because anchor 20 may not be centered within hole 22 each time the package is sealed. In various embodiments, D2 is between 1/1000 inch and ⅛ of an inch and more specifically, is between 1/100 inch and 1/10 inch. In a specific embodiment, D2 is about 1/64 of an inch (e.g., 1/64 of an inch plus or minus 5%), and in such embodiments, the difference between the diameter of hole 22 and the outer diameter of anchor 20 is about 1/32 of an inch (e.g., 1/32 of an inch plus or minus 5%).

Further, referring generally to FIG. 4 and FIG. 5, the two cohesive layers located on opposing inner surfaces of board 14 are shown as cohesive layers 64 and 66. As shown in FIG. 4, cohesive layers 64 and 66 contact the upper and lower surfaces, respectively, of flange 50. However, because the cohesive material does not form a bond with the material of flange 50, there is no direct attachment, bond or coupling that maintains the contact between cohesive layers 64 and 66 and flange 50. In contrast, as shown in FIG. 5, to the exterior of edge 56 of flange 50, cohesive layers 64 and 66 contact each other forming a bond in bond area 68. In general (as shown in FIG. 1), bond area 68 extends around and to the exterior of flange 50. As shown in FIG. 5, bond area 68 extends more than half of the distance inward from outer edge 40 toward edge 56 of flange 50. The bond formed between cohesive layers 64 and 66 within bond area 68 acts to trap product shell 12 within board 14.

In various embodiments, product shell 12 is made from a wide variety of plastic materials. In some embodiments, product shell 12 is made from a translucent or transparent plastic material. Product shell 12 may be formed from polyethylene, polypropylene, polyethylene terephthalate, polyvinylchloride or any other suitable packaging polymer material. In various embodiments, product shell 12 may be formed from a post-consumer recycled plastic material or an in-house (e.g., scrap) recycled plastic material. Product shell 12 may be formed from any suitable molding or formation processes, including thermoforming, injection molding, compression molding, extrusion, blow molding, etc.

In various embodiments, board 14 is formed from a wide variety of non-plastic materials. Board 14 may be formed from a fibrous material, such as corrugate, chip board, paper, etc. In various embodiments, the non-plastic or fibrous material of board 14 may include a layer of fibrous material and one or more layers of non-fibrous materials (e.g., plastics, laminates, foils, etc.). In addition, the outer and/or inner surfaces of board 14 may include various layers of ink, graphics, labels, stickers, printing, etc. related to the contents of package 10.

Referring to FIGS. 6-10, a package 100 is shown according to an exemplary embodiment. Package 100 is substantially similar to package 10 except for the differences discussed herein. Package 100 includes a product shell 102 and a board 104. As discussed above, product shell 102 is trapped between opposing portions of board 104. Product shell 102 includes anchors 106 that extend through anchor openings 108 to facilitate coupling of product shell 102 within board 104 as discussed above. In addition, package 100 is held together via a bond formed between opposing layers of cohesive material located on opposing inner surfaces of board 104.

FIG. 6 shows one side (e.g., a rear side) of package 100, and FIG. 7 shows another side (e.g., a front side) of package 100. Product shell 102 includes a product compartment 110. Product compartment 110 includes a first portion 112 that extends out from one of the outer surfaces (e.g., the rear outer surface 116) of board 104. Product compartment 110 includes a second portion 114 that extends out from one of the outer surfaces (e.g., the front outer surface 118) of board 104.

As shown in FIG. 8, board 104 includes two product openings that allow for product shell 102 to extend out of both the front and rear side of board 104 following assembly of package 100. Specifically, board 104 includes an upper section 120 that includes a first product opening 122 and a lower section 124 that includes a second product opening 126. Board 104 includes a hinge, shown as fold line 128 that allows upper section 120 and lower section 124 to be pivoted toward each other to capture product shell 102 between the inner surfaces of upper section 120 and lower section 124, as shown in FIG. 6 and FIG. 7.

In the embodiment shown in FIG. 8, anchor holes 108 are located adjacent fold line 128. In this embodiment, anchor holes 108 are located along what will become the lower lateral edge 130 of package 100, as shown in FIG. 6. Further, anchor openings 108 are aligned with each other such that a line bisecting the centers of each anchor opening 108 is substantially parallel to fold line 128.

Referring to FIG. 9 and FIG. 10, the two separate pieces that form product shell 102 are shown. Referring to FIG. 9, a first section 132 of product shell 102 that defines portion 114 of the product compartment is shown. First section 132 includes a peripheral flange 136 that extends around portion 114 of the product compartment and that defines the outer most edge 138 of first section 132. Flange 136 includes an expanded section 140 that has a greater width than the portions of flange 136 on either side of expanded section 140.

First section 132 of product shell 102 includes a pair of anchor posts 142 that extend from outward from and perpendicular to the plane defined by expanded section 140 As shown, anchor posts 142 are substantially cylindrical and are spaced apart such that each post 142 is located adjacent opposing corners of expanded section 140. In various embodiments, more than half of the length of expanded section 140 is located between anchor posts 142, and more specifically, more than 75% of the length of expanded section 140 is located between anchor posts 142. In various embodiments, this spacing provides spaced anchor points to support product shell 102 within board 104.

Referring to FIG. 10, a second section 150 of product shell 102 that defines portion 112 of the product compartment is shown. Second section 150 includes a peripheral flange 152 that extends around portion 112 of the product compartment and that defines the outer most edge 154 of second section 150. Flange 152 includes an expanded section 156 that has a greater width than the portions of flange 152 on either side of expanded section 156.

Second section 150 of product shell 102 includes a pair of anchor posts 158 that extend outward from and perpendicular to the plane defined by expanded section 156 As shown, anchor posts 158 are substantially cylindrical and are spaced apart such that each post 158 is located adjacent opposing corners of expanded section 156. In various embodiments, more than half of the length of expanded section 156 is located between anchor posts 158, and more specifically, more than 75% of the length of expanded section 156 is located between anchor posts 158. In various embodiments, this spacing provides spaced anchor points to support product shell 102 within board 104.

In general, each anchor 142 is friction fit within the corresponding anchor 158 to couple first section 132 to second section 150. This coupling between first section 132 and second section 150 of product shell 12 acts to maintain the relative positioning of first section 132 to second section 150 following assembly of product shell 102 around the product. Following assembly of product shell 102, board 104 is folded around product shell such that flange 136 and flange 152 are trapped within board 104. As discussed above, opposing layers of a cohesive material located on the inner surface of board 104 bonds tightly to the opposing cohesive layer following assembly to maintain the package 100 in the closed configuration shown in FIG. 6 and FIG. 7.

Referring to FIG. 11, a cross-sectional view of assembled anchor 106 located within anchor hole 108 is shown according to an exemplary embodiment. Both anchors 142 and anchors 158 are hollow generally cylindrical structures. The inner cavity of anchor 158 receives anchor 148. Further, the inner cavity of anchor 158 is sized such that he inner surface of anchor 158 engages and forms an interference or friction fit with the outer surface of anchor 146. Thus, anchors 106 include an outer wall formed from anchor 158 and an inner wall formed from anchor 146. In addition, package 100 includes a layer of cohesive 160 located on the inner surface of lower board section 124 and an opposing layer of cohesive 162 located on the inner surface of upper board section 120. In one embodiment, instead of being separate pieces, first section 132 and second section 150 may include a foldable hinge structure joining the two sections together, and in this embodiment, assembled anchor 106 acts to hold the shell in the closed, folded position.

As shown in the embodiment of FIG. 11, the material of second section 150 may have a thickness less than the thickness of the material of first section 132. In another embodiment, the material of second section 150 may have a thickness greater than the thickness of the material of first section 132. In another embodiment, the material of second section 150 may have a thickness substantially the same as the thickness of the material of first section 132.

In various embodiments, the present application relates to a method of making a and assembling a product package, such as packages 10 and 100, discussed above. In various embodiments a method of assembling a multi-piece package is provided. In such embodiments the method includes providing a plastic component configured to hold a product. In such embodiments, the plastic component includes a product compartment sized to receive the product, a planar outer portion at least partially surrounding the product compartment and a post extending outward from the planar outer portion. The method includes providing a non-plastic component. The non-plastic component includes a first segment having an outer surface and an inner surface, a second segment having an outer surface and an inner surface, a hinge coupling the first segment to the second segment, a product opening formed through the non-plastic component and a post opening cut or created through the non-plastic component. The method includes placing a product within the product compartment of the plastic component. The method includes closing the non-plastic component around the plastic component such that the planar outer portion of the plastic component is captured between opposing portions of the first segment and the second segment of the non-plastic component, such that the product compartment extends through the product opening and such that the post extends through the post opening. In various embodiments, the method includes applying a cohesive material, as discussed above, on opposing portions of the inner surface of the first segment of the non-plastic component and the inner surface of the second segment of the non-plastic component.

It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the inventive teachings and advantages of the subject matter described herein.

For purposes of this disclosure, the term “coupled” means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.

Claims

1. A theft-resistant multi-piece package comprising:

an integral, molded, plastic shell configured to hold a product, the plastic shell comprising: a product compartment sized to receive the product; a flange extending from an edge of the product compartment, the flange at least partially surrounding the product compartment, the flange defining a planar outer surface; and an anchor extending outwardly from and substantially perpendicular to the planar outer surface of the flange;

a fibrous board comprising: a first segment having an outer surface and an inner surface; a second segment having an outer surface and an inner surface; a hinge coupling the first segment to the second segment; a product opening cut through the fibrous board; and an anchor port formed through the fibrous board;

a first cohesive layer formed on the inner surface of the first segment of the fibrous board; and

a second cohesive layer formed on the inner surface of the second segment of the fibrous board;

wherein the fibrous board is folded along the hinge such that the first cohesive layer engages the second cohesive layer sealing the first segment of the fibrous board to the second segment of the fibrous board;

wherein the flange of the plastic shell is captured between opposing portions of the first segment of the fibrous board and the second segment of the fibrous board and the product compartment extends through the product opening; and

wherein the anchor extends through the anchor port such that engagement between an outer surface of the anchor and an inner edge of the anchor port, upon deflection of the product shell, resists movement of the plastic shell relative to the fibrous board.

2. The theft-resistant multi-piece package of claim 1 wherein a gap is located between the outer surface of the anchor and the inner edge of the anchor port.

3. The theft-resistant multi-piece package of claim 2 wherein the gap is between 1/100 inches and 1/10 inches.

4. The theft-resistant multi-piece package of claim 2 wherein the first cohesive layer and the second cohesive layer does not bond to the plastic shell such that the portions of the fibrous board adjacent to the anchor port are not bonded to the portion of the plastic shell adjacent to the anchor.

5. The theft-resistant multi-piece package of claim 1 wherein the anchor port is an opening separate from the product opening such that a portion of the fibrous board is located between the anchor port and the product opening.

6. The theft-resistant multi-piece package of claim 1 wherein the plastic shell further comprises a second anchor, wherein the fibrous board comprises a second anchor port, wherein the second anchor extends through the second anchor port such that engagement between an outer surface of the second anchor and an inner edge of the second anchor port, upon deflection of the product shell, resists movement of the plastic shell relative to the fibrous board.

7. The theft-resistant multi-piece package of claim 6 wherein the anchor and the second anchor are positioned on the flange such that both the anchor and the second anchor are located between a peripheral edge of the flange and the product compartment of the plastic shell.

8. The theft-resistant multi-piece package of claim 6 wherein the anchor port and the second anchor port are positioned on the flange such that a line intersecting the centers of the anchor port and the second anchor port is substantially parallel to the hinge.

9. The theft-resistant multi-piece package of claim 6 wherein the anchor port and the second anchor port are positioned on the flange such that a line intersecting the centers of the anchor port and the second anchor port is substantially parallel to a lateral edge of the fibrous board.

10. The theft-resistant multi-piece package of claim 6 wherein the anchor and the second anchor are positioned such that less than ⅛ inches is between the center of the anchors and the nearest lateral outer edge of the product shell.

11. The theft-resistant multi-piece package of claim 6 wherein the fibrous board includes a hanger opening configured to support the package on a display rack.

12. The theft-resistant multi-piece package of claim 6 wherein product compartment of the plastic shell is located between the anchor and the second anchor.

13. The theft-resistant multi-piece package of claim 12 wherein the plastic shell further comprises a third anchor and a fourth anchor, wherein the fibrous board comprises a third anchor port and a fourth anchor port, wherein the third anchor extends through the third anchor port and the fourth anchor extends through the fourth anchor port, wherein the product compartment is located between the third anchor and the fourth anchor.

14. The theft-resistant multi-piece package of claim 1 further comprising a product within the product compartment of the plastic shell, wherein a gap between an outer surface of the product and an inner surface of the product compartment adjacent the anchor is greater than ¼ inch.

15. A multi-piece package comprising:

a plastic component configured to hold a product, the plastic component comprising: a product compartment sized to receive the product; an outer portion at least partially surrounding the product compartment; and a post extending outward from the outer portion;

a non-plastic component comprising: a first segment having an outer surface and an inner surface; a second segment having an outer surface and an inner surface; a product opening located through the non-plastic component; and a post opening located through the non-plastic component;

wherein the outer portion of the plastic component is captured between opposing portions of the first segment of the non-plastic component and of the second segment of the non-plastic component following assembly; and

wherein the product compartment extends through the product opening and the post extends through the post opening following assembly.

16. The multi-piece package of claim 15 wherein a gap is located between the outer surface of the post and the inner edge of the post opening, wherein the gap is between 1/100 and 1/10 inches, wherein the post is positioned such that less than ⅛ inches is between the center of the post and the nearest lateral, outer edge of the plastic component.

17. The multi-piece package of claim 15 further comprising a cohesive material located on the inner surfaces of the first segment and the second segment of the non-plastic component, wherein the post opening is an opening separate from the product opening such that a planar portion of the non-plastic component is located between the post opening and the product opening.

18. The multi-piece package of claim 17 wherein the non-plastic component further includes a hanger opening configured to support the package from a display rack, wherein the post opening is an opening separate from the hanger opening such that a planar portion of the non-plastic component is located between the post opening and the hanger opening.

19. A method of assembling a multi-piece package comprising:

providing a plastic component configured to hold a product, the plastic component comprising: a product compartment sized to receive the product; a planar outer portion at least partially surrounding the product compartment; and a post extending outward from the planar outer portion;

providing a non-plastic component, the non-plastic component comprising: a first segment having an outer surface and an inner surface; a second segment having an outer surface and an inner surface; a hinge coupling the first segment to the second segment; a product opening formed through the non-plastic component; and a post opening located through the non-plastic component;

placing a product within the product compartment of the plastic component; and

closing the non-plastic component around the plastic component such that the planar outer portion of the plastic component is captured between opposing portions of the first segment and the second segment of the non-plastic component, the product compartment extends through the product opening and the post extends through the post opening.

20. The method of assembling a multi-piece package of claim 19 wherein a cohesive material is located on opposing portions of the inner surface of the first segment of the non-plastic component and the inner surface of the second segment of the non-plastic component.