Abstract:
Disclosed is a paperboard container with a top and bottom panel ( 10, 14 ), each having side panels ( 18, 20 ) that extend the length of either side are folded over and separated by an end panel to form an open ended substantially rectangular box having an interior chamber. A locking apparatus made from plastic is affixed to the top panel. The locking apparatus ( 32 ) includes a pair of spaced apart stop pieces ( 36 ) and an angled locking post ( 34 ). A guide apparatus ( 38 ) made from a molded plastic is affixed to the bottom panel. The guide apparatus includes a pair of spaced apart ramps ( 40 ). The locking apparatus ( 32 ) and the guide apparatus ( 38 ) are oriented within the chamber in such a manner as to cooperate to receive and retain at least one substantially flat insert having a cut out area ( 54 ) adapted to fit over the angled locking post.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    Typical shell packaging containers for blister package inserts (or the like) are made almost entirely from hard molded plastic. An alternative form of container packaging uses paperboard materials rather than molded plastic. Each type of container further strives to achieve a level of child-resistance with respect to accessing the blister package(s) within the containers. There are locking and unlocking mechanisms and features built-in to both the plastic shell containers and the paperboard containers that are designed to retain the blister package(s) securely within its respective outer container. A user must know how to disengage the lock mechanism in order to gain access to the blister package(s). Typically, the plastic lock/unlock mechanisms are more durable and stronger than the paperboard lock/unlock mechanisms. What is needed is a modified packaging system comprised mainly of a paperboard casing that only uses a portion of hard molded plastic that comprise the lock/unlock mechanisms. 
       SUMMARY OF THE INVENTION 
       [0002]    Disclosed is a paperboard container made from a paperboard material. Such material may be treated and/or may be tear-resistant. A top and bottom panel, each having side panels that extend the length of either side are folded over and separated by an end panel to form an open ended substantially rectangular box having an interior chamber. The side panels fold atop and may be attached to one another. A locking apparatus made from a molded plastic may be affixed to the top panel. The locking apparatus may include a pair of spaced apart stop pieces and an angled locking post that protrude away from the surface of the top panel. A guide apparatus made from a molded plastic may be affixed to the bottom panel. The guide apparatus may include a pair of spaced apart ramps. The locking apparatus and the guide apparatus are oriented within the chamber in such a manner as to cooperate to receive and retain at least one substantially flat insert (e.g., a blister package) having a cut out area adapted to fit over the angled locking post. 
         [0003]    To add strength to the overall structure, the top and bottom panels can be reinforced with secondary top and bottom panels that fold over and are adhered to their respective primary top and bottom panels. The secondary top and bottom panels include cut out areas to allow the molded plastic locking apparatus and guide apparatus to protrude through. This style of fitting allows for the plastic pieces to be held in place without the use of adhesive if so desired. The benefit of not using adhesive materials to adhere the plastic pieces to the board is it allows for complete separation of the comingled materials which improves the recyclability of the package. 
         [0004]    A push button cut out area may be oriented between the spaced apart stop pieces of the primary top panel provides a lock release mechanism. When a user depresses the push button cut out area on the top panel, the blister package insert will also be depressed such that its cut out area will become unhooked from the angled locking post. 
         [0005]    A finger cut out area at the open end of the paperboard container may also be included to assist the user in grasping the inserted blister package for easier removal. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is an illustration of a paperboard container prior to assembly according to an embodiment of the invention. 
           [0007]      FIG. 2  is an illustration of the paperboard container of  FIG. 1  shown partially assembled. 
           [0008]      FIGS. 3-5  are illustrations of the paperboard container of  FIGS. 1-2  shown in partially assembled states with molded plastic components attached thereto. 
           [0009]      FIG. 6  is an illustration of a blank blister package adapted to lockably fit within the paperboard container (once assembled). 
           [0010]      FIG. 7  illustrates a view of an assembled paperboard container with a blister package contained therein. 
           [0011]      FIG. 8  illustrates an open two panel paperboard container. 
           [0012]      FIG. 9  shows an the paperboard container of  FIG. 8  with the components attached thereto. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0013]      FIG. 1  is an illustration of a paperboard container  1  prior to assembly according to an embodiment of the invention. The paperboard container is generally comprised of an outside top panel  10 , an inside top panel  12 , an outside bottom panel  14 , an inside bottom panel  16  laid out end to end. Also shown are a pair of top side panels  18 , a pair of bottom side panels  20 , and an end panel  22  that are configured as shown. Also included are a variety of cut out areas including a lock and stop cut out area  26  positioned on the inside top panel  12 , a circular finger cut out area  28  that is bisected by an edge separating the inside top panel  12  and the outside top panel  10 , a push button cut out feature  30  positioned on the outside top panel  10 , and a pair of ramp cut out areas  24  positioned on the inside bottom panel  16 . 
         [0014]    The paperboard material is generally comprised of layers of paperboard that may be treated. The paperboard could be strengthened by coatings or by production processes. The paperboard could be improved for printing capabilities by coatings or production process steps. The inner structure me be made of molded plastic, injection molded, blow molded, thermoformed, or other similar means. In the alternative, the inner structure could be made of pressed paperboard, pressed metal, or pulped formed paper depending upon manufacturing preferences. 
         [0015]      FIG. 2  is an illustration of the paperboard container  1  of  FIG. 1  shown partially assembled. In this illustration, the inside top panel  12  is shown partially folded pivoting about the edge it shares with the outside top panel  10 . This is the same edge that bisects the circular finger cut out area  28 . Similarly, the inside bottom panel  16  is shown partially folded pivoting about the edge it shares with the outside bottom panel  14 . 
         [0016]      FIGS. 3-5  are illustrations of the paperboard container  1  of  FIGS. 1-2  shown in partially assembled states with molded plastic components attached thereto. There is shown a lock and stop apparatus  32  comprised of molded plastic that is vacuum packed and attached to the surface of the outside top panel  10 . The lock and stop apparatus  32  is comprised of a pair of thermo-formed blister stops  36  and a thermo formed blister lock post  34 . A more complete description of how the lock and stop apparatus functions relative to a blister package is set out below. 
         [0017]    Also shown is a molded plastic guide apparatus  38  that is vacuum packed and adhered to the surface of the outside bottom panel  14 . The plastic guide apparatus  38  is comprised of a pair of thermo-formed blister ramps  40 . A more complete description of how the guide apparatus functions relative to a blister package is set out below. 
         [0018]      FIG. 4  illustrates the paperboard container  1  partially assembled wherein the inside top panel  12  has been folded completely over and on top of the outside top panel  10 . Similarly, the inside bottom panel  16  has been folded completely over and on top of the outside bottom panel  14 . The circular finger cut out area  28  now appears as a semi-circle at one end of the paperboard package  1 . The lock and stop cut out area  26  is positioned to allow the lock and stop apparatus  32  and its sub-components (blister lock post  34  and blister stops  36 ) to show through the opening defined by the lock and stop cut out area  26 . Similarly, the ramp cut out areas  24  are positioned to allow the guide apparatus  38  and its sub-components (blister ramps  40 ) to show through the opening defined by the ramp cut out areas  24 . The top panel  12  and the bottom panel  16  may hold the plastic components (lock and stop apparatus etc) in place without the use of an adhesive. It is to be understood that manufacturing preferences will indicate what material is best suited for the additional components. 
         [0019]      FIG. 5  illustrates the paperboard container  1  partially assembled wherein the top panels  10 ,  12  and the bottom panels  14 ,  16  are shown being folded toward one another. The top panels  10 ,  12  and the bottom panels  14 ,  16  are separated by end panel  22  which defines the height dimension of the assembled paperboard container  1 . The left and right top side panels  18  and the left and right bottom side panels  20  will overlap one another respectively when the top panels  10 ,  12  and the bottom panels  14 ,  16  are fully folded. The side panels  18 ,  20  can then be adhered to one another in some fashion (e.g., gluing, adhesive tape, etc . . . ) to form the assembled paperboard container  1 . 
         [0020]    In its assembled state, the blister ramps  40 , the blister stops  36 , the blister lock post  34  and the push button cut-out feature  30  become oriented such that a locking mechanism adapted to receive at least one blister package is formed. 
         [0021]      FIG. 6  is an illustration of a blank blister package  50  adapted to lockably fit within the paperboard container (once assembled). The blister package  50  includes a leading edge  52  and a locking cut out area  54 . Not shown in this illustration are the plurality of individually sealed unit containers that are typically associated with blister packaging. 
         [0022]    In operation, a user would insert a blister package into the open end of a chamber defined by the assembled paperboard container  1 . The leading edge  52  of the blister package  50  travels toward the far end of the paperboard container  1 . Near the far end, the leading edge  52  will encounter blister ramps  40  that are angled and oriented such that the leading edge  52  will slide up and over the ramped surface. As the blister package  50  continues toward the far end of the paperboard container  1 , it may next encounter the angled blister lock post  34 . Angled blister lock post  34  may re-direct the leading edge back downward a bit until the locking cut out area  54  of the blister package  50  clears the blister lock post  34  and hooks over it. The locking cut out area  54  of the blister package  50  is aligned with the position of the blister lock post  34  when the blister package  50  is inserted into the paperboard container  1 . Shortly after the locking cut out area  54  of the blister package  50  clears the blister lock post  34  and hooks over it the leading edge  52  will encounter the protruding blister stops  36 . The blister package  50  is now fully inserted and locked within the paperboard container  1 . 
         [0023]      FIG. 7  illustrates a view of an assembled paperboard container  1  with a blister package  50  contained therein. To release the locking mechanism and remove the blister package from the paperboard container, the user grasps the exposed portion (defined by the finger cut out area  26 ) of blister package  50  in one hand while holding the other end of the paperboard container  1  in their other hand. The user then depresses (usually with the thumb) the push button cut out feature  30  on the outside top panel  10  of the paperboard container  1 . As the push button cut out feature  30  moves downward it contacts the surface of the blister package  50  also moving it downward. Once the blister package  50  has move sufficiently downward, the cut out area  54  of the blister package  50  will again clear and unhook from the blister lock post  34 . Once this occurs the user can pull the blister package  50  out of the paperboard container  1  without it catching on the blister lock post  34 . 
         [0024]      FIGS. 8 and 9  illustrate a different way to make this paperboard container. The paperboard container may have two panels, a top panel  10  and a bottom panel  14 . The two panels are connected together by at least one side panel  56 . It is to be understood the package could be formed with the top panel  10  connected to the bottom panel by end panel  22  and there could be two side panel  18  off of top panel  10  and two side panel  20  off of bottom panel  14 . In the current embodiment, at least one end panel  22  extends off one or more of the closed end sides of top panel  10  and bottom panel  14 . Top panel  10  has a push button cut out feature  30  that aligns with stop apparatus  32  which has two or more sub-components (blister lock post  34  and blister stops  36 ). In this two panel design, stop apparatus  32  may be adhered to top panel  10 . Guide apparatus  38  is aligned with stop apparatus  32  on bottom panel  14 . It may be adhered to bottom panel  14 . Stop apparatus  32  and guide apparatus  38  may be adhered to the panels with staples, tape, glue, pressure adhesive, heat seal adhesive, or any other adhesive like material. End flaps  22  may overlap and be sealed to form the closed end of the package. Side panels  18  and  20  may overlap and be sealed together to form a second side panel parallel to first side panel  56 . Blister card  50  may be slid into the package the leading edge  52  to match up with the inside of panels  22  or the closed end of the package. The locking cut out area  54  may align with locking post  34  such that the card is held in place until the user presses on cut out  30  lowering the blister card until locking cut out area  54  is able to slide past locking post  34 . 
         [0025]    It is to be understood that a wide variety of materials may be used to make the internal components (guide rails, locking elements, retaining elements and/or other such elements), including but not limited to plastic, plastic biopolymers and/or other plastic based compositions. It is to be understood that the one or more retaining elements may be a catch, an opening, a lip, a ledge, a flap, a blister, a bump, a protrusion, an indention or any elements or combinations thereof that would prevent the blister from being fully removed without undue force from the outer container or shell. 
         [0026]    It is believed that the present invention includes many other embodiments that may not be herein described in detail, but would nonetheless be appreciated by those skilled in the art from the disclosures made. Accordingly, this disclosure should not be read as being limited only to the foregoing examples or only to the designated embodiments.