PRODUCT PACKAGE AND RELATED METHOD

Abstract

A package has a tray slidably mounted in a carton that has a opening bordered by a number of flaps. One or more stops on the tray are positioned to engage at least one of the flaps in order to restrict outward movement of the tray The tray can be positioned with a stop located inwardly of, and locked in place by, one or more of the flaps. By depressing one or more of the flaps the previously locked stop will be cleared and allowed to move outwardly past the flaps.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application, Ser No. 61/928,578, filed 17 Jan., 2014, the contents of which are hereby incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a paper board folding carton with a plastic tray insert is provided as a multi-use system to deliver a product to the consumer and be reused once opened. Alternatively the arrangement may be operated multiple times before it has a structural failure.

2. Description of Related Art

Existing prior art solutions typically entail rigid plastics at high volumes and costly tooling, more robust outer cartons at higher costs with less esthetics regarding the finished unit, and such designs also have a higher degree of environmental impact to manufacture and dispose of during its life cycle.

SUMMARY OF THE INVENTION

In accordance with the illustrative embodiments demonstrating features and advantages of the present invention, there is provided a package including a carton having an opening and one or more flaps around the opening. The package also includes a tray slidably mounted in the carton and having one or more stops positioned to engage the one or more flaps in order to restrict outward movement of the tray.

In accordance with another aspect of the invention, a method is provided that employs a tray slidably mounted in a carton that has an opening bordered by one or more flaps. The tray has at least one stop. The method includes the step of positioning the tray with the at least one stop located inwardly of, and locked in place by, the one or more flaps. Another step is depressing at least one of the one or more flaps to clear the at least one stop and allow movement of the at least one stop outwardly past the one or more flaps.

The present arrangement provides a product package that integrates a first thermoformed tray, with an optional thermoform lid, with a second component, namely a paper board carton that transforms the package from a single use container to a multi-use system that can be opened and closed over a hundred times.

One exemplary feature of the present design is the integration between the plastic articles and paper board carton. Using four flaps on one end of a standard folding carton, they are folded into the cardboard carton to generate recoil energy in the paper board to spring out engaging the inner thermoformed part, in conjunction with a number of recessed surfaces or bosses on the plastic articles. The package can be kept closed until the consumer initiates the opening the unit.

Such an arrangement also maintains a similar relationship when opened, with additional surfaces keeping the plastic articles from being separated from the outer paper board carton, keeping the unit intact.

Once the unit is opened, a user now has access to the product or products by removing the product from the thermoformed package or from opening the hinged lid of the inner plastic article. After use of the product the user returns the products to the container, closes the unit, and stores in the “Stiletto Pak” until they need to use again. This design uses a two piece inner plastic articles but can also be done with a single inner tray.

BRIEF DESCRIPTION OF THE DRAWINGS

The above brief description as well as other objects, features and advantages of the present invention, including the package's shape, design and operation, will be more fully appreciated by reference to the following detailed description of illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings, wherein:

FIG. 1 shows a package with a single piece thermoformed plastic insert within a folded cardboard sleeve having four folded end tabs according to one embodiment.

FIG. 2 shows several cutaway views of the package with a single piece thermoformed plastic insert within a folded cardboard sleeve having four folded end tabs according to one embodiment

FIG. 3 shows several perspective and cutaway views of the package with a single piece thermoformed plastic insert within a folded cardboard sleeve having four folded end tabs illustrating the function of the folded tabs according to one embodiment.

FIG. 4 shows several views of a hinged two piece thermoformed plastic insert according to one embodiment.

FIG. 5 shows several perspective and cutaway views of the package with the hinged two piece thermoformed plastic insert within a folded cardboard sleeve having four folded end tabs illustrating the function of the folded tabs according to one embodiment.

FIG. 6 shows several cutaway views of the package with the hinged two piece thermoformed plastic insert within a folded cardboard sleeve having four folded end tabs according to one embodiment

FIG. 7 shows several views of hinged two piece thermoformed plastic insert according to one embodiment.

FIG. 8 shows several views of a two piece thermoformed plastic insert according to one embodiment.

FIG. 9 shows several views of the hinged lid for the two piece thermoformed plastic insert according to one embodiment.

DETAILED DESCRIPTION

(Stiletto Pack)

Referring to FIGS. 1-3, the illustrated package has a tray 10 that is slidably mounted in carton 12 Four flaps 14 border an opening in carton 12 (an upper flap, lower flap, and two side flaps). Tray 10 has a receptacle for receiving a product such as an e-cigarette. The forward end of tray 10 has a flange-like, lower finger tab 10A. The back end of tray 10 is enlarged and forms a stop shown as aft abutments 16 and 17.

Tray 10 may be blow molded and has a well that forms a stop 18 (also referred to as a forward abutment)

After loading product into tray 10, flaps 14 are folded inwardly before sliding tray 10 into carton 12. Eventually, stop 18 will move inwardly past lower flap 14, which flap will then lift and lock stop 18 in position as shown in FIG. 2

To release tray 10, a user will squeeze and slightly rotate tab 10A down against package 12 to depress lower flap 14, thereby allowing stop 18 to clear the flap The user will then use tab 10A to slide tray 10 outwardly into the dispensing position shown in FIG. 3.

Outward movement of tray 10 will be halted when stops 16 and 17 engage the side and upper flaps 14, respectively. The product can then be removed from tray 10, used, and then returned to the tray.

Tray 10 can then be pushed back inside carton 12 until stop 18 passes lower flap 14 to lock the tray in place again.

Referring to FIGS. 4-9, the illustrated package has a tray 30 slidably mounted inside carton 32. Four flaps 34 border an opening in carton 32. Lid 31 snaps onto tray 30 and has a forward hinged section that can swing up as shown in FIG. 4 to allow access to the product (not shown) in tray 30. The forward end of lid 31 has a finger tab 31A. The back end of tray 30 has a pair of ribs 36 acting as stops (also referred to as aft abutments).

Tray 30 may be blow molded with a floor having a forward plateau adjacent a well that forms a stop 38 (also referred to as a forward abutment)

After loading product into tray 30, flaps 34 are folded inwardly before sliding the tray into carton 32. Eventually, stop 38 will move inwardly past lower flap 34, which flap will then lift and lock stop 38 in position as shown in FIG. 6. It will be noticed that lower flap 34 is accessible at this time

To release tray 30, a user will squeeze lower flap 34 down against package 32 to depress that flap, thereby allowing stop 38 to clear the flap. The user will then grasp tab 31A through notch 32A in package 32 and pull tray 10 into the dispensing position shown in FIG. 4. Because two separate hand movements are required for this maneuver, this packaging is considered child resistant.

Outward movement of tray 30 will be halted when stops 36 engage the side flaps 34. The product can then be removed from tray 30 by lifting lid 31.

After closing lid 31, tray 30 can then be pushed back inside carton 32 until stop 38 passes lower flap 34 to lock the tray in place again.

While only certain features of the invention have been illustrated and described herein, many modifications, substitutions, changes or equivalents will now occur to those skilled in the art. It is therefore, to be understood that this application is intended to cover all such modifications and changes that fall within the true spirit of the invention.

Claims

1. A package comprising:

a carton having an opening and one or more flaps around said opening; and

a tray slidably mounted in said carton and having one or more stops positioned to engage said one or more flaps in order to restrict outward movement of said tray.

2. A package according to claim 1 wherein at least one of said one or more flaps is manually depressible to clear said at least one stop and increase outward mobility of said tray.

3. A package according to claim 1 wherein said one or more stops comprise a forward abutment and an aft abutment, at least one of said one or more flaps being manually deflectable to clear said forward abutment and enable outward movement of said tray until said aft abutment engages at least one of said one or more flaps.

4. A packaging method employing a tray slidably mounted in a carton that has an opening bordered by one or more flaps, the tray having at least one stop, the method comprising the steps of

positioning the tray with said at least one stop being located inwardly of, and locked in place by, said one or more flaps, and

depressing at least one of said one or more flaps to clear said at least one stop and allow movement of said at least one stop outwardly past said one or more flaps.

5. A packaging method according to claim 4 wherein said at least one stop comprises a forward and an aft abutment, the method comprising the step of:

pulling said forward abutment outwardly past said one or more flaps until said aft abutment engages at least one of said one or more flaps.