Abstract:
An improved insert card is provided. The various embodiments include improved hinges, locking tabs, ribs, detachable base panel with center bar, grips, fold-resisting abutments, and fold-over panels.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of priority of U.S. provisional application Ser. No. 60/803,301 filed on May 26, 2006, which is hereby incorporated by reference in its entirety. 

   FIELD OF THE INVENTION 
   This invention relates to sleeve-and-insert type packaging. More particularly, the invention relates to a novel insert for a sleeve-and-insert type package that is suitable for use as an integral blister card or a receiving tray. 
   BACKGROUND OF THE INVENTION 
   A sleeve-and-insert type of package is a package wherein a substantially planar member is housed within an enclosure from which it may be partially or fully removed to gain access to items held on one or more surfaces of the planar member. The planar member may be identified by several alternative names including but not limited to an “insert,” a “card,” an “insert card,” a “slide card,” and a “sliding element.” These terms will be used interchangeably herein. 
   Sleeve-and-insert type packaging is useful for a variety of purposes; including the sale and distribution of items that may be juxtaposed permanently or temporarily in some manner with respect to the insert. A sleeve-and-insert type of package is particularly useful as a so-called “unit-dose packaging system.” In a unit-dose packaging system medicaments such as pills are removably held to the planar member in individual, or unit doses, typically within a blister. In alternative embodiments unit-doses, such as held in syringes, patches, inhalers, pouches, and the like, are mounted to a tray. Unit dose packaging systems are useful as a means for dispensing an individual, or a unit dose of a medicament. Such systems are even more useful when they have the added features of providing resistance to the package being opened by a child, while at the same time facilitating ease of opening, closing and general use by older individuals whose manual dexterity may have decreased with age. These two features are typically referred to as “child-resistant” and “senior-friendly,” respectively. 
   Preventing or inhibiting undesired partial or full removal of the inner slide card from the sleeve/shell is important in helping facilitate resistance to child tampering and use by seniors. In addition, preventing or inhibiting widespread access to the items held by the sliding element is important to child-resistance. Thus, it will be appreciated that it is useful to have a unit dose package with additional novel features that prevent or inhibit the undesired access of items held by the inner card. 
   Because decreased cost and increased ease of manufacturing are desirable, it will likewise be appreciated that it is beneficial to have a child-resistant and senior-friendly unit dose package that is efficient to operate, is durable and sturdy, and simple to construct, thereby reducing the cost and inefficiencies of manufacture. 
   SUMMARY OF THE INVENTION 
   The present invention overcomes the shortcomings of the prior art by providing features that improve the ease of manufacturing, lower the cost of manufacturing, improve the ease of use, and improve the child-resistance features of an individual insert card as well as sleeve-and-insert package as a whole. These features include a monolithically formed slide card, blisters integral to the slide card, blisters integral to the slide card that are detachable, a detachable locking panel attached to the slide card, improved locking elements, features that increase the durability of the locking elements, ribs that improve the strength and durability of the slide card, ribs that improve the strength of the sleeve, and ribs that interfere with unintended access to the blisters such as by a child trying to bite their way through the sleeve and/or slide card. 
   According to one aspect of the invention, an improved locking panel with at least one reinforcement element to inhibit deformation hingedly extends from the base panel. In another embodiment, at least two locking panels hingedly extend from the base panel. According to a further aspect of the invention two adjacent locking panels are separated from one another, by a cut line or a slot or a similar means for separation. According to an additional aspect of the invention, the base panel has at least one reinforcement elements to inhibit deformation of the base panel. According to still an additional aspect of the invention, the base panel has an arrangement of one or more ribs. 
   In accordance with another aspect of the invention, the base panel includes a raised grip configured to improve access and withdrawal of the slide card from a sleeve. In accordance with still a further aspect of the invention, either the locking member or the base panel includes a fold-resisting abutment for improving lockability between the sleeve and card. In accordance with still another aspect of the invention, at least one fold-over panel is hingedly connected to the base panel, and either or both of the base panel and fold-over panel has at least one rib. In accordance with one more aspect of the invention, a fold-over panel is hingedly connected to the base panel. There the base panel and fold-over panel have complementary, cooperating ribs for nesting or interlocking the folded panels. 
   Also taught herein are insert cards comprising a monolithically formed base panel with at least one hingedly attached locking panel that includes at least one engaging edge. There, at least one blister is integrally formed within the base panel to define a blister opening configured to receive an item that is stored by the blister. Other features of the exemplary insert cards include a seal over the blister opening and at least one rib extending from the base panel. In some embodiments the rib is positioned proximate to the perimeter of the base panel but the ribs may be located anywhere on the insert card. 
   Additional features of some insert cards include an abutment that inhibits a face-contacting relationship between the base panel and locking panel, wherein at least a portion of the perimeter of the abutment is curved. Further, the base panel can include an extended grip portion for easier access once the insert card has been released from the sleeve. In other embodiments, the blisters are detachable for ease of use. In some of those embodiments the blisters are detachable so as to define a center bar that allows the insert card to fully function within the sleeve even after blisters are removed. In still other embodiments, the locking panel is detachable from the base panel. 
   Further described and taught herein are insert cards that include one or more hingedly attached fold-over cards. In those embodiments the fold-over cards can include features such as ribs, blisters, abutments, posts, and combinations and the like, that interface, interlock, or otherwise cooperate with one or more similar features of the base panel to nest the folded panels, lock the folded panels, or keep the folded panels spaced apart. 
   In addition to the insert cards described, taught and claimed herein, a packaging system that incorporates the insert cards is described, taught and claimed. The exemplary system includes a releasably lockable sleeve, as taught in previous applications filed by the present applicant, configured to receive an insert card described, taught or claimed herein. Further, the description includes a method of using the insert cards described, taught and claimed herein. Additional embodiments include insert cards wherein the items are not held to the base panel by blisters but by other means for securing, including clips, ties, receiving inserts, tabs, locking posts, tape, hook and loop fasteners, ribs, springs, combinations thereof, and the like. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of an exemplary embodiment of a slide card, according to the present invention. 
       FIG. 2  is a plan view of an exemplary embodiment of a slide card, according to the present invention. 
       FIG. 3  is a plan view of an exemplary embodiment of a slide card, according to the present invention. 
       FIG. 4  is a plan view of an exemplary embodiment of a slide card, according to the present invention. 
       FIG. 5  is a plan view of an exemplary embodiment of a slide card, according to the present invention. 
       FIG. 6  is a plan view of an exemplary embodiment of a slide card, according to the present invention. 
       FIG. 7  is a plan view of an exemplary embodiment of a slide card, according to the present invention. 
       FIG. 8  is a plan view of an exemplary embodiment of a slide card, according to the present invention. 
       FIG. 9  is a side elevation view of the exemplary slide card of  FIG. 8 . 
       FIG. 10  is a plan view of an exemplary embodiment of a slide card, according to the present invention. 
       FIG. 11  is a plan view of an exemplary embodiment of a slide card, according to the present invention. 
       FIG. 12  is a plan view of an exemplary embodiment of a slide card, according to the present invention. 
       FIG. 12   a  is a cross-section elevation view of the ribs of exemplary folded cards, of  FIG. 12 . 
       FIG. 13  is a plan view of an exemplary embodiment of a slide card, according to the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   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. 
   For the purposes of teaching and illustration, and not limitation or restriction, the illustrated embodiments of the present invention reference pharmaceutical products such as medicaments in the form of tablets, pills and the like. It is contemplated that the present invention is not limited to the pharmaceutical-related goods referenced with the illustrated embodiments, but is applicable to any small, delicate, sensitive, or portable item. Accordingly, the present invention can be used with all nature of small and portable items that the user may want to hold and store in a releaseably lockable container and dispense in a regulated manner. Further, the present invention is not limited to the blister packs referenced with the illustrated embodiments, but is applicable to any tray, card, rack, pack, pouch, and the like to which an item of any sort may be held, stored, attached, secured or otherwise associated with the item. 
   Referring now to  FIG. 1 , an exemplary embodiment of a slide card  100  is shown. The slide card  100  is primarily for use with a releaseably lockable sleeve, as taught in one or more prior applications or patents filed by the present applicant, and includes a base panel  110  and a locking panel  115 . The locking panel  115  includes an engaging edge  118 . The base panel  110  is connected to the locking panel  115  by a hinge  120 . The base panel  110  has formed cavities or blisters  125  for receiving an item. In the exemplary embodiment, the blisters  125  are integrally formed with the base panel  110  and a seal, such as a foil or paper substrate, is attached to the base panel  110  to enclose the item within each blister  125 . The items are thereby held in place within the blisters  125  until being removed by known methods. 
   The slide card  100  can be made of any material including paper or plastic, formed by manufacturing processes including thermo-forming or die-pressing. The hinge  120  can be formed in any configuration by forming a fold line, score line, cut line, perforation lines, or any combination thereof, and the like. The locking panel  115  is pivotable about the hinge  120  such that it can engage a locking element in the sleeve, and thereby inhibit undesired removal of the slide card  100  from the sleeve. In the embodiment shown in  FIG. 1 , the slide card  100  is a thermo-formed plastic blister card used to hold medicaments. 
   In the exemplary embodiments shown in  FIGS. 2-4 , the slide cards  200 ,  300 ,  500  include multiple locking panels  215 ,  315 ,  515 , respectively. The locking panels  215  of the slide card  200  are each defined by a hinge  220  and separated from one another by a cut line  230 . Similarly, the locking panels  315  are defined by a hinge  320  and separated from one another by a cutout  330 . The cutout may also be termed a slot. The illustrated locking panels  515  are triangular shaped and connected to the base panel  510  along respective hinges  520 . Alternative embodiments can include locking panels of alternative shape and additional number. 
   Each of the locking panels  215 ,  315 ,  515  on the respective slide cards  200 ,  300 ,  500  are independent from one another. Thereby, each of the locking panels independently engages a respective locking element of a related sleeve. Thus, to release the slide card from the sleeve, it is considered that one or more release mechanisms may be used to release the locking panels from their respective locking elements. For example, a single release mechanism may be used that releases each of the locking panels substantially simultaneously. Alternatively, each of the locking panels may have its own release mechanism. It is increasingly difficult to release the slide card from the sleeve as the number of release mechanisms that are required to be substantially simultaneously triggered to release the slide card from the sleeve increases. Accordingly, increasing the number of release mechanisms that are required to release the slide card improves the child resistance of the package. 
   Slide cards taught by the present invention may have at least one rib  235 ,  335 ,  535 . A rib, as taught by the present invention, is a raised member extending from a plane that is the surface of a base panel or the locking panel, or both. Ribs can extend in either direction, that is, upwardly or downwardly with respect to a surface of the panel, or both. The rib or a section of a rib may serve multiple purposes including, but not limited to, providing a barrier to a portion of the base panel (for example, forming a barrier around an item placed on the base panel), providing a barrier to resist application of a perpendicularly applied force (for example, crushing or biting), serving as a gripping structure to facilitate grasping of a base panel or locking member, and serving as structural reinforcement against deformation of the base panel or the locking panel, or both. 
   Certain embodiments of slide cards include at least one rib. Another advantage of the rib(s) taught herein is the increased rigidity to the slide card. The rib or ribs may be thermoformed or pressed into the slide card, or may be separately attached to the slide card. Referring to  FIGS. 2 and 3 , a U-shaped rib  235 ,  335  extends around the perimeter of the base panel  210 ,  310 , respectively. 
   Turning now to  FIG. 4 , there is shown an alternative embodiment in the form of a T-shaped rib  535  that extends along an edge and longitudinally along the substantial center of the base panel  510 . The slide card  500  further includes elongated ribs  536  that substantially align with respective locking panels  515  and are offset from the longitudinal portion of the rib  535 . Referring to  FIG. 5 , an L-shaped rib  735  extends around a portion of the perimeter of the base panel  710 . The slide card  700  further includes a longitudinal rib  736  to provide rigidity to a portion of the base panel  710 , which is offset from the rib  735 . Alternative embodiments (not shown) provide a slide card that includes a series or pattern of ribs which increase the rigidity of areas of the base panel and the locking panel, respectively. 
   It should be noted that the ribs are not limited to the locations, shapes, arrangements, or patterns described herein. Rather, the locations, shapes, arrangements, or patterns of the ribs are determined in order to increase the rigidity of the slide card, to accommodate the placement of blisters and other features, and provide other beneficial features. For slide cards that are thermoformed, a certain amount of rigidity is helpful to prevent or inhibit the slide card from curling or twisting after being formed. The ribs can be arranged to accommodate a desired blister layout or configuration, such as the layouts described herein. Accordingly, the location of ribs may be adapted to provide rigidity or other features without interfering with or obstructing the other elements of the slide card. 
   The ribs can be strategically located to provide beneficial features. For example, the ribs can be located to provide a child resistance feature, for example, such that the ribs prohibit biting into the card to access articles in the blisters. The location of each rib can provide additional functional benefits when the slide card is used in combination with a sleeve or outer carton. For example, disposing a rib at an end of the slide card, which corresponds with the open end of a sleeve, provides an end closure to the open end of the sleeve. Thereby, when the slide card is received in the sleeve, the rib protects the slide card and items contained therein from dust, pests, and unintended access. In the embodiments shown herein, the end of the slide card that corresponds to the open end of a sleeve is the end opposite the locking panel. 
   In certain embodiments, a slide card  100  is designed for being enclosed in a sleeve that includes a catch flap, as taught in previous applications filed by the present applicant. The catch flap is disposed at the open end of the sleeve such that, as the slide card  100  is pulled from the sleeve, the folded locking panel  115 ,  215 ,  315 ,  515 , of the slide card engages the catch flap, thereby preventing the slide card from being fully removed from the sleeve. If the slide card is inserted into the sleeve such that the side of the slide card from which the blisters protrude is adjacent to the wall of the sleeve that the catch flap is hingedly connected, the blisters may inadvertently interfere with the removal of the slide card. Specifically, the catch flap may engage one or more of the blisters, thereby preventing the slide card from being removed from the sleeve. In this case, ribs  235 ,  335 ,  535 ,  735  extend the length of the slide card to act as a bridge or as rails to prevent the blisters from engaging the catch flap as the slide card is removed from the sleeve. Here, also, but not necessarily, the rail portion of the ribs has a height that is no less than the height of blisters, allowing the catch flap to slide along the rails and not engage the blisters. The height of the rails and of the blisters is referenced relative to the base panel  210 ,  310 ,  510 ,  710 . 
   As shown in  FIGS. 6 and 7 , certain embodiments of slide cards  1100 ,  1300  include a raised grip  1140 ,  1340  that is disposed at the end of the base panel  1110 ,  1310 , respectively. The raised grip  1140 ,  1340  can be formed in a manner similar to the ribs  1135 ,  1335 . The size and shape of the raised grip  1140 ,  1340  is an ergonomic design decision, such that the raised grip  1140 ,  1340  facilitates access by the intended user. For example, the slide card  1100 ,  1300  can be captured between a user&#39;s thumb and finger, wherein the user&#39;s thumb contacts the convex surface and the user&#39;s finger contacts the opposite concave surface. In the embodiments shown in  FIGS. 6 and 7 , the raised grip  1140 ,  1340  is integral to the rib  1135 ,  1335 . However, in alternative embodiments, the raised grip  1140 ,  1340  may be detached or offset from the rib  1135 ,  1335  or the rib  1135 ,  1335  may be omitted. 
   Referring now to  FIGS. 8 and 9 , the ability of the locking panel  1515  of a slide card  1500  to be engaged by an aperture or panel that forms a part of the locking arrangement of the system&#39;s sleeve or shell (not shown), is enhanced by biasing the locking panel  1515  away from a substantially parallel condition with respect to the base panel  1510 . Fold-resisting features serve this purpose. The hinge  1520  serves as a fold-resisting mechanism to bias the locking panel  1515 . The amount of bias in the hinge  1520  may be controlled by additional manufacturing techniques including varying the thickness of the hinge  1520  or otherwise varying the degree to which a line forming the hinge  1520  is weakened to permit bending. 
   The base and locking panels  1510 ,  1515  of the slide card  1500  further include fold-resisting abutments  1545 ,  1550  that prevent the locking panel  1515  and base panel  1510  from being placed into a substantially parallel condition or face contacting arrangement with respect to one another. Although one fold-resisting abutment on either the locking panel  1515  or the base panel  1510  is sufficient to serve as a fold-resisting mechanism or element, more than one fold-resisting abutment may be used on either one or both panels  1510 ,  1515 . The use of opposing fold-resisting abutments  1545 ,  1550  on respective base  1510  and locking  1515  panels, provides the advantage of being able to minimize the height of each fold-resisting abutment  1545 ,  1550  while still achieving desirable fold resistance. Although each abutment may take many forms, an embossed abutment may be easily manufactured in a suitable substrate, particularly a substrate formed of plastic, paper, or a combination thereof, or other suitable materials. 
   The illustrated fold-resisting abutments  1545 ,  1550  are proximate to the hinge  1520 . Specifically, the fold-resisting abutment  1545  is disposed on the base panel  1510  and the fold-resisting abutment  1550  is disposed on the locking panel  1515  such that, when the locking panel  1515  is folded along the hinge  1520 , the fold-resisting abutments  1545 ,  1550  contact one another to provide support to the hinge  1520  or otherwise maintain the proper locking angle of the locking panel  1515 . In the exemplary embodiment, the fold-resisting abutment  1545  has a shape similar to a bubble or otherwise has a substantially semi-circular cross section. The fold-resisting abutment  1550  has a substantially rectangular cross section. It is noted that, in alternative embodiments, the fold-resisting abutments may have any size or shape that facilitates supporting the locking panel and hinge. 
   The fold-resisting abutment  1550  shown in  FIG. 8  includes a curved edge E that is proximal to the engaging edge  1518 . The edge E of the fold-resisting abutment  1550  is curved such that the locking panel  1515  resists buckling along the engaging edge  1525 . In addition, the fold-resisting abutment  1550  increases the rigidity of the locking panel  1515  to resist bending over the fold-resisting abutment  1545 . In other words, the locking panel  1515  may tend to fold at the edge E where the support of the fold-resisting abutment  1550  ends. The curvature of the curved edge E also resists the tendency of the locking panel  1515  to fold along a straight line and thus resists the undesired possibility of collapsing. With reference now to  FIG. 9 , a side elevation view of the slide card  1500  is shown. The locking panel  1515  is shown partially pivoted about the hinge  1520  with respect to the base panel  1510  to a position wherein it can engage one or more locking elements in a sleeve or shell to help form a locking arrangement. 
   Turning now to  FIG. 10 , a slide card  1700  includes a center bar  1755  defined by longitudinal and transverse lines of demarcation. Transverse lines of demarcation  1762  extend from the longitudinal lines of demarcation  1760  to define tear-away units  1765 . Each tear away unit  1765  is defined from a portion of the base panel  1710  and includes a blister  1725 . The center bar  1755  permits continued access to and use of the slide card  1700  within a sleeve as units  1765  are detached from the base panel  1710 . In the exemplary embodiment, the center bar  1755  is located in the center of the base panel  1710 . However, in alternative embodiments, the bar may be located in any suitable position. For example, the bar may be located adjacent to a longitudinal edge of the slide card  1700 . 
   Referring to  FIGS. 11-13 , embodiments of a slide card including a fold-over panel are shown. Beginning with  FIG. 11 , a slide card  1900  includes a fold-over panel  1970 . The fold-over panel  1970  is connected to the base panel  1910  by a hinge panel  1975 . Specifically, the hinge panel  1975  is hingedly connected to the panels  1910 ,  1970  along fold lines F. In this embodiment, the hinge panel  1975  includes an aperture P. The aperture P reduces the stress at the hinge panel  1975 . It is contemplated that a hinge may be defined by one or more apertures P and that the fold lines F may be omitted. The apertures P may be any suitable size or shape that facilitates reducing stress in a portion of the slide card between the base panel and the fold-over panel. It is further contemplated that the aperture P may be omitted and the fold lines may extend across the slide card to define a hinge panel. In alternative embodiments, it is contemplated that formed hinges or soft creasing may be used as a hinge. 
   With regard to  FIGS. 12 and 12   a,  a slide card  2000  includes a fold-over panel  2070  connected to the base panel  2010  by a hinge panel  2075 . Specifically, the hinge panel is connected to the panels  2010 ,  2070  along fold lines F. The base panel  2010  and the fold-over panel  2070  include U-shaped ribs  2035   a,    2035   b,  respectively. The U-shaped ribs  2035   a,    2035   b  correspond to one another such that, as the fold-over panel  2070  is folded to be substantially parallel to the base panel  2010 , the ribs  2035   a  on the base panel  2010  align and are in contact with the ribs  2035   b  on the fold-over panel  2070 . Specifically, the ribs  2035   a,    2035   b  are substantially similar in shape and are positioned substantially symmetrically about the hinge panel  2075 . As shown in  FIG. 12   a,  the ribs  2035   a,    2035   b  can be designed to matingly engage such that the slide card  2000  is maintained in the folded arrangement described above. The design of the ribs  2035   a,    2035   b  is not limited to that shown in  FIG. 12   a,  but include any corresponding cross-sections that facilitate maintaining the folded arrangement. For example, the cross-sections may be a protrusion and recess combination or each of the cross-sections may be defined by a common diagonal plane. In yet other embodiments, either set of ribs are wider and longer in order to receive the other set. In that configuration, the ribs are nested and the folded panels achieve a thinner profile. 
   With reference to  FIG. 13 , a slide card  2300  includes multiple fold-over panels  2370   a,    2370   b  connected to the base panel  2310  by hinge panels  2375   a,    2375   b,  respectively. Specifically, the hinge panels  2375   a,    2375   b  are connected to the base panel  2310  and to a respective fold-over panel  2370   a,    2370   b  along the fold lines F. In the exemplary embodiment, the hinge panel  2375   b  is wider than the hinge panel  2375   a  such that the fold-over panel  2370   a  can be folded onto the base panel  2310 , as described above, and the fold-over panel  2370   b  can subsequently be folded onto the fold-over panel  2370   a.  Thereby, the ribs  2335   a  of the fold-over panel  2370   a  are in contact with the ribs  2335   c  of the base panel  2010 , and the ribs  2335   b  of the fold-over panel  2370   b  are in contact with the outside surface of the fold-over panel  2370   a.    
   Alternative embodiments of the present invention include a slide card having a peelable backing, not shown. The peelable backing facilitates removal of items and can include foil or a combination of foil and tissue or kraft paper, and is sealed to the back of the blister. Frangible lines, such as perforated, cut, or score lines, are added to the peelable backing to define tabs which are peelable to expose the article within a blister. In this embodiment, a peel initiation area is located along the edge or perimeter of the slide card. In alternative embodiments, wherein a more child resistant peelable backing is desired, a peel initiation area may be located toward the center of the slide card. Advantageously, the slide card includes a stationary body member that may be engaged to grip the slide card before or after the tabs have been peeled away. It should be noted that the peelable backing can be incorporated into alternative embodiments, such as shown in  FIG. 10 . In that case, the center bar  1755  is, in effect, a stationary body member and, when a tear away unit  1765  is removed a small angled cut line defines the peel initiation location of a peelable backing. 
   It must be emphasized that 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.