Abstract:
An apparatus for packaging medication including a plurality of containers having a generally rectangular cross-section, each container for holding medication and one or more flexible sleeves, each flexible sleeve for accommodating two containers arranged in transverse ranks. The resulting package may be arrayed in multiple rows and ranks of containers.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/675,218, filed 24 Jul. 2012 and U.S. Provisional Patent Application Ser. No. 61/675,224, filed 24 Jul. 2012. The co-pending Provisional Applications are hereby incorporated by reference herein in their entirety and are made a part hereof, including but not limited to those portions which specifically appear hereinafter. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]    1. Field of the Invention 
         [0003]    This invention relates to a flexible sleeve for carrying a plurality of generally flat pill containers. 
         [0004]    2. Description of Prior Art 
         [0005]    Conventional pill bottles generally include a cylindrical body with a threaded child-safe cap. Such conventional pill bottles are expensive to ship because of the packaging and postage required. As such, mail order prescription services spend millions of dollars annually to box and ship prescriptions. Conventional mailing envelopes often result in crushed or otherwise compromised medications from the rigors of mail handling and sorting equipment, transport and delivery. 
         [0006]    A recently developed container for prescription medication is an “M-Pack” container manufactured by Juno Techologies LLC of San Diego, Calif. The M-Pack container is a generally flat box with a locking, sliding top for dispensing pills. The M-Pack container can be shipped in conventional mailers at much lower costs than conventional pill bottles and with lower risk of damage. However, a need arises for unitizing two or more containers in a single package for handling and shipment. These containers are described in more detail in Lee et al., U.S. Pat. No. 8,123,037, which is incorporated herein by reference. 
         [0007]    Conventional container carriers are often used to unitize a plurality of similarly sized containers, such as cans, bottles, jars and boxes and/or similar containers that require unitization. Flexible plastic ring carriers are one such conventional container carrier. 
         [0008]    Flexible plastic ring carriers having a plurality of container receiving apertures that each engage a corresponding container may be used to unitize groups of four, six, eight, twelve or other suitable groups of containers into a convenient multipackage. 
         [0009]    The present invention successfully unitizes a plurality of generally flat pill containers into a package that may be safely shipped through conventional means. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The above-mentioned and other features and objects of this invention will be better understood from the following detailed description taken in conjunction with the drawings wherein: 
           [0011]      FIG. 1  is a front perspective view of a pill container according to one preferred embodiment of this invention; 
           [0012]      FIG. 2  is a side elevational view of a sleeve for unitizing two containers according to one preferred embodiment of this invention; 
           [0013]      FIG. 3  is a side elevational view of a sleeve for unitizing four containers according to one preferred embodiment of this invention; 
           [0014]      FIG. 4  is a side elevational view of a generally continuous array of sleeves according to one preferred embodiment of this invention; 
           [0015]      FIG. 5  is a top view of a package of containers according to one preferred embodiment of this invention; 
           [0016]      FIG. 6  is a side elevational view of a sleeve for unitizing four containers according to one preferred embodiment of this invention; 
           [0017]      FIG. 7  is a top perspective view of a package according to one preferred embodiment of this invention; and 
           [0018]      FIG. 8  is a side elevational view of a generally continuous array of sleeves according to one preferred embodiment of this invention. 
           [0019]      FIG. 9  is a side elevational view of a flexible carrier according to one preferred embodiment of this invention; 
           [0020]      FIG. 10  is a side elevational view of a flexible carrier according to one preferred embodiment of this invention; 
           [0021]      FIG. 11  is a side elevational view of a flexible carrier according to one preferred embodiment of this invention; and 
           [0022]      FIG. 12  is a top view of a package of containers according to one preferred embodiment of this invention. 
       
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0023]      FIG. 1  shows an embodiment of a pill container  80  according to one preferred embodiment of this invention. The pill container  80  as described herein is preferably a generally flat housing with two parallel extending sidewalls and a slideable lockable cover. The pill container  80  or “container”  80  as used herein does not contemplate a generally cylindrical container having a threaded top as is conventionally associated with medication containers.  FIGS. 2-4 ,  6  and  8  show a flexible sleeve  10  for unitizing a group of such containers  80  in groups of two, four, or more containers and a resulting unitized package  100 . Embodiments of a resulting package are shown in  FIGS. 5 and 7 . Although  FIGS. 2-8  illustrate various structures for flexible sleeve  10  of the invention, the illustrations are exemplary, and the invention is not limited to the flexible sleeves  10  or package  100  shown. For example, flexible sleeve  10  may be alternatively configured and used to unitize ten, fourteen or any other desired number of containers. The containers  80  are preferably, though not necessarily, like-sized within a single flexible sleeve  10 . 
         [0024]    Each flexible sleeve  10  preferably includes at least two layers of flexible sheet  20  having a width and length defining therein a central passage  25  for receiving a pair of containers  80  as described in more detail below. The passages  25  are preferably arranged in rows so as to form one or more passages  25 , such as two adjacent passages  25  for a four container package  100  as shown in  FIG. 5 . 
         [0025]    One or more voids  15  are preferably formed within one or both layers of flexible sheet  20  for weight reduction, aesthetics, labeling and/or improved flexibility of the sleeve  10 . Such voids may be formed in a generally diamond pattern, with a logo or trademark, or any other preferred arrangement. It is preferable that corner portions of the sleeve  10  remain generally continuous for ease of insertion of individual containers  80  within the sleeve  10 . 
         [0026]    According to one preferred embodiment of this invention, such as shown in  FIGS. 2-8 , two layers of flexible sheet  20  are connected along two generally parallel edges, each with a weld  60  that joins the two layers of flexible sheet  20 . The two layers of flexible sheet  20  may be coextruded, welded, or otherwise joined together to create the sleeve  10  and the resulting passage  25 . A “weld” as used in the specification and claims may be defined as a hot weld, cold weld, lamination or any other manner of connection that joins two sheets of material known to those having ordinary skill in the art. 
         [0027]    As shown in  FIGS. 6-8 , sleeve  10  may further include a pair of cutouts  30  positioned generally between head ends of inserted containers  80  which permit greater flexibility between containers  80  when inserted into passage  25 . 
         [0028]    As shown in  FIG. 4 , as a result of multiple adjacent sleeves  10  being formed in a generally continuous manner, an array of sleeves  10 , such as shown in  FIGS. 4 and 8 , may be formed wherein a weld  60  is formed along an edge, then two central welds are formed, each providing a side edge of an adjacent sleeve  10 , followed by two additional welds  60 , continuing until an opposite side edge weld  60  is formed on an opposite side of the array. In this manner a generally continuous string of sleeves  10  may be manufactured. Between each pair of welds  60  dividing adjacent sleeves  10 , a perforation or similar line of weakness may be formed to make the array easily dividable into smaller arrays or individual sleeves  10 . 
         [0029]    The package resulting from flexible sleeve  10  includes two or more unitized containers  80 . Flexible sleeves  10  are generally applied to containers  80  by stretching flexible sheet  20  forming passage  25  around opposing containers  80 , and requiring the stretched carrier  10  to recover, thereby providing a tight engagement to a pair of containers  80 .  FIGS. 5 and 7  show embodiments having four containers  80  each wherein two containers  80  are each positioned in adjacent passages  25 . 
         [0030]    As a result of the described configuration in one preferred embodiment of this invention, the containers  80  are maintained within the package  100  in a spaced apart and consistent manner such that when the package  100  is inserted within a mailing envelope, the individual containers  80  can move and flex relative to each other but are still unitized together. As a result of this described arrangement, the mailing envelope may be handled with conventional mail handling and processing equipment without destroying the contents or otherwise resulting in a more bulky and expensive mailing. In addition, by fixing the position of the containers  80  relative to each other, they do not have a tendency to disorient and stack or ride relative to each other. In addition, the sleeve  10  minimizes weight further reducing mailing costs. 
         [0031]    According to one preferred embodiment of this invention as described above, the sleeve  10  is welded prior to application to individual containers  80 . However, according to another preferred embodiment of this invention, the sleeve  10  may be welded during application to individual containers  80 . In such a process, a first layer of flexible sheet  20  is positioned first and followed by placement of two or more containers  80  thereon. A second layer of flexible sheet  20  is overlayed the containers  80  and the first layer and welded along two generally parallel edges, each with a weld  60  that joins the two layers of flexible sheet  20  and thereby encloses the two or more containers  80  within the resulting passage  25 . 
         [0032]    According to yet another embodiment of this invention, two layers of flexible sheet  20  may be relatively offset such that a first layer has a different length than a second layer thereby creating a larger passage  25  when the two layers are welded. Likewise, one layer of flexible sheet  20  may be pre-stretched or pre-slacked prior to welding to result in a sleeve  10  having a desirable passage  25  for insertion or placement of the containers  80 . In this manner, the containers  80  may be later inserted or inserted in process as described above. 
         [0033]    According to another preferred embodiment,  FIGS. 9-11  show flexible carrier  110  for unitizing a group of such containers  80  in groups of two, four, or more containers and a resulting unitized package  200 . One embodiment of a resulting package is shown in  FIG. 12 . Although  FIGS. 9-12  illustrate various structures for flexible carrier  110  of the invention, the illustrations are exemplary, and the invention is not limited to the flexible carriers  110  or packages shown. For example, flexible carrier  110  may be alternatively configured and used to unitize ten, fourteen or any other desired number of containers. The containers  80  are preferably, though not necessarily, like-sized within a single flexible carrier  110 . 
         [0034]    Each flexible carrier  110  preferably includes at least one layer of flexible sheet  120  having a width and length defining therein a plurality of container receiving apertures  125 , each for receiving a container  80 . The plurality of container receiving apertures  125  are preferably arranged in longitudinal rows and longitudinal ranks so as to form an array of container receiving apertures  125 , such as two rows by two ranks for a four container package  200  as shown in  FIG. 5 . Container receiving apertures  125  are preferably generally rectangular however they may include a tab  130  or similar feature for maintaining the container  80  in the desired position within the package  200 . 
         [0035]    The package resulting from flexible carrier  110  includes a plurality of unitized containers. Flexible carriers  110  are generally applied to containers by stretching flexible sheet  120  surrounding container receiving apertures  125  around container  80 , and requiring the stretched carrier  110  to recover, thereby providing a tight engagement. 
         [0036]    As a result of the described configuration in one preferred embodiment of this invention, the containers  80  are maintained within the package  200  in a spaced apart and consistent manner such that when the package  200  is inserted within a mailing envelope, the individual containers can move and flex relative to each other but are still unitized together. As a result of this described arrangement, the mailing envelope may be handled with conventional mail handling and processing equipment without destroying the contents or otherwise resulting in a more bulky and expensive mailing. In addition, by fixing the position of the containers  80  relative to each other, they do not have a tendency to disorient and stack or ride relative to each other. In addition, the carrier  110  minimizes weight further reducing mailing costs. 
         [0037]    While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purpose of illustration, it will be apparent to those skilled in the art that flexible sleeve  10 , carrier  110  and package  100 ,  200  are susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention.