Abstract:
A lockable package includes an outer sleeve defined by connected first and second panels, the sleeve having at least one open end. An inner container is slidable within the sleeve, and having a first portion joined to a second portion, wherein at least one of a height and a width of the first portion is less than a corresponding height and width of the second portion. A difference between one of the height and the width of the first portion and the corresponding height and width of the second portion defines a ridge. A locking assembly is provided at the at least one open end of the sleeve and is configured to releasably engage the ridge, wherein the inner container is removable through the open end of the sleeve by disengaging the locking assembly from the ridge.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a unique package having two components, a first component is an outer shell or sleeve with foldable flaps, and a second component is a tray configured with ridges designed to lockingly engage free ends of the sleeve flaps, thereby locking the package in a closed state and preventing the tray from easily being removed from the outer sleeve. 
     2. Description of Related Art 
     It is common practice for industrial parts manufacturers, medical device, pharmaceutical, food industry, and other such companies to use various containers or packages to package articles, products and food stuff intended to be sold or delivered to consumers. Typically, such packages are of a simple and relatively inexpensive construction, but which include an obstacle to opening the package that deters or prevents theft. Attempts have been made to provide a package that contains sufficient impediments to deter theft of the contents without rendering the articles or products contained therein inaccessible. However, the mechanism serving as the obstacle to opening the package typically has a complicated design, which has increased the expense of production without providing a corresponding improvement in deterring theft. 
     For example, U.S. Pat. No. 3,761,010 to Rosenburg, Jr. (hereinafter Rosenburg) discloses a safety carton having a tray 10 that slides into a sleeve 20. A bottom wall panel 26 of the sleeve has an opening 30 defined between abutment pieces 32, 33. When assembled, the sleeve 20 has a first, larger aperture 31 defined therein overlapping a second, smaller aperture 30 defined therein. As shown in FIG. 4 of Rosenburg, a lower surface of the tray 10 is received within the first aperture 31 defined in the sleeve 20 such that the edges of the tray 10 are engaged by the edges of the abutment pieces 32, 33 and prevent the tray 10 from being withdrawn from the sleeve 20. 
     As shown in FIG. 5 of Rosenburg, to disengage or unlock the tray 10 from the abutment edges 32, 33 of the sleeve 20, a consumer bends one of the abutment pieces 32 or 33 as well as overlapping panel 22 downward while pushing the tray 10 upward through the openings 30, 31. The edge of the tray 10 is disengaged from the edge of the piece 32 or 33, thereby permitting the tray 10 be slidingly removed from the sleeve 20. The locking mechanism for the Rosenburg carton is limited to a single side, or bottom, and is therefore susceptible to being compromised by small children without much effort. 
     In another example, U.S. Pat. No. 5,244,093 to Carmichael et al. (hereinafter Carmichael) disclose a package 10 having a sleeve 14 defined by open top and bottom ends. As shown in FIG. 6 of Carmichael, retaining flaps 24 abut or engage a lid 30 of a lowermost package 12c at an underneath position. An edge of the flaps 24 engages a downwardly facing edge 37 of the lid flange 30 and the corner 38 of the package 12c wall 32. As such, the edges of the flaps 24 engaging the flange 36 prevent the lowermost package 12c from falling out of the open bottom end of the sleeve 14. While the flaps 24 prevent the package 12c from being removed from the bottom of the package 10, a simple retainer 26 formed by overlapping flaps 46a, 46b defines a closed upper end 22. Simply pushing packages 12a-12c upward would appear to rupture the retainer 26 and provide access thereto. 
     In yet another example, U.S. Pat. No. 5,379,890 to Mahler discloses jacket 10, 10′ for holding or storing a compact disc therein that has an interior space 14 in which a tray 60 is inserted. End flaps 34, 38 and 45, 45 are folded into the space 14 along fold lines 36, 40. When the tray 60 is withdrawn from the sleeve 10, 10′, the edges 48, 52 of the flaps 34, 38 and 45, 45 engage the rims 68, 74 of the tray 60, providing access to the contents of the tray 60 while preventing the tray 60 from being completely pulled out of the sleeve 10, 10′. 
     U.S. Pat. No. 4,895,296 to Trauschke discloses a sleeve 10 open at both ends 18 with a window provided in a side wall to provide a view to the products contained in the sleeve 10. Flaring right and left lips 20 and 22 are folded into an interior space of the sleeve 10 to permit packages to be loaded into the sleeve 10. The inner edges of the lips 20, 22 catch on the packages being withdrawn, and act as a latch to prevent the removal of the packages from the sleeve 10. The lips 20, 22 are readily compressed to release the enclosed package therefrom. 
     In another example, U.S. Pat. No. 3,670,881 to Dutscher discloses a display carton having a plastic tray A that is inserted into a paperboard sleeve B. As shown in FIGS. 1-3 and 5 of Dutscher, the tray A has side walls 11 and end walls 12 with flanges provided at their lowermost edge. Abutments 32 of the side panels 24, 24 engage flared lower ends 13, 13 of the walls 11 and 12 to lock the tray A in the sleeve B. 
     In a further example, U.S. Pat. No. 3,334,734 to Meyers discloses a package having a cover 2 that has tray engaging side flaps 9 and end flaps 10. The cover 2 has openings 3, 3 defined in an upper surface. A flange 14 of the tray 11 engages the edges of the flaps 9, 10, thereby preventing the tray 11 from being removed from the cover 2. 
     U.S. Pat. No. 4,319,680 to Hiemstra discloses an open ended sleeve 1 with flaps 6 bent into the interior space of the sleeve 1 from both ends of the sleeve. The edges of the flaps 6 engage flanges 3 of blister packs 4 inserted into the sleeve 1, thereby preventing the blister packs 4 from falling out of the sleeve 1. 
     SUMMARY OF THE INVENTION 
     It is an aspect of this invention to provide a package having a slidable tray, clamshell shaped or other closed container that is lockingly engaged by an outer sleeve. 
     Another aspect of this invention is to provide a unique package that provides an outer sleeve having at least one open end, wherein a locking assembly is provided at the at least one open end and prevents removal of the tray, clamshell shaped container, or other similarly closed container therethrough. That is, if the outer sleeve has two open ends, then it is an aspect of this invention to provide a locking assembly at each open end. 
     Yet another aspect of this invention is to provide a package having a locking assembly that releasably engages a ridge defined at a transition region of different sized portions of the tray, clamshell shaped container, or other similarly closed container. 
     The package includes a first component that is an outer sleeve, which can be tubular in shaped, and includes opposing top and bottom panels, and opposing left and right side panels connecting the top and bottom panels. It should be noted that the geometric shape of the package is in no way limited to tubular as it is within the scope of the invention for the sleeve to be circular, oval, triangular, pentagon, trapezoidal or any other suitable geometric configuration. It should be noted that the inner container, e.g., tray, clamshell shaped container, or other similarly closed container, is also envisioned as having a similar or other configuration that is suitable and lockingly function with the locking assembly of the outer sleeve. Moreover, as noted above, at least one end of the sleeve is open. Further, as note above, the inner container has been referred to as a tray, clamshell shaped container or other similarly closed container. Hereinafter, the inner container will be referred to as a tray for the sake of simplicity, but it should be noted that the terms clamshell shaped container or closed container should be considered interchangeable with the term tray and that the geometric configuration of the inner container, i.e., the tray, is strictly for illustrative purposes and in no way is intended to limit the shape and/or size of the inner container as the inner container may be configured to any suitable shape. 
     The package also includes a second component that is a tray which is slidable into and out of the sleeve. The tray includes a first portion joined to a second portion, wherein at least one of a height and a width of the first portion is less than a corresponding height and width of the second portion. A difference between one of the height and the width of the first portion and the corresponding height and width of the second portion defines a ridge that is releasably engaged by a locking assembly formed at the open end of the sleeve. 
     The left side panel, top panel and right side panel of the sleeve each include a locking tab extending into an interior space of the sleeve. A free end of each locking tab opposes the ridge of the tray. The free ends of the corresponding locking tabs define the locking assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other objects and features of this invention will be better understood from the following description, with reference to the accompanying drawings, wherein: 
         FIG. 1  is a top view of a disassembled outer sleeve of the package according to a preferred embodiment of the invention; 
         FIG. 2  is a top view of the outer sleeve of the package shown in  FIG. 1  in a an assembled state; 
         FIG. 3  is a side view of the outer sleeve shown in  FIG. 2 ; 
         FIG. 4  is a lower end view of a tray insertable into the outer sleeve according to a preferred embodiment of the invention; 
         FIG. 5  is a right side view of the tray shown in  FIG. 4 ; 
         FIG. 6  is a perspective view of the tray outside of the assembled outer sleeve; 
         FIG. 7  is a perspective view of the tray partially inserted into the outer sleeve; 
         FIG. 8  is a perspective view of the assembled package according to the preferred embodiment of the invention wherein the tray is completely inserted into the outer sleeve; 
         FIG. 9  is a perspective view of the assembled package shown in  FIG. 8 , wherein an open end of the outer sleeve is sealed closed; 
         FIG. 10  is a perspective view of the assembled package shown in  FIG. 9  with a portion broken away showing tabs of the outer sleeve lockingly engaging upper and side ridges of the tray according to the preferred embodiment of the invention; 
         FIG. 11  is a cross-sectional side view of an upper tab of the outer sleeve engaging an upper ridge of the tray taken along line  11 - 11  of  FIG. 9 ; and 
         FIG. 12  is a partial cross-sectional top view of a side tab of the outer sleeve engaging a side ridge of the tray taken along line  12 - 12  of  FIG. 8 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIG. 1 , the outer sleeve  20  of the package  10  ( FIG. 6 ) is formed from a flat, substantially rectangular shaped single blank  21 , ideally made form paperboard. However, it is within the scope of this invention to use any suitable material well known or later developed in the art, such as, for example, paper, plastic, metal, natural or man made, and the like. Furthermore, although not illustrated but well understood in the art, it is within the scope of this invention to use any suitable geometric shape, such as, for example, square, trapezoidal, circular, oval, and the like to form the outer sleeve  20 . 
     In the exemplary embodiment wherein the sleeve is rectangular, the outer sleeve  20  may include a top or upper panel  22  separated from a bottom or lower panel  24  by a pair of opposing left and right side panels  23   a ,  23   b . A seal panel  25  extends from a side of the bottom panel  24  that is opposite the side of the bottom panel  24  from which the left side panel  23   a  extends. As shown in  FIG. 3 , when the outer sleeve  20  is assembled, or at least partially assembled, the seal panel  25  sealingly engages the right side panel  23   b . In  FIG. 3 , the seal panel  25  is shown in dashed lines. It should be noted that when the sleeve is of another geometric configuration, such as, for example, a circle, oval, trapezoid, pentagon and the like, the number of side panels may increase or decrease, as is appropriate. As such, the discussion regarding the side panels should not be construed as in any way limiting the number or shape of the side panels. Moreover, although the exemplary embodiment is discussed in relation to four panels, i.e., top, bottom, left and right, it is within the scope of the present invention for the number of panels to increase or decrease, depending on the overall configuration of the sleeve. Also, the shape of the panels may correspondingly change as needed. 
     Alternatively, the top panel  22  may include an aperture or window W defined therein to permit a visual inspection of the contents of the package  10  therethrough. Moreover, it is within the scope of the invention for a material, either transparent or opaque in nature, to span the window W if necessary for the intended use of the package  10 . Furthermore, it is within the scope of the present invention wherein the bottom panel  24  may include a support panel  26  to enhance the strength or provide additional support to the bottom panel  24  to secure an item within the package  10 . The optional support panel  26  may also include graphic or other similar indicia thereon providing information with regards to the contents of the package  10 . 
     It should be noted that it is within the scope of the present invention for the seal panel  25  to sealingly engage the right panel  23   b  in any known, suitable manner, such as by an adhesive, ultrasonic welding, epoxy or any other manner that is conventional in the industry. Moreover, the dimensional configuration of the seal panel  25  shown in  FIGS. 1 and 3  is merely illustrative. It is within the scope of the invention for the seal panel  25  to be dimensioned according to the desired use of the package  10 , and as such, the seal panel  25  may be larger or smaller than that which is illustrated. The seal panel  25  should be sized so as to facilitate assembly of the outer sleeve  20 . Alternatively, it is also within the scope of the invention to configure the outer sleeve  20  to omit the seal panel  25 , wherein the outer sleeve  20  is formed by joining the right side panel  23   b  to a free side of the bottom panel  24 , the free side being the side of the bottom panel  24  from which the seal panel  25  would otherwise extend. 
     In an alternate embodiment, and one that is illustrated in the drawings, it is within the scope of the present invention for the package to possibly include a closure assembly when both ends of the package are not open ends. For example, an upper or first end of the bottom panel  24  and side panels  23   a  and  23   b  may include tabs that define a closure assembly  30 . The closure assembly  30  may includes a left side panel closure tab  33   a  extending from a first end of the left side panel  23   a,  a right side panel closure tab  33   b  extending from a first end of the right side panel  23   b,  and a bottom panel closure tab  34  extending from a first end of the bottom panel  24 , wherein a tongue  34   a  may extend from a free end of the bottom panel closure tab  34 . As shown in  FIGS. 9 and 10 , when the outer sleeve  20  is fully assembled, the left and right closure tabs  33   a  and  33   b  may be folded towards each other, and the bottom closure tab  34  folded over an outer surface of the left and right closure tabs  33   a  and  33   b . The tongue  34   a  could then be inserted into a gap defined between the top panel  22  and the closure tabs  33   a ,  33   b  and  34 . The aforementioned closure assembly  30  is merely illustrative for alternative embodiments of the package wherein both ends of the package are not open ends and one of the ends can possibly be a closed end. 
     Looking at  FIGS. 1 through 3 , lower or second ends of the side panels  23   a  and  23   b,  as well as the top panel  22 , form an exemplary embodiment of a locking assembly  40 . The locking assembly  40  includes a left side panel locking tab  43   a  extending from a second end of the left side panel  23   a,  a right side panel closure tab  33   b  extending from a second end of the right side panel  23   b,  and a top panel locking tab  42  extending from a second end of the top panel  22 . As shown in  FIGS. 6  through  12 , when the outer sleeve  20  is fully assembled, the left and right locking tabs  43   a  and  43   b,  as well as the top locking tab  42 , are folded into an interior space of the outer sleeve  20 , wherein free ends  44   a  and  44   b  of the left and right locking tabs  43   a  and  43   b,  respectively, and a free end  42   a  of the top locking tab  42   a,  are separated from an inner surface of the left and right side panels  23   a  and  23   b,  respectively, and the top panel  22  by a predetermined distance. 
       FIG. 11  provides an exemplary illustration of the free end  42   a  of the top locking tab  42  separated from the inner surface of the top panel  22 .  FIG. 12  provides an exemplary illustration of the free end  44   b  of the right locking tab  43   b  separated from the inner surface of the right side panel  23   b . A similar arrangement is provided for the free end  44   a  of the left locking tab  43   a,  which is not shown. 
     To assemble the outer sleeve, the bottom panel  24  can be folded over a first edge of the left side panel  23   a , and the bottom panel  24  and left side panel  23   a  can be folded over a first edge of the top panel  22 . The right side panel  23   b  may then be folded over a second edge of the top panel  22 , the second edge opposing the first edge. If provided, the seal panel  25  may be folded onto and joined to the right side panel  23   b  in any conventionally known manner. Alternatively, the free edge of the bottom panel  24 , which is defined or formed when the seal panel  25  is not provided, is then joined or attached to a free edge of the rights side panel  23   b  to form a tubular, partially assembled outer sleeve  20 . See  FIGS. 2 and 3 . 
     As shown in  FIGS. 4 and 5 , the exemplary inner container or tray  50  may include a first portion  51  integral to and extending from a second portion  52 , wherein the first portion  51  has a height and a width that is less than a height and width of the second portion  52 . The differences in height and width between the first and second portions  51  and  52  define a left side ridge  53 , an upper ridge  54  and a right side ridge  55 . As shown in  FIG. 4 , the left side ridge  53 , upper ridge  54  and rights side ridge  55  are surfaces of the tray  50  which connect the first and second portions  51  and  52  to each other. 
     The tray  50  may be formed from a transparent material, as shown in  FIGS. 6 through 10 . However, it is within the scope of the invention for the tray  50  to be formed from any other suitable material. The manner in which the tray  50  is formed may be chosen from any conventional manner and should be based on the intended use of the package  10 , so long as the manufacturing technique chosen is able to form the tray  50  to have at least one of the ridges  53  through  55 . 
     Looking at  FIG. 6 , to assemble the package  10 , the locking tabs  42 ,  43   a  and  43   b  of the locking assembly  40  are folded inward and into the interior space of the tubular outer sleeve  20 . The closure tabs  33   a ,  33   b , and  34  of the closure assembly  30  are maintained in an open state so as to receive the tray  50 . The tray  50  is slid into the sleeve  20  by first sliding the first portion  51  of the tray  50  into an opening defined by the closure tabs  33   a ,  33   b  and  34   a  maintained in an open state, as shown in  FIG. 7 . 
     As shown in  FIG. 8 , the tray  50  is further slid into the outer sleeve  20  and is completely placed within the sleeve  20  such that the first portion  51  is visible through an open end of the package  20 . Turning to  FIG. 9 , the left and right side closure tabs  33   a  and  33   b  are folded inward so as to be substantially parallel with a rear face of the second portion  52  of the tray  50 . The bottom closure tab  34  is then folded over and onto an outer surface of the left and right side closure tabs  33   a  and  33   b . The tongue  34   a  is then inserted into the gap defined between the top panel  22  and free edge of the left and rights side closure tabs  33   a  and  33   b  to seal the tray  50  within the outer sleeve  20 . 
     It should be noted that it within the scope of the invention for the bottom closure tab  34  to be adhered or otherwise affixed to the left and right side closure tabs  33   a  and  33   b  in any suitable manner that is conventional in the industry, such as by an adhesive, tape, epoxy, ultrasonic welding, and the like. Alternatively, the closure assembly may maintain the subject end of the outer sleeve in a closed state simply be securely retaining the tongue  34   a  in the gap defined between the top panel  22  and left and right side closure tabs  33   a  and  33   b.    
       FIGS. 10 through 12  will now be referenced to explain how the locking assembly  40  prevents the tray  50  from easily being removed from the open end of the outer sleeve  20 . In particular, the cutaway portion of the outer sleeve  20  illustrated in  FIG. 10  shows the free ends  42   a ,  44   a  and  44   b  of the top locking tab  42 , left side locking tab  43   a  and right side locking tab  43   b  of the outer sleeve  20  engaging or otherwise abutting the left side ridge  53 , upper ridge  54  and right side ridge  55 , respectively, of the tray  50  to lock the tray  50  within the outer sleeve  20  or otherwise prevent the tray  50  from easily being removed therefrom. 
     More specifically, looking at  FIG. 11 , which shows a cross-sectional side view of the tray  50  being securely maintained within the outer sleeve  20  of the package  10 , the top panel locking tab  42  is shown being folded inward into the interior space of the outer sleeve  20  and slightly angled toward an upper surface of the first portion  51  of the tray  50 . The free end  42   a  of the top panel locking tab  42  is maintained a predetermined distance from an inner surface of the top panel  22 . At the same time, the free end  42  of the top panel locking tab  42  may either be directly engaging the upper ridge  54  of the tray  50  or separated therefrom a distance that allows for a slight or nominal movement of the tray  50 , but otherwise prevents the tray  50  from being removed from an open end  60  of the outer sleeve  20 . 
     Similarly, looking at  FIG. 12 , which shows a partial cross-sectional top view of the tray  50  being securely maintained within the outer sleeve  20  of the package  10 , the right side panel locking tab  43   b  is shown being folded inward into the interior space of the outer sleeve  20  and slightly angled toward a right side surface of the first portion  51  of the tray  50 , The free end  44   b  of the right side panel locking tab  43   b  is maintained a predetermined distance from an inner surface of the right side panel  23   b . At the same time, the free end  44   b  of the right side panel locking tab  43   b  may either be directly engaging the right side ridge  55  of the tray  50  or separated therefrom a distance that allows for a slight or nominal movement of the tray  50 , but otherwise prevents the tray  50  from being removed from an open end  60  of the outer sleeve  20 . it should be noted that the free end  44   a  of the left side panel locking tab  43   a  may be configured and operate in an identical manner to that of the above-described free end  44   b  of the right side panel locking tab  43   b . As such, a description and illustration thereof is omitted herefrom to avoid redundancy. 
     Accordingly, the free end  44   a  of the left side panel locking tab  43   a  engaging the left side ridge  53  of the tray  50  or distanced therefrom a nominal distance to prevent removal of the tray  50  through the open end  60  of the outer sleeve  20 ; and/or the free end  42   a  of the top panel locking tab  42  engaging the upper ridge  54  of the tray  50  or distanced therefrom a nominal distance to prevent removal of the tray  50  through the open end  60  of the outer sleeve; and/or the free end  44   b  of the right side panel locking tab  43   b  engaging the right side ridge  54  of the tray  50  or distanced therefrom a nominal distance to prevent removal of the tray  50  through the open end  60  of the outer sleeve  20  effectively locks the tray  50  within the outer sleeve  20  of the package  10 . 
     To remove the tray  50  from the sleeve  20 , an individual can open or disengage the closure tabs  33   a ,  33   b  and  34  of the closure assembly  30  defined at the closed end of the package  10  in a conventional manner. Alternatively, if the individual desires to remove the tray  50  from the open end  60 , the individual can insert a thin object into the open end  60  of the outer sleeve  20  and disengage the free ends  42   a  and/or  44   a  and/or  44   b  of the locking tabs  42 ,  43   a  and  43   b , respectively, from the upper ridge and/or left side ridge  53  and/or right side ridge  54 , respectively. As such, the free ends  42   a ,  44   a , and  44   b  do not engage the relevant ridges  53 ,  54  and  55  of the tray  50  such that the tray  50  can be slid through the open end  60  of the outer sleeve  20 . 
     The above described structural configuration of the package  10  provides a package that is easy to use yet prevents unwanted access to the product(s) contained therein. 
     Many modifications may be made to adapt the teachings of the package of this invention to particular situations or materials without departing form the scope thereof. Therefore, the invention should not be limited to the particular embodiments disclosed herein, but includes all embodiments within the spirit and scope of the disclosure.