IE70321B1

IE70321B1 - Packaging of smoke alarm devices

Info

Publication number: IE70321B1
Application number: IE930998A
Authority: IE
Inventors: Michael Byrne; Michael Guinee; James Duignan; Keith Fawcett
Original assignee: E I Tech Ltd
Priority date: 1993-11-16
Filing date: 1993-12-22
Publication date: 1996-11-13
Also published as: GB2283727B; BE1006047A6; GB2283727A; GB9400042D0; IE930998A1

Abstract

A smoke alarm is packaged in a free standing clamshell package having an integral hinge 28. A clamshell half is mounted in an electrode base, and an information sheet is inserted into a blister portion 22. After insertion of the smoke alarm, an information sheet is placed in an engagement portion 24 with an aperture in the sheet receiving the smoke alarm. After closing of the clamshell, the two halves are welded along at least one side.

Description

70321 - la- "Packaciao of Ssaioke Alara Devices" The invention relates to packaging of smoke alarm devices,and in particular such devices for domestic use. A smoke alarm device is something which could, whenproperly used, save the lives of people in the event of a 5 fire in the home. Thus, when a manufacturer packages suchdevices, there are various extremely important objectivesin addition to the usual commercial objective of packagingthe device in such a way that it is aesthetically pleasingand looks well to the potential customer when stocked in 10 retail outlets. One such objective is that packagingshould in a very clear manner provide a large deal ofinformation for the consumer in a very clear manner whichis easily understood so that the device is used properly.Indeed, it is a well-known fact that smoke alarm devices 15 very rarely fail because of manufacturing faults but doquite often fail to provide the necessary alarm becausethey are not used properly by the consumer. Thus, theprovision of information in a very clear and easilyunderstandable manner in a packaged smoke alarm device is 20 an extremely important aspect. Another importantobjective is to ensure that the device is packaged in sucha way that it is not easily damaged during transit andstorage. Irrespective of how good the manufacturing andtesting procedures are, the product may still be damaged 25 after shipment and the only way in which the manufacturercan control this is by the way in which the device ispackaged.

From a purely commercial point of view it is alsoimportant that the device be packaged in such a way that 30 it has a very good appearance to the potential consumer sothat not only does it encourage additional sales of thedevices, but also encourages the consumer to buy higher- 70321 - 2 - specification modelse which models provide themanufacturer with a higher commercial margin. Smoke alarmdevices generally command quite a low retail price and itis therefore essential to build up sales to a high volumein order to make production more commercially viable andprofitable.

At present, smoke alarm devices are packaged on acardboard base onto which various advertising andtechnical information is imprinted, the device beingsurrounded by a plastics "blister" which is adhered to thecardboard base. The package is generally hung from a tagin a retail outlet, the tag being an aperture at the upperend of the cardboard base. One problem with sucharrangement is that the hang tag is easily torn, thusgiving the product a bad appearance and causing practicaldifficulties in storage of the product. A still furtherproblem is that the cardboard may be easily damaged or theblister and the packing may be separated by roughhandling, in which case at best the product does not havea good appearance and at worst, the product could bedamaged. A still further problem is that it is necessaryto hang the package in order to store it at a retailoutlet, which arrangement is not always convenient.Another problem is that all of the device projectsoutwardly from the cardboard backing sheet, thus makingthe product appear to be quite bulky. Indeed, in generalthis method of packaging provides very little versatilityin the manner in which the product is presented.

As described in GB 2185239 (Conair), US 4804984 (Haking),US 4749082 (Imperial Schrade), US 4687129 (VSI Fasteners),US 4558782 (Imperial Plastics) and US 3645384 (Wind), itis known to pack devices such as hair driers, a camera ora knife using clamshell packaging techniques. A problemwith such arrangements is that they do not provide the - 3 - specific requirements of smoke alarm device packaging suchas very durable packaging and provision of a large amountof customer information in a process which is veryinexpensive because of the high volume and low marginsinvolved.

The invention is directed towards providing a packagingmethod and a packaged smoke alarm device to overcome theseproblems .

According to the invention, there is provided a method ofpackaging a smoke alarm device, the method comprising thesteps of s - producing a clamshell packaging blank oftransparent plastics material having twointerengaging halves interconnected by an integralhinge, each half comprising an engagement portionfor nesting engagement with the other engagementportion, and each comprising a blister portion forenveloping a smoke alarm together with the otherblister portion the blister portions beingconfigured for enveloping a plurality of differentsmoke alarm models having broadly similar physicalcharacteristics, a blister portion being locatedand having formations to allow a packaged smokealarm unit to be free-standing with a lower sideedge and said formations engaging a surface; mounting one of the halves on a welding electrodebase; inserting an additional information sheet into theblister portion mounted in the electrode base; inserting a smoke alarm device into said blisterportion mounted in the electrode base; inserting an information sheet into the engagementportion of the half mounted on the electrode base; closing over the free half and engaging theengagement portions of the halves; and welding the two halves together along at least oneside.

According to another aspect, the invention provides apackaged smoke alarm unit comprising :- a clamshell packaging blank of transparentplastics material having two interengaging halvesinterconnected by an integral hinge, the halveshaving interengaging portions which are nestedtogether, the halves also comprising blisterportions enveloping a smoke alarm device, ablister portion being located and havingformations to allow the unit to be free-standingwith a lower side edge and said formationsengaging a surface, the two halves beingstitch-welded together along at least one side ofthe packaging blank; and an information sheet held in position between theengagement portions of the two halves.

Preferably, the two halves are welded together along twosides of the clamshell packaging blank.

Ideally, a top side of the packaging is not welded. 5 - In another embodiment, the engagement portion of each halfsurrounds the blister portion, and the information sheetsurrounds the smoke alarm device in the packaging blank.

Preferably, the engagement portions have snap-fit parts,5 preferably undercut configurations of the blank.

Preferably, the undercut configurations are at at leastone corner of an engagement portion.

In another embodiment, one half of the packaging blank hasa substantially deeper blister portion than the other for 10 reception of the smoke alarm device when it faces upwardlyaway from the blister portion and preferably the deeperblister portion has a depth approximately double that ofthe other blister portion. Ideally the deeper blisterportion has the formations to allow the packed smoke alarm 15 unit to stand freely.

The invention will be more clearly understood from thefollowing description of some embodiments thereof, givenby way of example only with reference to the accompanyingdrawings in which 20 Fig. 1 is a front view of a packaged smoke alarm device of the invention; Fig. 2 is a diagrammatic perspective view showing apackaging apparatus used in the method of theinvention; 25 Fig. 3 is a more detailed perspective view from above showing portion of the packaging apparatus; Fig. 4 is a perspective view showing a packaging blankused in the process; - 6 - Figs. 5, 6 and 7 are perspective views of a smoke alarm device, a backing information sheet, and a surround information sheet used in the process; Figs. 8A, 8B and 8C are perspective views showingdifferent packaging operations in detail; Fig. 9 is a diagrammatic, cross-sectional view showingsealing of a packaging blank; Fig. 10 is a perspective view from above showing thesealing operation; and Figs. 11A to HE inclusive are various views showing analternative packaging blank for use in the method ofthe invention.

Referring to the drawings and initially to Fig. 1 there isshown a packaged unit 1 which is a packaged smoke alarmdevice. The unit 1 comprises a smoke alarm device 2 whichis of the type for domestic use and which has lugs formounting on a wall or ceiling. The device 2 has a testbutton 3 mounted centrally on it. A clamshell package 4surround the device 2 and various information sheets andis sealed at stitch-welding seals δ. The unit 1 includesa hang-tag 5 for hanging of the product from a rail in aretail outlet. Various portions of the unit 1 aredescribed in more detail below.

Referringapparatusinvention, now to Fig. 2 there is shown a packaging10 for use in a packaging method of theThe apparatus 10 comprises a rotatable table 11 of aluminium material which is attached to an indexing unit, not shown. Four workstation base electrodes 12 are mounted on the table 11 and the table 11 is mounted on legs 13. These include internal auxiliary support walls - 7 - for packaging support. An upper electrode for use in awelding operation of the method is mounted above the table11 and this is part of a welding station 15» The baseelectrode 12 is shown in more detail in Fig. 3 and as isclear from this drawing, it forms a nest or seat forreception of a packaging blank used in the packagingmethod. The apparatus 10 includes a spiral guide 17 fixedto the central column. A safety door 18 is mounted at theinlet to the station 15 to prevent incorrectly assembledpackages from moving to the welding station 15.

Referring now to Fig. 4, a clamshell package or blank 4 isshown in more detail. The blank 4 comprises two "halves"20 and 21. The blank 4 is of integral transparentplastics material. The half 20 comprises a blisterportion 22 which is relatively deep and indeed has a depthof approximately two thirds of the depth of the smokealarm devices which it may accommodate. Variousadditional formations 23 are formed in the blister portion22 so that it can accommodate different models of smokealarm device having the same general shape but differingin physical construction by the addition or deletion oftags or lugs for securing to a wall or ceiling. The half20 also has an engagement portion 24 which is flat andrecessed with respect to a rim 26 which extends from asidewall 25 which extends upwardly with respect to theflat part of the engagement portion 24. The half 21comprises a blister portion 30 which is only approximatelyhalf of the depth of the blister portion 22 and hasregular contours without any additional formations. Thehalf 21 also comprises an engagement portion 31 having anaperture 33 corresponding with an aperture 27 of theengagement portion 24. The engagement portion 31 isconnected with a rim 32 by a downwardly-directed sidewall33 as viewed in Fig. 4. The two halves 20 and 21 arejoined by an integral two-way hinge 28. ~ 8 - A smoke alarm device 2 is shown in more detail in Fig. 5and an information backing sheet 40 is shown in Fig. 6.The sheet 40 is colour-printed with information on bothsides of it, the information printed on it beinginformation for installation and use of the smoke alarmdevice 2. In addition? there is a surround informationsheet 41 having a rectangular aperture 43 to allow itsurround the smoke alarm device 2 . Information printed onthe sheet 41 includes both technical and also advertisinginformation designed to provide a neat and attractiveappearance for the packaged smoke alarm device. The sheet41 has a hang tag aperture 43 corresponding to theapertures 27 and 33 of the packaging blank 4.

The packaging method of the invention is now describedwith reference to Figs. 8A? 8B and 8C. At one work-station of the indexing table 11? the half 20 of thepackaging blank 4 is mounted in the base electrode 12 asshown in Fig. 8. As described above the half 20 of theblank 4 has the deeper blister portion? beingapproximately two thirds of the depth of the smoke alarmdevice 2. The information sheet 40 is placed in theblister portion 22 also as shown in Fig. 8A. The sheet 40is placed so that the information which is to be viewedfrom the outside is facing downwardly. It will berecalled that the sheet is printed on both sides. Theindexing table 11 is then rotated so that the assembly ofFig. 8A is presented to another operator who inserts asmoke alarm device into the blister portion 22 facingupwardly as shown in Fig. 8B. The smoke alarm device 2nests quite easily and securely into the blister portion22 as it accommodates two thirds of the depth of the alarmdevice 2. It will be seen from Fig. 8B that only thatportion of the smoke alarm device 2 which has a neat?attractive looking regular appearance sits flush of the blister portion 22 and indeed^ the appearance of the smokealarm 2 is that it is slimmer than is actually the case.

As shown in Fig. 8CP the surround information sheet 41 isthen placed around the smoke alarm device 2. It will beappreciated from the drawings that the sheet 41 nestssecurely into the engagement portion 24 of the half 20between the sidewalls 25 and the smoke alarm device 2.The engagement portion 24 forms a seat or nest withinwhich the information sheet 40 is held in place. At thenext workstation, the half 21 is folded over so that theengagement portions 31 and 24 engage each other. Animportant aspect of the invention is the fact thatP asshown most clearly in Fig. 4, there is an undercut at thecorners of the engagement portion 31 and 24 so that thecorners of the engagement portion 31 snap into the cornersof the engagement portion 24. This is very important asit effectively locks the two halves together at the thirdwork station.

As the table rotatest the upper clamshell half is heldopen by the guide 17 and because of the guide's spiralarrangement the half is opened progressively as the tablerotates .

At the final workstation shown in Figs. 9 and 10P twohalves 20 and 21 are welded together with radio frequencywelding techniques. The upper electrode 14 has parallelbrass electrode members 50 which are aligned with the rims32 and 26 of the halves 21 and 20 respectively. Theelectrode members 50 have a saw-tooth lower profile andthe high frequency welding which takes place effectivelystitch-welds the two halves togethere the end result beingshown in Fig. 1. This leaves the top part of the packagedunit 1 free so that the consumer can put in his or herhand and tear the two halves apart after the unit has been 10 purchased. The upper electrode 14 is pre-heated to 90°C-100°C? thus minimising RF energy requirements. After RFwelding (typically 3 S) there is a dwell time of 0.5 to1.0 S for cooling? following which the electrode 14 isextracted. Foam pressure pads 51 mounted between themembers 50 ensure that there are no air gaps between theblister portions during welding. Further? thin plasticsstrips 52 on the base electrode help to prevent electrodearcing.

Referring now to Figs. 11A to HE inclusive? analternative construction of packaging blank for use in themethod of the invention is shown. The blank is indicatedby the numeral 60 and is for packaging of two smoke alarmdevices together. As is clear from the drawings? theblank 60 has rear and front halves 61 and 62 hingedtogether at an integral hinge 63. The halves 61 and 62have blister portions 22 and 30 respectively which areconfigured similarly to those described above. The halves60 and 61 also have engagement portions 64 and 65respectively which have undercut parts at four corners 66,67f 68 and 69. Backing information sheets used with theblank 67 are the same as the sheets 40 and the surroundsheet is only different by being longer to surround twoalarm devices. By use of the undercut corner formations66 to 69 and additional undercut formations 70 and 71, ablank 60 is held securely in position for the weldingoperation.

It will be appreciated that the invention provides apackaging method and also a packaging unit which is asignificant improvement over what has been availableheretofore. The packaging is much stronger than hasheretofore been the case and therefore? the unit canwithstand much more mishandling. There would be a muchlower discard rate because of damaged packaging and the - 11 alarm devices are much less likely to be damaged. Becausethe top side is open, the packaging is very easy to openwithout the need of a knifef which can be dangerous insuch a situation. The combination of stitch welding andthe open top side ensure that the consumer may easilyremove the device, howevere in the event of tampering byan unauthorised person, broken "stitches" provide anindication of tampering.

Because the packaging blank is of plastics material, thehang tag is not easily damaged and the product has a goodappearance. From the aesthetic point of view, the producthas a much neater and "slimmer" appearance because thepotential consumers view the product through the frontblister portion 30 which presents a slim-line appearanceof the product.

Another advantage of the invention is the fact that theformations 23 in the blister portion 22 allow the packageunit 1 to stand freely resting on a surface at the hinge28 and on the formations 23. This provides the option tothe retailer of allowing the products stand freely onshelves or alternatively to be hung from a rail. A further advantage is that the configuration of theengagement portions to provide for accurate fitting andsnapping together of the halves prior to radio frequencywelding so that this step may be carried out accuratelywith a low discard rate. Further the packaging blank maybe used with a wide range of smoke alarm .devices ofbroadly similar physical characteristics.

The invention is not limited to the embodiments hereinbefore described, but may be varied in construction and detail.

Claims

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1. A method of packaging a smoke alarm device, themethod comprising the steps of : - producing a clamshell packaging blank oftransparent plastics material having twointerengaging halves interconnected by anintegral hinge, each half comprising anengagement portion for nesting engagementwith the other engagement portion, and eachcomprising a blister portion for envelopinga smoke alarm together with the other blisterportion, the blister portions beingconfigured for enveloping a plurality ofdifferent smoke alarm models having broadlysimilar physical characteristics, a blisterportion being located and having formationsto allow a packaged smoke alarm unit to befree-standing with a lower side edge and saidformations engaging a surface; mounting one of the halves on a weldingelectrode base; inserting an additional information sheetinto the blister portion mounted in theelectrode base; inserting a smoke alarm device into saidblister portion mounted in the electrodebase; inserting an information sheet into theengagement portion of the half mounted on theelectrode base; 13 closing over the free half and engaging theengagement portions of the halves; and welding the two halves together along atleast one side.

2. A method as claimed in claim 1, wherein the twohalves are welded together along two sides of theclamshell packaging blank.

3. A method as claimed in claim 2, wherein a top sideof the packaging blank is not welded.

4. A method as claimed in any preceding claim,,wherein the welding operation stitch-welds thehalves together.

5. A method as claimed in any preceding claim,,wherein the engagement portion of each halfsurrounds the blister portion, and the informationsheet surrounds the smoke alarm device in thepackaging blank.

6. A method as claimed in any preceding claim,wherein the engagement portions have snap-fitparts .

7. A method as claimed in claim 5 wherein the snap-fit parts comprise undercut configurations of theblank.

8. A method as claimed in claim 7 where the undercutconfigurations are at at least one corner of anengagement portion. „ 14 =

9. A method as claimed in any preceding claim,wherein one half of the packaging blank has asubstantially deeper blister portion than theother for reception of the smoke alarm device whenit faces upwardly away from the blister portion.

10. A method as claimed in claim 9 wherein the deeperblister portion has a depth approximately doublethat of the other blister portion.

11. A method as claimed in claims 9 or 10 wherein theblister portion which has formations to allow thepacked smoke alarm unit to be free-standing is thedeeper blister portion.

12. A packaged smoke alarm unit comprising s- a clamshell packaging blank of transparentplastics material having two interengaginghalves interconnected by an integral hinge,the halves having interengaging portionswhich are nested together, the halves alsocomprising blister portions enveloping asmoke alarm device, a blister portion beinglocated and having formations to allow theunit to be free-standing with a lower sideedge and said formations engaging a surface,the two halves being stitch-welded togetheralong at least one side of the packagingblank; and an information sheet held in position betweenthe engagement portions of the two halves.

13. A unit as claimed in claim 12 wherein the blank iswelded along two sides of it. - 15

14. A unit as claimed in claims 12 or 13 wherein thetop side of the unit is free.

15. A unit as claimed in any of claims 12 to 14wherein the information sheet has an aperture tosurround the smoke alarm device.

16. A unit as claimed in any of claims 12 to 15wherein the engagement portions of the packagingblank halves are snap-fitted together.

17. A unit as claimed in claim 15engagement parts are snap-fittedundercut formations on the halves. wherein thetogether in

18. A unit as claimed in claim 17 wherein the undercutformations are at at least one corner of thepackaging blank.

19. A unit as claimed in any of claims 12 to 18(.wherein one half has a substantially deeperblister portion than the other half for receptionof the smoke alarm device when facing upwardlyaway from the blister portion.

20. A unit as claimed in claim 19 wherein the deeper blister portion has approximately double the depthof the other blister portion.

21. A unit as claimed in claim 20 wherein the blister portion which has formations to allow the unit to be free-standing is the deeper blister portion. 16

22.

23. 5 A method substantially as hereinbefore described,with reference to and as illustrated in theaccompanying drawings . A unit substantially as hereinbefore described,with reference to and as illustrated in theaccompanying drawings . Dated this 22nd day of December 1993CRUICKSHANK & CO. Agents for the Applicant1 Holies StreetDublin 2 10