Patent Publication Number: US-7896161-B2

Title: Child-resistant, senior friendly carded package and method of assembly

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a package for containing items, such as doses of medicine, that can be dispensed therefrom, and more particularly, the present invention relates to a carded booklet style package that includes a blister card and that has child-resistant, senior-friendly dispensing properties. 
     Paperboard carded packages including a blister card are disclosed, for example, by U.S. Pat. No. 4,125,190 issued to Davie, Jr. et al., U.S. Pat. No. 5,339,960 issued to Price, U.S. Pat. No. 5,954,202 issued to Mellon, U.S. Pat. No. 6,394,275 B1 and U.S. Pat. No. 6,659,280 B2 issued to Paliotta et al., and U.S. Pat. No. 6,951,282 B2 issued to Jones and by U.S. Patent Application Publication No. 2006/0289328 A1 of Hession. Also see U.S. Pat. No. 6,047,829 issued to Johnstone et al., U.S. Pat. No. 6,024,222 issued to Friberg et al., U.S. Pat. No. 6,675,972 B2 issued to Patterson, U.S. Pat. No. 6,964,338 B2 and U.S. Pat. No. 6,974,031 B2 issued to Kancsar et al., U.S. Pat. No. 7,000,768 B2 issued Morita et al., and U.S. Pat. No. 7,201,274 B2 issued to Paliotta et al. and U.S. Patent Application Publication Nos. 2004/0188311 A1 of Paliotta et al. and 2004/0108240 A1 issued to Ragot. 
     Although the above referenced carded packages disclosed by the above referenced patents and published applications may be satisfactory for their intended purpose, there is a need for a carded package of novel construction that provides a desired amount of child-resistance, yet from which tablets can be readily dispensed by an intended end-user, such as a senior citizen. Further, there is a needed for a novel and cost efficient method of assembling a carded package. 
     BRIEF SUMMARY OF THE INVENTION 
     According to the present invention, a child-resistant carded package for storing and dispensing tablets and like items is provided. The carded package assembly has a integral pair of opposed flaps. One flap carries the tablets or like items, and the other provides a booklet-style cover foldable between a position covering the tablets or like items and a position exposing the tablets or like items. 
     The carded package assembly is made from a first card bonded to a separate second card with a blister card captured therebetween. The blister card has a plurality of separate upstanding blister compartments in which the tablets or like items are separately contained. The first card has a flap forming part of the booklet-style cover and a flap including at least three panels folded together with each of the at least three panels including cut out openings or perforations defining punch outs. The second card has a flap forming part of the booklet-style cover and a flap having cut out openings. The blister card is sandwiched between the at least three panel flap of the first card and the flap of the second card having openings. In this configuration, the blister compartments project through the openings of the second card, and the cut out openings and punch outs of the first card are located behind the blister compartments and define paths through which the tablets or like items are required to be dispensed from the package. 
     According to another aspect of the present invention, a method of assembling a child-resistant carded package is provided. The method includes bonding a first card to a separate second card with a blister card captured therebetween to form a carded package assembly having a pair of opposed flaps with one of the flaps supporting the blister card and the other of the flaps being a booklet-style cover foldable between a position concealing the blister compartments of the blister card and a position exposing the blister compartments of the blister card. Before the above referenced bonding step, the first card is provided in blank form, and a part of the blank is folded into a convolute configuration forming a flap at least three panels thick. Thereafter, the at least three panels are secured together. In this condition, the first card includes a flap for forming part of the booklet-style cover and the at least three panel thick flap. Each of the at least three folded panels includes cut out openings or perforations defining punch outs. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention should become apparent from the following description when taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  is perspective view of a carded package assembly according to the present invention; 
         FIG. 2  is a cross-sectional view of the assembly taken along line  2 - 2  of  FIG. 1 ; 
         FIG. 3  is a cross-sectional view of the assembly taken along line  3 - 3  of  FIG. 1 ; 
         FIG. 4  is a perspective view of a blank of a first card for use in making the assembly of  FIG. 1 ; 
         FIG. 5  is a perspective view of the first card of  FIG. 4  after a first fold; 
         FIG. 6  is a perspective view of the first card of  FIG. 4  after a second convolute fold; and 
         FIG. 7  is an exploded view of the carded package assembly of  FIG. 1 ; and 
         FIG. 8  is a perspective view of an exterior side of the carded package assembly of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A carded package  10  according to the present invention is illustrated in  FIGS. 1 and 8 . The package  10  contains tablets  12  and/or like separate items and provides child-resistant, senior-friendly dispensing properties. For example, the tablets  12  can be doses of medicine, vitamins, supplements, or any other product that is provided in tablet or like form. 
     As best illustrated in  FIGS. 1 and 8 , the fully assembled carded package  10  has a pair of opposed flaps,  14  and  16 , provided in a so-called booklet-style. The flap  14  carries the tablets  12 , and the flap  16  provides a booklet-style cover. For example, the flap  16  is foldable about a sidewall, or edge binding,  18  of the package  10  to a position covering the tablets  12  (for instance, see  FIG. 2 ) and to a position exposing the tablets  12  to the end user in the same manner a book cover enables access to the pages of a book. The tablets  12  are neither readily viewable nor dispensable from the package  10  when the package  10  is in the closed position shown in  FIG. 2 . Various means such as tabs, slots, adhesive strips, hook and loop fasteners, clips, shrink wrap, a sleeve or the like (not shown) can be used to retain the package  10  in the closed position, if desired. 
     The carded package  10  includes and is assembled from a first card  20 , a separate second card  22 , and a blister card  24 . According to one preferred contemplated embodiment of the present invention, the package  10  is constructed solely of these three components. See  FIG. 7 . 
     The blister card  24  carries a plurality of separate items, such as tablets  12 , in separate blister compartments  26  so that the items can be dispensed individually, or in sets, from the blister card  24 . The blister card  24  can be made of plastic, paperboard, paper, foil or the like. For example, the card  24  can include a transparent plastic layer  28  defining the compartments  26  and a rupturable paper and/or foil backing layer  30  laminated to a rear side of the layer  28  to seal the items in the compartments  26 . 
     The first and second cards,  20  and  22 , are each preferably formed of a paperboard material, for example a SBS (solid bleached sulfate) paperboard stock material. Of course, materials other than paperboard and materials within a range of thicknesses can be used. However, preferably the material used for the cards,  20  and  22 , should enable the cards to be provided in a relatively flat blank form on which panels, fold lines, openings, and perforations can be readily formed and/or defined. In addition, preferably one side of the blanks of the cards,  20  and  22 , should be capable of being coated with a continuous or discontinuous layer of a heat and/or pressure activated adhesive. Further, the opposite side of the blanks of the cards,  20  and  22 , should preferably be glossy or otherwise of a desired texture and/or appearance for forming the visible external surfaces of the package  10 . 
     As best illustrated in  FIG. 4 , the first card  20  in black form is relatively elongate and defines four primary panels. The panel  32  ultimately is used to form part of the flap  16  forming the book-style cover of the package  10 . The panels  34 ,  36  and  38  are used to form a rear part of the flap  14  to which the blister card  24  is secured. The blank of the first card  20  also includes a relatively thin panel  40  which forms part of the sidewall, or edge binding,  18  of the booklet-style package  10 . Further, fold lines  42 ,  44 ,  46  and  48  define the boundaries of the various panels of the first card  20  about which the blank is folded to form and/or use the package  10 . The side  50  of the first card  20  shown exposed in  FIG. 4  is the side of the card  20  preferably coated with a layer of heat and/or pressure activated adhesive. 
     As best illustrated in  FIG. 5 , the blank of the first card  20  is first folded along fold line  48  such that panel  38  confronts and overlies the adjacent panel  36 . As shown by arrow “A” in  FIG. 5 , the panel  38  is preferably folded or pivoted in a counter-clockwise direction in the example illustrated in  FIG. 5 . In the folded position, the adhesive layer of panel  36  confronts the adhesive layer of panel  38 , and these confronting adhesive layers will ultimately be used to bond these two layers together. 
     After the fold illustrated in  FIG. 5  is completed, the blank of the first card  20  is folded along line  46  preferably in a counter-clockwise direction as shown by an arrow “B” illustrated in  FIG. 6 . For purposes of this application, this is termed “convolute folding” and is in contrast to bellows or accordion style folding. In the convolute fold, the panels extend in a spiral, wound or rolled configuration instead of an alternating bellows type configuration. Accordingly, in the example provided in  FIG. 6 , the panel  38  confronts and lies directly above the panel  34 , and the panel  36  confronts and lies directly above the panel  38 . Pressure and/or heat is applied to the three panels,  34 ,  36  and  38  to bond them together in the convolute-folded condition shown in  FIG. 6 . The adhesive layer of panel  34  bonds to the non-adhesive glossy side of panel  38 , and the confronting adhesive layers of panels  36  and  38  bond panels  36  and  38  together. This thereby leaves the glossy (non-adhesive) sides of the panels  34  and  38  exposed as external surfaces of the folded blank. 
     The second card  22  in blank form can be provided having a pair of primary panels  52  and  54  connected via a relatively narrow panel  56  which ultimately forms part of the sidewall, or edge binding,  18  of the package  10 . Fold lines  58  and  60  define the boundaries of these panels. Preferably, the underside  62  of the second card  22  as illustrated in  FIG. 7  is coated with a pressure and/or heat activated adhesive, and the top side  64  is glossy or otherwise provides a desired texture and/or appearance required of the external surfaces of the package  10 . 
     As best illustrated in  FIG. 7 , the blister card  24  is positioned between the convolute-folded three panel structure of the first card  20  and the panel  54  of the second card  22 . The first and second cards,  20  and  22 , are brought together and heat and/or pressure is applied to activate the adhesive layer on the underside  62  of the second card and the side  50  of panel  32  of the first card  20 . This adhesively bonds panel  52  of the second card  22  to the panel  32  of the first card  20  and the panel  54  of the second card  22  to the panel  36  of the first card  20 . In this condition, the blister card  24  is captured between the panel  54  of the second card  22  and the panel  36  of the first card  20 . With respect to flap  14 , this forms a four layer paperboard panel (not counting any layers of the blister card). The flap  12  forming the booklet-style cover and the sidewall  18  of the package  10  are provided as two layer structures in the illustrated example. 
     As best shown in  FIG. 4  with respect to the first card  20  and  FIG. 7  with respect to the second card  22 , some of the panels include either cut-out openings or perforations defining punch outs. For example, the panel  54  of the second card  22  includes a series of openings  66  which register and are aligned to receive the upstanding blister compartments  26  of the blister card  24 . Thus as best shown in  FIGS. 1 and 2 , the blister compartments  26  extend through the openings  66  and project above the plane defined by the panel  54  of the second card  22 . 
     The panel  36  of the first card  20  includes perforations  68  with define a series of small panels, or punch outs,  70 . As best shown in  FIG. 7 , the panel  36  directly engages the underside, or backing layer,  30  of the blister card  24 , and the punch outs  70  are at least somewhat aligned behind the blister compartments  36 . Thus, until a sufficient amount of pressure is applied to a tablet  12  to break the perforations  68  of the a punch out  70 , the tablet  12  cannot be removed from the package  10 . 
     The panels  34  and  38  are located on an opposite side of panel  36  relative to the blister card  24 . These panels,  34  and  38 , each include a series of openings  72  that are aligned with each other and at least somewhat behind the blister compartments  26 . Thus, for a tablet  12  to be dispensed from the package  10 , it must pass through the rupturable backing layer  30  of the blister card  24 , the punch out sections  70  of panel  36 , and the openings  72  of panels  34  and  38 . The punch outs  70  and openings  72  define the path through which of the tablets  12  are required to take to be dispensed from the package  10 . 
     As best illustrated in  FIG. 4 , preferably the perforations  68  or peripheral edges of the punch outs  70  of the panel  36  do not exactly correspond with the openings  72  in the panels  34  and  38 . For example, the size of the punch outs  70  relative to size of the openings  72  can be different, the shape of the punch outs  70  relative to the shape of the openings  72  can be different, and/or the punch outs  70  can be offset relative to the openings  72 . The purpose of the above arrangement is to adjust the resistance required to be overcome for a tablet  12  to be dispensed from the package  10 . For example, when the perforations  68  do not exactly align with the edges of the openings  72 , a greater amount of force will typically be required to break the perforations  68 . In the illustrated example, the punch outs  70  are oval in plan and the openings  72  are circular in plan. Thus, the ends of the oval punch out  70  extend beyond the boundary of the circular opening  72 , while the elongate flattened sides of the oval  70  cut across, or dissect, the circular shaped opening  72 . By way of example, the package  10  can be designed, for instance, to require a force of at least about 8 to about 12 pounds of pressure to be exerted on the blister compartment  26  and/or tablet  12  for the tablet  12  to be dispensed from the package  10 . 
     Another aspect of the package  10  is that the blister card  24  is relatively centered on the flap  14  such it is framed within a relatively wide margin  74  where panel  36  of the first card  20  directly engages and is adhesively bonded to the panel  54  of the second card  22 . In the margin  74 , the flap  14  is four layers thick. Thus, the margin section  74  of the package  10  is not readily torn by a child and cannot be readily bitten or chewed through to access the tablets  12 . Further, the four layers are adhesively bonded together and do not provide any section of the package  10  that can readily be pried apart by a child. These features along with the amount of force required to dispense a tablet  12  enable the package  10  to provide desired levels of child resistance. 
     When the package  10  is initially distributed to the end user, it can include a peel-away tamper indicating sheet  76  or the like. See  FIG. 8 . This removable sheet or sticker  76  initially covers the openings  72  that would otherwise be visually perceptible on the underside of the package  10 . If the sheet  76  is completely or partially removed, this may indicate a used package or a package that may have been subject to tampering. If the sheet  76  is properly secured to the package  10 , the end user must first remove this sheet  76  before dispensing tablets  12  from the package  10 . Indicia, instructions, or other information (not shown) may be printed or applied on various external surfaces of the package  10 . 
     Turning to the method of assembling the package  10 , the first card  20  is preferably provided in blank form, for instance as illustrated in  FIG. 4 . Operations forming cut outs, perforations, and fold lines can be preformed on the blank and/or during manufacture of the blank. In addition, a heat or pressure sensitive adhesive may by applied to one side of the blank before or during its manufacture. Further, printing or separately applied labels can be provided on the blank during or after its manufacture. Thereafter, the convolute folds (discussed above) can be provided to the blank to produce a flap  14  with at least three layers, and heat and/or pressure can be applied to bond the at least three layer structure together. 
     After the at least three layer structure is formed, the blister card  24  can be aligned between the first and second cards,  20  and  22 , and pressure and/or heat can be applied to the cards,  20  and  22 , to adhesively bond the first and second cards,  20  and  22 , together with the blister card  24  captured therebetween. The arrangement of the punch outs  70  and openings  66  and  72  can be provided as discussed above. A tamper-indicating release sheet  76  can be applied over the openings  72  that would otherwise be exposed on an underside of the package  10 , and the flaps,  14  and  16 , of the package can be positioned and/or secured in the closed book condition (see  FIG. 2 ). 
     Various modifications to the package and its method of assembly can be used. For instance, the number of panels can be increased, and the shape, size and/or pattern of the perforations and openings can be changed. Further, different types of adhesives and other means can be used to bond the panels of the carded package together. 
     While preferred packages and methods of assembly have been described in detail, various modifications, alterations, and changes may be made without departing from the spirit and scope of the package and method according to the present invention as defined in the appended claims.