All paper blister type package

Abstract

A paper-based package that can be manufactured using existing blister pack packaging equipment is provided. The package components comprise a face card and a tray blank that can be shipped flat and loaded easily into existing blister package equipment. The package may be formed in the machine just prior to the filling operation, and a paper-to-paper seal may be achieved in the same fashion as in a traditional plastic blister face card seal. Fold lines are formed in the tray blank by ablation.

1 . A paper blister type package for holding one or more products, the package comprising:
 a paper face card made from a first blank and having a front side and a back side;   a paper tray made from a second blank and having a product facing side and a back side and comprising a tray bottom, two opposing tray side walls attached to the tray bottom along side fold lines and extending upwardly from the tray bottom to side flange fold lines, two opposing tray end walls attached to the tray bottom along end fold lines and extending upwardly from the tray bottom to end flange fold lines, the tray further comprising two opposing side flanges and two opposing end flanges, each side flange extending outwardly from and attached to a tray side wall along a side flange fold line, each end flange extending outwardly from and attached to a tray end wall along an end flange fold line, the side fold lines; and   a heat seal coating adhering the face card to the two opposing side flanges and the two opposing end flanges, wherein   each end fold line, each side flange fold line and each end flange fold line comprises one or more shallow channels located on the product facing side of the tray blank.   
     
     
         2 . The paper blister type package of  claim 1  wherein:
 each channel is visibly apparent only on the product facing side of the tray blank. 
 
     
     
         3 . The paper blister type package of  claim 1  wherein:
 the number of channels varies among the fold lines. 
 
     
     
         4 . The paper blister type package of  claim 1  wherein:
 each fold line comprises two to three channels. 
 
     
     
         5 . The paper blister type package of  claim 1  wherein:
 each side fold line comprises three parallel channels; 
 each side flange fold line comprises three parallel channels; 
 each end fold line comprises two parallel channels; and 
 each end flange fold line comprises two parallel channels. 
 
     
     
         6 . The paper blister type package of  claim 1  wherein:
 at least one channel comprises discontinuities. 
 
     
     
         7 . The paper blister type package of  claim 1  wherein:
 each channel comprises discontinuities. 
 
     
     
         8 . The paper blister type package of  claim 7  wherein:
 the discontinuities among the channels forming at least one fold line are aligned. 
 
     
     
         9 . The paper blister type package of  claim 7  wherein:
 the discontinuities among the channels forming each fold line are aligned. 
 
     
     
         10 . The paper blister type package of  claim 7  wherein:
 the discontinuities among the channels forming at least one fold line are staggered. 
 
     
     
         11 . The paper blister type package of  claim 1  wherein:
 each tray side wall and each tray end wall is rectangular; and 
 the tray side walls and the tray end walls are perpendicular to the tray bottom and form substantially closed vertical corners. 
 
     
     
         12 . The paper blister type package of  claim 1  wherein:
 the face card defines a window through which the one or more products may be viewed. 
 
     
     
         13 . The paper blister type package of  claim 12  wherein:
 the window is of a shape that prevents the products from being removed through the window. 
 
     
     
         14 . The paper blister type package of  claim 1  wherein:
 each tray side wall and each tray end wall is trapezoidal; and 
 each tray side and each tray end wall forms an obtuse included angle with the tray bottom. 
 
     
     
         15 . A method of making a paper blister package comprising the steps of:
 Step  101 : Cutting paperboard into a face card and a tray blank, and forming fold lines in the tray blank to create a tray blank having a product facing side and a back side and comprising a tray bottom, two opposing tray side walls attached to the tray bottom along side fold lines and extending outwardly from the tray bottom to side flange fold lines, two opposing tray end walls attached to the tray bottom along end fold lines and extending outwardly from the tray bottom to end flange fold lines, the tray further comprising two opposing side flanges and two opposing end flanges, each side flange extending outwardly from and attached to a tray side wall along a side flange fold line, each end flange extending outwardly from and attached to a tray end wall along an end flange fold line, the side fold lines, the end fold lines, the side flange fold lines and the end flange fold lines formed by ablating the product facing surface of the tray blank to create channels;   Step  102 : Applying a heat seal coating to the face card and/or the tray blank;   Step  103 : Loading products to be packaged, face cards and tray blanks into feeding chutes;   Step  104 : Transferring a tray blank from a feeding chute to a nesting tray and locating the tray blank onto the nesting tray using a vacuum equipped forming block;   Step  105 : Forming a tray by lowering the forming block into a recess of the nesting tray, thereby forcing the tray blank to fold along its side fold lines, end fold lines, side flange fold lines and end flange fold lies and assume the shape of a formed tray, and then withdrawing the forming block from the recess;   Step  106 : Loading product into the formed tray while the formed tray still resides in the nesting tray;   Step  107 : Removing a face card from a feeding chute and placing the face card on top of the formed tray; and   Step  108 : Adhering the face card to the tray by heating the heat seal coating.   
     
     
         16 . The method of  claim 15  wherein, during the tray forming step, side extensions and end extensions of the forming block press the tray flanges against a top surface of the nesting tray. 
     
     
         17 . The method of  claim 15  wherein, during the fold line forming step, two or more parallel channels are formed for each fold line. 
     
     
         18 . The method of  claim 17  wherein, during the fold line forming step, at least one channel is formed with discontinuities. 
     
     
         19 . The method of  claim 17  wherein, during the fold line forming step, at least two parallel channels are formed with discontinuities that are aligned. 
     
     
         20 . The method of  claim 17  wherein, during the fold line forming step, at least two parallel channels are formed with discontinuities that are staggered with respect to each other.