Patent Publication Number: US-11396411-B2

Title: Child resistant paperboard box

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from U.S. Provisional Application Ser. No. 63/073,275 filed Sep. 1, 2020, the content of which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to packaging and, more particularly, to a child resistant paperboard box. 
     2. Description of the Related Art 
     Cartons or other paperboard containers may be used for holding and storing small items. In some implementations, the items held or stored in the containers may be harmful to certain users, such as children (e.g., a pharmaceutical drug). A user may desire to hold or store items in a lockable, child-resistant container. 
     Child-proof containers, i.e., containers that at least small children cannot open are desirable for a plurality of goods, which could be harmful to the children and/or to the surroundings. Such goods can be, e.g., medical pills, matches or needles. 
     For such purposes, well-functioning child-proof containers have been more or less developed. In most cases, these containers are formed with ledge-shaped locking members projecting from the flat side surface of the casing. These conventional locking members, however, have generally only a very modest locking ability, which can often be overcome without large or extreme forces, by merely pushing the box in its normal direction of opening, and this can often also be accomplished by small children. 
     U.S. Pat. No. 4,401,210 to Anjou discloses one such child-proof container consisting of a casing and a box displaceably arranged therein, whereby the side walls of the casing at the interior are provided with locking members located diagonally to each other and intended to cooperate with recesses in the side walls of the box, whereby the locking members are arranged to be able to be moved away from locking position in the recesses via external forces, which can be applied with two fingers diagonally on the casing to give this a rhomboidic shape, whereby at the same time a pressure force exerted by a third finger can push the box out of the container. 
     U.S. Pat. No. 6,641,031 to Evans et al. discloses a method and another child resistant carton assembly that includes a carton having a body panel. A locking panel is spaced apart from the body panel. The locking panel and the body panel define a locking chamber. A tray is slidably mounted in the carton. The tray includes a locking tab adapted to releasably engage the locking panel such that at least an insert portion of the locking tab is disposed in the locking chamber. 
     U.S. Pat. No. 6,976,576 to Intini discloses a child-resistant/senior friendly dispensing package comprising a dispensing member having a dispensing cavity and a product storage cavity, where the dispensing member is mounted within a sleeve that is movable from a first stored position to a second position, and where the dispensing cavity is external to the housing to permit dispensing of the product. The dispensing package also includes a device having first and second locks that must be operated either sequentially or simultaneously in order to move the dispensing cavity exteriorly of the housing, where the device preferably permits the dispensing of only a single tablet or product. 
     There is a need for a child-proof container, which functions well to safely prohibit opening by a person who unfamiliar with the opening method and which, at the same time, does not require high forces to correctly open the container. 
     SUMMARY OF THE INVENTION 
     Disclosed is a paperboard box, which is configured in a child-resistant manner. The paperboard box includes a paperboard tray and a paperboard over-sleeve that is closed at one end and open at the opposite end. The paperboard tray is housed within the paperboard over-sleeve. The paperboard tray and the paperboard over-sleeve are locked together by interlocking tabs, where one tab is located on the inside of the paperboard over-sleeve and another tab is located on the outside of the paperboard tray. These two tabs engage with each other and prevent the paperboard box from being opened through normal force when attempting to slide the paperboard tray out from the bottom of the paperboard over-sleeve. 
     In order to open the paperboard box and access products located within the paperboard tray, (i) a sleeve divider tab located within the inside of the tray must be pushed or folded downward, (ii) the tray must be slid to the opposite side of the paperboard over-sleeve—beyond the now folded tab of the paperboard over-sleeve, and (iii) the paperboard tray is then unlocked to permit its removal by pulling it out of the open end of the paperboard over-sleeve to a position that permits access to products within the paperboard tray. 
     In order to close the paperboard box, the paperboard tray must be slid back to the opposite side of the paperboard over-sleeve, and then pushed into the paperboard over-sleeve. 
     Other objects and features of the present invention will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for purposes of illustration and not as a definition of the limits of the invention. It should be further understood that the drawings are not necessarily drawn to scale and that, unless otherwise indicated, they are merely intended to conceptually illustrate the structures and procedures described herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       An exemplary embodiment of the invention is explained in greater detail below with reference to the drawings, this comprising schematic and greatly simplified figures in which: 
         FIG. 1  is an illustration of the paperboard box in accordance with the invention; 
         FIG. 2  is an illustration of an end view of the paperboard box in accordance with the invention; 
         FIG. 3  is an illustration of the paperboard tray in accordance with an embodiment of the invention; 
         FIG. 4  is an illustration of the paperboard tray in accordance with a preferred embodiment of the invention; 
         FIG. 5  is a plan view illustration of the paperboard over-sleeve in an unfolded state in accordance with the invention; 
         FIG. 6  is a plan view illustration of the paperboard over-sleeve in an unfolded state in accordance with an alternative preferred embodiment of invention; 
         FIGS. 7, 8 and 9  are illustrations of the paperboard box in accordance with an alternative preferred embodiment of the invention; 
         FIG. 10  is a plan view illustrating the paperboard tray of  FIG. 3  in an unfolded state; 
         FIG. 11  is a plan view illustrating the paperboard tray of  FIG. 4  in an unfolded state; 
         FIG. 12  is an illustration of the paperboard box in a partially opened state in accordance with the invention; 
         FIG. 13  is a cross-sectional illustration along  9 - 9  of the paperboard box of  FIG. 8  in a restricted state; 
         FIG. 14  is an illustration of another end view of the paperboard box with the paperboard tray in a locked and inserted state in accordance with the invention; 
         FIG. 15  is an illustration of another end of the paperboard with the paperboard tray at an unlocked and inserted state in accordance with the invention; 
         FIG. 16  is an illustration of the paperboard in an opened state in accordance with the invention; and 
         FIG. 17  is a cross-sectional illustration along  13 - 13  of the paperboard box of  FIG. 12  in an opened state in accordance with the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS 
       FIG. 1  is an illustration of the paperboard box  100  that is configured in a child-resistant manner. With reference to  FIG. 1 , the paperboard box  100  is formed from a paperboard over-sleeve  110  and a paperboard tray  115  that is lockingly inserted within the paperboard over-sleeve  110  to create a locked storage compartment. 
     The paperboard box  100  is constructed from a material, such as cardboard, which provides resistive properties, while at the same time is thin enough to be folded into the final form of the paperboard box  100 . The paperboard box  100  is manufactured from 18 point to 22 point, preferably 20 point, board grade paper, which is a grade of paper made for packaging, as opposed to finished grade paper. The paper grade has been found to be a critical aspect of the invention and thus it has been found that the grade of 20 points provides the optimal level of resilience to provide required resistive or properties associated with resilience. The paperboard over-sleeve  110  and paperboard tray  115  are folded into mutually engaging rectangular forms, where the final assembly is held in shape via a suitable glue, in a manner known to the skilled person. In order to provide resistance to merely tearing the paperboard box  100  apart to gain entry, the box is provided with a plastic laminate layer. In this way, a child cannot simply tear the box apart without resorting to more destructive methodologies, such as cutting the box with scissors. 
     As shown in  FIG. 1 , the paperboard over-sleeve  110  includes a flap that includes first and second sleeve tabs  120   a ,  120   b , where the first sleeve tab  120   a  is resiliently biased in a manner that resists transverse or lateral movement of the paperboard tray  115  when the paperboard tray  115  is in the closed position, as depicted in  FIG. 1 . The second sleeve tab  120   b  engages with a first tray tab  135  of the paperboard tray  115  (see  FIG. 3 ) in a locking manner when the paperboard tray  115  is pulled along the longitudinal axis of the paperboard box  100  to an open position. 
       FIG. 2  shows an end view of the paperboard box  100  in accordance with the invention. Here, a sleeve divider tab  125  is shown arranged adjacent to the paperboard tray  115 . The sleeve divider tab  125  extends along the interior of the paperboard tray  115  and creates a channel within which the paperboard tray  115  is locked in place by the sleeve divider tab  125 . The sleeve divider tab  125  is circumferentially rotatable about an axis that extends lengthwise or longitudinally of the paperboard box  100  to permit transverse or lateral movement of the paperboard tray  115  when seeking to open the paperboard tray  115  to gain access to product stored within the paperboard tray  115 . 
       FIG. 3  is an illustration of the paperboard tray  115  in accordance with an embodiment of the invention. With reference to  FIG. 3 , the paperboard tray  115  is formed in the shape of a rectangle and includes an upper opening  130 , a first tray tab  135  and a second tray tab  140 , where the first tray tab  135  engages in a locking manner with the second sleeve tab  120   b  of the paperboard tray  115  (see  FIG. 1 ) when the paperboard tray  115  is pulled along the longitudinal axis of the paperboard box  100  to the open position. 
       FIG. 4  is an illustration of the paperboard tray  115  in accordance with a preferred embodiment of the invention. In the preferred embodiment, the paperboard tray  115  has closed upper and lower surfaces, where an opening is provided at one end that includes a first tray tab  135  and a second tray tab  140 , where the first tray tab  135  engages in a locking manner with the second sleeve tab  120   b  of the paperboard tray  115  (see  FIG. 1 ) when the paperboard tray  115  is pulled along the longitudinal axis of the paperboard box  100  to the open position. As opposed to providing the upper opening  130  of the prior described embodiment, the presently contemplated preferred embodiment includes cutouts  145   a ,  145   b , in this way, the paperboard tray  115  of the preferred embodiment is easier to manufacture and more flexible in the types of product that can be housed in the paperboard box  100  without adding an additional piece or insert. 
       FIG. 5  is a plan view illustration of the paperboard over-sleeve  110  in an unfolded state in accordance with the invention. As depicted in  FIG. 5 , the paperboard over-sleeve  110  has a flap that includes the first and second sleeve tabs  120   a ,  120   b , the divider tab  125 , first and second u-shaped cutouts  150 ,  155 , a triangular shaped cutout  160 , an internal sleeve locking tab  165  and an upper sleeve tab  170 . In assembled form, the first sleeve tab  120   a  is resiliently biased in a manner that resists transverse or lateral movement of the paperboard tray  115  when the paperboard tray  115  is in the closed position depicted in  FIG. 1 . The second sleeve tab  120   b  engages, in a locking manner, with a first tray tab  135  of the paperboard tray  115  (see Fla  3 ) when the paperboard tray  115  is pulled along the longitudinal axis of the paperboard box  100  to an open position to prevent complete removal of the paperboard tray  115  from within the paperboard over-sleeve  110 . The internal tray locking tab  165 , on the other hand, engages with the first tray tab  135  of the paperboard tray  115  and prevents the paperboard box  100  from being opened through normal force when attempting to slide the paperboard tray  115  from within the paperboard over-sleeve  110  to reveal its contents. The first and second u-shaped cutouts  150 ,  155  are provided to permit access during removal of the paperboard tray  115 . 
       FIG. 6  is a plan view illustration of the paperboard over-sleeve  110  in an unfolded state in accordance with an alternative preferred embodiment of the invention. Here, the paperboard over-sleeve  110  is provided with a folding indentation section  180  that rests against the sleeve divider tab  125  when the paperboard tray  115  is locked in place by the sleeve divider tab  125  (see  FIGS. 7 and 8 ). By providing the folding indentation section  180 , the sleeve divider tab  125  requires a greater level of force to circumferentially rotate the sleeve divider tab  125  in the direction indicated by arrow A (see  FIG. 9 ). When the required force is provided, e.g., when opening the paperboard box  100 , the folding indentation section  180  moves into a final position in the direction indicated by arrow(s) C (see  FIGS. 7 and 9 ), whereby the inner edge of the folding indentation section  180  moves to a position to form a planar edge with the upper edge of the paperboard over-sleeve  110 . 
       FIG. 10  is a plan view of the paperboard tray  115  in an unfolded state. As shown, the paperboard tray  115  includes an opening  130 , a first tray tab  135  and a second tray tab  140 , where the first tray tab  135  engages in a locking manner with the second sleeve tab  120   b  of the paperboard tray  115  (see  FIG. 1 ) when the paperboard tray  115  is pulled along the longitudinal axis of the paperboard box  100  to the open position. The first tray tab  135  engages with the second sleeve tab  120   b  of the paperboard over-sleeve  115  (see  FIG. 5 ) in a locking manner when the paperboard tray  115  is pulled along the longitudinal axis of the paperboard box  100  to an open position. The first tray tab  135  engages with the second sleeve tab  120   b  of the paperboard over-sleeve  110  and thus prevents the paperboard box  100  from being opened through normal force when attempting to slide the paperboard tray  115  out from the within the paperboard over-sleeve  110 . 
       FIG. 11  is a plan view of the paperboard tray  115  in accordance with the preferred embodiment in an unfolded state. The paperboard tray  115  includes a first tray tab  135  and a second tray tab  140 , where the first tray tab  135  engages in a locking manner with the second sleeve tab  120   b  of the paperboard tray  115  (see  FIG. 1 ) when the paperboard tray  115  is pulled along the longitudinal axis of the paperboard box  100  to the open position. The paperboard tray  115  also includes cutouts  145   a ,  145   b  such that the paperboard tray  115  is easier to manufacture and more flexible in the types of product that can be housed in the paperboard box  100  without adding an additional piece or insert. 
       FIG. 12  shows the paperboard box  100  in a partially opened state. Here, the internal tray locking tab  165  has engaged with the first tray tab  135  of the paperboard tray  115  such that the paperboard tray  115  cannot extend tram the paperboard box  100  through normal force to reveal its content. The locking engagement of the internal tray locking tab  165  with the first tray tab  135  is shown in  FIG. 13 , which is a cross-sectional illustration along  9 - 9  of the paperboard box  100  in the partially opened state. 
       FIG. 14  shows an end view of the paperboard box  100  with the paperboard tray  115  in a locked and inserted state in accordance with the invention. The sleeve divider tab  125  is shown arranged adjacent to the paperboard tray  115 . The sleeve divider tab  125  extends along the interior of the paperboard tray  115  and creates a channel within which the paperboard tray  115  is locked in place by the sleeve divider tab  125 . The sleeve divider tab  125  is circumferentially rotatable about an axis, in a direction indicated by arrow A, which extends lengthwise or longitudinally of the paperboard box  100  to permit transverse or lateral movement, indicated by arrow B, of the paperboard tray  115  when seeking to open the paperboard tray  115  to gain access to product stored within the paperboard tray  115 . 
       FIG. 15  shows the end of the paperboard box  100  with the paperboard tray  115  at an unlocked and inserted state in accordance with the invention. Here, the sleeve divider tab  125  has been rotated and the paperboard tray  115  has been moved transversely or laterally, in the directions indicated by arrows A and B shown in  FIG. 14 , such that it is now possible to slide the paperboard tray  115  lengthwise or along the longitudinal axis of the paperboard box  100  to gain access to product stored within the paperboard tray  115 . In this state, the second sleeve tab  120   b  engages with the first tray tab  135  of the paperboard tray  115  (see  FIG. 3 ) in a locking manner to prevent complete removal of the paperboard tray  115  from within the paperboard over-sleeve  110 . 
       FIG. 16  shows the paperboard box  100  in an opened state. Here, the second sleeve tab  120   b  has engaged with the first tray tab  135  of the paperboard tray  115  (see  FIG. 3 ) in a locking manner to prevent complete removal of the paperboard tray  115  tram within the paperboard over-sleeve  110 . The locking engagement of the second sleeve tab  120   b  with the first tray tab  135  is shown in  FIG. 17 , which is a cross-sectional illustration along  13 - 13  of the paperboard box  100  in the opened state. 
     The inventive child-resistant paperboard box  100  advantageously includes a sleeve divider tab  125  and requires the paperboard tray  115  to be slid from one side to the other so as to “unlock” the paperboard box  100  before the paperboard tray  115  can be pulled from the paperboard over-sleeve  110 . 
     Thus, in accordance with the disclosed embodiments of the invention, in order to open the paperboard box  100 , the paperboard box  100  is held in both hands with the top of the box facing up and a first side facing proximately, i.e., toward the body of the person seeking to open the paperboard box. While applying equal pressure to all tabs, they are push down and the paperboard tray  115  is pulled/slid toward the body of the person seeking to open the paperboard box  100 . 
     Once the paperboard tray  115  is completely pulled and touches the wall of the paperboard over-sleeve, fingers are placed on opposite sides of the end of the tray-(one on each side) to pull/slide the paperboard tray  115  from out the paperboard over-sleeve until it catches, i.e., the tabs engage. The box is now open. 
     In order to close the inventive paperboard box  100 , with the paperboard tray  115  fully extended from the paperboard over-sleeve  110 , fingers are placed at opposite sides of the ends the paperboard tray  115 . The paperboard tray  115  is now slid/pushed distally, i.e., away from the body of the person seeking to close the paperboard box  100  toward the opposite side of the paperboard over-sleeve  110 . 
     Once the paperboard tray  115  is completely pushed to the opposite wall of the paperboard over-sleeve  110 , the paperboard tray  115  can now be slid/pushed back into the sleeve until it “clicks” in place to thereby lock the paperboard box  110 . 
     Thus, while there have been shown, described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the methods described and the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements or structure shown which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that elements or structure shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.