Patent Publication Number: US-7588149-B2

Title: Unit dose container with locking sleeve

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application is a continuation of International Application No. PCT/US03/033667, filed Oct. 22, 2003, which claims priority to U.S. Provisional Application No. 60/419,975 filed Oct. 22, 2002. The aforementioned applications are herein incorporated by reference. 

   FIELD OF THE INVENTION 
   The present invention relates generally to apparatus and methods of packaging and dispensing items or products, and more specifically, the present invention is directed to a locking container including a tray for dispensing items. 
   BACKGROUND OF THE INVENTION 
   Locking containers, especially childproof locking containers in which multiple movements must be applied to open the container, have many uses. One use for locking containers includes medicine containers. Locking caps on medicine bottles are well known. The locking caps usually require alignment and tipping, axial pressure, or inward radial squeezing while turning the locking caps to remove the locking caps from the containers and provide access to the medicine therein. 
   Many medicines are packaged in flat boxes formed from paperboard sleeves, which are difficult to secure with childproof locks. Such medicines are also generally packaged in blister packs having blisters or compartments formed from a plastic sheet and sealed by a paper layer or foil, which is punctured or ruptured to release a dose from a corresponding blister. Generally, when a paperboard sleeve containing blister packs are opened the entire contents of the package are exposed, making all of the doses immediately available. This easy access poses a danger to an unintended user, such as a child. 
   Accordingly, there remains in the art a need for inexpensive flat boxes that include locks which require multiple coordinated motions for opening the boxes and gaining access to a limited number of doses at one time. There is also a need for apparatus and methods for packaging and dispensing items that provide easy limited access for an adult while providing a high degree of security against an unintended user, such as a child. 
   SUMMARY OF THE INVENTION 
   The present invention overcomes the deficiencies of the known art and the problems that remain unsolved by providing a child-resistant locking container that is inexpensive and easy to assemble. The child-resistant locking container includes a sleeve having a locking mechanism that prevents or at least frustrates the unintentional withdraw of a tray holding medicine. The sleeve includes an unlocking member wherein pressure may be exerted on the unlocking member to bias the member inward to release the locking mechanism, thereby allowing a user to pull the tray from the sleeve. The child-resistant locking container includes security features which mandate a combination of coordinated, sequential motions, including pressing and holding the unlocking member while pulling the tray outward and then releasing the unlocking member to gain access to a limited number of items at one time. 
   In accordance with one embodiment of the present invention, there is provided a system for dispensing items comprising a tray, including a control slot extending through the tray and a plurality of compartments where each compartment may or may not hold at least one item, a sleeve including a lug, the lug extending through the control slot of the tray for guiding the tray within the sleeve, detents positioned within the sleeve and cooperating with the tray for preventing sliding of the tray, and a biaser connected to the sleeve for biasing the detents out of engagement with the tray for sequentially limiting the sliding of the tray through the sleeve. 
   Advantageously, the tray includes detent holes arranged on the tray for cooperatively engaging with the detents to prevent the tray from sliding. The tray further includes a stopping end for engaging with the lug and preventing the unintentional removal of the tray from the sleeve. Preferably the sleeve includes a base and top where the base and the top include inward facing interlocking pins and receivers for connecting the base and top together, to form a closed end and an open end opposite the closed end. The tray is configured to slide through the open end. The top includes resilient springs extending inward into the sleeve through gaps which are opposite from the biaser; the springs urging against the tray to engage the detents within the detent holes. 
   In alternative embodiments of the present invention, there are provided methods of packaging items within a container. One method comprises the steps of: constructing a tray to include a slot extending through the tray and a plurality of compartments for holding items, loading and sealing at least one item into a compartment of the tray, placing the tray onto a base where the base includes a lug extending through the slot for guiding the tray, attaching a top to the base to form a sleeve including a void and an open end configured to receive the tray, positioning detents within the sleeve where the detents cooperate with the tray for preventing sliding of the tray, and connecting a biaser to the sleeve for biasing the detents out of engagement with the tray for sequentially limiting the sliding of the tray through the open end of the sleeve. 
   Regarding the embodiments described herein, as well as those covered by the claims, the locking container may be loaded or reloaded with a new tray at the manufacturer, by the user at home, or at any location by a health care provider. The locking container may be disposable or reusable and may or may not be transparent, to allow a user to view the contents of the container. In addition, the locking container may or may not include patent information indicia, or indicators such as an arrow or directives for indicating to a user which direction to slide the tray. 
   In another embodiment of the present invention, there is provided a device for dispensing items, comprising: a tray including a slot extending through the tray and a plurality of compartments; a sleeve including means for stopping, means for stopping extending through the slot of the tray; means for locking configured within the sleeve, means for locking cooperating with the tray for preventing sliding of the tray; and means for unlocking connected to the sleeve, means for unlocking configured to manipulatively bias means for locking out of engagement with the tray for sequentially limiting the sliding of the tray. 
   Embodiments of the present invention provide a tray for holding items, comprising: a card including a slot protruding through the card, a plurality of compartments where at least one compartment holds at least one item, a plurality of holes arranged on the card, and a tab formed at one end of the card for aiding in grasping the card. Preferably, but not necessarily the slot extends centrally on the card and forms a stopping end and a closing end. In one design the plurality of compartments are configured into a plurality of rows where at least a first row is disposed on a first side of the slot and at least a second row is disposed on an opposite second side of the slot. In another design the tray includes a plurality of holes that are serially disposed in rows, where a first row of holes is disposed on a first side of the slot and a second row is disposed on an opposite second side of the slot. 
   Regarding the embodiments described herein, as well as those covered by the claims, the card may or may not be disposable and may comprise a conventional blister package or tray having compartments formed of a single layer plastic top material and dimensioned to fit within a locking sleeve. Further, the terms “top” and “base” and “bottom” are merely directional in order to distinguish one section from another. Accordingly the terms are not limitations but may be used interchangeably. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a bottom perspective view of a locking container, according to the present invention. 
       FIGS. 2 and 3  are top perspective views of locking containers, according to the present invention. 
       FIG. 4  is an exploded view of the locking container of  FIG. 3 . 
       FIGS. 5 and 6  are exploded views of a locking sleeve, according to the present invention. 
       FIGS. 7 and 8  are cross-sectional views of locking containers, according to the present invention. 
       FIGS. 9 and 10  are perspective views of a base engaging with a tray, according to the present invention. 
       FIG. 11  is a perspective view of the locking container, according to the present invention. 
       FIG. 12  is a cross-sectional view of the locking container showing the attachment of a base and a top, according to the present invention. 
       FIGS. 13 and 14  are cross-sectional views of the locking container showing the relationship of the base, top and tray, according to the present invention. 
   

   DETAILED DESCRIPTION 
   As required, detailed embodiments of the present invention are disclosed herein. It will be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. 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 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 limiting but serve as a basis for the claims and for teaching one skilled in the art to variously employ the present invention. 
   Further, it will be understood that the present invention is applicable to the packaging, storing, and dispensing of various items or products including but not limited to pills, tablets, capsules, lozenges, drug delivery devices, medications, non-medications, and all manner of small and portable items or products that a user may wish to keep secure and dispense in a regulated manner. 
   Referring now to the drawings, wherein like elements are represented by like numerals, there is shown in  FIG. 1  a bottom perspective view of a locking container  10 . The locking container  10  includes a tray  12  and a locking sleeve  14 , comprising a base  16  and a top  18  that are attached together to form a void and at least one open end. The locking container  10  further includes means for unlocking the tray  12  from the locking sleeve  14 . One non-limiting example of means for unlocking includes a manipulable biaser  20  comprising a T-shaped release bar  24  that is formed in an opening  21  of the base  16  and is connected to and integrally formed with the locking container  10  by a thin resilient section or lever  22 . Other means for unlocking include release bars of various shapes and individual release buttons. A user releaseably slides tray  12  from locking sleeve  14  by exerting pressure and pushing on the free end of the T-shaped release bar  24  to free tray  12 . The locking container  10  further includes a recess  28  formed in the open end of base  16  to enable a user to grip an exposed end  26  of tray  12 . The locking container  10  may include indicia or an indicator, such as an arrow  29  for directing a user with regard to which direction to slide the tray  12 . 
     FIG. 2  shows a top perspective view of the locking container  10  and tray  12 . As shown in  FIG. 2 , tray  12  includes item-containing compartments or blisters  30  for correspondingly holding at least one item  31 , typically in each blister  30 . The illustrated item-containing blisters  30  are arranged in four columns  32 . It will be noted that the item-containing blisters  30  may be arranged in different orientations on the tray  12  without departing from the scope of the claims. Tray  12  may be fabricated or constructed from the same materials, strengths and thicknesses as conventional blister package trays. The blisters  30  may be formed in a single layer plastic top. The tray  12  includes a backing sheet comprising a sealed paper or foil base operable to seal at least one item  31  within at least one corresponding blister  30  and is dimensioned to fit within the locking sleeve  14 . 
   With reference now to both  FIGS. 1 and 2 , the tray  12  further includes a control slot  34 , which slideably guides the tray  12  within the locking sleeve  14  and forms a stopping end that prevents the tray  12  from completely sliding out of the locking sleeve  14 . The tray  12  includes a plurality of receiving apertures or holes  36  that for the purpose of teaching and not limitation, are positioned in parallel series on the tray  12  and disposed between blisters  30 . The holes  36  cooperate with means for locking  56  the tray  12  within the locking sleeve  14 , as best illustrated in  FIG. 4 . One non-limiting example of means for locking  56  includes detents  56 , which are formed on the base  16  of the locking container  10 . Each detent  56  cooperates with a corresponding hole  36  to lock tray  12  in place and prevent the extraction of tray  12 . The detents  56  sequentially align with the parallel series of holes  36  in order to limit access to a particular number of items  31  at one time. Means for locking further include catches, posts, springs, and the like, all of which may be positioned at various locations or in various configurations. 
   The tray  12  includes a rib  38  positioned at one end of the tray  12 . As best illustrated in  FIG. 3 , when tray  12  is completely inserted within the locking sleeve  14 , rib  38  presses up against the inside surface of top  18  and the rib  38  closes the open end  40  of the locking sleeve  14 , preventing access to the item-containing blisters  30 . Rib  38  includes a tab  42  which fits within cutout  44  when the tray  12  is fully inserted within locking sleeve  14 . The tab  42  aids in sliding the tray  14  outward from the locking sleeve  14 . 
   The top  18  of the locking container  10  includes openings  46  and means for urging  48 . One non-limiting example of means for urging  48  includes resilient springs  48 . The springs  48  press or urge tray  12  against base  16  to engage the detents  56  with correspondingly holes  36 . It will be understood that means for urging  48  may comprise other suitable mechanisms that urge or press tray  12  against the base  16  such as springs of all kinds, ribs, posts, lugs, and the like, and combinations thereof. 
   Referring now to  FIG. 4 , there is shown an exploded view of a locking container  10  including a tray  12  disposed on a base  16 . The top  18  includes connecting pins  51  and a central pin  55 . The connecting pins  51  and the central pin  55  extend downward from the inside surface of top  18 . The base  16  includes cylinders  50 , which are positioned along side walls  52  of the base  16 . Each individual cylinder  50  includes an aperture and energy director  60  for correspondingly receiving and securing pins  51 . The base  16  further includes a stop or means for stopping  54 . Non-limiting examples of a stop or means for stopping  54  include a lug or post  54 . Other examples include springs, catches, detents, and the like, all of which act to stop or frustrate complete withdraw of a tray  12  from the container  10 . The lug  54  is centered near recess  28  at the open end  40  of the base  16  to engageably receive central pin  55 . The lug  54  extends through the control slot  34  of tray  12  and cooperates with the stopping end  84  of the control slot  34  to prevent the tray  12  from being easily extracted from the locking sleeve  14 . As shown, detents  56  project through holes  36  of tray  12  to lock tray  12  within the locking sleeve  14 . The tray  12  includes rib  58 , located at one end of the tray  12 , and raised dots  59  which extend upward from tray  12 . The rib  58  and raised dots  59  ride against the inside surface of the top  18  to stabilize the tray  12  as the tray  12  is extended from the locking sleeve  14 . 
   In one method of assembly, the tray  12  is placed on base  16  so that lug  54  extends through the control slot  34 . The top  18  is subsequently pressed onto the base  16 . The pins  51  and the central pin  55  are correspondingly inserted within the apertures of the cylinders  50  and stop  54 . Energy directors  60  inside the cylinders  50  and side energy directors  62 , which are disposed along side walls  52  of the base  16 , help fuse and weld the top  18  to the base  16  under pressure and ultrasonic energy. 
     FIG. 5  is an exploded view of the locking sleeve  14  showing the inner surface of top  18  and base  16 . As illustrated, top  18  of the locking sleeve  14  includes connecting pins  51  and central pin  55 , which extend from cylindrical bases  61  and  65 . The top  18  further includes ribs  64  that include inner ends  68 . The ribs  64  are spaced apart to form gaps  66 . The springs  48  extend inward into the locking sleeve  14  through the gaps  66 . The springs  48  urge tray  12  against guides  70 , which are disposed on the inside surface of base  16  as best illustrated in  FIG. 6 . The ribs  64  and springs  48  are of sufficient height so that the item-containing blisters  30  are spaced from the inside of the top  18 . The head  24  of the biaser  20  is aligned with the springs  48 , to allow a user to manipulate the tray  12  in the direction of the springs  48  and release the tray  12  from detents  56 . 
     FIG. 6  is an exploded view of the locking sleeve  14  showing the inner surface of base  16  and the top  18 . As illustrated, base  16  includes guides  70  for guiding and facilitating the sliding of tray  12 . Base  16  further includes ridges  72  located at the inside of side walls  52 . The ridges  72  fit inside of complementary side walls of top  18 . Biaser  20  includes a rib  74  disposed on the inside of head  24  that cooperates with detents  56 . When the biaser  20  is pushed inward, the rib  74  is also pushed inward so as to warp an adjacent part of tray  12  toward the top  18  against the force of springs  48 , thereby disengaging the detents  56  from the holes  36  and releasing tray  12  to slide freely. As best shown in  FIG. 4 , the detents  56  correspondingly engage with holes  36  in order to hold and prevent the tray  12  from sliding. Detents  56  may include straight or hook-shaped, holding or locking inward faces  76 . The detents  56  may also include sloping outer faces or ramp surfaces  78  that are configured to warp the tray  12  away from the detents  56 , allowing free inward movement of tray  12 . It will be noted that the detents  56  may include other suitable configurations of geometric shapes without departing from the scope of the present claims. 
   Referring now to  FIGS. 7 and 8 , there is shown a longitudinal cross-section view of the locking container  10 . Detents  56  are shown with the locking or holding faces  76  engaging holes  36 . In operation, the tray  12  is disengaged or unlocked by pushing biaser  20  inward. The inward movement of the biaser head  24  causes rib  74  to warp tray  12  toward top  18 , in the area between inward facing ends  68  of ribs  64 . The warping of the tray  12  disengages the detents  56  from holes  36 , allowing tray  12  to be pulled outward from the locking sleeve  14 . The tray  12  may be slid outward until the detents  56  reengage with the next series of holes  36 , thereby limiting the amount of items  31  a user will have access to per sequence of unlocking and accessing. 
   As shown in  FIG. 8 , the detents  56  may include hooks  80  to ensure against unwanted outward movement of the tray  12 . To gain access to additional items, the biaser  20  is again pushed and held inward to warp the tray  12  and disengage the detents  56  from holes  36 , thereby allowing tray  12  to be slid out further from sleeve  14  to allow access to another limited amount of items  31 . The detents  56  are selectively engaged within the parallel series of holes  36  to limit the dosage to a certain amount of items  31 . In one embodiment of the present invention, a push, hold, pull and release sequence limits the exposure of blisters or blisters  36  to four. It will be understood that the holes  36  may be configured on the tray  12  to expose different quantities of blisters  36  at one time. After an item  31  is removed from an item-containing blister  30 , reverse pressure is applied to tray  12  to reinsert it within the locking sleeve  14 . The detents  56  include sloping ramp surfaces facing the open end of said sleeve  14  for biasing said tray  12  away from the detents  56  and disengaging the detents  56  upon sliding the tray  12  inward towards the closed end of the locking sleeve  14 . 
     FIGS. 9 and 10  are perspective views of the base  16  and the tray  12 . In  FIG. 9 , the tray  12  is fully extended outward from base  16 , generally denoted as  82 . The base  16  includes means for stopping  54 , which engages with a stopping end  84  for preventing the tray  12  from being completely removed from the locking sleeve  14 . As described, means for stopping includes stop  54  that extends through the control slot  34  of tray  12 . The end  84  of control slot  34  engages with or abuts against the lug  54  to prevent the tray  12  from being extended out further. 
   It will be understood that in one alternative embodiment of the present invention, the locking container  10  of the present invention may be either disposable or reusable. In addition, tray  12  may be disposable so that a new tray  12  may be replaced within the locking container  10 . Thus, the same locking container  10  may be refilled with a new tray  12 . To that end, stop or lug  54  only partially extends between the base  16  and top  18  to form a gap (not shown). Manipulating the tray  12  through the gap permits complete withdraw of the tray  12  from the container  10 . 
   As seen in  FIG. 10 , the tray  12  is shown in an innermost position  86 . The lug  54  extends through control slot  34  of tray  12  and engages with or abuts against the end  88  of the control slot  34 . The end  92  of tray  12  abuts the inside of the end wall  94  of base  16 . The detents  56  extend through holes  36  of tray  12  to secure tray  12  within the locking container  10 . The rib  38  closes the open end  40  of the locking sleeve  14 , preventing access to the item-containing blisters  30 . Rib  38  includes a tab  42  which fits within cutout  44  when the tray  14  is fully inserted within locking sleeve  14 . The tab  42  aids in sliding the tray  14  outward from the locking sleeve  14 . 
     FIG. 11  is a perspective view of the locking container  10 . As shown, the biaser  20  includes a lever integrally formed with the base  16 . The lever includes a hinge end that is hinged to said base  16  and a free end  24  that freely moves into the sleeve  14  for warping tray  12 . The free end  24  of the lever is relatively wider and the hinged end is relatively narrower. The tray  12  is removed from the locking sleeve  14  by manipulating the biaser  20  inward and pulling tray  12 , at recess  28 , in the direction of arrow  29 . It will be understood that the locking sleeve  14  may include a label, information, text, directions or other printed material. 
   Referring now to  FIG. 12 , there is shown a cross-sectional view of the locking sleeve  14  including a base  16  and a top  18  where the base  16  and the top  18  are attached or molded together to form the locking sleeve  14 . The biaser  20  is molded to project inward into the locking sleeve  14  and the outer surface of the biaser  20  includes frictional grooves  96  to aid in pushing the biaser  20  inward. The springs  48  are molded to extend inward into the locking sleeve  14  from the surface of top  18  and the springs  48  extend slightly beyond the inward extension of ribs  64 . 
     FIGS. 13 and 14  are cross-sectional views of the locking container  10 . Tray  12  has been inserted within the locking sleeve  14 . The springs  48  urge or press against tray  12 , which pushes the biaser  20  outward to a position level with base  16 . The sloping back surfaces  78  of the detents  56  and the inward surfaces of ribs  64  are used along with other tray-contacting surfaces to facilitate sliding of the tray  12 . The free end  24  of the lever has an inward extension  74  for contacting with and warping tray  12 . 
   Alternative embodiments of the present invention include methods of packaging items or products within a locking container  10 . One method includes the steps of constructing a tray  12  to include a slot  34  extending through the tray  12 , and a plurality of item-containing compartments or blisters  30 . This method further includes the steps of loading and sealing at least one item  31  into at least one compartment  30  of tray  12 . The tray  12  may be formed as a conventional blister package including a plurality of item-containing blisters  30 . A conventional backing sheet or layer of plastic, or foil, or paper, seals each compartment  30 , except those intentionally left open or unfilled. 
   The tray  12  is placed on the sliding guides  70  of base  16  and the stop  54  extends through the control slot  34  of tray  12 . Means for locking  56  engage with or protrude through receiving apertures  36  of tray  12 . The top  18  and base  16  are then connected together to form a locking sleeve  14  including a void and an open end. This method further includes the step of positioning means for locking  56  within said sleeve  14  to cooperate with the tray  12  in order to prevent the tray  12  from sliding within the locking sleeve  14 . This method further includes the step of connecting a biaser  20  to the locking sleeve  14  for biasing means for locking  56  out of engagement with the tray  12  for sequentially limiting the sliding of the tray  12  through the locking sleeve  14 . 
   In a further embodiment of the present invention, there is shown a method of dispensing at least one item  31  from a locking container  10 . This method of dispensing at least one item  31  includes pressing the biaser  20  inward to warp a part of tray  12  between ribs  64  against the force of springs  48  away from base  16  so that detents  56  disengage away from corresponding holes  36 . This method of dispensing further includes sliding tray  12  out from the open end  40  of the locking sleeve  14 . Pressure is then applied to an item-containing blister  30  to punch or rupture the backing sheet and remove an item  31  from the item-containing blister  30 . The tray  12  is then slid back into the locking sleeve  14  to allow the detents  56  to engage with the holes  36  to securely hold the tray  12  within the locking container  10 . 
   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. Many variations of combinations may be made to the above-described embodiments without departing from the scope of the claims. All such variations of combinations are included herein by the scope of this disclosure and the following claims.