Display pack and packaging method and apparatus

Abstract

A display pack for a consumer product is made of two sheets of corrugated cardboard and a clear plastic container with a flat insertion portion sandwiched between the cardboard sheets. The two cardboard sheets are adhered together in a peripheral area of the package by a heat-sensitive adhesive, and the corrugations of the cardboard sheets are crushed and flattened in the peripheral area. To seal the package, the peripheral area of the two cardboard sheets is subject to sufficient pressure to crush the corrugations inside the cardboard sheets and flatten them in that area. Heat is applied to the outer side of the cardboard sheets in the peripheral area and conducted to the adhesive material between the two sheets to activate the adhesive material. A sealer machine with a heated sealing press or parallel sets of heated rollers may be used to carry out the sealing process.

1 . A display pack for a product, comprising:
 a first and a second overlaying corrugated cardboard sheets, the first cardboard sheet having a first upper facing, a first lower facing and a first inner corrugated member with first corrugations and first air gaps between the first upper and first lower facings, the second cardboard sheet having a second upper facing, a second lower facing and a second inner corrugated member with second corrugations and second air gaps between the second upper and second lower facings, the first and second overlaying corrugated cardboard sheets forming a layered structure having an outer peripheral edge and an original thickness, at least one of the first and second cardboard sheets defining an opening;   at least one container having a flat insertion portion and a chamber portion for holding the product, the insertion portion having an outer edge and being sandwiched between the first and second cardboard sheets and the chamber portion protruding from a plane of the cardboard sheets via the opening, the overlaying cardboard sheets having at least one peripheral area extending inwardly from the outer peripheral edge to an inner area between the at least one peripheral area and the opening; and   an adhesive between the first and the second corrugated cardboard sheets in the at least one peripheral area to adhere the two corrugated cardboard sheets,   wherein the inner area includes at least one uncrushed area with substantially the original thickness and at least one crushed area in which the first and second air gaps therein are substantially eliminated, and   wherein the at least one peripheral area includes at least one crushed area in which the first and second air gaps therein are substantially eliminated.   
     
     
         2 . A display pack of  claim 1 , wherein the first and second corrugated cardboard sheets are formed from a folded single sheet of corrugated cardboard. 
     
     
         3 . A display pack of  claim 1 , wherein the at least one crushed area of the peripheral area includes a portion of the outer peripheral edge and extends inwardly from the outer peripheral edge about one-half inch to an inner boundary that extends generally parallel to the outer peripheral edge. 
     
     
         4 . A display pack for a product, comprising:
 a first and a second overlaying corrugated cardboard sheets, the first cardboard sheet having a first upper facing, a first lower facing and a first inner corrugated member with first corrugations and first air gaps between the first upper and first lower facings, the second cardboard sheeting having a second upper facing, a second lower facing and a second inner corrugated member with second corrugations and second air gaps between the second upper and second lower facings, the first and second overlaying corrugated cardboard sheets forming a layered structure having an original thickness, an outer peripheral edge and first and second outer surfaces, each of the first and second cardboard sheets defining an opening, the overlaying cardboard sheets having at least one peripheral area extending inwardly of the outer peripheral edge to an inner boundary and an inner area between the at least one peripheral area and the openings;   at least a first container and a second container, each container member having a flat insertion portion and a chamber portion, each insertion portion having an outer edge and being sandwiched between the first and second cardboard sheets and each chamber portion protruding from a plane of the cardboard sheets via a respective opening; and   an adhesive between the first and the second corrugated cardboard sheets in at least a portion of the at least one peripheral area to adhere the two corrugated cardboard sheets;   wherein the inner area has substantially the original thickness and the at least one peripheral area is crushed with reduced first and second air gaps therein to a thickness less than the original thickness.   
     
     
         5 . A display pack of  claim 4 , wherein the two container members are formed from a single piece of plastic. 
     
     
         6 . A display pack of  claim 4 , wherein the at least one peripheral area is crushed to form a depressed area on at least one of the first and second surfaces of the display pack. 
     
     
         7 . A display pack of  claim 4 , wherein the depressed area is only on the first surface of the display pack. 
     
     
         8 . A display pack of  claim 4 , wherein the depressed area is only on the second surface of the display pack. 
     
     
         9 . A display pack of  claim 4  having a first depressed area on the first surface and a second depressed area on the second surface. 
     
     
         10 . A display pack of  claim 4 , wherein the at least one crushed peripheral area includes a portion of the outer peripheral edge and extends inwardly from the outer peripheral edge about one-half inch to the inner boundary which extends generally parallel to the outer peripheral edge. 
     
     
         11 . A display pack of  claim 4 , wherein the first and second corrugated cardboard sheets are formed from a folded single sheet of corrugated cardboard. 
     
     
         12 . A display pack for two or more products, comprising:
 a first and a second overlaying corrugated cardboard sheets, the first cardboard sheet having a first upper facing, a first lower facing and a first inner corrugated member with first corrugations and first air gaps between the first upper and first lower facings, the second cardboard sheeting having a second upper facing, a second lower facing and a second inner corrugated member with second corrugations and second air gaps between the second upper and second lower facings, the first and second overlaying corrugated cardboard sheets forming a layered structure having an original thickness, an outer peripheral edge and first and second outer surfaces, at least one of the first and second cardboard sheets defining two or more openings, the overlaying cardboard sheets having at least one peripheral area extending inwardly of the outer peripheral edge to an inner boundary and at least one inner area between the at least one peripheral area and at least one of the openings;   at least one container having a flat insertion portion and two or more chamber portions, the insertion portion having an outer edge and being sandwiched between the first and second cardboard sheets and each chamber portion protruding from a plane of the cardboard sheets via a respective opening; and   an adhesive between the first and the second corrugated cardboard sheets in at least a portion of the at least one peripheral area to adhere the two corrugated cardboard sheets;   wherein the inner area has substantially the original thickness and the at least one peripheral area is crushed with reduced first and second air gaps therein to a thickness less than the original thickness.   
     
     
         13 . A display pack for products, comprising:
 a first and a second overlaying corrugated cardboard sheets, the first cardboard sheet having a first upper facing, a first lower facing and a first inner corrugated member with first corrugations and first air gaps between the first upper and first lower facings, the second cardboard sheeting having a second upper facing, a second lower facing and a second inner corrugated member with second corrugations and second air gaps between the second upper and second lower facings, the first and second overlaying corrugated cardboard sheets forming a layered structure having an original thickness, an outer peripheral edge and first and second outer surfaces, at least one of the first and second cardboard sheets defining two or more openings, the overlaying cardboard sheets having at least one peripheral area extending inwardly of the outer peripheral edge to an inner boundary and an inner area between the at least one peripheral area and at least one of the openings;   two or more containers, each container having a flat insertion portion and a chamber portion, each insertion portion having an outer edge and being sandwiched between the first and second cardboard sheets and each chamber portion protruding from a plane of the cardboard sheets via a respective opening; and   an adhesive between the first and the second corrugated cardboard sheets in at least a portion of the at least one peripheral area to adhere the two corrugated cardboard sheets;   wherein the inner area has substantially the original thickness and the at least one peripheral area is crushed with reduced first and second air gaps therein to a thickness less than the original thickness.   
     
     
         14 . A display pack for a product, comprising:
 a first and a second overlaying sheets, the first sheet having a first upper facing, a first lower facing and a first inner corrugated member with first corrugations and first air gaps between the first upper and first lower facings, the second sheet comprising a sheet of paper, the first and second overlaying sheets forming a layered structure having an original thickness, an outer peripheral edge and first and second outer surfaces, the first sheet defining a first opening, the second sheet defining a second opening, the overlaying sheets having at least one peripheral area extending inwardly of the outer peripheral edge to an inner boundary and an inner area between the at least one peripheral area and the openings;   a first container having a first insertion portion and a first chamber portion, a second container having a second insertion portion and a second chamber portion, each of the insertion portion having an outer edge and being sandwiched between the first and second sheets, each chamber portion protruding from a plane of the sheets via a respective opening; and   an adhesive between the first and the second sheets in at least a portion of the at least one peripheral area to adhere the two sheets;   wherein the inner area has substantially the original thickness and the at least one peripheral area is crushed with reduced first air gaps therein to a thickness less than the original thickness.   
     
     
         15 . A display pack of  claim 16 , wherein the at least one peripheral area is crushed to form a depressed area on at least one surface of the display pack. 
     
     
         16 . A display pack for a product, comprising:
 a first and a second overlaying sheets, the first sheet having a first upper facing, a first lower facing and a first inner corrugated member with first corrugations and first air gaps between the first upper and first lower facings, the first and second overlaying forming a layered structure having an original thickness and an outer peripheral edge, at least one of the sheets having two or more openings;   a first container having a first insertion portion and a first chamber portion, a second container having a second insertion portion and a second chamber portion, each insertion portion having an outer edge and being sandwiched between the first and second sheets, each chamber portion protruding from a plane of the sheets via a respective opening, the overlaying sheets having at least one peripheral area inwardly of the outer peripheral edge and an inner area between the at least one peripheral area and at least one of the openings; and   an adhesive between the first and the second sheets in the at least one peripheral area to adhere the two sheets;   wherein the inner area has substantially the original thickness and the at least one peripheral area is crushed with reduced first air gaps therein in which the first corrugations are substantially flattened to a thickness less than the original thickness.   
     
     
         17 . A display pack for a product, comprising:
 a first and a second overlaying sheets, the first sheet having a first upper facing, a first lower facing and a first inner corrugated member with first corrugations and first air gaps between the first upper and first lower facings, the second sheet comprising a sheet of paper, the first and second overlaying forming a layered structure having an original thickness and an outer peripheral edge, at least one of the sheets having two or more openings;   a container having at least one insertion portion, a first chamber portion and a second chamber portion, the at least one insertion portion having an outer edge and being sandwiched between the first and second sheets, each chamber portion protruding from a plane of the sheets via a respective opening, the overlaying sheets having at least one peripheral area inwardly of the outer peripheral edge and an inner area between the at least one peripheral area and at least one of the openings; and   an adhesive between the first and the second sheets in the at least one peripheral area to adhere the two sheets;   wherein the inner area has substantially the original thickness and the at least one peripheral area is crushed with reduced first air gaps therein in which the first corrugations are substantially flattened to a thickness less than the original thickness.   
     
     
         18 . A display pack for a product, comprising:
 a corrugated cardboard sheet and a sheet of paper overlaying each other in a stacked configuration, the cardboard sheet having an upper facing, a lower facing and an inner corrugated member with corrugations defining air gaps between the upper and lower facings, the stacked configuration having an outer peripheral edge and an original thickness, the paper sheet defining at least one opening;   at least one container having a flat insertion portion and a chamber portion for holding the product, the insertion portion being sandwiched between the cardboard sheet and the sheet of paper and the chamber portion protruding from a plane of the stacked configuration via the opening, the stacked configuration having an inner portion extending around the opening, and at least one peripheral area extending from the inner portion to and including at least a segment of the outer peripheral edge; and   an adhesive between the corrugated cardboard sheet and the sheet of paper in at least a portion of the peripheral area to adhere the corrugated cardboard sheet and the sheet of paper,   wherein the inner portion has substantially the original thickness, and the at least one peripheral area of the stacked configuration having a portion of the upper facing, the inner corrugated member, and the lower facing is crushed with reduced air gaps.   
     
     
         19 . A display pack of  claim 18 , further comprising at least one litho sheet laminated onto one or both of the corrugated cardboard sheet and the flat sheet of paper. 
     
     
         20 . A display pack for a product, comprising:
 a corrugated cardboard sheet and a flat sheet of paper overlaying each other in a stacked configuration, the cardboard sheet having an upper facing, a lower facing and an inner corrugated member with corrugations defining air gaps between the upper and lower facings, the stacked configuration having an outer peripheral edge and an original thickness, the paper sheet defining at least one opening;   at least one container having a flat insertion portion and a chamber portion for holding the product, the insertion portion being sandwiched between the cardboard sheet and the paper sheet and the chamber portion protruding from a plane of the stacked configuration via the opening, the stacked configuration having an inner portion extending around the opening and covering at least a portion of the insertion portion, and at least one peripheral area extending from the inner portion to and including at least a segment of the outer peripheral edge; and   an adhesive between the corrugated cardboard sheet and the paper sheet in at least a portion of the peripheral area to adhere the corrugated cardboard sheet and the flat sheet,   wherein the inner portion has substantially the original thickness, and the at least one peripheral area of the stacked configuration having a portion of the upper facing, the inner corrugated member, and the lower facing is crushed with reduced air gaps.