Child resistant and tamper evident segmented container packaging system for consumable goods

Abstract

A packaging system comprises a plurality of individual, hermetically sealed segments. The segments are configured to receive and store consumable products, and each one includes tamper evident frangible connections and a child resistant lock / release mechanism. The child resistant release mechanism is operable only after an individual packaging segment is released from a multi-pack unit by disconnecting the frangible connections for the individual packaging segment.

Description

PATENT COOPERATION TREATY APPLICATIONInventors: Simon C. KnightDocket No.: 53144-00014TITLECHILD RESISTANT AND TAMPER EVIDENT SEGMENTED CONTAINER PACKAGING SYSTEM FOR CONSUMABLE GOODSCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to United States provisional patent application serial no. 63 / 735,364 filed on December 18. 2024, which is incorporated by reference.TECHNICAL FIELD

[0002] The present invention relates to a packaging system for consumable goods and, more particularly, to a child resistant and tamper evident system for sealing individual consumables in which the packaging for single consumable may be separated from the main pack.BACKGROUND

[0003] Consumable goods, such as food, disposable personal care items, and medical or recreational medications, often require packaging that is airtight and tamper-evident. In many instances, it is also desirable to have measure of child-resistance, meaning that opening the packaging requires the use of two hands and / or two separate but coordinated motions or actions.

[0004] A variety of mechanisms have been employed to meet these needs. One of the more basic forms of tamper evidence involves the use of a shrink wrap plastic sleeve fitted137299834.1around an existing packaging solution. The resulting seal from this approach usually is not sufficiently hermetic, and the positioning of the wrap on an exterior surface makes it susceptible to accidental tearing or removal.

[0005] Another common approach is through the use of a “blister pack”. Here, a base substrate is used to individually package and seal portions / servings of the consumable good. Examples can be found in United States patent 7,226,628 and United States patent publication 2009 / 0057185, as well as European patent publication EP1211191A1. While these systems can be functionally effective, their aesthetic is not preferred, and the end users sometimes find it difficult to peal away the overlaid film. Also, consumer goods manufacturers usually enclose these type of blister packs in a separate box or container, thereby creating additional waste.

[0006] In both instances, the shrink wrap and blister packs usually require the use of different compositions (e g., metallic foils, cardboard or plastic substrates, polymeric films, etc.), with the use of disparate materials presenting challenges to recycling and, once again, underscoring an undesirable aesthetic. Further, these packaging solutions may be hermetic and tamper evident but they do not, on their own, provide any child resistant opening features except, perhaps, for the difficulties all consumers may have in separating the blister film from the substrate.

[0007] Cigarette manufacturers have proposed a number of individual packaging solutions. United States patent publication 2016 / 0031634 contemplates a pocketed packaging insert that receives single elongate elements, such as cigarettes. United States patent publication 2006 / 0231447 and international patent publication W02009 / 000678A1 show cigarette-specific blister packs for carrying a small subset of such items (presumably for resale in smaller quantities than a common pack). None of these solutions appear to237299834.1contemplate child resistant features, and they seem to suffer from the same issues as the previously mentioned solutions with respect to aesthetics and / or hermetic sealing.

[0008] Lastly, ‘‘interlinking’" containers were proposed in United States patent publication 2016 / 0068303, along with a subsequent and similar disclosure in United States patent 11,319,110. In both documents, a series of identical container modules are formed with one sidewall having a cavity with coupling detents and the opposing sidewall having a cooperating male connector. Generally speaking, both of these arrangements require each module to be formed individually and subsequently fitted together. To the extent any consideration is given to integral tamper evident and / or child resistant features, a springbased tab is formed the container so as to be received in a specially formed cap.

[0009] In view of the foregoing, a packaging system for individual dispensing of consumable goods that has tamper evidence, child resistant opening features, and / or hermetic sealing is needed. Such a system should include a pleasing aesthetic formed from a single polymeric material. A system that allowed for intuitive opening and use would also be welcomed.SUMMARY

[0010] A two-piece, polymeric packaging system with individual, frangible segments is contemplated. Each segment is formed from the top and bottom pieces and forms a discrete product delivery element. Each segment also possesses both tamper evidence and a child resistant opening feature that requires complex, coordinated action to remove the two shells. The shells can be formed from a molding operation, and the components are configured so as to create a hermetic seal within each segment that is only released when the segment is detached from the main body and only after the child lock has been disengaged.337299834.1

[0011] Specific reference is made to the appended claims, drawings, and description below, all of which disclose elements of the invention. While specific embodiments are identified, it will be understood that elements from one described aspect may be combined with those from a separately identified aspect. In the same manner, a person of ordinary' skill will have the requisite understanding of common processes, components, and methods, and this description is intended to encompass and disclose such common aspects even if they are not expressly identified herein.DESCRIPTION OF THE DRAWINGS

[0012] Operation of the invention may be better understood by reference to the detailed description taken in connection with the following illustrations. These appended drawings form part of this specification, and any information on / in the drawings is both literally encompassed (i.e., the actual stated values) and relatively encompassed (e g., ratios for respective dimensions of parts). In the same manner, the relative positioning and relationship of the components as shown in these drawings, as well as their function, shape, dimensions, and appearance, may all further inform certain aspects of the invention as if fully rewritten herein. Unless otherwise stated, all dimensions in the drawings are with reference to inches, and any printed information on / in the drawings form part of this written disclosure.

[0013] In the drawings and attachments, all of which are incorporated as part of this disclosure:

[0014] Figure I is an isometric view of the segmented packaging system showing the top, front, and side views according to various aspects contemplated herein, although it will be understood that any number of discrete elements (i.e., individual packaging containers) may be provided.437299834.1

[0015] Figure 2A is a front view highlighting the frangible connections between the discrete segments and highlighting the protruding tab at the proximal end, and Figure 2B is a bottom view highlighting the child resistant release tabs, both according to the aspect shown in Fig. 1.

[0016] Figure 3 A is an exploded, perspective view (similar to the isometric view7of Fig. 1) of the top and bottom shells according to the aspect in Fig 1, with Figure 3B showing a reverse perspective view (relative to the view7of Fig. 3A) of the top shell and Figure 3C showing a perspective view (similar to the view7of Fig. 3 A) of the bottom shell.

[0017] Figure 4 is an isolated perspective view7of an interior portion of the bottom shell as contemplated in Fig. 3C, highlighting the ramped sealing wall, tab apertures at opposing ends of each segment, and the frangible bridges connecting the discrete segments in the bottom shell.

[0018] Figure 5 is an isolated reverse perspective view7(similar to that of Fig. 3B) of an interior portion of the top shell as contemplated in Fig. 3A, highlighting the slotted tab offset from the outer shell at the head of each segment and the ramped tab at the opposing end, along with the frangible bridges connecting the discrete segments in the top shell.

[0019] Figure 6 is a cross sectional axial side view of a discrete segment from the aspect in Fig. 1, highlighting the fitment of the top and bottom shells, including the sealed positioning of the ramped walls and tabs relative to the apertures and, separately, the bead and groove engagement of the top and bottom shells.

[0020] Figure 7 is a perspective view of a discrete segment from the system in Fig. 1, highlighting the frangible bridges that would form an integral connection between the series of segments in the system.

[0021] Figure 8 is a perspective of a discrete segment according to a second aspect of the system in which the child resistant features comprise a squeeze release537299834.1

[0022] Figures 9a and 9b are complementary exploded, perspective views of the top and bottom shells from the second aspect in Fig. 8A.

[0023] Figure 10 is a cross sectional axial side view of the aspect in Fig. 8.

[0024] Figure I l a cross sectional, exploded, transverse side view of the top and bottom shells in the second aspect taken along the interface of the squeeze release components in the head of the segment so as to highlight fitment of those components at the distal end and, separately, the lap joint engagement of the top and bottom shells.

[0025] Figure 12A is an exploded isometric view of the aspect in Fig. 1, but with a tubular consumable product positioned within the interior of each segment, and Figure 12B is an axial side view a segment with the product as contemplated in Fig. 12A.DETAILED DESCRIPTION

[0026] Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the respective scope of the invention. As such, the following description is presented by way of illustration only and should not limit in any way the various alternatives and modifications that may be made to the illustrated embodiments and still be within the spirit and scope of the invention.

[0027] As used herein, the words “example” and “exemplary” mean an instance, or illustration. The words “example” or “exemplary” do not indicate a key or preferred aspect or embodiment. The word “or” is intended to be inclusive rather an exclusive, unless context suggests otherwise. As an example, the phrase “A employs B or C.” includes any inclusive permutation (e.g., A employs B; A employs C; or A employs both B and C). As another637299834.1mater, the articles “a’' and “an” are generally intended to mean “one or more” unless context suggest otherwise.

[0028] References to horizontal and vertical are relative to the drawings. Generally, references to coupling or atachment in this disclosure are to be understood as encompassing any of the conventional means used in this field, such as by way of of snap- or force fiting of components, threaded connections, bead-and-groove, and slot-and-liange assemblies and the like. Similarly, the term engagement may involve coupling or an abuting relationships, depending upon the context. Finally, to the extent the discrete segmented compartments formed by these systems tend to have cylindrically shaped cavities, the elongated, lengthwise direction may also be referred to as the axial direction whereas the width cuts transverse to that axis. All of these terms should be considered in the context in which it is used, and any perceived ambiguity can potentially be resolved by referring to the drawings, the description, and the general understanding and expectations in this field.

[0029] With reference to Figures 1 through 12B, the packaging system contemplates two separate integrally formed shells. Each shell can be molded using the same polymeric composition, so as to simplify manufacturing and reduce costs. Further, the polymeric composition can be selected to match the desired aesthetic for the product, with glossy, opaque, and / or high sheen compositions being specifically formulated through the judicious use of additives, as is commonly known in the molding field.

[0030] The shells are formed to initially couple together so as to define and hermetically seal a series of individual product cavities, which are associated with individual packaging segments. Thus, the product should be loaded into one of the shells prior to coupling the two shells together. The shells themselves couple by the joining of cooperating child resistant features provided on each of the shells so as to create a multi-pack unit, as will be described in greater detail below. Also, the interfacing edges of the shells will fit together so as to737299834.1completely seal each product cavity, with the use of bead-and-groove or lap joint connections providing proper alignment and good fit.

[0031] In a preferred embodiment, each product cavity' is identical in terms of size and construction, as this allows for mass production and packaging of identical consumable products. The product cavity' will be positioned between the shells, although in some aspects, the child resistant feature may further divide and seal the internal volume.

[0032] The packaging segments are joined by frangible connections, such as series of thin, breakable strips or bridges connecting the segments / cavities in each shell. In some aspects, the bridges on each shell align and overlap, so as to create gaps between each bridge. In this manner, the frangible connections provide tamper evidence, insofar as it is impossible for a user to open an individual segment / cavity without detaching it from the larger multipack unit.

[0033] While child resistant opening features are provided in each segment, an individual segment can only be opened after it is first detached. Thus, the frangible connections provide a form of tamper evidence.

[0034] Separately (and as noted elsewhere herein), the child resistant features require a complex and coordinate series of actions in order to release and open the segment. In one aspect, a tab must be flexed axially away from the product while separating force is applied between the shells in order to expose the product cavity. In a separate aspect, compressive force must be applied at one axial end of the segment, again while separating force is applied, in order to open and expose the product cavity.

[0035] As seen in Fig. 1, when fully assembled, the packaging system 1 has individual packaging segments 30. Segments 30 are connected to one another via frangible connections 40, such as thinned bridges, perforations, thinned grooves, or other commonly encountered837299834.1structures. While seven segments are shown in the illustrations, virtually any number of segments could be provided in the system 1.

[0036] The segments 30 are formed when the top shell 10 and bottom shell 20 are initially formed and then coupled together. Prior to coupling, consumable product(s) 60 can be disposed in a portion of the top shell 10 or bottom shell 20 that subsequent defines product cavities (P). In some aspects, the shells 10, 20 are configured so that the product cavities P have an enlarged proximal end 30a (in comparison to the opposing / distal end). The segment cavities are then aligned and the shells 10, 20 are snap-fitted together, in part based upon the attachment mechanisms inherent to the child resistant features 50 described below.

[0037] Each shell 10, 20 has a solid panel 11, 21 forming the top / bottom of the segment 30. Two opposing / lateral sidewalls 12, 22 and two opposing end walls 13, 23 (e.g., proximal and distal) further define the cavity. Cooperating sealing features 14, 24 run along the terminal edge of each shell, with bead-and-groove or lap joint connections ensuring a snug fit. In some aspects, coupling features can formed on portions or all of these terminal edges of the walls 12, 13, 22, 23 to further enhance the connection of the shells 10, 20.

[0038] Each shell 10, 20 includes frangible connectors 40 disposed along, on, and / or between the sidewalls 12, 22 of adjoining segments. Connectors 40 may be thin bridges 40a as shown, although a single flange or a series of flanges can be provided, with a thinned groove, weakened slit, or perforations defining the breakage point. In one aspect, the bridges on the top shell 10 align with the bridges on the bottom shell 20 so that, when the shell 10. 20 are coupled, these bridges present as a single element (as seen best in Fig. 2B) with spaced apart gaps between the series of bridges. In this manner, the frangible connector 40 provides an intuitive break off so that a user can "snap off’ one of the end segments 30.

[0039] Only after the segment 30 is detached from the main unit of system 1 can the child resistant (CR) mechanism 50 on that segment be easily accessed and operated. In some937299834.1aspects, the CR mechanism is positioned at a wider end of the segment, near its axial end, with a more conventional coupling mechanism positioned at the opposing end. For example, a ramped catchment 31 can be provided on one shell, with the opposing shell having an aperture 32, so as to create a coupling mechanism that can also pivot slightly as the shells are separated. A sealing wall 33 can be disposed at this end, possibly so that either the catchment 31 or the aperture 32 is provided on the wall 33.

[0040] In the aspect seen in Figs. 2A-7, the child lock 50 includes a slotted tab 51, spanning from one sidewall to the other along the interior cavity of the each segment on one of the shells and extending downward beyond the terminal edge of the shell. The tab 51 includes a slot or aperature 51a configured to receive a ramped catchment 53 provided on a sealing wall 52 of the opposing shell. When the shells are coupled, the slotted tab 41 abuts the sealing wall 52 so that the catchment 53 rests in the slot 51a (the wall 52 also extends beyond the terminal edge of its shell). The bottom end of the tab 51 protrudes out of an tab aperture 54 formed in the panel of each segment in the opposing shell. Thus, the tab 51 can be urged axially away from the sealing wall 52 in order to release the catchment 53, while the use simultaneously applies separation form by grasping and pulling the segment sidewalls and / or end walls upward / downward (i.e., so as to separate the shells).

[0041] In the aspect shown in Figs. 8-11, the child lock 50 is released by squeezing the side walls of the shell having a pair of opposing slotted tabs 55 extending down from the sidewalls of one of the shells. Each tab 55 has a slot or aperture 55a that is configured to receive internal catchments 56 provided on the opposing shell. To release the mechanism 50, the user squeezes the sidewalls of the shell inward while pulling the segment apart.

[0042] The top shell 10 and bottom shell 20 can be made from the same polymeric material or from compatible materials (so as to allow for single stream recycling). This1037299834.1approach also allows for the same molding procedure to be employed during manufacture, while still allowing for one-step recycling.

[0043] In one aspect, the packaging system stores individual portions of consumables in individual segments. These segments each have tamper evident and child resistant features, and the system itself comprises a first shell integrally formed as a single element and a second shell integrally formed as a single element. The first and second shells are initially coupled to form a multi-pack unit with a plurality of packaging segments, wherein each packaging segment is: i) attached to adjacent segment(s) by way of frangible connections, ii) hermetically sealed along an interface between the first and second shells, and iii) includes a child resistant release mechanism that is operable only after an individual packaging segment is released from the multi-pack unit by disconnecting the frangible connections for the individual packaging segment. Additional features include any one or combination of the following:• wherein the interface includes a bead and groove or lap joint connection;• wherein the child release mechanism includes a tab with a slot on the first shell that couples a sealing wall having a ramp configured to be received in the slot so as to define a product cavity in each packaging segment and wherein the tab: i) protrudes through an aperture formed in the second shell, and ii) flexes away from the product cavity so as to disengage the child release mechanism and expose the product cavity;• wherein the child release mechanism is a squeeze release wherein the first shell includes a pair of opposing slotted tabs within a first axial end of each packaging segment and wherein the second shell includes a pair of opposing catchment in the first axial end configured to couple to each of the slotted tabs so that the catchments are released when compressive force is applied to the first axial end of the individual packaging segment so as to disengage the child release mechanism and expose the product cavity; wherein the child release mechanism is disposed at a first axial end of each packaging segment;1137299834.1• wherein each packaging segment includes a ramp-and-slot connection between the first and second shells at a second axial end of each packaging segment;• wherein the first and second shells are made from the same polymeric composition;• wherein the frangible connections include a plurality of bridge segments on each of the first and second shells; and• wherein the bridge segments on the first and second shells are spaced apart axially and arranged so as to define lateral gaps between each packaging segment..

[0044] Common polymers amenable to injection molding, extrusion, or other common forming processes should have particular utility’. Thus, any single or combination of polyolefins could be used, including polymers and / or copolymers such as polypropylene and / or high or low density polyethylene. If a clear plastic is preferred, polyethylene terephthalate (PET) is amenable to injection molding processes disclosed herein. Labels can be affixed to the final shell(s). or these can be embossed, etched, or printed on to enhance the desired aesthetics.

[0045] All components should be made of materials having sufficient flexibility and structural integrity, as well as a chemically inert nature. The materials should also be selected for workability, cost, and weight.

[0046] Any reference to engagement, coupling, or attachment in this disclosure are to be understood as encompassing any of the conventional means used in this field, and coupled elements will generally move as a single unit. These means can take the form of snap-fitting, frictional / force-fitting, threaded connections, bead-and-groove, and bayonet-style / slot-and- flange assemblies. Use of adhesives or discrete fasteners is not preferred, owing to the multiplicity of parts and added complexity' in assembling the closure system. Ultimately, any implicit or explicit reference to engagement, coupling, or attachment should be considered in the context in which it is used, and any perceived ambiguity can potentially be resolved by referring to the drawings.1237299834.1

[0047] Although the present embodiments have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the invention is not to be limited to just the embodiments disclosed, and numerous rearrangements, modifications and substitutions are also contemplated. The exemplary embodiment has been described with reference to the preferred embodiments, but further modifications and alterations encompass the preceding detailed description. These modifications and alterations also fall within the scope of the appended claims or the equivalents thereof.1337299834.1

Claims

CLAIMSWhat is claimed is:

1. A packaging system for storing individual portions of consumables in individual segments with each segment having tamper evident and child resistant features, the system comprising: a first shell integrally formed as a single element; a second shell integrally formed as a single element; wherein first and second shells are initially coupled to form a multi-pack unit with a plurality of packaging segments; and wherein each packaging segment is: i) attached to adjacent segment(s) by way of frangible connections, ii) hermetically sealed along an interface between the first and second shells, and iii) includes a child resistant release mechanism that is operable only after an individual packaging segment is released from the multi-pack unit by disconnecting the frangible connections for the individual packaging segment.

2. The packaging system of claim 1 wherein the interface includes sealing features (14, 24) formed as a bead and groove or lap joint connection.

3. The packaging system of claim 1 wherein the child release mechanism includes a tab with a slot on the first shell that couples a sealing wall having a catchment configured to be received in the slot so as to define a product cavity in each packaging segment and wherein the tab: i) protrudes through an aperture formed in the second shell, and ii) flexes away from the product cavity so as to disengage the child release mechanism and expose the product cavity.

4. The packaging system of claim 1 wherein the child release mechanism is a squeeze release wherein the first shell includes a pair of opposing slotted tabs within a first axial end of each packaging segment and wherein the second shell includes a pair of opposing catchments in the first axial end configured to couple to each of the slotted tabs so that the catchments are1437299834.1released when compressive force is applied to the first axial end of the individual packaging segment so as to disengage the child release mechanism and expose the product cavity.

5. The packaging system of claim 1 wherein the child release mechanism is disposed at a first axial end of each packaging segment.

6. The packaging system of claim 5 wherein each packaging segment includes a ramp-and- slot connection between the first and second shells at a second axial end of each packaging segment.

7. The packaging system of claim 6 wherein either the ramp or the aperture is provided on a sealing wall extending from an end wall formed on either the first shell or the second shell.

8. The packaging system of claim 1 wherein the first and second shells are made from the same polymeric composition.

9. The packaging system of claim 1 wherein the frangible connections include a plurality of bridge segments on each of the first and second shells.10 The packaging system of claim 9 wherein the bridge segments on the first and second shells are spaced apart axially and arranged so as to define lateral gaps between each packaging segment.1537299834.1

Images