Dispenser package arrangement and methods

Abstract

A package arrangement is described for containing multiple sheet products and dispensing the sheet products individually. The package arrangement includes three or more substrates where sheet products are sandwiched between adjacent substrates. A second side of each substrate includes an attachment zone surrounding a film pocket area. The first side of the substrate also includes a pull tab area adjacent to the substrate perimeter for grasping when peeling a substrate off of the stack.

1 . A package arrangement for containing multiple sheet products and dispensing the sheet products individually, comprising: 
 (a) a base substrate comprising a first and second side;    (b) a first sheet product;    (c) a first substrate, including a first side, second side, and perimeter edge, the second side of the first substrate including: 
 (i) an outer attachment zone defined by an outer perimeter and an inner perimeter, wherein the second side of the first substrate is attached to the first side of the base substrate at the outer attachment zone;  
 (ii) a product pocket area within the inner perimeter of the outer attachment zone, wherein the product pocket area comprises an unattached zone that is unattached to the base substrate, and  
 (iii) a pull tab area adjacent to a portion of the perimeter edge of the first substrate wherein the pull tab area comprises a pull tab zone that is unattached to the base substrate;  
 (iv) wherein the first sheet product is positioned between the base substrate and the first substrate at the product pocket area;  
   (d) a second sheet product; and    (e) a second substrate, including a first side, second side, and perimeter edge, the second side of the second substrate including:    (i) a second outer attachment zone defined by an outer perimeter and an inner perimeter, wherein the second side of the second substrate is attached to the first side of the first substrate at the second outer attachment zone;    (ii) a second product pocket area within the inner perimeter of the second outer attachment zone, wherein the second product pocket area comprises an unattached zone that is unattached to the first substrate, and    (iii) a second pull tab area adjacent to a portion of the perimeter edge of the second substrate wherein the pull tab area comprises a second unattached zone that is unattached to the first substrate;    (iv) wherein the second side of the second substrate is attached to the second side of the first substrate at the outer attachment zone, wherein the second sheet product is positioned between the first substrate and second substrate at the second product pocket area.    
   
   
       2 . A package arrangement according to  claim 1  wherein at least one of the base substrate, first substrate, and second substrate comprise a thermoplastic manual; 
 (a) wherein the second side of the first substrate is attached to the first side of the base substrate at the outer attachment zone by a peelable bond;    (b) wherein the second side of the second substrate is attached to the first side of the first substrate at the second outer attachment zone by a peelable bond using ultrasonic vibrations.    
   
   
       3 . A package arrangement according to  claim 2  wherein the peelable bonds are formed using heat.  
   
   
       4 . A package arrangement according to  claim 2  wherein the peelable bonds are formed using ultrasonic vibrations.  
   
   
       5 . A package arrangement according to  claim 1:   (a) wherein outer attachment zone comprises an outer adhesive field;    (b) wherein the second outer attachment zone comprises a second outer adhesive field.    
   
   
       6 . A package arrangement according to  claim 5  wherein the second side of the first substrate further comprises an inner adhesive zone comprising an inner adhesive field within the first product pocket area, wherein the inner adhesive field adheres the first sheet product to the first product pocket area.  
   
   
       7 . A package arrangement according to  claim 4  wherein the first side of the first substrate is free of exposed adhesive.  
   
   
       8 . A package arrangement according to  claim 1:   (a) wherein the outer attachment zone comprises an outer cohesive field;    (b) wherein the second outer attachment zone comprises a second cohesive field;    (c) wherein the first side of the base substrate comprises a third outer cohesive field, wherein the third outer cohesive field overlaps the outer cohesive field of the second side of the first substrate; and    (d) wherein the first side of the first substrate comprises a fourth outer cohesive field, wherein the fourth outer cohesive field overlaps the third outer cohesive field of the second side of the second substrate.    
   
   
       9 . A package arrangement according to  claim 1  further comprising: 
 (a) a third sheet product;    (b) a third substrate, including a first side, second side, and perimeter edge, the second side of the third substrate including: 
 (i) a third outer attachment zone defined by an outer perimeter and an inner perimeter, wherein the second side of the third substrate is attached to the first side of the second substrate at the third outer attachment zone;  
 (ii) a third product pocket area within the inner perimeter of the third outer attachment zone, wherein the third product pocket area comprises an unattached zone that is unattached to the second substrate, and  
 (iii) a third pull tab area adjacent to a portion of the perimeter edge of the third substrate wherein the pull tab area comprises a third pull tab unattached zone that is unattached to the second substrate;  
 (iv) wherein the third sheet product is positioned between the second substrate and third substrate at the third product pocket area.  
   
   
   
       10 . A package arrangement according to  claim 1  further comprising: 
 (a) a base layer attached to the second side of the base substrate, the base layer comprising a perimeter portion that extends beyond the perimeter of the base substrate.    
   
   
       11 . A package arrangement according to  claim 10  wherein the base layer is more rigid than the first substrate.  
   
   
       12 . A package arrangement according to  claim 10  wherein the base layer includes an opening in the base perimeter portion.  
   
   
       13 . A package arrangement according to  claim 1  wherein the first and second substrates are flexible.  
   
   
       14 . A package arrangement according to  claim 1  wherein the first and second substrates are comprised of one of plastic, foil, and paper.  
   
   
       15 . A package arrangement according to  claim 1  wherein the sheet product pocket area of the first substrate is rectangular, wherein the first sheet product is rectangular, wherein the outer and inner perimeters of the outer adhesive zone are rectangular.  
   
   
       16 . A package arrangement according to  claim 1  wherein the first substrate is rectangular and the pull tab area of the first substrate is located along one edge of the first substrate.  
   
   
       17 . A package arrangement according to  claim 1  wherein the first substrate is rectangular and the pull tab area of the first substrate is located at a corner of the first substrate.  
   
   
       18 . A package arrangement according to  claim 1  wherein the first substrate is rectangular and the pull tab area of the first substrate is located at a corner of the first substrate, wherein the second side of the first substrate further comprises second, third, and fourth pull tab areas located at corners, wherein the second, third, and fourth pull tab areas are free of exposed adhesive.  
   
   
       19 . A package arrangement according to  claim 1  wherein the pull tab area of the first substrate is located along the entire perimeter of the first substrate.  
   
   
       20 . A package arrangement according to  claim 1  wherein the base substrate, first substrate, and second substrate are rectangular.  
   
   
       21 . A package arrangement according to  claim 1  wherein the base substrate, first substrate, and second substrate are circular.  
   
   
       22 . A package arrangement according to  claim 1  wherein the outer attachment zone of the first substrate extends inwardly from portions of the first substrate perimeter edge a distance of about one quarter inch.  
   
   
       23 . A package arrangement according to  claim 1  wherein the first substrate is larger than the second substrate and the first substrate includes an extension portion that extends beyond the perimeter of the second substrate.  
   
   
       24 . A package arrangement according to  claim 1  wherein the first and second sheet products are flat and flexible.  
   
   
       25 . A package arrangement according to  claim 26  wherein the first and second sheet products are selected from the group of soluble films, diagnostic strips, transdermal pads, and medical pads.  
   
   
       26 . A package arrangement for containing multiple sheet products and dispensing the sheet products individually, comprising: 
 (a) base substrate comprising a first and second side;    (b) a first sheet product;    (c) a first substrate, including a first side, second side, and perimeter edge, the second side of the first substrate including: 
 (i) an outer adhesive zone defined by an outer perimeter and an inner perimeter, wherein the outer adhesive zone comprises an outer adhesive field;  
 (ii) a product pocket area within the inner perimeter of the outer adhesive zone, wherein the product pocket area comprises an adhesive void that is free of exposed adhesive, and  
 (iii) a pull tab area adjacent to a portion of the perimeter edge of the first substrate wherein the pull tab area comprises a pull tab adhesive void that is free of exposed adhesive;  
 (iv) wherein the second side of the first substrate is adhered to the first side of the base substrate by the outer adhesive field, wherein the first sheet product is positioned between the base substrate and the first substrate at the pocket area;  
   (d) a second sheet product; and    (e) a second substrate, including a first side, second side, and perimeter edge, the second side of the second substrate including: 
 (i) a second outer adhesive zone defined by an outer perimeter and an inner perimeter, wherein the second outer adhesive zone comprises a second outer adhesive field;  
 (ii) a second product pocket area within the inner perimeter of the second outer adhesive zone, wherein the second product pocket area comprises an adhesive void free of exposed adhesive, and  
 (iii) a second pull tab area adjacent to a portion of the perimeter edge of the second substrate wherein the pull tab area comprises a second pull tab adhesive void free of exposed adhesive;  
 (iv) wherein the second side of the second substrate is adhered to the second side of the first substrate by the outer adhesive field, wherein the second sheet product is positioned between the first substrate and second substrate at the second product pocket area.  
   
   
   
       27 . A package arrangement according to  claim 26  wherein the second side of the first substrate further comprises an inner adhesive zone comprising an inner adhesive field, wherein the inner adhesive field adheres the first sheet product to the first product pocket area, wherein the inner adhesive field is surrounded by the adhesive void area of the product pocket area.  
   
   
       28 . A package arrangement according to  claim 26  wherein the second side of the second substrate further comprises a second inner adhesive zone comprising a second inner adhesive field, wherein the second inner adhesive field adheres the second sheet product to the second product pocket area, wherein the second inner adhesive field is surrounded by the adhesive void area of the product pocket area.  
   
   
       29 . A package arrangement according to  claim 26  further comprising: 
 (a) a third sheet product;    (b) a third substrate, including a first side, second side, and perimeter edge, the second side of the third substrate including: 
 (i) a third outer adhesive zone defined by an outer perimeter and an inner perimeter, wherein the third outer adhesive zone comprises a third outer adhesive field;  
 (ii) a third product pocket area within the inner perimeter of the third outer adhesive zone, wherein the third product pocket area comprises an adhesive void free of exposed adhesive, and  
 (iii) a third pull tab area adjacent to a portion of the perimeter edge of the third substrate wherein the pull tab area comprises a third pull tab adhesive void free of exposed adhesive;  
 (iv) wherein the second side of the third substrate is adhered to the first side of the second substrate by the third outer adhesive field, wherein the third sheet product is positioned between the second and third substrates at the third product pocket area.  
   
   
   
       30 . A package arrangement according to  claim 26  wherein the first side of the first substrate is free of exposed adhesive.  
   
   
       31 . A package arrangement according to  claim 26  wherein the second side of the first substrate is coated with adhesive and the product pocket area and pull tab area of the first substrate further comprise a varnish covering the adhesive.  
   
   
       32 . A package arrangement according to  claim 26  wherein the second side of the first substrate is coated with adhesive and the product pocket area and pull tab of the first substrate area comprise a covering layer covering the adhesive.  
   
   
       33 . A package arrangement according to  claim 32  wherein the covering layer comprises a plastic film.  
   
   
       34 . A package arrangement according to  claim 32  wherein the covering layer comprises paper.  
   
   
       35 . A package arrangement according to  claim 26  wherein the outer adhesive field of the first substrate extends inwardly from portions of the first substrate perimeter edge a distance of about one quarter inch.  
   
   
       36 . A package arrangement according to  claim 26  wherein the first and second sheet products are selected from the group of soluble films, diagnostic strips, transdermal pads, and medical pads.  
   
   
       37 . A package arrangement for containing multiple soluble films and dispensing the soluble films individually, comprising: 
 (a) a base substrate comprising a first and second side;    (b) a first film;    (c) a first substrate, including a first side, second side, and perimeter edge, the second side of the first substrate including: 
 (i) an outer adhesive zone defined by a rectangular outer perimeter and a rectangular inner perimeter, wherein the outer adhesive zone comprises an outer adhesive field;  
 (ii) a film pocket area within the inner perimeter of the outer adhesive zone, wherein the film pocket area comprises an adhesive void zone that is free of exposed adhesive, and  
 (iii) a pull tab area adjacent to a portion of the perimeter edge of the first substrate wherein the pull tab area comprises a pull tab adhesive void zone that is free of exposed adhesive;  
 (iv) wherein the second side of the first substrate is adhered to the first side of the base substrate by the outer adhesive field, wherein the first film is positioned between the base substrate and the first substrate at the film pocket area; and  
   (d) a second film;    (e) a second substrate, including a first side, second side, and perimeter edge, the second side of the second substrate including: 
 (i) a second outer adhesive zone defined by an outer perimeter and an inner perimeter, wherein the second outer adhesive zone comprises a second outer adhesive field;  
 (ii) a second film pocket area within the inner perimeter of the second outer adhesive zone, wherein the second film pocket area comprises an adhesive void free of exposed adhesive, and  
 (iii) a second pull tab area adjacent to a portion of the perimeter edge of the second substrate wherein the pull tab area comprises a second pull tab adhesive void free of exposed adhesive;  
 (iv) wherein the second side of the second substrate is adhered to the second side of the first substrate by the outer adhesive field, wherein the second film is positioned between the first substrate and second substrate at the second film pocket area; and  
   (f) wherein the pull tab area of the first substrate includes an extension portion that extends beyond the perimeter of the base substrate and the second pull tab area of the second substrate extends beyond the perimeter of the first substrate.    
   
   
       38 . A method of dispensing an individual sheet product from a package that contains multiple sheet products; said method including steps of: 
 (a) grasping a perimeter pull tab area of a top flexible substrate on a stack of a plurality of substrates, wherein the pull tab area comprises an unattached area, wherein the substrates are attached to each other at a zone of attachment on a second side of each substrate;    (b) partially peeling the top flexible substrate off of the stack to expose a sheet product overlapping a product pocket area on the second side of the substrate, wherein the product pocket area is defined within an inner perimeter of the zone of attachment, wherein the product pocket area is not attached to the adjacent substrates; and    (c) removing the sheet product from the product pocket area.    
   
   
       39 . The method of dispensing a sheet product of  claim 38  further comprising continuing to peel the top substrate off of the stack.  
   
   
       40 . A process of manufacturing a package arrangement for containing multiple sheet products and dispensing the sheet products individually, wherein the package arrangement is a stack of substrates with a sheet product between each pair of adjacent substrates, including: 
 (a) placing a sheet product onto a first side of a first substrate, wherein the first side of the first substrate includes an adhesive pattern and an adhesive void zone that is free of exposed adhesive;    (b) placing a second sheet product onto a first side of a second substrate, wherein the first side of the second substrate includes an adhesive pattern and an adhesive void zone that is free of exposed adhesive;    (c) placing a third sheet product onto a first side of a third substrate, wherein the first side of the third substrate includes an adhesive pattern and an adhesive void zone that is free of exposed adhesive;    (e) stacking the first substrate, second substrate and third substrate so that the adhesive patterns hold the stack together.    
   
   
       41 . A process of manufacturing a package arrangement according to  claim 40  further comprising: 
 (a) the adhesive pattern covering substantially all of the first substrate, and    (b) applying a deadening material to the first substrate, wherein the adhesive void zone is created.    
   
   
       42 . A process of manufacturing a package arrangement according to  claim 40  further wherein the adhesive is applied with screen printing techniques.  
   
   
       43 . A process of manufacturing a package arrangement according to  claim 40  wherein a static charge is applied to the first substrate to hold the sheet product.  
   
   
       44 . A process of manufacturing a package arrangement for containing multiple sheet products and dispensing the sheet products individually, wherein the package arrangement is a stack of substrates with a sheet product between each pair of adjacent substrates, including: 
 (a) placing a sheet product onto a first substrate,    (b) placing a sheet product onto a second substrate,    (c) stacking the second substrate material onto the first substrate,    (d) stacking a third substrate onto the second substrate;    (d) applying a sealing platen tool to the substrate stack, wherein an attachment zone is formed that surrounds the sheet products.    
   
   
       45 . A process of manufacturing a package arrangement according to  claim 44  wherein the sealing platen tool is heated.  
   
   
       46 . A process of manufacturing a package arrangement according to  claim 44  wherein the sealing platen tool vibrates ultrasonically.