Blister packaging

BACKGROUND OF THE INVENTION
Field of the Invention

The present invention relates generally to packaging, specifically but not exclusively, to sleeve-and-drawer style packages for consumer goods for home and laundry care type applications such as liquid-tabs or pods for laundry detergent, dishwasher detergent, other cleaning agents and the like, food items, toys, hardware, and electrical items and high-value items, such as consumer electronics and the like, that are provided in unit doses or individual portions. More specifically, but not exclusively, the invention relates to lockable sleeve-and-drawer style packaging having an internal slidable receptacle, that is releasably lockable within an outer sleeve to provide a child-resistant, senior-friendly and/or secure package for items dispensed individually over time.

State of the Art

In the field of packaging, particularly in the field of homecare and laundry care products, quantities of detergents and cleaning agents are often supplied in individual portions. For example, laundry detergent is now often supplied in unit dose “pods” or “liquid-tabs”. Multiple “pods” are typically provided in re-sealable pouches or lidded boxes so that a user can dispense individual items over a period of time. However, these items may be harmful if ingested by a child or pet and it is recognised that it would be beneficial to provide packaging for such items that is more secure and/or more child resistant.

It is already known in the field of healthcare and medication packaging to provide consumers or patients with sleeve-and-drawer style secure packaging that has child-resistant features to restrict or prevent access to the package contents by a child. Typically the contents are small-sized pharmaceuticals, such as capsules, tablets and drugs contained in blister packs for unit-dose type dispensing. At the same time, it is useful for the intended user to be able to access the products contained within the package with some degree of ease. As such it is beneficial if the packaging is also “senior-friendly”. Many packages are available that comprise an inner slide card or drawer that holds articles in blisters or in trays. The inner slide card, with the articles, is then slidable inside an outer sleeve. The inner slide card is usually retained and locked inside the outer sleeve by a locking flap that engages the outer sleeve. An unlocking mechanism is usually provided on the outer sleeve to permit the disengagement of the inner slide card from the outer sleeve. Such unlocking mechanisms often require some dexterity to operate or require user realisation that co-ordinated operation of more than one feature is required; this may make the package child-resistant. In some instances, this may also make the package less senior-friendly than is desirable. It may be desirable to assist an authorised user of the package with accessing the package products.

It has been recognised that such lockable packaging would be beneficial for securing bulkier or larger sized items such as laundry pods and the like, either for facilitating their containment and individual dispensing over time and/or for child-resistant and/or security reasons. Further considerations in the development of such unit-dispensing sleeve-and-drawer style packages are the need for such packages to be repeatedly opened, re-closed and optionally locked and unlocked many times without failure. It is also desirable to keep the cost of the packaging as low as possible, whilst maintaining its durability. A further consideration is that the size of the package relative to the size of the products being packaged is preferably minimised, not only to reduce its production costs by using less material, but also to reduce shipping costs.

BRIEF SUMMARY OF THE INVENTION

According to certain embodiments, there is provided a package comprising an outer sleeve and a lockable receptacle, the lockable receptacle comprising a main body having one or more product-holding blisters and the outer sleeve providing a cavity for the lockable receptacle having a closed or closeable rear end and an open or openable front end through which the lockable receptacle is insertable and through which the lockable receptacle is withdrawable, the package comprising a stopping mechanism for preventing the lockable receptacle from being fully withdrawn from the outer sleeve, the first part of the stopping mechanism being formed as part of the outer sleeve and being disposed proximate the front end thereof, the second part of the stopping mechanism being formed as part of the lockable receptacle and being disposed proximate a rear end thereof, wherein the lockable receptacle additionally comprises a supporting mechanism formed proximate to the second part of the stopping mechanism for ensuring proper co-operation of the first and second parts of the stopping mechanism and wherein the supporting mechanism comprises one or more false blisters or appendages.

Optionally, one or more product-holding blisters that are disposed closest to the second part of the stopping mechanism formed on the lockable receptacle are defined as rear-most product-holding blisters and wherein at least one of said one or more false blisters or appendages is formed contiguously with and co-joins a rear-most product-holding blister.

Alternatively one or more product-holding blisters that are disposed closest to the second part of the stopping mechanism formed on the lockable receptacle are defined as rear-most product-holding blisters and wherein at least one of said one or more false blisters or appendages is formed separately from and has a separate top opening from a rear-most product-holding blister.

Optionally, the maximum width of one or more or all of said one or more false blisters or appendages is less than the maximum width of all of said one or more product-holding blisters.

Optionally, said one or more product-holding blisters are integrally formed product-holding blisters.

Product-holding blisters according to some embodiments of the invention may have a depth of between about 3 cm and about 5 cm.

The first part of the stopping mechanism may be a folded front end flap provided on the outer sleeve. The second part of the stopping mechanism may comprise a foldable locking foot.

Optionally, the foldable locking foot is an integrally formed part of the lockable receptacle or wherein the foldable locking foot is provided by an auxiliary slide card affixed to the main body of the lockable receptacle that has the one or more product-holding blisters.

Optionally, the lockable receptacle is generally a molded plastics construct comprising a product in each of said one or more product-holding blisters and having a sealing film or other material disposed to cover and seal each of the one or more product-holding blisters.

According to some embodiments of the invention, the product-holding blisters may be used to hold or contain laundry liquid pods. The term “product-holding” is not necessarily intended to mean a blister actually holding a product, but may also refer to a blister capable of holding or supporting a product. Likewise the term “product-receiving” does not necessarily mean that a product is received in the blister, but that it can be.

According to other embodiments of the invention, there is provided a lockable receptacle comprising: a main body having one or more product-receiving blisters; a second part of a stopping mechanism disposed proximate a rear end of the lockable receptacle; and a supporting mechanism formed proximate to the second part of the stopping mechanism for ensuring proper co-operation of the second part of the stopping mechanism with a first part thereof formed on an outer sleeve and wherein the supporting mechanism comprises one or more false blisters or appendages.

Optionally, one or more product-receiving blisters that are disposed closest to the second part of the stopping mechanism formed on the lockable receptacle are defined as rear-most product-receiving blisters and wherein at least one of said one or more false blisters or appendages is formed contiguously with and co-joins a rear-most product-receiving blister.

Alternatively, one or more product-receiving blisters that are disposed closest to the second part of the stopping mechanism formed on the lockable receptacle are defined as rear-most product-receiving blisters and wherein at least one of said one or more false blisters or appendages is formed separately from or spaced apart from, and has a separate top opening from, a rear-most product-receiving blister.

Optionally, the maximum width of one or more or all of said one or more false blisters or appendages is less than the maximum width of all of said one or more product-receiving blisters.

Optionally, said one or more product-receiving blisters each have a depth and wherein said one or more false blisters or appendages has a depth that is the same as the depth of said product-receiving blisters.

Said one or more product-receiving blisters may be integrally formed product-holding blisters, and may have a depth of between about 3 cm and about 5 cm.

Optionally, the second part of the stopping mechanism comprises a foldable locking foot.

Optionally, the lockable receptacle is generally a molded plastics construct comprising a product in each of said one or more product-receiving blisters and having a sealing film or other material disposed to cover and seal each of the one or more product-holding blisters. The products may be laundry liquid pods.

It is envisaged and intended that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings may be taken independently or in any combination thereof. For example, features described in connection with one embodiment are applicable to all embodiments unless there is incompatibility of features.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming particular embodiments of the present invention, various embodiments of the invention can be more readily understood and appreciated by one of ordinary skill in the art from the following descriptions of various embodiments of the invention when read in conjunction with the accompanying drawings in which:

FIG. 1 is a plan view of a blank for forming an outer sleeve for use with a lockable receptacle in forming a package according to various embodiments of the invention;

FIG. 2A is a plan view of the top of a lockable receptacle according to various embodiments of the invention;

FIG. 2B is a side elevation of the lockable receptacle of FIG. 2A according to various embodiments of the invention;

FIG. 3 is a perspective view of a package comprising an outer sleeve a lockable receptacle according to various embodiments of the invention;

FIG. 4 is a perspective view of the package of FIG. 3 wherein the lockable receptacle is disposed in an extended position in which the lockable receptacle is withdrawn to such an extent that access to all blisters is possible and yet the lockable receptacle remains locked to the outer sleeve and supported in an open-drawer style position according to various embodiments of the invention;

FIG. 5 is a cross-sectional view, taken along the line XX, of the closed package of FIG. 3, in which it is shown how the first part of the two part-locking mechanism of interacts with a second part provided on a lockable receptacle to lock the lockable receptacle within the outer sleeve;

FIG. 5A is an enlarged view of the rear closed end of the package shown in cross-section in FIG. 5;

FIG. 6 is a cross-sectional view of a package according to various embodiments of the invention, wherein the lockable receptacle is disposed in a fully extended position in which the lockable receptacle is withdrawn to such an extent that access to all blisters is possible and yet the lockable receptacle remains locked and anchored to the outer sleeve and supported in an open-drawer style position by operation of the supporting mechanism in conjunction with a two-part stopping mechanism;

FIG. 7 is a cross-sectional view of a similar package to that shown in FIG. 6, wherein a lockable receptacle not having a supporting mechanism according to various embodiments of the present invention is disposed in a fully extended position in which the lockable receptacle is withdrawn to such an extent that access to all blisters is possible; however, the lockable receptacle does not remain locked and anchored to the outer sleeve, the stopping mechanism is failing and the lockable receptacle is shown disadvantageously falling out of the outer sleeve;

FIG. 8 is a plan view of a top of a lockable receptacle according to various embodiments of the invention; and

FIG. 9 is a plan view of a top of a lockable receptacle according to various embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Detailed descriptions of various embodiments of the outer sleeves, lockable receptacles, packages and blanks are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. Indeed, it will be understood that the outer sleeves, lockable receptacles, packages and blanks described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting.

According to various embodiments of the invention, packages can be used to store a variety of products. More specifically, lockable receptacles according to various embodiments can be used for the storage of products such as, for example, detergents and other cleaning agents for use in washing machines, dishwashers and the like in “pod” or large-size capsule form, healthcare or pharmaceutical products, garden products, smokeless tobacco, cigarettes, food-items (for example loose leaf tea and coffee pods), confectionary, toys, electrical items or any product stored in a pouch, blister or compartment, and the like, without departing from the scope and embodiments of the present invention.

Generally, various embodiments of the invention include a package comprising: an outer sleeve 110 (see FIGS. 3, 4, 5, 5A and 6); a lockable receptacle 70 (see FIGS. 2A, 2B, 4, 5, 5A and 6); and one or more stopping mechanisms 30/74 for restricting or preventing the lockable receptacle 70 from being fully withdrawn from the outer sleeve 110. More specifically, embodiments of the invention include a brace-style supporting mechanism that may improve the effectiveness or ensure proper operation of the stopping mechanism. Preferably, the stopping mechanism 30/74 comprises two primary parts: a first end flap 30 which is provided at an open front end of the outer sleeve 110, and a second part 74, or locking foot, which is provided by the lockable receptacle 70.

Additional optional aspects of embodiments of the invention include a two-part complementary locking mechanism 60/74 for locking the lockable receptacle 70 in a fully inserted position within the outer sleeve 110 (also referred to as a closed position). The package also therefore optionally comprises a release mechanism 50 for unlocking the two-part locking mechanism. The two-part locking mechanism may provide an optional child-resistant feature.

The brace-style supporting mechanism 80 may be utilized with a variety of package arrangements according to embodiments of the invention, wherein a lockable receptacle 70, particularly one having product-holding blisters 78a, 78b, 78c, is slidably moveable into and out of an outer sleeve 110 and yet remains locked or engaged with the front end of the outer sleeve 110 to prevent its complete withdrawal from the outer sleeve 110. Such packages may be beneficial in applications where repeated use of the package is required to individually dispense, over a period of time, items contained in product-holding blisters 78a, 78b, 78c provided on or as part of the lockable receptacle 70. Advantageously, but nevertheless optionally, the two-part locking mechanism 60/74 of some embodiments of the invention may enable packages to be utilized in applications where child-resistance is desired (for example where the items contained in the product-holding blisters 78a, 78b, 78c of the lockable receptacle 70 are potentially harmful or toxic, such as cleaning agents). However, the application of the brace-style supporting mechanism 80 is not so limited and its application in other forms of packaging, such as secure packaging for high-value and/or delicate products, is envisaged.

A lockable receptacle 70 having a brace-style supporting mechanism 80 according to various embodiments of the invention is illustrated in FIGS. 2A, 2B, 4, 5, 5A and 6. The lockable receptacle 70 is optionally primarily formed from plastics material. The lockable receptacle 70 has a main body 72 that is fully receivable and retainable within an outer sleeve (such as an outer sleeve 110 formed from a blank 10 shown in FIG. 1 and described below). The lockable receptacle 70 comprises a series of product-holding blisters 78a, 78b, 78c, each for retaining a single product or single portion of a product. Optionally, and by way of exemplary illustration only, the lockable receptacle 70 comprises three product-holding blisters 78a, 78b, 78c arranged in a 3×1 array. The product-holding blisters 78a, 78b, 78c are optionally molded (for example blow molded or press-molded) out of the main body portion 72. A perforable or peelable sealing film or material (not shown) is affixable, optionally by means of adhesive or other bonding agent, to a flanged part of the main body 72 that surrounds open tops 84a, 84b, 84c of the product-holding blisters 78a, 78b, 78c (see FIG. 2B). Such film or material may include barrier properties to preserve the environment within a blister. For example, a film or material may provide certain moisture barrier properties to prevent moisture escape and/or entry into a blister. The product-holding blisters 78a, 78b, 78c optionally each have tapered sides and a base portion 82a, 82b, 82c respectively. The base portions 82a, 82b, 82c may slide along a floor of the outer sleeve 110 that is provided by a bottom panel 16.

A lockable receptacle 70 may include the second part 74 of the two-part complementary mechanical locking mechanism 60/74 and the second part 74 of the two-part stopping mechanism 30/74. The two-part stopping mechanism 30/74 may enable a user to withdraw the lockable receptacle 70 from the outer sleeve 110 only to a limited extent to prevent the lockable receptacle 70 from becoming completely separated from the outer sleeve 110. This avoids a user having to re-insert the lockable receptacle 70 within the outer sleeve 110 and more easily enables the lockable receptacle 70 to be slid back into the outer sleeve 110 to return to its fully inserted closed position.

The second part 74 of the two-part complementary mechanical locking mechanism 60/74 and the second part 74 of the two-part stopping mechanism 30/74 are optionally provided by a single component on the lockable receptacle 70. For example, the second part 74 may be a locking tail flap or locking foot. The lockable receptacle 70 is optionally formed as a unitary one piece plastics molded construct and the second part 74 is integrally formed therewith. The second part 74 may be connected to the main body portion 72 by means of a hinge connection, which in some embodiments is optionally a living hinge 76 as illustrated in FIG. 2B. According to other embodiments of the invention, a second part 74 may be separate from and attached to the main body portion 72.

To facilitate proper engagement of the second part 74, particularly with the first end flap 30 of the two-part stopping mechanism 30/74, but also optionally with the first part 60 of the two-part complementary locking mechanism 60/74, the supporting mechanism 80 is provided. According to some embodiments of the invention, the supporting mechanism 80 is a brace-style supporting mechanism formed as a “false blister”, at least the rear end 92 of which is disposed adjacent the second part 74 when the second part 74 is folded about living hinge 76 as illustrated in FIGS. 2A and 2B. The front end of a supporting mechanism 80 may be conjoined with the rearmost product-holding blister 78c. Stated differently, a supporting mechanism 80—or “false blister”—may be contiguously formed with, and molded as a co-joining part of, the rearmost product-holding blister 78c or as an “appendage” to the rearmost product-holding blister 78c. A false blister or supporting mechanism 80 may substantially span the depth of the outer sleeve 110 to brace between the second part 74 and floor 16 of the outer sleeve 110.

In some embodiments, the shape of the main body 72 of the lockable receptacle 70 may be tapered such that upon inserting the lockable receptacle 70 into the outer sleeve 110 the leading end (defined by hinge connection 76) of the lockable receptacle 70 is slightly narrower in width than the width of the outer sleeve 110. In such an arrangement, and as shown in the Figures, the supporting mechanism 80 has a maximum width W2 that is less than the maximum width W1 of the adjacent and co-joining product-holding blister 78c. In other envisaged arrangements, the supporting mechanism 80 alternatively has a maximum width that is equal to or greater than the maximum width of the adjacent product-holding blister 78c. The sides of the supporting mechanism 80 are contiguously formed with the sides of the adjacent and co-joining product-holding blister 78c such that the two parts (the supporting mechanism 80 and the product-holding blister 78c) can be molded together as a unitary molded formation. As such, the supporting mechanism 80 may have a maximum depth that is equal to the maximum depth of the adjacent product-holding blister 78c. In this way a bottom 84 of the supporting mechanism 80 is disposed in the same plane as the bottom 82c of the adjacent product-holding blister 78c as illustrated in FIG. 2B.

The product-holding blisters 78a, 78b (also referred to as product-receiving blisters particularly when no product is present) are identical in their size and shape having a top opening 84a, 84b that is a uniform square-shape with rounded corners as illustrated in the Figures. The rear-most product-holding blister 78c is notionally the same shape as the openings of the product-holding blisters 78a, 78b, albeit due to the contiguous formation of the appended supporting mechanism 80, the shape of the overall opening of the rear-most product-holding blister 78c and co-joining appended supporting mechanism 80, the opening is approximately “T”-shaped as is best seen in FIG. 2A. While particular shapes of the product-holding blisters 78a, 78b, and 78c are illustrated, it is understood that the shape and size of a blister may be selected for the particular application for which the lockable receptacle is to be used.

According to some embodiments of the invention, the supporting mechanism 80 may comprise one or more false blisters that are formed as a separate false blister that is not contiguous with, and thus spaced apart from, a rear-most product-holding blister 78c. For example, a lockable receptacle 70 having a supporting mechanism 80 separate from a blister 78 is illustrated in FIG. 8. Why the embodiment illustrated in FIG. 8 includes a single supporting mechanism 80 having a defined shape, it is understood that multiple supporting mechanisms 80 could be used and in any desired shape. The ues of a separate supporting mechanism 80 may be beneficial where it is required to match the shape of the product-holding blister 78c closely to the shape of a product in order to minimize movement of the product when held within the product-holding blister 78c. In many embodiments, however, the supporting mechanism 80 comprises one or more false blisters that extend between the plane of the main body 72 and a plane ‘H’ containing the bottoms 82a, 82b, 82c of the product-holding blisters 78a, 78b, 78c (see FIG. 6). In other words, the maximum depth of a contiguous supporting mechanism 80 (or of any separate false blisters) is about equal to (or only slightly less than) the maximum depth of the product-holding blisters 78a, 78b, 78c. This enables the supporting mechanism 80 to act as a bracing support to ensure a good engagement between the second part 74 and the first end flap 30 of the two-part stopping mechanism 30/74. Additionally, the supporting mechanism 80 acting as a bracing support may optionally ensure good engagement between the second part 74 and the first part 60 of the two-part locking mechanism 74/60. This is described further below with reference to FIGS. 6 and 7.

Turning now in more detail to the outer sleeve 110, reference is made to FIG. 1, wherein the blank 10 for forming the outer sleeve 110 is illustrated. The blank 10 is formed of a foldable substrate, for example paperboard, optionally having at least one coated and printed side. In other embodiments, the blank 10 may be formed from any one or a combination of: paper, paperboard, fibreboard, plastics material, coated material, uncoated material and printed material. According to some embodiments, the blank 10 may be a sheet of paperboard having a polymer based tear resistant coating on one side thereof, for example the blank 10 may be formed from Printkote® EasySeal Plus paperboard.

The blank 10 comprises, in series: an inner top panel 12, a first side panel 14, a bottom panel 16, a second side panel 18, and an outer top panel 20, hinged one to the next by means of longitudinally extending fold lines 22, 24, 26 and 28 respectively.

Rear end flaps 34, 36 are hinged by fold lines 42, 44 to the “rear” ends of the bottom panel 16 and outer top panel 20. These rear end flaps 34, 36, in use, are folded approximately 90° about fold lines 42 and 44 and are affixed in face contacting relationship to one another to form a composite end wall 34/36 for the outer sleeve 110 (see FIGS. 5, 5A and 6). The composite end wall 34/36 may be referred to herein as a “rear end wall”.

A first end flap 30 and an optional second front end flap 32 are hinged by fold lines 38 and 40 to the “open” ends of the inner top panel 12 and bottom panel 16 respectively. Fold line 38 is optionally interrupted by an aperture 46 which provides a recess by which a user can grasp a portion of the lockable receptacle 70 to assist in sliding it from the closed position into an open or partially open position. The first and second end flaps 30, 32, in use, are folded approximately 180° about fold lines 38 and 40. The first end flap 30 is not necessarily affixed to the inside surface of the inner top panel 12, whereas the second front end flap 32 preferably is affixed in face contacting relationship to the bottom panel 16. Once folded and formed in this way, the first and second end flaps 30, 32 each optionally serve to provide a smooth finish to the “open” end of the outer sleeve 110, and the first end flap 30 serves as the first part of the stopping mechanism provided for preventing or at least mitigating against the complete withdrawal and separation of the lockable receptacle 70 from the outer sleeve 110.

A blank 10 may also comprise elements for forming the first part 60 of the two-part locking mechanism 74/60. The elements include: an aperture 62 and a first edge 64 formed in the inner top panel 12 (the first edge 64 being defined by the aperture 62). The aperture 62 may be considered as a recess into which, in use in the locked configuration, the second part 74 may be at least partially inserted as its free edge (the edge opposite to the hinge connection 76) abuts, engages or otherwise connects with the locking edge 64. A blank 10 may further comprise elements for forming the release mechanism denoted generally by reference 50. The elements for forming the release mechanism 50 optionally include: an outer moveable tab 52 formed in the outer top panel 20; and an inner tab 56 formed in the inner top panel 12. Each moveable tab 52, 56 is preferably, but nevertheless optionally, integrally formed within the blank 10. Each moveable tab 52, 56, may include an anchored portion and a free edge which is defined by a cut or other frangible connection such that the free edge is separated from the remainder of the outer top panel 20 and inner top panel 12 respectively. The moveable tabs 52, 56 are thereby moveable below the plane of the panel from which they are formed (the outer top panel 20 and inner top panel 12 respectively). Optionally, the outer moveable tab 52 formed in the outer top panel 20 is the same width as the innermost moveable tab 56 in the inner top panel 12.

The outer moveable tab 52 may be defined by a first side edge, a second side edge and a front edge 54 (which may in some embodiments be frangibly connected to the outer top panel 20 until its first use is required). The first and second side edges are optionally substantially parallel to one another and each terminate in an acutely radiussed arcuate cut line termination to prevent the further propagation of the cut side edges into or through the outer top panel 20. The front edge 54 spans between and terminates in the first and second side edges. In this way a generally “U”-shaped moveable tab 52 is defined. The roughly “U”-shaped moveable tab 52 is preferably, but nevertheless optionally, disposed in a substantially medial position within the outer top panel 20.

Turning in more detail to the construction of the outer sleeve 110 from the blank 10, the blank 10 may be oriented so that its uncoated, unprinted side faces out. Optionally, the first and second end flaps 30, 32 are folded about fold lines 38, 40 and optionally only the second front end flap is affixed to the inside face (non-printed face) of the bottom panel 16. To affix the second end flap 32 to the bottom panel 16 adhesive (such as hot melt glue) may be applied to one or both of the second end flap 32 and the bottom panel 16. Then, the inner top panel 12 together with the first side panel 14 may be folded about fold line 24 to bring the inner top panel 12 and first side panel 14 into face contacting relationship with the inside faces of the bottom panel 16 and second side panel 18 respectively.

Optionally, adhesive may be applied to parts of the inner top panel 12 and/or to parts of the outer top panel 20. The outer top panel 20 is then folded about fold line 28 to bring it into face-contacting relationship with the inner top panel 12 such that the outer top panel 20 and the inner top panel 12 are affixed together. At this point, construction of the outer sleeve 110 is not entirely completed since the rear end wall 34/36 has not been assembled. In this state, however, the outer sleeve 110 is in a flat form (not shown). It has been folded and part assembled and it is in this flat form that the outer sleeve 110 would preferably be shipped to a converting plant. As such, construction of the outer sleeve 110 may be fully completed at a converting plant, where the outer sleeve 110 is opened into a tubular form, loaded from one or both of the open (front) or rear ends with a product-holding lockable receptacle 70. Then, the rear end wall 34/36 is constructed by folding the rear end panels 34, 36 about fold lines 42, 44 and into affixed and face contacting relationship. Preferably, the bottom rear end flap 34 is folded first and the top rear end flap 36 is affixed thereto.

In various embodiments, a lockable receptacle 70 may be loaded through the open front end, after the rear end wall 34/36 has been constructed. To install the lockable receptacle 70 into the outer sleeve 110, the second part 74 is folded toward the main body 72 and optionally, in this form, the lockable receptacle 70 is slidably pushed into the outer sleeve 110, leading with the hinge connection 76, through the open front end and towards the closed rear end wall 34/36. The package in a closed configuration is shown in FIG. 3. The lockable receptacle 70 is automatically locked in the closed configuration within the outer sleeve 110 by operation of the two-part complementary locking mechanism 74/60. This is best illustrated in FIG. 5A, wherein it can be seen that, due to the natural resilience of the material from which the second part 74 and/or lockable receptacle 70 is at least in part formed, the folded second part 74 unfolds slightly, into the gap or recess provided by the aperture 62. In this way, the second part 74 catches on the locking edge 64 provided by the internal face of the cut locking edge 64.

Once the outer sleeve 110 is assembled, the release mechanism 50 is also formed. As can also be seen in FIG. 5A, the moveable tab 52 is disposed in at least partial super position above the moveable tab 56 and is disposed in registry with the aperture 62 such that the outer tab 52 can be depressed into the aperture. Optionally in conjunction with tab 56, the outer tab 52 can be used to dislodge the second part 74 out of engagement with the recess 62 and locking edge 64. Simultaneously, the lockable receptacle 70 can be withdrawn from the outer sleeve 110. The thumb recess 46/48 may assist a user in grasping the lockable receptacle 70, when it is disposed fully within the outer sleeve 110, in order to withdraw it from the outer sleeve 110. In dependence upon the extent to which the lockable receptacle 70 is withdrawn from the outer sleeve 110, access to one or more or all of the product-holding blisters 78a, 78b, 78c can be gained. As such it will be realized that a user may hold the package in one hand and with that same hand, depress the moveable tab 52, whilst at the same time, gripping and pulling an end edge of the lockable receptacle 70 with their other hand. This may provide a child-resistant locking mechanism.

Withdrawal of the lockable receptacle 70 is shown in perspective view in FIG. 4, wherein a notional horizontal plane in which the bases 82a, 82b, 82c of each product-holding blisters 78a, 78b, 78c and the base 84 of the supporting mechanism 80 rest. As is best viewed in FIG. 6, in the fully withdrawn position, the stopping mechanism 30/74 acts to prevent the lockable receptacle 70 from becoming fully separated or detached from the outer sleeve 110. The second part 74 catches between the ceiling of the outer sleeve 110 (provided by the inner top panel 12) and the first end flap 30. Optionally, the second part 74 and first end flap 30 are sized such that at the full extent of the permitted travel of the lockable receptacle 70, the leading edge of the second part 74 abuts or contacts the hinge connection 38 between the first end flap 30 and the inner top panel 12. As such a portion of the lockable receptacle 70 having a length substantially equal to the second part 74 remains within the outer sleeve 110 (see FIG. 4 and FIG. 6).

The product-holding blisters 78a, 78b, 78c may accommodate larger sized articles, such as laundry detergent pods. The product-holding blisters 78a, 78b, 78c optionally have a depth which is about 10 times greater than the depth of blisters typically used in such sleeve-and-drawer style packages for use with pharmaceutical products such as relatively small tablets and capsules. Optionally, the depth of the product-holding blisters 78a, 78b, 78c may be about 3 cm to about 5 cm and preferably about 3.5 cm. The outer sleeve 110 is dimensioned such that it is only slightly larger than the lockable receptacle 70 such that the lockable receptacle 70 is accommodated therein in a relatively close-fitting manner. As such the lockable receptacle 70 is constrained laterally (in the x-direction) by the first and second side walls 14, 18 and is constrained longitudinally (in the y-direction) by the rear end wall 34/36 and the two-part locking mechanism 60/74. The lockable receptacle 70 is further constrained in the direction of a z-axis of the outer sleeve 110 by the top wall 12/20 and the bottom panel 16, because the depth of the outer sleeve 110 (defined as the distance between the inner ceiling provided by the inner top panel 12 and the inner floor provided by the bottom panel 16) is only slightly greater than the depth of the lockable receptacle 70 (i.e. the depth of the product-holding blisters 78a, 78b, 78c).

As shown in FIG. 6, the supporting mechanism 80 is beneficially provided to provide a support approximately beneath the second part 74 to ensure that the second part 74 can maintain a sufficiently strong engagement with the first end flap 30 of the stopping mechanism (and optionally additionally with the first part of the locking mechanism 60). Reference is made to FIG. 7 wherein the benefit provided by the supporting mechanism 80 is further illustrated in respect of a lockable receptacle 170 that does not form part of the claimed invention and does not have a supporting mechanism. As can be seen in FIG. 7, because such a lockable receptacle 170 has deep-fill blisters 178a, 178b, 178c and is unsupported in the region below the locking foot, the lockable receptacle 170 can tilt as it reaches its fully extended position. The angled position of such a lockable receptacle 170 compromises the operation of the stopping mechanism and the locking foot can become disengaged from the first front flap 130. Disadvantageously therefore such a lockable receptacle 170 can become completely separated from the outer sleeve 110. Advantageously, however, the present invention mitigates against such a problem by the provision of a supporting mechanism 80 provided to ensure that the lockable receptacle 70 remains constrained in the direction of a z-axis of the outer sleeve 110 by the top wall 12/20 and the bottom panel 16. The supporting mechanism 80 resists any forces placed upon the part of the lockable receptacle 70 that is disposed outside the outer sleeve 110 (see FIG. 6) that could cause rotation of the lockable receptacle 70 and thereby disengagement of the stopping mechanism 30/74. The supporting mechanism 80 maintains the part of the lockable receptacle 70 that is disposed inside the outer sleeve 110 (when the lockable receptacle 70 is in the fully extended position) and maintains the part of the lockable receptacle 70 that is disposed outside the outer sleeve 110 in a level position, wherein the bases 82a, 82b, 82c, 84 of all of the product-holding blisters 78a, 78b, 78c, and supporting mechanism 80 rest in the same notional horizontal plane H. Beneficially, the provision of the supporting mechanism 80 in the form of an integrally molded blister requires no additional material and requires no additional assembly steps. A differently shaped molding tool is all that is required and as such the present invention provides a low cost solution that ensures consistent repeated opening and closing of the sleeve-and-drawer style package.

While various embodiments of the present invention have been described in terms of specific embodiments illustrated, it will be understood that no limitations are intended thereby to the details of construction or design, the present invention contemplating and including any novel feature or novel combination of features which are herein disclosed.

It can be appreciated that various changes may be made within the scope of the present invention, for example, the size, number, configuration, position and relative placement, shape and physical formation of each product-holding blister, supporting mechanism, the locking structure and the moveable tabs of the release mechanism may be adjusted to suit the intended purpose of the package.

A lockable receptacle 70 according to various embodiments of the invention may be used in conjunction with other styles of outer sleeve. For example, in other envisaged embodiments, the outer sleeve may be a plastics two-part construction rather than a folded paperboard construction. In other envisaged embodiments, other number and configuration of product-holding blisters are provided, for example in other envisaged embodiments, the product-holding blisters are arranged in a 2×3 array as illustrated in FIG. 9, a 3×3 array, or any other desired configuration.

In other embodiments, the lockable receptacle may comprise two parts: a first blister portion comprising the product-holding blisters; and a second slide card portion which is attached to the first blister portion and which provides the second part of a two-part complementary locking mechanism in the form of a foldable locking tail flap. In some embodiments wherein the locking receptacle comprises blisters in an arrangement of more than one blister wide, one or more or all of the rear-most blisters may have a false blister disposed adjacent thereto and/or associated therewith. In an arrangement where more than one false blister is provided the false blister may have the same or different shape, size and configuration. Additionally in arrangements wherein the locking receptacle comprises blisters in an arrangement of more than one blister wide, one or more false blisters may be provided that are not aligned with the rows of product-holding blisters. For example, in a 3×3 arrangement of product-holding blisters, a lockable receptacle may comprise two false blisters, each formed in the region behind and roughly overlapping one and a half of the rearmost product-holding blisters.

In other embodiments, the first end flap 30 may be similarly sized to the second part 74 such that the free edge of the first end flap 30 abuts or contacts the hinge connection 76 between the second part 74 and main body 72 of the lockable receptacle 70 at the same time as the free-edge of the second part 74 contacts the hinge connection 38.

In other embodiments, the supporting mechanism may be provided by any number of appendages or formations substantially spanning the region proximate to and beneath the second part 74. In such embodiments, the appendages or formations do not form a contiguous extension of a rear-most blister. In still other embodiments, the appendages, formations or false blisters are not exactly equal in depth to the depth of the product-holding or do not extend in line with the bases of the product-holding blisters but only stop above the bottom panel of an outer sleeve a short distance such that rotation of the lockable receptacle is still minimized and sufficiently so as to prevent the locking foot disengaging from the first part of the stopping mechanism.

In other embodiments, the two-part locking mechanism and release mechanism illustrated herein is not provided. In such embodiments an alternative locking mechanism/release may be provided, for example a release mechanism utilizing a demarcated pressing zone rather than an outer moveable release tab may be used.

The arrangement of panels of the blank is different in other envisaged embodiments, indeed in some embodiments, the outer sleeve comprises a three-ply top wall.

While various embodiments have been described with reference to the use of both a brace-style supporting mechanism 80 in conjunction with one or more locking mechanisms, it is understood that various embodiments of the invention include a receptacle 70 without a locking mechanism. In such embodiments, a supporting mechanism 80 may be incorporated with a blister package having one or more blisters where there is a need or a desire to support the blister package when fully or partially withdrawn from an outer sleeve.

It will be recognized that as used herein, directional references such as “top”, “bottom”, “front”, “back”, “end”, “side”, “inner”, “outer”, “upper” and “lower” do not necessarily limit the respective panels to such orientation, but merely serve to distinguish these panels from one another. Any reference to “hinged connection” should not be construed as necessarily referring to a single fold line only; indeed it is understood that hinged connection can be formed from one or more of the following: a short slit, a frangible line or a fold line without departing from the scope of the invention.

The phrase “in registry with” as used herein refers to alignment of two or more elements in an erected package, such as a moveable tab formed in an outer top panel and a moveable tab formed in an inner top panel. Those elements in registry with each other may be aligned with each other in the direction of the thickness of the overlapping panels.

Having thus described certain particular embodiments of the invention, it is understood that the invention defined by the appended claims is not to be limited by particular details set forth in the above description, as many apparent variations thereof are contemplated. Rather, the invention is limited only be the appended claims, which include within their scope all equivalent devices or methods which operate according to the principles of the invention as described.

Number	Name	Date	Kind
3648918	Van Inwagen	Mar 1972	A
8066121	Sack et al.	Nov 2011	B2
8191710	Clarke	Jun 2012	B2
20090134054	Lee et al.	May 2009	A1
20090184023	Brollier et al.	Jul 2009	A1
20120234701	Albrecht et al.	Sep 2012	A1

Number	Date	Country
2305575	Apr 2011	EP
WO 2012112538	Aug 2012	WO
2013151806	Oct 2013	WO

Blister packaging

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