Child-resistant packaging container and blank and method for making the same

p-0002This application claims priority to U.S. provisional patent application Ser. No. 61/372,198, filed Aug. 10, 2010, the entirety of which is herein incorporated by reference.

FIELD OF THE INVENTION

p-0003This invention relates in general to packaging containers and, more particularly, to packaging containers that are child-resistant and senior friendly.

BACKGROUND OF THE INVENTION

p-0004The number of available consumer pharmaceuticals continues to grow for use in the diagnosis, cure, treatment and/or prevention of diseases or injuries. In fact, the use of pharmaceuticals is so prevalent that there are very few households where they are not present. Due to the chemical nature of many of these medicines, any unintended uses or overdoses may have very damaging or lethal consequences. This is especially true with children who do not understand or appreciate the dangers involved. Accordingly, there has been a need to make the packaging childproof. However, because many people who use pharmaceuticals are elderly and may have lost some of their physical strength and/or coordination, it is also important that any such packaging also be readily usable by senior citizens.

p-0005Therefore, there is a need to produce a packaging container that allows senior citizens and other intended users, but not children, to access the contents of the packaging.

SUMMARY OF THE INVENTION

p-0006The present invention is an improvement over the prior product packaging in the way that the packaging container secures the contents to prevent access from children, while still permitting a senior citizen to access the contents. In particular, the packaging container securely retains a slidable blister card or sheet within a housing that does not allow access to the contents until multiple steps are performed.

p-0007In one embodiment, the packaging container includes a bottom member and a top or cover that form a housing including a sleeve for receiving part of the blister card or sheet. The housing members may comprise a paper-based material, although it is appreciated that other materials may be used and not depart from the scope of the present invention.

p-0008The bottom member may be formed from a blank having a bottom panel, a sleeve bottom panel, a central panel, and a pair of wing members. In order to form the bottom member, the central panel is folded on top of the sleeve bottom panel so that a flap at the end of the central panel extends through a corresponding flap opening in the sleeve bottom panel. The central panel and sleeve bottom panel may then be folded over the bottom panel so that the flap extends upwardly, and slots on the bottom panel and sleeve bottom panel are aligned.

p-0009In order to construct the sleeve, sleeve side panels are folded upward until perpendicular with the sleeve bottom panel, wherein the wing members may be folded across and attached to one another. Once the bottom member is assembled, the cover, which may be a substantially seamless formed tray having an opening in one end, may be placed over and attached to the bottom member.

p-0010A blister sheet or card having one end folded down to form a flap having a pair of nodes extending outwardly therefrom may then be inserted with the flap side down into the opening of the housing until the nodes are biased into engagement with the slots on the sleeve bottom panel and bottom panel. In order to release the blister sheet, notches in the slots of the bottom panel may be pressed to bias the nodes out of engagement with the slots while the blister sheet is pulled axially out of the housing. The flap on the blister card will engage the flap extending into the interior of the housing to prevent the blister card from being completely withdrawn from the housing.

p-0011It is therefore an object of the present invention to provide a new packaging container that is child-resistant and senior-friendly.

p-0012Yet another object of the present invention is to provide a new packaging container that is better for the environment than conventional packaging containers.

p-0013Still another object of the present invention is to provide a new packaging container that is safer to open.

p-0014Yet another object of the present invention is to provide a packaging container that inhibits theft and the inadvertent opening of the packaging.

p-0015Other objects, features and advantages of the invention will be apparent from the following detailed disclosure, taken in conjunction with the accompanying sheets of drawings, wherein like reference numerals refer to like parts.

BRIEF DESCRIPTION OF THE DRAWINGS

p-0016<figref idrefs="DRAWINGS">FIG. 1</figref> is a top perspective view of one embodiment of the packaging container of the present invention.

p-0017<figref idrefs="DRAWINGS">FIG. 2</figref> is a bottom view of the packaging container shown in <figref idrefs="DRAWINGS">FIG. 1</figref>.

p-0018<figref idrefs="DRAWINGS">FIG. 3</figref> is a top prospective view of the packaging container of <figref idrefs="DRAWINGS">FIG. 1</figref> with a blister card extending outwardly therefrom.

p-0019<figref idrefs="DRAWINGS">FIG. 4</figref> is a bottom perspective view of another embodiment of the packaging container of the present invention.

p-0020<figref idrefs="DRAWINGS">FIG. 5</figref> is a top perspective view of a blank for the bottom member of the packaging container shown in <figref idrefs="DRAWINGS">FIG. 4</figref>.

p-0021<figref idrefs="DRAWINGS">FIG. 6</figref> is a bottom perspective view of a blank for the bottom member of the packaging container shown in <figref idrefs="DRAWINGS">FIG. 5</figref>.

p-0022<figref idrefs="DRAWINGS">FIG. 7</figref> is a top perspective view of the blank for the bottom member of the packaging container shown in <figref idrefs="DRAWINGS">FIG. 5</figref> with the central panel folded under the sleeve bottom panel.

p-0023<figref idrefs="DRAWINGS">FIG. 8</figref> is a top perspective view of the blank for the bottom member of the packaging container shown in <figref idrefs="DRAWINGS">FIG. 5</figref> with the sleeve bottom panel and central panel folded over the bottom panel.

p-0024<figref idrefs="DRAWINGS">FIG. 9</figref> is a top perspective view of the bottom member showing the wing members of the blank being folded over to form a sleeve.

p-0025<figref idrefs="DRAWINGS">FIG. 10</figref> is a side perspective view of the bottom member of the packaging container shown in <figref idrefs="DRAWINGS">FIG. 4</figref>.

p-0026<figref idrefs="DRAWINGS">FIG. 11</figref> is a top perspective view of a blister card for use with the second embodiment of the packaging container of the present invention.

p-0027<figref idrefs="DRAWINGS">FIG. 12</figref> is a bottom perspective view of the blister card shown in <figref idrefs="DRAWINGS">FIG. 11</figref> for use with the second embodiment of the packaging container of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

p-0028While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail several specific embodiments, with the understanding that the present disclosure is to be considered merely an exemplification of the principles of the invention and the application is limited only to the appended claims.

p-0029Referring now to the drawings, and particularly to <figref idrefs="DRAWINGS">FIGS. 1 through 3</figref>, one embodiment of the improved product packaging container of the present invention, generally designated by the numeral <b>100</b>, is shown having a housing <b>102</b> and a blister card or sheet <b>104</b> having a plurality of blisters or chambers <b>106</b> for storing the product <b>108</b> to be dispensed. In the embodiments shown and disclosed, the housing is made of a bottom member <b>110</b> and a cover or tray <b>112</b>. The bottom member <b>110</b> and tray <b>112</b> can be two separate pieces or can be attached along one or more edges and not depart from the scope of the present invention.

p-0030In order to prevent access to the pills or other products <b>108</b> to be dispensed when within the housing from children, the housing <b>102</b> is preferably made from a material that is tear-resistant. One example of a material that may be used is a SBS board coated with a laminated material having directional grains that, when criss-crossed, adds strength to the housing and protects against tearing or tampering in two directions. A suitable coating is manufactured under the trademark VALERON™ by Valeron Strength Films. While VALERON is made from a polyethylene material, other such coatings such as, but not limited to, polypropylene or polyester may be used. The material used also is preferably printable to allow for advertising, promotional or other information to be displayed on the housing. While a SBS board with a cross-laminated coating is preferred, it is appreciated that other tear-resistant materials including, but not limited to, cloth films, cloth and plastic films, heat sealable boards and other coatings, also may be used and not depart from the scope of the present invention. Examples of cloth films and cloth and plastic films include those films sold under the names SCRIM and CLAF. A corrugate stock also may be used to achieve a more rigid finished packaging product.

p-0031The packaging container is adapted to be childproof by permitting the blister sheet <b>104</b> to be securely retained in a stored position within the housing <b>102</b> and only releasable upon the execution of a particular series of steps that are not likely to be figured out be a child. The packaging container is also adapted to inhibit the complete removal of the blister sheet <b>104</b> from the housing <b>102</b> by limiting the axial movement of the blister sheet <b>104</b>.

p-0032The bottom member of the housing, as showing in <figref idrefs="DRAWINGS">FIGS. 9 and 10</figref>, may also define an interior sleeve for receiving the blister sheet. Referring now to <figref idrefs="DRAWINGS">FIGS. 5 through 9</figref>, the bottom member of the housing may be formed from an integral blank <b>200</b>. The blank includes a bottom panel <b>202</b>, a sleeve bottom panel <b>204</b> and a central panel <b>206</b>. An end panel <b>208</b> joins the bottom panel <b>202</b> and the sleeve bottom panel <b>204</b> along fold lines <b>210</b> and <b>212</b>. Central panel <b>206</b> is joined to the sleeve bottom panel <b>204</b> along fold line <b>214</b>. A pair of sleeve side panels <b>220</b>, <b>222</b> or members extend along the side of the sleeve bottom panel <b>204</b> and are joined to the sleeve bottom panel <b>204</b> and a pair of wing members <b>224</b>, <b>226</b> by fold lines <b>228</b>, <b>230</b>, and <b>232</b>, <b>234</b> respectively. In one embodiment, one of the wing members <b>224</b> is sized to extend substantially across the width of the sleeve bottom panel <b>204</b> when folded over.

p-0033Each of the bottom panel <b>202</b> and sleeve bottom panel <b>204</b> include a pair of rectangular slots <b>240</b>, <b>242</b> with a pair of semi-circular notches <b>244</b>, <b>246</b> extending therewithin. The slots and notches are located on the panels so that when the bottom member is formed, the slots and notches line up with one another. A pair of openings <b>250</b> are formed on the end of the central panel <b>206</b> to provide additional space between the two pair of slots <b>240</b>, <b>242</b>. While a pair of slots are shown and disclosed, referring to <figref idrefs="DRAWINGS">FIG. 2</figref>, it is appreciated that one, or more than two, slots or openings may be used and not depart from the scope of the present invention. It is further appreciated that the slots may be of a variety of sizes and shapes, and may be used without the notches and not depart from the scope of the present invention.

p-0034On the end of the back side of the central panel <b>206</b>, a flap <b>260</b> extends inwardly. Flap opening <b>262</b> in the sleeve bottom panel <b>204</b> is sized to permit the flap <b>260</b> to extend into the sleeve interior when constructed. A semi-circular slot <b>264</b> may be formed in the end of the bottom panel <b>202</b> and the end panel <b>208</b> to create an opening in the end of the packaging container <b>100</b>, as shown in <figref idrefs="DRAWINGS">FIG. 1</figref>, to permit fingers or the like to extend into the housing <b>102</b> and grab the blister sheet <b>104</b> to assist in its removal from the housing <b>102</b> to dispense the pills or other contents <b>108</b>.

p-0035While three panels are shown and disclosed, it is appreciated that the bottom member may be formed without the central panel, wherein the flap would extend inwardly from the sleeve bottom panel.

p-0036The bottom member <b>110</b> may be formed in the following manner. While the various parts may be attached using adhesive, it is appreciated that they may be connected and held together by using any known means. As shown in <figref idrefs="DRAWINGS">FIG. 7</figref>, the central panel <b>206</b> is folded over and attached to the sleeve bottom panel <b>204</b> along fold line <b>214</b> so that the flap <b>260</b> extends through the flap opening <b>262</b> and the openings <b>250</b> are aligned with the slots <b>242</b> and notches <b>246</b>. Referring to <figref idrefs="DRAWINGS">FIG. 8</figref>, the sleeve bottom panel <b>204</b> and central panel <b>206</b>, along with the end panel <b>208</b> can then be folded over along fold line <b>210</b> and attached to the bottom panel <b>202</b>. Sleeve slide panels <b>220</b>, <b>222</b> may be folded along fold lines <b>228</b>, <b>230</b> to extend substantially perpendicular to the sleeve bottom panel <b>204</b>. Wing member <b>224</b> may then be folded along fold line <b>232</b> to extend over the opening created by the sleeve side panels <b>220</b>, <b>222</b> and the sleeve bottom panel <b>204</b> such that the other wing member <b>226</b> may be folded along fold line <b>234</b> and attached to wing member <b>224</b> to define a sleeve for receiving part of the blister sheet <b>104</b> as disclosed in more detail below.

p-0037In the embodiment shown in <figref idrefs="DRAWINGS">FIG. 1</figref>, the top <b>112</b> of the housing <b>102</b> may be in the form of a tray having an opening <b>114</b> in one end and a rim <b>116</b> that extends around the remainder of the tray. In constructing the package, the tray may be placed over the formed bottom member so that the rim <b>116</b> may be attached to the portion of the bottom panel <b>202</b> around the sleeve.

p-0038In order to further assist in the prevention of theft of the package <b>100</b> and its contents, the interconnection between the walls of the top or cover <b>112</b> are preferably substantially seamless. Accordingly, the walls will not tend to separate or be easily separated by the consumer to facilitate the unwanted opening of the packaging container and removal of the contents. Additionally, the corners (if any) and/or sides of the chamber may be reinforced to further prevent any tampering with the chamber or its contents. Examples of chambers having reinforced corners and sides include, but are not limited to, chambers having their edges reinforced with fiber-reinforced tape or a fiber laminate, similar to a set-up box.

p-0039It is further appreciated that the tray may also contain an electronic security device such as, but not limited to, a product sensor/transmitter that will set off an alarm to indicate that a consumer or customer may be passing a security sensor and thereby leaving the store with an unpurchased product. Such a sensor would be deactivated upon payment for the product at the point of purchase.

p-0040Referring to <figref idrefs="DRAWINGS">FIG. 11</figref>, one embodiment of a blister sheet <b>104</b> for use with the present invention is shown. The blister sheet or card <b>104</b> is made from a substantially rigid material such as, but not limited to, aluminum or plastic. The blisters <b>106</b>, which are preferably transparent to permit the contents <b>108</b> to be viewed, include a chamber that extends outwardly and a rim about the bottom of the chamber that interacts with the blister sheet to secure the blister in place. While the blister pack is shown as having thirty substantially round blisters <b>106</b>, it is appreciated that the blister pack may have any number of blisters of varying sized and shapes and not depart from the scope of the present invention. A plurality of dispensing slots are formed on the bottom of the blister sheet <b>104</b> and are covered with a thin film or foil sheet <b>300</b> so that the pills <b>108</b> contained in blisters can be pushed through.

p-0041One end of the blister sheet <b>104</b> is folded over along line <b>304</b> to create a flap <b>302</b> that angles downwardly and inwardly. The material of the blister sheet is resilient so that when the flap is pushed upward toward the bottom of the blister sheet, the flap attempts to return to its original angled position. A pair of nodes <b>306</b> are spaced apart on the top of the flap <b>302</b> a distance that coincides with the distance between the pair of slots <b>240</b>, <b>242</b> on the sleeve bottom panel <b>204</b> and packaging bottom panel <b>206</b>. Raised areas <b>310</b> may be located at the other end of the blister sheet to provide a gripping area for a user to assist in removal of the blister sheet <b>104</b>.

p-0042In operation, the blister sheet <b>104</b> is inserted into the opening <b>114</b> at the end of the package container <b>100</b> and slid until the nodes <b>306</b> of the flap <b>302</b> are biased into engagement with the slots <b>240</b>, <b>242</b> of the sleeve bottom panel <b>204</b> and packaging bottom panel <b>202</b>, thereby limiting further axial movement of the blister sheet <b>104</b> relative to the housing <b>102</b>. To release the blister sheet <b>104</b>, a user must push down on the notches on the bottom panel <b>202</b> of the packaging container <b>100</b> to push the nodes <b>306</b> out of engagement with the slots <b>240</b>, <b>242</b>, and grasp the exposed end of the blister sheet <b>104</b>. The blister sheet <b>104</b> may then be slid and withdrawn from the housing until flap <b>302</b> engages the flap <b>260</b> on the inside of the housing <b>102</b> to prevent further withdrawal. Once the pill <b>108</b> is removed, the blister sheet <b>104</b> may be pushed back into the packaging housing <b>102</b> until the nodes <b>306</b> engage the slots <b>240</b>, <b>242</b> so as to lock the blister sheet <b>104</b> in place.

p-0043It will be understood that modifications and variations may be effected without departing from the scope of the novel concepts of the present invention, but it is understood that this application is limited only by the scope of the appended claims.