Patent Publication Number: US-2022219870-A1

Title: Child-resistant packaging for regulated products

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application No. 63/137,590, filed Jan. 14, 2021, which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure generally relates to product packaging. More specifically, the present disclosure relates to child-resistant packaging for storing regulated products therein. 
     BACKGROUND 
     Regulated products are generally required to be sold and stored in child-resistant packaging so that children cannot access the contents therein. 
     For example,  cannabis  is becoming legal for recreational and medicinal use in an increasing number of countries around the world. In these countries,  cannabis  is commonly commercially available in the form of pre-rolled joints (or “pre-rolls”), similar in form to cigarettes. Pre-rolls are convenient in that a user does not need to roll their own joint in order to smoke  cannabis.    
     Pre-rolls are generally sold individually or in groups of two to ten. Individually sold pre-rolls are typically packaged in plastic tubes having a child-resistant lid, similar to those used for prescription pill bottles. Groups of pre-rolls, however, are typically sold in packaging similar to that used for cigarettes—i.e. a pack in which a plurality of pre-rolls may be stored. 
     As a result, the child-resistant features used for the pre-roll packages are considerably different from those used for the individually sold pre-rolls. For example, the pre-roll packages may be outfitted with child-resistant features that are single-use in that, once the packaging is opened, the child-resistant feature will no longer function (e.g. the package may be perforated such that the top may be torn off). Alternatively, some pre-roll packages include a plastic insert having tabs that extend out of apertures formed in the package that may be depressed in order to allow the plastic insert to be removed. However, such configurations complicate manufacturing, as multiple types of materials are required to produce a single package. Further, after multiple uses, the plastic insert may become permanently deformed, making it difficult even for adults to remove the insert from the package. 
     Thus, there exists a need for child-resistant packaging for regulated products that is easy to manufacture and capable of being opened multiple times without affecting the usability thereof. 
     SUMMARY 
     The present disclosure recognizes that there are problems with existing child-resistant packaging for regulated products, including those for containing  cannabis  products. 
     In one aspect, the present disclosure relates to a child-resistant package for a regulated product, the package comprising: a housing having an open end, a plurality of release tabs formed in a wall thereof, and a locking edge defined on an inside surface thereof; and an insert for containing the regulated product slidably received through the open end of the housing, the insert having: an openable end for accessing the regulated product, the openable end openable when the insert is at least partially removed from the housing; and a locking tab positioned on an outside surface of the insert having a plurality of ends that are each aligned with one of the plurality of release tabs, the locking tab biased such that each of the plurality of ends contact the locking edge when sliding the insert out of the housing without depressing the plurality of release tabs. 
     In another aspect, the present disclosure relates to use of the child-resistant package described herein for storing a regulated product. The regulated product may comprise one or more  cannabis  products. 
     Other aspects and features of the methods of the present disclosure will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features of the present disclosure will become more apparent in the following detailed description in which reference is made to the appended drawings. The appended drawings illustrate one or more embodiments of the present disclosure by way of example only and are not to be construed as limiting the scope of the present disclosure. 
         FIG. 1  shows a front perspective view of a closed child-resistant package according to an embodiment of the present disclosure. 
         FIG. 2  shows a back perspective view of the child-resistant package shown in  FIG. 1 . 
         FIG. 3  shows a plan view of an inside of a housing of a child-resistant package according to an embodiment of the present disclosure. 
         FIG. 4  shows a back perspective view of an insert of a child-resistant package according to an embodiment of the present disclosure. 
         FIG. 5  shows a front perspective view of an open child-resistant package according to an embodiment of the present disclosure. 
         FIG. 6  shows a plan view of a housing blank for a child-resistant package according to an embodiment of the present disclosure. 
         FIG. 7  shows a plan view of an insert blank for a child-resistant package according to an embodiment of the present disclosure. 
         FIG. 8  shows a plan view of an insert blank for a child-resistant package according to an embodiment of the present disclosure. 
         FIG. 9  shows a plan view of a housing blank for a child-resistant package according to an embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure generally relates to child-resistant packaging and, in particular, to child-resistant packaging for a regulated product. The child-resistant packages of the present disclosure afford a number of advantages over conventional packages. For example, the child-resistant packages may be used multiple times without affecting their usability. As described above, some conventional child-resistant packages, such as those having a plastic insert defining deformable tabs, may become permanently deformed after multiple uses, which may make it more difficult to access the regulated product contained therein or, in some cases, may make it so that a child can easily slide the insert out of the package. 
     Another advantage of the child-resistant packages of the present disclosure is that they may be manufactured with relative ease. In more detail, the child-resistant packages may be formed of a simple two-piece construction. As well, each piece of the two-piece construction may advantageously be formed of the same material. Such configurations significantly simplify the manufacturing process, which may greatly reduce the costs associated with the production of the child-resistant packages. As well, due to the simplicity of production, the manufacturing processes may be readily upscaled to industrially relevant levels, meaning that the child-resistant packages of the present disclosure are not limited to smaller-scale applications (e.g. craft  cannabis  products). In contrast, as described above, conventional child-resistant packaging for regulated products may comprise multiple pieces that are each formed of a different material, which complicates the manufacturing process significantly. 
     Yet another advantage of child-resistant packages of the present disclosure is that they may be biodegradable. As discussed above, conventional child-resistant packaging may include one or more plastic components. Unfortunately, in the same manner as cigarette packs, product packaging for regulated products such as  cannabis  products is often not disposed of properly. Thus, a package that is biodegradable may be particularly advantageous, as, in the event that it is not properly disposed of, it will at least degrade over time without having any potentially environmentally harmful components such as plastics, metals, and the like remain. 
     Reference will now be made in detail to exemplary embodiments of the disclosure, wherein numerals refer to like components, examples of which are illustrated in the accompanying drawings that further show exemplary embodiments, without limitation. 
     In some embodiments, the present disclosure relates to a child-resistant package for a regulated product, the package comprising: a housing having an open end, a plurality of release tabs formed in a wall thereof, and a locking edge defined on an inside surface thereof; and an insert for containing the regulated product slidably received through the open end of the housing, the insert having: an openable end for accessing the regulated product, the openable end openable when the insert is at least partially removed from the housing; and a locking tab positioned on an outside surface of the insert having a plurality of ends that are each aligned with one of the plurality of release tabs, the locking tab biased such that each of the plurality of ends contact the locking edge when sliding the insert out of the housing without depressing the plurality of release tabs. 
     As used herein, “regulated product” refers to a consumer product that is regulated in some capacity by a government agency. Examples of regulated products include tobacco products,  cannabis  products, pharmaceuticals, and the like. 
     As used herein, “child-resistant package” or “child-resistant packaging” means a packaging product that is configured to be difficult for children to open but readily openable by adults to reduce the likelihood that children may access the contents contained therein. 
     As used herein, “housing” refers to a component of the child-resistant package that slidably receives the insert therein. The housing has a body with at least one open end, through which the insert is slidably received. The body of the housing may be any suitable shape such as, for example, a rectangular prism. In such configurations, the body may have a front wall and a back wall that are larger than the sidewalls thereof. 
     The housing also has a locking edge defined on an inside surface of its body. As used herein, “locking edge” refers to a feature of the housing used to prevent the insert from being removed once received therein. The locking edge extends from the inside surface of the housing such that the locking tab of the insert can contact it when a user attempts to remove the insert from the housing, thereby stopping the insert from moving any further. As will be discussed below, the locking edge may be formed using a number of configurations. 
     The housing also has a plurality of release tabs formed in a wall thereof. As used herein, “release tabs” refer to portions of the body of the housing that may be depressed to, in turn, depress the ends of a locking tab of the insert to thereby allow the insert to be removed from the housing (e.g. by pulling the insert out of the housing). The release tabs may be formed by cutting the tabs into the body of the housing, for example. Alternatively, the release tabs may be formed in the wall of the housing by marking them thereon. The release tabs are aligned with the ends of the locking tab of the insert such that depressing the release tabs depresses the ends of the locking tab, as will be described below. The release tabs are also positioned close enough to the locking edge that the locking tab cannot return to its initial position before passing the locking edge when a user attempts to remove the insert from the housing while depressing the release tabs. 
     As used herein, “insert” refers to a component of the child-resistant package that is configured to contain therein the regulated product and to be slidably received within the housing. The insert has a body with an openable end for accessing the regulated product contained therein when the insert is at least partially removed from the housing. That is, the openable end is not openable when it is positioned within the housing. The body of the insert is generally the same shape as the housing so that it may be readily received therein and so that the locking tab of the insert may be easily aligned with the release tabs of the housing. 
     In some embodiments, the insert also has a locking tab positioned on an outside surface thereof. As described above, the locking tab has a plurality of ends and is biased such that its ends will abut the locking edge when attempting to pull the insert out of the housing without depressing the release tabs, thus preventing the insert from being removed. The ends of the locking tab are aligned with the release tabs of the housing such that depressing the release tabs also depresses the ends of the locking tab. Because of the bias, after the locking tab has been moved away from the release tabs (e.g. while removing the insert from the housing) or after the release tabs are no longer depressed, it will return to its initial position. Further, as will be discussed below, the locking tab is generally arranged such that is does not prevent the insert from being slid into the housing. 
     Thus, in operation, depressing the release tabs of the housing depresses the ends of the locking tab such that they do not contact the locking edge when pulling the insert out of the housing, thereby allowing the insert to be removed. The insert may then be slid back into the housing, at which point the locking tab will return to its initial position to render the package child-resistant. 
     Referring now to  FIG. 1 , there is shown an example of a child-resistant package  10  for a regulated product according to an embodiment of the present disclosure. The child-resistant package  10  comprises a housing  20  and an insert  30  slidably received within the housing  20 . 
     The housing  20  has an open end though which the insert  30  is slidably received. The open end of the housing  20  may have cut-outs  29  formed therein to facilitate the removal of the insert  30  from the housing  20  by exposing a portion of the insert  30  for a user to grip while pulling the insert  30  out of the housing  20 . The cut-outs  29  may be formed in the sidewalls of the housing  20 , as shown in  FIG. 1 . In another embodiment, the cut-outs  29  may be formed in the front and back walls of the housing  20 . In some embodiments, the cut-outs  29  may be formed in a combination of front, back, or sidewalls of the housing  20 . Further, in the illustrated embodiment, the cut-outs  29  are curvilinear, but other shapes are possible and are contemplated. For example, in some embodiments, the cut-outs  29  may be generally square-shaped. 
     As shown in  FIG. 2 , the housing  20  also has a plurality of release tabs  22  formed in a wall thereof. In the illustrated embodiment, the plurality of release tabs  22  comprises two tabs; however, other numbers of release tabs  22  may be used if so desired. For example, in some embodiments, the housing  20  may comprise one or more additional release tabs (not shown) in another side thereof, such as a sidewall. As described above, the plurality of release tabs  22  may be formed by cutting them into the housing  20 , as shown in  FIG. 2 . In such embodiments, the cut portion of the housing  20  that defines the release tabs  22  is depressible into the housing  20 , while the uncut portions provide a slight bias away from the insert  30  so that the release tabs do not remain depressed after use. Alternatively, as described above, the release tabs  22  may otherwise be marked on the housing  20  but not cut into the housing  20 . The marked release tabs  22  indicate the portions of the housing  20  for a user to depress. 
     The release tabs  22  may be shaped in order to facilitate their pressing by the fingers of a user. That is, the release tabs  22  may be dimensioned large enough so that they are easy to depress by adult fingers. For example, in some embodiments, the release tabs  22  may have a width of about 7.5 mm to about 15 mm. In some embodiments, the release tabs  22  have a length of about 5.0 mm to about 10 mm. Further, it is noted that, while the release tabs  22  are a generally rounded shape in the illustrated embodiment, other shapes are possible and are contemplated. In some embodiments, the release tabs  22  may be generally squared. 
     Further, in the embodiment illustrated in  FIG. 2 , the release tabs  22  are generally horizontally aligned. However, other arrangements are possible and are contemplated. For example, in some embodiments, the release tabs  22  may be aligned generally vertically, diagonally, etc. 
     The housing  20  also comprises a locking edge  24 , as shown in  FIG. 3 . As described above, the locking edge  24  provides a surface for a locking tab  32  of the insert  30  (see  FIG. 4 ) to abut in order to prevent the insert  30  from being removed from the housing  20 . In some embodiments, the locking edge  24  may be a piece of material adhered to the inside surface of the housing  20 . In another embodiment, the locking edge  24  may be formed by cutting a section of housing  20  and bending the section downwardly into the housing  20  such that it may abut the locking tab  32  of the insert  30  when attempting to slide the insert out of the housing  20 . In the illustrated embodiment, the locking edge  24  is defined by an inner panel  26 . In some embodiments, the inner panel  26  is a separate piece of material adhered to the housing  20 . In a particular embodiment, the inner panel  26  is a portion of the housing  20  folded and adhered to an inside surface thereof. 
     In some embodiments, the inner panel  26  has a recess  28  formed therein that defines an additional locking edge  24   a . The additional locking edge  24   a  may prevent the insert  30  from being completely removable from the housing  20 . In more detail, in operation, when the insert  30  is being slid out of the housing  20 , the locking tab  32  will return to its initial position as it moves away from the depressed release tabs  22 , at which point the locking tab  32  is capable of contacting the additional locking edge  24   a . As shown in  FIG. 3 , the locking edge  24   a  is positioned above the locking edge  24 . Thus, after the locking tab  32  returns to its initial position, the locking tab  32  will then abut the additional locking edge  24   a , thereby preventing the insert  30  from being further removed from the housing  20 . As will be discussed below, due to the arrangement of the locking tab  32 , it may be slid back out of the recess  28  without abutting another edge thereof, thereby allowing the insert  30  to be easily pushed back into the housing  20 . Such embodiments may be beneficial, as a user is prevented from completely removing and subsequently losing the insert  30 , which may affect the child-resistance of the package  10 . 
     It is noted that, while in the illustrated embodiment the recess  28  has a generally rectangular shape, any shape is possible so long as the recess  28  still defines the additional locking edge  24   a.    
     In general, the locking edge  24  and, if present, the locking edge  24   a  have a height that allows the locking tab  32  to contact them when not depressed by the release tabs  22 . In some embodiments, the locking edges  24 ,  24   a  may have about a height of about 0.1 mm to about 1 mm. As well, it is noted that, while the illustrated embodiment shows the locking edges  24 ,  24   a  extending across a majority of width of the housing  20 , such a configuration is not required. Rather, the locking edges  24 ,  24   a  may be functional as long as they extend along enough of the width of the housing  20  that they are contactable by each end of the locking tab  32 . 
     Further, as discussed above, in some embodiments, the locking edge  24  is positioned close enough to the release tabs  22  that the locking tab  32  cannot return to its initial position before passing thereover when a user attempts to remove the insert  30  while depressing the release tabs  22 . In some embodiments, the locking edge  24  is positioned about 0.1 mm to about 3 mm away from the release tabs  22 . 
     Referring now to  FIG. 4 , there is shown a perspective back view of the insert  30  completely removed from the housing  20  according to an embodiment of the present disclosure. The insert  30  has an openable end  36  for accessing the regulated product contained therein. As discussed above, the openable end  36  is only openable when the insert  30  is at least partially removed from the housing  20 , as shown in  FIG. 5 . The openable end  36  may be hingedly openable, as in the illustrated embodiment, in which the openable end  36  hinges away from the body of the insert  30  to allow access to the contents thereof. In such embodiments, if the insert  30  is not at least partially removed from the housing  20 , the openable end  36  cannot open, as a portion of the openable end  36  abuts an inside surface of the housing  20 , thereby preventing it from hinging open. 
     As discussed above, the insert  30  also has the locking tab  32  positioned on an outside surface thereof. The locking tab  32 , if not depressed via the release tabs  22 , prevents the insert  30  from being slidably removed from the housing  20 . In more detail, the locking tab  32  comprises a plurality of ends  34  and is biased such that, when not depressed by the release tabs  22 , the plurality of ends  34  will contact the locking edge  24  when attempting to slide the insert  30  out of the housing  20 , thereby preventing the insert  30  from being removed from the housing  20 . As shown in  FIG. 4 , the biasing of the locking tab  32  may result in the locking tab  32  being angled towards the top of the insert  30  such that it forms an acute angle with the wall of the insert  30 . Such configurations may be beneficial, as the insert  30  may be easily slid back into the housing  20  without the locking tab  32  abutting features of the housing  20  such as the recess  28  to prevent the receiving of the insert  30 . 
     The number of ends  34  of the locking tab  32  may correspond to the number of release tabs  22 . In more detail, in some embodiments, in use, each release tab  22  depresses an end  34  so that the locking tab  32  may pass below the locking edge  24  when the insert is being slid out of the housing  20 . However, in other embodiments, one release tab  22  may be configured to depress more than one end  34  of the locking tab  32 . Thus, it follows that the locking tab  32  is positioned on the insert  30  such that each end  34  thereof is aligned with a release tab  22  so that they may be depressed thereby. 
     In some embodiments, the locking tab  32  is formed of a separate piece of material that is adhered to the insert  30 . In another embodiment, the locking tab  32  is formed from the same piece of material as the insert  30  (e.g. cut into the insert  30  in the same manner as the release tabs  22  and the housing  20  described above) and folded upwards towards the top of the insert  30  so that the locking tab  32  is biased to abut the locking edge  24  when the insert  30  is being removed from the housing  20 . Such a configuration is used in the embodiment illustrated in  FIG. 4  and beneficially allows the insert  30  to be formed of only a single piece of material. 
     Further, as shown in  FIG. 4 , the ends  34  of the locking tab  32  may be spaced away from each other. Such configurations may be beneficial, as depressing only one of the ends  34  will not result in the entire locking tab  32  being depressed, which may increase the child-resistance of the package  10 . Further, as shown in the embodiment illustrated in  FIG. 4 , the ends  34  of the locking tab  32  may be generally square with a curvilinear edge bridging the two ends  34 . However, the ends  34  may be any other suitable shape, so long as they have sufficient surface area to be depressed by the release tabs  22 . 
     In a further embodiment, the insert  30  may define two or more internal compartments  38  for containing multiple regulated products separately therein, as shown in  FIG. 5 . The compartments  38  may be defined by a separate piece of material positioned in the insert  30 . Alternatively, the compartments  38  may be defined by a portion of the insert  30  folded into itself. Such configurations may be beneficial, as the compartments  38  and insert  30  may be formed using only a single piece of material. Further, it is noted that, while the embodiment illustrated in  FIG. 4  has two internal compartments  38  defined within the insert  30 , there may be 3, 4, 5, 6, or more internal compartments  38  defined within the insert  30 , if so desired. 
     In some embodiments, each of the housing  20  and the insert  30  may each be independently formed of a paperboard material. In some embodiments, each of the housing  20  and the insert  30  may be coated with a cellophane. Thus, as previously described herein, the housing  20  and the insert  30 , and, as a result, the package  10 , may be biodegradable. 
     In another embodiment, the housing  20 , the insert  30 , or a combination thereof may be reinforced with a reinforcement material such as a foil, a plastic, or the like. In such embodiments, the reinforcement material may be a biodegradable plastic. Suitable biodegradable plastics include polylactic acids (PLAs), polyhydroxyalkanoates (PHAs), complexed starches, and the like. 
     Further, as previously described herein, the housing  20  and the insert  30  may be formed of a single piece of material such that the resulting package  10  has a simple two-piece construction. In some embodiments, each of the housing  20  and the insert  30  may be formed of a single piece of paperboard material that has been folded to form the components thereof.  FIG. 6  and  FIG. 7  show, respectively, examples of non-constructed paperboard blanks of the housing  20  and the insert  30 . As used herein, “blanks” refer to pieces of material that have been cut such that they can be subsequently folded into a selected component. The blanks may be cut into appropriate shapes using any suitable industrial equipment, such as a die. In  FIG. 6  and  FIG. 7 , the blanks may be folded along the dashed lines to form the housing  20  and the insert  30 . Folded portions may be adjoined using any suitable industrial adhesive such as a hot-melt glue or a cold glue. It is noted that features such as the release tabs  22  and the locking tab  32  that may be cut into the housing  20  or insert  30  may be marked on the blanks and cut into the respective components after folding or, alternatively, may be cut into the blanks prior to folding. 
       FIG. 7  also illustrates an optional inner frame  40 . The inner frame  40  may be a separate piece that is adherable into the insert  30  to provide additional structural support thereto. In some embodiments, the inner frame  40  may also define one or more of the internal compartments  38 . Further, the inner frame  40  may comprise one or more tabs  42  for maintaining the openable end  36  in a closed position after pulling the insert  30  out of the housing  20 . In more detail, the one or more tabs  42  may be formed in the inner frame  40  along portions that are to be folded to define the edges thereof, as shown in  FIG. 7 . After folding, the one or more tabs  42  will extend out beyond the now-defined edge such that they capable of contacting an inner portion of the openable end  36  when in a closed position to thereby maintain the openable end  36  in the closed position via a friction fit. 
     It is noted that while  FIG. 6  and  FIG. 7  each show only one example of blanks for forming the housing  20  and insert  30 , other configurations of blanks are possible and are contemplated. For example,  FIG. 8  shows another example of a blank for forming the insert  30  and  FIG. 9  shows another example of a blank for forming the housing  20 . As described above, the blanks may be folded along the dashed lines to form the housing  20  and the insert  30 . Folded portions may be then adjoined using any suitable industrial adhesive. Further, it is noted that, in the embodiment illustrated in  FIG. 8 , there is no separate inner frame  40 . Rather, the features of the inner frame  40  may be integrated into the blank, as evidenced by the one or more tabs  42 . 
     In the present disclosure, all terms referred to in singular form are meant to encompass plural forms of the same. Likewise, all terms referred to in plural form are meant to encompass singular forms of the same. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. 
     As used herein, the term “about” refers to an approximately +/−10% variation from a given value. It is to be understood that such a variation is always included in any given value provided herein, whether or not it is specifically referred to. 
     It should be understood that the compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of or “consist of the various components and steps. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. 
     For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited. 
     Therefore, the present disclosure is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, the disclosure covers all combinations of all those embodiments. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted. 
     Many obvious variations of the embodiments set out herein will suggest themselves to those skilled in the art in light of the present disclosure. Such obvious variations are within the full intended scope of the appended claims.