US20160083127A1 - Blister package assemblies and systems and methods for producing said assemblies - Google Patents
Blister package assemblies and systems and methods for producing said assemblies Download PDFInfo
- Publication number
- US20160083127A1 US20160083127A1 US14/856,739 US201514856739A US2016083127A1 US 20160083127 A1 US20160083127 A1 US 20160083127A1 US 201514856739 A US201514856739 A US 201514856739A US 2016083127 A1 US2016083127 A1 US 2016083127A1
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- United States
- Prior art keywords
- sheet
- blister
- product
- window
- portions
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B11/00—Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material
- B65B11/50—Enclosing articles, or quantities of material, by disposing contents between two sheets, e.g. pocketed sheets, and securing their opposed free margins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B5/00—Packaging individual articles in containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, jars
- B65B5/02—Machines characterised by incorporation of means for making the containers or receptacles
- B65B5/024—Machines characterised by incorporation of means for making the containers or receptacles for making containers from preformed blanks
- B65B5/028—Machines characterised by incorporation of means for making the containers or receptacles for making containers from preformed blanks for making containers from two or more blanks
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B51/00—Devices for, or methods of, sealing or securing package folds or closures; Devices for gathering or twisting wrappers, or necks of bags
- B65B51/02—Applying adhesives or sealing liquids
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D73/00—Packages comprising articles attached to cards, sheets or webs
- B65D73/0078—Packages comprising articles attached to cards, sheets or webs the articles being retained or enclosed in a folded-over or doubled card
- B65D73/0085—Packages comprising articles attached to cards, sheets or webs the articles being retained or enclosed in a folded-over or doubled card within a window, hole or cut-out portion
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D73/00—Packages comprising articles attached to cards, sheets or webs
- B65D73/0078—Packages comprising articles attached to cards, sheets or webs the articles being retained or enclosed in a folded-over or doubled card
- B65D73/0085—Packages comprising articles attached to cards, sheets or webs the articles being retained or enclosed in a folded-over or doubled card within a window, hole or cut-out portion
- B65D73/0092—Packages comprising articles attached to cards, sheets or webs the articles being retained or enclosed in a folded-over or doubled card within a window, hole or cut-out portion combined with a preformed enclosure, e.g. a bulb
Definitions
- the present disclosure relates to one or more blister package assemblies and/or one or more systems and methods for producing the one or more blister package assemblies.
- the assemblies and systems and methods are utilized to package and/or protect one or more products and/or to display one or more products using a new and different blister card construction format.
- thermoformed plastic and the backing is made from a paper-based material, for example, cardboard or paperboard, metal foil or one of many available plastics or a combination of any of these varied materials.
- traditional blister card systems such as, for example, rotary or inline systems
- standard blister machine tooling such as, for example, blister framing tooling that has to be made exactly to fit and hold each blister, card and product and then feed each blister, card and product into the necessary sealing heated head section, which requires a custom heat sealing head to come down, heat seal the card, product and blister together which must exactly match all blisters and products needed to be sealed.
- This standard blister sealing process squeezes and heats the card together for completing its sealing process, which causes visible card crushing, marks and indentations in the final product which is one disadvantage of these standard blister sealing processes.
- the assemblies and methods set forth in the present disclosure will produce and seal multiple and unlimited blister package designs styles for almost any different blister package assemblies required by any manufacturer, for storing and enclosing almost any different product(s) having different sizes and/or shapes, with or without, the use of pre-formed plastic cavities.
- film or a plastic cavity with this new process, large savings are achieved by eliminating or reducing the required multiple tooling needed and the complete elimination of any currently used sealing equipment machines and their very high operating costs.
- the present assemblies and methods will reduce total packaging costs, production times and labour requirements associated with producing and sealing the different blister package assemblies by utilizing one or more of the following structural features and/or elements: a sheet or card having one or more scorings, foldings or petitioning to provide at least two, three, four, nine or more foldable portions; at least one cut-out window formed in the sheet; one or more compliant or stretchable films connected to a back side of the sheet and covering the at least one cut-out window(s) for enclosing at least one product between the one or more compliant films and at least one folded portion of the sheet; a conveyor belt system which may be continuously moving; two or more supports associated with the conveyor belt system for supporting at least one portion of the sheet during the production of the assembly; one or more moveable elements associated with the conveyor belt system for folding portions of the sheet onto each other to produce the folded assembly; a vacuum holding device associated with the conveyor belt system for applying a vacuum holding force to sheet or card positioned on the conveyor belt system; and an adjustable pocket or cavity, adjustable in both width
- a plurality of adjustable product blister depths can be achieved for almost any product by angle adjustments made to the moveable elements position with respect to the position of the card.
- the adjustable product blister depths adjust in any and all axis's and planes required for the correct film pocket size.
- the moveable elements will allow for infinite blister depth adjustment, without tools, for making any required blister depth that may be needed for each and every product a manufacturer or customer wishes to have blister packaged a certain way and with a special look.
- tension in the stretchable film is relaxed which results in an increased width and/or depth of film pocket size for receiving the product.
- the present systems and methods, for producing the present blister package assemblies operate completely without any of the above-mentioned standard blister machine tooling. Instead, the present systems and methods utilize a machine assembly comprising movable convey belts that are slidable over the moveable box supports which operate a support bases for the movable convey belts. Said movable conveyor belts and box support are movable from side to side to provide one or more adjustable cavities that adjustable sizes, shapes, depths and/or configurations for receiving cards, blisters and/or products having different sizes, shapes, depths and/or configurations. As a result, the present systems and methods may quickly accommodate almost any size, shape and depth card, blister and/or possible and may fit almost any sized product sealable within the present blister package assemblies.
- the present systems and methods does not utilize the heated head; thus no crushing, marks or indentations occur with respect to the final blister package assemblies produced by the present systems and methods. Instead, the present systems and methods utilize folding and sealing with one or more selected from adhesive, cohesive, pressure and a heat tunnel to seal the present blister package assemblies.
- the newest graphic print and design features which are not available to any other current blister system due to their sealing process (i.e., holding, squeezing and heating of the cards to complete and seal their package) may be utilized and/or incorporated into the present blister package assemblies and present systems and methods for producing said blister package assemblies.
- systems and methods may package retail products, provide a sheet divided into a first part and a second part, wherein the first and second parts of the sheet are foldable with respect to each other, wherein the first part of the sheet has at least one window formed in the sheet, load a pre-formed blister, having at least one pocket preloaded with at least one retail product, into the window formed in the sheet such that a portion of the pre-formed blister and a portion of the at least one retail product extends through the window formed in the sheet, and fold the second part onto the first part to produce a blister product assembly such that the at least one retail product is located between a portion of the pre-formed blister and a portion of the second part of the sheet.
- the systems and methods may have a blister product assembly production rate from about 100 assemblies/minute to about 450 assemblies/minute.
- the sheet may be made of paper-based materials, plastic or polymer-based materials or a combination thereof.
- the pre-formed blister may be made of a rigid or semi-rigid plastic.
- the pre-formed blister may be made of at least one polymer material.
- systems and methods may further comprise coating an adhesive onto one or more sides of a flange of the pre-formed blister before the pre-formed blister is loaded into the window formed in the sheet.
- systems and methods may further comprise adhering the first and second parts of the sheet together, via the adhesive coated onto one or more sides of the flange of the pre-formed blister, when, or after, the second part is folded onto the first part of the sheet.
- systems and methods may further comprise adhering the first and second parts of the sheet together via cohesion or an adhesive when, or after, the second part is folded onto the first part of the sheet to produce the blister product assembly.
- systems and methods may further comprise dispensing the sheet onto a conveyor belt prior to loading the pre-formed blister into the window formed in the sheet.
- systems and methods may further comprise placing the pre-formed blister, by hand or by machine, into the window formed in the sheet for loading the pre-formed blister into the window.
- the second part of the sheet may have a window formed therein for receiving at least a portion of the pre-formed blister and/or a portion of the at least one retail product.
- the systems and methods may package retail products, position a sheet on a conveyor belt system comprising an adjustable cavity, wherein the sheet is divided into a first part and a second part, wherein the first and second parts of the sheet are foldable with respect to each other, wherein the first part of the sheet has at least one window formed in the sheet, wherein the window formed in the sheet is positioned above the adjustable cavity of the conveyor belt system when the sheet is positioned on the conveyor belt system, load a pre-formed blister, having at least one pocket preloaded with at least one retail product, into the window formed in the sheet such that a portion of the pre-formed blister and a portion of the at least one retail product extends through the window formed in the sheet and into the adjustable cavity of the conveyor belt system, and fold the second part onto the first part to produce a blister product assembly such that the at least one retail product is located between a portion of the pre-formed blister and a portion of the second part of the sheet.
- the systems and methods may further comprise adjusting a width and/or depth of the adjustable cavity of the conveyor belt system to correspond to or to be similar to dimensions of the at least one retail product and/or the pre-formed blister prior to loading the at least one retail product and/or the pre-formed blister into the window formed in the sheet.
- the systems and methods may further comprise providing downward vacuum holding forces onto the sheet by a vacuum producing device of the conveyor belt system after the sheet is positioned on the conveyor belt system and/or providing downward vacuum holding forces onto the at least one retail product by the vacuum producing device after the at least one retail product is loaded into the window formed in the sheet.
- the method may have a blister product assembly production rate from about 100 assemblies/minute to about 450 assemblies/minute.
- systems and methods may further comprise coating an adhesive onto one or more sides of a flange of the pre-formed blister before the pre-formed blister is loaded into the window formed in the sheet.
- systems and methods may further comprise adhering the first and second parts of the sheet together, via the adhesive coated onto one or more sides of the flange of the pre-formed blister, when, or after, the second part is folded onto the first part of the sheet.
- systems and methods may further comprise adhering the first and second parts of the sheet together via cohesion or an adhesive when, or after, the second part is folded onto the first part of the sheet to produce the blister product assembly.
- systems and methods may further comprise placing the pre-formed blister, by hand or by machine, into the window formed in the sheet for loading the pre-formed blister into the window.
- the second part of the sheet may have a window formed therein for receiving at least a portion of the pre-formed blister and/or a portion of the at least one retail product.
- FIG. 1 illustrates a front plan view of a blister package assembly with a product enclosed therein in an embodiment.
- FIG. 2 illustrates a front plan view of a blister package assembly with more than one product enclosed therein in an embodiment.
- FIG. 3 illustrates a front plan view of a top side of a sheet of card stock paper petitioned into at least three portions and having at least one window formed therein and at least one compliant or stretchable film covering the at least one window in an embodiment.
- FIG. 4 illustrates a front plan view of a bottom side of a sheet of card stock paper petitioned into at least one, two or three portions and having at least one window formed therein and at least one compliant or stretchable film connected to the portions of the sheet and covering the at least one window in an embodiment.
- FIG. 5 illustrates a top plane view of a portion of the sheet shown in FIG. 4 showing one of the moveable elements in correct position to produce a properly sized product blister film pocket, just prior to being folded onto another portion of the sheet in an embodiment.
- FIG. 7 illustrates a top plan view of the sheet shown in FIG. 6 after two portions of the sheet have been folded and sealed together onto the remaining portion of the sheet. Locking the product in place with multiple holding systems.
- a fugitive adhesive or other holding method such as, but not limited to, other adhesive types, cohesive, double sided tape etc., as a method to securely hold the product from behind, to the front side A 3 of a portion of the sheet.
- the film blister pocket will lock the product into place from behind the front side A 1 of an additional portion of the sheet with the film pocket adhered to the back side B 1 of that additional portion, to produce the blister package assembly in an embodiment.
- FIG. 8 illustrates a partial cross-sectional view of a blister package assembly having a product (i) connected to a portion of a folded sheet, (ii) extending through the window formed in the sheet, and (iii) enclosed between the at least one compliant, stretchable and heat shrinkable film and the portion of the sheet in which the product is connected to in an embodiment.
- FIG. 9 illustrates a partial cross-sectional view of a blister package assembly provided on a conveyor or moving belt that has an adjustable cavity and vacuum holding device applying vacuum holding force to an adjacent portion of the card and the product position in the window in an embodiment.
- FIG. 10 illustrates a front plan view of a bottom side of a sheet petitioned into three portions, having at least one window formed therein, and at least one compliant or stretchable film connected to the portions of the sheet and covering the at least one window having a product positioned therein in an embodiment.
- FIG. 11 illustrates a front plan view of the bottom side of the sheet shown in FIG. 9 with one portion folded onto another portion and a portion of the product in an embodiment.
- FIG. 12 illustrates a front plan view of the bottom side of the sheet shown in FIGS. 10 and 11 with a second portion folded onto the other portions to form the folded assembly in an embodiment.
- FIG. 14 illustrates a front plan view of the bottom side of the sheet shown in FIG. 13 with upper and lower foldable portions folded onto the first portion of the sheet and the product in an embodiment.
- FIG. 15 illustrates a front plan view of the bottom side of the sheet shown in FIGS. 13 and 14 with left and right foldable portions folded onto the first portion of the sheet to form the folded assembly in an embodiment.
- FIG. 16 illustrates a front plan view of the front side of the folded assembly produced by folding the plurality of foldable portions onto the first portion of the sheet as shown in FIGS. 13-15 in an embodiment.
- FIG. 17 illustrates a front plan view of a product connected to a carrier in an embodiment.
- FIG. 18 illustrates a top plan view of a front side of a folded assembly displaying the product connected to the carrier as shown in FIG. 17 in an embodiment.
- FIG. 19 illustrates a front plan view of a sheet of card stock paper petitioned into three portions and having two windows formed therein and a product connected to a carrier and sealed in a bag of film in an embodiment.
- FIG. 20 illustrates the front plan view shown in FIG. 19 , wherein a portion of the sheet has been folded onto the middle portion forming a pocket between the portions for receiving the product and carrier sealed in the bag of film in an embodiment.
- FIG. 21 illustrates the front plan view shown in FIG. 20 , wherein the product and carrier sealed in the bag of film is inserted into the pocket formed between the portions in an embodiment.
- FIG. 22 illustrates the front plan view shown in FIG. 21 , wherein the entire lengths of the product and carrier are inserted into the pocket formed between the portions in an embodiment.
- FIG. 23 illustrates the front plan view shown in FIG. 22 after the third portion has been folded onto the other two portions enclosing at least portions of the carrier between the portions of the sheet in embodiment.
- FIG. 24 illustrates a front plan view of a sheet of card stock paper petitioned into three portions and having two windows formed therein and a product connected to a carrier and sealed in a bag of film in an embodiment.
- FIG. 25 illustrates the front plan view shown in FIG. 24 , wherein the product and carrier sealed in the bag of film has been positioned on the middle portion of the sheet in an embodiment.
- FIG. 26 illustrates the front plan view shown in FIG. 25 , wherein a first outer portion of the sheet has been folded onto the middle portion such that the product extends outwardly from the window of the folded outer portion in an embodiment.
- FIG. 27 illustrates the front plan view shown in FIG. 26 , wherein a second outer portion of the sheet has been folding onto the middle and first outer portions such that the product extends outwardly from the windows formed in the first and second outer portions in an embodiment.
- FIG. 28 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into two portions and having a window formed in one portion in an embodiment.
- FIG. 29 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into three portions and having a window formed in the middle portion in an embodiment.
- FIG. 30 illustrates a front plan view of a product connected to a carrier and/or sealed in a bag of film in an embodiment.
- FIG. 31 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into at least two portions and having a window formed in one portion in an embodiment.
- FIG. 32 illustrates a front plan view of a product a pre-formed blister sized to receive the product whereby an adhesive layer is provided on the pre-formed blister in an embodiment.
- FIG. 33 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into at least two portions and having a product and pre-formed blister loaded into a window formed in one portion and sealed closed using adhesive or cohesive on the pre-formed blister or card in an embodiment.
- FIG. 34 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into two portions and having a window formed in one portion that is covered with at least one stretchable film in an embodiment.
- FIG. 35 illustrates a top plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment.
- FIG. 36 illustrates a first side plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment.
- FIG. 37 illustrates a second side plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment.
- FIG. 38 illustrates a first end plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment.
- FIG. 39 illustrates a second end plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment.
- FIG. 40 illustrates a perspective view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment.
- FIG. 41 illustrates a partial perspective plan view of a blister pack machine system having movable box supports slidable on horizontal crossbars in an embodiment.
- the present disclosure sets forth blister package assemblies and/or methods of producing blister package assemblies for packaging, securing, storing, enclosing, protecting, displaying and/or offering-for-sale one or more products.
- the assemblies and methods may package one or more products, enclosed between at least one compliant or stretchable film at least one portion of a sheet of card stock paper or other selected material, such that the one or more products extend through at least one window formed in the sheet.
- one or more windows may be formed in the sheet whereby each window is sized and shaped to display one or more products, which may be the same products, different products or a combination thereof.
- portions of the sheet may be folded over each other to produce the folded blister package assemblies such that the product may extend through a window formed in a portion of the sheet and be enclosed between the compliant or stretchable film and one or more folded portions of the sheet. It should be understood that the following terms may be used interchangeably throughout the present disclosure: sized; shaped; adapted; and configured.
- the present systems and methods may provide at least one folded blister package assembly 2 (hereinafter “assembly 2 ”) as shown in FIG. 1 , configured to package at least one product 4 .
- a folded blister package assembly 100 (hereinafter “assembly 100 ”) may be sized, shaped and/or configured to package, for example, a plurality of products 4 (hereinafter “products 4 ”) as shown in FIG. 2 .
- products 4 a plurality of products 4
- the present disclosure is not limited to a specific embodiment of the number of products 4 which may be packaged within the assembly 2 and/or the assembly 100 (hereinafter collectively referred to as “assemblies 2 , 100 ”).
- the assembly 100 may package three products 4 as shown in FIG. 2 ; however, it should be understood that the assembly 100 may be shaped, sized and/or configured to package, store and/or display any number of products 4 as known to one of ordinary skill in the art.
- the products 4 may be, for example, cosmetic products, consumer products, food products, hard goods, durable goods, soft goods, pharmaceuticals, replacement parts, aerosols, consumables, consumer-grade goods, professional-grade goods and/or the like.
- the products 4 may be at least one or more products.
- the products 4 may be, for example, cosmetics, analgesics, medications, pharmaceuticals, razors, razor blades, camera film, batteries, videos, DVDs, smoking cessation products, infant formula, lip sticks, nail polishes, toothbrushes, vitamins, personal care products, home care products, toothbrushes, foodstuffs, packaged foods, kitchen supplies, bags, boxes, containers and/or the like.
- the products 4 which may be secured, stored, displayed and/or dispensed via the assemblies 2 , 100 , may be the same products, similar products, different products or a combination of same and different products. In embodiments, the products 4 may have same, similar and/or different sizes, shapes and/or configurations.
- the products 4 that may be any product(s) known to one of ordinary skill in the art that are configured, adapted, shaped and/or sized to be packed or stored within the assemblies 2 , 100 .
- the assemblies 2 , 100 and/or the products 4 may be accessible by a consumer through a front-side of a divider or shelf system (not shown in the drawings).
- the assemblies 2 , 100 may have a cut-out opening 40 (shown in FIGS. 13-16 ) which may enable the assemblies 2 , 100 to be suspended from a hook or a peg (not shown in the drawings) associated with the divider or shelf system.
- a consumer may remove and/or separate the assemblies 2 , 100 from divider or shelf system and/or from the hook or peg to examine the products 4 packaged, secured, stored, enclosed, protected and/or displayed within the assemblies 2 , 100 . If desirable, the consumer may purchase or offer-to-buy the assemblies 2 , 100 and/or the products 4 .
- the products 4 may be separated and/or removed from the assemblies 2 , 100 by the consumer and the assemblies 2 , 100 may be discarded and/or recycled by the consumer.
- Easy open features like, but not limited to, rear perforated pull tabs or tear tapes etc. to assist package opening can be added upon request or as desired.
- FIGS. 1 and 2 show the folded assemblies 2 , 100 , respectively, which comprise at least one sheet 5 (hereinafter “sheet 5 ”) made of materials, such as, for example, paper-based materials, plastic or polymer-based materials or a combination thereof.
- sheet 5 may be made of any materials that are capable, physically, of being folded onto and/or over itself to produce, form and/or assemble the folded assemblies 2 , 100 .
- the sheet 5 may be made of one or more materials selected from the group consisting of paper corrugated or wood based materials, blister boards, coated styrene butadiene styrene, corrugated fibreboard, E-Flute corrugated fibreboard, stone paper, ceramic sheets, wood, melamine, standardized layers or sheets or combinations thereof. It should be understood that the present disclosure is not limited to a specific embodiment of the materials that may be used to make the sheet 5 .
- the sheet 5 may consist of a single layer of material. In other embodiments, the sheet 5 may consisting of more than one layer of material which may be connect, attached, adhered or laminated together to form the sheet 5 . It should be understood that the present disclosure in not limited to specific embodiment of the number of layers of material that may be utilized to form sheet 5 .
- the sheet 5 may be divided or partitioned into two, three, four, nine or more portions by a dividing or partitioning process or method.
- the three or more portions of the sheet 5 may be formed or produced by a scoring process, such as, for example, a side cut scoring process or the like.
- a scoring process such as, for example, a side cut scoring process or the like.
- one or more scores or folds may be positioned, provided and/or located between each of the three or more portions.
- additional height dimension may be added to the folded assembly 2 .
- gussets and/or other pull-out features may be provided or positioned in the additional height dimension that may be provided by the two or more scores or folds between each of the three or more portions of the sheet 5 .
- the sheet 5 may be divided or partitioned into a first portion 6 , a second portion 8 and a third portion 10 (hereinafter collectively referred to as “portions 6 , 8 , 10 ”) as shown in FIGS. 3-5 .
- Each of the portions of the sheet 5 has a front side and a back side located opposite with respect to the front side of each portion.
- the first portion 6 has a front side A 1 and a back side B 1
- the second portion 8 has a front side A 2 and a back side B 2
- the third portion 10 has a front side A 3 and a back side B 3 as shown in FIGS. 3 and 4 .
- the sheet 5 , the first portion 6 , the second portion 8 and/or the third portion 10 may be produced, cut, scored and/or formed by one or more die-cut and/or scoring tools or equipment.
- the present disclosure should not be deemed as limited to a specific embodiment of a size and/or a shape of an outer perimeter of the sheet 5 , the first portion 6 , the second portion 8 and/or the third portion 10 .
- indicia 12 may be printed onto, displayed on and/or applied to one or more surfaces of the assemblies 2 , 100 .
- the indicia 12 may be printed onto or applied onto the one or more surfaces of the assemblies 2 , 100 by one or more known printing and/or application techniques.
- the indicia 12 may comprise at least one of graphics, letters, numbers, symbols, photographs, holographics, pictures, scratch-n-sniff features, trademarks, designs, images, characters and/or the like.
- the indicia 12 may be associated with and/or indicative of the products 4 packaged, stored and/or enclosed within the assemblies 2 , 100 . Further, the indicia 12 may be associated with and/or indicative of a supplier of the products 4 , a manufacturer of the products 4 , a distributor of the products 4 and/or a third party associated with the products 4 .
- the indicia 12 may be in the form of, but not limited to, printed indicia that is printed or electronically transferred onto the one or more surface of the assemblies 2 , 100 .
- the indicia 12 may be in the form of an adhesive label or attachment which may be applied or adhered to the one or more surface of the assemblies 2 , 100 .
- the indicia 12 may be any indicia that may be displayed on one or more surface of the assemblies 2 , 100 as known to one of ordinary skill in the art.
- the indicia 12 may be printed onto or displayed on the front side A 1 of the first portion 6 and the front side A 2 of the second portion 8 as shown in FIGS. 1-4 and 7 .
- the indicia 12 is displayed on front and rear sides of the assemblies 2 , 100 after the assemblies 2 , 100 are produced by folding the portions 6 , 8 , 10 onto each other and/or by adhering at least two portions of the portions 6 , 8 , 10 to each other as shown in FIGS. 1 , 2 and 7 .
- the indicia 12 displayed on the front side A 1 of the first portion 6 may be displayed on the front side of the assemblies 2 , 100 after the assemblies 2 , 100 have been produced, formed and/or assembled.
- the indicia 12 displayed on the front side A 2 of the second portion 8 may be displayed on the rear side of the assemblies 2 , 100 after the assemblies 2 , 100 have be produced, formed and/or assembled.
- the folded assemblies 2 , 100 may be produced, formed and/or assembled by at least one automation process or by human labour.
- the portions 6 , 8 , 10 of the sheet 5 may be folded and/or adhered to produce, form and/or assembly the folded assemblies 2 , 100 by human hands or by at least one mechanical apparatus.
- the at least one mechanical apparatus may comprise a continuous moving conveyor belt (see FIGS. 9 , 35 and 39 - 41 ) that transports the sheet 4 from one place to another while the portions 6 , 8 , 10 are being folded over or onto each other and/or are being adhered to each other to produce, form and/or assemble the folded assemblies 2 , 100 .
- the at least one mechanical apparatus may be, but not limited to, a conveyor belt system 30 (shown in FIG. 9 ) having stationary and movable parts which may utilized to fold and/or adhere the portions 6 , 8 , 10 to each other to produce, form and/or assemble the folded assemblies 2 , 100 .
- the sheet 5 has at least one window 14 (hereinafter “the window 14 ”) formed therein for displaying, housing, securing and/or storing the products 4 after the portions 6 , 8 , 10 are folded onto each other and/or adhered to each other to form the assemblies 2 , 100 .
- the sheet 5 may have one window 14 for displaying, housing, securing and/or storing the product 4 as shown in FIGS. 1 , 3 - 6 and 8 or the sheet 5 may have a plurality of windows 14 for displaying housing, securing and/or storing more than one product 4 as shown in FIG. 2 .
- the window 4 is formed in one of the portions 6 , 8 , 10 of the sheet 5 .
- the window 4 may be formed in the first portion 6 as shown in FIGS. 1-6 and 8 - 11 and may extend through the sheet 5 from the front side A 1 of the first portion 6 to the back side B 1 of the first portion 6 .
- the window 14 is configured to receive, house and/or store at least a portion of the products 4 after the folded assemblies 2 , 100 are produced, formed and/or assembled by folding the portions 6 , 8 , 10 onto each other and/or adhering the portions 6 , 8 , 10 together.
- the window 14 formed in the sheet 5 may be configured to receive two or more products 4 (not shown in the drawings).
- the windows 14 may be, for example, but not limited to, cut-out windows formed in the sheet by cut-out or punch-out techniques as known to one of ordinary skill in the art.
- the window 14 may be configured to receive, house and/or store at least a portion of the product 4 and may have a perimeter that may be smaller than, the same as, substantially the same as, substantially similar to, or greater than the perimeters of the product 4 .
- the perimeters of the window 14 may comprise a geometrical shape selected from a circular shape, an oval shape, a square shape, a rectangular shape, a triangular shape, a polygonal shape and combinations thereof.
- the perimeters of the window 14 may be smaller than, the same as, substantially similar to or corresponding to the perimeters of the products 4 .
- the perimeters of the windows 14 may be differently shaped perimeters as shown in FIG. 2 .
- the products 4 may firmly fit or be positioned within the window 14 or within the perimeters of the window 14 after the portions 6 , 8 , 10 are folded onto each other and/or joined together.
- the product 4 may be adhered, bonded or glued, connected, attached and/or secured to the front side A 3 of the third portion 10 of the sheet 5 before the assemblies 2 , 100 are produced, formed and/or assembled by folding the portions 6 , 8 , 10 onto each other and/or joining the portions 6 , 8 , 10 .
- at least one first adhesive layer 16 (hereinafter “the first adhesive layer 16 ”) may adhere a back side of the product 4 to the front side A 3 of the third portion 10 of the sheet 5 as shown in FIG. 8 .
- the product 4 may be connected, attached, secured and/or adhered to the third portion 10 of the sheet 5 via first adhesive layer 16 .
- the first adhesive layer 16 may be applied to the back side of the product 4 or to the front side A 3 of the third portion before the product 4 and the third portion 10 are adhered or joined together.
- the first adhesive layer 16 may be, but not limited to, a fugitive adhesive or glue, a credit card glue, a E-z-release glue, a hotmelt adhesive, a pressure-sensitive adhesive, a cold glue, a cohesive, a double sided tape, a single sided tape with an adhesive on its back side, an animal glue or combinations thereof.
- film 18 At least a portion of the window 14 or the window in its entirety is covered by at least one compliant film 18 (hereinafter “film 18 ”) which is connected, attached or adhered to the back side of the sheet 5 .
- the film 18 may be connected, attached and/or adhered to the back side B 1 of the first portion 6 , the back side B 2 of the second portion 8 and/or the back side B 3 of the third portion 10 as shown in FIG. 4 .
- the outer perimeter the film 18 in an unstretched state or manner, may be large enough that the film 18 may cover more than the window 14 and/or may allow the film 18 to be connected, attached and/or adhered to one or more portions of the back side B 1 of the first portion 6 , the back side B 2 of the second portion 8 and/or the backs side B 3 of the third portion 10 .
- the film 18 In the unstretched state or manner, the film 18 may extend across the window 14 in a firmly tensioned or a relaxed state or manner.
- the film 18 may be made from, but is not limited to, at least one clear compliant film or heat activated clear film. Heat active films become loose or relaxed and extremely pliant when activated by heat, and then subsequently harden when cooled.
- the at least one heat activated film may be, for example, a skin film as known to one of ordinary skill in the art.
- the film 18 may be any film layer type that is capable of being laminated and/or attached to the back side of the sheet 5 , which may provide a plurality of characteristics that may be derived from different materials used in each layer of a multiple layered film 18 , as well as a total number of film layers that may be combined to produce the multiple layered film 18 .
- the film 18 may be made of, but not limited to, a flexible rubber or rubber-like material or a polymeric packaging material that may or may not have one or more holes or pores formed therein.
- the film 18 may comprise one or more film layers which may or may not be made of the same material.
- the film 18 may be a composite film made of two or more different materials.
- the film 18 may be crosslinked or crosslinkable.
- the film 18 may be produced by monoaxial or biaxial stretching prior to connecting, attaching and/or adhering the film 18 to the sheet 5 .
- the film 18 may have an orientation, such, as, for example, a uniaxial or biaxial orientation
- the film 18 may have, but not limited to, a film thickness in a range of about 15 to about 250 microns, about 10 to about 25 microns, about 15 to about 30 microns or may be about 16.4545 microns.
- the film 18 may exhibit one or more of the following characteristics:
- a tensile strength in the machine direction in a range of about 1.25 to about 60 ⁇ 1000 psi, about 6 to about 6.5 ⁇ 1000 psi, about 4.9 to about 7 ⁇ 1000 psi, about 5.8 to about 6.1 ⁇ 1000 psi, about 8.5 to about 9.2 ⁇ 1000 psi, about 5 to about 10 ⁇ 1000 psi or about 2.5, 13, 16, 17, 18, 20, 48 or 52 ⁇ 1000 psi;
- a melting point in a range of about 65 to about 350° C.
- second adhesive layers 20 may be positioned on, provided on and/or applied to one or more portions of the top side and/or bottom side of the sheet 5 .
- the second adhesive layers 20 may be applied to or provided on one or more portions of the top side A 1 of the first portion 6 , the bottom side B 1 of the first portion 6 , the top side A 2 of the second portion 8 , the bottom side B 2 of the second portion 8 , the top side A 3 of the third portion 10 and/or the bottom side B 3 of third portion 10 .
- the second adhesive layers 20 is applied to or provided on the back side of the sheet 5 such that the film 18 is adhered to the back side of the sheet 5 via the second adhesive layers 20 prior to the production of the assemblies 2 , 100 .
- the second adhesive layers 20 applied to or provided on the sheet 5 adheres or attaches the portions 6 , 8 , 10 together when the portions 6 , 8 , 10 are folded onto each other to produce, form and/or assembly the assemblies 2 , 100 .
- the second adhesive layers 20 may comprise, but is not limited to, a pressure-sensitive adhesive, a crosslinkable adhesive, a heat-activatable adhesive, a hotmelt adhesive, a cohesive, a double sided tape, a single sided tape with an adhesive on its back side or combinations thereof.
- Adhesive strengths of the second adhesive layers 20 may be greater than an adhesive strength of the first adhesive layer 16 .
- the adhesive strength of the second adhesive layers 20 sufficiently bonds or adheres the portions 6 , 8 , 10 together to produce the assemblies 2 , 100 such that tempering with and/or theft of the product 4 enclosed within the assemblies 2 , 100 is prevented or significantly reduced.
- the second adhesive layers 20 may be applied to or positioned on the front and back sides of the sheet 5 by application techniques or processes as known to one of ordinary skill in the art.
- the second adhesive layer 20 located on the bottom side B 3 of the third portion 10 adheres the bottom side B 3 of the third portion 10 to the bottom side B 2 of the second portion 8 . Further, the second adhesive layer 20 on the top side A 3 of the third portion 10 adheres the top side A 3 of the third portion 10 to the bottom side B 1 of the first portion 6 , and the second adhesive layer 20 on the bottom side B 1 of the first portion 6 adheres the bottom side B 1 of the first portion 6 to the top side A 3 of the third portion 10 .
- the third portion 10 and the film 18 are located or positioned between the bottom side B 1 of the first portion 6 and the bottom portion B 2 of the second portion 8 as shown in FIG. 8 .
- the top side A 1 of the first portion 6 , displaying indicia 12 , and the top side A 2 of the second portion 8 , displaying indicia 12 are exposed or facing outward such that the indicia 12 is displayed to or viewable by a consumer viewing the assemblies 2 , 100 as shown in FIGS. 1 , 2 and 7 .
- the product 4 was positioned in the window 14 formed in the first portion 6 prior to the folding of the portions 6 , 8 , 10 onto each other.
- the first adhesive layer 16 adheres the product 4 to the top side A 3 of the third portion 10
- the product 4 pushes against and/or stretches the film 18 covering the window 14 and extends outwardly away from the top side A 1 of the first portion 6 .
- the film 18 is stretched outwardly by the product 4 and the product 4 is enclosed, housed, stored and/or secured between the film 18 and the second portion 8 , the third portion 10 and/or the first adhesive layer 16 .
- the first adhesive layer 16 may be excluded from the assemblies 2 , 100 and the film 18 may apply a force to the product 4 in the direction towards the top side A 3 of the third portion 10 .
- the product 4 may be held or maintained in position within the window 14 between film 18 , the second portion 8 and/or the third portion 10 .
- the consumer may, if desired, examine and/or view the product 4 which extends outwardly from the window 14 formed in the first portion 6 of the sheet 5 as shown in FIGS. 1 and 2 .
- the window 14 allow the consumer or another third party to visually and/or physically examine the product 4 being displayed and/or packaged by the assemblies 2 , 100 .
- a consumer may desire to purchase the product 4 being displayed and/or packaged by the assemblies 2 , 100 .
- the first adhesive layer 16 , the second adhesive layer 20 , the sheet 5 and/or the film 18 may prevent or substantially prevent the product 4 from being separated or removed from the assemblies 2 , 100 .
- the first adhesive layer 16 , the second adhesive layer 20 , the sheet 5 and/or the film 18 may prevent or reduce theft of, damage to and/or destruction of the product 4 by firmly securing the product 4 within the assemblies 2 , 100 .
- the film 18 When the product 4 pushes against or stretches the film 18 outwardly away from the top side A 1 of the first portion 6 , the film 18 may be contoured to one or more outer surfaces of the product 4 and/or the product 4 may be completely enclosed between the film 18 and first adhesive layer, the second portion 8 and/or the third portion 10 .
- the film 18 , the portions 6 , 8 , 10 and/or the first adhesive layer 16 may prevent or reduce theft of, damage to, destruction of, opening of, activating of, tampering with and contamination of the product 4 . Additionally, enclosing the product 4 may reduce exposure to dust, dirt and/or surrounding environmental conditions and/or elements.
- FIG. 1 shows the assembly 2 displaying the product 4 in the window 14 enclosed between the film 18 and the portions 6 , 8 , 10 of the sheet 5 .
- FIG. 2 shows the assembly 100 displaying a plurality of products 4 in a plurality of windows 14 enclosed between the film 18 and the portions 6 , 8 , 10 of the sheet 5 .
- FIG. 3 shows the front side of the sheet 5 comprising the top side A 1 of the first portion 6 , the top side A 2 of the second portion 8 , the top side A 3 of the third portion 10 , the window 14 , and the film 18 covering the window 14 .
- FIG. 4 shows the back side of the sheet 5 comprising the back side B 1 of the first portion 6 , the back side B 2 of the second portion 8 , the back side B 3 of the third portion 10 , the window 14 covered by the film 18 , the second adhesive layers 20 positioned on the outer edges of the bottom side B 1 of the first portion 6 and the bottom side B 3 of the third portion 10 , and the film 18 connected or adhered to the bottom side of the sheet 5 via the second adhesive layers.
- FIG. 5 shows the product 4 positioned in the window 14 and supported in the window 14 by the film 18 covering the window 14 and the bottom side B 3 of the third portion 10 being folded onto the bottom side B 2 of the second portion 8 .
- the product 4 may be hand loaded into the window 14 of the sheet 5 or may be automatically loaded by a fed machine or apparatus.
- the product pushes or stretches the film 18 covering the window outward with respect to the top side A 1 of portion 6 of the sheet 5 .
- a film pocket having an initial depth and/or width, is formed which contains and/or housing the product.
- the film 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width.
- the product 4 may be more accurately positioned in and/or displayed within the window 14 and/or the film pocket having the adjustable depth and/or width.
- the sheet 5 is conveyed into subsequent next machine section or station, where the sheet 5 will be automatically glued or adhered, folded and sealed to produce the folded assembly 2 .
- the first adhesive 16 and/or the second adhesive 20 may be applied to one or more portions of the portions 6 , 8 , 10 to facilitate securing the portions 6 , 8 , 10 to each other to produce the folded assembly 2 .
- the folding may be accomplished by human hands; however, the conveyor belt system 30 , which may be continuously moving, may be utilized to produce the folded assembly 2 .
- stationary elements 22 may be positioned under the first portion 6 and adjacent to the top side A 1 of the first portion 6 .
- the sheet 5 or the first portion 6 of the sheet 5 may be supported and/or maintained in a fixed position via the stationary elements 22 .
- At least one movable machinery rail or element 24 (hereinafter “movable element 24 ”) may lift the third portion 10 upwards and/or towards the first portion 6 as shown in FIG. 5 .
- the third portion 10 is folded onto the second portion 8 and the bottom side B 3 of the third portion 10 is adjacent to or in direct contact with the bottom side B 2 of the second portion 8 .
- the second adhesive layer 20 on the bottom side B 3 of the third portion 10 connects, attaches and/or adheres the bottom side B 3 of the third portion 10 to the bottom side B 2 of the second portion.
- the movable element 24 is adjacent to the top side A 3 of the third portion 10 as shown in FIG. 6 .
- the positioning angle of the movable element 24 may be adjusted to adjust the depth of the film pocket formed by the film 18 that houses the product 4 .
- the adjusted positioning angle of the movable element 24 regulates, adjusts and/or controls the product film blister depth upwardly or downwardly as required or desired.
- the stationary elements 22 and/or the movable element 24 may fed, handle and transport the sheet 5 through a package finishing process to produce, form and/or assemble the assemblies 2 , 100 .
- the sheet 5 may be automatically dispensed with film adhered thereto, and then the sheet 5 may be fed onto a specialized conveyor for loading the product 4 by hand or automatically.
- FIG. 6 shows the second adhesive layers 20 positioned on the top side A 3 of the third portion 10 and the bottom side B 1 of the first portion 6 of the sheet 5 which is supported by the stationary elements 22 .
- the movable element 24 is subsequently positioned under the second portion 8 , located below the third portion 10 after the folding of the third portion 10 onto the second portion 8 , and lifts the second and third portions 8 , 10 upwards and/or towards the bottom side B 1 of the first portion 6 .
- the top side A 3 of the third portion 10 is folded onto the bottom side B 1 of the first portion 6 as shown in FIG. 7 .
- the film 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width.
- the product 4 may be more accurately positioned in and/or displayed within the window 14 and/or the film pocket having the adjustable depth and/or width.
- the third portion 10 may be folded onto the first portion 6 by hand.
- the top side A 3 of the third portion 10 and the bottom side B 1 of the first portion 6 are connected, attached and/or adhered together via the second adhesive layers positioned on the top side A 3 of the third portion 10 and/or the bottom side B 1 of the first portion 6 .
- the product 4 is enclosed, packed, encircled and/or stored between the film 18 and the second portion 8 and/or the third portion 10 as shown in FIG. 8 .
- the film may be micro-perforated with micro-openings or micro-pores (not shown in the drawings) which may be invisible to the naked eye.
- the micro-openings or micro-pores may extend across a portion of the surface area of the film 18 or across the entire surface area of the film 18 .
- the micro-openings or micro-pores allow air to escape or pass as the portions 6 , 8 , 10 are being folded onto each other to produce the assembly 2 . Additionally, the micro-openings or micro-pores allow or facilitate improved adhesive penetration by the second adhesive layers and improved bond strength between the portions 6 , 8 , 10 of the sheet 5 .
- the first adhesive layer 16 may be applied and/or positioned directly onto the back side of the product 4 and/or onto an area of the top side A 3 of the third portion 10 .
- the top side A 3 of the third portion 10 applies force to the back side of the product 4 which causes the product 4 to push against and/or stretch the film 18 outwardly away from the top side A 1 of the first portion 6 as shown in FIG. 8 .
- a pocket is formed by the film 18 that matches or substantially matches the outer perimeter of the product 4 .
- the pockets depth adjustment is made by changing the angles of the elements with respect to the position of the sheet 5 .
- the first adhesive layer 16 adheres the back side of the product 4 to the top side A 3 of the third portion 10 to secure and protect the product 4 within the assembly 2 . Moreover, the first adhesive layer 16 may prevent or substantially reduce movement of, turning of and/or any unwanted position changes of the product 4 after production of the assembly 2 .
- the assembly 2 may be passed through a low temperature heat tunnel, which eliminates or substantially reduces any wrinkles or folds that may have formed in the film 18 caused by the product 4 .
- the product 4 wrapped within the film 18 exhibits a surprising and unexpected sparkling finished appearance.
- the low temperature heat tunnel may be maintained at, but is not limited to, a temperature range from about 100° F. to about 350° F. The necessary temperature of the heat tunnel is directly related to production speed of the assembly 2 .
- the temperature of the heat tunnel should be maintained at a range of about 200° F. to 300° F.
- the assembly 2 may completely pass through the heat tunnel in a time duration of greater than 0.1 second to no more than 5 seconds. In embodiments, the time duration may be from 0.25 to 3 seconds, 0.5 to 2.5 seconds or 1 to 2 seconds.
- FIG. 9 shows a partial cross-sectional view of a folded assembly 2 , which was produced by the method illustrated in FIG. 5-7 , positioned on the conveyor belt system 30 .
- an adjustable cavity 32 may be built or incorporated into the conveyor belt system 30 which may be adjustable to a width and/or depth that corresponds to the dimensions of the product 4 and/or dimensions of the film pocket formed by the film 18 housing the product 4 .
- the placement and/or position of the product 4 in the film pocket may be controlled and/or adjusted by the adjustable cavity 32 of the conveyor belt system 30 .
- a vacuum producing device 34 may be built or incorporated into the conveyor belt system 30 such that the vacuum producing device 34 may apply or provide downward vacuum holding forces (illustrated by the downward arrows towards the vacuum producing device 34 ) to the sheet 5 , the top side A 1 of the first portion 6 , the product 4 and/or the film 18 .
- downward vacuum holding forces illustrated by the downward arrows towards the vacuum producing device 34
- the sheet 5 , the top side A 1 of the first portion 6 , the product 4 and/or the film 18 may be held or pulled tightly or firmly against a top side of the conveyor belt system 30 during the assembly process for producing and/or folding the folded assembly 2 .
- the vacuum holding forces may be applied by the vacuum producing device 34 during one or more portions of the assembly process or during the entire assembly process for producing the folded assembly 2 .
- At least one section or portion of the sheet 5 may be held flat against the conveyor belt system 30 via the vacuum holding forces, and another section or portion of the sheet may be controlled or moved up or down by the at least one movable element 24 .
- physical control of the depth film pocket may be achieved by the conveyor belt system 30 .
- high speed control of the film pocket and product is essential to a successful machine outcome.
- An added value added by inclusion of the vacuum holding force to the conveyor belt system 30 , with adjustable cavity, may be exact sheet/card and film pocket is exact product position and control through the entire process.
- Another added advantage from adding vacuum holding forces to the conveyor belt system 30 is that a downward holding force may be exerted on both the film pocket and product 4 , when the film 18 may be micro-perforated, which may allow the air and therefore the vacuum force to also pass through the film 18 and apply the same downward force onto the product 4 and not just to the film 18 into the adjustable cavity.
- This extra card/sheet control, film pocket and product holding force may a significant advantage over known conveyor belt system. As a result, it may be extremely significant and influential in achieving the highest line speeds possible, while still maintaining the correct product and film pocket control through the complete assembly process, to produce very high quality carded and acceptable finished goods.
- FIGS. 10-12 show another method of folding the portions 6 , 8 , 10 to produce the folded assembly 2 .
- the first portion 6 may be located or positioned between the second and third portions 8 , 10 , may have the window 14 formed therein, whereby the film 18 may be connected and/or covering the back sides of the portions 6 , 8 , 10 and the product 4 may be loaded into the window 14 and contacting the film 18 covering the window 14 .
- the width of the third portion 10 may be less than the widths of the first and second portions 6 , 8 as shown in FIGS. 10 and 11 or may be the same or substantially the same as the widths of the first and second portions 6 , 8 as illustrated by the dashed lines shown in FIG. 10 .
- the second adhesive layer 20 may be applied onto or provided at one or more portions of the back side B 1 of the first portion 6 , the back side B 2 of the second portion 8 and/or the back side B 3 of the third portion.
- the first adhesive layer may be applied onto the back side of the product 4 and/or provided at one or more portions of the back side B 2 of the second portion and/or the back side B 3 of the third portion 10 .
- the conveyor belt system 30 may have at least two stationary elements 22 , which may be positioned and/or located under the first portion 6 , and/or at least two movable elements 24 whereby one movable element 24 is positioned or located under the second portion 8 and another movable element 24 is positioned or located under the third portion 10 .
- the stationary elements 22 support the card 5 and the movable elements 24 rise or move to fold and/or adhere the back side B 3 of the third portion 10 and the back side B 2 of the second portion 8 onto the back side B 1 of the first portion 6 to produce the folded assembly 2 .
- the movable element 24 positioned under the third portion 10 may move, rise and/or lift the third portion 10 such that the bottom side B 3 of the third portion 10 is folded onto and/or adhered to the bottom side B 1 of the first portion 6 as shown in FIG. 11 .
- a portion of the product 4 may be enclosed and/or positioned between the bottom side B 3 of the third portion 10 and the film 18 covering the window 14 .
- one or more portions of the top side A 3 of the third portion 10 may have the second adhesive layer 20 applied thereon for adhering the second and third portion 8 , 10 together to produce the folded assembly 2 .
- the film 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width.
- the product 4 may be more accurately positioned in and/or displayed within the window 14 and/or the film pocket having the adjustable depth and/or width.
- the movable element 24 positioned under the second portion 8 may move, rise and/or lift the second portion 8 such that the bottom side B 2 of the second portion 8 is folded onto and/or adhered to the bottom side B 1 of the first portion 6 and/or the top side A 3 of the third portion 10 to produce the folded assembly 2 as shown in FIG. 12 .
- the remaining and/or uncovered portion of the product 4 may be enclosed, sealed, secured and/or positioned between the bottom side B 2 of the second portion 8 and the film 18 covering the window 14 .
- the second adhesive layer 20 seals and/or adheres the portions 6 , 8 , 10 together to produce the folded assembly 2 and/or the first adhesive layer 16 secures and/or adheres the product to second and third portions 8 , 10 .
- the film 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width.
- the product 4 may be more accurately positioned in and/or displayed within the window 14 and/or the film pocket having the adjustable depth and/or width.
- the sheet 5 may be divided, separated, petitioned, cut, scored and/or folded into a plurality of foldable portions as shown in FIG. 13 .
- the window 14 is formed in the first portion 6 of the sheet 5 , the top and bottom edges of the first portion 6 are attached and/or connected to the third portion 10 which is foldable onto the back side B 1 of the first portion 6 , and the left and right edges of the first portion 6 are attached and/or connected to the second portion 8 which is foldable onto the back side B 1 of the first portion 6 .
- the film 18 may be attached or connected to or may cover one or more portions of the back sides of the portions 6 , 8 , 10 . In an embodiment, the film 18 may be attached or connected to or may cover all back sides of the portions 6 , 8 , 10 as shown in FIG. 13 .
- the product 4 may be loaded into and/or positioned in the window 14 on the film 18 such that the film pocket extending outwardly way from the top side A 1 of the first portion is formed by the film 18 and the product 4 .
- the third portion 10 located at the top and bottom edges of the first portion 6 may be fold inward and/or onto the back side B 1 of the first portion 6 as illustrated by the arrow extending from the bottom side B 3 of the third portion 10 to the bottom side B 1 of the first portion 6 as shown in FIG. 10 .
- upper and lower portions of the second portion 8 may also fold inward and/or onto the back side B 2 of the second portion as shown in FIG. 14 .
- the back side of the product 4 may be at least partially covered by the third portion 10 such that at least a portion of the product 4 in the film pocket is enclosed between the film 18 and the third portion 10 .
- the film 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width.
- the product 4 may be more accurately positioned in and/or displayed within the window 14 and/or the film pocket having the adjustable depth and/or width.
- the second portion 8 located on at the right and left edges of the first portion 6 may be folded inward and/or onto the back side B 1 of the first portion 6 as illustrated by the arrows extending from the back side B 2 of the second portion 8 to the bottom side B 1 of the first portion 6 .
- the second portion 8 located on the right and left edges of the first portion 6 may contact each other and/or may seal the product 4 within the folded assembly 2 as shown in FIG. 15 .
- the folded assembly 2 is provided and the product 4 is sealed, secured and/or enclosed between the film 18 and the second and third portions 8 , 10 of the sheet 5 as shown in FIGS. 15 and 16 .
- the film 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width.
- the product 4 may be more accurately positioned in and/or displayed within the window 14 and/or the film pocket having the adjustable depth and/or width.
- First adhesive layers 20 may be provided or applied onto one or more portion of the back sides of the portions 6 , 8 , 10 of the sheet as shown in FIG. 13 .
- the first adhesive layers 20 may adhere the portions 6 , 8 , 10 together to produce or form the folded assembly 2 .
- the first adhesive layer 16 may be provided or applied to the product 4 and/or one or more portions of the back sides B 2 , B 3 of the second and third portions 8 , 10 as shown in FIG. 10 .
- the second adhesive layer 16 may adhere the product 4 to at least a portion of the second and third portions 8 , 10 when the second and third portions 8 , 10 are folded onto the back side B 1 of the first portion 6 .
- FIG. 17 shows the product 4 connected, attached and/or adhered to a carrier 42 prior to the product 4 and carrier 42 being loaded into the window 14 that is covered with the film 18 .
- the first adhesive 16 layer may be applied to the product 4 and/or the carrier 42 prior to connecting the product 4 and the carrier 42 together. As a result, the first adhesive layer 16 may adhere the product 4 to the carrier 42 prior to placing the product 4 and carrier 42 in the window 14 of the first portion 6 .
- the carrier 42 may be made of one or more materials selected from the group consisting of paper corrugated or wood based materials, blister boards, coated styrene butadiene styrene, corrugated fibreboard, E-Flute corrugated fibreboard, stone paper, ceramic sheets, wood, melamine, standardized layers or sheets or combinations thereof. It should be understood that the present disclosure is not limited to a specific embodiment of the materials that may be used to make the top card 10 , the bottom card 20 and/or the carriers 30 of the system 2 .
- the perimeter of the carrier 42 may have the same or substantially the same shape, size, configuration and/or dimensions as the perimeter of the window 14 of the first portion 6 .
- the perimeter or outer edges of the carrier 42 may contact, abut and/or be adjacent to the perimeter or outer edges of the window 14 as shown in FIG. 18 . Frictional forces may be applied to or present at the perimeter or outer edges of the carrier and the perimeter or outer edges of the carrier 42 .
- the carrier 42 may be firmly connected, attached and/or secured to the perimeter of the window 14 such that the carrier 42 and the product 4 may not be separated or removed from the window 14 without application of an external force or pressure.
- the product 4 is firmly connected, attached and/or secured within the window 14 via the carrier 42 .
- Producing, forming and assembling the assemblies 2 , 100 via the conveyor belt 30 having stationary elements 22 , at least one movable element 24 , and, optionally, a heat tunnel achieve fast, high speed production of the assemblies 2 , 100 .
- production of the assemblies 2 , 100 may be as high as four-hundred (400) assemblies per minute or greater.
- FIG. 19 shows a back side of a sheet 5 petitioned, cut or scored into three portions 6 , 8 , 10 and having a window 14 formed in the first portion 6 and the third portion 10 , and a product 4 connected, attached, adhered, banded and/or affixed to a carrier 42 .
- the product 4 and carrier 42 are sealed in a bag made of a film material, such as, film 18 .
- the window 14 may extend to or end at the one side of the perimeter of the third portion 10 of the sheet 5 .
- the windows 14 may be sized, shaped and/or configured to receive and/or house the product 4 sealed in the bag of film 18 .
- at least a portion of the product 4 may extend through the windows 14 after the first and third portions 6 and 10 have been folded onto the second portion 8 .
- One or more portions of the back sides B 1 , B 2 and/or B 3 of the first, second and third portions 6 , 8 , 10 may be coated with and/or may be provided with an adhesive, cohesive, sealant material and/or adhesive tape, such as, for example, the first adhesive 16 and/or the second adhesive 20 .
- an adhesive, cohesive, sealant material and/or adhesive tape such as, for example, the first adhesive 16 and/or the second adhesive 20 .
- more than one portion of the back side B 1 of the first portion 6 and/or the back side B 3 of the third portion 10 may be provided or coated with the first adhesive 16 as shown in FIG. 19 .
- the first adhesive 16 on the third portion 10 adheres, connects, attaches and/or fastens the back side B 3 of the third portion 10 to the back side B 2 of the second portion 8
- the first adhesive 16 on the first portion 6 adheres, connects, attaches and/or fastens the back side B 1 of the first portion 6 the front side A 3 of the third portion 10 .
- FIG. 20 illustrates the back side B 3 of the third portion 10 of the sheet 5 having been folded onto the back side B 2 of the second portion such that the top side A 3 of the third portion 10 is exposed and/or adjacent to the back side B 1 of the first portion 6 .
- the second and third portions 8 , 10 are connected, attached, adhered and/or secured together by the adhesive 16 and a pocket 50 is formed, produced and/or provided between the back sides B 2 , B 3 of the second and third portions 8 , 10 , respectively.
- the pocket 50 formed between the second and third portions 8 , 10 is sized shaped and/or configured to at least partially receive, house, store and/or enclose the product 4 and carrier 42 that may sealed in the bag of film 18 .
- FIG. 21 illustrates the product 4 and carrier 42 sealed in the bag of film 18 being inserted into the pocket 50 formed between the back sides B 2 , B 3 of the second and third portions, respectively.
- the product 4 and carrier 42 sealed in the bag of film 18 may be inserted into the pocket 50 by hand, by machine or a combination thereof.
- the dimensions of the pocket 50 and/or the window 14 may be sized, shaped and/or configured such that the product 4 and/or the carrier 42 may be correctly aligned and/or held in a required or predetermined product placement position automatically by insertion into the pocket 50 and/or window 14 of the third portion 10 .
- the correct alignment and/or holding is achieved automatically as the sealed product 4 and/or carrier 42 are loaded, inserted and/or slid in the pocket 50 formed between the second and third portion 8 , 10 .
- the pocket 50 created by folding the third portion 10 onto the second portion 8 may form, create and/or provide a matching lock-fit for the product 4 and/or carrier 42 which may automatically position, secure, enclose, house and/or fix the carrier 42 holding the film wrapped product 4 in a correct or predetermined position as the product 4 and/or carrier 42 are inserted or slid into the pocket 50 .
- FIG. 22 shows entire lengths of the product 4 and carrier 42 , sealed in the bag of film 18 , inserted, moved, slid and/or positioned into the pocket 50 formed between the second and third portions 8 , 10 .
- a portion of the back side B 2 of the second portion 8 may be exposed below the bottom of the product 4 and/or the carrier 42 .
- One or more portions of the carrier 42 positioned the back sides B 2 , B 3 of the second and third sides 8 , 10 connect, attach, secure and/or fix the one or more portions of the carrier 42 to the sheet 5 .
- the product 4 may be connected, attached, secured to the sheet 5 via the pocket 50 and/or the carrier 42 .
- the first adhesive 16 on the back side B 1 of the first portion 6 may connect, attach and/or adhere the back side B 1 of the first portion 6 to front side A 3 of the third portion 10 .
- the first portion 6 may be connected, attached and/or adhered to the second and/or third portions 8 , 10 via the first adhesive 16 .
- one or more portions of the product 4 may extend through the window 14 and/or away from the front side A 1 of the first portion 6 .
- one or more portions of the front side A 1 of the first portion 6 may display or be provided with indicia 12 .
- One or more portions 6 , 8 , 10 of the sheet 5 may be folded onto one another or each other by hand or by use of one or more machines, such as, for example, movable element 24 .
- the assembly 2 may then pass through the heat tunnel to remove any film folds and/or wrinkles that may be present in the bag of film 18 that seals the product 4 and/or the carrier 42 .
- Passing through the heat tunnel may also provide a glossy shine or appearance to film 18 sealed around the product 4 .
- a rear card cut out (not shown in the drawing) with perforations and/or score lines may be provided in second portion 8 such that the assembly 2 may be easy opened to facilitate removal of the sealed product 4 and/or carrier 42 .
- FIGS. 19-23 provide significant improvements as to how the sheet 5 and carrier 42 may quickly join together into the proper requested or predetermined product position format, in an easier, faster and much more exact and automatic product positioning process. These embodiments provide adjustments made to the sheet 5 and carrier 42 joining system that offer many more inherent assembly advantages for either hand assemblies, machine assemblies or combinations thereof. These embodiments may be utilized with almost any size or shaped product to be carded and the correct position alignment may automatically be achieve when the assembly 2 and/or carrier 42 are utilized in the presently disclosed manner.
- FIGS. 19-23 may eliminate the movement of products that may occur in a blister pack without adding extra items or adhesives, which may slow the assembly process. Also with all standard blister packages, the outside edges of blister packages may get “crushed” all around the cards outer edge which may also occur around each product on the blister package. This “crushing” is inherently caused by the standard blister packaging requires sealing process (i.e., time, temperature and pressure) and this “crushing” often happens to each and every blister card currently produced by known blister machines. The card “crushing” which may be totally eliminated along with problems with product movement by the assemblies and processes set forth in the present disclosure. Additionally, improved graphics may be achieved because the present assemblies and processes avoid the use of a blister coating to be applied over the printed artwork.
- FIG. 24 shows a back side of a sheet 5 petitioned, cut or scored into three portions 6 , 8 , 10 and having a window 14 formed in the first portion 6 and the third portion 10 , and a product 4 connected, attached, adhered, banded and/or affixed to a carrier 42 .
- the product 4 and carrier 42 are sealed in a bag made of a film material, such as, film 18 .
- the windows 14 may be sized, shaped and/or configured to receive and/or house the product 4 sealed in the bag of film 18 . As a result, at least a portion of the product 4 may extend through the windows 14 after the first and third portions 6 and 10 have been folded onto the second portion 8 .
- One or more portions of the back sides B 1 , B 2 and/or B 3 of the first, second and third portions 6 , 8 , 10 , respectively, may be coated with and/or may be provided with an adhesive, cohesive, sealant material and/or adhesive tape, such as, for example, the first adhesive 16 and/or the second adhesive 20 .
- an adhesive, cohesive, sealant material and/or adhesive tape such as, for example, the first adhesive 16 and/or the second adhesive 20 .
- more than one portion of the back side B 1 of the first portion 6 and/or the back side B 3 of the third portion 10 may be provided or coated with the second adhesive 16 as shown in FIG. 24 for connecting, sealing and/or adhering the first, second and/or third portions 6 , 8 , 10 together or to one another.
- the first adhesive 16 may be coated and/or provided on at least one portion of the back side B 2 of the second portion 8 and may connect, attach, secure and/or adhere the product 4 and/or the carrier 42 sealed in the bag of film 18 to the second portion 8 .
- the second adhesive 20 on the third portion 10 adheres, connects, attaches and/or fastens the back side B 3 of the third portion 10 to the back side B 2 of the second portion 8
- the second adhesive 20 on the first portion 6 adheres, connects, attaches and/or fastens the back side B 1 of the first portion 6 the front side A 3 of the third portion 10 .
- the product 4 and carrier 42 may be enclosed, sealed, packaged and/or secured within or between one or more of the first, second and/or third portions 6 , 8 , 10 of the sheet 5 .
- the carrier 42 may be sized, shaped and/or configured such that more than one product 4 may be connected, attached, secured and/or adhered to the carrier 42 which may subsequently be sealed in the film 18 (not shown in the drawings).
- the first and third portions 6 , 10 may have more than one window 14 formed therein such that the more than one product 4 , connected to the carrier 42 , may extend through the more than one widow 14 formed in the first and third portions 6 , 10 when the first and third portions 6 , 10 may be folded onto the second portion 8 .
- FIG. 25 shows the product 4 and carrier 42 , sealed in the bag of film, have been positioned on or moved onto the back side B 2 of the second portion 8 of the sheet 5 .
- the product 4 and carrier 42 are connected, attached, adhered and/or secured to the back side B 2 of the second portion 8 via the first adhesive 16 .
- the third portion 10 is folding and/or moved towards the back side B 2 of the second portion 8 .
- At least portions of the product 4 and/or the carrier 42 may be located, positioned, enclosed and/or secured between the back sides B 2 , B 3 of the second and third portions 8 , 10 , respectively, as shown in FIG. 26 .
- the back side B 3 of the third portion 10 may be connected, attached, adhered and/or secured to the back side B 2 of the second portion 8 via the second adhesive 20 on the back side B 3 of the third section 10 .
- one or more portions of the carrier 42 may be positioned, located, enclosed and/or surrounded between the one or more portions of the second and third portions 8 , 10 .
- one or more portions of the product 4 may extend outwardly through the window 14 of the third portion 10 and/or away from the front side A 3 of third portion 10 as the third portion 10 is being folded onto the second portion 8 and/or after the second and third portions have been adhered together.
- the film 18 wrapped around or enclosing the product 4 and the carrier 42 may be pull tighter against or closer to the product 4 and/or the carrier 42 by force applied by the third portion 10 when the third portion 10 is folded onto the second portion 8 .
- FIG. 27 shows the folded assembly 2 that is formed, produced and/or provided after the back side B 1 of the first portion 6 has been folded onto the front side A 3 of the third portion 10 .
- the back side B 1 of the first portion 6 is folded and/or moved onto the front side A 3 of the third portion 10
- at least portions of the product 4 and/or the carrier 42 may be located, positioned, enclosed and/or secured between the back side B 2 of the second portion 8 and at least one the back sides B 1 , B 3 of the first and third portions 6 , 10 , respectively, as shown in FIG. 27 .
- the back side B 1 of the first portion 6 may be connected, attached, adhered and/or secured to the front side A 3 of the third portion 10 via the second adhesive 20 on the back side B 1 of the first section 6 .
- one or more portions of the carrier 42 may be positioned, located, enclosed, surrounded between the one or more portions of the first portion 6 and at least one second and third portions 8 , 10 .
- one or more portions of the product 4 may extend outwardly through the window 14 of the first portion 8 and/or away from the front side Alof the first portion 6 as the first portion 6 is being folded onto the third portion 10 and/or after the first and third portions 6 , 10 have been adhered together.
- At least one portion of the product 4 and/or the carrier 42 are packaged, enclosed, stored and/or secured between at least portions of the first, second and/or third portions 6 , 8 , 10 to provide the folded assembly 2 .
- One or more portions of the front side A 1 of the first portion 6 may display and/or be provided with indicia 12 associated with the product 4 .
- the bond strength between the backside B 1 of the first portion 6 and the front side A 3 of the third portion may be the same as or greater the bond strength between the backsides B 2 , B 3 of the second and third portions 8 , 10 , respectively.
- the adhesive strength of the second adhesive 20 provided on the first portion 6 may be the same as or greater than the adhesive strength of the second adhesive 20 provided on the third portion 10 .
- folding of the first portion 6 onto the third portion 10 may form, produce and/or provide the folded assembly 2 which is firmly connected, adhered, sealed and/or secured for securely packaging the one or more products 4 therein.
- the assembly 2 after being produced or provided by folding the portions 6 , 8 , 10 onto each other, may then pass through the heat tunnel to remove any film folds and/or wrinkles that may be present in the bag of film 18 that seals the product 4 and/or the carrier 42 . Passing through the heat tunnel may also provide a glossy shine or appearance to the film 18 sealed around the product 4 .
- a rear card cut out (not shown in the drawing) with perforations and/or score lines may be provided in the second portion 8 such that the assembly 2 may be easy opened to facilitate removal of the sealed product 4 and/or carrier 42 .
- Loading the product 4 and carrier 42 onto the second portion 8 and/or the folding of the first and third portions 6 , 10 onto each other and/or onto the second portion 8 may be accomplished by hand, by one or more machines (i.e., movable element 24 ), or by combinations thereof.
- the sheet 5 may be divided, separated, petitioned, cut, scored and/or foldable into two portions 6 , 8 as shown in FIG. 28 or into three portions 6 , 8 , 10 as shown in FIG. 29 .
- the first portion 6 of the sheet 5 may have at least one window 14 formed through the sheet 5 as shown in FIGS. 28 and 29 .
- the front side A 1 of the first portion 6 may display front card indicia 12 as shown in FIG. 1 .
- the product 4 may be connected, attached and/or adhered to the carrier 42 prior to the product 4 and carrier 42 being loaded into the window 14 as shown in FIG. 30 .
- the first adhesive 16 layer and/or the second adhesive layer 20 may be applied to the product 4 and/or the carrier 42 prior to connecting the product 4 and the carrier 42 together.
- the first adhesive layer 16 and/or the second adhesive layer may connect, attach and/or adhere the product 4 to the carrier 42 prior to placing the product 4 and carrier 42 in the window 14 of the first portion 6 .
- the product 4 and carrier 42 may be sealed or wrapped in a bag made of the film 18 prior to being into the window 14 of the first portion 6 .
- the perimeter of the carrier 42 may have a different or substantially different shape, size, configuration and/or dimensions as the perimeter of the window 14 of the first portion and/or as the perimeter of the product 4 as shown in FIG. 30 .
- the product 4 and carrier 42 sealed or wrapped in the bag of film 18 may be manually, or by machine, loaded into the window 14 of the first portion 6 .
- the outer edges of the perimeter of the carrier 42 may extend outwardly and/or away from the window 14 such that the outer edges contact one or more portions of the backside B 1 of the first portion 6 when the product 4 and the carrier 42 may be loaded into the window 14 of the first portion 6 .
- the backside B 2 of the second portion 8 may be folded onto the backside B 1 of the first portion 6 as shown in FIG. 28 .
- the outer edges of the carrier 42 may be secured, located, positioned, connected and/or attached to one or more portion of the backside B 1 of the first portion 6 and/or backside B 2 of the second portion 8 .
- at least the outer edges of the carrier 42 may be secured within or between the backsides B 1 , B 2 of the first and second portions 6 , 8 .
- the backside B 3 of the third portion 10 may be folded onto the top side A 2 of the second portion 8 .
- the first and/or second adhesives 16 , 20 provided on at least one of the backsides B 1 , B 2 , B 3 of the portions 6 , 8 , 10 , may connect, adhere, attach and/or join the portions 6 , 8 , 10 together to form the assembly 2 as shown in FIG. 1 .
- the outer edges of the carrier 42 secured between the first and second portions 6 , 8 may significantly improve substrate to substrate adhesion between the portions 6 , 8 , without the film layers 18 getting in the way of a significant card to card sealing between the portions 6 , 8 .
- the product 4 may be fugitive glued to the carrier 42 and overwrapped in a bag of film 18 .
- the top side A 1 of the first portion may be feed onto the conveyor belt face down and then may be loaded from behind with the carrier 42 and bagged product 4 loaded into the cutout window 14 . Then the other one or two sides may be glued and compression folded over and closed.
- the film 18 shown in FIG. 30 is a polyolefin.
- the sheet 5 may be divided, separated, petitioned, cut, scored and/or foldable into at least two portions 6 , 8 as shown in FIG. 31 .
- the first portion 6 of the sheet 5 may have at least one window 14 formed through the sheet 5 as shown in FIG. 31 .
- the front side A 1 of the first portion 6 may display front card indicia 12 as shown in FIG. 1 .
- a pre-formed blister 101 (hereinafter “blister 101 ”) may be sized and/or shaped to receive the product 4 as shown in FIG. 32 .
- the blister 101 may be made of a rigid or semi-rigid plastic or polymer material.
- the blister 101 may be made of recycled polyethylene terephtalate.
- a flange 102 of the blister 101 may be coated or may receive the first adhesive 16 and/or the second adhesive 20 for adhering the first and second portions 6 , 8 together after the backside B 2 of the second portion 8 has been folded onto the backside B 1 of the first portion 6 .
- the first adhesive 16 and/or the second adhesive 20 may be provided on both sides of the flange 102 of the blister 101 .
- the product 4 may be loaded into a pocket of the blister 101 .
- the window 14 of the first portion 6 may be sized and/or shaped to receive the product and/or the pocket of the blister 101 as shown in FIG. 33 .
- the first adhesive 16 and/or second adhesive 20 provided on the flange 102 of the blister 101 may connect, attach and/or adhere the blister 101 to the first portion 6 when the blister 101 and the product 4 are loaded into the window 14 .
- the backside B 2 of the second portion 8 may be folded onto the backside B 1 of the first portion 6 .
- the exposed adhesive on the flange 102 of the blister 101 may connect, attach and/or adhere to the backside B 2 of the second portion 8 .
- the backsides B 1 , B 2 of the first and second portions 6 , 8 may be connected, attached and/or adhered to each other via the adhesives on the flange 102 of the blister 101 .
- the flange 102 of the blister 101 may be located, positioned and/or secured between the backsides B 1 , B 2 of the first and second portions 6 , 8 .
- the product 4 and/or the blister 101 may be secured between the first and second portions 6 , 8 to produce the assembly 2 as shown in FIG. 1 .
- one or more portions of the backsides B 1 , B 2 of the first and second portions 6 , 8 may be provided with the first and/or second adhesives 16 , 20 which may connect, attach and/or adhere the first and second portions 6 , 8 together when the second portion 8 is folded onto the first portion 6 .
- the sheet 5 may be dispensed onto a conveyor belt, the blister 101 and the product 4 may be placed by hand or machine into the window 14 , and then one or more portions of the sheet 5 and/or blister 101 may be glued and folded to produce the assembly 2 .
- production of assemblies 2 may be at about 100 assemblies to about 450 assemblies per minute.
- Current blister machine typically cycle, at best, about 20 cycles to about 22 cycles per minute.
- producing the assembly 2 by coating both sides of the flange 102 of the blister 101 may or may not require tooling.
- the sheet 5 may be divided, separated, petitioned, cut, scored and/or foldable into at least two portions 6 , 8 , and the window 14 may be formed in the first portion 6 and covered with the film 18 as shown in FIG. 34 .
- the product 4 may be loaded, by hand or machine, into the window 14 , and one or more portions of the backsides B 1 , B 2 of the first and second portions 6 , 8 may be glued and folded onto each other to produce the assembly 2 as shown in FIG. 1 .
- the first adhesive 16 and/or the second adhesive 20 may be provided on one or more portions of the backsides B 1 , B 2 of the first and second portions 6 , 8 before the first and second portions 6 , 8 are folded onto each other to produce the assembly 2 .
- the product 4 may push, force and/or stretch the film 18 outwardly when the first and second portions 6 , 8 are folded onto each other to produce the assembly 2 .
- production of the assemblies 2 may be at about 100 assemblies to about 450 assemblies per minute. As a result, producers and/or manufactures of the assemblies 2 may achieve speeds that are about 5 times to about 7 times faster than typical known blister sealing systems. Moreover, production of the assembly 2 may eliminate “crush” marks from conventional blister packaging. In an embodiment, production of the assembly 2 may not require seal tooling to run or be utilized, which is a significant cost savings to the producer and/or manufacture of the assembly 2 .
- assemblies 2 , 100 may be produced, created, folded and/or sealed via a blister pack machine system 200 (hereinafter “system 200 ′) as shown in FIGS. 35-41 .
- system 200 ′ a blister pack machine system 200
- one or more sheets 5 may be loaded onto the system 200 , whereby one or more products 4 and/or blisters 101 (optionally loaded with one or more products 4 ) may be subsequently loaded, placed, dropped and/or positioned within the one or more windows 14 formed in the one or more sheets 5 , by hand or by machine, and the one or more portions 6 , 8 and/or 10 of the one or more sheets 5 may be folded onto each other to seal or close the one or more sheets 5 and/or to produce the assemblies 2 , 100 .
- the system 200 may comprise a body having a total length defined between a first end 204 and a second end 206 and a total width defined between a first side 208 and a second side 210 .
- the system 200 may comprise a plurality of conveyor belts 212 (hereinafter “belts 212 ”) which may extend along the entire length of the system 200 or at least along a portion of the entire length of the system 200 .
- Each belt 212 may rotate around and/or may encircle one or more box supports 214 (hereinafter “supports 214 ”) which may physically provide support to the conveyor belt along the entire length of the system 200 or at least along a portion of the entire length of the system 200 .
- the supports 214 may be made of a metal material or a stiff plastic or polymer material. As each belt 212 rotates around the supports 214 , the tension or firmness of the belt 212 may remain constant, or substantially constant, as a result of the physical support provided by the supports 214 . In embodiments, an inner circumference of each belt 212 may be same as, substantially the same as, or greater than an outer circumference of the all of the supports 214 that support each belt 212 .
- crossbars 216 may extend across the entire width of the system 200 between the first side 208 and the second side 210 (hereinafter collectively known as “sides 208 , 210 ”), as shown in FIGS. 35 , 39 and 41 .
- the sides 208 , 210 may be connected, attached and/or fixed to each other via the crossbars 216 .
- the supports 214 are movable connected, attached and/or fixed to the crossbars 216 such that the supports, along with the belts 212 , may slide to any position between the sides 208 , 210 .
- the supports 214 and belts 212 are adjustable to any position between the sides 208 , 210 such that adjustable cavities 218 (hereinafter “cavities 218 ”) are provided or formed between the belts 212 as shown in FIG. 35 .
- the cavities 218 may be sized, shaped, configured and/or adapted to receive the one or more products 4 and/or one or more blisters 101 as shown in FIG. 41 .
- the supports 214 and/or belts 212 may be located at a first position to provide a first cavity 218 that is sized and/or shaped to receive products 4 and/or blisters 101 have a first size, a first shape and/or a first depth.
- the supports 214 and/or belts 212 may be moved to a second position to provide a second cavity 218 that is sized and/or shaped to receive products 4 and/or blister 101 having a second size, a second shape and/or a second depth.
- the first size may be greater than or less than the second size
- the first shape may be different than the second shape
- the first depth may be greater than or less than the second depth.
- the first end 204 of the system 200 may have loading components 220 (hereinafter “components 220 ”) which may comprise rollers, bars, platforms and/or the like as shown in FIGS. 35 , 38 and 40 .
- the one or more sheets 5 may be loaded onto the belts 212 via the components 220 such that the windows 14 of the sheets 5 may be aligned with or may overlap the cavities 218 formed between the belts 212 and/or the supports 214 as shown in FIG. 41 .
- the products 4 and/or the blisters 101 are loaded into the windows 14 of the sheets 5 , the products 4 and/or the blisters 101 are positioned or located within the cavities 218 between the belts 212 and/or the supports 214 .
- one or more trucks or holdown wheels 222 may be positioned and/or located along the length of the belts 212 as shown in FIGS. 35-37 and 40 .
- the wheels 222 may comprises rollers or components that maintain or holddown the sheets 5 onto the belts 212 as the sheets 5 move along the belts 212 from the first end 204 to the second end 206 of the system 200 .
- the vacuum producing device 34 may be incorporated into the system 200 and/or located between the belts 212 and/or within the cavities 218 such that the vacuum provided by the vacuum producing device 34 holds or maintains the sheets 5 in contact with the outer surface of the belts 212 as the sheets 5 move along the length, or portion of the length, of the belts 212 .
- the sheets 5 may be in substantial contact, or complete contact, with the outer surface of the belts 212 while the sheets move along the entire length, or at least a portion of the entire length, of the belts 212 via the wheels 222 and/or the vacuum producing device 34 .
- the wheels 222 may be movably connected, attached or fixed to the body of the system 200 via one or more rods 224 (hereinafter “rods 224 ”) and/or one or more arms 226 (hereinafter “arms 226 ”) as shown in FIGS. 35 and 36 .
- the wheels 222 may be adjustable via rods 224 and/or arms 226 such that the wheels 222 may be positioned or movable to locations that are adjacent to and/or directly over the outer surface of the adjustable belts 212 .
- the system 200 may have a first folding mechanism 228 (hereinafter “first mechanism 228 ”) and/or a second folding mechanism 230 (hereinafter “second mechanism 230 ”) located adjacent to or near the second end 206 of the system 200 .
- the first mechanism 228 may top fold at least one of the portion 6 , 8 , 10 of the sheets 5 onto the other portions of the sheets 5 to enclose the products 4 and/or blisters 101 therein and to produce, create and/or form the assemblies 2 , 100 .
- the second mechanism 230 may fold at least one of the portions 6 , 8 , 10 of the sheets 5 sideway onto the other portions of the sheets 5 to enclose the products 4 and/or blister 101 therein and to produce, create and/or form the assemblies 2 , 100 .
- the second mechanism 230 may be shaped as one or more curved or rounded blades that side folds the portions of the sheets 5 onto each other to produce the assemblies 2 , 100 .
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Abstract
Systems and methods package retail products and provide a sheet divided into a first part and a second part, wherein the first and second parts of the sheet are foldable with respect to each other, wherein the first part of the sheet has at least one window formed in the sheet. Further, the systems and methods load a pre-formed blister, having at least one pocket preloaded with at least one retail product, into the window formed in the sheet such that a portion of the pre-formed blister and a portion of the at least one retail product extends through the window formed in the sheet. Moreover, the systems and methods fold the second part onto the first part to produce a blister product assembly such that the at least one retail product is located between a portion of the pre-formed blister and a portion of the second part of the sheet.
Description
- This application is a non-provisional application claiming the benefit under 35 U.S.C. 119(e) of U.S. Provisional Patent Application Nos. 62/054,679, filed on Sep. 24, 2014, and 62/212,304, filed on Aug. 31, 2015, which are incorporated herein by reference in their entireties.
- The present disclosure relates to one or more blister package assemblies and/or one or more systems and methods for producing the one or more blister package assemblies. The assemblies and systems and methods are utilized to package and/or protect one or more products and/or to display one or more products using a new and different blister card construction format.
- Blister card systems are generally used to display, organize and dispense products stored therein. The blister card systems traditionally are hung or suspended from hooks and/or pegs are easily removed from the hooks and/or pegs by consumers for examination and/or purchase of the products by the consumers. The hooks and/or pegs, attached to display shelves, often suspend the products from one or more cut-outs formed within packaging of the blister card systems. Known blister card systems have pre-formed plastic packaging which includes at least one pre-formed plastic cavity sized or configured to receive and store one or more products, coated cards are required to seal either the blister to the card or the card to the card with the blister held in between the two cards. Both methods require a special machine that applies heat and/or pressure over time in a special cavity, to complete the sealing process. Often the preformed plastic cavity is made from thermoformed plastic and the backing is made from a paper-based material, for example, cardboard or paperboard, metal foil or one of many available plastics or a combination of any of these varied materials.
- The size and shape of the preformed plastic cavity is based on the size and shape of the products being stored and enclosed within the preformed plastic cavity of the blister card system. Because different products, more often than not, have different sizes and/or shapes, the sizes and shapes of the preformed plastic cavities must also have different corresponding sizes and/or shapes. As a result, this requires special blister mould tooling to be manufactured to produce correctly sized blisters that properly hold the product to the card. Also required, as well, are a complete and separate set of additional specialized blister machine sealing tooling, which are required for each product, to seal the blister loaded with product to the card or card to card with the blister in between, for final assembly. Specialized machines must be used to seal the blister with the product inside to the card or for card to card sealing with the blister in between the cards. Currently all blister cards are produced this way. Each and every product to be placed onto a blister card requires both a preformed plastic cavity, mould tooling for same that has been designed and manufactured for each and every different product size and/or shape to be carded, plus the additional and expensive sealing equipment tooling required to attach the blister to the speciality coated card, which requires very specialized machines which are necessary to seal each preformed plastic cavity which has a different size and/or shape in order to adhere to the specially coated blister card using time, heat and pressure. Moreover, producing and sealing different preformed plastic cavities having different sizes and/or shapes requires manufactures or producers to purchase, utilize, maintain and repair multiple tooling and/or sealing equipment and machines. As a result, the purchasing, utilizing, maintaining and repairing of the multiple tooling and/or sealing equipment or machines required to produce and seal different sized and/or shaped preformed plastic cavities makes manufacturing different blister card systems for different products costly, untimely and often very labour intensive.
- Moreover, traditional blister card systems, such as, for example, rotary or inline systems, require the above-mentioned standard blister machine tooling, such as, for example, blister framing tooling that has to be made exactly to fit and hold each blister, card and product and then feed each blister, card and product into the necessary sealing heated head section, which requires a custom heat sealing head to come down, heat seal the card, product and blister together which must exactly match all blisters and products needed to be sealed. This standard blister sealing process squeezes and heats the card together for completing its sealing process, which causes visible card crushing, marks and indentations in the final product which is one disadvantage of these standard blister sealing processes.
- The assemblies and methods set forth in the present disclosure will produce and seal multiple and unlimited blister package designs styles for almost any different blister package assemblies required by any manufacturer, for storing and enclosing almost any different product(s) having different sizes and/or shapes, with or without, the use of pre-formed plastic cavities. When using film or a plastic cavity with this new process, large savings are achieved by eliminating or reducing the required multiple tooling needed and the complete elimination of any currently used sealing equipment machines and their very high operating costs. Moreover, the present assemblies and methods will reduce total packaging costs, production times and labour requirements associated with producing and sealing the different blister package assemblies by utilizing one or more of the following structural features and/or elements: a sheet or card having one or more scorings, foldings or petitioning to provide at least two, three, four, nine or more foldable portions; at least one cut-out window formed in the sheet; one or more compliant or stretchable films connected to a back side of the sheet and covering the at least one cut-out window(s) for enclosing at least one product between the one or more compliant films and at least one folded portion of the sheet; a conveyor belt system which may be continuously moving; two or more supports associated with the conveyor belt system for supporting at least one portion of the sheet during the production of the assembly; one or more moveable elements associated with the conveyor belt system for folding portions of the sheet onto each other to produce the folded assembly; a vacuum holding device associated with the conveyor belt system for applying a vacuum holding force to sheet or card positioned on the conveyor belt system; and an adjustable pocket or cavity, adjustable in both width and depth, built into the conveyor belt system. A plurality of adjustable product blister depths can be achieved for almost any product by angle adjustments made to the moveable elements position with respect to the position of the card. The adjustable product blister depths adjust in any and all axis's and planes required for the correct film pocket size. The moveable elements will allow for infinite blister depth adjustment, without tools, for making any required blister depth that may be needed for each and every product a manufacturer or customer wishes to have blister packaged a certain way and with a special look. As the foldable portions are being folded, tension in the stretchable film is relaxed which results in an increased width and/or depth of film pocket size for receiving the product.
- The present systems and methods, for producing the present blister package assemblies, operate completely without any of the above-mentioned standard blister machine tooling. Instead, the present systems and methods utilize a machine assembly comprising movable convey belts that are slidable over the moveable box supports which operate a support bases for the movable convey belts. Said movable conveyor belts and box support are movable from side to side to provide one or more adjustable cavities that adjustable sizes, shapes, depths and/or configurations for receiving cards, blisters and/or products having different sizes, shapes, depths and/or configurations. As a result, the present systems and methods may quickly accommodate almost any size, shape and depth card, blister and/or possible and may fit almost any sized product sealable within the present blister package assemblies.
- The present systems and methods does not utilize the heated head; thus no crushing, marks or indentations occur with respect to the final blister package assemblies produced by the present systems and methods. Instead, the present systems and methods utilize folding and sealing with one or more selected from adhesive, cohesive, pressure and a heat tunnel to seal the present blister package assemblies. As a result, the newest graphic print and design features which are not available to any other current blister system due to their sealing process (i.e., holding, squeezing and heating of the cards to complete and seal their package) may be utilized and/or incorporated into the present blister package assemblies and present systems and methods for producing said blister package assemblies.
- In embodiments, systems and methods may package retail products, provide a sheet divided into a first part and a second part, wherein the first and second parts of the sheet are foldable with respect to each other, wherein the first part of the sheet has at least one window formed in the sheet, load a pre-formed blister, having at least one pocket preloaded with at least one retail product, into the window formed in the sheet such that a portion of the pre-formed blister and a portion of the at least one retail product extends through the window formed in the sheet, and fold the second part onto the first part to produce a blister product assembly such that the at least one retail product is located between a portion of the pre-formed blister and a portion of the second part of the sheet.
- In an embodiment, the systems and methods may have a blister product assembly production rate from about 100 assemblies/minute to about 450 assemblies/minute.
- In an embodiment, the sheet may be made of paper-based materials, plastic or polymer-based materials or a combination thereof.
- In an embodiment, the pre-formed blister may be made of a rigid or semi-rigid plastic.
- In an embodiment, the pre-formed blister may be made of at least one polymer material.
- In an embodiment, the systems and methods may further comprise coating an adhesive onto one or more sides of a flange of the pre-formed blister before the pre-formed blister is loaded into the window formed in the sheet.
- In an embodiment, the systems and methods may further comprise adhering the first and second parts of the sheet together, via the adhesive coated onto one or more sides of the flange of the pre-formed blister, when, or after, the second part is folded onto the first part of the sheet.
- In an embodiment, the systems and methods may further comprise adhering the first and second parts of the sheet together via cohesion or an adhesive when, or after, the second part is folded onto the first part of the sheet to produce the blister product assembly.
- In an embodiment, the systems and methods may further comprise dispensing the sheet onto a conveyor belt prior to loading the pre-formed blister into the window formed in the sheet.
- In an embodiment, the systems and methods may further comprise placing the pre-formed blister, by hand or by machine, into the window formed in the sheet for loading the pre-formed blister into the window.
- In an embodiment, the second part of the sheet may have a window formed therein for receiving at least a portion of the pre-formed blister and/or a portion of the at least one retail product.
- In embodiments, the systems and methods may package retail products, position a sheet on a conveyor belt system comprising an adjustable cavity, wherein the sheet is divided into a first part and a second part, wherein the first and second parts of the sheet are foldable with respect to each other, wherein the first part of the sheet has at least one window formed in the sheet, wherein the window formed in the sheet is positioned above the adjustable cavity of the conveyor belt system when the sheet is positioned on the conveyor belt system, load a pre-formed blister, having at least one pocket preloaded with at least one retail product, into the window formed in the sheet such that a portion of the pre-formed blister and a portion of the at least one retail product extends through the window formed in the sheet and into the adjustable cavity of the conveyor belt system, and fold the second part onto the first part to produce a blister product assembly such that the at least one retail product is located between a portion of the pre-formed blister and a portion of the second part of the sheet.
- In an embodiment, the systems and methods may further comprise adjusting a width and/or depth of the adjustable cavity of the conveyor belt system to correspond to or to be similar to dimensions of the at least one retail product and/or the pre-formed blister prior to loading the at least one retail product and/or the pre-formed blister into the window formed in the sheet.
- In an embodiment, the systems and methods may further comprise providing downward vacuum holding forces onto the sheet by a vacuum producing device of the conveyor belt system after the sheet is positioned on the conveyor belt system and/or providing downward vacuum holding forces onto the at least one retail product by the vacuum producing device after the at least one retail product is loaded into the window formed in the sheet.
- In an embodiment, the method may have a blister product assembly production rate from about 100 assemblies/minute to about 450 assemblies/minute.
- In an embodiment, the systems and methods may further comprise coating an adhesive onto one or more sides of a flange of the pre-formed blister before the pre-formed blister is loaded into the window formed in the sheet.
- In an embodiment, the systems and methods may further comprise adhering the first and second parts of the sheet together, via the adhesive coated onto one or more sides of the flange of the pre-formed blister, when, or after, the second part is folded onto the first part of the sheet.
- In an embodiment, the systems and methods may further comprise adhering the first and second parts of the sheet together via cohesion or an adhesive when, or after, the second part is folded onto the first part of the sheet to produce the blister product assembly.
- In an embodiment, the systems and methods may further comprise placing the pre-formed blister, by hand or by machine, into the window formed in the sheet for loading the pre-formed blister into the window.
- In an embodiment, the second part of the sheet may have a window formed therein for receiving at least a portion of the pre-formed blister and/or a portion of the at least one retail product.
- So that the features and advantages of the present disclosure can be understood in detail a more particular description of the systems and methods may be had by reference to the embodiments thereof that are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only some typical embodiments of the present systems and methods and are therefore not to be considered limiting of its scope, for the systems and methods may admit to other equally effective embodiments.
-
FIG. 1 illustrates a front plan view of a blister package assembly with a product enclosed therein in an embodiment. -
FIG. 2 illustrates a front plan view of a blister package assembly with more than one product enclosed therein in an embodiment. -
FIG. 3 illustrates a front plan view of a top side of a sheet of card stock paper petitioned into at least three portions and having at least one window formed therein and at least one compliant or stretchable film covering the at least one window in an embodiment. -
FIG. 4 illustrates a front plan view of a bottom side of a sheet of card stock paper petitioned into at least one, two or three portions and having at least one window formed therein and at least one compliant or stretchable film connected to the portions of the sheet and covering the at least one window in an embodiment. -
FIG. 5 illustrates a top plane view of a portion of the sheet shown inFIG. 4 showing one of the moveable elements in correct position to produce a properly sized product blister film pocket, just prior to being folded onto another portion of the sheet in an embodiment. -
FIG. 6 illustrates a top plane view of the sheet shown inFIG. 5 after the portion of the sheet has been folded onto another portion of the sheet in an embodiment locking in the product depth for the blister pocket. -
FIG. 7 illustrates a top plan view of the sheet shown inFIG. 6 after two portions of the sheet have been folded and sealed together onto the remaining portion of the sheet. Locking the product in place with multiple holding systems. A fugitive adhesive or other holding method such as, but not limited to, other adhesive types, cohesive, double sided tape etc., as a method to securely hold the product from behind, to the front side A3 of a portion of the sheet. The film blister pocket will lock the product into place from behind the front side A1 of an additional portion of the sheet with the film pocket adhered to the back side B1 of that additional portion, to produce the blister package assembly in an embodiment. -
FIG. 8 illustrates a partial cross-sectional view of a blister package assembly having a product (i) connected to a portion of a folded sheet, (ii) extending through the window formed in the sheet, and (iii) enclosed between the at least one compliant, stretchable and heat shrinkable film and the portion of the sheet in which the product is connected to in an embodiment. -
FIG. 9 illustrates a partial cross-sectional view of a blister package assembly provided on a conveyor or moving belt that has an adjustable cavity and vacuum holding device applying vacuum holding force to an adjacent portion of the card and the product position in the window in an embodiment. -
FIG. 10 illustrates a front plan view of a bottom side of a sheet petitioned into three portions, having at least one window formed therein, and at least one compliant or stretchable film connected to the portions of the sheet and covering the at least one window having a product positioned therein in an embodiment. -
FIG. 11 illustrates a front plan view of the bottom side of the sheet shown inFIG. 9 with one portion folded onto another portion and a portion of the product in an embodiment. -
FIG. 12 illustrates a front plan view of the bottom side of the sheet shown inFIGS. 10 and 11 with a second portion folded onto the other portions to form the folded assembly in an embodiment. -
FIG. 13 . illustrates a front plan view of a bottom side of a sheet petitioned into a plurality of foldable portions, having at least one window formed in a first portion of the sheet, and at least one stretchable film connected to the plurality of foldable portions of the sheet in an embodiment. -
FIG. 14 illustrates a front plan view of the bottom side of the sheet shown inFIG. 13 with upper and lower foldable portions folded onto the first portion of the sheet and the product in an embodiment. -
FIG. 15 illustrates a front plan view of the bottom side of the sheet shown inFIGS. 13 and 14 with left and right foldable portions folded onto the first portion of the sheet to form the folded assembly in an embodiment. -
FIG. 16 illustrates a front plan view of the front side of the folded assembly produced by folding the plurality of foldable portions onto the first portion of the sheet as shown inFIGS. 13-15 in an embodiment. -
FIG. 17 illustrates a front plan view of a product connected to a carrier in an embodiment. -
FIG. 18 illustrates a top plan view of a front side of a folded assembly displaying the product connected to the carrier as shown inFIG. 17 in an embodiment. -
FIG. 19 illustrates a front plan view of a sheet of card stock paper petitioned into three portions and having two windows formed therein and a product connected to a carrier and sealed in a bag of film in an embodiment. -
FIG. 20 illustrates the front plan view shown inFIG. 19 , wherein a portion of the sheet has been folded onto the middle portion forming a pocket between the portions for receiving the product and carrier sealed in the bag of film in an embodiment. -
FIG. 21 illustrates the front plan view shown inFIG. 20 , wherein the product and carrier sealed in the bag of film is inserted into the pocket formed between the portions in an embodiment. -
FIG. 22 illustrates the front plan view shown inFIG. 21 , wherein the entire lengths of the product and carrier are inserted into the pocket formed between the portions in an embodiment. -
FIG. 23 illustrates the front plan view shown inFIG. 22 after the third portion has been folded onto the other two portions enclosing at least portions of the carrier between the portions of the sheet in embodiment. -
FIG. 24 illustrates a front plan view of a sheet of card stock paper petitioned into three portions and having two windows formed therein and a product connected to a carrier and sealed in a bag of film in an embodiment. -
FIG. 25 illustrates the front plan view shown inFIG. 24 , wherein the product and carrier sealed in the bag of film has been positioned on the middle portion of the sheet in an embodiment. -
FIG. 26 illustrates the front plan view shown inFIG. 25 , wherein a first outer portion of the sheet has been folded onto the middle portion such that the product extends outwardly from the window of the folded outer portion in an embodiment. -
FIG. 27 illustrates the front plan view shown inFIG. 26 , wherein a second outer portion of the sheet has been folding onto the middle and first outer portions such that the product extends outwardly from the windows formed in the first and second outer portions in an embodiment. -
FIG. 28 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into two portions and having a window formed in one portion in an embodiment. -
FIG. 29 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into three portions and having a window formed in the middle portion in an embodiment. -
FIG. 30 illustrates a front plan view of a product connected to a carrier and/or sealed in a bag of film in an embodiment. -
FIG. 31 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into at least two portions and having a window formed in one portion in an embodiment. -
FIG. 32 illustrates a front plan view of a product a pre-formed blister sized to receive the product whereby an adhesive layer is provided on the pre-formed blister in an embodiment. -
FIG. 33 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into at least two portions and having a product and pre-formed blister loaded into a window formed in one portion and sealed closed using adhesive or cohesive on the pre-formed blister or card in an embodiment. -
FIG. 34 illustrates a front plan view of a backside of a sheet of card stock paper petitioned into two portions and having a window formed in one portion that is covered with at least one stretchable film in an embodiment. -
FIG. 35 illustrates a top plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment. -
FIG. 36 illustrates a first side plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment. -
FIG. 37 illustrates a second side plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment. -
FIG. 38 illustrates a first end plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment. -
FIG. 39 illustrates a second end plan view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment. -
FIG. 40 illustrates a perspective view of a blister pack machine system for loading, folding and/or sealing blister card assemblies in an embodiment. -
FIG. 41 illustrates a partial perspective plan view of a blister pack machine system having movable box supports slidable on horizontal crossbars in an embodiment. - The present disclosure sets forth blister package assemblies and/or methods of producing blister package assemblies for packaging, securing, storing, enclosing, protecting, displaying and/or offering-for-sale one or more products. The assemblies and methods may package one or more products, enclosed between at least one compliant or stretchable film at least one portion of a sheet of card stock paper or other selected material, such that the one or more products extend through at least one window formed in the sheet. In embodiments, one or more windows may be formed in the sheet whereby each window is sized and shaped to display one or more products, which may be the same products, different products or a combination thereof. In embodiments, portions of the sheet may be folded over each other to produce the folded blister package assemblies such that the product may extend through a window formed in a portion of the sheet and be enclosed between the compliant or stretchable film and one or more folded portions of the sheet. It should be understood that the following terms may be used interchangeably throughout the present disclosure: sized; shaped; adapted; and configured.
- Referring now to the drawings wherein like numerals refer to like parts, the present systems and methods may provide at least one folded blister package assembly 2 (hereinafter “
assembly 2”) as shown inFIG. 1 , configured to package at least oneproduct 4. In embodiments, a folded blister package assembly 100 (hereinafter “assembly 100”) may be sized, shaped and/or configured to package, for example, a plurality of products 4 (hereinafter “products 4”) as shown inFIG. 2 . Moreover, it should be understood that the present disclosure is not limited to a specific embodiment of the number ofproducts 4 which may be packaged within theassembly 2 and/or the assembly 100 (hereinafter collectively referred to as “assemblies assembly 100 may package threeproducts 4 as shown inFIG. 2 ; however, it should be understood that theassembly 100 may be shaped, sized and/or configured to package, store and/or display any number ofproducts 4 as known to one of ordinary skill in the art. - The
products 4 may be, for example, cosmetic products, consumer products, food products, hard goods, durable goods, soft goods, pharmaceuticals, replacement parts, aerosols, consumables, consumer-grade goods, professional-grade goods and/or the like. In embodiments, theproducts 4 may be at least one or more products. Theproducts 4 may be, for example, cosmetics, analgesics, medications, pharmaceuticals, razors, razor blades, camera film, batteries, videos, DVDs, smoking cessation products, infant formula, lip sticks, nail polishes, toothbrushes, vitamins, personal care products, home care products, toothbrushes, foodstuffs, packaged foods, kitchen supplies, bags, boxes, containers and/or the like. In embodiments, theproducts 4, which may be secured, stored, displayed and/or dispensed via theassemblies products 4 may have same, similar and/or different sizes, shapes and/or configurations. Theproducts 4 that may be any product(s) known to one of ordinary skill in the art that are configured, adapted, shaped and/or sized to be packed or stored within theassemblies - The
assemblies products 4 may be accessible by a consumer through a front-side of a divider or shelf system (not shown in the drawings). In embodiments, theassemblies FIGS. 13-16 ) which may enable theassemblies assemblies products 4 packaged, secured, stored, enclosed, protected and/or displayed within theassemblies assemblies products 4. After which, theproducts 4 may be separated and/or removed from theassemblies assemblies -
FIGS. 1 and 2 show the foldedassemblies sheet 5”) made of materials, such as, for example, paper-based materials, plastic or polymer-based materials or a combination thereof. In embodiments, thesheet 5 may be made of any materials that are capable, physically, of being folded onto and/or over itself to produce, form and/or assemble the foldedassemblies sheet 5 may be made of one or more materials selected from the group consisting of paper corrugated or wood based materials, blister boards, coated styrene butadiene styrene, corrugated fibreboard, E-Flute corrugated fibreboard, stone paper, ceramic sheets, wood, melamine, standardized layers or sheets or combinations thereof. It should be understood that the present disclosure is not limited to a specific embodiment of the materials that may be used to make thesheet 5. - In embodiments, the
sheet 5 may consist of a single layer of material. In other embodiments, thesheet 5 may consisting of more than one layer of material which may be connect, attached, adhered or laminated together to form thesheet 5. It should be understood that the present disclosure in not limited to specific embodiment of the number of layers of material that may be utilized to formsheet 5. - The
sheet 5 may be divided or partitioned into two, three, four, nine or more portions by a dividing or partitioning process or method. In embodiments, the three or more portions of thesheet 5 may be formed or produced by a scoring process, such as, for example, a side cut scoring process or the like. As a result, one or more scores or folds may be positioned, provided and/or located between each of the three or more portions. When two or more scores or folds are present between each of the three or more portions, additional height dimension may be added to the foldedassembly 2. As a result, gussets and/or other pull-out features may be provided or positioned in the additional height dimension that may be provided by the two or more scores or folds between each of the three or more portions of thesheet 5. - In embodiments, the
sheet 5 may be divided or partitioned into afirst portion 6, asecond portion 8 and a third portion 10 (hereinafter collectively referred to as “portions FIGS. 3-5 . Each of the portions of thesheet 5 has a front side and a back side located opposite with respect to the front side of each portion. For example, thefirst portion 6 has a front side A1 and a back side B1, thesecond portion 8 has a front side A2 and a back side B2, and thethird portion 10 has a front side A3 and a back side B3 as shown inFIGS. 3 and 4 . Thesheet 5, thefirst portion 6, thesecond portion 8 and/or thethird portion 10 may be produced, cut, scored and/or formed by one or more die-cut and/or scoring tools or equipment. The present disclosure should not be deemed as limited to a specific embodiment of a size and/or a shape of an outer perimeter of thesheet 5, thefirst portion 6, thesecond portion 8 and/or thethird portion 10. - In embodiments, indicia 12 (hereinafter “
indicia 12”) may be printed onto, displayed on and/or applied to one or more surfaces of theassemblies indicia 12 may be printed onto or applied onto the one or more surfaces of theassemblies indicia 12 may comprise at least one of graphics, letters, numbers, symbols, photographs, holographics, pictures, scratch-n-sniff features, trademarks, designs, images, characters and/or the like. Theindicia 12 may be associated with and/or indicative of theproducts 4 packaged, stored and/or enclosed within theassemblies indicia 12 may be associated with and/or indicative of a supplier of theproducts 4, a manufacturer of theproducts 4, a distributor of theproducts 4 and/or a third party associated with theproducts 4. - In embodiments, the
indicia 12 may be in the form of, but not limited to, printed indicia that is printed or electronically transferred onto the one or more surface of theassemblies indicia 12 may be in the form of an adhesive label or attachment which may be applied or adhered to the one or more surface of theassemblies indicia 12 may be any indicia that may be displayed on one or more surface of theassemblies - In an embodiment, the
indicia 12 may be printed onto or displayed on the front side A1 of thefirst portion 6 and the front side A2 of thesecond portion 8 as shown inFIGS. 1-4 and 7. As a result, theindicia 12 is displayed on front and rear sides of theassemblies assemblies portions portions FIGS. 1 , 2 and 7. For example, theindicia 12 displayed on the front side A1 of thefirst portion 6 may be displayed on the front side of theassemblies assemblies indicia 12 displayed on the front side A2 of thesecond portion 8 may be displayed on the rear side of theassemblies assemblies - The folded
assemblies portions sheet 5 may be folded and/or adhered to produce, form and/or assembly the foldedassemblies FIGS. 9 , 35 and 39-41) that transports thesheet 4 from one place to another while theportions assemblies FIG. 9 ) having stationary and movable parts which may utilized to fold and/or adhere theportions assemblies - The
sheet 5 has at least one window 14 (hereinafter “thewindow 14”) formed therein for displaying, housing, securing and/or storing theproducts 4 after theportions assemblies sheet 5 may have onewindow 14 for displaying, housing, securing and/or storing theproduct 4 as shown inFIGS. 1 , 3-6 and 8 or thesheet 5 may have a plurality ofwindows 14 for displaying housing, securing and/or storing more than oneproduct 4 as shown inFIG. 2 . In embodiments, thewindow 4 is formed in one of theportions sheet 5. For example, thewindow 4 may be formed in thefirst portion 6 as shown inFIGS. 1-6 and 8-11 and may extend through thesheet 5 from the front side A1 of thefirst portion 6 to the back side B1 of thefirst portion 6. - The
window 14 is configured to receive, house and/or store at least a portion of theproducts 4 after the foldedassemblies portions portions window 14 formed in thesheet 5 may be configured to receive two or more products 4 (not shown in the drawings). Thewindows 14 may be, for example, but not limited to, cut-out windows formed in the sheet by cut-out or punch-out techniques as known to one of ordinary skill in the art. - In embodiments, the
window 14 may be configured to receive, house and/or store at least a portion of theproduct 4 and may have a perimeter that may be smaller than, the same as, substantially the same as, substantially similar to, or greater than the perimeters of theproduct 4. The perimeters of thewindow 14 may comprise a geometrical shape selected from a circular shape, an oval shape, a square shape, a rectangular shape, a triangular shape, a polygonal shape and combinations thereof. In an embodiment, the perimeters of thewindow 14 may be smaller than, the same as, substantially similar to or corresponding to the perimeters of theproducts 4. In embodiments, the perimeters of thewindows 14 may be differently shaped perimeters as shown inFIG. 2 . In embodiments, theproducts 4 may firmly fit or be positioned within thewindow 14 or within the perimeters of thewindow 14 after theportions - The
product 4 may be adhered, bonded or glued, connected, attached and/or secured to the front side A3 of thethird portion 10 of thesheet 5 before theassemblies portions portions adhesive layer 16”) may adhere a back side of theproduct 4 to the front side A3 of thethird portion 10 of thesheet 5 as shown inFIG. 8 . As a result, theproduct 4 may be connected, attached, secured and/or adhered to thethird portion 10 of thesheet 5 via firstadhesive layer 16. During production of theassemblies adhesive layer 16 may be applied to the back side of theproduct 4 or to the front side A3 of the third portion before theproduct 4 and thethird portion 10 are adhered or joined together. - In embodiments, the first
adhesive layer 16 may be, but not limited to, a fugitive adhesive or glue, a credit card glue, a E-z-release glue, a hotmelt adhesive, a pressure-sensitive adhesive, a cold glue, a cohesive, a double sided tape, a single sided tape with an adhesive on its back side, an animal glue or combinations thereof. After theassemblies assemblies product 4 displayed therein. When removing theproduct 4 from the firstadhesive layer 16, no residue of the firstadhesive layer 16 is present on the back side of theproduct 4. As a result, no damage will be caused to theproduct 4 by the firstadhesive layer 16 and/or by the removal of theproduct 4 from theassemblies product 4 from theassemblies - As shown in
FIGS. 1-6 and 8, at least a portion of thewindow 14 or the window in its entirety is covered by at least one compliant film 18 (hereinafter “film 18”) which is connected, attached or adhered to the back side of thesheet 5. For example, thefilm 18 may be connected, attached and/or adhered to the back side B1 of thefirst portion 6, the back side B2 of thesecond portion 8 and/or the back side B3 of thethird portion 10 as shown inFIG. 4 . Thefilm 18 may be, but is not limited to, a stretchable, heat shrinkable film which may, in an embodiment, be a clear compliant plastic film layer, such as, but not limited to, a polyolefin film layer that may be adhered to the bottom side of thesheet 5. Thefilm 18 may comprise a single film layer or more than one film layer. Thefilm 18 may be at least a single sheet film having an outer perimeter which may be configured to cover the at least onewindow 14, at least a portion of the back side of thesheet 5, at least a majority of the back side of thesheet 5 or all of the back side of thesheet 5. The outer perimeter thefilm 18, in an unstretched state or manner, may be large enough that thefilm 18 may cover more than thewindow 14 and/or may allow thefilm 18 to be connected, attached and/or adhered to one or more portions of the back side B1 of thefirst portion 6, the back side B2 of thesecond portion 8 and/or the backs side B3 of thethird portion 10. In the unstretched state or manner, thefilm 18 may extend across thewindow 14 in a firmly tensioned or a relaxed state or manner. - In embodiments, the
film 18 may be made from, but is not limited to, at least one clear compliant film or heat activated clear film. Heat active films become loose or relaxed and extremely pliant when activated by heat, and then subsequently harden when cooled. For example, the at least one heat activated film may be, for example, a skin film as known to one of ordinary skill in the art. In embodiments, thefilm 18 may be any film layer type that is capable of being laminated and/or attached to the back side of thesheet 5, which may provide a plurality of characteristics that may be derived from different materials used in each layer of a multiple layeredfilm 18, as well as a total number of film layers that may be combined to produce the multiple layeredfilm 18. - In embodiments, the
film 18 may be made of, but not limited to, a flexible rubber or rubber-like material or a polymeric packaging material that may or may not have one or more holes or pores formed therein. Thefilm 18 may comprise one or more film layers which may or may not be made of the same material. In embodiments, thefilm 18 may be a composite film made of two or more different materials. In embodiments, thefilm 18 may be crosslinked or crosslinkable. In an embodiment, thefilm 18 may be produced by monoaxial or biaxial stretching prior to connecting, attaching and/or adhering thefilm 18 to thesheet 5. As a result, thefilm 18 may have an orientation, such, as, for example, a uniaxial or biaxial orientation Thefilm 18 may have, but not limited to, a film thickness in a range of about 15 to about 250 microns, about 10 to about 25 microns, about 15 to about 30 microns or may be about 16.4545 microns. In embodiments, thefilm 18 may exhibit one or more of the following characteristics: - (i) a haze (ASTM Test Method D1003-95) in a range of about 2.5 to about 70%, or about 3, 5.5 or 8%;
- (ii) a gloss (ASTM Test Method D2457-90) in a range of about 90 to about 115% or about 107%;
- (iii) a density (ASTM Test Method D-1505) in a range of about 0.95 to about 1.20 g/cm3 or about 1.08 g/cm3;
- (iv) a coefficient of friction (ASTM Test Method D-1894-95) in a range of about 0.1 to about 0.55 f/ss, kinetic, or about 0.20 or 0.25 f/ss, kinetic;
- (v) a tensile strength in the machine direction (ASTM Test Method D882) in a range of about 1.25 to about 60×1000 psi, about 6 to about 6.5×1000 psi, about 4.9 to about 7×1000 psi, about 5.8 to about 6.1×1000 psi, about 8.5 to about 9.2×1000 psi, about 5 to about 10×1000 psi or about 2.5, 13, 16, 17, 18, 20, 48 or 52×1000 psi;
- (vi) a tensile strength in the transverse direction (ASTM Test Method D882-95) in a range of about 4 to about 7×1000 psi, about 2.5 to about 4.6×1000 psi, about 7 to about 21×1000 psi or about 14, 16, 17, 18, 20 or 32×1000 psi;
- (vii) an elongation at break in the machine direction (ASTM Test Method D882-95) in a range of about 100 to about 600%, about 400 to about 800%, about 550 to about 650%, about 250 to about 350% or about 150, 400 or 600%;
- (viii) an elongation at break in the transverse direction (ASTM Test Method D882-95) in a range of about 10 to about 150%, about 500 to about 1000%, about 750 to about 950%, about 700 to about 800% or about 20, 100, 650 or 850%; and
- a melting point in a range of about 65 to about 350° C.
- One or more second adhesive layers 20 (hereinafter “second
adhesive layers 20”) may be positioned on, provided on and/or applied to one or more portions of the top side and/or bottom side of thesheet 5. For example, the second adhesive layers 20 may be applied to or provided on one or more portions of the top side A1 of thefirst portion 6, the bottom side B1 of thefirst portion 6, the top side A2 of thesecond portion 8, the bottom side B2 of thesecond portion 8, the top side A3 of thethird portion 10 and/or the bottom side B3 ofthird portion 10. Further, the second adhesive layers 20 is applied to or provided on the back side of thesheet 5 such that thefilm 18 is adhered to the back side of thesheet 5 via the secondadhesive layers 20 prior to the production of theassemblies adhesive layers 20 applied to or provided on thesheet 5 adheres or attaches theportions portions assemblies - In embodiments, the second adhesive layers 20 may comprise, but is not limited to, a pressure-sensitive adhesive, a crosslinkable adhesive, a heat-activatable adhesive, a hotmelt adhesive, a cohesive, a double sided tape, a single sided tape with an adhesive on its back side or combinations thereof. Adhesive strengths of the second adhesive layers 20 may be greater than an adhesive strength of the first
adhesive layer 16. Moreover, the adhesive strength of the secondadhesive layers 20 sufficiently bonds or adheres theportions assemblies product 4 enclosed within theassemblies sheet 5 by application techniques or processes as known to one of ordinary skill in the art. - As shown in
FIGS. 3 and 4 , the secondadhesive layer 20 may be applied to or positioned on an outer edge, opposite to the edge adjacent to thesecond portion 8, of the top side A3 and bottom side B3 of thethird portion 10. Further, the secondadhesive layer 20 may be applied to an outer edge, opposite to the edge adjacent to thesecond portion 8, of the bottom side B1 of thefirst portion 6 as shown inFIG. 4 . The secondadhesive layer 20 of the first andthird portions portions portions assemblies - When the
portions assemblies adhesive layer 20 located on the bottom side B3 of thethird portion 10 adheres the bottom side B3 of thethird portion 10 to the bottom side B2 of thesecond portion 8. Further, the secondadhesive layer 20 on the top side A3 of thethird portion 10 adheres the top side A3 of thethird portion 10 to the bottom side B1 of thefirst portion 6, and the secondadhesive layer 20 on the bottom side B1 of thefirst portion 6 adheres the bottom side B1 of thefirst portion 6 to the top side A3 of thethird portion 10. As a result, thethird portion 10 and thefilm 18 are located or positioned between the bottom side B1 of thefirst portion 6 and the bottom portion B2 of thesecond portion 8 as shown inFIG. 8 . Moreover, the top side A1 of thefirst portion 6, displayingindicia 12, and the top side A2 of thesecond portion 8, displayingindicia 12, are exposed or facing outward such that theindicia 12 is displayed to or viewable by a consumer viewing theassemblies FIGS. 1 , 2 and 7. - In
FIG. 8 , theproduct 4 was positioned in thewindow 14 formed in thefirst portion 6 prior to the folding of theportions portions adhesive layer 16 adheres theproduct 4 to the top side A3 of thethird portion 10, and theproduct 4 pushes against and/or stretches thefilm 18 covering thewindow 14 and extends outwardly away from the top side A1 of thefirst portion 6. As a result, thefilm 18 is stretched outwardly by theproduct 4 and theproduct 4 is enclosed, housed, stored and/or secured between thefilm 18 and thesecond portion 8, thethird portion 10 and/or the firstadhesive layer 16. - In an embodiment, the first
adhesive layer 16 may be excluded from theassemblies film 18 may apply a force to theproduct 4 in the direction towards the top side A3 of thethird portion 10. As a result, theproduct 4 may be held or maintained in position within thewindow 14 betweenfilm 18, thesecond portion 8 and/or thethird portion 10. - Subsequently the consumer may, if desired, examine and/or view the
product 4 which extends outwardly from thewindow 14 formed in thefirst portion 6 of thesheet 5 as shown inFIGS. 1 and 2 . Thewindow 14 allow the consumer or another third party to visually and/or physically examine theproduct 4 being displayed and/or packaged by theassemblies product 4 via thewindow 14, a consumer may desire to purchase theproduct 4 being displayed and/or packaged by theassemblies - The first
adhesive layer 16, the secondadhesive layer 20, thesheet 5 and/or thefilm 18 may prevent or substantially prevent theproduct 4 from being separated or removed from theassemblies adhesive layer 16, the secondadhesive layer 20, thesheet 5 and/or thefilm 18 may prevent or reduce theft of, damage to and/or destruction of theproduct 4 by firmly securing theproduct 4 within theassemblies - When the
product 4 pushes against or stretches thefilm 18 outwardly away from the top side A1 of thefirst portion 6, thefilm 18 may be contoured to one or more outer surfaces of theproduct 4 and/or theproduct 4 may be completely enclosed between thefilm 18 and first adhesive layer, thesecond portion 8 and/or thethird portion 10. By enclosing theproduct 4, thefilm 18, theportions adhesive layer 16 may prevent or reduce theft of, damage to, destruction of, opening of, activating of, tampering with and contamination of theproduct 4. Additionally, enclosing theproduct 4 may reduce exposure to dust, dirt and/or surrounding environmental conditions and/or elements. -
FIG. 1 shows theassembly 2 displaying theproduct 4 in thewindow 14 enclosed between thefilm 18 and theportions sheet 5.FIG. 2 shows theassembly 100 displaying a plurality ofproducts 4 in a plurality ofwindows 14 enclosed between thefilm 18 and theportions sheet 5.FIG. 3 shows the front side of thesheet 5 comprising the top side A1 of thefirst portion 6, the top side A2 of thesecond portion 8, the top side A3 of thethird portion 10, thewindow 14, and thefilm 18 covering thewindow 14. In embodiments, the second adhesive layer may be positioned on the outer edge of the top side A3 of thethird portion 10 of thesheet 5 for connecting, attaching and/or adhering an additional structural feature to theassembly 2, such as, for example, a hologram, a product sample and/or a selling feature or the like. -
FIG. 4 shows the back side of thesheet 5 comprising the back side B1 of thefirst portion 6, the back side B2 of thesecond portion 8, the back side B3 of thethird portion 10, thewindow 14 covered by thefilm 18, the secondadhesive layers 20 positioned on the outer edges of the bottom side B1 of thefirst portion 6 and the bottom side B3 of thethird portion 10, and thefilm 18 connected or adhered to the bottom side of thesheet 5 via the second adhesive layers. -
FIG. 5 shows theproduct 4 positioned in thewindow 14 and supported in thewindow 14 by thefilm 18 covering thewindow 14 and the bottom side B3 of thethird portion 10 being folded onto the bottom side B2 of thesecond portion 8. Theproduct 4 may be hand loaded into thewindow 14 of thesheet 5 or may be automatically loaded by a fed machine or apparatus. When theproduct 4 is loaded, the product pushes or stretches thefilm 18 covering the window outward with respect to the top side A1 ofportion 6 of thesheet 5. As a result, a film pocket, having an initial depth and/or width, is formed which contains and/or housing the product. When the bottom side B3 of thethird portion 10 is folded onto the bottom side B2 of thesecond portion 8, thefilm 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width. As a result, theproduct 4 may be more accurately positioned in and/or displayed within thewindow 14 and/or the film pocket having the adjustable depth and/or width. - After the
sheet 5 is dispensed and loaded with theproduct 4, thesheet 5 is conveyed into subsequent next machine section or station, where thesheet 5 will be automatically glued or adhered, folded and sealed to produce the foldedassembly 2. Prior to producing the folded assembly, thefirst adhesive 16 and/or the second adhesive 20 may be applied to one or more portions of theportions portions assembly 2. The folding may be accomplished by human hands; however, theconveyor belt system 30, which may be continuously moving, may be utilized to produce the foldedassembly 2. In embodiment, at least to stationary machinery rails or elements 22 (hereinafter “stationary elements 22”) may be positioned under thefirst portion 6 and adjacent to the top side A1 of thefirst portion 6. As a result, thesheet 5 or thefirst portion 6 of thesheet 5 may be supported and/or maintained in a fixed position via thestationary elements 22. At least one movable machinery rail or element 24 (hereinafter “movable element 24”) may lift thethird portion 10 upwards and/or towards thefirst portion 6 as shown inFIG. 5 . As a result, thethird portion 10 is folded onto thesecond portion 8 and the bottom side B3 of thethird portion 10 is adjacent to or in direct contact with the bottom side B2 of thesecond portion 8. The secondadhesive layer 20 on the bottom side B3 of thethird portion 10 connects, attaches and/or adheres the bottom side B3 of thethird portion 10 to the bottom side B2 of the second portion. As a result, themovable element 24 is adjacent to the top side A3 of thethird portion 10 as shown inFIG. 6 . The positioning angle of themovable element 24 may be adjusted to adjust the depth of the film pocket formed by thefilm 18 that houses theproduct 4. As a result, the adjusted positioning angle of themovable element 24 regulates, adjusts and/or controls the product film blister depth upwardly or downwardly as required or desired. - The
stationary elements 22 and/or the movable element 24 (hereafter collectively referred to as “elements sheet 5 through a package finishing process to produce, form and/or assemble theassemblies sheet 5 may be automatically dispensed with film adhered thereto, and then thesheet 5 may be fed onto a specialized conveyor for loading theproduct 4 by hand or automatically. -
FIG. 6 shows the secondadhesive layers 20 positioned on the top side A3 of thethird portion 10 and the bottom side B1 of thefirst portion 6 of thesheet 5 which is supported by thestationary elements 22. Themovable element 24 is subsequently positioned under thesecond portion 8, located below thethird portion 10 after the folding of thethird portion 10 onto thesecond portion 8, and lifts the second andthird portions first portion 6. As a result, the top side A3 of thethird portion 10 is folded onto the bottom side B1 of thefirst portion 6 as shown inFIG. 7 . When the top side A3 of thethird portion 10 is folded onto the bottom side B1 of thefirst portion 6, thefilm 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width. As a result, theproduct 4 may be more accurately positioned in and/or displayed within thewindow 14 and/or the film pocket having the adjustable depth and/or width. - Alternatively, the
third portion 10 may be folded onto thefirst portion 6 by hand. The top side A3 of thethird portion 10 and the bottom side B1 of thefirst portion 6 are connected, attached and/or adhered together via the second adhesive layers positioned on the top side A3 of thethird portion 10 and/or the bottom side B1 of thefirst portion 6. As a result, theproduct 4 is enclosed, packed, encircled and/or stored between thefilm 18 and thesecond portion 8 and/or thethird portion 10 as shown inFIG. 8 . - In an embodiment, the film may be micro-perforated with micro-openings or micro-pores (not shown in the drawings) which may be invisible to the naked eye. The micro-openings or micro-pores may extend across a portion of the surface area of the
film 18 or across the entire surface area of thefilm 18. The micro-openings or micro-pores allow air to escape or pass as theportions assembly 2. Additionally, the micro-openings or micro-pores allow or facilitate improved adhesive penetration by the second adhesive layers and improved bond strength between theportions sheet 5. - Prior to folding the
third portion 10 onto thefirst portion 6, the firstadhesive layer 16 may be applied and/or positioned directly onto the back side of theproduct 4 and/or onto an area of the top side A3 of thethird portion 10. As thethird portion 10 is folded onto thefirst portion 6, the top side A3 of thethird portion 10 applies force to the back side of theproduct 4 which causes theproduct 4 to push against and/or stretch thefilm 18 outwardly away from the top side A1 of thefirst portion 6 as shown inFIG. 8 . As a result, a pocket is formed by thefilm 18 that matches or substantially matches the outer perimeter of theproduct 4. The pockets depth adjustment is made by changing the angles of the elements with respect to the position of thesheet 5. The firstadhesive layer 16 adheres the back side of theproduct 4 to the top side A3 of thethird portion 10 to secure and protect theproduct 4 within theassembly 2. Moreover, the firstadhesive layer 16 may prevent or substantially reduce movement of, turning of and/or any unwanted position changes of theproduct 4 after production of theassembly 2. - After the
assembly 2 has been produced and theproduct 4 is enclosed and packaged within theassembly 2. Theassembly 2 may be passed through a low temperature heat tunnel, which eliminates or substantially reduces any wrinkles or folds that may have formed in thefilm 18 caused by theproduct 4. As a result, theproduct 4 wrapped within thefilm 18 exhibits a surprising and unexpected sparkling finished appearance. Further, by passing theassembly 2 through the low temperature heat tunnel, thefilm 18 wraps tightly or closely around theproduct 4. The low temperature heat tunnel may be maintained at, but is not limited to, a temperature range from about 100° F. to about 350° F. The necessary temperature of the heat tunnel is directly related to production speed of theassembly 2. If the production speed is high, such as, for example, three-hundred assemblies per minute, then the temperature of the heat tunnel should be maintained at a range of about 200° F. to 300° F. Theassembly 2 may completely pass through the heat tunnel in a time duration of greater than 0.1 second to no more than 5 seconds. In embodiments, the time duration may be from 0.25 to 3 seconds, 0.5 to 2.5 seconds or 1 to 2 seconds. -
FIG. 9 shows a partial cross-sectional view of a foldedassembly 2, which was produced by the method illustrated inFIG. 5-7 , positioned on theconveyor belt system 30. In embodiments, anadjustable cavity 32 may be built or incorporated into theconveyor belt system 30 which may be adjustable to a width and/or depth that corresponds to the dimensions of theproduct 4 and/or dimensions of the film pocket formed by thefilm 18 housing theproduct 4. As a result, the placement and/or position of theproduct 4 in the film pocket may be controlled and/or adjusted by theadjustable cavity 32 of theconveyor belt system 30. - In embodiments, a vacuum producing device 34 may be built or incorporated into the
conveyor belt system 30 such that the vacuum producing device 34 may apply or provide downward vacuum holding forces (illustrated by the downward arrows towards the vacuum producing device 34) to thesheet 5, the top side A1 of thefirst portion 6, theproduct 4 and/or thefilm 18. As a result of the downward vacuum holding forces, thesheet 5, the top side A1 of thefirst portion 6, theproduct 4 and/or thefilm 18 may be held or pulled tightly or firmly against a top side of theconveyor belt system 30 during the assembly process for producing and/or folding the foldedassembly 2. The vacuum holding forces may be applied by the vacuum producing device 34 during one or more portions of the assembly process or during the entire assembly process for producing the foldedassembly 2. - In embodiments, at least one section or portion of the
sheet 5 may be held flat against theconveyor belt system 30 via the vacuum holding forces, and another section or portion of the sheet may be controlled or moved up or down by the at least onemovable element 24. As a result, physical control of the depth film pocket may be achieved by theconveyor belt system 30. In embodiments, high speed control of the film pocket and product is essential to a successful machine outcome. - An added value added by inclusion of the vacuum holding force to the
conveyor belt system 30, with adjustable cavity, may be exact sheet/card and film pocket is exact product position and control through the entire process. Another added advantage from adding vacuum holding forces to theconveyor belt system 30, is that a downward holding force may be exerted on both the film pocket andproduct 4, when thefilm 18 may be micro-perforated, which may allow the air and therefore the vacuum force to also pass through thefilm 18 and apply the same downward force onto theproduct 4 and not just to thefilm 18 into the adjustable cavity. This extra card/sheet control, film pocket and product holding force may a significant advantage over known conveyor belt system. As a result, it may be extremely significant and influential in achieving the highest line speeds possible, while still maintaining the correct product and film pocket control through the complete assembly process, to produce very high quality carded and acceptable finished goods. -
FIGS. 10-12 show another method of folding theportions assembly 2. Thefirst portion 6 may be located or positioned between the second andthird portions window 14 formed therein, whereby thefilm 18 may be connected and/or covering the back sides of theportions product 4 may be loaded into thewindow 14 and contacting thefilm 18 covering thewindow 14. The width of thethird portion 10 may be less than the widths of the first andsecond portions FIGS. 10 and 11 or may be the same or substantially the same as the widths of the first andsecond portions FIG. 10 . The secondadhesive layer 20 may be applied onto or provided at one or more portions of the back side B1 of thefirst portion 6, the back side B2 of thesecond portion 8 and/or the back side B3 of the third portion. The first adhesive layer may be applied onto the back side of theproduct 4 and/or provided at one or more portions of the back side B2 of the second portion and/or the back side B3 of thethird portion 10. - As shown in
FIG. 10 , theconveyor belt system 30 may have at least twostationary elements 22, which may be positioned and/or located under thefirst portion 6, and/or at least twomovable elements 24 whereby onemovable element 24 is positioned or located under thesecond portion 8 and anothermovable element 24 is positioned or located under thethird portion 10. As a result, thestationary elements 22 support thecard 5 and themovable elements 24 rise or move to fold and/or adhere the back side B3 of thethird portion 10 and the back side B2 of thesecond portion 8 onto the back side B1 of thefirst portion 6 to produce the foldedassembly 2. - In embodiments, the
movable element 24 positioned under thethird portion 10 may move, rise and/or lift thethird portion 10 such that the bottom side B3 of thethird portion 10 is folded onto and/or adhered to the bottom side B1 of thefirst portion 6 as shown inFIG. 11 . As a result, a portion of theproduct 4 may be enclosed and/or positioned between the bottom side B3 of thethird portion 10 and thefilm 18 covering thewindow 14. In embodiments, one or more portions of the top side A3 of thethird portion 10 may have the secondadhesive layer 20 applied thereon for adhering the second andthird portion assembly 2. When the bottom side B3 of thethird portion 10 is folded onto the bottom side B1 of thefirst portion 8, thefilm 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width. As a result, theproduct 4 may be more accurately positioned in and/or displayed within thewindow 14 and/or the film pocket having the adjustable depth and/or width. - In embodiments, the
movable element 24 positioned under thesecond portion 8 may move, rise and/or lift thesecond portion 8 such that the bottom side B2 of thesecond portion 8 is folded onto and/or adhered to the bottom side B1 of thefirst portion 6 and/or the top side A3 of thethird portion 10 to produce the foldedassembly 2 as shown inFIG. 12 . As a result, the remaining and/or uncovered portion of theproduct 4 may be enclosed, sealed, secured and/or positioned between the bottom side B2 of thesecond portion 8 and thefilm 18 covering thewindow 14. In embodiments, the secondadhesive layer 20 seals and/or adheres theportions assembly 2 and/or the firstadhesive layer 16 secures and/or adheres the product to second andthird portions second portion 8 is folded onto the bottom side B1 of thefirst portion 6, thefilm 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width. As a result, theproduct 4 may be more accurately positioned in and/or displayed within thewindow 14 and/or the film pocket having the adjustable depth and/or width. - In embodiments, the
sheet 5 may be divided, separated, petitioned, cut, scored and/or folded into a plurality of foldable portions as shown inFIG. 13 . Thewindow 14 is formed in thefirst portion 6 of thesheet 5, the top and bottom edges of thefirst portion 6 are attached and/or connected to thethird portion 10 which is foldable onto the back side B1 of thefirst portion 6, and the left and right edges of thefirst portion 6 are attached and/or connected to thesecond portion 8 which is foldable onto the back side B1 of thefirst portion 6. Thefilm 18 may be attached or connected to or may cover one or more portions of the back sides of theportions film 18 may be attached or connected to or may cover all back sides of theportions FIG. 13 . - The
product 4 may be loaded into and/or positioned in thewindow 14 on thefilm 18 such that the film pocket extending outwardly way from the top side A1 of the first portion is formed by thefilm 18 and theproduct 4. Thethird portion 10 located at the top and bottom edges of thefirst portion 6 may be fold inward and/or onto the back side B1 of thefirst portion 6 as illustrated by the arrow extending from the bottom side B3 of thethird portion 10 to the bottom side B1 of thefirst portion 6 as shown inFIG. 10 . As a result, upper and lower portions of thesecond portion 8 may also fold inward and/or onto the back side B2 of the second portion as shown inFIG. 14 . - The back side of the
product 4 may be at least partially covered by thethird portion 10 such that at least a portion of theproduct 4 in the film pocket is enclosed between thefilm 18 and thethird portion 10. When the bottom side B3 of thethird portion 10 is folded onto the bottom side B1 of thefirst portion 6 and/or the bottom sides B2 of the upper and lower portions of thesecond portion 8 are folded on the bottom side B2 of thesecond portion 8, thefilm 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width. As a result, theproduct 4 may be more accurately positioned in and/or displayed within thewindow 14 and/or the film pocket having the adjustable depth and/or width. - The
second portion 8 located on at the right and left edges of thefirst portion 6 may be folded inward and/or onto the back side B1 of thefirst portion 6 as illustrated by the arrows extending from the back side B2 of thesecond portion 8 to the bottom side B1 of thefirst portion 6. Thesecond portion 8 located on the right and left edges of thefirst portion 6 may contact each other and/or may seal theproduct 4 within the foldedassembly 2 as shown inFIG. 15 . As a result, the foldedassembly 2 is provided and theproduct 4 is sealed, secured and/or enclosed between thefilm 18 and the second andthird portions sheet 5 as shown inFIGS. 15 and 16 . When the bottom side B2 of thesecond portion 8 is folded onto the bottom side B1 of thefirst portion 6, thefilm 18 at the film pocket may become more relaxed or may have an increased relaxation and the initial depth and/or width of the film pocket may be increased to an adjustable depth and/or width. As a result, theproduct 4 may be more accurately positioned in and/or displayed within thewindow 14 and/or the film pocket having the adjustable depth and/or width. - First
adhesive layers 20 may be provided or applied onto one or more portion of the back sides of theportions FIG. 13 . When the second andthird portions first portion 6, the firstadhesive layers 20 may adhere theportions assembly 2. In embodiments, the firstadhesive layer 16 may be provided or applied to theproduct 4 and/or one or more portions of the back sides B2, B3 of the second andthird portions FIG. 10 . As a result, the secondadhesive layer 16 may adhere theproduct 4 to at least a portion of the second andthird portions third portions first portion 6. -
FIG. 17 shows theproduct 4 connected, attached and/or adhered to acarrier 42 prior to theproduct 4 andcarrier 42 being loaded into thewindow 14 that is covered with thefilm 18. The first adhesive 16 layer may be applied to theproduct 4 and/or thecarrier 42 prior to connecting theproduct 4 and thecarrier 42 together. As a result, the firstadhesive layer 16 may adhere theproduct 4 to thecarrier 42 prior to placing theproduct 4 andcarrier 42 in thewindow 14 of thefirst portion 6. Thecarrier 42 may be made of one or more materials selected from the group consisting of paper corrugated or wood based materials, blister boards, coated styrene butadiene styrene, corrugated fibreboard, E-Flute corrugated fibreboard, stone paper, ceramic sheets, wood, melamine, standardized layers or sheets or combinations thereof. It should be understood that the present disclosure is not limited to a specific embodiment of the materials that may be used to make thetop card 10, thebottom card 20 and/or thecarriers 30 of thesystem 2. - The perimeter of the
carrier 42 may have the same or substantially the same shape, size, configuration and/or dimensions as the perimeter of thewindow 14 of thefirst portion 6. When theproduct 4 andcarrier 42 are loaded and/or positioned within thewindow 14 prior to folding the second andthird portions first portion 6, the perimeter or outer edges of thecarrier 42 may contact, abut and/or be adjacent to the perimeter or outer edges of thewindow 14 as shown inFIG. 18 . Frictional forces may be applied to or present at the perimeter or outer edges of the carrier and the perimeter or outer edges of thecarrier 42. As a result of the frictional forces, thecarrier 42 may be firmly connected, attached and/or secured to the perimeter of thewindow 14 such that thecarrier 42 and theproduct 4 may not be separated or removed from thewindow 14 without application of an external force or pressure. Moreover, theproduct 4 is firmly connected, attached and/or secured within thewindow 14 via thecarrier 42. - The
assemblies sheet 5 may comprise a tamper evident system or element (not shown in the drawings). The tamper evident element may comprise, but is not be limited to, detectable nano-particles, watermarks, 3-D security images or elements, RFID tags, bar codes, 3-D security ribbons and color-changing elements or ink wells. The tamper evident element provides an anti-counterfeiting feature for theassemblies - Producing, forming and assembling the
assemblies conveyor belt 30 havingstationary elements 22, at least onemovable element 24, and, optionally, a heat tunnel achieve fast, high speed production of theassemblies assemblies -
FIG. 19 shows a back side of asheet 5 petitioned, cut or scored into threeportions window 14 formed in thefirst portion 6 and thethird portion 10, and aproduct 4 connected, attached, adhered, banded and/or affixed to acarrier 42. Theproduct 4 andcarrier 42 are sealed in a bag made of a film material, such as,film 18. Thewindow 14 may extend to or end at the one side of the perimeter of thethird portion 10 of thesheet 5. Thewindows 14 may be sized, shaped and/or configured to receive and/or house theproduct 4 sealed in the bag offilm 18. As a result, at least a portion of theproduct 4 may extend through thewindows 14 after the first andthird portions second portion 8. - One or more portions of the back sides B1, B2 and/or B3 of the first, second and
third portions first adhesive 16 and/or thesecond adhesive 20. For example more than one portion of the back side B1 of thefirst portion 6 and/or the back side B3 of thethird portion 10 may be provided or coated with the first adhesive 16 as shown inFIG. 19 . The first adhesive 16 on thethird portion 10 adheres, connects, attaches and/or fastens the back side B3 of thethird portion 10 to the back side B2 of thesecond portion 8, and the first adhesive 16 on thefirst portion 6 adheres, connects, attaches and/or fastens the back side B1 of thefirst portion 6 the front side A3 of thethird portion 10. -
FIG. 20 illustrates the back side B3 of thethird portion 10 of thesheet 5 having been folded onto the back side B2 of the second portion such that the top side A3 of thethird portion 10 is exposed and/or adjacent to the back side B1 of thefirst portion 6. As a result, the second andthird portions pocket 50 is formed, produced and/or provided between the back sides B2, B3 of the second andthird portions pocket 50 formed between the second andthird portions product 4 andcarrier 42 that may sealed in the bag offilm 18. -
FIG. 21 illustrates theproduct 4 andcarrier 42 sealed in the bag offilm 18 being inserted into thepocket 50 formed between the back sides B2, B3 of the second and third portions, respectively. Theproduct 4 andcarrier 42 sealed in the bag offilm 18 may be inserted into thepocket 50 by hand, by machine or a combination thereof. The dimensions of thepocket 50 and/or thewindow 14 may be sized, shaped and/or configured such that theproduct 4 and/or thecarrier 42 may be correctly aligned and/or held in a required or predetermined product placement position automatically by insertion into thepocket 50 and/orwindow 14 of thethird portion 10. As a result of the size, shape and/or configuration of thepocket 50 and/or thewindow 14, the correct alignment and/or holding is achieved automatically as the sealedproduct 4 and/orcarrier 42 are loaded, inserted and/or slid in thepocket 50 formed between the second andthird portion pocket 50 created by folding thethird portion 10 onto thesecond portion 8 may form, create and/or provide a matching lock-fit for theproduct 4 and/orcarrier 42 which may automatically position, secure, enclose, house and/or fix thecarrier 42 holding the film wrappedproduct 4 in a correct or predetermined position as theproduct 4 and/orcarrier 42 are inserted or slid into thepocket 50. -
FIG. 22 shows entire lengths of theproduct 4 andcarrier 42, sealed in the bag offilm 18, inserted, moved, slid and/or positioned into thepocket 50 formed between the second andthird portions second portion 8 may be exposed below the bottom of theproduct 4 and/or thecarrier 42. One or more portions of thecarrier 42 positioned the back sides B2, B3 of the second andthird sides carrier 42 to thesheet 5. As a result, theproduct 4 may be connected, attached, secured to thesheet 5 via thepocket 50 and/or thecarrier 42. -
FIG. 23 shows the foldedassembly 2 after the back side B1 of thefirst portion 6 has been folded onto the front portion A3 of thethird portion 10. As a result, at least portions of thecarrier 42 are enclosed, housed, secured and/or encircled in at least portions of thefirst portion 6 and thesecond portion 8 and/or thethird portion 10. Further, at least portions of thecarrier 42 are enclosed, housed and/or secured between the back side B2 of thesecond portion 8 and at least one of the back sides B1, B3 of the first andthird portions carrier 42 is secured to the foldedassembly 2 via theportions sheet 5. The first adhesive 16 on the back side B1 of thefirst portion 6 may connect, attach and/or adhere the back side B1 of thefirst portion 6 to front side A3 of thethird portion 10. As a result, thefirst portion 6 may be connected, attached and/or adhered to the second and/orthird portions first adhesive 16. - As the
first portion 6 is being folded onto thesecond portion 8, one or more portions of theproduct 4 may extend through thewindow 14 and/or away from the front side A1 of thefirst portion 6. Moreover, one or more portions of the front side A1 of thefirst portion 6 may display or be provided withindicia 12. One ormore portions sheet 5 may be folded onto one another or each other by hand or by use of one or more machines, such as, for example,movable element 24. Theassembly 2 may then pass through the heat tunnel to remove any film folds and/or wrinkles that may be present in the bag offilm 18 that seals theproduct 4 and/or thecarrier 42. Passing through the heat tunnel may also provide a glossy shine or appearance to film 18 sealed around theproduct 4. In embodiments, a rear card cut out (not shown in the drawing) with perforations and/or score lines may be provided insecond portion 8 such that theassembly 2 may be easy opened to facilitate removal of the sealedproduct 4 and/orcarrier 42. - The embodiments shown in
FIGS. 19-23 provide significant improvements as to how thesheet 5 andcarrier 42 may quickly join together into the proper requested or predetermined product position format, in an easier, faster and much more exact and automatic product positioning process. These embodiments provide adjustments made to thesheet 5 andcarrier 42 joining system that offer many more inherent assembly advantages for either hand assemblies, machine assemblies or combinations thereof. These embodiments may be utilized with almost any size or shaped product to be carded and the correct position alignment may automatically be achieve when theassembly 2 and/orcarrier 42 are utilized in the presently disclosed manner. - The embodiments shown in
FIGS. 19-23 may eliminate the movement of products that may occur in a blister pack without adding extra items or adhesives, which may slow the assembly process. Also with all standard blister packages, the outside edges of blister packages may get “crushed” all around the cards outer edge which may also occur around each product on the blister package. This “crushing” is inherently caused by the standard blister packaging requires sealing process (i.e., time, temperature and pressure) and this “crushing” often happens to each and every blister card currently produced by known blister machines. The card “crushing” which may be totally eliminated along with problems with product movement by the assemblies and processes set forth in the present disclosure. Additionally, improved graphics may be achieved because the present assemblies and processes avoid the use of a blister coating to be applied over the printed artwork. -
FIG. 24 shows a back side of asheet 5 petitioned, cut or scored into threeportions window 14 formed in thefirst portion 6 and thethird portion 10, and aproduct 4 connected, attached, adhered, banded and/or affixed to acarrier 42. Theproduct 4 andcarrier 42 are sealed in a bag made of a film material, such as,film 18. Thewindows 14 may be sized, shaped and/or configured to receive and/or house theproduct 4 sealed in the bag offilm 18. As a result, at least a portion of theproduct 4 may extend through thewindows 14 after the first andthird portions second portion 8. - One or more portions of the back sides B1, B2 and/or B3 of the first, second and
third portions first adhesive 16 and/or thesecond adhesive 20. For example, more than one portion of the back side B1 of thefirst portion 6 and/or the back side B3 of thethird portion 10 may be provided or coated with the second adhesive 16 as shown inFIG. 24 for connecting, sealing and/or adhering the first, second and/orthird portions second portion 8 and may connect, attach, secure and/or adhere theproduct 4 and/or thecarrier 42 sealed in the bag offilm 18 to thesecond portion 8. The second adhesive 20 on thethird portion 10 adheres, connects, attaches and/or fastens the back side B3 of thethird portion 10 to the back side B2 of thesecond portion 8, and the second adhesive 20 on thefirst portion 6 adheres, connects, attaches and/or fastens the back side B1 of thefirst portion 6 the front side A3 of thethird portion 10. Upon folding thethird portion 10 onto thesecond portion 8 and thefirst portion 6 onto thethird portion 10, theproduct 4 andcarrier 42 may be enclosed, sealed, packaged and/or secured within or between one or more of the first, second and/orthird portions sheet 5. - In embodiments, the
carrier 42 may be sized, shaped and/or configured such that more than oneproduct 4 may be connected, attached, secured and/or adhered to thecarrier 42 which may subsequently be sealed in the film 18 (not shown in the drawings). The first andthird portions window 14 formed therein such that the more than oneproduct 4, connected to thecarrier 42, may extend through the more than onewidow 14 formed in the first andthird portions third portions second portion 8. -
FIG. 25 shows theproduct 4 andcarrier 42, sealed in the bag of film, have been positioned on or moved onto the back side B2 of thesecond portion 8 of thesheet 5. As a result, theproduct 4 andcarrier 42 are connected, attached, adhered and/or secured to the back side B2 of thesecond portion 8 via thefirst adhesive 16. Also shown inFIG. 25 is thethird portion 10 being folding and/or moved towards the back side B2 of thesecond portion 8. After the back side B3 of thethird portion 10 is folded and/or moved onto the back side B2 of thesecond portion 8, at least portions of theproduct 4 and/or thecarrier 42 may be located, positioned, enclosed and/or secured between the back sides B2, B3 of the second andthird portions FIG. 26 . The back side B3 of thethird portion 10 may be connected, attached, adhered and/or secured to the back side B2 of thesecond portion 8 via the second adhesive 20 on the back side B3 of thethird section 10. Further, one or more portions of thecarrier 42 may be positioned, located, enclosed and/or surrounded between the one or more portions of the second andthird portions product 4 may extend outwardly through thewindow 14 of thethird portion 10 and/or away from the front side A3 ofthird portion 10 as thethird portion 10 is being folded onto thesecond portion 8 and/or after the second and third portions have been adhered together. Furthermore, thefilm 18 wrapped around or enclosing theproduct 4 and thecarrier 42 may be pull tighter against or closer to theproduct 4 and/or thecarrier 42 by force applied by thethird portion 10 when thethird portion 10 is folded onto thesecond portion 8. -
FIG. 27 shows the foldedassembly 2 that is formed, produced and/or provided after the back side B1 of thefirst portion 6 has been folded onto the front side A3 of thethird portion 10. After the back side B1 of thefirst portion 6 is folded and/or moved onto the front side A3 of thethird portion 10, at least portions of theproduct 4 and/or thecarrier 42 may be located, positioned, enclosed and/or secured between the back side B2 of thesecond portion 8 and at least one the back sides B1, B3 of the first andthird portions FIG. 27 . As a result, the back side B1 of thefirst portion 6 may be connected, attached, adhered and/or secured to the front side A3 of thethird portion 10 via the second adhesive 20 on the back side B1 of thefirst section 6. Further, one or more portions of thecarrier 42 may be positioned, located, enclosed, surrounded between the one or more portions of thefirst portion 6 and at least one second andthird portions product 4 may extend outwardly through thewindow 14 of thefirst portion 8 and/or away from the front side Alof thefirst portion 6 as thefirst portion 6 is being folded onto thethird portion 10 and/or after the first andthird portions product 4 and/or thecarrier 42 are packaged, enclosed, stored and/or secured between at least portions of the first, second and/orthird portions assembly 2. One or more portions of the front side A1 of thefirst portion 6 may display and/or be provided withindicia 12 associated with theproduct 4. In embodiments, the bond strength between the backside B1 of thefirst portion 6 and the front side A3 of the third portion may be the same as or greater the bond strength between the backsides B2, B3 of the second andthird portions first portion 6 may be the same as or greater than the adhesive strength of the second adhesive 20 provided on thethird portion 10. As a result, folding of thefirst portion 6 onto thethird portion 10 may form, produce and/or provide the foldedassembly 2 which is firmly connected, adhered, sealed and/or secured for securely packaging the one ormore products 4 therein. - The
assembly 2, after being produced or provided by folding theportions film 18 that seals theproduct 4 and/or thecarrier 42. Passing through the heat tunnel may also provide a glossy shine or appearance to thefilm 18 sealed around theproduct 4. In embodiments, a rear card cut out (not shown in the drawing) with perforations and/or score lines may be provided in thesecond portion 8 such that theassembly 2 may be easy opened to facilitate removal of the sealedproduct 4 and/orcarrier 42. Loading theproduct 4 andcarrier 42 onto thesecond portion 8 and/or the folding of the first andthird portions second portion 8 may be accomplished by hand, by one or more machines (i.e., movable element 24), or by combinations thereof. - In embodiments, the
sheet 5 may be divided, separated, petitioned, cut, scored and/or foldable into twoportions FIG. 28 or into threeportions FIG. 29 . Thefirst portion 6 of thesheet 5 may have at least onewindow 14 formed through thesheet 5 as shown inFIGS. 28 and 29 . The front side A1 of thefirst portion 6 may displayfront card indicia 12 as shown inFIG. 1 . Theproduct 4 may be connected, attached and/or adhered to thecarrier 42 prior to theproduct 4 andcarrier 42 being loaded into thewindow 14 as shown inFIG. 30 . The first adhesive 16 layer and/or the secondadhesive layer 20 may be applied to theproduct 4 and/or thecarrier 42 prior to connecting theproduct 4 and thecarrier 42 together. As a result, the firstadhesive layer 16 and/or the second adhesive layer may connect, attach and/or adhere theproduct 4 to thecarrier 42 prior to placing theproduct 4 andcarrier 42 in thewindow 14 of thefirst portion 6. Theproduct 4 andcarrier 42 may be sealed or wrapped in a bag made of thefilm 18 prior to being into thewindow 14 of thefirst portion 6. - The perimeter of the
carrier 42 may have a different or substantially different shape, size, configuration and/or dimensions as the perimeter of thewindow 14 of the first portion and/or as the perimeter of theproduct 4 as shown inFIG. 30 . Theproduct 4 andcarrier 42 sealed or wrapped in the bag offilm 18 may be manually, or by machine, loaded into thewindow 14 of thefirst portion 6. The outer edges of the perimeter of thecarrier 42 may extend outwardly and/or away from thewindow 14 such that the outer edges contact one or more portions of the backside B1 of thefirst portion 6 when theproduct 4 and thecarrier 42 may be loaded into thewindow 14 of thefirst portion 6. After theproduct 4 andcarrier 42 is loaded into the window, the backside B2 of thesecond portion 8 may be folded onto the backside B1 of thefirst portion 6 as shown inFIG. 28 . As a result, the outer edges of thecarrier 42 may be secured, located, positioned, connected and/or attached to one or more portion of the backside B1 of thefirst portion 6 and/or backside B2 of thesecond portion 8. Moreover, at least the outer edges of thecarrier 42 may be secured within or between the backsides B1, B2 of the first andsecond portions third portion 10 is present as shown inFIG. 29 , the backside B3 of thethird portion 10 may be folded onto the top side A2 of thesecond portion 8. After theportions second adhesives portions portions assembly 2 as shown inFIG. 1 . - The outer edges of the
carrier 42 secured between the first andsecond portions portions portions product 4 may be fugitive glued to thecarrier 42 and overwrapped in a bag offilm 18. The top side A1 of the first portion may be feed onto the conveyor belt face down and then may be loaded from behind with thecarrier 42 and baggedproduct 4 loaded into thecutout window 14. Then the other one or two sides may be glued and compression folded over and closed. In an embodiment, thefilm 18 shown inFIG. 30 is a polyolefin. - In embodiments, the
sheet 5 may be divided, separated, petitioned, cut, scored and/or foldable into at least twoportions FIG. 31 . Thefirst portion 6 of thesheet 5 may have at least onewindow 14 formed through thesheet 5 as shown inFIG. 31 . The front side A1 of thefirst portion 6 may displayfront card indicia 12 as shown inFIG. 1 . A pre-formed blister 101 (hereinafter “blister 101”) may be sized and/or shaped to receive theproduct 4 as shown inFIG. 32 . In embodiments, theblister 101 may be made of a rigid or semi-rigid plastic or polymer material. In an embodiment, theblister 101 may be made of recycled polyethylene terephtalate. In embodiments, aflange 102 of theblister 101 may be coated or may receive thefirst adhesive 16 and/or thesecond adhesive 20 for adhering the first andsecond portions second portion 8 has been folded onto the backside B1 of thefirst portion 6. In embodiments, thefirst adhesive 16 and/or the second adhesive 20 may be provided on both sides of theflange 102 of theblister 101. - The
product 4 may be loaded into a pocket of theblister 101. Thewindow 14 of thefirst portion 6 may be sized and/or shaped to receive the product and/or the pocket of theblister 101 as shown inFIG. 33 . Thefirst adhesive 16 and/or second adhesive 20 provided on theflange 102 of theblister 101 may connect, attach and/or adhere theblister 101 to thefirst portion 6 when theblister 101 and theproduct 4 are loaded into thewindow 14. The backside B2 of thesecond portion 8 may be folded onto the backside B1 of thefirst portion 6. The exposed adhesive on theflange 102 of theblister 101 may connect, attach and/or adhere to the backside B2 of thesecond portion 8. At a result, the backsides B1, B2 of the first andsecond portions flange 102 of theblister 101. Moreover, theflange 102 of theblister 101 may be located, positioned and/or secured between the backsides B1, B2 of the first andsecond portions product 4 and/or theblister 101 may be secured between the first andsecond portions assembly 2 as shown inFIG. 1 . In embodiments, one or more portions of the backsides B1, B2 of the first andsecond portions second adhesives second portions second portion 8 is folded onto thefirst portion 6. - In embodiments, the
sheet 5 may be dispensed onto a conveyor belt, theblister 101 and theproduct 4 may be placed by hand or machine into thewindow 14, and then one or more portions of thesheet 5 and/orblister 101 may be glued and folded to produce theassembly 2. As a result, production ofassemblies 2 may be at about 100 assemblies to about 450 assemblies per minute. Current blister machine typically cycle, at best, about 20 cycles to about 22 cycles per minute. Moreover, producing theassembly 2 by coating both sides of theflange 102 of theblister 101 may or may not require tooling. - In embodiments, the
sheet 5 may be divided, separated, petitioned, cut, scored and/or foldable into at least twoportions window 14 may be formed in thefirst portion 6 and covered with thefilm 18 as shown inFIG. 34 . Theproduct 4 may be loaded, by hand or machine, into thewindow 14, and one or more portions of the backsides B1, B2 of the first andsecond portions assembly 2 as shown inFIG. 1 . In an embodiment, thefirst adhesive 16 and/or the second adhesive 20 may be provided on one or more portions of the backsides B1, B2 of the first andsecond portions second portions assembly 2. Theproduct 4 may push, force and/or stretch thefilm 18 outwardly when the first andsecond portions assembly 2. In embodiments, production of theassemblies 2 may be at about 100 assemblies to about 450 assemblies per minute. As a result, producers and/or manufactures of theassemblies 2 may achieve speeds that are about 5 times to about 7 times faster than typical known blister sealing systems. Moreover, production of theassembly 2 may eliminate “crush” marks from conventional blister packaging. In an embodiment, production of theassembly 2 may not require seal tooling to run or be utilized, which is a significant cost savings to the producer and/or manufacture of theassembly 2. - In embodiments,
assemblies system 200′) as shown inFIGS. 35-41 . For example, one ormore sheets 5 may be loaded onto thesystem 200, whereby one ormore products 4 and/or blisters 101 (optionally loaded with one or more products 4) may be subsequently loaded, placed, dropped and/or positioned within the one ormore windows 14 formed in the one ormore sheets 5, by hand or by machine, and the one ormore portions more sheets 5 may be folded onto each other to seal or close the one ormore sheets 5 and/or to produce theassemblies - In an embodiment, the
system 200 may comprise a body having a total length defined between afirst end 204 and asecond end 206 and a total width defined between afirst side 208 and asecond side 210. Thesystem 200 may comprise a plurality of conveyor belts 212 (hereinafter “belts 212”) which may extend along the entire length of thesystem 200 or at least along a portion of the entire length of thesystem 200. Eachbelt 212 may rotate around and/or may encircle one or more box supports 214 (hereinafter “supports 214”) which may physically provide support to the conveyor belt along the entire length of thesystem 200 or at least along a portion of the entire length of thesystem 200. Thesupports 214 may be made of a metal material or a stiff plastic or polymer material. As eachbelt 212 rotates around thesupports 214, the tension or firmness of thebelt 212 may remain constant, or substantially constant, as a result of the physical support provided by thesupports 214. In embodiments, an inner circumference of eachbelt 212 may be same as, substantially the same as, or greater than an outer circumference of the all of thesupports 214 that support eachbelt 212. - A plurality of crossbars 216 (hereinafter “
crossbars 216”) may extend across the entire width of thesystem 200 between thefirst side 208 and the second side 210 (hereinafter collectively known as “sides FIGS. 35 , 39 and 41. As a result, thesides crossbars 216. Thesupports 214 are movable connected, attached and/or fixed to thecrossbars 216 such that the supports, along with thebelts 212, may slide to any position between thesides supports 214 andbelts 212 are adjustable to any position between thesides cavities 218”) are provided or formed between thebelts 212 as shown inFIG. 35 . Thecavities 218 may be sized, shaped, configured and/or adapted to receive the one ormore products 4 and/or one ormore blisters 101 as shown inFIG. 41 . In embodiments, thesupports 214 and/orbelts 212 may be located at a first position to provide afirst cavity 218 that is sized and/or shaped to receiveproducts 4 and/orblisters 101 have a first size, a first shape and/or a first depth. Subsequently, thesupports 214 and/orbelts 212 may be moved to a second position to provide asecond cavity 218 that is sized and/or shaped to receiveproducts 4 and/orblister 101 having a second size, a second shape and/or a second depth. Moreover, the first size may be greater than or less than the second size, the first shape may be different than the second shape, and the first depth may be greater than or less than the second depth. - In embodiments, the
first end 204 of thesystem 200 may have loading components 220 (hereinafter “components 220”) which may comprise rollers, bars, platforms and/or the like as shown inFIGS. 35 , 38 and 40. The one ormore sheets 5 may be loaded onto thebelts 212 via thecomponents 220 such that thewindows 14 of thesheets 5 may be aligned with or may overlap thecavities 218 formed between thebelts 212 and/or thesupports 214 as shown inFIG. 41 . Thus, when theproducts 4 and/or theblisters 101 are loaded into thewindows 14 of thesheets 5, theproducts 4 and/or theblisters 101 are positioned or located within thecavities 218 between thebelts 212 and/or thesupports 214. - In embodiments, one or more trucks or holdown wheels 222 (hereinafter “
wheels 222”) may be positioned and/or located along the length of thebelts 212 as shown inFIGS. 35-37 and 40. Thewheels 222 may comprises rollers or components that maintain or holddown thesheets 5 onto thebelts 212 as thesheets 5 move along thebelts 212 from thefirst end 204 to thesecond end 206 of thesystem 200. Alternatively or additionally, the vacuum producing device 34 may be incorporated into thesystem 200 and/or located between thebelts 212 and/or within thecavities 218 such that the vacuum provided by the vacuum producing device 34 holds or maintains thesheets 5 in contact with the outer surface of thebelts 212 as thesheets 5 move along the length, or portion of the length, of thebelts 212. As a result, thesheets 5 may be in substantial contact, or complete contact, with the outer surface of thebelts 212 while the sheets move along the entire length, or at least a portion of the entire length, of thebelts 212 via thewheels 222 and/or the vacuum producing device 34. Thewheels 222 may be movably connected, attached or fixed to the body of thesystem 200 via one or more rods 224 (hereinafter “rods 224”) and/or one or more arms 226 (hereinafter “arms 226”) as shown inFIGS. 35 and 36 . As a result, thewheels 222 may be adjustable viarods 224 and/orarms 226 such that thewheels 222 may be positioned or movable to locations that are adjacent to and/or directly over the outer surface of theadjustable belts 212. - In embodiments, the
system 200 may have a first folding mechanism 228 (hereinafter “first mechanism 228”) and/or a second folding mechanism 230 (hereinafter “second mechanism 230”) located adjacent to or near thesecond end 206 of thesystem 200. Thefirst mechanism 228 may top fold at least one of theportion sheets 5 onto the other portions of thesheets 5 to enclose theproducts 4 and/orblisters 101 therein and to produce, create and/or form theassemblies second mechanism 230 may fold at least one of theportions sheets 5 sideway onto the other portions of thesheets 5 to enclose theproducts 4 and/orblister 101 therein and to produce, create and/or form theassemblies second mechanism 230 may be shaped as one or more curved or rounded blades that side folds the portions of thesheets 5 onto each other to produce theassemblies sheets 5 are being folded onto each other to form theassemblies first mechanism 228 and/or thesecond mechanism 230, adhesives, cohesion, pressure and/or heat from a heat tunnel seal the portions of thesheets 5 together such that theproducts 4 and/or theblisters 101 are enclosed therein and/or protected from subsequent tampering and/or environmental conditions. After sealing, theassemblies belts 212 and/or thesystem 200 for shipping and/or distribution. - It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems and/or methods. Also, various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, and are also intended to be encompassed by the present disclosure.
Claims (20)
1. A method for packaging retail products, the method comprising:
providing a sheet divided into a first part and a second part, wherein the first and second parts of the sheet are foldable with respect to each other, wherein the first part of the sheet has at least one window formed in the sheet;
loading a pre-formed blister, having at least one pocket preloaded with at least one retail product, into the at least one window formed in the sheet such that a portion of the pre-formed blister and a portion of the at least one retail product extends through the at least one window formed in the sheet; and
folding the second part of the sheet onto the first part of the sheet to produce a blister product assembly such that the at least one retail product is located between a portion of the pre-formed blister and a portion of the second part of the sheet.
2. The method according to claim 1 , wherein the method has a blister product assembly production rate from about 100 assemblies/minute to about 450 assemblies/minute.
3. The method according to claim 1 , wherein the sheet is made of paper-based materials, plastic or polymer-based materials or a combination thereof.
4. The method according to claim 1 , wherein the pre-formed blister is made of a rigid or semi-rigid plastic.
5. The method according to claim 1 , wherein the pre-formed blister is made of at least one polymer material.
6. The method according to claim 1 , further comprising:
coating an adhesive onto one or more sides of a flange of the pre-formed blister before the pre-formed blister is loaded into the at least one window formed in the sheet.
7. The method according to claim 6 , further comprising:
adhering the first and second parts of the sheet together, via the adhesive coated onto one or more sides of the flange of the pre-formed blister, when, or after, the second part is folded onto the first part of the sheet.
8. The method according to claim 1 , further comprising:
adhering the first and second parts of the sheet together via cohesion or an adhesive when, or after, the second part is folded onto the first part of the sheet to produce the blister product assembly.
9. The method according to claim 1 , further comprising:
dispensing the sheet onto a conveyor belt prior to loading the pre-formed blister into the window formed in the sheet.
10. The method according to claim 1 , further comprising:
placing the pre-formed blister, by hand or by machine, into the window formed in the sheet for loading the pre-formed blister into the window.
11. The method according to claim 1 , wherein the second part of the sheet has a window formed therein for receiving at least a portion of the pre-formed blister and/or a portion of the at least one retail product.
12. A method for packaging retail products, the method comprising:
positioning a sheet on a conveyor belt system comprising an adjustable cavity, wherein the sheet is divided into a first part and a second part, wherein the first and second parts of the sheet are foldable with respect to each other, wherein the first part of the sheet has at least one window formed in the sheet, wherein the at least one window formed in the sheet is located above the adjustable cavity of the conveyor belt system when the sheet is positioned on the conveyor belt system;
loading a pre-formed blister, having at least one pocket preloaded with at least one retail product, into the at least one window formed in the sheet such that a portion of the pre-formed blister and a portion of the at least one retail product extends through the at least one window formed in the sheet and into the adjustable cavity of the conveyor belt system; and
folding the second part of the sheet onto the first portion to produce a blister product assembly such that the at least one retail product is located between a portion of the pre-formed blister and a portion of the second part of the sheet.
13. The method according to claim 12 , further comprising:
adjusting a width and/or depth of the adjustable cavity of the conveyor belt system to correspond to dimensions of the at least one retail product and/or the preformed blister prior to loading the pre-formed blister into the at least one window formed in the sheet.
14. The method according to claim 12 , further comprising at least one selected from:
providing downward vacuum holding forces onto the sheet by a vacuum producing device of the conveyor belt system after the sheet is positioned on the conveyor belt system; and
providing downward vacuum holding forces onto the at least one retail product by the vacuum producing device after the at least one retail product is loaded into the at least one window formed in the sheet.
15. The method according to claim 12 , wherein the method has a blister product assembly production rate from about 100 assemblies/minute to about 450 assemblies/minute.
16. The method according to claim 12 , further comprising:
coating an adhesive onto one or more sides of a flange of the pre-formed blister before the pre-formed blister is loaded into the window formed in the sheet.
17. The method according to claim 16 , further comprising:
adhering the first and second parts of the sheet together, via the adhesive coated onto one or more sides of the flange of the pre-formed blister, when, or after, the second part is folded onto the first part of the sheet.
18. The method according to claim 1 , further comprising:
adhering the first and second parts of the sheet together via cohesion or an adhesive when, or after, the second part is folded onto the first part of the sheet to produce the blister product assembly.
19. The method according to claim 1 , further comprising:
placing the pre-formed blister, by hand or by machine, into the window formed in the sheet for loading the pre-formed blister into the window.
20. The method according to claim 1 , wherein the second part of the sheet has a window formed therein for receiving at least a portion of the pre-formed blister and/or a portion of the at least one retail product.
Priority Applications (1)
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US14/856,739 US20160083127A1 (en) | 2014-09-24 | 2015-09-17 | Blister package assemblies and systems and methods for producing said assemblies |
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US201462054679P | 2014-09-24 | 2014-09-24 | |
US201562212304P | 2015-08-31 | 2015-08-31 | |
US14/856,739 US20160083127A1 (en) | 2014-09-24 | 2015-09-17 | Blister package assemblies and systems and methods for producing said assemblies |
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US20200085349A1 (en) * | 2016-12-26 | 2020-03-19 | Metronom Health, Inc. | Adhesive systems having an aggressive adhesive outer ring along its bottom perimeter and having a low effective modulus of elasticity |
US10633128B2 (en) * | 2015-09-29 | 2020-04-28 | Swisslog Ag | Method and installation for producing a support for a product packaged in a unitary dose |
US20200139739A1 (en) * | 2018-11-05 | 2020-05-07 | Xerox Corporation | Method and apparatus for printing on media full bleed |
US20220144466A1 (en) * | 2019-02-26 | 2022-05-12 | Tepotec Mavins Sàrl | Security vacuum packaging and method for closing the security vacuum packaging |
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Publication number | Priority date | Publication date | Assignee | Title |
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US10633128B2 (en) * | 2015-09-29 | 2020-04-28 | Swisslog Ag | Method and installation for producing a support for a product packaged in a unitary dose |
US20200085349A1 (en) * | 2016-12-26 | 2020-03-19 | Metronom Health, Inc. | Adhesive systems having an aggressive adhesive outer ring along its bottom perimeter and having a low effective modulus of elasticity |
US20200139739A1 (en) * | 2018-11-05 | 2020-05-07 | Xerox Corporation | Method and apparatus for printing on media full bleed |
US20220144466A1 (en) * | 2019-02-26 | 2022-05-12 | Tepotec Mavins Sàrl | Security vacuum packaging and method for closing the security vacuum packaging |
US11897642B2 (en) * | 2019-02-26 | 2024-02-13 | Tepotec Mavins Sàrl (Gmbh, Llc) | Security vacuum packaging and method for closing the security vacuum packaging |
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