Abstract:
There is disclosed a packaging apparatus designed to accommodate a plurality of primary packages in a secure child-resistant manner. A plurality of primary packages for storing packaging contents each include at least one aperture. A secondary package houses the plurality of primary packages. A traveler mechanism is coupled with the plurality of primary packages and adapted to fit within the secondary package in a lockable slidable fashion. The traveler mechanism securely retains the plurality of primary packages.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    One form of pharmaceutical packaging is a blister pack. A blister pack is comprised of a generally flat substrate on one side and a plurality of bubble like cavities on the other side. Within each cavity is stored a unit dose of a pharmaceutical such as a pill, tablet, or capsule. The contents within the cavity need not be pharmaceutical per se, however. When a consumer wishes to access the contents of a blister, he presses down on the cavity ‘bubble’ causing the contents to pierce the bottom surface (usually foil or the like) of the blister pack. 
         [0002]    Blister packs are a convenient primary form of packaging. However, blister packs generally require a secondary form of packaging. The secondary form of packaging serves to protect the primary package as well as providing a convenient form for labeling. More importantly, however, the secondary packaging can also provide a means for securing the primary package from children as a safety feature since the contents of the primary packages can often be dangerous. 
         [0003]    One of the safety measures associated with the secondary packaging is the ability to ‘lock’ and ‘unlock’ a primary package within a secondary package. Secondary packages have been comprised of many materials including paperboard packaging solutions and hard plastic shell type solutions. In general, the secondary packages receive a primary package and can securely seat it within a chamber such that it can not be withdrawn without manipulating a locking mechanism. A typical locking mechanism includes catches that prevent the primary package from being withdrawn unless a tab type mechanism can be separated from a tab catch mechanism. 
         [0004]    Typical packaging solutions only accommodate a single primary package within a secondary package. In these solutions, the primary package itself is in a direct cooperative relationship with the secondary package. This can be inefficient if the contents of the primary package are used up rather quickly or if the primary package can only accommodate a relatively small number of discrete items. 
         [0005]    Blister packs are not the only form of primary packaging that can be accommodated in the solutions described above. Such systems can protect primary packages that contain, for instance, medical devices such as syringes, dermal strip medications, liquid vials or ampules, etc. The primary package can be used to store and protect just about anything that can be retained by the relatively flat primary packaging medium. 
         [0006]    What is needed is a single secondary packaging solution that can accommodate multiple primary packages in a secure child resistant manner. 
       SUMMARY OF THE INVENTION 
       [0007]    In one embodiment there is disclosed a packaging apparatus designed to accommodate a plurality of primary packages in a secure child-resistant manner. A plurality of primary packages for storing packaging contents each include at least one aperture. A secondary package houses the plurality of primary packages. A traveler mechanism is coupled with the plurality of primary packages and adapted to fit within the secondary package in a lockable slidable fashion. The traveler mechanism securely retains the plurality of primary packages. 
         [0008]    The secondary package is comprised of plastic top and bottom portions that can be snap fit (or glued or otherwise adhered) together such that when fit together, the secondary package defines an interior chamber that is open on one end and closed on the opposite end. The secondary package is further comprises an elongated tapered stop on the interior surface of at least one of the top and bottom portions of the secondary package and at least one traveler stop on the interior surface of at least one of the top and bottom portions of the secondary package positioned near the open end of the interior chamber. 
         [0009]    The secondary package further comprises a locking tab release positioned such that depressing the locking tab release while the traveler mechanism is in the locked position within the secondary package will cause the release tab stop of the traveler mechanism to clear the elongated tapered stop of the secondary package allowing the traveler mechanism to unlock and be slidably withdrawn from the secondary package. 
         [0000]    The top and bottom portions of the secondary package further include a thumb/finger indent at the open end front edge to assist a person when grasping a primary package contained within the secondary package. 
         [0010]    The traveler mechanism is comprised of top and bottom portions that can be snap fit (or glued or otherwise adhered) together such that when fit together, the traveler mechanism can be seated within the interior chamber of the secondary package in a lockable and slidable fashion. The traveler mechanism further comprises a flexible release tab that includes a release tab stop on at least one of the top and bottom portions of the traveler mechanism such that the release tab stop will abut the elongated tapered stop in a locked position that prevents the traveler mechanism from sliding outward. The traveler mechanism further comprises a flat surface adapted to engage the at least one traveler stop to prevent the traveler mechanism from being completely withdrawn from within the interior chamber of the secondary package and at least one post adapted to fit within the at least one aperture of the plurality of primary packages. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is a perspective view of the components that form a hard plastic sleeve packaging solution comprised of primary and secondary packaging and a traveler mechanism according to an embodiment of the invention. 
           [0012]      FIG. 2  is another perspective view of the components that form a hard plastic sleeve packaging solution showing the primary packaging coupled with the traveler mechanism according to an embodiment of the invention. 
           [0013]      FIG. 3  is a see through perspective view of the hard plastic sleeve packaging solution showing the primary packaging coupled with the traveler mechanism and seated within the secondary packaging according to an embodiment of the invention. 
           [0014]      FIG. 4  is another see through perspective view of the hard plastic sleeve packaging solution showing just the traveler mechanism seated within the secondary packaging according to an embodiment of the invention. 
           [0015]      FIG. 5  is a first perspective view of the traveler mechanism in a closed position according to an embodiment of the invention. 
           [0016]      FIG. 6  is a second perspective view of the traveler mechanism in a closed position according to an embodiment of the invention. 
           [0017]      FIG. 7  is a third perspective view of the traveler mechanism in an open position according to an embodiment of the invention. 
           [0018]      FIG. 8  is a first see through cut-away side view of  FIG. 4 . 
           [0019]      FIG. 9  is a second see through cut-away side view of  FIG. 4 . 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0020]    The present invention describes an improved packaging system comprised of a hard plastic shell secondary package adapted to receive and house a plurality of primary packages (such as, for instance, a plurality of blister packs) via a traveler mechanism. Rather than having the plurality of primary packages connect directly in a cooperative relationship with the secondary package, the plurality of primary packages are coupled with the traveling mechanism. The traveling mechanism is then coupled with the secondary package in a cooperative relationship that permits the traveler to be securely housed within the secondary package yet also allows the traveler mechanism to be substantially withdrawn to expose the contents of the primary packages. 
         [0021]    For ease of description, the hard plastic shell may also be referred to as a sleeve package throughout this disclosure. The sleeve package is generally formed from two pieces of plastic (top and bottom) that snap fit to one another. Once fitted together, one end of the sleeve package remains substantially open and an interior chamber is formed that is adapted to receive and house a plurality of primary packages. There are one or more locking and unlocking mechanisms on and about the sleeve package and the traveler mechanism that operate to securely retain the plurality of primary packages within the sleeve package. To withdraw and expose the primary packages, a consumer must know how to operate the secondary package to release the locking mechanism(s). These locking mechanisms provide the entire packaging solution with an enhanced degree of child resistant safety features. 
         [0022]      FIG. 1  is a perspective view of the components that form a plastic sleeve packaging solution comprised of primary and secondary packaging and a traveler mechanism according to an embodiment of the invention. The secondary package  100  comprised of a top piece  102  and bottom piece  104  is shown assembled. The top piece  102  and the bottom piece  104  are generally snap fit (or glued or adhered in some other manner) together using a plurality of reciprocating connections (not shown). The result is a secondary package  100  that is closed at one end and open  106  at the other end. The top  102  and bottom  104  pieces also include a thumb/finger indent at the open end front edge to assist a person when grasping a primary package contained within the secondary package. 
         [0023]    The traveler mechanism  200  is also comprised of a top piece  204  and bottom piece  206  and is shown assembled. In its assembled state, the traveler mechanism  200  is adapted to fit snugly yet slidably within the open end of the secondary package  100 . The top piece  204  and the bottom piece  206  can share a common edge seam  202  and are generally snap fit together using a plurality of reciprocating connections. The edge seam  202  is not a requirement, however, meaning the top piece  204  and bottom piece  206  can be separate from one another and snap fit together. Also shown are a pair of posts  230  that are designed to accept the plurality of primary packages via apertures prior to snap fitting the top piece  204  to the bottom piece  206 . A pair of primary packages  300  in the form of blister packs are also shown. The primary packages further include the aforementioned apertures  310  that fit over the posts  230  of the traveler mechanism  200 . 
         [0024]      FIG. 2  is another perspective view of the components that form a plastic sleeve packaging solution showing the primary packaging  100  coupled with the traveler mechanism  200  according to an embodiment of the invention. In this illustration, the primary packages  300  have been looped over the posts  230  (not seen here) and the top piece  204  and the bottom piece  206  have been snap fit (or glued or adhered in some other manner) together. The combination of the traveler mechanism  200  and the primary packages  300  are ready for placement within the secondary package  100 . 
         [0025]    The preferred method of constructing the entire packaging system first loops the primary packages  300  over the posts  230  of the traveler mechanism  200 . The traveler mechanism  200  is then snap fit together to produce what is shown in  FIG. 2 . The next step would be to place the combined traveler mechanism  200  and primary packages  300  on top of the bottom piece  104  of the secondary package  100  such that the traveler mechanism  200  will slide along the bottom surface of the bottom piece  104 . The top piece  102  of the secondary package  100  can then be snap fit to the bottom piece  104  thereby securing the traveler mechanism  200  within the chamber defined by the assembled secondary package  100 . The open end of the secondary package  100  is carved slightly inward and includes a plurality of traveler stops  110  such that the traveler mechanism  200  can not be completely withdrawn from the secondary package  100 . The opening is slightly smaller than the size of traveler mechanism  200 . The flat edge of the traveler mechanism  220  will contact the traveler stops  110  of the secondary package  100  to prevent the traveler from being completely withdrawn. Also shown is the locking tab release  120  on the top piece  102  of the secondary package  100 . 
         [0026]      FIG. 3  is a see through perspective view of the plastic sleeve packaging solution showing the primary packaging  300  coupled with the traveler mechanism  200  and seated within the secondary packaging  100  according to an embodiment of the invention. In this illustration, the secondary packaging  100  is shown as transparent allowing a view to the inside of the secondary packaging  100 . The primary packaging and traveler mechanism  200  have been inserted completely within the secondary packaging such that the child resistant locking mechanisms have engaged. In this instance, the inside surface of the top piece  102  of the secondary package  100  includes an elongated tapered stop  130  just forward of the locking tab release  120 . As will be more fully described later, the traveler mechanism  200  slides over the elongated tapered stop  130  until it catches on the other side of the stop  130 . Once caught, the traveler mechanism  200  can only be released using the locking tab release  120 . 
         [0027]      FIG. 4  is another see through perspective view of the plastic sleeve packaging solution showing just the traveler mechanism  200  seated within the secondary packaging  100  according to an embodiment of the invention. This view eliminates the primary packaging  300  from view so that the interaction between the traveler mechanism  200  and the secondary packaging  100  can be seen. As described earlier, the traveler mechanism  200  will slide over the elongated tapered stop  130  until it catches on the other side of the stop  130 . The traveler mechanism  200  includes a combination flexible release tab  205  and release tab stop  210 . As the traveler mechanism  200  slides over the elongated tapered stop  130 , the flexible release tab  205  is deformed until it springs back into place one the elongated tapered stop  130  has been cleared. At this point the release tab stop  210  will engage the elongated tapered stop  130  if the traveler mechanism  200  is pulled outward preventing the withdrawal of the traveler mechanism  200 . Only when the flexible release tab  205  has been deformed again to allow the release tab stop  210  to clear the elongated tapered stop  130  can the traveler mechanism  200  be withdrawn. This occurs when the locking tab release  130  on the secondary package  100  is depressed inward by the user enough to cause the flexible release tab  205  to deform. The traveler mechanism  200  can now be withdrawn up to the point where the flat edge  220  meets the traveler stops  110  of the secondary packaging  100 . 
         [0028]    It should be noted that the locking mechanisms just described can be placed on the top portion of the packaging system, the bottom portion of the packaging system or on both the top and bottom portions of the packaging system. 
         [0029]      FIG. 5  is a first perspective view of the traveler mechanism  200  in a closed position according to an embodiment of the invention. The purpose of the traveler mechanism  200  is to (1) receive and secure a plurality of primary packages  300 , and (2) slidably and securely engage with a secondary package  100  such that the primary packages  300  can be accessed by a user of the packaging system. 
         [0030]    To achieve the first purpose, the traveler mechanism  200  includes a pair of posts  230  that are adapted to fit within corresponding apertures  310  of the primary packages  300  to securely connect and retain the primary packages  300  to the traveler mechanism  200 . Securing and retaining the primary packages  300  to the traveler mechanism  200  is a process that begins before the traveler mechanism is fully assembled as shown in  FIG. 5 . 
         [0031]    To achieve the second purpose, the traveler mechanism  200  has been constructed and shaped to fit within the chamber defined by the assembled secondary packaging  100 . In one embodiment, the traveler mechanism  200  is comprised of two pieces that can be snap fit to one another to form the single mechanism. The two piece structure permits exposing the aforementioned posts  230  such that the primary package apertures  310  can be looped over the posts  230  before the traveler mechanism  200  is snap fit (or glued or otherwise adhered) together. The traveler mechanism  200  design allows the traveler mechanism  200  and primary packages  300  combination to be seated within the chamber defined by the assembled secondary packaging  100  such that it can slide back and forth within the chamber. There are components on both the traveler mechanism  200  and the secondary packaging  100  that cooperate at either end of the chamber. On the open end of the chamber, the traveler mechanism includes a flat surface  220  that will engage a traveler stop  110  on the secondary package  100  to prevent the traveler mechanism  200  (and primary packages  300 ) from being completely separated from the secondary packaging  100 . On the closed end of the chamber, the traveler mechanism includes a combination flexible release tab  205  that includes a release tab stop  210  that can be depressed inward when an external force is applied. The combination flexible release tab  205  that includes a release tab stop  210  is designed to engage and cooperate with elongated tapered stop  130  that is part of the inner upper surface of the secondary packaging  100 . As the traveler mechanism  200  slides further into the chamber of the secondary package  100  it eventually encounters the elongated tapered stop  130  and begins to depress inward as it rides up the tapered aspect of the elongated tapered stop  130 . Once it clears the length of the elongated tapered stop  130  the combination flexible release tab  205  that includes a release tab stop  210  snaps back to its original position such that the release tab stop  210  abuts the non-tapered straight edge of the elongated tapered stop  130 . In this ‘locked’ position, the traveler mechanism  200  can not be withdrawn (without unlocking) because the release tab stop  210  will engage the non-tapered straight edge of the elongated tapered stop  130  whenever the combination traveler mechanism  200  and primary packages  300  is attempted to be withdrawn. 
         [0032]    While the traveler mechanism  200  (and secondary packaging  100 ) interaction above has been described as applied with respect to the top portion of the traveler mechanism  200 , it may also be applied to the bottom portion of the traveler mechanism  200  either in lieu of the top portion or in addition to the top portion. 
         [0033]      FIG. 6  is a second perspective view of the traveler mechanism  200  in a closed position according to an embodiment of the invention. This illustration affords another view of the combination flexible release tab  205  that includes a release tab stop  210 . 
         [0034]      FIG. 7  is a third perspective view of the traveler mechanism  200  in an open position according to an embodiment of the invention. This illustration shows how the posts  230  can be exposed prior to assembly such that the primary packages  300  can be looped over the posts  230  via the apertures  310  included on the primary packages  300 . A pair of post snap fit connectors  235  are illustrated that will engage the hollowed out tops of the posts  230  when the traveler mechanism  200  is snapped (or glued or otherwise adhered) into the closed position. 
         [0035]      FIG. 8  is a first see through cut-away side view of  FIG. 4 . This illustration affords a view of the traveler mechanism  200  (without primary packages  300  attached) in the locked position within the secondary package  100 . The combination flexible release tab  205  that includes a release tab stop  210  is shown abutting up against the non-tapered straight edge of the elongated tapered stop  130 . If a user were to try to slide the traveler mechanism  200  out of the secondary package  100  without releasing the locking mechanism, the release tab stop  210  would engage the non-tapered straight edge of the elongated tapered stop  130  enough to prevent withdrawal of the traveler mechanism  200 . However, if the locking tab release  120  on the top piece  102  of the secondary package  100  were to be depressed enough by the user, it would depress the combination flexible release tab  205  that includes a release tab stop  210  to the point that the flexible release tab  205  would clear the non-tapered straight edge of the elongated tapered stop  130  enough to allow the traveler mechanism to be withdrawn. 
         [0036]      FIG. 8  further shows that the locking and release components and mechanisms ( 110 ,  120 ,  130   205 ,  210 ) can be (but do not necessarily need to be) duplicated on the top and bottom surfaces of the packaging solution. 
         [0037]      FIG. 9  is a second see through cut-away side view of  FIG. 4 . This illustration affords a different view of the traveler mechanism  200  (without primary packages  300  attached) in the locked position within the secondary package  100 . The combination flexible release tab  205  that includes a release tab stop  210  is again shown abutting up against the non-tapered straight edge of the elongated tapered stop  130 . 
         [0038]    The description above has described a locking/release mechanism in which the traveler mechanism  200  is completely contained within the secondary package  100 . An alternative embodiment is one in which the secondary package  100  includes an aperture rather than a locking tab release  120  and the release tab stop  210  on traveler mechanism  200  is inverted such that it protrudes from the aperture on the secondary package  100 . In this embodiment, the user would apply an inward force on the inverted release tab stop to force it back within the interior chamber of the secondary package  100  to ‘unlock’ the packaging solution at which time the traveler mechanism  200  could be withdrawn from the secondary package to expose the attached primary packages  300 . 
         [0039]    The size and depth of the secondary package  100  and traveler mechanism  200  are generally a function of the number and depth of the primary packages  300 . The greater the number of primary packages to be included in a packaging solution, the deeper the secondary package  100  and traveler mechanism  200 . 
         [0040]    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 preferred embodiments.