Abstract:
A self-locking package comprising a sleeve having a self-initializing locking tab and a slidable insert. The sleeve comprises a plurality of panels forming a substantially quadrilateral cross section. The locking tab extends between a top panel and a bottom panel and is offset from corners of the qudralateral. An insert for retaining an item is at least partially insertable within an opening of the sleeve and includes a notch formed in at least one portion of the perimeter of the insert, such that when the insert is properly inserted into the sleeve, the locking tab seats within the notch to substantially prevent relative movement between the insert and the sleeve.

Description:
FIELD OF THE DISCLOSURE 
       [0001]    The present disclosure relates generally to a self-locking merchandise package and more particularly to a package with a sleeve having a self-initializing locking tab. 
       BACKGROUND OF RELATED ART 
       [0002]    Packaging containers including foldable tabs for retaining a slidable insert are generally well known. For example, U.S. Pat. No. 6,168,073, describes a storage container having an integrally formed inner and outer member. The inner member is slidably movable between a retracted position within the outer member and an extended position extending from the front opening of the outer member. The outer surface of the outer member includes accessible and moveable securement tabs at the end near the opening to temporarily secure the inner member within the outer member as desired. The securement tabs may be re-actuated as many times as desired. 
         [0003]    Similarly, U.S. Pat. No. 3,521,810 describes an adjustable length container having an outer sleeve slidable over an inner sleeve. The inner sleeve includes a plurality of slits along the length of the container and the outer sleeve includes a plurality of slits that are capable of being forced inward by a tab formed on the outer sleeve to lock the sleeves together and to prevent relative movement of the sleeve. The lock may be repeatably removed and reapplied as desired to adjust the length of the container. 
         [0004]    U.S. Pat. No. 7,882,953 describes another example of an externally accessible locking tab disposed on the end portion of a sleeve to temporarily maintain a slidable insert therebetween. The package includes a sleeve having foldable tabs at the top and bottom that lock into indents at the top and bottom of the insert. Finally, U.S. Pat. No. 7,389,875 describes a package having an insert slidable into a sleeve. The sleeve includes a locking member having a tortuous path including an arch-shaped portion extending into the rectangular cross section to releasably retain the insert. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]      FIG. 1  is a top perspective view of an example package in accordance with one example of the present disclosure. 
           [0006]    FIGS  2 A and  2 B each illustrate a plan view of a face of an example blank which may be utilized to construct an outer sleeve of the example package of  FIG. 1   
           [0007]      FIG. 3  is a perspective view showing on example method of assembling the example blank of  FIGS. 2A and 2B . 
           [0008]      FIG. 4  is a bottom elevational view of the assembled sleeve of  FIG. 3  prior to opening. 
           [0009]      FIG. 5  is a bottom elevational view of the assembled sleeve of  FIG. 3  after opening and showing deployment of the self-initializing locking tab. 
           [0010]    FIG  6 . is a top plan view of an example tray for use in combination with the example sleeve of  FIG. 5 . 
           [0011]      FIG. 7  is a bottom elevational view of the example tray of  FIG. 6 . 
           [0012]      FIG. 8  is a top perspective view of the example assembled package of  FIG. 1 , showing a portion of the sleeve removed to expose the locking tab and notch. 
           [0013]      FIG. 9  is a front elevational view of the example assembled package of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    The following description of example methods and apparatus is not intended to limit the scope of the description to the precise forms detailed herein. Instead the following description is intended to be illustrative so that others may follow its teachings. 
         [0015]    There remains a need for improvement over the known locking sleeves. For example, in the present disclosure, the example package generally includes an outer folded sleeve having a self-initializing locking tab and an inner formed tray. The tray, when inserted into the sleeve is used to contain product and prevents easy removal. When the two pieces are assembled, the interlock between the sleeve and the tray is difficult to detect and the pieces difficult to separate. The outer sleeve is capable of being folded essentially flat and has a locking tab that deploys automatically when erected from the flat position into the final profile shape. The tray, meanwhile, includes a reverse shaped notch that the erected locking tab on the sleeve keys into. 
         [0016]    Because of at least the above-described features, the package described herein provides an advantage over the known locking sleeves. For instance, the in the describe package, no additional equipment or operations are necessary to facilitate the internal locking feature. Insertion of the tray into the sleeve is easy, while removal of the tray is difficult without damaging the outer sleeve. The item(s) in the container tray may be completely secured within the sleeve preventing removal of the item, and the packaging around the outer sleeve may be used to obscure the locking mechanism, thus making it difficult to detect and overcome. 
         [0017]    Referring to  FIG. 1 , an example package assembly  10  is generally shown. The example package  10  includes an insert, such as, a product tray  12  and a locking sleeve  14 . As illustrated, the example sleeve  14  is adapted to receive and lockingly retain the tray  12  as will be described in detail below. The tray  12  may be any packaging tray suitably sized to contain a merchandise item therein. Similarly, the sleeve  14  may be suitably sized to at least partially enclose the tray  12  and/or any item contained by the tray  12  within the sleeve  14 . Both the tray  12  and the sleeve  14  may be formed of any suitable paper, metal, and/or plastic material including, but not limited to, polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyethylene teraphthalate glycol (PETG), polylactic acid (PLA), polypropylene (PP), oriented polystyrene (OPS), or the like. Either of the tray  12  or the sleeve  14  may be constructed of a resilient and/or otherwise flexible material, or may alternatively comprise a substantially rigid material. Additionally, in at least one example, the tray  12  is thermoformed and/or otherwise molded to provide a custom cavity  13  (in this example, a rectangular shaped depression) to retain the merchandise item therein. The example cavity  13  includes end walls  15  that prevent access to the cavity  12  when the tray  12  is retained by the sleeve  14 . 
         [0018]    As will be detailed below, once assembled, the locking sleeve  14  creates an interlock with the tray  12  such that the package  10  is difficult to separate. In this example, the interlock is located offset from the open end of the sleeve  14  and the closed end  15  of the tray  12  such that physical interaction with the interlock may be difficult when the tray  12  is retained in the sleeve  14 . Additionally, in at least one example, the locking mechanism may be hidden from external view (through printing, graphics, constructions, etc) thus making the interlock mechanism difficult to detect and/or defeat. 
         [0019]    As illustrated in  FIGS. 2A ,  2 B, the example sleeve  14  is shown prior to assembly as a sleeve blank  16 . The example sleeve blank  16  includes a generally quadrate sheet of transparent plastic material having generally parallel top an bottom edges  20 ,  22 , and generally parallel first and second side edges  24 ,  26 , respectively. The blank  16  defines a first face  28  ( FIG. 1A ) and a second face  30  ( FIG. 1B ). In this example, the first face  28  will ultimately become the outer face of the assembled sleeve  14 , while the second face  30  will ultimately become the inner face of the sleeve  14 . It will be understood that the blank  16  may be at least partially formed of a material that is transparent, translucent, opaque, clear, or any combination thereof. Additionally, the blank  16  may include graphics, printing, texturing, and/or any other surface ornamentation and/or design on either face  28 ,  30  as desired. 
         [0020]    In this example, the blank  16 , when assembled, forms the sleeve  14  with a generally rectangular cross section with open ends as will be described. Accordingly, in this example the sleeve  16  includes first, second, third, and forth fold lines  32 ,  34 ,  36 ,  38 , respectively provided generally parallel to the side edges  24 ,  26  for dividing the blank  16  into five panels  40 ,  42 ,  44 ,  46 , and  48 . The fold lines  32 ,  34 ,  36 ,  38  may be any fold line, and/or any suitable line of weakness, such as for example, a perforated line. Additionally, in this example, at least the fold lines  32 ,  34  are perforated sufficiently so that the may be torn and/or otherwise broken along the fold line  32 ,  34  to open the package  10  once fully assembled. It will be appreciated that in other examples, additional or alternative perforations, apertures, and/or other opening means (tabs, adhesives, etc.) may be provided at the same or different locations as desired. 
         [0021]    In the example blank  16 , the first panel  40  and the third panel  44  are substantially equal width, and the second panel  42  and the third panel  46  are similarly substantially equal width. Together the first, second, third and fourth panels  40 ,  42 ,  44 , and  46  form the sleeve  14  when folded in the same direction along the fold lines  32 ,  34 ,  36 ,  38 . The example panel  48  is an adhesive panel suitable for accepting an adhesive  50  on the first face  28 . In this example, the panel  48  is illustrated as depending from the fourth panel  46 , but may depend from the first panel  40  in other examples. Additionally, while the adhesive  50  is illustrated as being applied to the first face  28  of the panel  48 , it will be understood that the adhesive may be applied to any surface or combination of surfaces in any pattern as desired. In this example, the adhesive  50  is a substantially permanent adhesive, disposed in a linear pattern, although any suitable adhesive may be utilized in any suitable pattern. 
         [0022]    Depending at least partially from the panel  48  is a locking tab  52 . The example locking tab  52  is separated from the panel  48  along the top edge  54  and the bottom edge  56  and it connected to the panel  48  at a fold line  58 . The fold line  58 , in this example, is offset from the fold line  38  towards the side edge  26 . The locking tab also includes a second fold line  60 . In this example, the distance between the fold line  58  and the second fold line  60  of the locking tab  52  is at least the same or greater width as the width of the panel  46 . The fold lines divide the locking tab into a locking portion  52 A and a adhesive portion  52 B. The second face  30  of the adhesive portion  52 B of the locking tab  52  may be provided with an adhesive  62 . Similar to the adhesive  50 , the adhesive  62  is a substantially permanent adhesive, disposed in a spot pattern, and may be any suitable adhesive in any suitable pattern, disposed on any suitable surface, such as for example, the surface  30  of the panel  44 . 
         [0023]    Referring to  FIG. 3 , to assemble the sleeve  14 , the example sleeve blank  16  is first folded about the fold line  38  such that the adhesive  62  (hidden from view in  FIG. 3 ) on the locking tab  52  contacts and adheres to the second face  30  of the panel  44 . The blank  16  is then folded about the fold line  34  until the second face  30  of the panel  40  contacts and adheres to the adhesive  50  on the first face  28  of the panel  48 . Thus, as is evident, the example sleeve  14  forms a hollow container having two open ends to allow passage of the example tray  12  therein. It will be appreciated that the method, steps, and/or order of assembling the sleeve  14  may vary without departing from the scope of the present disclosure. 
         [0024]    Turning to  FIG. 4 , the example assembled sleeve  14  is illustrated in a bottom elevational view, with the sleeve  14  rotated from  FIG. 3  such that the panel  40  is now at the bottom. In the illustrated example, it can be seen that the sleeve  14  folds essentially flat, which may be beneficial in storing, shipping, and/or otherwise handling the sleeve  14 . When the sleeve  14  is ready for final assembly with a corresponding tray  12 , the sleeve  14  is opened by folding the sleeve  14  along the remaining fold lines  36  and  32  as illustrated in  FIG. 5 . Upon opening the sleeve  14 , the locking tab  52  is self-initializing in that it is automatically deployed in a locking position wherein the locking portion  52 A of the locking tab  52  is offset from the panel  46 . In this example, the locking tab  52 , the panel  46  and portions of the panels  40 ,  44  form a quadrilateral. 
         [0025]    The relative offset position of the locking portion  52 A from the panel  46  is dependent upon the offset dl of the fold line  58  from the fold line  38 , as well as the length of the locking portion  52 A between the fold lines  58  and  60 . In this example, the offset distance of the locking portion  52 A from the panel  46  increases as the locking portion moves away from the panel  40  (d 1 ) toward the panel  44  (d 2 ) because the overall length of the locking portion  52 A is slightly greater than the width of the panel  46 . It will be understood, however, that the length of the locking portion  52 A may be adjusted to adjust the offset distance from the panel  46  as desired. 
         [0026]    Additionally, in this example, the locking portion  52 A is defined as an uninterrupted panel without any fold lines, hinges, or any other lines of weakness. Thus, the maximum offset distance of the locking portion  52 A from the panel  46  will be the offset distance d 2 . Accordingly, in the examples presented, the locking portion  52 A will not extend beyond the maximum offset distance d 2  under normal circumstances, i.e., when the sleeve  14  and/or the locking portion  52 A are not under the influence of any forces manipulating the shape beyond the intended design. 
         [0027]    Furthermore, in this example, the sleeve  14  when examined from the bottom elevational view presents a generally rectangular profile, which because of the flexibility of the example material may be manipulated into a trapezoidal profile having a slightly arced upper panel. It will be appreciated by one of ordinary skill in the art that the profile shape of the sleeve  14  may be varied as desired. 
         [0028]    Finally, while the example sleeve  14  is illustrated with only one locking tab  52  formed on a single side of the sleeve  14 , it will be understood that the sleeve  14  may include multiple locking tabs  52 , either along one panel of the sleeve  14 , or along multiple panels. 
         [0029]    Referring to  FIGS. 6 and 7 , there is illustrated an example of the tray  12  for use in combination with the sleeve  14 . In this example, the tray  12  is a three-dimensional tray for retaining merchandise and, as noted above, in at least one example, the tray  12  is thermoformed and/or otherwise molded to provide a custom cavity  13  (in this example, a rectangular shaped depression) to retain the merchandise item therein. The cavity  13  includes end walls  15  to close the open end of the sleeve  14  and to prevent removal of any item in the cavity  13  when the tray  12  is retained in the sleeve  14 . In other examples, the cavity may be molded to retain other merchandise items, such as, for example, disposable razors, or any other item. In this example, the tray  12  includes an exterior surface end elevational profile corresponding to the interior profile of the sleeve  14 . In order to better secure the tray  12  within the sleeve  14 , in this example the general profile of the tray  12  (see  FIG. 7 ) is within a relatively small tolerance of the interior profile of the sleeve  14 , and has a profile larger than the profile of the sleeve  14  in combination with the locking tab  52 . 
         [0030]    The example tray  12 , includes an indent, depression, channel, etc, such as a notch  80  formed in a portion of the tray  12  and located such that when properly inserted into the sleeve  14 , the notch  80  will matingly engage with the locking tab  52 . As seen in  FIG. 6 , the width N of the example notch  80  substantially corresponds to the width of the locking tab  52 . The notch  80  may also include at least one cammed surface  82  to bias and/or retain the locking tab  52  within the notch  80  when the locking tab  52  is seated within the notch  80  upon assembly. Still further, in at least one example, the leading edge of the tray  12  (e.g., the edge inserted into the sleeve  14  during assembly, see  FIG. 1 ) and/or the trailing edge of the tray  12  may include a cammed surface  84  to assist in translating the locking tab  52  toward the panel  46  to allow the sleeve  14  to traverse the tray  12 . 
         [0031]    Referring again to  FIG. 1 , an example method of assembling the package  10  is illustrated. In this example, the opened sleeve  14  is ready to receive the tray  12 , which has already been provided with the item to be packaged. Although not shown in  FIG. 1 , it will be appreciated that the locking tab  52  is deployed as illustrated in  FIG. 5 . In this example, the tray  12  approaches the sleeve  14  at an angle, such as for example, at approximately twenty-five degrees. In this manner, the leading edge of the tray  12  may contact the locking tab  52 , and the tray  12  may be rotated to depress the locking tab towards the panel  46  and allow the tray  12  to slide into the sleeve  14 . Alternatively, as noted above the leading edge of the tray  12  may be provided with a rounded, smooth, or otherwise cammed surface  84 , and/or a reduced cross section to similarly allow the tray  12  to pass beyond the locking tab  52 . 
         [0032]    Once sufficiently inserted into the sleeve  14 , the locking tab  52  aligns with the notch  80 , and the locking tab  52  is free to resiliently rebound into its non-depress state, thus seating the locking tab  52  into the notch  80  as is illustrated in  FIG. 8 . As shown in  FIG. 8 , the locking tab  52  is fully seated into the notch  80  such that relative movement of the tray  12  in the sleeve  14  is sufficiently prevented. In other words, in this example, the seating of the locking tab  52  within the notch  80  is sufficient so as to prevent sliding of the tray  12  out of the sleeve  14 , thus securing the contents of the tray  12  within the sleeve  14  by preventing opening of the package  10  without destroying the package  10 . Therefore, the package  10  provides a sufficient theft deterrent, by preventing covert removal of the contents of the package  10 . 
         [0033]    Because a legitimate consumer may wish to remove the tray  12  from the sleeve  14 , without having to resort to manually ripping and/or otherwise destroying the package  10 , one or more of the fold lines of the sleeve  14  may be perforated to allow a purchaser to easily open the package  10 . As illustrated in the example of  FIGS. 2A ,  2 B, and  8 , the top of the panel  42  is provided with an arcuate portion  42   a.  The arcuate portion  42   a  forms a tab sufficient to allow a purchaser to grab and rip the panel  42  from the sleeve  14  along the perforated fold tabs  32  and  34 . It will be appreciated that the sleeve  10  may be provided with an additional and/or alternative opening portions including apertures, removable labels, perforated sections, or any other suitable opening means. Thus, in this example, it will be understood that the package  10  is not intended for reuse and/or multiple open/close cycles, but it can be appreciated that by providing certain materials, such as an unlock tool or various non-deformable materials, the package  10  may be reused as desired. 
         [0034]    As shown in the example of  FIG. 9 , the disclosed package  10  may provide for at least one additional benefit. In particular, as noted above, the sleeve  14  may comprise a portion that is at least transparent to allow a person and/or machine to view the product disposed inside the tray  12 . This visual reference may be for the benefit of inventory control, or may be for visual marketing purposes. Regardless of the transparency of the sleeve  14 , the sleeve  14  may also be provided with at least one opaque area  100  such as mentioned above a printing, graphic, label, etc, to obscure the locking tab  52  from external view thus making the locking tab  52  difficult to detect and/or defeat. 
         [0035]    Additionally, the cross section of the sleeve  14  ad the tray  12  may allow the package to be displayed standing on a support surface  102 , thus obviating the need to hang the package. 
         [0036]    Finally, as shown in  FIGS. 1A ,  1 B, at least one of the panels, in this example, panel  40 , may be provided with an additional and/or integrated appendage, portion, and/or accessory to provide a convenient way to display the assembled package  10 . For instance, if it is desired to hang the package  10 , at least one hanging aperture  104  may be provided on at the appendage to allow the package to be display by hanging. 
         [0037]    Although certain example methods and apparatus have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus, and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.