Patent Abstract:
A child resistant, senior friendly packaging system is designed to securely hold multiple unit dose products and formed out of natural fiber or synthetic materials, or any combination thereof. The packaging system comprises a movable insert that can locked in an inaccessible position and comprises a physically detachable unlocking mechanism that can engage the locking mechanism of the movable insert in order to unlock the movable insert permitting movement into an accessible position. The unlocking mechanism can be in the form of an access card that is a part of the system or is user supplied.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     The present application claims the benefit of U.S. Provisional Application No. 60/736,732, filed Nov. 15, 2005, herein incorporated by reference. 
     
    
     BACKGROUND  
       [0002]     The invention is directed to child resistant, senior friendly packaging designed to securely hold multiple unit dose products and formed out of natural fiber or synthetic materials, or any combination thereof.  
         [0003]     The field of packaging is challenged to provide the end user with packaging designed, or constructed, to hold multiple unit doses in a package that is child resistant and yet senior friendly. The criteria of child resistance requires a package be designed in a manner so that it is extremely difficult for a child (under the age of five) to gain access to any of the unit doses. The criteria of senior friendliness requires a package that is designed to have the unit doses easily accessed by a mature adult who may be arthritic or weak. Clearly, these two criteria are difficult to balance, i.e., making a package difficult for a child to open, but easy for a senior to open.  
         [0004]     Known packages, in their most basic form, may simply rely on features such as pull tabs to cover the cell cavities holding the unit dose product. tabs to cover the cell cavities holding the unit dose product. Examples of such packages are disclosed in U.S. Pat. Nos. 3,129,817; 3,610,410; 3,809,220; 3,809,221; 3,811,564; 3,835,995; 3,872,970; 3,899,080; 3,905,479; 3,912,081; 3,912,082; 3,921,805; 3,924,746; 3,924,747; 3,941,248; 4,011,949; 4,120,400; 4,125,190; 4,192,422; 4,231,477; 4,485,915; 4,506,789; 5,046,618; 5,172,812; 5,310,060; 5,529,188; 6,047,829; 6,375,956; and 6,523,691 as well as U.S. patent publication nos. 2001/0017273; 2002/0185404; and 2003/0064381.  
         [0005]     These references and any other reference cited herein are incorporated by reference.  
         [0006]     Tabs designed in such a manner, which are difficult for children to remove, are normally not senior friendly; conversely, tabs that can be easily removed by mature adults are normally not child resistant. Integrated tabs of this type can be defined as “first level” resistance in paperboard packaging.  
         [0007]     In certain instances, it maybe desirable if the package requires the individual to perform a sequence of steps, perhaps simultaneously. An illustration of this is for an individual to first read a set of specific instructions and then perform a sequence of steps simultaneously. For example, the product can be opened by holding package in the left hand, while pressing down on a lock release, and pulling out a slide card with the right hand. Typically, children under the age of five have great difficulty reading and comprehending instructions, while simultaneously attempting to perform a series of sequential steps, thereby rendering the package child resistant. Examples of this are disclosed in U.S. patent publication nos. 2004/0099565 and 2004/0045858, as well as U.S. Pat. No. 6,752,272.  
         [0008]     However, a complete packaging system designed with the aforementioned features can be further defined as both child resistant and senior friendly. For example, Mature adults are able to read and comprehend instructions and can perform a series of sequential steps simultaneously.  
         [0009]     Such a multi step packaging system is advantageous in that it prevents young children from accessing unit dose products, while allowing mature adults access to the individual unit doses contained therein. Additionally, this type of package can be opened and closed repeatedly, which is particularly advantageous when there are unused unit doses remaining inside the package. A package, as described, can continue to provide reassurance that the complete package maintains its child resistant and senior friendly characteristics throughout the dispensing life of the package.  
         [0010]     Known packaging systems containing both child resistant and senior friendly features are disadvantageous, in that certain mature adults may find it difficult to gain access to the unit dose product. For example, an adult with arthritis in the joints of the hands may have difficulty in performing a series of sequential steps, such as grasping and holding the package, pressing down on a lock release, and pulling out a slide card containing unit dose product. Such packaging systems, which encumber access to the unit dose product by a mature adult, may have the very features, which are child resistant, circumvented in such a manner that the complete package no longer provides child resistance.  
         [0011]     Therefore, it is preferable to provide an option whereby the child resistant features can be disengaged, long term. For example, some styles of child resistant bottle caps are manufactured with one end containing internal screw threads and a locking mechanism, while the opposite end contains external screw threads only. Such a system is disclosed by U.S. Pat. No. 6,926,161.  
       SUMMARY  
       [0012]     It is the object of the invention to provide a complete packaging system containing multi step child resistance and senior friendly features. In addition, this packaging system may be configured to allow for long term disabling of the child resistant features.. Within the scope of this new invention is a multiple lock system, a detachable and reusable access card and card slot.  
         [0013]     This object is solved according to an embodiment of the invention by providing a lock system, designed into a single integrated or unibody package, which is released through the use of a detachable and reusable access card. The invention is to be broadly construed as any single integrated or unibody package with a lock system released by any type of reusable card. For example, a credit card, picture ID card, or drivers license. However, the preferred embodiments described below utilize a packaging system formed out of paperboard, natural fiber or synthetic materials or any combination thereof and designed to securely hold multiple unit dose products.  
         [0014]     According to preferred embodiments of the invention, an outer folding carton, containing a detachable and reusable access card, and an internal slide tray are formed out of paperboard or synthetic paperboard material, or any combination thereof.  
         [0015]     The access card is detached from one of a plurality of side panels and inserted into a card slot in one of a plurality of end panels.  
         [0016]     Should the access card remain in the card slot, the multiple lock system is temporarily disabled and the package is placed into a non-child resistant, or open state. Removing the access card reactivates the multiple lock system and returns the package to the previously child resistant condition. 
     
    
     DESCRIPTION OF THE DRAWINGS  
       [0017]     The invention is explained below based on drawings showing the various embodiments of the invention.  
         [0018]      FIG. 1  is a pictorial diagram of an unassembled outer folding carton having five panels;  
         [0019]      FIG. 1A  is a pictorial diagram of an alternate embodiment of the unassembled outer folding carton having three panels, and with offset locking holes;  
         [0020]      FIG. 2  is a pictorial diagram of a completely assembled internal slide tray;  
         [0021]      FIG. 3A  is an image of an assembled outer folding carton and internal slide tray in a basically closed configuration;  
         [0022]      FIG. 3B  is an image of an assembled outer folding carton and internal slide tray in an open and pre-use configuration;  
         [0023]      FIG. 4  is an image of the assembly in an open and ready-for-use but locked configuration  
         [0024]      FIG. 5  is an image of the assembly showing the insertion of the access card;  
         [0025]      FIG. 6  is an image of the assembly showing the unlocked configuration and the internal slide tray partially extended;  
         [0026]      FIG. 7  is an image similar to that of  FIG. 6 , with the internal slide tray fully extended and opened;  
         [0027]      FIG. 8  is a cut-away image (not seen in normal use) showing the access card and internal slide tray extended;  
         [0028]      FIG. 9  is a cut-away image showing the access card partially removed to reveal the catch-holes;  
         [0029]      FIG. 10  is a cut-away image showing the back side of the internal slide tray;  
         [0030]      FIG. 11  is an image of a 2-card variation for the internal slide tray; and  
         [0031]      FIG. 12  is an image showing a storage area for holding leaflets, enclosures, customer instructions, regulatory information, sales or marketing information, or product literature. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0032]     An embodiment of the invention comprises an outer folding carton containing a detachable and reusable access card, and an internal slide tray.  
         [0033]      FIG. 1  illustrates an exemplary outer folding carton  10 , comprising a plurality of panels  12 ,  16 ,  20 ,  24 ,  28  that are designed to be folded along fold portions  14 ,  18 ,  22 ,  26  with selected panels glued together. A first panel  12  is folded along a first fold portion  14 , and then the first panel  12  along with a second panel  16  are folded along a second fold portion  18  and the first panel  12  is glued to a third panel  20  such that a gap approximately the width of the first  14  and second  18  fold portion is formed between a) the glued first  12  and third  20  panels, and b) the second panel  16 . The first three panels  12 ,  16 ,  20 , when assembled, comprise a first primary section  100  that will hold the internal slide tray  50 .  
         [0034]     The first panel  12  has a tab  44  that is used as a protruding guide for the access card  34  card when the carton is assembled. The lower pane extension  40  of the second panel  16  and the lower panel extension with slot  38  of the third panel  20 , when assembled, extend in a direction perpendicular to the plane of the drawing page, creating depth or thickness to the carton and thereby forming a corner at which the access card slot  42  is present.  
         [0035]     It should be noted that the description below refers to the slide tray  50  in an embodiment of the invention. However, the invention contemplates any slidable element, such as a movable tray, slide card or package.  
         [0036]     The fourth panel  24  and the fifth panel  28  are glued together at selected portions along fold line  26  and form a second primary section  110 . Thus, in its assembled condition, the outer folding carton appears as two primary sections  100 ,  110 , each having panels glued together. The first primary section  100  comprises the first through third panels  12 ,  16 ,  20 , and the second primary section  110  comprises the fourth and fifth panels  24 ,  28 . The first three fold sections  14 ,  18 ,  22  have two fold lines so that the panels are separated from one another with a distance sufficient to accommodate the thickness of the internal slide tray  50 . During manufacturing the first panel to be folded and glued will be panel  28 , followed by panel extensions  48 , then panels  12  and  16 .  
         [0037]     The internal slide tray  50 , as illustrated in  FIG. 2 , comprises a first panel  54  and a second panel  56  that are folded together along a fold portion  52 . These panels are configured to hold, e.g., single dose units, such as a bubble pack  60 ′, although obviously any mechanism for holding the product can be utilized. The fold portion  52  comprises two fold lines so that the panels  54 ,  56 , when folded together, have a gap between them large enough to accommodate the product.  
         [0038]     The internal slide tray  50  further comprises an end tab  58  that may further comprise two sub-tabs  59 . This tab  58  and sub-tabs  59  are configured to interact with the outer folding carton  10  in a manner that will be explained below.  
         [0039]     It should be noted that the internal slide tray  50  is formed from two separate cardboard layers. The internal slide tray  50  may be constructed either as a single piece unit (the top and bottom layers simply folded over) or as a two-piece unit, as illustrated in  FIG. 11 , where the two pieces are affixed one on top of the other. Accordingly, it can be seen that a perforated bottom portion of the single dose unit bubble pack  60 ′ would be matched with a top portion which is a hole having the general shape of the dose unit. A plastic portion of the bubble pack  60 ′ would then protrude through this top portion hole.  FIG. 11  illustrates the bottom layer  54  and top layer  54 ′ of the first panel of the internal slide tray, the bottom layer  52  and top layer  52 ′ of the fold portion of the internal slide tray, and the bottom layer  56  and top layer  56 ′ of the second panel of the internal slide tray. The end-tab  58  and sub-tab  59 , discussed in more detail below, need only be present on one of the layers. An additional end tab  58 ′ may be provided for support.  
         [0040]     In its assembled state, as illustrated by  FIG. 3A , the outer folding carton  10  comprises the second primary section  110  on top. The fourth panel  24  and fifth panel  28  are glued together in portions. The fourth panel comprises a cover tab  30  that inserts into a cover tab slot  32  in its closed position.  
         [0041]      FIG. 3B  illustrates the outer folding carton  10  in an initially opened pre-use state. The cover tab  30  has not been separated from the fifth panel  28  and is still attached by a perforation. Similarly, an access card  34  remains attached to the fifth panel  28  before it has been separated and inserted into the access card storage slot  36 . The user would partially separate the cover tab  30  from its perforations so that the tab  30  is hinged to the fifth panel  28  upon first use. Similarly, the user would completely separate the access card  34  and insert it into the access card storage slot  36 .  
         [0042]      FIG. 4  illustrates the outer folding carton  10  in its initially opened, but locked, configuration after the tab  30  and access card  34  have been separated. The access card  34  is removed from its position on the fifth panel  28  (which may be originally perforated to permit its easy separation from the fifth panel  28 ) and inserted into a card storage slot  36  where it can be kept when the assembly is not in use. The second primary section  110  is attached to the first primary section  100  via the third fold portion  22 . In this open configuration, the second panel  16  is visible on the right-hand side. It should be noted that the image  FIGS. 3-10  reflect a carton that has been cut to reveal detail. The split-open portions of the first primary section  100  at the bottom and right-hand side would ordinarily be joined to the first primary section  100  in normal use. In the configuration shown in  FIG. 4  (the locked configuration), the internal slide tray cannot be removed for reasons that are explained in more detail below.  
         [0043]     It should be noted that in one embodiment, the access card  34  is the same width as a standard credit card or driver&#39;s license, so that in the event the access card  34  is lost or damaged, the user can still make use of the package using the standard credit card or drivers license. Furthermore, it is also possible that a holding mechanism may be provided so that the access card can be permanently installed to allow access for situations where, e.g., there are no children present or when the convenience of a non-child resistant design is desired. The holding mechanism can comprise glue, adhesive, cohesion, or physical elements, such as some form of interference, frictional, magnetic or other known holding mechanisms.  
         [0044]      FIG. 5  illustrates the insertion of the access card  34  into a card slot  42  on the third panel  42 . When the access card  34  is fully inserted, the internal slide tray  50  can be extended permitting access to its contents.  
         [0045]      FIG. 6  illustrates the unlocked configuration of the assembly. The access card  34  is fully inserted into the slot  42 , and the internal slide tray  50  is partially extended. In  FIG. 6 , the first panel of the internal slide tray  54  is visible, as are the perforated tabs  60  on the backside of the single dose unit bubble packs  60 ′.  
         [0046]     As can be seen in  FIG. 7 , when the internal slide tray  50  is extended, it can be unfolded along fold portion  52 ′ and the full contents on both the first  54 ′ and second panels  56 ′ are visible and accessible.  
         [0047]      FIG. 8  illustrates a cut-away view of the outer folding carton  10  that would normally not be visible during normal use, since the first panel  12  is glued to the third panel  20 . To create the cut-away view, a slice has been made along the second fold portion  18  that normally connects the second panel  16  and the third panel  20 . This view reveals the first fold portion  14  that connects the first panel  12  and the second panel  16 . The second panel  16  comprises a flap  48  that is glued to the second panel  16  for strength and stability. In this view, the access card  34  can be seen in its inserted position.  
         [0048]      FIG. 9  is similar to  FIG. 8 , except that the access card  34  has been withdrawn to reveal the presence of locking holes  46  present in the first panel  12 . A card stop  34 ′ can also be seen. The card stop  34 ′ being wider than the slot  42  prevents the access card  34  from being inserted so far so that it cannot be retrieved after use.  
         [0049]      FIG. 10  is similar to  FIG. 9 , except that the internal slide tray  50  has been flipped over to reveal the locking mechanism. Accordingly, without the access card  34  being inserted, the sub-tabs  59  engage the locking holes  46  due to a slight bias of the sub-tabs  59  against the surface of the first panel  12  created by the fold connecting the end tab  58  to the second panel  56  of the internal slide tray  50 . Since this second panel  56  of the internal slide tray is normally pressed against the surface of the first panel  12 , the sub-tabs  59  get caught in the locking holes  46  and prevent the internal slide tray  50  from being extended.  
         [0050]     However, once the access card  34  has been inserted, it covers the locking holes  46  and prevents the sub-tabs  59  from engaging these holes. The internal slide tray  50  can then be extended until its end tab  58  engages the non-glued flap  48 ′ of the first panel  12  and prevents removal of the internal slide tray  50 . The internal slide tray  50  can then easily be re-inserted, and the card  34  removed and placed back in the card storage slot  36  for safe keeping.  
         [0051]      FIG. 12  illustrates an embodiment utilizing a storage area  36 ′ for holding leaflets, enclosures, customer instructions, regulatory information, sales or marketing information, or product literature.  
         [0052]      FIG. 1A  illustrates an alternate simplified three-panel embodiment of the invention. The primary difference is that the access card  34  has an access card tab  34 ″ that is initially affixed to the first panel  12  at an upper notch portion  13  of first panel  12  via perforations or other know affixing mechanism. A user access portion  13 ′ is provided within the upper notch portion that is not filled with the tab  34 ″ initially, which permits the user to separate the access card  34  from the first panel  12  upon first use.  FIG. 1A  also illustrates a pattern of four locking holes  46  in the third panel that provides an enhanced locking function. These offset holes are designed to interface with the subtabs  59  of the internal slide tray  50 .  
         [0053]     For the purposes of promoting an understanding of the principles of the invention, reference has been made to the preferred embodiments illustrated in the drawings, and specific language has been used to describe these embodiments. However, no limitation of the scope of the invention is intended by this specific language, and the invention should be construed to encompass all embodiments that would normally occur to one of ordinary skill in the art.  
         [0054]     The particular implementations shown and described herein are illustrative examples of the invention and are not intended to otherwise limit the scope of the invention in any way. For the sake of brevity, conventional aspects may not be described in detail. Furthermore, the connecting lines, or connectors shown in the various figures presented are intended to represent exemplary functional relationships and/or physical or logical couplings between the various elements. It should be noted that many alternative or additional functional relationships, physical connections or logical connections may be present in a practical device. Moreover, no item or component is essential to the practice of the invention unless the element is specifically described as “essential” or “critical”. Numerous modifications and adaptations will be readily apparent to those skilled in this art without departing from the spirit and scope of the present invention.  
       TABLE OF REFERENCE CHARACTERS  
       [0000]    
       
           10  outer folding carton  
           12  first panel of outer folding carton  
           13  upper notch portion  
           13 ′ user access portion of the upper notch portion  
           14  first fold portion of outer folding carton  
           16  second panel of outer folding carton  
           18  second fold portion of outer folding carton  
           20  third panel of outer folding carton  
           22  third fold portion of outer folding carton  
           24  fourth panel of outer folding carton  
           26  fourth fold portion of outer folding carton  
           28  fifth panel of outer folding carton  
           30  covertab  
           32  cover tab slot  
           34  access card  
           34 ′ access card stop  
           34 ″ access card tab  
           36  access card storage slot  
           36 ′ storage area  
           38  lower panel extension with slot  
           40  lower panel extension  
           42  access card slot  
           44  panel tab  
           46  locking holes  
           48  glued flap  
           48 ′ non-glued flap  
           50  internal slide tray  
           52 ,  52 ′ bottom and top layers of the fold portion of internal slide tray  
           54 ,  54 ′ bottom and top layers of the first panel of internal slide tray  
           56 ,  56 ′ bottom and top layers of the second panel of internal slide tray  
           58  end tab  
           58 ′ additional end tab  
           59  sub-tab  
           60  perforated tabs  
           60 ′ single dose unit bubble pack  
           100  first primary section of outer folding carton  
           110  second primary section of outer folding carton

Technology Classification (CPC): 1