Abstract:
A blank ( 10 ) for forming a secondary package without a heat-seal process is disclosed. The secondary package can be an inner slide card configured to receive one or more blister packs ( 51 ). A pocket opening ( 30 ) can be formed in one panel ( 14 ) of the blank ( 10 ). Receiving portions ( 44 ) can be formed on one or more panels. A blister pack ( 51 ) can be inserted into the secondary package through the pocket opening ( 30 ). The receiving portions ( 44 ) can mechanically interact with edges ( 56 ) of a blister pack ( 51 ) to retain the blister pack ( 51 ) in a desired position. The exit regions of an inserted blister pack ( 51 ) can be aligned with gates ( 40 ) formed in a panel ( 12 ) of the secondary package. When the blister pack ( 51 ) is in the proper orientation relative to the secondary package, the blister pack ( 51 ) can be locked in place mechanically, glued in place, or both.

Description:
RELATED APPLICATION 
     This application claims priority to U.S. Provisional Patent Application No. 60/869,004, filed Dec. 7, 2006, the entirety of which is hereby incorporated by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to packaging. More specifically, the present disclosure is directed to a secondary package for a blister pack. 
     BACKGROUND 
     Medications in the form of tablets, pills, capsules, gel tablets, and the like, are typically placed and sealed within a primary package, such as a conventional blister pack. Frequently, the primary package is then placed into a secondary package, such as a traditional box or carton, for eventual purchase and consumption of the medication by the end-user. It is also known to enhance the functionality and usefulness of a primary and/or secondary package. One example of such an enhanced package, which includes child resistant features, is Applicant&#39;s DOSEPAK® brand line of consumer products packaging. 
     In some embodiments, the DOSEPAK® brand line of consumer products packaging includes a blister pack secured within, or to, an inner slide card that is itself placed in an outer sleeve. Features and elements found on both the inner slide card and outer sleeve allow the inner card to be releasably locked within the outer sleeve. In these embodiments, the result is a child-resistant package that can still be manipulated with relative ease by an end-user with limited dexterity or strength. The DOSEPAK® brand line of consumer products packaging has found wide acceptance, particularly in the healthcare industry where blister packs are prevalent. These and other features of the DOSEPAK® brand line can be more clearly appreciated by referring to U.S. Pat. Nos. 6,047,829; 6,230,893B1; 6,412,636B1, and 6,752,272B1. 
     The process of filling and shipping the blister packs, with or without secondary packaging, is typically the responsibility of the so-called “filler”—usually the manufacturer who produces the items held by the blisters or another party contracted for that service. Fillers that secure blister packs to secondary packages such as a card typically so do using a heat-seal process. As understood by those skilled in the art, heat-sealing includes mounting a blister pack to an adhesive coated paperboard substrate, and applying heat so that the blister pack is secured to the paperboard or trapped between layers of paperboard. Examples of coated paperboard substrates used in heat-sealing include Applicant&#39;s EASYSEAL™ and EASYSEAL PLUS™ brand coated paperboard products. 
     With the present disclosure, the Applicant seeks to create a need and a market for a secure secondary package that does not require a heat-sealing process. 
     SUMMARY 
     A blank for forming a secondary package without a heat-seal process is disclosed. The secondary package can be an inner slide card configured to receive one or more blister packs. The secondary package blank can be formed from one piece of material, or can be assembled from several separate and distinct pieces of material. The blank can include several panels. A pocket opening can be formed in one of the panels. Receiving portions can be formed on one or more of the panels. The receiving portions can be formed by cutting the substrate to a desired configuration, or by adding other material, such as, adhesive tape or glue. After a blank is erected to form a blister pack secondary package, a blister pack can be inserted into the secondary package through the pocket opening formed in one of the panels. In some embodiments, the receiving portions mechanically interact with edges of the blister pack to retain the blister pack in a desired position. The exit regions of an inserted blister pack can be aligned with gates formed in a panel of the secondary package. When the blister pack is in the proper orientation relative to the secondary package, the blister pack can be locked in place mechanically, glued in place, or both. No heat sealing is required to form the secondary package, or to hold the blister pack in the desired orientation. 
     Accordingly, an embodiment of the disclosure includes a blank for forming a blister pack secondary package. The blank includes a base panel and a top panel with at least one blister receiving aperture. A means for connecting can be located on either or both of the base panel and the top panel. The blank also includes at least one receiving flange proximate to the receiving aperture. A blister pack receiving pocket is defined, at least in part, by the means for connecting and the receiving aperture when the top panel is connected to the base panel. 
     According to an aspect of the disclosure, the blister receiving aperture includes an insert edge. 
     According to another aspect of the disclosure, the receiving flange is configured to receive a blister flange. 
     Another embodiment of the disclosure includes a package for receiving and holding a blister pack. The package of the blister pack includes a secondary package. The secondary package includes a base panel, and a top panel with at least one blister receiving aperture. A means for securing can be located on either or both of the base panel and the top panel. The package can also include at least one receiving flange proximate to the blister receiving aperture and a blister pack receiving pocket configured to receive and hold a blister pack. The blister pack receiving pocket is defined, at least in part, by the means for connecting and the blister receiving aperture. 
     According to another aspect of the disclosure, the blister receiving pocket is further defined by a pocket opening. 
     According to another aspect of the disclosure, the blister pack further includes a leading edge connected to one of said top panel and said base panel. 
     These and other features will be further described with reference to the attached drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of a blank, according to an exemplary embodiment of the present disclosure. 
         FIG. 2  is a plan view of a blank, according to an alternative embodiment of the present disclosure. 
         FIGS. 3A-3D  are perspective views showing four stages of assembling an exemplary blank to form a secondary package. 
         FIG. 4  is a plan view of a blank, according to another alternative embodiment of the present disclosure. 
     
    
    
     DESCRIPTION 
     As required, detailed embodiments of the present disclosure are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of the disclosure 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 disclosure. 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 disclosure. 
     Referring now to the figures, wherein similar elements are designated with similar numbers,  FIG. 1  illustrates an exemplary blank  10  for forming a secondary package, in this case an inner slide card configured to receive a blister pack. Further, the illustrated blanks are shown and described in terms of unitary blanks but it is contemplated that the blanks of the present disclosure can be constructed and erected from separate and/or discrete panels that are joined or assembled together. The panels can be joined together using any suitable adhesives, tapes, labels, hot melt. Alternatively, the pieces can be made using EASYSEAL PLUS™ brand paperboard. As all the various embodiments of blister packs, including those with various types of backings such as paper and/or foil, and those made of various materials such as plastic, aluminum, and paper, and those with various types of child-resistant features, and combinations of these, are all well known to those skilled in the art and the structure or function of the blister packs referenced herein will not be further described. 
     In addition, the illustrated slide card is configured to be releasably received by an outer sleeve, such as those taught in various pending U.S. and foreign patent applications and patents related to the DOSEPAK® brand family of products. Accordingly, the relationship between the illustrated slide card and an outer sleeve will not be further taught herein. Also the materials used as the substrate of the blank  10  can be selected from among any of the well-known materials or combinations of materials and will not be further taught herein. 
     Continuing with reference to  FIG. 1 , the illustrated blank  10  for forming a secondary package includes a base panel  12 , a top panel  14  foldably attached to the base panel  12  along a first fold line  16 , a spine  18  foldably attached to the base panel  12  along a second fold line  20 , a cover panel  22  foldably attached to the spine  18  along a third fold line  24 , and a locking panel  26  foldably attached to the base panel  12  along a fourth fold line  28 . In an alternative embodiment, not illustrated here, the secondary package  10  does not include the locking panel  26 . In still another alternative embodiment, not illustrated here, the secondary package  10  does not include the locking panel  26 , top cover  22 , or spine  18  or their associated fold lines  20 ,  24 , and  28 . 
     The top panel  14  further includes a blister pack receiving aperture  30 . The perimeter of the illustrated receiving aperture  30  is generally the same shape as the perimeter of the top panel  14 , being defined by opposing side edges  32   a ,  32   b , an end edge  34 , and an insert edge  36 . The insert edge  36  begins and terminates at opposing, outwardly turning—with respect to the void that is the receiving aperture  30 —radius cuts  38   a ,  38   b . In the illustrated embodiment the receiving aperture  30  perimeter is slightly larger than the outside perimeter of the group of gates  40  located on the base panel  12 . The gates  40  are provided to impede removal of an item from a blister of a blister pack. Here, as illustrated, each gate  40  is defined by perforations. The perforations that define a gate  40  can be severed, and therefore, a gate  40  is removed, before or in conjunction with removing an item from a respective blister of a blister pack. In alternative embodiments, the gates  40  are apertures and do not further impede the removal of an item from a blister. 
     In erecting the illustrated blank  10  to form a slide card, one or more areas of adhesive  42  initially can be located on the top panel  14  proximate to the respective side edges  32   a ,  32   b , to connect the top panel  14  to the base panel  12 . When connecting the respective panels  12 ,  14 , the areas on the top panel  14  between the respective side edges  32   a ,  32   b  and means for connecting or means for securing  42  are not connected to the base panel  12 , thereby creating receiving flanges  44   a ,  44   b  as will be further described with reference to  FIGS. 3A-3D . While the illustrated blank  10  includes two areas of adhesive, it should be understood that any means for connecting or means for securing  42  can be used to connect the top panel  14  to the base panel  12 . The means for connecting or means for securing  42  can include, but are not limited to, chemical connecting products such as cold adhesive, hot adhesive, epoxy, combinations thereof, and the like, as well as mechanical connecting products such as staples, stitching, punches, rivets, combinations thereof, and the like, as well as chemical/mechanical connecting products such as welding, single face or double face tape, combinations thereof, and the like. In some embodiments, an area seal using EASYSEAL PLUS™ paperboard is employed to form and seal the blank. In alternative embodiments, the means for connecting  42  also can be located proximate the end edge  34  and/or the leading edge  36 . In alternative embodiments, the adhesive  42  is initially located on the base panel  12 . 
       FIG. 2  illustrates an alternative embodiment of an exemplary blank  10  for forming a secondary package, in this case an inner slide card configured to receive a blister pack. The elements shown in  FIG. 2  are similar to those shown in  FIG. 1 , the only difference being the orientation of some elements located on the top panel  14 , which are, generally speaking, the mirror image of the same top panel elements shown in  FIG. 1 . 
       FIGS. 3A-3D  are perspective views that collectively illustrate an exemplary method of folding and erecting the blank  10  to form a secondary package. Beginning with  FIG. 3A , the blank  10  of  FIG. 2  is illustrated in perspective, after the cutting and forming process is completed and after the illustrated means for connecting  42  is positioned on the top panel  14 . The top panel  14  then can be folded along the fold line  16 , as shown in  FIG. 3B , such that the means for connecting  42  connect the top panel  14  to the base panel  12  in a face-contacting orientation. Notice here that the insert edge  36  is orientated toward the spine  18 . 
     Turning now to  FIG. 3C , a fully constructed but not yet fully erected secondary package is illustrated. The reader will understand that connecting the top panel  14  to the base panel  12  creates a blister pack receiving pocket  50 , defined by the receiving flanges  44   a ,  44   b , and the portions of material along the end edge  34  and insert edge  36  that are not attached to the base panel  12 . After the blank has been erected to this point, the insert edge  36  can function as a pocket opening  52 .  FIG. 3C  also shows a conventional blister pack  51 , both before and after being loaded into the fully constructed secondary package. To load the blister pack  51  into the receiving pocket  50 , the filler moves the blister pack leading edge  54  toward the pocket opening  52  in the direction of the arrow “A”. More specifically, the filler slides the leading edge  54  over the insert edge  36  and under the radius cuts  38   a ,  38   b  to align and initiate the engaging of the blister pack side edges  56   a ,  56   b  with the receiving flanges  44   a ,  44   b . Once the blister pack side edges  56   a ,  56   b  are correctly positioned under the radius cuts  38   a ,  38   b , the filler fully inserts the blister pack  51  into the receiving pocket  50  by pushing the blister pack  51  until the side edges  56   a ,  56   b  are substantially completely inserted within the receiving flanges  44   a ,  44   b  and blister pack leading edge  54  passes under the receiving aperture end edge  34 . The filler can then slide the blister pack trailing edge  58  back and under the insert edge  36 , such that the entire perimeter of the blister pack  51  is captured between the top panel  14  and base panel  12 . In various embodiments the blister packs may be loaded from the opposite end, such as when the top panel  14  is cut as illustrated in  FIG. 1 , and in various embodiments the blister pack may be further secured to the secondary package with additional means for connecting  42 . 
       FIG. 3D  shows the completion of the constructing and folding of the illustrated blank  10  of  FIG. 3A , to erect a secondary package in the form of an inner slide card. After inserting the blister pack  51  in the receiving pocket  50 , the spine  18  and cover panel  22  are folded along the respective fold lines  20 ,  24  so that the cover panel  22  is located over the blister pack  51  and is substantially parallel to the base panel  12 . The locking panel  26  is likewise folded along its adjacent fold line  28 , either upwardly as shown or downwardly—depending on the configuration of the outer sleeve that will receive the inner slide card. 
     For some applications the constructing and filling process illustrated by  FIGS. 3A-3D  is completed by a single party at one location, such as a manufacturer or filler. For other applications, the constructing steps shown in  FIGS. 3A-3B  are completed by one party at one location and the secondary package is then sent to a filler at another location who completes the filling steps shown in  FIGS. 3C-3D . In shipping the constructed but empty blank between parties, it may be shipped flat as best shown in  FIG. 3C  or it may be shipped pre-folded as best shown in  FIG. 3D . 
       FIG. 4 , another packaging blank, according to an alternative embodiment of the present disclosure, is illustrated. Where the elements introduced and described above are present and substantially similar in the elements present is this embodiment, the same element number has been used with the addition of the prefix “1”. For example, the base panel  12  shown in  FIG. 1  is substantially similar to the base panel  112  shown in  FIG. 4 . Accordingly, the elements shown in the exemplary embodiment illustrated in  FIG. 4  will be introduced and only those features that warrant further discussion will be described. 
     Continuing with reference to  FIG. 4 , a blank  110  for an alternative secondary package includes a base panel  112 . A top panel  114  is hingedly connected to the base panel  112  along fold line  116 . A spine panel  118  is hingedly connected to the base panel  112  along fold line  120 , and to a cover panel  122  along fold line  124 . A locking panel  126  is hingedly connected to the base panel  112  along fold line  128 . In an alternative embodiment, not illustrated here, the blank  110  for a secondary package does not include a locking panel  126 . In yet another alternative embodiment, not illustrated here, the blank  110  for a secondary package does not include a locking panel  126 , a cover panel  122 , or a spine panel  118 . 
     The top panel  114  further includes a blister pack receiving aperture  130 . In the illustrated embodiment the receiving aperture  130  is substantially the same size as a gate  140  located on the base panel  112 , and the two are operationally aligned when the top panel  114  is folded over and placed in face-contacting orientation with the base panel  112 . In addition, means for connecting  142  is shown located on the top panel  114 . One possible orientation of a blister pack  151  is also illustrated in  FIG. 4 . 
     In  FIG. 4 , the adhesive  142  is located on the inside face (the visible face) of the top panel  114 , and is protected by a peelable backing such as is often found with an adhesive-backed label or double-face tape. Also, as illustrated in this embodiment, the means for connecting or means for securing  142  is located around the perimeter of the top panel  114  but not within the center of the top panel  114 . That area—bounded by the adhesive  142  and where a majority of the blister pack  151  is positioned, forms receiving flanges  144   a ,  144   b  and a blister pack receiving pocket  150  when the blank  110  for the secondary package is constructed and erected. 
     In constructing and filling the illustrated embodiment, the peelable backing of the adhesive  142  is removed and a blister pack  151  is placed so that the blister protrudes through the blister aperture  130 . In the illustrated embodiment, the blister pack leading edge  154  overlaps the adhesive  142 , to further secure the blister pack  151 . The top panel  114  is then folded to overlay and contact the base panel  112 . The adhesive  142  then secures the top panel  114  to the base panel  112 , thereby trapping the blister pack  151  along the receiving flanges  144   a ,  144   b  within the blister receiving pocket  150 . The spine panel  118 , the cover panel  122 , and the locking panel  126  are then folded to erect the secondary package as described above. 
     The embodiments illustrated and described herein are directed to a secondary package that accommodates a single blister pack. In alternative embodiments, not illustrated here, the blanks are configured to hold more than one blister pack on the same or different combinations of top and base panels. In other embodiments, the blank is not a unitary blank but comprises individual blank portions. 
     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 disclosure. 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.