Abstract:
A child-resistant package ( 100 ) is formed from a sleeve ( 14 ) comprising a top ( 16 ) and a base ( 18 ), at least one of which is an outer wall of the sleeve ( 14 ). A release mechanism ( 20 ) for facilitating access to the contents of the package ( 100 ) is disposed in the outer wall ( 16 ). A decoy cover ( 60 ) having at least one outermost panel ( 62 ) is disposed in relation to the outer wall ( 16 ) to obscure the release mechanism ( 20 ). The package ( 100 ) may include an insert ( 12 ) that is held within the sleeve ( 14 ) by a locking mechanism that is disengaged by the release mechanism ( 20 ). The decoy cover ( 60 ) is attached to the outer wall ( 16 ) in a manner that facilitates repeated successive removal and reattachment of the decoy cover ( 60 ). The decoy cover ( 60 ) may further include one or more additional panels ( 64 ) disposed in flat-face condition with the outermost panel ( 62 ).

Description:
RELATED APPLICATIONS 
     This application claims priority to U.S. Application No. 60/776,021, filed Feb. 23, 2006, the entirety of which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates generally to a child-resistant package for storing and dispensing items or products, and more specifically, the present invention is directed to a package including a locking mechanism, a releasing mechanism, and a decoy cover that obscures the releasing mechanism. 
     BACKGROUND OF THE INVENTION 
     Most child-resistant packaging relies on locking mechanisms with a release mechanism that requires adult skills, such as cognitive thought, strength, and/or dexterity, to access the contents of the package. However, release mechanisms that require strength may make the package inaccessible by older adults. Additionally, release mechanisms that require cognitive thought or dexterity may be triggered accidentally by a child. 
     Associated locking and release mechanisms are particularly useful in packages that utilize inserts. For example, many medicines are packaged in blister cards that are inserted in a sleeve and secured in the sleeve by a locking mechanism. Such blister cards have bubbles formed from a plastic sheet wherein the bubbles are sealed by a paper layer or foil. The paper layer or foil is punctured or ruptured as a typical means of releasing one dose from a corresponding bubble. Generally, when the release mechanism for the locking mechanism is triggered, the inserted blister card can be partially or fully removed from the sleeve so that the contents of the package are partially or fully exposed. 
     There remains in the art a need for packaging that is increasingly child-resistant, especially where the contents can be exposed when the release mechanism of a package is triggered. 
     SUMMARY OF THE INVENTION 
     The present invention overcomes the shortcomings of the prior art by providing a decoy cover for a child-resistant package that creates an additional barrier for children to overcome in order to attain access to the contents of the package, while facilitating adult use and maintaining low cost of manufacture. The decoy cover can be applied to packages that include a release mechanism disposed in an outer wall of the package, wherein the release mechanism is used to gain access to the contents of the package. 
     In one aspect of the invention, a package is formed from a sleeve that has at least one outer wall. A release mechanism for facilitating access to the contents of the package is disposed in the outer wall. A decoy cover having an outermost panel is disposed in relation to the outer wall to obscure the release mechanism. 
     In a further aspect of the invention, a package is formed from a sleeve that has an outer wall and an insert is held within the package by a locking mechanism. A release mechanism for facilitating at least partial removal of the insert is disposed in the outer wall. A decoy cover is disposed in relation to the outer wall to obscure the release mechanism. 
     In another aspect of the invention, the decoy cover is attached to the outer wall in a manner that facilitates repeated successive removal and reattachment. 
     The foregoing has broadly outlined some of the aspects and features of the present invention, which should be construed to be merely illustrative of various potential applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by combining various aspects of the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded view of a prior art child-resistant package including elements for forming a sleeve and an insect. 
         FIG. 2  is an alternative exploded view of the child-resistant package of  FIG. 1 . 
         FIG. 3  is a perspective view of an exemplary embodiment of a child-resistant package with insert, according to the present invention. 
         FIG. 4  is a perspective view of another exemplary embodiment of a child-resistant package with insert, according to the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     As required, detailed embodiments of the present invention are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms, and Combinations thereof. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as an illustration, specimen, model or pattern. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known components, systems, materials or methods have not been described in detail in order to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. 
     Referring now to the drawings, wherein like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of exemplary embodiments of a child-resistant package, according to the present invention. Generally described, the basic package includes a blister card and an outer sleeve. Sometimes, herein for simplicity, the outer sleeve will simply be referred to as a sleeve. The blister card is retained in the outer sleeve by a locking mechanism to form the basic package. The blister card can be released from the outer sleeve by a release mechanism. In accordance with the teachings of the invention, a decoy cover is disposed on an outer wall of the outer sleeve to cover and otherwise obscure the release mechanism, making it more difficult for a child to gain access to the contents of the package. This enhances or increases the child-resistance characteristic of the package. 
       FIGS. 1 and 2  illustrate exemplary embodiments of elements for forming a sleeve  14  together with an insert in the form of a blister card  12  for ultimately forming a child-resistant package  10  in accordance with the teachings of the present invention. The outer sleeve  14  includes a top  16  and a base  18  that form the outer walls of the sleeve  14 . In  FIG. 2  the orientation of the of the insert  12 , top  16  and base  18  are inverted and rotated 180 degrees as compared to  FIG. 1  in order to more clearly show all of the features of the elements. The top  16  and the base  18  may be integrally connected and the outer sleeve  14  may be formed in any suitable manner and from any material suitable for forming a container or package in general. For example, the outer sleeve  14  may be molded from plastic or may be formed from a paperboard blank that is folded to erect the outer sleeve, or a combination thereof, and the like. 
     The blister card  12  has blisters  30  that can contain one or more articles. Here, for purposes of teaching and not limitation, the articles are doses of medication. The blisters  30  are arranged on the blister card  12  in two columns  32  to avoid obstruction by the internal features of the outer sleeve  14  as the blister card  12  slides within the outer sleeve  14 . The illustrated blister card  12  further includes an aperture  34  that is designed to receive a detent, as further described below. The blister card  12  is constructed of the same materials with strengths and thicknesses as are conventional in blister cards sold in traditional cardboard sleeves. 
     The top  16  and the base  18  include elements that are designed to selectively position, retain, and release the blister card  12  or otherwise form a locking mechanism and a release mechanism. The illustrated release mechanism includes a push button  20  that is integrally formed in the outer sleeve  14 . The push button  20  in the embodiment illustrated is essentially a spring-loaded member that is deflectable. The push button  20  is defined in the top  16  by a U-shaped channel  21 , wherein the channel  21  fully extends through the top  16 . The push button  20  can be allowed to deflect by a resilient living hinge section  22  that is disposed at the supported end of the push button  20 . A free end  24  is defined as the end of the push button  20  that opposes the supported end of the push button  20 . 
     The illustrated locking mechanism includes a detent  29  that is adjacent to the free end  24  of the push button  20 . The detent  29  extends inwardly from the inside surface of the top  16  and the upper surface of the detent  29  slants upwardly. More specifically, the highest portion of the upper surface of the detent  29  is closest to the push button  20 . The locking mechanism further includes means for engaging, such as flat springs  48  that extend inwardly from openings  46 . The openings  46  are disposed in the base  18 . Other means for engaging include ribs, leaf springs, dagger springs, and the like, which exert a compressive force. 
     Other elements are provided to facilitate partially withdrawing the blister card  12  from the locking sleeve. A cutout  28  is provided in the outer edge of top  16  to expose a portion of the blister card, which can then be gripped. Ribs  56  are optionally included in the inside surface of the top  16 . The ribs  56  on the inside of the top  16  facilitate sliding the blister card  12  within the outer sleeve  14 . There is also a rib  58  on the inside surface of the push button  20  that facilitates engaging the blister card  12 . The base  18  includes a retainer  54  such that the blister card  12 , once inserted in the outer sleeve  14 , cannot easily be fully removed from the outer sleeve  14 . The retainer  54  extends inwardly from an opening in the base  18 . 
     In some embodiments, the top  16  and the base  18  may further include elements that facilitate assembling the outer sleeve  14 . For example, as shown, the top  16  includes hollow cylinders  50  and the base  18  includes pins  51 . Each cylinder  50  corresponds to a respective pin  51  such that, as each pin  51  is received in a respective cylinder  50 , the outer sleeve  14  is formed. A blister card  12  can be inserted into the sleeve  14  or can be placed in the sleeve  14  during assembly of the sleeve  14 . A fully-formed sleeve  14  is shown in  FIGS. 3 and 4 . 
     In forming the sleeve  14 , as the blister card  12  is substantially fully inserted, the slanted upper surface of the detent  29  allows the blister card  12  to slide over the detent  29  and deflect the springs  48  until the detent  29  is received in the aperture  34 . As the detent  29  is received in the aperture  34 , the springs  48  force a portion of the blister card  12  against the top  18  and retain the detent  29  in the aperture  34 . The blister card  12  is thereby secured in the outer sleeve  14  to form the package  10 . 
     The blister card  12  can be extended or partially removed from the outer sleeve  14  by depressing the push button  20  and simultaneously pulling the blister card  12  from the opening of the outer sleeve  14 . Depressing the push button  20  moves the blister card  12  toward the base  18  such that the detent  29  is disengaged from the aperture  34  and the springs  48  are deflected. Thereby, the blister card  12  can be extended from the outer sleeve without being obstructed by the detent  29 . The blister card  12  can continue to be removed from the outer sleeve  14  until the aperture  34  is engaged by the retainer  54 . 
       FIG. 3  illustrates an exemplary embodiment of a child-resistant package  100  wherein a decoy cover  60  is attached to cover or otherwise obscure the push button  20 , according to the present invention. The decoy cover  60  may be only one panel that serves as an outermost panel  62  that is releasably secured over the release mechanism. For example, the panel  62  may be in the form of a sticker attached by an adhesive. The material used to form the outer sleeve  14 , the material used to form the decoy cover  60 , and a type of adhesive can be chosen such that the decoy cover  60  can be repeatedly successively secured to, and detached from, the outer sleeve  14 . In certain exemplary embodiments, the material used to form the decoy cover  60  is chosen to be substantially impenetrable such that a child cannot push through the decoy cover  60  to engage the release mechanism. In the exemplary embodiment, the decoy cover  60  is large enough to substantially cover the entire top surface of the outer sleeve  14 . However, the decoy cover  60  can be any size that is suitable to cover the push button  20 . In additional embodiments, a camouflage material is used to form the decoy cover  60 . For example, a material that is substantially visually similar to the material used to form the outer wall  16  of the outer sleeve  14  to which the decoy cover  60  is attached can be used to camouflage the release mechanism of the outer sleeve  14 . 
     The outermost cover panel  62  may include a tab T. The distal end of each cover flap can be releasably secured to the outer wall  16  by means of an adhesive such that the tab T can be releasably adhered to the outer cover  14 . Thereby, the decoy cover  60  covers the push button  20 . The tab T may initiate lifting of the outermost panel  62  to pull the decoy cover  60  from the surface of the outer sleeve  14  so the user can access the push button  20 . 
     Referring now to  FIG. 4 , another exemplary embodiment of a child-resistant package  100  is shown wherein the decoy cover  60  includes at least one additional panel  64  sandwiched between the outermost panel  62  and the outer wall  16  of the sleeve  14 . In this embodiment, a first edge of each cover flap  62 ,  64  is attached in hinge-like fashion to the outer wall  16 . Multiple cover flaps can be used to provide product information, instructions, or other text or graphics to the user. 
     In additional exemplary embodiments, the decoy cover is formed from a substantially rigid material and the outer sleeve and decoy cover include mechanical elements that allow the decoy cover to be secured and released from the outer sleeve. For example, the decoy cover can be a door that is hingedly attached along one edge of the outer sleeve. The distal end of the door can be secured to another edge of the outer sleeve with a mechanical mechanism such as a latch, a catch, a snapping mechanism, Velcro®, a detent and aperture arrangement, and the like. In further exemplary embodiments, the decoy cover can be a door that slides in a slot. 
     To an extent, a portion of the effectiveness of the decoy cover relies on cognitive skill differences between young children and adults. Young children typically do not use the scientific method in solving problems. That is, they do not generate and test hypotheses related to the problems they face. In fact, the problem-solving behavior of young children exhibits a so-called win-shift pattern. In other words, a child will typically attempt incorrect solutions repeatedly and only shift to a correct solution after it is found by accident. Thus, additional child-resistance can be provided by hiding or disguising the correct solution such that it will not even be attempted. 
     In this way, the decoy cover makes it necessary for a child to go through an additional stage of accidental discovery to obtain access to the contents of the package. Thus, for example, if the decoy cover is used to disguise the release mechanism of a package, and that release mechanism requires dexterity, the child will have to first accidentally discover the release mechanism of the package and then, additionally, accidentally trigger the release mechanism to access the contents of the package. The package is then resistant to a greater number of children, including those who do not discover the release mechanism and those who do discover the release mechanism, but do not correctly trigger the release mechanism. 
     The scope of the invention is not limited to the exemplary embodiments of packages shown in  FIGS. 1-4 . Rather, the invention is applicable to any package with an outer sleeve that includes a release mechanism accessible from an outer wall for releasing a structure from the outer sleeve. 
     The law does not require and it is economically prohibitive to illustrate and teach every possible embodiment of the present claims. Hence, the above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims.