Theft-resistant product packaging and related manufacturing process

Abstract

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

What is claimed is: 
     
         1 . A process for manufacturing theft-resistant product packaging, comprising the steps of:
 forming a theft-resistant security pattern of thickened plastic areas on a plastic substrate; and   securing the plastic substrate to a back cover so as to enclose a product therebetween.   
     
     
         2 . The process of  claim 1 , wherein the forming step comprises the steps of:
 heating the plastic substrate to its impression forming point; and   impression rolling the heated plastic substrate to form the security pattern of thickened plastic areas.   
     
     
         3 . The process of  claim 1 , wherein the forming step comprises the steps of:
 dispensing pieces of thermoplastic or bio-film material over a surface of the plastic substrate;   heating the pieces of thermoplastic or bio-film material to their impression forming point; and   impression rolling the heated pieces of thermoplastic or bio-film material on the plastic substrate to form the security pattern of thickened plastic areas.   
     
     
         4 . The process of  claim 2  or  claim 3 , wherein the impression rolling step comprises the steps of:
 feeding the plastic substrate between a pair of impression rollers having at least one set of impression teeth with embossed or recessed portions; and 
 impressing the security pattern of thickened plastic areas. 
 
     
     
         5 . The process of  claim 2  or  claim 3 , further comprising the step of cooling the heated pieces of thermoplastic or bio-film material to fix them together. 
     
     
         6 . The process of  claim 1 , wherein the security pattern comprises a plurality of ridges interspersed with recesses or grooves interspersed with plateaus, wherein the ridges or plateaus are configured in square, rectangular, diamond, trapezoidal, triangular, circular, and/or ringed shapes, or a repetitive pattern of a symbol, design or logo. 
     
     
         7 . The process of  claim 6 , wherein the plurality of ridges interspersed with recesses or grooves interspersed with plateaus or the repetitive pattern, is inline or offset. 
     
     
         8 . The process of  claim 6 , further comprising the step of embossing a symbol, design or logo on at least one of the recesses or plateaus. 
     
     
         9 . The process of  claim 1 , wherein the security pattern comprises a repetitive pattern of a symbol, design or logo. 
     
     
         10 . The process of  claim 1 , further comprising the step of impressing an interior portion devoid of thickened plastic areas on the plastic substrate, wherein the formed theft resistant material has the security pattern of thickened plastic areas along a perimeter area of the theft-resistant material. 
     
     
         11 . The process of  claim 1 , further comprising the step of extruding, thermoforming, or injection molding the plastic substrate, wherein the forming step is performed simultaneously with the extruding, thermoforming, or injection molding step. 
     
     
         12 . The process of  claim 1 , further comprising the step of shaping the plastic substrate to form a cavity configured to accept the product. 
     
     
         13 . A theft-resistant product package, comprising:
 an enclosed packaging structure made from thermoplastic material, the enclosed packaging structure having front and back surfaces spaced apart by at least one side wall around the perimeter of the front and back surfaces; and   a plurality of indentations disposed in the at least one side wall, wherein each of said plurality of indentations extends from the front surface to the back surface.   
     
     
         14 . The theft-resistant product package of  claim 13 , wherein the enclosed packaging structure has a generally round, square, rectangular, triangular or polygonal shape. 
     
     
         15 . The theft-resistant product package of  claim 13 , wherein the front surface of the enclosed packaging structure has an open interior portion having only thermoplastic material devoid of any blockages or obstructions. 
     
     
         16 . The theft-resistant product package of  claim 15 , wherein the back surface of the enclosed packaging structure has an open interior portion having only thermoplastic material devoid of any blockages or obstructions. 
     
     
         17 . The theft-resistant product package of  claim 13 , wherein the enclosed packaging structure comprises two halves with a longitudinal line dividing the front and back surfaces in half. 
     
     
         18 . A theft-resistant product package, comprising;
 a front shell comprising a formed plastic substrate having areas of thickened plastic, wherein the areas of thickened plastic form a security pattern on the plastic substrate; and   a back cover secured to the front shell so as to form a cavity configured to contain a product.   
     
     
         19 . The theft-resistant product package of  claim 18 , wherein the areas of thickened plastic are integral with the plastic substrate and formed by extrusion, thermoforming, injection molding or impression rolling of the plastic substrate. 
     
     
         20 . The theft-resistant product package of  claim 18 , wherein the security pattern comprises a plurality of ridges interspersed with recesses or grooves interspersed with plateaus, wherein the ridges or plateaus are configured in square, rectangular, diamond, trapezoidal, triangular, circular, and/or ringed shapes, or a repetitive pattern of a symbol, design or logo. 
     
     
         21 . The theft-resistant product package of  claim 20 , wherein the plurality of ridges interspersed with recesses or grooves interspersed with plateaus or the repetitive pattern, is inline or offset. 
     
     
         22 . The theft-resistant product package of  claim 18 , wherein the security pattern comprises a repetitive pattern of a symbol, design or logo. 
     
     
         23 . A theft-resistant product package, comprising:
 a front shell having a security pattern of cut-resistant strands disposed within or adjacent to a plastic substrate, wherein the cut-resistant strands are disposed generally side-by-side in a single plane and each strand is alternatingly, intermittently wound around adjacent strands; and   a back cover secured to the front shell so as to form a cavity configured to contain a product.   
     
     
         24 . The theft-resistant product package of  claim 23 , wherein the cut-resistant strands comprise metal, ceramic, glass, carbon fiber, fabric or fiber optic materials. 
     
     
         25 . The theft-resistant product package of  claim 23 , wherein the cut-resistant strands include a hard, outer shell comprising a hardened adhesive, a powdered metal, or a ceramic material. 
     
     
         26 . The theft-resistant product package of  claim 23 , wherein the plastic substrate comprises a laminate of thermoplastic or bio-film material formed around the security pattern. 
     
     
         27 . The theft-resistant product package of  claim 26 , wherein the plastic substrate comprises first and second laminates of thermoplastic or bio-film material disposed on opposite sides of the security pattern and formed around the security pattern. 
     
     
         28 . The theft-resistant product package of  claim 23 , wherein the front shell is preformed with a recess conforming to a shape of the product. 
     
     
         29 . The theft-resistant product package of  claim 23 , wherein the back cover comprises a cardboard, wood, metal, plastic or a second security pattern of cut-resistant strands disposed within or adjacent to a second plastic substrate. 
     
     
         30 . The theft-resistant product package of  claim 23  or  claim 29 , wherein the back cover is secured to the front shell at its edges by a fold, a bond, glue or staples. 
     
     
         31 . The theft-resistant product package of  claim 23 , further comprising a symbol, design or logo embossed on the plastic substrate in an open area of the security pattern. 
     
     
         32 . The theft-resistant product package of  claim 23 , wherein the front shell has the security pattern along a perimeter area such that an interior portion of the front shell is devoid of the security pattern.