LOCKING ARRANGEMENT FOR SLEEVE-AND-ENDCAP PACKAGE

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to improvements in the field of product packaging, and in particular to advantageous aspects of an improved locking arrangement for a sleeve-and-endcap package.

2. Description of the Prior Art

Product packaging is a highly competitive industry, in which there is an ongoing effort to develop new package designs. A successful design must typically satisfy a number of often conflicting criteria, including: security, esthetic appearance, cost, ease of use, and the like. With respect to cost, it is noted that even a relatively small per-package savings in materials or labor can have a significant impact on the bottom line.

One type of product packaging that is currently used for a number of different types of products is a “sleeve-and-endcap” design, comprising a stiff outer sleeve, and rigid endcaps that fit closely within the sleeve's upper and lower ends. The sleeve is typically fabricated from a sheet of plastic that is cut into a blank that is then rolled (or folded) and glued to form a tube with open ends. The endcaps are typically formed from a suitable plastic material using an injection-molding technique.

In an assembled sleeve-and-endcap package, the endcaps are typically held in place by friction. In order to prevent unintended opening, and to discourage theft, additional components are commonly added to the assembled package to prevent the endcaps from being easily removed. Such components may include, for example, adhesive tape, staples, shrink-wrap, and the like. However, these techniques suffer from a number of drawbacks, including the amount of labor and materials required to construct the package, the esthetic appearance of the finished package, and the secureness of the attachment between the endcaps and the sleeve ends.

SUMMARY OF THE INVENTION

Aspects of the invention provide a locking arrangement for a sleeve-and-endcap package.

An exemplary package according to an aspect of the invention comprises a sleeve having one or more open ends, and a rigid endcap that fits closely within a respective open sleeve end. The endcap is insertable into the open sleeve end and is slidable along a generally longitudinal path to its final, installed position.

The sleeve comprises one or more locking tabs extending inwardly from one or more sleeve panels. Each locking tab includes a contact edge that has a transverse orientation relative to the longitudinal endcap path.

The endcap comprises one or more locking bumps extending outwardly from the outer circumferential surface of the endcap body. Each locking bump includes a contact surface that has a transverse orientation relative to the longitudinal path.

The sleeve, locking tab, endcap, and locking bump are configured such that when the endcap is in its final, installed position within a sleeve end, outward movement of the endcap along the longitudinal pathway prevented by the engagement of the locking tab contact edge and the locking bump contact surface.

Further aspects of the invention are directed to additional features and alternative configurations with respect to the sleeve, sleeve locking tabs, endcap and endcap locking bumps.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an exploded view of a sleeve-and-endcap package according to an aspect of the invention.

FIGS. 2A-2D show, respectively, left, front right, and rear views of the package shown in FIG. 1, fully assembled.

FIGS. 3A-3C are a series of diagrams illustrating, with respect to the package shown in FIG. 1, the installation of the upper endcap into the upper sleeve opening.

FIGS. 4A-4C are a series of closeup views of the rightmost portion of FIGS. 3A-3C.

FIG. 5 shows a perspective cutaway view of a portion of the upper endcap and sleeve opening of the FIG. 1 package, corresponding to FIGS. 3C and 4C.

FIGS. 6 and 7 are cross section diagrams of the sleeve of the FIG. 1 package, illustrating structural aspects of the sleeve contributing to the resilient deflectability of the sleeve locking tabs.

FIGS. 8A-8C are a series of diagrams illustrating the construction of the FIG. 1 sleeve from a blank cut from a sheet of plastic or other suitable material.

FIG. 9 shows (a) bottom and (b) front views of the upper endcap of the FIG. 1 package. FIGS. 9-1 through 9-5 illustrate variations in the configuration of the locking bumps of the FIG. 9 endcap.

FIGS. 10A-10C are a series of diagrams of exemplary locking sleeve-and-endcap packages, illustrating alternative cross-sectional profiles and alternative configurations of the locking components, according to further aspects of the invention.

FIGS. 11A-11E are a series of diagrams illustrating alternative shapes for endcap locking bumps, according to further aspects of the invention.

FIGS. 12A-12C are a series of diagrams of the upper portions of exemplary packages according to further aspects of the invention, wherein the sleeve locking tabs are provided with cutout portions that at least partially surround respective endcap locking bumps.

DETAILED DESCRIPTION

Aspects of the invention are directed to structures and techniques that, in a sleeve-and-endcap package, provide secure locking of one or more endcaps it its respective sleeve end. As discussed below, aspects of the invention can be used to create an endcap that is readily insertable into a sleeve and that, once fully seated, is securely locked in position. As further discussed below, the locking structures can be designed to be inconspicuous, such that they are virtually unnoticeable to a casual observer. Alternatively, the locking structures can be designed to contribute to the overall esthetic appearance of the package. For example, the locking bumps can incorporate the shape of a corporate logo or other design.

According to an aspect of the invention, the locking structure comprises one or more outwardly extending endcap bumps and one or more inwardly extending sleeve tabs corresponding in position to respective endcap bumps. The endcap bumps and the sleeve tabs are respectively positioned such that when the endcap is fully seated in its final position within a sleeve opening, removal of the endcap from the sleeve opening is prevented by the structural interaction of corresponding endcap bump surfaces and sleeve tab contact edges. As discussed below, there need not be a one-to-one correspondence between the locking tabs and the locking bumps. For example, in package 10, shown in FIG. 1, there are three endcap locking bumps for each sleeve locking tab.

There are now provided definitions for a number of terms used herein, followed by a detailed description of exemplary practices of the invention.

Definitions

It is generally intended that the terms used herein comport with standard usage in the packaging industry and the English language. The following definitions are provided to clarify, rather than replace, standard usage.

As used herein, the term “sleeve” refers to a tubular or tube-like packaging component having one or more openings. In the practices of the invention described herein, upper and lower openings are created by forming a sheet of material into a sleeve comprising a tube with open ends. The respective sleeve edges at the open ends form the rims of the sleeve openings. A sleeve can be suitably fabricated from one or more sheets of plastic, paperboard, cardboard, or other suitable material, or combination thereof. Generally speaking, it is desirable for the sleeve material to be stiff and to be resiliently deformable. It will be appreciated that aspects of the present invention can also be practiced with different types of sleeves, including sleeves fabricated from different materials or combinations of materials.

The term “endcap” refers to a rigid, or substantially rigid, component that is configured such that it can be used to plug up a sleeve opening by being inserted therein. An endcap typically includes a flange or like structure to prevent the endcap from being inserted into the sleeve opening beyond a selected depth. The endcap can be fabricated from any material that is moldable or otherwise shapeable to form the described locking bumps and other endcap components, and that is rigid enough to achieve a desired locking action. Thus, suitable endcap materials may include, depending upon the particular application: injection-molded plastics, thermoformed plastics, molded pulp, and the like.

The assembling together of a sleeve and an endcap can be equivalently described as inserting an endcap into a sleeve or, alternatively, installing a sleeve onto an endcap. For the purposes of the present discussion, the assembly of the package is described in terms of inserting an endcap into a sleeve.

As used herein, the terms “inward” and “inward direction” refer to the direction in which an endcap travels when it is loaded into a respective sleeve end, and the terms “outward” and “outward direction” refer to the opposite direction, i.e., the direction in which an endcap travels with it is removed from a sleeve end.

As used herein, the term “longitudinal” is used to describe a path or direction that is substantially in alignment with the path along which an endcap travels within a sleeve. As discussed below, the path is not necessarily a straight line. The term “radial” is used to describe a direction extending radially outward from the center of a package, sleeve, or endcap, that is substantially perpendicular to the path along which the endcap travels within the sleeve. The terms “transverse” and “lateral” are used to refer to a direction along a package, sleeve, or endcap, that is substantially perpendicular to the path along which the endcap travels within the sleeve.

It is further noted that in the following description, the designations “upper,” “lower,” “front,” “rear,” “left,” and “right” are arbitrary. Thus, for example, unless otherwise specified, any description with respect to an “upper endcap” or “upper sleeve end” also applies to any other endcap or sleeve end, regardless of its particular orientation in a given context.

As used herein, the adverb “substantially” is used inclusively. Thus, for example, depending upon the particular context in which it is used, the term “substantially rigid” can refer to a component that is completely rigid, as well as to a component that is not completely rigid, but that is sufficiently rigid to achieve a given result.

The term “or” is also used inclusively. Thus, unless immediately followed by a phrase such as “but not both,” the phrase “A or B”m includes: “A” by itself “B” by itself; and both “A” and “B.”

In addition, unless explicitly stated otherwise, the recitation of a single element in the description of an exemplary practice of an invention shall not be read to exclude additional such elements. Thus, for example, unless explicitly stated otherwise, the term “a tab” is equivalent to “one or more tabs,” “at least one tab,” and other like terms.

There are now described a number of exemplary practices of the invention.

Exemplary Practices of the Invention

FIG. 1 shows an exploded perspective view of an exemplary sleeve-and-endcap package 10 according to an aspect of the invention, comprising a sleeve 20, an upper endcap 30, and a lower endcap 40 that are assembled together to form an enclosure around a retail item or other object loaded therein.

FIGS. 2A-2D show, respectively, left, front, right, and rear views of package 10 after it has been fully assembled. In actual use, a retail item would typically be loaded into package 10 prior to final assembly. For the purposes of the clearly illustrating the package components, all of the exemplary packages described herein are depicted as empty.

Sleeve 20 has a pointed oval cross-sectional profile, and comprises a convexly curved front panel 21 and a convexly curved rear panel 22 that meet at vertices 23 and 24 to form a hollow tube. The upper end of sleeve 20 includes a pointed oval opening 25 having a rim 251 defined by the upper edges of panels 21 and 22. The lower end of sleeve 20 includes a pointed oval opening 26 having a rim 261 defined by the lower edges of panels 21 and 22.

As described below, sleeve 20 may suitably be fabricated from a sheet of suitable material that is die-cut and scored to form a blank containing the sleeve components. A flap 211 extends from front panel 21, and is creased and adhered to rear panel 22 to close the sleeve 20 at vertex 24. Other techniques may be used. For example, sleeve 20 may be implemented using a “rolled” tube.

Upper endcap 30 comprises a body having an outer circumferential surface 31 that is shaped to fit closely within the pointed oval opening 25 at the top of sleeve 20. Similarly, lower endcap 40 comprises an outer circumferential surface 41 that is shaped to fit closely in the pointed oval opening 26 at the bottom of sleeve 20. As illustrated with respect to upper endcap 30 in FIGS. 3A-3C and 4A-4C, discussed below, the inner end of the outer circumferential surface of one or both endcaps may include a rounded-off or beveled portion 37 to facilitate insertion of the endcap into a respective sleeve opening.

Each of endcaps 30 and 40 is slidable along a respective longitudinal path 32, 42 within the upper and lower sleeve openings 25 and 26, until it reaches a final, assembled position. In package 10, the final assembled positions for endcaps 30 and 40 are defined by endcap flanges 33 and 43, which butt up, respectively, against upper and lower rims 251 and 261, thereby preventing endcap 30 and 40 from advancing further into the sleeve 20.

It is noted that in certain situations flanges 33 and 43 may not be necessary. For example, if a rigid product is “trapped” between endcaps 30 and 40, the product itself could prevent the endcaps 30 and 40 from slipping further into sleeve 20.

It is noted that a package according to the present invention can be made in any of a virtually limitless number of cross-sectional shapes, as desired. These include traditional shapes, such as pillow packs, rectangles, triangles, squares, and the like. Other profile shapes may be used, including, for example, polygonal shapes, as well as circular shapes, elliptical shapes, and shapes including a combination of flat and curved sides, both symmetrical and asymmetrical. It is noted that the number of sleeve panels varies with the cross-sectional profile. For example, in the case of a package having a circular or elliptical profile, the sleeve may have only one single panel that extends all the way around the sleeve circumference.

It is also noted that in package 10, the upper and lower endcaps 30 and 40 and their respective openings are identical with each other. However, it would also be possible to practice the invention with non-identical endcaps, or with only a single endcap. Further, in package 10, endcaps 30 and 40 are inserted into sleeve 20 along substantially straight paths 32 and 42. However, it would also be possible to practice the invention using a sleeve and endcap arrangement in which one or both endcaps travels along a path having a different geometry, such as a curved path, a helical path, or a segmented path.

Sleeve 20 further includes a set of upper locking tabs 271, 272 and lower locking tabs 273, 274. In the present example, the locking tabs are implemented as extensions of panels 21 and 22 that are folded inward (i.e., into the interior of sleeve 20) at the upper and lower sleeve rims 251, 261 at respective crease lines 281-284. Each locking tab 271-274 provides a respective contact edge 291-294, at least a portion of which has a transverse orientation relative, respectively, to longitudinal paths 32 and 42.

As used herein, the term “transverse orientation” is used to describe an orientation of the contact edge that allows it to block movement along a respective longitudinal path. A transverse orientation with respect to the longitudinal pathway is typically, but not necessarily, perpendicular or close to perpendicular to a respective longitudinal path.

In the present example, sleeve 20 is provided with four locking tabs 271-274. Front upper and lower locking tabs 271 and 273 extend, respectively, from the center of upper and lower ends of sleeve front panel 21. Rear upper and lower locking tabs 272 and 274 extend, respectively, from the center of the upper and lower ends of sleeve rear panel 22. As discussed below, any or all of the locking tabs 271-274 can have other locations and can span and extend from more than one panel. Further, a plurality of tabs can extend from a single panel. It would also be possible to design a package wherein the locking tabs, rather than extending from panels 21 and 22 at rims 251 and 261, instead extend from respective locations on the inward surfaces of panels 21 and 22.

Each endcap 30, 40 has a substantially rigid body fabricated from plastic, or other suitable material. In the present example, the endcaps are fabricated using an injection molding technique. In the present example, endcaps 30 and 40 are substantially hollow. The hollow construction of the endcaps allows the endcaps to be light and minimizes the amount of material required.

Further, in package 10, endcaps 30 and 40 are provided with cavities 34, 44 for closely receiving an item (not shown) to be packaged. By suitably configuring cavities 34 and 44 and the size and shape of sleeve 20, it is possible to create a package in which the packaged product is securely seated in receiving cavities 34 and 44 in both the upper and lower endcaps 30 and 40, and in where there is a desired amount of separation between the packaged product and the sleeve panels 21 and 22. This arrangement provides a significant amount of protection to the packaged product. In addition, if the sleeve 20 is fabricated from a clear material, a significant portion of the packaged product can be displayed without having to open the package.

It is noted that endcap cavities 34, 44 may be omitted in certain situations. For example, “loose-fill” products (such as candies, golf balls, etc.) do not require endcap cavities. In that case, one or both endcaps 30, 40 can be provided with a flat interior surface, or other desired surface configuration.

Endcaps 30 and 40 are each provided with locking bumps 351-356, 451-456 corresponding in position to the sleeve locking tabs 271-274. (Front locking bumps 351-353, 451-453 are shown in FIGS. 1 and 2B. Rear locking bumps 354-356 and 454-456 are shown in FIG. 2D.) In package 20, there is a three-to-one relationship between locking bumps and locking tabs: each locking tab corresponds to three locking bumps.

From the present description, it will be apparent that aspects of the invention can be practiced using different configurations, including configurations having different groupings of aligned locking bumps and locking tabs. For example, a package may have a one-to-one relationship between locking bumps and locking tabs. Alternatively, a package may have a single locking bump that is aligned with a plurality of locking tabs.

The locking bumps 351-356, 451-456 extend outwardly from the each endcap's outer circumferential surface 31, 41. Each locking bump provides a contact surface 361-366, 461-466, at least a portion of which has a transverse orientation, relative to a respective longitudinal path 32, 42. The optimal height of the locking bumps relative to the endcap circumferential surface is determined by a number of factors, including the thickness and stiffness of the sleeve material, the closeness of the fit between the endcaps and the sleeve openings, and the preciseness of the molding of the locking bumps. If these parameters are carefully controlled, it is possible to achieve a strong locking action with a locking bump having a height on the order of ˜1 mm, or less.

As described below, the locking bumps 351-356, 451-456 and locking tabs 271-274 are positioned relative to each other and to the sleeve 20 and endcaps 30, 40 such that, when the endcaps 30, 40 reach their final, installed positions, outward movement of the endcaps 30, 40 is prevented by a structural interaction between the sleeve contact edges 291-294 and respective endcap bump contact surfaces 361-366 and 461-466.

FIGS. 3A-3C are a series of cross section diagrams (not drawn to scale), taken through the plane 3-3 (FIG. 2B) illustrating the insertion of the upper endcap 30 into the upper sleeve opening 25, and the subsequent interaction between the upper locking tabs 271 and 272 and the center upper endcap locking bumps 352 and 355. To facilitate a clearer view of the operation of locking tabs and locking bumps, the rightmost portions of FIGS. 3A-3C have been enlarged and presented as corresponding FIGS. 4A-4C.

In FIGS. 3A and 4A, the endcap 30 is positioned over the upper opening 25, with the pointed oval endcap outer circumferential, surface 31 aligned with the pointed oval upper sleeve rim 251, and with locking bumps 351-353 aligned with locking tab 271, and with locking bumps 354-356 aligned with the locking tubs 272. (In FIGS. 3A-3C and 4A-4C, only the central locking bumps 352 and 355 are depicted. However, it will be appreciated that the description of aspects of the invention with respect to locking bumps 352 and 355 also applies to locking bumps 351, 353, 354, and 356.)

As shown in FIGS. 3A and 4A, the locking tabs 271 and 272 have been folded into the interior of the sleeve 20, and point generally in an inward direction, i.e., towards the interior of sleeve 20, away from endcap 30. It is noted that the respective angles between the locking tabs 271 and 272 and panels 21 and 22 have been enlarged for the purposes of illustration. In actual practice, these angles will, typically be smaller. In some designs, the locking tabs 271 and 272 may be initially position such that they flat, or substantially flat, against the interior surfaces of panels 21 and 22.

As mentioned above, the sleeve 20 is fabricated from a stiff, resiliency deformable material. These material properties cause locking tabs 271 and 272 to be at least somewhat resiliently deflectable around the “hinge” provided by the respective creases 281, 282 at the base of tabs 271 and 272. Thus, if tabs 271 and 272 are deflected radially outward (i.e., in the direction of the interior surfaces of respective panels 21 and 22), they will tend to return to their starting position. The inward and outward deflection of tab 272 is indicated by double-headed arrow 295 in FIG. 4A. Depending upon the particular design, in a given package according to the present invention, the amount of deflection (i.e., the length of double-headed arrow 295) can be quite small, i.e., less than 1 mm.

It is noted that other factors may contribute to the resilient deformability of the locking tabs, including the resilient elasticity of the sleeve material or the resilient deformability of the sleeve profile. These other factors are discussed below, and illustrated in FIGS. 6 and 7.

The endcap 30 then travels in an inward direction along longitudinal path 32 into the sleeve opening. As shown in FIGS. 3B and 4B, the endcap, locking bumps, sleeve, and locking tabs are configured such that as the endcap 30 is inserted into the opening 25, bumps 352, 355 are urged against respective locking tabs 271, 272, causing them to be deflected out of the way, thereby allowing the endcap 30 to be freely moved along the longitudinal path 32.

FIGS. 3C and 4C show the endcap 30 after it has reached its final destination, wherein endcap flange 33 butts up against upper sleeve rim 251. The resilience of the locking tabs 271 and 272 cause them to fan open after they are clear of bumps 352 and 355. In essence, the locking tab contact edges 291 and 292 are “captured” at the respective corners formed respectively, by bump contact surfaces 362, 365 and circumferential surface 31.

FIG. 5 shows a perspective cutaway view of the upper right portion of package 10, Illustrating the locking action of sleeve tab 272 and endcap locking bump 355. It will be seen that upward (i.e., outward) movement of the endcap 30 relative to the sleeve 20 is prevented by engagement between the locking tab 272 and the locking bump 355. Downward (i.e., inward) movement of the endcap 30 relative to the sleeve 20 is prevented by engagement between the upper sleeve rim 251 and the flange 33.

If an attempt is made to pull the endcap 30 out of the sleeve 20 along the longitudinal path 32, the sleeve tab contact edge 292 will “grab” the bump contact surface 365, thereby halting outward movement. If a sleeve-and-endcap package according to the present invention is carefully designed and fabricated, it is possible to achieve a locking action that is strong enough to prevent premature or unauthorized opening of the package by most, if not all, typical retail customers.

It is noted that other structural aspects of the sleeve may contribute, to some degree, to the resilient deflectability of the sleeve tabs. For example, the sleeve material may have some amount of resilient elasticity, allowing it to be resiliently stretched outward a short distance. Alternatively, some resilient deflectability of the locking tabs may be provided by means of a resilient deformation of the sleeve's cross-section profile.

FIG. 6 is a cross section diagram of an exemplary sleeve 60, illustrating how resilient stretching of the sleeve material may contribute to the resilient deflectability of locking tabs 671 and 672. For the purposes of illustration, the amount of stretching has been greatly enlarged. Sleeve 60 comprises front and rear panels 61 and 62 meeting at vertices 63 and 64 to form a pointed oval shape, with locking tabs 671 and 672 folded inwardly at the respective centers of panels 61 and 62.

It will be appreciated that, if the sleeve and endcaps are carefully designed and manufactured, it is possible to achieve a tight fit between the endcap outer circumferential surface and the inner surface of the sleeve opening, while still permitting relatively free movement of the endcap along its longitudinal path.

As illustrated in FIG. 6, if the sleeve material has a sufficient degree of resilient elasticity, and if the endcap and locking bumps are sufficiently rigid and closely fitting with the sleeve opening, it may be possible for some resilient deflectability of the locking tabs to be provided by an outward stretching of the sleeve material in the direction of arrows 601 and 602, resulting in an outward deflection of the locking tabs in that direction by a small distance D1.

The upper portion of FIG. 6 shows a cross section diagram of sleeve 60, prior to stretching. The lower portion of FIG. 6 shows a cross diagram of sleeve 60, after the insertion of an endcap has caused the sleeve to stretch outward at arrows 601 and 602. The resilience of the sleeve material tends to cause the locking tabs 671 and 672 to return to their original position in the direction of arrows 603 and 604.

FIG. 7 is a cross section diagram of an exemplary sleeve 70, illustrating how resilient deformation of the sleeve profile may contribute to the resilient deflectability of locking tabs 771 and 772. For the purposes of illustration, the amount of deformation has been greatly enlarged. Sleeve 70 comprises front and rear panels 71 and 72 meeting at vertices 73 and 74 to form a pointed oval shape, with locking tabs 771 and 772 folded inwardly at the respective centers of panels 71 and 72.

As illustrated in FIG. 7, depending upon the rigidity, shape, and fit of the endcap within the sleeve opening, insertion of the endcap into the sleeve opening may result in a deformation of the sleeve profile, wherein the sides of the sleeve profile are deformed outwards in the direction of arrows 701 and 702, and the top and bottom of the sleeve profile are deformed inwardly in the direction of arrows 703 and 704. The result is an outward deflection of the locking tabs 771 and 772 by a small distance D2 in the direction of arrows 701 and 702.

The upper portion of FIG. 7 shows exemplary sleeve 70 prior to deformation. The lower portion of FIG. 7 shows exemplary sleeve 70 after deformation. The resilience of the profile shape will tend to cause the locking tabs to return to their original position.

Returning to FIG. 5, it will be seen that the locking action between the locking tab 272 and the locking bumps 354-356 can be disabled in a number of different ways, both destructive and non-destructive. For example, the lock will be released if the locking tab 272 can be deflected towards the sleeve panel 22 allowing it to clear the locking bumps 354-356. It would be possible, for example, to design a “key” or other tool that could fit between the sleeve panel 22 and the endcap 30 to allow the locking tab 272 to be deflected without damaging the package 10.

In addition, a destructive technique can be used to permanently disable the locking feature, i.e., through the removal of the locking tab 272 or locking bumps 354-356. Such a feature could be implemented, for example, by providing a tear-away or breakaway portion of the sleeve tab or endcap bumps.

FIGS. 8A-8C are a series of diagrams illustrating the construction of a tabbed sleeve 80 of the same type as sleeve 20 shown in FIG. 1. According to an aspect of the invention, sleeve 80 is fabricated from one or more sheets of plastic, paperboard, or cardboard, or a combination thereof, that is trimmed and scored to form a flat blank containing the sleeve components.

FIG. 8A shows a front view of sleeve 80, that can be used to fabricate the sleeve 20 shown in FIG. 1. Blank 80 is cut from a sheet of suitable material, which is scored to form the following components: front panel 81; real panel 82; assembly flap 811; and locking tabs 871-874. These components are defined by the outer perimeter of the blank 80 and the following score lines: center score line 83; attachment flap score line 84; and locking tab scores lines 881-884.

Blank 80 is formed into a tube by folding it in half at center score line 83, and then affixing assembly flap 811 to a corresponding surface portion 821 of rear panel 82. Flap 811 can be attached to rear panel 82 by using a suitable technique, including gluing, welding, or the like.

FIG. 8B is a rear view of the assembled sleeve 80. FIG. 8C is a rear view of the assembled sleeve 80 with locking tabs 871-874 folded inwards along respective scores lines 881-884.

In typical practice, a packaging provider will ship the assembled sleeves to a manufacturer as flattened tubes. Depending upon the manufacturer's requirements, the flattened tubes can be shipped with the locking tabs not folded in, or folded in. If the sleeves are to be shipped with the locking tabs folded in, the locking tabs 871-874 can be folded in using a folding machine or by hand prior to the attachment of flap 811 to rear pane surface 821. Although unusual, it would also be possible for a packaging provider to ship raw blanks to the manufacturer.

FIG. 9 shows (a) bottom and (b) front views of the upper endcap 30 of package 10 (FIG. 1), and is provided in order to illustrate the geometrical configuration of locking bumps 351-356 relative to the other endcap components.

As noted above, in package 10, the upper and lower endcaps 30 and 40 are identical. Thus, the present discussion also applies to the corresponding elements of lower endcap 40. Also, for the purposes of the present discussion, the endcap cavity 34 has been omitted.

As shown in FIG. 9, the outer circumferential surface 31 of endcap 30 comprises a front surface 311 and a rear surface 312 that meet at left and right vertices 313 and 314. Front locking bumps 351-353 are closely grouped at the center of the front surface 311. The front locking bump contact surfaces 361-363 lie generally in the same horizontal plane.

In endcap 30, the front locking bumps 351-353 and the rear locking bumps 354-356 are symmetrically positioned. The rear view of endcap 30 is identical to the front view shown in FIG. 9(b). Rear locking bumps 354-356 are closely grouped at the center of the rear surface 312. The rear locking bump contact surfaces lie generally in the same horizontal plane containing the front locking bump contact surfaces 361-363.

FIGS. 9-1 through 9-5 are a series of drawings illustrating Variations A-E of the design of endcap 30, in which modifications have been made with respect to the number and/or positioning of the locking bumps 351-356. In all other respects, the endcaps depicted in FIGS. 9-1 through 9-5 are identical to endcap 30 in FIG. 9.

It will be appreciated that a modification in the number and/or positioning of the locking bumps 351-356 will typically require a corresponding modification of the number and/or positioning of the respective sleeve locking tabs.

It will further be appreciated that the front locking bumps need not be symmetrical with the rear locking bumps. Thus, for example, an endcap may be configured to have a front set of locking bumps according to one of the described variations, and the rear set of locking bumps according to another described variation.

Each of FIGS. 9-1 through 9-5 is now discussed in turn.

FIG. 9-1 (Var. A): In Variation A, front locking bumps 351A-353A and rear locking bumps 354A-356A have been spaced apart, respectively, on the endcap front and rear surfaces 311 and 312. By positioning the “corner” locking bumps 351A, 353A, 354A, and 356A proximate to the endcap side vertices 313, 314, it is possible to achieve a firmer locking action towards the side vertices of the assembled package, if desired.

FIG. 9-2 (Var. B): In Variation B, the two locking bumps 351B, 356B at the left side of the endcap have been merged into a single V-shaped locking bump at the left endcap vertex 313, and the two locking bumps 353B, 354B at the right side of the endcap have been merged into a single V-shaped locking bump at the right endcap vertex 314.

Variation B provides an even firmer locking action at the side vertices of an assembled package. In a sleeve modified in accordance with Variation B, the sleeve locking tabs corresponding to locking bumps 351B/356B and 353B/354B may also be merged into respective single tabs at the sleeve vertices.

In FIGS. 9-3 through 9-5 (Vars. C, D, and E), the number of locking bumps has been reduced.

FIG. 9-3 (Var. C): In Variation C, the endcap has been provided with a single front locking bump 351C and a single rear locking bump 352C.

FIG. 9-4 (Var. D): In Variation D, the endcap has been provided with two closely spaced front locking bumps 351D, 352D and two closely spaced rear locking bumps 353D, 354D.

FIG. 9-5 (Var. E): In Variation E, the endcap have been provided with two widely spaced front locking humps 351E, 352E and two widely spaced rear locking bumps 353E, 354E.

FIGS. 10A-10C are a series of diagrams illustrating exemplary sleeve-and-endcap packages 10a-c according to further aspects of the invention, characterized by differently shaped cross-sectional profiles, and locking bump/tab configurations. Each of FIGS. 10A-10C shows the upper portion of a package 100a-c, comprising a sleeve 101a-c and endcap 102a-c. The sleeves are provided with inwardly folded locking tabs 103a-c, corresponding in position with endcap locking bumps 104a-c.

As shown in FIGS. 10A-10C, packages 100a-100c display the following distinguishing characteristics:

FIG. 10A: Package 100a has a square profile, with locking tabs 103a and locking bumps 104a located at the corners of the square. Each tab 103a straddles a pair of abutting panels, and has a central crease.

FIG. 10B: Package 100b has an elliptical (or oval) profile, with three closely-spaced locking bumps 104b centrally located at the front, and three correspondingly spaced locking bumps 104b centrally located at the back. Each of the front and rear groups of locking bumps corresponds to a single corresponding locking tab 103b. In this case, the sleeve has only a single continuous panel. In package 100b, it will be seen that, because there are no vertices, it may be possible to twist the endcap within the sleeve opening, thereby disengaging the endcap locking tabs and endcap locking bumps. Such a release feature may be desirable. If not, as discussed below, the sleeve locking tabs can be provided with cutouts that fit around the locking bumps to prevent the endcap from being twisted within the sleeve opening.

FIG. 10C: Package 100c has a hybrid shape, convexly curved front and rear panels, and two straight, relatively short side panels. The sleeve 101c includes two locking tabs 103c that extend across the width of each of the side panels. The endcap Includes two pairs of centrally located locking bumps 104c at the straight sides of the package, each of the pairs of locking bumps 104c corresponding in position to a respective locking tab 103c.

FIGS. 11A-11E are a series of diagrams illustrating exemplary alternative shapes for the locking bumps. These include: square 110a, with locking bump surface 111a; rectangular 110b, with locking bump surface 111b; circular 110c, with locking bump surface 111c; elliptical 110d, with locking bump surface 111d; and triangular 110e, with locking bump surface 111e. The depicted locking bumps 110a-10e may be combined with matching locking tab cutouts, such as those depicted in FIGS. 12A-12C, and discussed below. Alternative, the depicted locking bumps 110a-110e may be used with the “straight” locking tab edges used, for example, in the FIG. 1 package 10.

It is noted that these shapes are presented as examples. It will be appreciated that the range of possible shapes for the locking tabs is virtually limitless. Any shape can be used, so long as it presents a surface that is capable of engaging a locking tab contact edge.

FIGS. 12A-12C are a series of diagrams illustrating a further of aspect of the invention, in which the locking tabs are provided with one or more cutouts that are shaped to surround, or partially surround, corresponding endcap locking bumps.

FIG. 12A shows a diagram of the upper portion of an exemplary package 120A, comprising an interlocking endcap 121A and sleeve 122A. Endcap 121A is provided with a plurality of square locking humps 123A, and sleeve 122A is provided with a corresponding locking tab 124A.

Sleeve locking tab 124A includes three cutout sections 125A, corresponding in position to locking bumps 123A. It will be seen that, each of the three cutout sections 125A presents three sides of a square that, when endcap 121A is fully seated in sleeve 122A, surround a corresponding three sides of a respective square locking bump 123A. It will further be seen that each of the three sides of each sleeve cutout 125A provides three contact edges that butt up against three respective contact surfaces on a respective endcap locking bump 123A.

The use of locking tabs with cutouts matching the shape of corresponding locking bumps can serve a number of different purposes. For example, locking tabs can provide a firmer locking action along the longitudinal pathway, since each locking tab is provided with a respective set of locking tab contact edges instead of sharing a single contact edge.

In addition, because contact edges are provided in both longitudinal and lateral orientations, locking action is provided both to prevent the endcap from being pulled straight out of the sleeve, and further to prevent the endcap from being twisted in a lateral direction (indicated by double-headed arrow 126A in FIG. 12A). Lateral locking may be desirable, for example, in a package in which the shape of a package's cross-sectional profile and the locations of the locking tabs and locking bumps are such that twisting of the endcap within the endcap sleeve opening would cause the locking bumps and locking tabs to be pulled out of alignment with each other, thereby disabling the locking feature.

It is noted that lateral locking will typically not be necessary if a package profile does not allow easy twisting of the endcap within the sleeve opening. For example, in exemplary package 10 shown in FIG. 1, the pointed oval shape of the profile, with its two sharp vertices 23 and 24, makes twisting of the endcaps 30, 40 within their respective sleeve openings 25, 26 at least somewhat more difficult.

FIGS. 12B and 12C show exemplary sleeve-and-endcap packages 120B, 120C according to a further aspect of the invention, in which the endcap locking bumps are surrounded on all skies by corresponding sleeve tab cutouts.

Package 120B comprises an endcap 121B that fits into a corresponding sleeve 122B. Endcap 121B is provided with one or more locking bumps 123B, and sleeve 122B is provided with one or more corresponding locking tabs 124B. Each locking tab 124B is provided with a respective cutout hole 125B that is shaped to completely surround a respective endcap locking bump 123B, when the endcap 121B is fully installed in sleeve 122B.

Package 120C comprises a set of functional elements corresponding to those of package 120B, i.e.: endcap 121C, sleeve 122C, locking bump 123C, sleeve locking tab 124C, and sleeve locking tab cutout 125C.

It will be seen that in packages 120B and 120C, the locking tab cutouts 125B and 125C define contact edges on all sides of locking bumps 123B and 123C. Thus, the use of cutouts 125B and 125C may provide greater security, compared with the “three-sided” cutout 125A illustrated in FIG. 12A. In addition, the use of one or more locking tabs with “all-sided” cutouts may decrease the overall number of locking tabs or locking bumps required to achieve a desired locking action.

In package 120B, shown in FIG. 12B, the locking bump 123B and the locking tab cutout 125B both have circular shapes. In package 120C, shown in FIG. 12C, the locking bump 123C and the locking tab cutout 125C both have extended elliptical shapes. Other shapes may be employed, as desired. For example, it may be desired for the locking bump to have a particular esthetic shape, or to have the shape of a corporate logo.

A desired sleeve tab cutout shape may be readily implemented by modifying the die used to cut the sleeve blank. Also, it should be noted that cutouts can be used in a number of different ways. For example, one cutout can be shaped to fit around a plurality of bumps. In addition, cutouts may be provided for fewer than all of the endcap bumps.

Conclusion

While the foregoing description includes details which will enable those skilled in the art to practice the invention, it should be recognized that the description is illustrative in nature and that many modifications and variations thereof will be apparent to those skilled in the art having the benefit of these teachings. It is accordingly intended that the invention herein be defined solely by the claims appended hereto and that the claims be interpreted as broadly as permitted by the prior art.

LOCKING ARRANGEMENT FOR SLEEVE-AND-ENDCAP PACKAGE

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