Medical packaging systems, method of loading a medical packaging system and method of opening a medical packaging system

Abstract

Medical packaging systems and methods are for one or more injectors containing a medicament. The medical packaging system may include a box having a first panel, a second panel substantially parallel to the first panel, and a third panel substantially perpendicular to the first and second panels, and an interior formed by at least the first, second, and third panels. The at least one injector may dispose within the interior of the box, where at least a portion of the first panel is integrally formed with at least one fixed portion of the box and releasably attached to at least one fixed portion of the box to allow the first panel to be opened to allow access to the interior of the box. The third panel may be configured to allow access to the interior of the box for insertion of the at least one injector in a first position.

Description

MEDICAL PACKAGING SYSTEMS, METHOD OF LOADING A MEDICAL PACKAGING SYSTEM AND METHOD OF OPENINGA MEDICAL PACKAGING SYSTEMPriority

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 640,269 filed on April 30, 2024, the entire disclosure of which is expressly incorporated herein by reference.Technical Field

[0002] This disclosure relates generally to methods and systems for packaging at least one injector, and more particularly direct to methods and systems for packaging a plurality of injectors and an informational sheet to provide an improved layout to an end user.Background

[0003] Injectors (e.g., injector pens and / or autoinjectors) are often supplied to a user for administration of medication. Some injectors are designed to facilitate administration of the medication at home, thus increasing patient adherence.Summary

[0004] Improvements in the packaging of the injectors are needed. For example, the packaging should be easy to load for insertion of the injectors and easy to be opened by a user for access to the injectors. Furthermore, although the injectors are designed to be easy to use, the user should be aware of an informational sheet (e.g., instructions for use, IFU) prior to accessing the injectors. The informational sheet should be prominently displayed when opening the packaging to avoid the user from disregarding important information on the injector and / or medication prior to administration.

[0005] The foregoing needs are met by the various embodiments as disclosed herein.

[0006] A first aspect of the present disclosure is directed to a medical packaging system including: at least one injector containing a medication; and a box including a first panel, a second panel substantially parallel to the first panel, and a third panel substantially perpendicular to the first and second panels, and an interior formed by at least the first, second, and third panels, wherein the at least one injector is disposed within the interior of the box, wherein at least a portion of the first panel is integrally formed with at least one fixed portion of the box and releasably attached to the at least one fixed portion of the box to allow the first panel to be opened to allow access to the interior of the box, and wherein the thirdpanel is configured to allow access to the interior of the box for insertion of the at least one injector in a first position, and configured to be fixed to a portion of the box in a second position to prevent reopening of the third panel.

[0007] In some embodiments, the medical packaging system of the first aspect may include one or more of the following features. The medical packaging system includes an informational sheet, wherein the box includes at least one partition and a sheet compartment in the interior of the box formed between the first panel and the at least one partition, the informational sheet being received in the sheet compartment, and wherein the box includes at least one injector compartment in the interior of the box formed between the at least one partition and the second panel, the at least one injector being received in the at least one injector compartment. The box includes at least one divider, the at least one injector compartment includes a plurality of injector compartments separated by the at least one divider, and the at least one injector includes a plurality of injectors, each of the injector compartments receiving one of the plurality of injectors. The at least one divider is releasably attached to the at least one partition. The at least one divider includes a plurality of dividers, and the at least one partition includes a partition, wherein the plurality of dividers are releasably attached to the partition. The at least one partition is configured to prevent access to the at least one injector compartment until the at least one partition is opened. The at least one partition is releasably attached to at least one second fixed portion of the box to allow the at least one partition to be opened to allow access to the at least one injector compartment. The at least one partition extends parallel to the first panel and the second panel when the box is assembled. The at least one fixed portion is on the first panel. The at least the portion of the first panel is configured to pivot to open. The at least one injector includes at least one autoinjector. The at least one injector includes a plurality of injectors.

[0008] A second aspect of the present disclosure is directed to a medical packaging system including: at least one injector; an informational sheet; and a box including a first panel, a second panel, and at least one partition, wherein the box includes a sheet compartment formed between the first panel and the at least one partition, the informational sheet being received in the sheet compartment, and wherein the box includes at least one injector compartment formed between the at least one partition and the second panel, the at least one injector being received in the at least one injector compartment.

[0009] In some embodiments, the medical packaging system of the second aspect may include one or more of the following features. The box includes at least one divider, the at least one injector compartment includes a plurality of injector compartments separated by the at least one divider, and the at least one injector includes a plurality of injectors, each of the injector compartments being configured to receive one of the plurality of injectors. The at least one divider is releasably attached to the at least one partition. The at least one divider includes a plurality of dividers, the at least one partition includes a partition, and the plurality of dividers are releasably attached to the partition. The at least one partition is configured to prevent access to the at least one injector compartment until the at least one partition is opened. At least a portion of the first panel is releasably attached to at least one fixed portion of the box to allow the first panel to be opened to allow access to the sheet compartment. The at least one fixed portion is on the first panel. The at least one portion of the first panel is configured to pivot to open. The at least one partition is releasably attached to at least one second fixed portion of the box to allow the at least one partition to be opened to allow access to the at least one injector compartment. The at least one partition extends parallel to the first panel and the second panel when the box is assembled. The box includes at least one third panel configured to allow access to the sheet compartment for insertion of the informational sheet and the at least one injector compartment for insertion of the at least one injector. The at least one third panel is substantially perpendicular of the first panel and the second panel. The at least one third panel is configured to be fixed to the second panel to prevent reopening of the at least one third panel. The at least one injector includes at least one autoinjector. The at least one injector includes a plurality of injectors.

[0010] A third aspect of the present disclosure is directed to a method of opening a medical packaging system, the method including: opening at least a portion of a first panel to access a sheet compartment containing an informational sheet; and opening at least a portion of a partition to access at least one injector compartment containing at least one injector and formed between the partition and a second panel.

[0011] In some embodiments, the method may include one or more of the following features. Opening at least the portion of the first panel includes detaching a frangible portion of the first panel. The method includes removing the informational sheet prior to opening at least the portion of the partition. Opening at least the portion of the partition includes detaching a frangible portion of the partition. The at least one injector compartment includes a pluralityof injector compartments separated by at least one divider. Opening at least the portion of the partition includes detaching a frangible portion between the partition and the at least one divider.Brief Description of the Drawings

[0012] The present application is further understood when read in conjunction with the appended drawings. For the purpose of illustrating the subject matter, there are shown in the drawings exemplary embodiments of the subject matter; however, the presently disclosed subject matter is not limited to the specific methods, devices, and systems disclosed. In the drawings:

[0013] FIG. 1 illustrates a first embodiment of a medical packaging system in a closed configuration according to the present disclosure.

[0014] FIG. 2 illustrates the medical packaging system of FIG. 1 in a first open configuration.

[0015] FIG. 3 illustrates the medical packaging system of FIGS. 1-2 in a second open configuration.

[0016] FIG. 4 illustrates a box of the medical packaging system of FIGS. 1-3 in a preassembled configuration.

[0017] FIG. 5 illustrates the box of the medical packaging system of FIGS. 1-4 in a flattened configuration.

[0018] FIG. 6 illustrates the box of the medical packaging system of FIGS. 1-5 in an expanded configuration.

[0019] FIG. 7 illustrates a flow chart for a method of assembling the box of the medical packaging system of FIGS. 1-6.

[0020] FIG. 8 illustrates a flow chart for a method of loading the medical packaging system ofFIGS. 1-7.

[0021] FIG. 9 illustrates a flow chart for a method of opening the medical packaging system ofFIGS. 1-8.

[0022] FIGS. 10 and 11 illustrate a second embodiment of the medical packaging system.

[0023] FIG. 12 illustrates a box of a third embodiment of the medical packaging system in a pre-assembled configuration.

[0024] Aspects of the disclosure will now be described in detail with reference to the drawings, wherein like reference numbers refer to like elements throughout, unless specified otherwise.Detailed Description of Illustrative Embodiments

[0025] The present disclosure is directed to a medical packaging system for at least one injector, and in some embodiments a plurality of injectors. The medical packaging system may include a packaging or box formed by a plurality of panels. The packaging may be accessed from a first direction (e.g., laterally) for loading the injectors and a second direction (e.g., from above) for the user to open and access the injectors, where the first direction and the second direction are substantially perpendicular. The packaging may have an interior with at least one compartment for containing the at least one injector. In some embodiments, the packaging may include a plurality of compartments individually containing a plurality of injectors. The packaging may further contain a sheet including information on the injector and / or medication, such as instructions for use (IFU). The interior of the packaging may include a separate compartment that receives the informational sheet for display upon opening the box prior to accessing the injectors. At least one partition may separate the sheet compartment from the at least one injector compartment. For example, the informational sheet may be accessed by lifting a first top panel by detaching one or more frangible portions to reveal the sheet compartment containing the sheet, while the at least one partition keeps the injectors at least partially hidden. The at least one partition may then be lifted to reveal the at least one injector. A plurality of injector compartments may be separated in respective injector compartments by at least one divider frangible connected to the at least one partition.

[0026] Figs. 1-6 illustrate a first embodiment of a packaging system 10 for at least one container 200. In some embodiments, the packaging system may be a medical packaging system 10, and the at least one container 200 may be at least one injector 200. The packaging system 10 may include a box 100 having a plurality of panels enclosing an interior. The panels may include a first panel 102, a second panel 104, a third panel 106, a fourth panel 107, a fifth panel 108, and a sixth panel 110.

[0027] As illustrated in Figs. 1-3, the first panel 102 may be a top panel when the box 100 is assembled and resting on a surface (e.g., a tabletop), such that the top panel 102 may be lifted by the user to provide access to contents of the box 100. The second panel 104 may be a bottom panel when the box 100 is resting on the surface, such that the bottom panel 104 maycontact the surface to support the box 100. As illustrated in Figs. 5 and 6, the third panel 106 and / or fourth panel 107 may be side panels that may be initially in an open position prior to loading the box 100 to provide access to a loader through at least one opening 130. The at least one opening 130 may be in communication with the interior of the box 100, and the at least one opening 130 may be in a plane substantially perpendicular to the top panel 102 and / or the bottom panel 104. The side panels 106, 107 may each be pivotably attached to the top panel 102 to close the at least one opening 130. However, it is also contemplated that the side panels 106, 107 may, additionally or alternatively, be pivotably attached to one or more of the bottom panel 104, the fifth panel 108, and / or the sixth panel 110. The fifth panel 108 may be a front flap facing the end user when resting on the surface. The sixth panel 110 may be a rear panel that may provide a pivoting connection to at least a portion of the top panel 102 when the box 100 is opened, as illustrated in FIGS. 2 and 3. When the box 100 is assembled, the top panel 102 and the bottom panel 104 may be substantially parallel along a first plane, the side panels 106, 107 may be substantially parallel along a second plane, and the front flap 108 and the rear panel 110 may be substantially parallel along a third plane. The first plane, the second plane, and the third plane may be substantially perpendicular in a cartesian coordinate system.

[0028] As further illustrated in FIG. 1, the box 100 may have a cuboidal shape in a packaged configuration formed by a length (L), a width (W), and a depth (D). The top panel 102 and the bottom panel 104 may have a first surface area defined by the length (L) and the width (W). The third panel 106 and the fourth panel 107 may have a second surface area defined by the width (W) and the depth (D). The front flap 108 and the rear panel 110 may have a third surface area defined by the length (L) and the depth (D). The length (L) may be greater than the width (W), and the width (W) may be greater than the depth (D). Thus, the first surface area may be greater than the third surface area, and the third surface area may be greater than the second surface area. The first surface area may provide a favorable layout to the user when the box 100 is placed on the surface, for example, displaying a plurality of the injectors 200 in a side-by-side arrangement. The depth (D) of the box 100 may reduce the profile of the box 100 to facilitate handling and delivery.

[0029] At least a portion of the top panel 102 may be releasably attached to a first fixed portion of the box 100 to allow the top panel 102 to be opened by a user for access to compartments in the interior of the box 100. For example, as illustrated in FIG. 1, one ormore first frangible portions 112 may be lines extending through the first panel 102 along or in the general direction of the width (W). In some embodiments, the one or more first frangible portions 112 may separate the first panel 102 into a moveable portion 102a and one or more fixed portions 102b. Accordingly, in some embodiments, at least a portion of the first panel 102 may be integrally formed with a first fixed portion of the box 100 and releasably attached to the first fixed portion of the box 100. At least a portion of the rear of the top panel 102 may be pivotably attached to the rear panel 110, such that at least a portion of the top panel 102 may be moved or lifted relative to the remainder of the box 100 in a pivoting configuration providing access to the compartments in the interior of the box 100. The pivotable attachment of the top panel 102 may reduce the number of parts of the box 100 and facilitate reclosure and / or disposal. As further illustrated in FIG. 1, the one or more first frangible portions 112 may additionally extend through the front flap 108 along or in the general direction of the depth (D) of the box 100 separating the front flap 108 into a moveable portion 108a and first and second fixed portions 108b. Thus, the box 100 may be opened by a user detaching the one or more first frangible portions 112 along the front panel 108 to lift the moveable portion 108a relative to the fixed portions 108b and / or detaching the one or more first frangible portions 112 along the top panel 102 to lift the moveable portion 102a relative to the fixed portions 102b to open the box. In some embodiments (not shown), the one or more first frangible portions 112 may, additionally or alternatively, at least partially extend through edges and / or corners of the box 100 connecting the respective panels allowing additional area of the top panel 102 and / or front flap 108 to be movable or liftable increasing exposure to the compartments of the box 100. The one or more first frangible portions 112 may be perforated, weakened, and / or scored to provide a predictable opening of the box 100. An aperture and / or handle 114 may be provided on the moveable portion 108a of the front flap 108 and / or the moveable portion 112a of the front flap 108 to facilitate opening. The handle 114 may include a frangible line 114a (e.g., a perforation) to allow for separation and / or opening of an aperture to accommodate fingers of a user for grasping and opening of the box 100.

[0030] As illustrated in a first open configuration of FIG. 2, the user may have access to a sheet compartment 136 containing an informational sheet 300 after opening the top panel 102 and / or front flap 108. The sheet compartment 136 may be in an upper portion of the box 100 when the box is resting on the surface. As further illustrated in FIG. 6, the sheetcompartment 136 may be defined vertically between the top panel 102 and a partition 116 and laterally between an upper portion of the front flap 108 and an upper portion of the rear panel 110. The sheet compartment 136 may have a depth of less than half of the depth (D) of the box 100. In some embodiments, the sheet compartment 136 have a depth of about one- third or less of the depth (D) of the box 100, due to the minimal depth needed for the informational sheet 300. In the first open configuration, the sheet compartment 136 may prominently display the informational sheet 300, while the partition 116 covers the injectors 200 and keeps the injectors 200 at least partially hidden. For example, the partition 116 may extend substantially the entire width (W) and / or length (L) of the box 100 preventing access to the injectors 200. The partition 116 may completely obstruct or allow obstructed visibility of one or more of the injectors 200, for example through one or more apertures of the partition 116. The partition 116 may, additionally or alternatively, not be layered under other panels that obstruct the injectors 200, such as the fixed portions 102b of the top panel 102. The informational sheet 300 may be made of paper, cardboard, and / or plastic. In some embodiments, the informational sheet 300 may be made of paper and be folded in half or into thirds before being inserted into the sheet compartment 136. The informational sheet 300 may include printed indicia and / or text providing information on the medication and / or injector 200, instructions for use (IFU) of the medication and / or injector 200, and / or any relevant cautions and warnings.

[0031] The partition 116 may extend laterally through the box 100, substantially parallel to the top panel 102 and the bottom panel 104. At least a portion of the partition 116 may be releasably attached to a first fixed portion of the box 100 to allow the partition 116 to be opened to allow access to the at least one injector 200. For example, as illustrated in FIG. 2, one or more second frangible portions 118 may be lines that extend through the partition 116 separating the partition 116 into a moveable portion 116a and one or more fixed portions 116b. In some embodiments (not shown), the one or more second frangible portions 118 may, additionally or alternatively, at least partially extend through edges and / or comers of the box 100 connecting the respective panels allowing additional area of the partition 116 to be movable or liftable increasing exposure to the compartments of the box 100. In some embodiments (not shown), the one or more second frangible portions 118 may be disposed only along the front edge of the moveable portion 116a, such as the edge between the partition 116 and the front flap 108. The one or more second frangible portions 118 may beperforated, weakened, and / or scored to provide a predictable opening of the partition 116. An aperture and / or handle 120 may be provided on the moveable portion 116a of the partition 116 to facilitate opening. Similar to the handle 114, the handle 120 may include a frangible line (not shown, e.g., a perforation) to allow for separation and / or opening of an aperture to accommodate fingers of a user for grasping. In some embodiments, the one or more frangible portions 112 may separate the partition 116 into a plurality of partitions 116 to allow for individual access to each of the injectors 200.

[0032] As illustrated in FIGS. 2-4, a front panel 122 may join the bottom panel 104 and the partition 116 and be fixed to the front flap 108 along a line when the box 100 is assembled, for example with adhesive, glue, tape, and / or welding. The front panel 122 may have a length shorter than a length of the rear panel 110 (along the depth, D), such that the partition 116 is vertically spaced from the top panel 102 when the box is assembled forming the sheet compartment 136, as illustrated in FIG. 6. A rear flap 124 may extend from an edge of the partition 116 and be fixed to the rear panel 110 along a line when the box 100 is assembled, for example with adhesive, glue, tape, and / or welding. Each of the front flap 108 and the rear panel 110 may have a pair of flaps 132 configured to be folded inside of the side panels 106, 107 when closed. Each of the side panels 106, 107 may have a flap 134 configured to be folded perpendicular to the respective side panel 106, 107 and be received vertically between the flaps 132 and the bottom panel 104 to secure the side panels 106, 107 in a closed configuration. The side panels 106, 107 (e.g., at the flaps 134) may be fixed to the box 100 (e.g., at the bottom panel 104 with adhesive, glue, tape, and / or welding) in the closed configuration to prevent reopening of the side panels 106, 107.

[0033] As illustrated in a second open configuration of FIG. 3, the user may have access to at least one compartment 126 containing at least one injector 200 after opening the partition 116. The injector compartments 126 may be in a lower portion of the box 100 when the box is resting on the surface. The partition 116 may form an upper surface of the plurality of compartments 126 containing the injectors 200. The at least one compartment 126 may include a plurality of compartments 126 individually containing a plurality of injectors 200. As further illustrated in FIG. 6, the injector compartments 126 may be defined vertically between the partition 116 and the bottom panel 104 and laterally in a side-by-side arrangement between a lower portion of the front flap 108 and a lower portion of the rear panel 110. The plurality of injector compartments 126 may be separated by an insert 140having at least one divider 142 formed as panel(s) extending between an upper portion 144 and a lower portion 146, as illustrated in FIG. 4. The upper portion 144 may be fixed to a bottom surface of the moveable portion 116a of the partition 116, and the bottom portion 146 may be fixed to an upper surface of bottom panel 104. The at least one divider 142 may be positioned vertically between the partition 116 and the bottom panel 104, substantially parallel to the front flap 108 and the rear panel 110. The upper portion 144 may be releasably attached to a top of the at least one divider 142 to allow separation and lifting of the moveable portion 116a of the partition 116 and access to the injector compartments 126, while the at least one divider 142 remains in place to separate the injectors 200, as illustrated in FIG. 3. For example, each of the at least one divider 142 may be attached to the upper portion 144 at a frangible portion (e.g., a weakened, perforated, and / or scored line) that is detached when the moveable portion 116a of the partition 116 is lifted to expose the injector compartments 126. The box 100 may include a plurality of the dividers 142 separating three or more of the injector compartments 126. For example, the box 100 may include three dividers 142 separating four injector compartments 126 each receiving an injector 200, as illustrated in FIG. 3.

[0034] The insert 140 may be formed from a single sheet or panel of material. One or more divider 142 and respective upper portion 144 may be separated from the lower portion 146 by a cut 148, as illustrated in FIG. 4. The at least one divider 142 may be formed at a first fold line 149 relative to the lower portion 146. The upper portion 144 may be formed by a second fold line 150 relative to the at least one divider 142. Thus, the upper portion 144 and the lower portion 146 may extend at an angle relative to the at least one divider 142 defined by the respective fold lines 149, 150. For example, the upper portion 144 and the lower portion 146 may extend substantially parallel to each other and substantially perpendicularly of the at least one divider 142 when the insert 140 is formed into the box 100 having a cuboidal shape. The upper portion 144 may support the frangible attachment of the at least one divider 142 to the movable portion 116a. If the upper portion 144 were to be omitted or made too small, the frangible attachment between the at least one divider 142 and the movable portion 116a may unintentionally split disrupting the integrity of the box 100. The at least one divider 142 may have a bottom (e..g., formed by the first fold line 149 with the lower portion 146) and the top (e.g., formed by the second fold line 150 with the upper portion 144) being substantially parallel. The at least one divider 142 may have at least one vertical side 152 formed by thecut 148 and extending at an acute angle between the upper portion 144 and the lower portion 146. For example, both vertical sides 152 may extend at the acuate angle to form the at least one divider 142 in a substantially parallelogram shape. In some embodiments (as illustrated in Fig. 4), the insert 140 may be formed from the same sheet of material as at least one of the panels of the box 100. For example, the insert 140 may be formed from a panel of the box 100 that is pivotably attached to the bottom panel 104, such that the insert 140 may be pivoted during insertion between the bottom panel 104 and the partition 116. In some embodiments (not shown), the insert 140 and / or one or more of the components of the insert 140 may be formed from a second sheet of material and attached when assembling the box 100.

[0035] The injector 200 may be any type of injector pen, autoinjector, syringe (with or without an integrated needle safety system), and / or manual injector configured to deliver a medication to a patient. In some embodiments, the injector 200 may be an autoinjector actuated by pushing a distal portion of the injector against skin of a patient at an injection site. The injector 200 may be held at the injection site until a volume of the medication has been expelled from a prefilled syringe disposed within the injector into the injection site. The prefilled syringe may include a syringe barrel having a chamber enclosing the medication. The syringe barrel may be in communication with a needle at a distal portion for puncturing the skin with the chamber sealed by a stopper at a proximal portion. The needle may be integrally attached to the syringe barrel or be placed in communication with the syringe barrel upon initiation of an injection. The injector 200 may have a drive mechanism that advances the stopper through the chamber of the syringe barrel to deliver the medication. An exemplary embodiment of the injector is described in U.S. Patent Nos. 11,541,177, the entire disclosure of which is expressly incorporated herein by reference.

[0036] The medication may be any biologically active or drug-containing flowable substance, such as a liquid, solution, or fine suspension. Representative drugs include pharmaceuticals such as peptides, proteins (e.g., insulin, insulin analogues, and C-peptide), and hormones, biologically derived or active agents, hormonal and gene-based agents, nutritional formulas and other substances in both solid (dispensed) or liquid form. The medication may include parathyroid hormone, a luteinising hormone, a follicle-stimulating hormone, an insulin, a GLP-1 agonist, a GIP agonist, a glucagon receptor agonist, an amylin analogue, and / or combinations thereof. For example, the medication may include one ormore of teriparatide, abaloparatide, liraglutide, semaglutide, tirzepatide, and cagrilintide. In some embodiments, the packaging system may be used for non-biologically active and / or non-medical applications, such as packaging at least one vial containing water.

[0037] FIG. 7 illustrates a method 1000 of assembling the box 100. The method 1000 may be performed at a manufacturing facility that at least partially produces the box 100. The manufacturing facility of the method 1100 may, additionally or alternatively, form the sheet(s) of material that constitutes the box 100. The method 1000 may be performed by an assembler at the manufacturing facility with access to the sheet of material. The assembler may be a human, a machine (e.g., a robot), or a combination thereof, such that the human may perform some of the steps and the robot may perform some of the steps. In some embodiments, the method 1000 may be performed along an assembly line, such that one or more of the steps may be performed at different assembly stations.

[0038] The box 100 may be initially received as the sheet(s) of material (e.g., cardboard). The sheet may be formed with a number of features, including panels and / or fold lines forming the panels that may be folded and secured to form the box 100. The sheet(s) may further include one or more frangible portions (e.g., perforations) and / or cuts, such as frangible portions 112, 118 and / or cuts 148. The method 1000 may include initially forming one or more of the panels, the fold lines, the frangible portions 112, 118 and / or the cuts 148. In some embodiments, one or more of the features may be pre-formed.

[0039] In step 1002, the assembler may place the insert 140 over an upper surface of the bottom panel 104 and fix the bottom portion 146 of the insert 140 to the upper surface of the bottom panel 104. In some embodiments (as illustrated in FIG. 4), the insert 140 may be formed from a panel of the sheet of material that is pivotably attached to the bottom panel 104 by a fold line, such that the insert 140 may be placed over the upper surface of the bottom panel 104 by pivoting the insert 140 relative to the bottom panel 104 at the fold line. In some embodiments (not shown), the insert 140 may be formed from a second sheet of material and placed over the upper surface of the bottom panel 104 without pivoting. The bottom portion 146 of the insert 140 may be fixed to the upper surface of the bottom panel 104, for example with an adhesive 141 on the bottom panel 104 and / or an adhesive 143 on the bottom portion 146 of the insert 140. Each of the adhesives 141, 143 may be on the underside of the respective component and not be visible in the view of Fig. 4.

[0040] In step 1004, the assembler may position the partition 116 over the insert 140 and fix the upper portion 144 of the insert 140 to a lower surface of the movable portion 116a of the partition 116. For example, the upper portion 144 may have an adhesive 145 to be fixed to the lower surface of the movable portion 116a. The partition 116 may be positioned by folding at fold lines connecting the front panel 122. When in place, the at least one divider 142 may extend vertically between the lower panel 104 and the partition 116 to at least partially form the at least one injector compartment 126 therebetween. The upper portion of the at least one divider 142 may be frangible attached to the upper portion 144 of the insert 140 allowing separation of the movable portion 116a from the at least one divider 142 when the partition 116 is opened to allow access to the at least one injector compartment 126, as illustrated in Fig. 3.

[0041] In step 1006, the assembler may fix the rear flap 124 to the rear panel 110, for example with an adhesive 123 on the rear panel 110. The adhesive 123 may be on the underside of the rear panel 110 and not be visible in the view of Fig. 4. The rear flap 124 may extend from the partition 116, and the rear panel 110 may extend between the bottom panel 104 and the top panel 102. The rear panel 110 may be pivoted relative to the bottom panel 104 to vertically orient the rear panel 110 along the rear flap 124. As illustrated in FIG. 6, the rear flap may be pivoted upward to extend toward the top panel 102 when assembled.

[0042] In step 1008, the assembler may position the top panel 102 over the partition 116 to at least partially form the sheet compartment 136. The top panel 102 may be positioned by pivoting at a fold line relative to the rear panel 110, and the top panel may be spaced vertically from the partition 116 due to the rear panel 110 having a vertical height (D) larger than the front panel 122.

[0043] In step 1010, the assembler may fix the front flap 108 to the front panel 122, for example with adhesive 109 on the fixed portions 108b of the front flap 108. The front flap 108 may extend from the top panel 102, and the front panel 122 may extend between the bottom panel 104 and the partition 116. The adhesive 109 may be on the underside of the front flap 108 and not be visible in the view of Fig. 4.

[0044] In step 1012, the assembler may press the box 100 into a flattened configuration to facilitate shipping and / or handling, as illustrated in Fig. 5. The box 100 may be pressed manually, mechanically, and / or robotically. The flattened configuration may be formed by folding the edge joining the front flap 108 and the bottom panel 104 and the edge joining thetop panel 102 and the rear panel 110, such that the top panel 102 and the front flap 108 are substantially aligned and the bottom panel 104 and the rear panel 110 are substantially aligned. The top panel 102 and the front flap 108 may closely overly and be substantially parallel to the bottom panel 104 and the rear panel 110 with the partition 116 therebetween. The at least one divider 142 may be folded down, positioned between and substantially parallel to the partition 116 and the bottom panel 104 (not shown). The side panels 106, 107 may further be substantially aligned with the top panel 102. Other flattened configurations are contemplated such as being formed by folding at the edge joining the top panel 102 and the front flap 108 and the edge joining the bottom panel 104 and the rear panel 110.

[0045] FIG. 8 illustrates a method 1100 of loading the medical packaging system 10. The method 1100 may be performed at the same or different manufacturing facility as the method 1000. The manufacturing facility of the method 1100 may, additionally or alternatively, produce the injectors 200 and / or medication and / or fill the injectors 200 with the medication. The method 1100 may be performed by a loader at the manufacturing facility with access to the pre-filled injectors 200. The loader of method 1100 may be the same or different as the assembler of the method 1000. The loader may be a human, a machine (e.g., a robot), or a combination thereof, such that the human may perform some of the steps and the robot may perform some of the steps. In some embodiments, the method 1100 may be performed along an assembly line, such that one or more of the steps may be performed at different assembly stations.

[0046] In step 1102, the loader may receive the box 100 in the first, flattened configuration, for example as illustrated in FIG. 5 and discussed with reference to step 1012.

[0047] In step 1104, the loader may expand the box 100 into a three-dimensional shape to expand at least one of the side openings 130. When expanding, the box 100 may increase in depth (D) and decrease in width (W), as illustrated in FIG. 6. The front flap 108 and the rear panel 110 may pivot into a substantially vertical configuration, and the top panel 102 may vertically separate from the bottom panel 104. The injector compartment 126 and the sheet compartment 136 may expand based on the movement of the panels 102-110. The partition 116 may extend substantially parallel to the top panel 102 and the bottom panel 104, and the at least one divider 142 may extend substantially parallel to the front flap 108 and the rear panel 110. The side openings 130 may also expand into a substantially parallelogram orrectangular configuration providing access to the injector compartment 126 and the sheet compartment 136.

[0048] In step 1106, the loader may insert at least one injector 200 through the at least one side opening 130 into at least one injector compartment 126. In some embodiments, the loader may insert a plurality of injectors 200 through the at least one side opening 130. The plurality of injectors 200 may be inserted into separate injector compartments 126 in the lower portion of the box 100, such that the injectors 200 are positioned in a side-by-side arrangement. The injector compartments 126 may be separated by the dividers 142 which retains the injectors 200 in a parallel orientation. The plurality of injectors 200 may be inserted through the same side opening 130 or different side openings 130.

[0049] In step 1108, the loader may insert the informational sheet 300 through the at least one side opening 130. The informational sheet 300 may be inserted into the sheet compartment 136 in the upper portion of the box 100. The informational sheet 300 may be inserted through the same side opening 130 or a different side opening 130 than one or more of the injectors 200. Steps 1106 and 1108 may be performed in any order.

[0050] In step 1110, the loader may close the at least one side opening 130 with the respective side panel 106, 107. The flaps 132 may be folded to at least partially cover the at least one side opening 130. The side panel 106, 107 may be folded over the flaps 132, and the flaps 134 of the side panel 106, 107 may be folded and inserted vertically between the flaps 132 and the bottom panel 104 to secure the side panel 106, 107 in a closed configuration. The side panels 106, 107 may retain the plurality of injectors 200 and the informational sheet 300 inside of the box 100. The loader may fix the side panels 106, 107 (for example at the flaps 134 to the bottom panel 104 with adhesive, glue, tape, and / or welding) to prevent reopening of the side panels 106, 107. In some embodiments, one of the side panels 106, 107 may be closed and / or fixed prior to at least one of steps 1106 and 1108 to partially close the box 100, and another of the side panels 106, 107 may be closed and fixed after steps 1106 and 1108 to fully close the box 100. The box 100 may be further covered with a protective material, such as a plastic and / or heat shrink wrap.

[0051] FIG. 9 illustrates a method 1200 of opening the packaging system 10 and removing the informational sheet 300 and / or the at least one injector 200. The method 1200 may be performed by a user or a healthcare provider for the user. The method 1200 may provide an intuitive unpackaging of the injectors 200 with a prominent display of the informational sheet300 providing information on the medication and / or injector 200 prior to providing access to the injectors 200.

[0052] In step 1202, the user may receive the medical packaging system 10. The packaging system 10 may include the box 100 with the at least one injector 200 and the informational sheet 300 packaged in the method 1100. The user may remove any protective packaging from the box 100.

[0053] In step 1204, the user may release at least a portion of the top panel 102 and / or the front flap 108 by detaching the one or more first frangible portions 112. In step 1206, the user may lift the at least the portion of the top panel 102 and / or the front flap 108 to expose the informational sheet 300 in the sheet compartment 136. In step 1208, the user may remove the informational sheet 300 from the sheet compartment 136 of the box 100.

[0054] In step 1210, the user may release at least a portion of the partition 116 by detaching the one or more second frangible portions 118. In step 1212, the user may lift the at least the portion of the partition 116 to expose at least one injector 200 in the injector compartments 126. In step 1214, the user may remove at least one injector 200 from the injector compartments 126 of the box 100. In some embodiments, user may remove a plurality of injectors 200 from the box 100. In some embodiments, the user may reclose the partition 116 and / or the box 100 after removing at least one injector 200 for storing other injectors 200 for later use.

[0055] Figs. 10 and 11 illustrate a second embodiment of a packaging system 10’ for at least one injector 200. The disclosure of the first embodiment of the packaging system 10 is expressly incorporated herein, except when otherwise indicated. The packaging system 10’ may include a box 400 having a plurality of panels. The panels may include a first panel 402, a second panel 404, a third panel 406, a fourth panel 407, a fifth panel 408 and a sixth panel 410. The first panel 402 may be a top panel and may be opened to provide access to the at least one injector 200 for a user. The second panel 404 may be a bottom panel. The third panel 406 and / or fourth panel 407 may be side panels that may be initially in an open position when the box 400 is pre-assembled to provide access to a loader through at least one opening in communication with the compartments (as illustrated in FIG. 5 and discussed with reference to the first embodiment of the packaging system 10). The third panel 406 may be pivotably attached to the top panel 402, and the fourth panel 407 may be pivotably attached to the bottom panel 404. However, it is also contemplated that the side panels 406, 407 may,additionally or alternatively, be pivotably attached to one or more of the fifth panel 408, and / or the sixth panel 410. The fifth panel 408 may be a front panel. The sixth panel 410 may be a rear panel. As illustrated in FIGS. 10 and 11, the box 400 may be opened by a user by pivoting at least portion of the front panel 408 and / or the third panel 406 relative to at least a portion of the bottom panel 404 at a pivot line.

[0056] Fig. 12 illustrates a third embodiment of a packaging system 10” for at least one injector 200. The disclosure of the first and second embodiments of the packaging system 10, 10’ is expressly incorporated herein, except when otherwise indicated. For example, similar to the first and / or second embodiments, the packaging system 10” may include a box 500 having a plurality of panels. The panels may include a first panel 502, a second panel 504, a third panel 506, a fourth panel 507, a fifth panel 508 and a sixth panel 510. The first panel 402 may be a top panel and may be opened to provide access to the at least one injector 200 for a user. The second panel 504 may be a bottom panel. The third panel 506 and / or fourth panel 507 may be side panels that may be initially in an open position when the box 500 is pre-assembled to provide access to a loader through at least one opening in communication with the compartments (as illustrated in FIG. 5 and discussed with reference to the first embodiment of the packaging system 10). The third panel 506 may be pivotably attached to the top panel 502, and the fourth panel 507 may be pivotably attached to the bottom panel 504. However, it is also contemplated that the side panels 506, 507 may, additionally or alternatively, be pivotably attached to one or more of the fifth panel 508, and / or the sixth panel 510. The fifth panel 508 may be a front panel. The sixth panel 510 may be a rear panel. As illustrated in FIGS. 10 and 11, the box 500 may be opened by a user by pivoting at least portion of the third panel 506 relative to at least a portion of the bottom panel 504 at a pivot line 509. The pivot line 509 may be along a width of the bottom panel such that a portion of the bottom panel 504 may pivot with the third panel 506.

[0057] With reference to the second and / or third embodiments, at least a portion of the top panel 402, 502 may be releasably attached to a first fixed portion of the box to allow the top panel 502, 502 to be opened by a user to allow access to the compartments of the box 400, 500. For example, as illustrated in FIG. 12, one or more frangible portions 512 may extend through the top panel 402, 502 along or in the general direction of the width (w) separating the top panel 502 into a moveable portion 402a, 502a and one or more fixed portions 402b, 502b. The one or more frangible portions 512 may be lines extending through the front panel408, 508 and the rear panel 510 along or in the general direction of the depth (D) of the box 400, 500 separating the front panel 408, 508 into a moveable portion 508a and a fixed portion 508b and the rear panel 510 into a moveable portion 510a and a fixed portion 510b. Thus, the box 400, 500 may be opened by detaching the one or more frangible portions 512 along the top panel 502, the front panel 508, and the rear panel 510 to lift the moveable portions 502a, 508a, 510a relative to the fixed portions 502b, 508b, 510b. The one or more frangible portions 512 may be perforated, weakened, and / or scored to provide a predictable opening of the box 100.

[0058] As illustrated in FIG. 10, after opening the top panel 402, 502, front panel 402, 508, and / or the rear panel 410, 510, the user may have access to a compartment containing the informational sheet 300. The sheet compartment 436 may be in an upper portion of the box 500 when the box is resting on the surface. As further illustrated in FIG. 6, the sheet compartment 436 may be defined vertically between the top panel 502 and at least one partition 516 and laterally between an upper portion of the front panel 408, 508 and an upper portion of the rear panel 410, 510. The sheet compartment 436 may have a depth of less than half of the depth (D) of the box 400, 500. In some embodiments, the sheet compartment 436 have a depth of about one-third or less of the depth (D) of the box 400, 500. The sheet compartment 436 may prominently display the informational sheet 300, while the at least one partition 416, 516 covers the at least one injector 200 and keeps at least one the injector 200 at least partially hidden. At least one divider 452, 552 may separate a plurality of injectors 200 in a side-by-side arrangement, as discussed with regard to the first embodiment. The at least one partition 416, 516 may allow obstructed visibility of one or more of the injectors 200, for example between partitions 452 and / or through one or more openings 517 of the partition 516. The one or more openings 517 may include a single opening (as illustrated in FIG. 12) or separate openings for each injector compartment. As discussed above with respect to the first embodiment, the at least one divider 452, 552 may be a component of an insert 540. The at least one divider 542 may be formed as panel(s) extending between a first portion 544 of the insert 540 and a second portion 146 of the insert 546. The first portion 544 may be fixed to an upper surface of the bottom panel 504 for example with adhesive 545, and the second portion 546 may be fixed to a lower surface of the partition 516. The at least one divider 542 may be positioned vertically between the partition 516 and the bottom panel 504, substantially parallel to the front flap 508 and the rear panel 510.

[0059] As illustrated in FIG. 12, a front panel 522 may join the bottom panel 504 and the partition 416, 516 and be fixed to the front panel 508 when the box 100 is assembled, for example with an adhesive 523. A rear flap 524 may extend from an edge of the partition 516 and be fixed to the rear panel 510 when the box 100 is assembled, for example with an adhesive 525. Each of the front panel 508 and the rear panel 510 may have a pair of flaps 532 configured to be folded inside of the side panels 506, 507 when closed. Each of the side panels 506, 507 may have a flap 534 configured to be folded perpendicular to the respective side panel 506, 507 and be received vertically between the flaps 532 and the bottom panel 504 to secure the side panels 506, 507 in a closed configuration. The side panels 506, 507 (for example at the flaps 534 to the bottom panel 504 with adhesive, glue, tape, and / or welding) to prevent reopening of the side panels 506, 507.

[0060] While systems and methods have been described in connection with the various embodiments of the various figures, it will be appreciated by those skilled in the art that changes could be made to the embodiments without departing from the broad inventive concept thereof. It is understood, therefore, that this disclosure is not limited to the particular embodiments disclosed, and it is intended to cover modifications within the spirit and scope of the present disclosure as defined by the claims.

Claims

What is claimed is:

1. A medical packaging system comprising: at least one injector containing a medication; and a box including a first panel, a second panel substantially parallel to the first panel, and a third panel substantially perpendicular to the first and second panels, and an interior formed by at least the first, second, and third panels, wherein the at least one injector is disposed within the interior of the box, wherein at least a portion of the first panel is integrally formed with at least one fixed portion of the box and releasably attached to the at least one fixed portion of the box to allow the first panel to be opened to allow access to the interior of the box, and wherein the third panel is configured to allow access to the interior of the box for insertion of the at least one injector in a first position, and configured to be fixed to a portion of the box in a second position to prevent reopening of the third panel.

2. The medical packaging system of claim 1, further comprising: an informational sheet, wherein the box includes at least one partition and a sheet compartment in the interior of the box formed between the first panel and the at least one partition, the informational sheet being received in the sheet compartment, and wherein the box includes at least one injector compartment in the interior of the box formed between the at least one partition and the second panel, the at least one injector being received in the at least one injector compartment.

3. The medical packaging system of claim 2, wherein the box includes at least one divider, the at least one injector compartment includes a plurality of injector compartments separated by the at least one divider, and the at least one injector includes a plurality of injectors, each of the injector compartments receiving one of the plurality of injectors.

4. The medical packaging system of claim 3, wherein the at least one divider is releasably attached to the at least one partition.

5. The medical packaging system of claim 4, wherein the at least one divider includes a plurality of dividers, and the at least one partition includes a partition, wherein the plurality of dividers are releasably attached to the partition.

6. The medical packaging system of at least one of claims 2-4, wherein the at least one partition is configured to prevent access to the at least one injector compartment until the at least one partition is opened.

7. The medical packaging system of at least one of claims 2-6, wherein the at least one partition is releasably attached to at least one second fixed portion of the box to allow the at least one partition to be opened to allow access to the at least one injector compartment.

8. The medical packaging system of at least one of claims 2-7, wherein the at least one partition extends parallel to the first panel and the second panel when the box is assembled.

9. The medical packaging system of at least one of claims 1-8, wherein the at least one fixed portion is on the first panel.

10. The medical packaging system of at least one of claims 1-9, wherein the at least the portion of the first panel is configured to pivot to open.

11. The medical packaging system of at least one of claims 1-10, wherein the at least one injector includes at least one autoinjector.

12. The medical packaging system of at least one of claims 1-11, wherein the at least one injector includes a plurality of injectors.

13. A method of loading a medical packaging system, the method comprising: receiving a box in a flattened configuration, the box having at least one opening in communication with a sheet compartment between a first panel and a partition and at least one injector compartment between the partition and a second panel, wherein the first panel has at least one frangible portion; expanding the box into an expanded configuration to expand the at least one opening; inserting an informational sheet through the at least one opening and into the sheet compartment;inserting at least one injector through the at least one opening and into the at least one injector compartment; and closing the at least one opening with at least one third panel.

14. The method of claim 13, wherein the first panel is substantially perpendicular to the at least one third panel when closed.

15. The method of claim 13 or claim 14, wherein inserting the at least one injector includes inserting a plurality of injectors individually into a plurality of injector compartments, the plurality of injector compartments being separated at least one divider.

16. The method of at least one of claims 13-15, further comprising fixing the at least one third panel to the second panel to prevent reopening of the at least one third panel.

17. A medical packaging system comprising: at least one injector; an informational sheet; and a box including a first panel, a second panel, and at least one partition, wherein the box includes a sheet compartment formed between the first panel and the at least one partition, the informational sheet being received in the sheet compartment, and wherein the box includes at least one injector compartment formed between the at least one partition and the second panel, the at least one injector being received in the at least one injector compartment.

18. The medical packaging system of claim 17, wherein the box includes at least one divider, the at least one injector compartment includes a plurality of injector compartments separated by the at least one divider, and the at least one injector includes a plurality of injectors, each of the injector compartments being configured to receive one of the plurality of injectors.

19. The medical packaging system of claim 18, wherein the at least one divider is releasably attached to the at least one partition.

20. The medical packaging system of claim 19, wherein the at least one divider includes a plurality of dividers, the at least one partition includes a partition, and the plurality of dividers are releasably attached to the partition.

21. The medical packaging system of at least one of claims 17-20, wherein the at least one partition is configured to prevent access to the at least one injector compartment until the at least one partition is opened.

22. The medical packaging system of at least one of claims 17-21, wherein at least a portion of the first panel is releasably attached to at least one fixed portion of the box to allow the first panel to be opened to allow access to the sheet compartment.

23. The medical packaging system of claim 22, wherein the at least one fixed portion is on the first panel.

24. The medical packaging system of claim 22 or claim 23, wherein the at least one portion of the first panel is configured to pivot to open.

25. The medical packaging system of at least one of claims 17-24, wherein the at least one partition is releasably attached to at least one second fixed portion of the box to allow the at least one partition to be opened to allow access to the at least one injector compartment.

26. The medical packaging system of at least one of claims 17-25, wherein the at least one partition extends parallel to the first panel and the second panel when the box is assembled.

27. The medical packaging system of at least one of claims 17-26, wherein the box includes at least one third panel configured to allow access to the sheet compartment for insertion of the informational sheet and the at least one injector compartment for insertion of the at least one injector.

28. The medical packaging system of claim 27, wherein the at least one third panel is substantially perpendicular of the first panel and the second panel.

29. The medical packaging system of claim 27 or claim 28, wherein the at least one third panel is configured to be fixed to the second panel to prevent reopening of the at least one third panel.

30. The medical packaging system of at least one of claims 17-29, wherein the at least one injector includes at least one autoinjector.

31. The medical packaging system of at least one of claims 17-30, wherein the at least one injector includes a plurality of injectors.

32. A method of opening a medical packaging system, the method comprising: opening at least a portion of a first panel to access a sheet compartment containing an informational sheet; and opening at least a portion of a partition to access at least one injector compartment containing at least one injector and formed between the partition and a second panel.

33. The method of claim 32, wherein opening at least the portion of the first panel includes detaching a frangible portion of the first panel.

34. The method of claim 32 or claim 33, further comprising removing the informational sheet prior to opening at least the portion of the partition.

35. The method of at least one of claims 32-34, wherein opening at least the portion of the partition includes detaching a frangible portion of the partition.

36. The method of at least one of claims 32-35, wherein the at least one injector compartment includes a plurality of injector compartments separated by at least one divider.

37. The method of claim 36, wherein opening at least the portion of the partition includes detaching a frangible portion between the partition and the at least one divider.

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