Patent Publication Number: US-7581642-B2

Title: Child-resistant, senior-friendly unit dose container

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims the benefit under 35 USC §119(e) of U.S. Provisional Patent Application No. 60/757,429, filed Jan. 9, 2006. 

   BACKGROUND OF THE INVENTION 
   The present invention relates to a container, or package, for containing items, such as doses of medicine, that can be dispensed therefrom, and more particularly, the present invention relates to a unit dose package that includes a blister or blister card and that has child-resistant, senior-friendly dispensing properties. 
   Paperboard unit dose packages for use in dispensing medicine tablets are disclosed by U.S. Pat. No. 6,047,829 issued to Johnstone et al., U.S. Pat. No. 6,874,636 B2 issued to Paliotta et al., and U.S. Pat. No. 6,230,893 B1 issued to Karow. Other containers for pills and the like are disclosed by U.S. patent application Publication Nos. 2005/0183981 A1 of Gelardi, 2005/0115862 A1 of Maietta, and 2005/0199527 A1 of Ellis et al., and by U.S. Pat. Nos. 4,192,422 and 4,120,400 issued to Kotyuk, U.S. Pat. No. 4,817,819 issued to Kelly, U.S. Pat. No. 6,349,831 B1 issued to Buss, U.S. Pat. No. 6,789,677 B2 issued to Maietta, U.S. Pat. No. 4,126,224 issued to Laauwe et al., U.S. Pat. No. 6,896,137 B2 issued to McHutchinson, U.S. Pat. No. 6,460,693 B1 issued to Harrold, U.S. Pat. No. 5,082,137 issued to Weinstein, U.S. Pat. No. 3,942,630 issued to Phillips, U.S. Pat. No. 5,878,887 issued to Parker et al., U.S. Pat. No. 6,401,926 B1 issued to Lo, U.S. Pat. Nos. 4,511,032 and 6,679,381 B1 issued to Bush, U.S. Pat. No. 6,021,901 issued to Wolfe, U.S. Pat. No. 6,832,686 B2 issued to Donegan, U.S. Pat. No. 5,346,069 issued to Intini, U.S. Pat. No. 6,913,149 B2 issued to Gelardi et al., U.S. Pat. No. 6,863,175 B2 issued to Gelardi, U.S. Pat. No. 6,540,081 B2 issued to Balz et al., U.S. Pat. No. 3,504,788 issued to Gray, U.S. Pat. No. 5,740,938 issued to Hofmann et al., and U.S. Pat. No. 4,048,050 issued to Hillman. 
   Although the above referenced unit dose packages and pill boxes disclosed by the above referenced patents and published applications may be satisfactory for their intended purposes, there is a need for a unit dose package of novel construction that is difficult for a child to open, yet readily opened and closed by an intended end-user, such as a senior citizen. Preferably, the container includes a blister, blister card, tray or the like on which numerous items, such as doses of medicine, are individually secured. The blister, blister card or tray should be able to be slid between a retracted position in which the items are protected and housed within the package and a dispensing position in which the blister, blister card or tray extends in an exposed condition from the package, but remains connected to the package. 
   BRIEF SUMMARY OF THE INVENTION 
   According to the present invention, a child-resistant and senior-friendly unit dose package has a hollow container body and a tray with a plurality of items secured thereto for being dispensed from the container body. The container body has an end with an elongate opening defined by a rim, and the tray is slidable between a retracted position in which the tray is located within the container body and a dispensing position in which the tray extends through the opening of the container body and is accessible by an end-user. The package includes a separate cap removably securable to the container body to seal the opening and prevent access of the items on the tray by young children and the like. 
   In a preferred embodiment, the container body and cap are made of plastic, and the engagement of lugs within slots enables the cap to be secured to the container body. Preferably, a spring, such as a leaf spring, urges the lugs into a captured position within the slots. Thus, removal of the cap from the container body requires hand pressure exerted simultaneously in both downward and lateral directions on the cap. Further, preferably the tray is a blister card and the elongate opening of the container body is substantially rectangular corresponding to the end profile of the blister card. A mechanism for preventing complete removal of the blister card from the container body is also provided. 

   
     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 container and cap combination according to the present invention; 
       FIG. 2  is a perspective view showing the cap of  FIG. 1  while being removed from the container of  FIG. 1 ; 
       FIG. 3  is a perspective view showing the cap of  FIG. 1  removed from the container of  FIG. 1 ; 
       FIG. 4  is a cross-sectional view of the container, cap and blister card taken along line  4 - 4  of  FIG. 1 ; 
       FIG. 5  is a cross-sectional view of the container and cap taken along a plane extending perpendicular to the end wall of the cap; 
       FIG. 6  is a cross-section view of the container similar to  FIG. 4 , except with the cap removed and the card extended therefrom; 
       FIG. 7  is a perspective view of a second embodiment of a container and cap combination according to the present invention; 
       FIG. 8  is a perspective view showing the cap being removed from the container of  FIG. 7 ; 
       FIG. 9  is a perspective view showing the cap removed from the container of  FIG. 7 ; 
       FIG. 10  is an elevational view showing the tray of the container of  FIG. 7  in a dispensing position; 
       FIG. 11  is a cross-sectional view of the container and tray of  FIG. 10  taken along line  11 - 11 ; 
       FIG. 12  is an end view of the container and tray of  FIG. 10  taken along line  12 - 12 ; 
       FIG. 13  is cross-sectional view of the cap in a condition secured to the container of  FIG. 7 ; 
       FIG. 14  is a cross-sectional view of the cap in a depressed condition relative to the container of  FIG. 7 ; 
       FIG. 15  is a cross sectional view of the cap being removed from the container of  FIG. 7 ; 
       FIG. 16  is a cross sectional view of the cap removed from the container of  FIG. 7 ; and 
       FIG. 17  is a perspective view of the assembly of the cap of  FIG. 7 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   A first embodiment of a package  10  according to the present invention is illustrated in  FIGS. 1-6  and includes a container body  12 , a tray or card  14  to which a plurality of dispensable items  16  are secured, and a cap  18 . The body  12  extends between closed and open ends,  20  and  22 , and the cap  18  is securable to the body  12  to seal the open end  22  and removable from the body  12  to permit the tray  14  to be freely slid through the open end  22  into a dispensing position. The cap  18  can be repeatedly attached to and removed from the container  12  until all items  16  have been dispensed from the tray  14 . By way of example, the tray  14  can be a blister card containing doses of medicine, and a child-resistant, senior-friendly connection can be formed between the container body  12  and cap  18 . 
   The hollow container body  12  is preferably made of plastic and is shaped to house a blister card or the like. Thus, the body  12  can be generally flat and substantially rectangular, for instance, as illustrated in  FIG. 1 . The mouth, or finish,  24  of the container body  12  can form an outwardly tapered neck  26  as best illustrated in  FIG. 4  and can include a rim  28  that defines a substantially rectangular, elongate opening  30  through which the blister card or the like can extend. The container body  12  can be formed as an integral molded piece or can be the assembly of two or more separately formed pieces. For example, the body  12 , or components thereof, can be made by injection-molding, blow-molding, thermoforming, or like techniques. 
   The cap  18  is also preferably made of plastic via injection-molding, blow-molding, thermoforming, or like technique and includes an end wall  32  and peripheral sidewall  34  depending therefrom. The end wall  32  is substantially rectangular for covering the elongate opening  30  of the container body  12 , and the sidewall  34  is of a size to closely fit about the finish  24  of the container body  12 . Preferably, the cap  18  can be snapped onto the finish  24  and requires multiple simultaneously manipulations by the end-user to be removed from the container body  12 . For example, the container body  12  and cap  18  can be designed so that removal is accomplished only by the simultaneous actions of depressing the cap  18  relative to the container body  12  and sliding the cap  18  laterally relative to the container body  12 . See arrow “A” in  FIG. 2 . 
   In the illustrated embodiment of the present invention, the mechanism for creating the child-resistant, senior-friendly cap-to-container body connection is provided by a series of cooperating lugs  36  and slots  38 . The slots  38  provide pathways along which the lugs  36  are permitted to travel when the cap  18  is engaged to the container body  12 . As best illustrated in  FIG. 3 , the lugs  36  extend inwardly from the sidewall  34  of the cap  18 , and the slots  38  are formed in an external face of the finish  24  of the container body  12 . Alternatively, the lugs can extend from the finish, and the slots can be formed in the cap. 
   In the illustrated embodiment, there are two slots  38  on each side of the elongate opening  30 , and each slot  38  includes an open top  40  through which a lug  36  can pass and a reversely turned section  42  in which the lug  36  can be captured. Accordingly, the slots  38  have a substantially “J” or “U” shaped configuration as best illustrated in  FIG. 5 . The upper portion of each reversely turned section  42  includes perimeter walls  44  that prevent movement of the lug  36  both in an upward direction as well as in lateral directions. A spring or like mechanism  46  exerts a force on the cap  18  and container body  12  so that the cap  18  is resiliently biased away from the container body  12 . Thus, when the lugs  36  are located within the reversely turned sections  42  of the slots  38 , the spring  46  exerts a force between the cap  18  and container body  12  that prevents the lugs  36  from escaping the reversely turned sections  42 . This locks the cap  18  to the container body  12  and prevents unwanted removal of the cap  18  by young children or the like. 
   Preferably, the spring  46  is a leaf spring or the like and is mounted on the underside  48  of the end wall  32  of the cap  18  so that, when the cap  18  is engaged to the container body  12 , the spring  46  engages the rim  28  of the container body  12 . Other types of springs can be used. An applied cap  18  can only be removed from the container body  12  by depressing the cap  18  against the force of the spring  46  and by simultaneously sliding the cap  18  laterally relative to the container body  12  so that the lugs  36  exit the reversely turned sections  42  of the slots  38  and escape the slots  38  through the top openings  40 . These simultaneous manipulations are not readily accomplished by a young child, but can readily be accomplished by an adult. 
   After an item  16  is dispensed, the cap  18  can be readily re-applied to the finish  24  of the container body  12  by aligning the lugs  36  of the cap  18  with the open tops  40  of the slots  38 . When the cap  18  is pressed onto the finish  24  of the container body  12 , the lugs  36  are automatically directed and snap into the reversely turned sections  42  of the slots  38 . Thereafter, the lugs  36  are retained in this captured position under the force of the spring  46 . 
   The tray  14  is preferably a blister card or the like that carries items  16  in separate blister compartments  50  so that the items  16  can be removed one at a time from the card  14 . The tray or blister card  14  can be made of plastic, paperboard, paper, foil or the like. In addition, as illustrated in  FIG. 4 , the tray  14  can include a fold or hinge  52  that permits the tray  14  to be folded upon itself before being inserted into the container body  12  through the elongate opening  30 . 
   A tray locking mechanism is used to prevent complete removal of the tray or card  14  from the container body  12 . For example, the tray  14  can be placed in a retracted position (see  FIG. 4 ) in which the tray  14  is housed within the container body  12 . The cap  18  can be applied to and/or removed from the container body  12  when the tray  14  is in the retracted position. After the cap  18  is removed from the container body  12 , the tray  14  is free to slide through the elongate opening  30  to a dispensing position (see  FIG. 6 ). Preferably, a locking flange  54  or the like extends from a face  56  of the tray  14  at a distal end  58  of the tray  14  and is prevented from passing beyond the elongate opening  30  of the container body  12  by an inturned flange  60  extending from an inner surface of the finish  24  of the container body  12 . The blister card  14  can be unfolded to expose the blister compartments  50 , while the distal end  58  of the blister card  14  remains captured or tethered to the container body  12 . Other alternative tray locking mechanisms can be utilized. 
   In use, the plastic, relatively-rigid, substantially-rectangular package  10  can be used to store a blister card  14  carrying a predetermined amount of tablets, such as doses of prescribed or over-the-counter medicines, vitamins, supplements, or the like. Indicia, such as days, dates, or other information, can be displayed directly on the card to provide the end-user with reminders as to the rate at which the doses should be taken. Indicia can also be applied to the front and back of the container body and to the end wall of the cap. Further, the cap  18  and container body  12  can include alignment markings, such as grooves  62  that aid the user in properly aligning the cap  18  with the container body  12 . 
   The end-user removes the cap  18  by pressing the cap  18  toward the container body  12  and simultaneously sliding the cap  18  in a lateral direction as can be indicated by arrows or like indicia on the cap  18 . After the cap  18  is removed, the end-user can grip an exposed portion  64  of the blister card  14  adjacent the finish  24  of the container body  12  and slide the proximal end  66  of the blister card  14  out of the container body  12 . Alternatively, the blister card  14  may be caused to slide out of the container body  12  via a quick hand flicking motion of the container body  12 . When the distal end  58  of the blister card  14  reaches the elongate opening  30  of the container body  12 , further movement of the blister card  14  is prevented. In this dispensing position, the card  14  extends from the mouth  24  of the container body  12  and may or may not require unfolding to permit the end-user to access the blister compartments  50 . After one or more tablets  16  are removed from the blister card  14 , the blister card  14  can be refolded and returned to within the container body  12  to a fully retracted storage position. Thereafter, the cap  18  can be reapplied and snapped into place on the container body  12 . This process can be repeated until all blister compartments  50  are empty at which time the container body  12  and cap  18  can be reused, recycled, or discarded. 
   A second embodiment of a package  110  of the present invention is illustrated in  FIGS. 7-17 . The package  110  is similar in most respects to package  10  discussed above. For example, the package  110  includes a container body  112 , a tray or blister card  114  to which a plurality of dispensable items are secured, and a cap  118 . The body  112  extends between closed and open ends,  120  and  122 , and the cap  118  is securable to the body  112  to seal the open end  122 . The cap  118  is removable from the body  112  to permit the tray  114  to freely slide through the open end  122  into a dispensing position. See  FIG. 10 . The cap  118  can be repeatedly attached to and removed from the container  112  until all items have been dispensed from the tray  114 . 
   The cap  118  is snapped onto the finish  124  of the container body  112  and requires multiple simultaneously manipulations by the end-user to be removed from the container body  112 . The container body  112  and cap  118  are designed so that removal is accomplished only by the simultaneous actions of depressing the cap  118  relative to the container body  112  and sliding the cap  118  laterally relative to the container body  112 . See arrow “B” in  FIG. 8 . 
   A child-resistant, senior-friendly cap-to-container body connection is provided by a series of cooperating lugs  136  and slots  138 . The slots  138  provide pathways along which the lugs  136  are permitted to travel when the cap  118  is engaged to the container body  112 . As best illustrated in  FIG. 9 , the lugs  136  extend inwardly from the sidewall  134  of the cap  118 , and the slots  138  are formed in an external face of the finish  124  of the container body  112 . Alternatively, the lugs can extend from the finish, and the slots can be formed in the cap. 
   There are two slots  138  on each side of the elongate opening  130  of the container body  112 , and each slot  138  includes an open top  140  through which a lug  136  can pass and a reversely turned section  142  in which the lug  136  can be captured. Accordingly, the slots  138  have a substantially “J” or “U” shaped configuration as best illustrated in  FIG. 9 . The upper portion of each reversely turned section  142  includes perimeter walls  144  that prevent movement of the lug  136  both in an upward direction as well as in lateral directions. A spring or like mechanism  146  exerts a force on the cap  118  and container body  112  so that the cap  118  is resiliently biased away from the container body  112 . Thus, when the lugs  136  are located within the reversely turned sections  142  of the slots  138 , the spring  146  exerts a force between the cap  118  and container body  112  that prevents the lugs  136  from escaping the reversely turned sections  142 . See  FIG. 13 . This locks the cap  118  to the container body  112  and prevents unwanted removal of the cap  118  by young children or the like. 
   The spring  146  of the package  110  has an H-shaped configuration and is curved, or bowed, along its length. See  FIG. 17 . The spring  146  is mounted on the underside  148  of the end wall  132  of the cap  118  and is captured thereto by the lugs  136  and abutments  160  of the cap  118 . When the cap  118  is secured to the container body  112 , the spring  146  applies a force to lock the lugs  136  within the slots  138 . See  FIG. 13 . When pressure is exerted on the cap  118  as shown by arrow “C” in  FIG. 14 , the spring  146  flattens thereby permitting the lugs  136  to exit the slots  138 . Upon removal of the cap  118  from the container body  112 , the spring  146  automatically and resiliently returns to its original and memorized bowed configuration. See  FIGS. 15 and 16 . 
   A cap assembly is illustrated in  FIG. 17 . In this embodiment, the cap  118  is simultaneously molded with the spring  146  in the same mold and of the same material. Upon removal of the cap assembly from the mold, the cap  118  is connected to the spring  146  via an arm  162 . The arm and spring  146  can be pivoted as shown by arrow “D” in  FIG. 17  to locate the spring  146  and arm  162  within the cap  118 . Alternatively, the arm can be broken away from the cap  118  and spring  146 , as shown in phantom in  FIG. 17 , and discarded. Thereafter, the spring  146  is inserted into the cap  118  beyond the lugs  136 . 
   The tray  114  is preferably a blister card that carries items in separate blister compartments  150  and that includes one or more end blister compartments  164 . See  FIGS. 10 and 11 . The compartments  164  extend laterally to a greater extent on the card  114  relative to compartments  150 . Accordingly, the compartments  150  fit between a pair of posts  166  extending within the container body  112  and permit the card  114  to be positioned to the dispensing position shown in  FIG. 10 . However, the compartments  164  do not fit between the posts  166 , thereby capturing the card  114  to the container body  112 . 
   In addition to the posts  166 , the container body  112  also includes a spine  168  extending centrally within the container body  112  between the blister compartments  150 . The spine  168  and posts  166  rigidify the container body  112  and prevent unintended compression of the container body  112 . However, since the posts  166  and spine  168  extend from only one side of the container body  112 , the card  114  is permitted to slide relative to the posts  166  and spine  168  within the container body  112  between the retracted position and the dispensing position. 
   While preferred unit dose packages have been described in detail, various modifications, alterations, and changes may be made without departing from the spirit and scope of the unit dose package according to the present invention as defined in the appended claims.