Blister packaging and methods of forming the same

Abstract

A method of forming a blister package with product in one method includes providing a blister card. An interior portion of the blister card is removed so as to form an opening. A blister pack is inserted into the opening. The blister pack includes a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls. The blister pack forms at least one undercut in an interior thereof. The product is placed into the interior of the blister pack. A plug is placed into the at least one undercut of the blister pack so as to close the interior of the blister pack. The plug is of the same size and shape as the interior portion of the blister card.

What is claimed is: 
     
         1 . A method of forming a blister package with product, the method comprising the acts of:
 providing a blister card;   removing an interior portion of the blister card so as to form an opening;   inserting a blister pack into the opening, the blister pack including a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls, the blister pack forming at least one undercut in an interior thereof;   placing the product into the interior of the blister pack; and   placing a plug into the at least one undercut of the blister pack so as to close the interior of the blister pack, the plug being of the same size and shape as the interior portion of the blister card.   
     
     
         2 . The method of  claim 1 , wherein the removing of the interior portion is performed by die cutting. 
     
     
         3 . The method of  claim 1 , wherein the removing of the interior portion is assisted by nicks, perforations, lines of weaknesses, cut lines, scores or any combination thereof. 
     
     
         4 . The method of  claim 3 , wherein the removing of the interior portion is performed by punching. 
     
     
         5 . The method of  claim 1 , wherein the product is placed into the interior of blister pack after the blister pack is inserted into the opening. 
     
     
         6 . The method of  claim 1 , wherein the blister package is formed in the absence of adhesive, tape or fasteners. 
     
     
         7 . The method of  claim 1 , wherein the interior portion includes at least one indentation. 
     
     
         8 . The method of  claim 1 , wherein the at least one flange is exactly one flange that extends continuously from the plurality of walls. 
     
     
         9 . The method of  claim 1 , wherein the interior portion of the blister card is the plug. 
     
     
         10 . The method of  claim 1 , wherein the plurality of walls further forms a stop, the stop inhibiting or preventing the plug from further extending into the interior of the blister pack. 
     
     
         11 . The method of  claim 1 , wherein the blister card and the plug comprises paperboard and the blister pack comprising polymeric material. 
     
     
         12 . The method of  claim 11 , wherein the blister card and the plug comprises corrugated paperboard and the blister pack comprising polymeric material. 
     
     
         13 . A method of forming a blister package with product, the method comprising the acts of:
 providing a blister card with an opening;   inserting a blister pack into the opening, the blister pack including a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls, the blister pack forming at least one undercut in an interior thereof;   placing the product into the interior of the blister pack; and   placing a plug into the at least one undercut of the blister pack so as to close the interior of the blister pack, the plug being of the same size and shape as the opening of the blister card.   
     
     
         14 . The method of  claim 13 , wherein the blister package is formed in the absence of adhesive, tape or fasteners. 
     
     
         15 . The method of  claim 13 , wherein the plurality of walls further forms a stop, the stop inhibiting or preventing the plug from further extending into an interior of the blister pack. 
     
     
         16 . The method of  claim 13 , wherein the blister card and the plug comprises paperboard and the blister pack comprising polymeric material. 
     
     
         17 . A method of forming a blister package with product, the method comprising the acts of:
 providing a blister card, the blister card comprising corrugated paperboard;   removing an interior portion of the blister card so as to form an opening;   inserting a blister pack into the opening, the blister pack including a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls, the plurality of walls assisting in forming the at least one undercut, the blister pack including polymeric material;   placing the product into the interior of the blister pack; and   placing the interior portion of the blister card into the at least one undercut of the blister pack to form a plug to close the interior of the blister pack,   wherein the blister package is formed in the absence of adhesive, tape or fasteners.   
     
     
         18 . A blister package containing product, the blister package comprising:
 a blister card with an opening forming therein;   a blister pack inserted through the opening, the blister pack including a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls, the blister pack forming at least one undercut in an interior thereof;   the product being located into the interior of the blister pack; and   a plug placed into the at least one undercut of the blister pack so as to close the interior of the blister pack, the plug being of the same size and shape as the opening of the blister card.   
     
     
         19 . The blister package of  claim 18 , wherein the blister package is formed in the absence of adhesive, tape or fasteners. 
     
     
         20 . The blister package of  claim 18 , wherein the blister card and the plug comprises paperboard and the blister pack comprising polymeric material.