CHILD RESISTANT LOCKING CONTAINER

Abstract

A child resistant container includes an outer housing defining an internal cavity. An inner drawer has a product receiving area. A first end of the inner drawer is received within the internal cavity. A catch is located at the inner drawer. The catch is configured to restrict movement of the inner drawer relative to the outer housing, and the catch is integrally formed with the inner drawer. A release is configured to act on the catch.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/254,456 (filed Oct. 11, 2021, and entitled “CHILD RESISTANT PACKAGING”), the entirety of which is herein incorporated by reference.

TECHNICAL FIELD OF THE INVENTION

The present application generally relates to child resistant packaging, and more particularly, but not exclusively, to a child resistant container configured to prevent young children from easily accessing product(s) housed within the container.

BACKGROUND

Child resistant packaging, commonly referred to as child-proof packaging, is designed to prevent children from easily accessing items which are housed within the packaging. Child resistant packaging is commonly utilized with regard to products which could be harmful to children, such as products which are potentially harmful or toxic if ingested.

The legalization of marijuana in a number of states has generated an increased interest in child resistant packaging as child resistant packaging is often legally required for marijuana related products. Child resistant packaging takes a variety of forms, but typically relies upon a user to perform multiple actions simultaneously (e.g., press and turn, depress a button and pull, etc.). In this manner, child resistant packaging provides adults with reasonably easy access to the product but reduces the likelihood that a young child may access the product.

Child resistant packaging of the prior art includes a number of significant drawbacks. For example, present manufacturing techniques often require intensive manual labor to hand assemble and glue various areas of the packaging, especially the locking devices.

Many locking devices of prior art child resistant packaging rely upon polymeric or metallic locking members to provide sufficient strength. These locking members are positioned upon and/or into the packaging by hand and are adhered to the packaging by hand. As will be appreciated to a person of skill, the intensive labor required by such prior art packaging adds considerable expense to the overall childproof container significantly adds to the economic cost of the packaging.

Moreover, due to the current labor shortage, some types of child resistant packaging have become difficult to acquire (e.g., as the manufacturing facilities are having difficulty providing the necessary labor to hand assemble the packaging). Although prior art child resistant packaging can function to prevent children from easily accessing the product housed in the packaging, further technological developments are desirable in this area.

SUMMARY

One embodiment of the present application is directed to a child resistant container. The child resistant container includes an outer housing defining an internal cavity. An inner drawer has a product receiving area. A first end of the inner drawer is received within the internal cavity. A catch is located at the inner drawer, and the catch is integrally formed with the inner drawer. The catch is configured to restrict movement of the inner drawer relative to the outer housing. The child resistant container includes a release configured to act on the catch.

The inner drawer can be slidably received within the internal cavity. The outer housing can extend over the product receiving area when the inner drawer is slid into the internal cavity. The catch can be a locking tab. The inner drawer and the locking tab can be formed of a unitary die cut.

A fold can be located between the first end of the inner drawer and the locking tab. The locking tab can extend along a lower surface of the inner drawer toward a second end of the inner drawer.

The child resistant container can include a tab engaging protrusion located at an internal surface of the outer housing. Contact between a distal end of the locking tab and the tab engaging protrusion can restrict the inner drawer from sliding outwardly relative to the outer housing.

The release can take the form of a button configured to pivot inwardly from the outer housing, and the button can be formed into a material of the outer housing. The button, when depressed by a user, can be configured to move the locking tab inwardly so that the inner drawer can be slid outwardly from the internal cavity.

The release can include two buttons located at the outer housing. The buttons can be foldably connected to the outer housing. The catch can have two locking tabs, and the locking tabs can be foldably connected to the first end of the inner drawer.

The buttons and the outer housing can be formed of a unitary die cut of solid bleached sulphate board. The locking tabs and the inner drawer can be formed of a second unitary die cut of solid bleached sulphate board.

Another form of the present application is directed to a container. The container has an outer sleeve having an interior cavity. An inner drawer extends between a first end and a second end. The inner drawer has a product receiving area, and the outer sleeve is configured to extend over the product receiving area to prevent access to the product receiving area. A locking tab is located at the inner drawer, and the locking tab is integrally formed with the inner drawer from a single portion of material.

A tab engaging protrusion is located at an internal surface of the outer sleeve, and the tab engaging protrusion is configured to engage the locking tab to restrict sliding movement of the inner drawer relative to the outer sleeve. A release mechanism is located at an external surface of the outer sleeve. The release mechanism is configured to act upon the locking tab to prevent the tab engaging protrusion from engaging the locking tab.

The inner drawer and the locking tab can be foldably formed from a single die cut. The locking tab can be attached to the first end of the inner drawer at a fold.

The release mechanism can be a button. The button can be formed in the outer sleeve, and the button can be configured to contact the locking tab to move the locking tab away from the tab engaging protrusion when the button is depressed.

The outer sleeve can extend between a first end and a second end. The outer sleeve can substantially define a rectangular prism. A separation prevention tab can be located at the second end of the outer sleeve. A product retaining insert can be located in the product receiving area.

Yet another embodiment of the present application is directed to a method for forming a child resistant container. The method includes folding a first portion of material to form an outer sleeve having an interior cavity. An internal surface of the outer sleeve has a tab engaging protrusion.

The method includes providing a second portion of material. The second portion of material includes a locking tab integrally formed with the second portion of material. The method includes mechanically folding the second portion of material to form an inner drawer extending between a first end and a second end. The method includes folding the locking tab outwardly from the first end. The method includes inserting the first end of the inner drawer through an opening in the outer sleeve and into the interior cavity.

Providing the second portion of material can include die cutting the second portion of material from a material feedstock. The second portion of material can be a unitary die cut. The method can include foldably forming the inner drawer, the locking tab, and a product receiving area from the unitary die cut.

The method can include adhering the tab engaging protrusion to the internal surface of the outer sleeve. The tab engaging protrusion can be configured to engage a distal end of the locking tab. Sliding movement of the inner drawer relative the outer sleeve can be restricted when the distal end of the locking tab is engaged by the tab engaging protrusion.

The method can include die cutting the first portion of material from a material feedstock. A release button can be die cut into the outer sleeve. The release button, when depressed, can be configured to act upon the locking tab to prevent the tab engaging protrusion from engaging the locking tab to enable sliding movement of the inner drawer relative the outer sleeve.

Providing a second portion of material can include die cutting the second portion of material from a sheet of solid bleached sulphate board.

Other embodiments include unique child resistant apparatuses, systems, and methods. Further embodiments, inventions, forms, objects, features, advantages, aspects, and benefits of the present application are otherwise set forth or become apparent from the description and drawings included herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:

FIG. 1 is a bottom perspective view of an exemplary child resistant container according to a first form of the present application, which illustrates the child resistant container in a fully separated configuration;

FIG. 2A is a plan view of an exemplary outer sleeve of the child resistant container of FIG. 1, which depicts the sleeve in a flattened, unassembled configuration;

FIG. 2B is a plan view of an exemplary inner drawer of the child resistant container of FIG. 1, which depicts the inner drawer in a flattened, unassembled configuration;

FIG. 2C is a plan view of an exemplary product insert, which depicts the insert in a flattened, unassembled configuration;

FIG. 3 depicts an end view of the outer sleeve, which depicts an opening in the outer sleeve;

FIG. 4 is a top view of the inner drawer, which depicts the inner drawer in an assembled configuration;

FIG. 5 is a bottom view of the inner drawer, which depicts the inner drawer ready for insertion into the outer sleeve;

FIG. 6A depicts a bottom view of a fully assembled child resistant container, which depicts the inner drawer being pulled outwardly from the outer sleeve;

FIG. 6B depicts a top view of the child resistant container in an open configuration; and

FIG. 7 depicts a partial cross-sectional view of an end portion of the child resistant container in a closed configuration.

The accompanying drawings incorporated in and forming a part of the specification illustrate various forms and features of the present application; however, the present application should not be construed as being limited to those specific embodiments depicted in the drawings.

DETAILED DESCRIPTION

For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, any alterations and further modifications in the illustrated device, and any further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

The child resistant containers of the present application are configured to prevent a young child from gaining access to the item(s) housed therein. To open the child resistant containers from a closed configuration requires that multiple steps be performed simultaneously. It is believed that young children do not yet have the dexterity required to perform these multiple steps simultaneously; therefore, they cannot access the item(s) housed within the child resistant container. In this manner, the child resistant containers of the present application are well suited to house a variety of items which may be toxic, harmful, and or illegal for young children. Such items may include, but are not limited to, marijuana related products such as vape pens, edibles, or the like.

Referring now to FIG. 1, an exemplary child resistant container 100 according to a first form of the present application will now be described. The child resistant container 100 is depicted as including an outer housing 102 and a tray 104. The exemplary tray 104 is depicted as being completely separated from the outer housing 102 in FIG. 1. However, as will be described herein, the tray 104 is configured to be positioned within the outer housing 102. When the child resistant container 100 is in a closed configuration, the outer housing 102 is configured to cover the item(s) (not shown) which are housed within the tray 104. When in this closed configuration, a locking mechanism restricts movement of the tray 104 relative the outer housing 102.

Referring now to FIGS. 1, 4, and 6B, the exemplary tray 104 includes a first end 140, a second end 142, an upper portion 402, a lower surface 136, and opposing sides 144, 146. The tray 104 includes a product receiving area 404. The tray 104 is depicted as having a substantially rectangular prismatic shape 134.

The tray 104 includes a catch 128. The catch 128 is configured to restrict movement of the tray 104 relative to the outer housing 102. The catch 128 is depicted as taking the form of a first locking tab 130 and a second locking tab 132. The locking tabs 130, 132 are integrally formed with the tray 104, as will be described further with regard to FIG. 2B. A proximal end 152 of the locking tabs 130 is located at the first end 140 of the tray 104 and can be integrally formed with the lower surface 136 of the tray 104 (e.g., the locking tabs 130, 132 are cut from the same material as the lower surface 136 of the tray 104 and the locking tabs 130, 132 remain attached to the lower surface 136 of the tray 104).

A separation 156 can be located between the locking tabs 130, 132 so that distal ends 154 of the locking tabs 130, 132 can move independent one another.

The tray 104 is sized so that the first end 140 of the tray 104 can be slid into an opening 110 (shown in FIG. 3) of the outer housing 102. In a preferred form, the tray 104 includes exterior dimensions which are smaller than internal dimensions of the outer housing 102 so that the tray 104 can fully slide within the outer sleeve 102 (e.g., with the outer housing 102 fully covering the upper portion 402 of the tray 104). The tray 104 will be described hereinafter as inner drawer 104 as the inner drawer 104 slides into and out of the outer housing 102.

Prior to insertion of the first end 140 of the inner drawer 104 into the opening 110 of the outer housing 102 (e.g., during assembly of the child resistant container 100), the distal ends 154 of the locking tabs 130, 132 are folded outwardly, away from the upper portion 402 (e.g., toward the lower surface 136), as is illustrated in FIG. 5.

The inner drawer 104 has a product receiving area 404, which is depicted as product receiving cavity 404. This product receiving cavity 404 is configured to house a product therein. Although it is contemplated that the child resistant container 100 can be used to prevent children from accessing a variety of products, in one non-limiting form, the product receiving area 404 is configured to house marijuana related products such as vape pens, edibles, or the like. A product retaining insert 268 can be disposed within the product receiving area 404.

Referring to FIGS. 1, 3 and 6A, the outer housing 102 will now be described. The exemplary outer housing 102 is depicted as extending between a first end 106 and a second end 108. The outer housing 102 includes an upper surface 203, a lower surface 112, and two opposing side walls 116, 118. The outer housing 102 is depicted as having a substantially rectangular prismatic shape 105.

The outer housing 102 includes an interior cavity 302. The opening 110 is depicted as being located in the second end 108 of the outer housing 102. The opening 110 provides access for the first end 140 of the inner drawer 104 to pass into the interior cavity 302. When the first end 140 of the inner drawer 104 is slid into the interior cavity 302, and the outer housing 102 is in a closed configuration, the outer housing 102 extends over, and fully covers the product receiving area 404. As the outer housing 102 at least partially covers the inner drawer 104 when the child resistant container 100 is in a closed configuration, the outer housing 102 will be described hereinafter as outer sleeve 102.

When the child resistant container 100 is in a closed configuration, the inner drawer 104 is preferably fully inserted into the outer sleeve 102, and the outer sleeve 102 fully covers the product receiving area 404, preventing direct access to the product receiving area 404. To pull the inner drawer 104 outwardly from the outer sleeve 102, and to access the product contained in the product receiving area 404, the child resistant container 100 requires multiple steps be performed simultaneously (e.g., depressing button 120 while pulling on the inner drawer 104) to open as will be discussed hereinafter.

Finger receiving cutouts 126 can be located in the side walls 116, 118 of the outer sleeve 102, at the second end 108 of the outer sleeve. When the child resistant container 100 is in a closed configuration, the inner drawer 104 can be almost entirely located within the interior cavity 302 of the outer sleeve 102 and the outer sleeve 102 can fully cover the opposing sides 144, 146. These finger receiving cutouts 126 enable a user 602 to easily grasp the second end 142 of the inner drawer 104 (e.g., such as between a thumb and index finger).

The locking mechanism 702 of the child resistant container 100 will now be described. FIG. 7 depicts a partial cross-sectional view of an end portion of the child resistant container 100 in a closed configuration (e.g., depicting the first end 106 of the outer sleeve 102 and the first end 140 of the drawer 104 when the inner drawer 104 is fully inserted into the interior cavity 302). The exemplary locking mechanism includes the previously described locking tabs 130, 132, a tab engaging protrusion 208, and a release 158.

The tab engaging protrusion 208 is located at an inner surface 304 of the outer sleeve 102. The tab engaging protrusion 208 is depicted as protruding inwardly from the inner surface 304, away from the lower surface 112 of the outer sleeve 102. As is illustrated, the tab engaging protrusion 208 includes a ledge-type form.

When the child resistant container 100 is placed in a closed configuration, the locking tabs 130, 132 are sandwiched between the lower surface 112 of the outer sleeve 102 and the lower surface 136 of the inner drawer 104. The distal ends 154 of the locking tabs 130, 132 can contact and move along the inner surface 304 of the outer sleeve 102.

The locking mechanism 702 restricts and limits movement of the inner drawer 104 relative the outer sleeve 102. When the user 602 begins to pull the inner drawer 104 outwardly from the outer sleeve 102 (e.g., to gain access to the product housed within the product receiving cavity 404), the distal ends 154 of the locking tabs 130, 132 will move along the inner surface 304 of the outer sleeve 102 until they contact the tab engaging protrusion 208. This contacting engagement between the distal ends 154 and the tab engaging protrusion 208 restricts the inner drawer 104 from sliding outwardly to where the product receiving cavity 404 may be accessed. The contacting engagement between the distal ends 154 and the tab engaging protrusion 208 serves to lock the child resistant container 100 in the closed configuration shown in FIG. 7.

The lower surface 112 of the outer sleeve 102 and the lower surface 136 of the inner drawer 104 preferably are located within a close proximity (e.g., with sufficient room for the locking tabs 130, 132 to slide therebetween, but with little additional room). This close proximity is believed to substantially reduces the likelihood that the locking tabs 130, 132 will merely bend or deform, thereby enabling the inner drawer 104 to be pulled outwardly relative the outer sleeve 102. Should the locking tabs 130, 132 begin to bow in response to the force exerted on the distal ends 154 thereof, the bend would contact either the lower surface 136 of the inner drawer 112 or the interior surface 304 of the outer sleeve 102 due to the close proximity therebetween.

To transition the child resistant container 100 from the closed configuration (best shown in FIG. 7) to the open configuration 604 (as shown in FIG. 6B), the user 602 must simultaneously depress a release 158 and slide the second end 142 of the inner drawer 104 outwardly (e.g., with the second end 142 of the inner drawer 104 moving outwardly and away from the first end 106 of the outer sleeve 102).

The release 158 is accessible from outside the outer sleeve 102. Depressing the release 158 (as is best shown in FIG. 6A), places the locking mechanism 702 of the child resistant container 100 in an unlocked configuration so that the user 602 may slide the second end 142 of the inner drawer 104 outwardly to the open configuration 602.

The release 158 is depicted as taking the form of a depressible button 120. In a preferred form, the release 158 includes two depressible buttons 120 and 148. The buttons 120 and 148 are depicted as being located in the lower surface 112 of the outer sleeve 102, toward the first end 106 of the outer sleeve 102.

These buttons 120, 148 are depicted as being formed into the lower surface 112 of the outer sleeve 102. The buttons 120, 148 are defined by a U-shaped cut 149. The buttons 120, 148 each extend between a proximal end 160, across the uncut axis 124 at the top of the U-shaped cut 149, and a distal end 150 toward the bottom of the U-shaped cut 149. The button 120 is located below the first locking tab 130 and the button 148 is located below the second locking tab 132.

The buttons 120, 148 are spaced apart so that a typical user 602 will utilize two fingers to contact and depress both of the buttons 120, 148 at the same time. Therefore, a typical user 602 will need to utilize multiple fingers on both hands simultaneously to unlock the locking mechanism 702 (e.g., by depressing buttons 120, 148 with one hand) and to slide the inner drawer 104 outwardly (e.g., grabbing the opposing side walls 144, 146 through the finger cutouts 126 with the opposing hand). It is believed that young children will not possess the dexterity required to perform these tasks simultaneously; therefore, said young children will not be able to slide the inner drawer 104 outwardly to access the product located within the product receiving cavity 404.

Referring to FIGS. 6A, 6B, and 7, opening the child resistant container 100 from the closed configuration (best shown in FIG. 7) will now be described. The user 602 will depress the buttons 120, 148 with one hand, as is shown in FIG. 6A. As the buttons 120, 148 are depressed by the user 602, the buttons 120, 148 will pivot around axis 124 and the distal ends 150 of the buttons 120, 148 will move inwardly to contact the locking tabs 130, 132.

As the first locking tab 130 and the second locking tab 132 are contacted by the button 120 and the button 148, respectively, the locking tabs 130, 132 are moved away from the tab engaging protrusion 208. The proximal end 152 of the locking tabs 130, 132 is pivotally connected with the lower surface 136 of the inner drawer 104 via the fold 152. In response to the force exerted on the tabs 130, 132 by the buttons 120, 148, the locking tabs 130, 132 will pivot inwardly toward the lower surface 136 and away from the tab engaging protrusion 208 (e.g., the distal ends 154 are moved inwardly and upwardly relative the tab engaging protrusion 208).

In this manner, as the user 602 continues to depress both of the buttons 120, 148 the user 602 can begin to pull the second end 142 of the inner drawer 104 outwardly from the outer sleeve 102 (e.g., with the second end 142 of the inner drawer 104 moving outwardly and away from the first end 106 of the outer sleeve 102). As the distal ends 154 of the locking tabs 130, 132 are moved inwardly and away from the tab engaging protrusion 208, the distal ends 154 of the locking tabs 130, 132 will fail to be engaged by the tab engaging protrusion 208; therefore, the locking tabs 130, 132 will pass freely over the tab engaging protrusion 208 without interference therefrom. The user 602 may then slide the inner drawer 104 outwardly to the open configuration 604 depicted in FIG. 6B. The user 602 may then access and remove the product located within the product receiving cavity 404.

Referring to FIGS. 3 and 6B, the outer sleeve 102 can include a separation prevention tab 227. This separation prevention tab 227 is located at the second end 108 of the outer sleeve 102 and is folded inwardly over fold 201 into the opening 110. As the inner drawer 104 slides outwardly from the closed position, the distal ends 154 of the locking tabs 130, 132 slide further away from the first end of the outer sleeve 102 and toward the opening 110.

The separation prevention tab 227 engages the distal ends 154 of the locking tabs 130, 132 prior to the distal ends 154 exiting the interior cavity 302 through the opening 110. The engagement of the locking tabs 130, 132 by the separation prevention tab 227 is configured to prevent the inner drawer 104 from being fully removed from the opening 110 in the outer sleeve 102. In this manner, the first end 140 of the inner drawer 104 is retained in the interior cavity 302 (e.g., the first end 140 of the inner drawer 104 does not pass out through the opening 110) when the child resistant container 100 is in the open configuration 604.

Once the first end 140 of the inner drawer 104 is inserted through the opening 110 and into the interior cavity 302 (e.g., during assembly of the child resistant container 100) the inner drawer 104 can remain coupled with the outer sleeve 102. The separation prevention tab 227 reduces the likelihood that the inner drawer 104 will be accidentally removed from the outer sleeve 102 (e.g., by inadvertently pulling the inner drawer 104 completely out from the outer sleeve 102).

To close the child resistant container 100 from the open configuration 604, the inner drawer 104 can be slid back into the outer sleeve 102 by pushing the second end 142 of the inner drawer 104 toward the first end 106 of the outer sleeve 102. As the inner drawer 104 slides through the opening 110 of the outer sleeve 102 and into the receiving cavity, the locking tabs 130, 132 will easily pass over the tab engaging protrusion 208. When sliding the inner drawer 104 toward the first end 106 of the outer sleeve, the tabs 130, 132 are pressed toward the lower surface 136. As the proximal end 152, which is connected to the lower surface 136 at the fold 230, fails to provide a suitable engagement surface to contact and engage with the tab engaging protrusion 208, the locking tabs 130, 132 freely pass over the tab engaging protrusion 208 and the child resistant container 100 can be placed in the closed configuration.

Should the user 602 desire to reopen the child resistant container 100, the user 602 must then depress the buttons 120, 148 simultaneously as they pull the second end 142 of the inner drawer 104 outwardly and away from the first end 106 of the outer sleeve 102.

FIG. 2A depicts a plan view of the outer sleeve 102 in a flattened, unassembled state. The outer sleeve 102 is preferably formed from a unitary sheet 236 of material 207, which is depicted as unitary die cut 202. This unitary die cut 202, including all features which will be present in the outer sleeve 102, but in a flattened state, is cut from a sheet of material 207 feedstock utilizing a mechanized stamping die. For example, the lower surface 112, the upper surface 203, the side walls 116, 118, the first end 106, the separation prevention tab 227, and the buttons 120, 148 (defined by the U-shaped cut 149) formed into the material 207 of the unitary die cut 202 by the die. The die cut 202 fails to include any joining of materials as the material 207 extends throughout the unitary die cut 202 without the need for any joining therein.

The outer sleeve 102 is foldably formed from the unitary die cut 202. Exemplary fold lines 201 are depicted as dotted lines. The fold lines 201 can be stamped into the material 207 during the die cutting operation to ease further folding operations.

It has been discovered that use of the unitary die cut 202 to form the outer sleeve 102 can greatly reduce labor costs as the folding and forming of the outer sleeve 102 from the unitary die cut 202 can be accomplished mechanically, via mechanized folding and adhering machines as are known. As will be appreciated, the full mechanization of the assembly of the outer sleeve 102 will significantly decrease the labor costs relative the hand assembled and adhered components of prior art child resistant packages.

The plan view of FIG. 2A depicts the outer surface 212 of the material 207 (e.g., the outer surface 212 being the surface of the flattened, unassembled unitary die cut 202 of the material 207 which will predominantly face outwardly relative the interior cavity 302 when the outer sleeve 102 is fully assembled). Although adhesive is not typically applied upon the die cut 202 prior to the mechanized folding and adhering operations, exemplary adhesive portions 209 and 214 are depicted upon the die cut 202 to further clarify the mechanized adhering operation. Adhesive portions 209 are located on the outer surface 212 of the material 207 and adhesive portions 214 are located on the inner surface (not shown) of the material 207, which is opposite the outer surface 212. As will be appreciated, adhesive may be applied to one or more cooperating adhesive portions 209, 214 as the adhesive between the cooperating portions will contact both portions.

A wing panel 204 extends outwardly from the side 116. This wing panel 204 includes a cut away portion 206, which extends under the buttons 120, 148. When the unitary die cut 202 is folded and the wing panel 204 is adhered to the inner surface 304 of the outer sleeve 102, a thickness 205 of the material 207 of the wing panel 204 defines the tab engaging protrusion 208. As would be understood to a person of skill in the art, once the outer sleeve 102 is folded along die lines 201, and the wing 204 is adhered to the rear surface 112, the unitary die cut 202 has been formed into a three-dimensional shape. At this stage in formation, the interior cavity 302 of the outer sleeve 102 is mostly formed; however, the first end 106 of the outer sleeve 102 has not yet been formed and closed.

The end flap panels 219, 221, 223, and 229 of the unitary die cut 202 will form the first end 106, which is a closed end. The flap panels 219 and 223 are folded inwardly toward the receiving cavity 302. Adhesive is located between adhesive portion 214 on flap panel 221 and the adhesive portion 209 on the flap panel 229, with the flap panel 221 located outwardly relative the flap panel 229. When the flap panels 221 and 229 are adhered, the first end 106 is formed.

Adhesive is located between the adhesive portion 214 of open end flap panel 225 and the adhesive portion 214 on an interior surface (not shown) of the upper surface 203. The open end flap panel 225 is folded inwardly and adhered with the interior surface of the upper surface 203, to increase the strength to the outer sleeve 102 toward the opening 110.

The separation prevention tab 227 is folded inwardly into the opening 110. Preferably, the separation prevention tab 227 is not adhered to the inner surface 304 of the lower surface 112 so that the separation prevention tab 227 can readily interact with and engage the locking tabs 130, 132 (e.g., with the locking tabs 130, 132 extending into a pocket created between the separation prevention tab 227 and the inner surface 304 of the lower surface 112). As was previously described, the separation prevention tab prevents the inner drawer 104 from being fully withdrawn from the outer sleeve 102 (e.g., preventing the inner drawer 104 from fully separating from the outer sleeve 102).

FIG. 2B depicts an exemplary die cut 238 from which the inner drawer 104 can be foldably formed. This die cut 238 depicts a plan view of the inner drawer 104 in a flattened, unassembled state. The inner drawer 104 is formed of a unitary sheet 240 of material 264, which is depicted as the unitary die cut 238. This unitary die cut 238 preferably includes all the features which will be present in the inner drawer 104; however, such features are depicted in a flattened state.

The features present in the inner drawer 104 are cut from a sheet of material 264 feedstock utilizing a mechanized stamping die. For example, the first end 140, the second end 142, the upper portion 402, the lower surface 136, the opposing sides 144, 146, and the locking tabs 130, 132 are formed into the material 264 of the unitary die cut 238 by the die. As is illustrated, the locking tabs 130, 132 are depicted as being die cut along cut line 254 from the material 264 of the first end 140 of the inner drawer 104 and the material of the inner end panel 252. The integral forming of the locking tabs 130, 132 with the unitary die cut 238 is highly advantageous as the manual labor required by locking devices of the prior art is eliminated, and the construction of the inner drawer 104 can be almost entirely mechanized via the mechanized stamping die, a mechanized folding machine, and mechanized adhesive machine. The unitary die cut 238 fails to include any joining of materials as the material 264 extends throughout the unitary die cut 202 without the need for any joining therein.

The inner drawer 104 is foldably formed from the unitary die cut 238. Exemplary typical fold lines 230 are depicted as dotted lines 230 and reverse fold lines 232 are depicted as segmented dotted lines 232. The typical fold lines 230 can be stamped into the material 264 during the die cutting operation to ease further folding operations. The reverse fold lines 232 can be take the form of perforations which are stamped into the material 264 during the die cutting operation.

It has been discovered that use of the unitary die cut 238 to form the inner drawer 104 can greatly reduce labor costs as the folding and forming of the inner drawer 104 from the unitary die cut 238 can be accomplished mechanically, via mechanized folding and adhering machines as are known. As will be appreciated, the full mechanization of the assembly of the inner drawer 104, in addition to the full mechanization of the outer sleeve 102 can significantly decrease the labor costs relative the hand assembled and adhered prior art child resistant packages.

The plan view of FIG. 2B depicts an outer surface 244 of the material 264 (e.g., the outer surface 244 being the surface of the flattened, unassembled unitary die cut 238 of the material 264 which defines the exterior facing surfaces of the inner drawer 104). However, the outer surface 244 also includes the inner side panels 246, 248 and inner end panels 250, 252 which are oriented inwardly toward the product receiving cavity 404.

Assembling the unitary die cut 238 of FIG. 2B into the assembled inner drawer 104 of FIG. 4, which does not include a product retaining insert 268, will now be described. As was discussed with regard to FIG. 2A, although adhesive is not typically applied upon the die cut 238 prior to the mechanized folding and adhering operations, exemplary adhesive portions 242 are depicted upon the die cut 238 to further describe the mechanized adhering operation. Adhesive portions 242 are located on the inner surface (not shown) of the material 264, which is located opposite to the outer surface 244. As will be appreciated, adhesive may be applied to one or more cooperating adhesive portions 244 as the adhesive between the cooperating portions will contact both portions.

The die cut 238 is mechanically folded at typical fold lines 230 and reverse fold lines 232. The first end 140 of the inner drawer 104 is formed by folding the first end 140 panel upwardly relative the lower surface 136 with the inner end panel 252 folded downwardly. The lower panel 262 rests upon an interior surface 406 of the lower surface 136. As is illustrated in FIG. 4, during this folding of the first end 140, the locking tabs 130, 132 are not folded; rather, they can remain outwardly oriented as is shown in FIG. 4.

The second end 142 of the inner drawer 104 is formed by folding the second end panel 142 upwardly relative the lower surface 136. The inner end panel 250 is folded downwardly and the lower panel 260 rests upon the interior surface 406.

Lower adhering panels 256 and 258 are adhered with the interior surface 406 of the lower surface 136, with a portion of the lower adhering panels 256, 258 resting atop the lower panels 260, 262 to secure the lower panels 260, 262 to the interior surface 406. In this manner, the three-dimensional inner drawer 104 as illustrated in FIG. 4 (e.g., having opposing sides 144, 146, and ends 140, 142 extending upwardly to define the product receiving cavity 404), including the locking tabs 130, 132 extending outwardly from the first end 140, is formed of an almost entirely mechanized process.

As has been discussed, the locking tabs 130, 132 are integrally formed with the inner drawer 104 to form a unitary die cut 238 which is a single, unitary sheet 240 of material 264. In this manner, rather than orienting and adhering polymer or metallic locking devices by hand, per the teachings of the prior art, the locking tabs 130, 132 are cut and formed by through the mechanized processes described herein. The locking tabs 130, 132 remain attached with the lower surface 136 of the tray 104, with material 264 extending therebetween. The only separation between the lower surface 136 and the locking tabs 130, 132 is the fold 230.

In one specific, non-limiting form, the adhesive utilizes to join the outer sleeve 102, the inner drawer 104, and the product retaining insert 268 can take the form extruder adhesive, such as 4002B extruder adhesive. Although the child resistant container 100 is described herein as being held together through adhesives, in further forms it is contemplated that the child resistant container 100 can be held together through a variety of tapes, mechanical fasteners, epoxies, or other fastening means, as would be known to a person of skill in the art.

Moreover, although specific mechanized folding and adhering operations have been described herein, these specific folding and adhering operations are to be construed as non-limiting unless specifically stated to the contrary. It is contemplated that a wide variety of mechanical folding and adhering processes may be utilized to form the inner drawer 104 and the outer sleeve 102.

In one specific, non-limiting form, the material 264 of the inner drawer 104 and the material 207 of the outer sleeve 102 are both solid bleached sulfate board, commonly referred to as SBS board. 18 point SBS board has been determined to impart sufficient strength to the child resistant container 100 (including the locking tabs 130, 132 which are integrally formed with the lower surface 136 of the inner drawer 104) to prevent a young child from easily accessing the product within the product receiving cavity 404 (e.g., via continually pulling hard to attempt to overpower the locking tabs 130, 132, attempting to tear into the material 207 of the outer sleeve 102, etc.).

However, it is contemplated that the materials 264 and 207 may take the form of SBB, FBB, various other cardboards, heavyweight papers, composite materials, polymers, or other materials with suitable strength for the desired application. A tear-resistant coating (not shown) may be applied to the materials 264 and 207 to further strengthen the child resistant container 100 and reducing the likelihood that a young child would be able to tear into the outer sleeve 102. One exemplary, non-limiting tear-resistant coating is a 1.2 mil anti scratch thermal lamination, item 30F244 sold under the trade name Derprosa; however, the use of various other suitable tear-resistant coatings, as would be known to a person of skill, are contemplated herein.

Product retaining inserts are commonly utilized within the packaging industry, and with regard to marijuana related products, to prevent the products from being tossed around, and potentially damaged, within the packaging. An exemplary product retaining insert 268, to be located within the cavity 404, will now be described. Referring to FIGS. 2C and 6B, the exemplary product retaining insert 268 is depicted as taking the form of a vape cartridge insert 268 which is designed to receive and retain a vape cartridge (not shown) within the product receiving cavity 404.

This product retaining insert 268 can be formed from a die cut 266. FIG. 2C depicts an upper surface 272 of the die cut 266. The die cut 266 can be a unitary die cut 266 in which the features of the assembled product retaining insert 268 are all formed into a single unitary sheet of material 270. The material 270 can be the same as materials 264 and 207; however, the product retaining insert 268 can be formed from a variety of materials 270 as will be understood to a person of skill.

The product retaining insert 268, as depicted in FIG. 6B, is foldably formed from the die cut 266. Adhesive portions 276 are located on the upper surface 272 of the die cut 266 and adhesive portions 274 are located on the lower surface (not shown) of the die cut 266, opposite the upper surface 272. The die cut 266 can be mechanically folded along fold lines 288.

The product retaining insert 268 can be adhered into the product receiving cavity 404 of the inner drawer 104. As is best illustrated in FIG. 6B, the side panels 284 can be adhered to the inner side panel 248 and the side panels 282 can be adhered with the inner side panels 248. The first end panel 278 is depicted as being adhered with the inner end panel 252 and the second end panel 280 can be adhered with the inner end panel 250.

Once the outer sleeve 102 and inner drawer 104 are fully assembled, the inner drawer 104 can be inserted into the outer sleeve 102. As has been described herein, the locking tabs 130, 132 are folded, at the fold line 230, rearwardly toward the lower surface 136. The first end 140 of the inner drawer 104 can now be inserted into the opening 110. As the first end 140 of the inner drawer 104 is slid through the interior cavity 302 toward the first end 106 of the outer sleeve 102, the distal ends 154 of the locking tabs 130, 132 will pass over the tab engaging protrusion 208 and the child resistant container 100 is placed in a closed configuration with the locking mechanism 702 locked.

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as permitted under the law. Accordingly, the scope of the present invention should be considered in terms of the following claims and is understood not to be limited to the details of structure and operation shown and described in the specification and drawings.

It should be understood that while the use of the word preferable, preferably, or preferred in the description above indicates that feature so described may be more desirable, it nonetheless may not be necessary and any embodiment lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow.

In reading the claims it is intended that when words such as “a,” “an,” “at least one” and “at least a portion” are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. Unless specifically stated to the contrary in the claim, the language “at least one of X, Y, and Z” should be interpreted as including both the conjunctive and disjunctive forms. Specifically, the language “at least one of X, Y, and Z” is intended to encompass the following permutations of X, Y, and Z: X alone; Y alone; Z alone; X and Y; X and Z; Y and Z; and X, Y, and Z. Further, when the language “at least a portion” and/or “a portion” is used the item may include a portion and/or the entire item unless specifically stated to the contrary.

Claims

1. A child resistant container, comprising:

an outer housing defining an internal cavity;

an inner drawer having a product receiving area, wherein a first end of the inner drawer is received within the internal cavity;

a catch located at the inner drawer, wherein the catch is integrally formed with the inner drawer, and wherein the catch is configured to restrict movement of the inner drawer relative to the outer housing; and

a release configured to act on the catch.

2. The child resistant container of claim 1, wherein the inner drawer is slidably received within the internal cavity.

3. The child resistant container of claim 2, wherein the outer housing extends over the product receiving area when the inner drawer is slid into the internal cavity.

4. The child resistant container of claim 3, wherein the catch is a locking tab, and wherein the inner drawer and the locking tab are formed of a unitary die cut.

5. The child resistant container of claim 4, further comprising a fold between the first end of the inner drawer and the locking tab, and wherein the locking tab extends along a lower surface of the inner drawer toward a second end of the inner drawer.

6. The child resistant container of claim 4, further comprising a tab engaging protrusion located at an internal surface of the outer housing, and wherein contact between a distal end of the locking tab and the tab engaging protrusion restricts the inner drawer from sliding outwardly relative to the outer housing.

7. The child resistant container of claim 6, wherein the release further comprises a button configured to pivot inwardly from the outer housing, and wherein the button is formed into a material of the outer housing.

8. The child resistant container of claim 7, wherein the button, when depressed by a user, is configured to move the locking tab inwardly so that the inner drawer can be slid outwardly from the internal cavity.

9. The child resistant container of claim 1, wherein the release further comprises two buttons located at the outer housing, wherein the buttons are foldably connected to the outer housing, wherein the catch further comprises two locking tabs, and wherein the locking tabs are foldably connected to the first end of the inner drawer.

10. The child resistant container of claim 9, wherein the buttons and the outer housing are formed of a unitary die cut of solid bleached sulphate board, and wherein the locking tabs and the inner drawer are formed of a second unitary die cut of solid bleached sulphate board.

11. A container, comprising:

an outer sleeve having an interior cavity;

an inner drawer extending between a first end and a second end, wherein the inner drawer has a product receiving area, and wherein the outer sleeve is configured to extend over the product receiving area to prevent access to the product receiving area;

a locking tab located at the inner drawer, wherein the locking tab is integrally formed with the inner drawer from a single portion of material;

a tab engaging protrusion located at an internal surface of the outer sleeve, wherein the tab engaging protrusion is configured to engage the locking tab to restrict sliding movement of the inner drawer relative to the outer sleeve; and

a release mechanism located at an external surface of the outer sleeve, wherein the release mechanism is configured to act upon the locking tab to prevent the tab engaging protrusion from engaging the locking tab.

12. The container of claim 11, wherein the inner drawer and the locking tab are foldably formed from a single die cut, and wherein the locking tab is attached to the first end of the inner drawer at a fold.

13. The container of claim 11, wherein the release mechanism is a button, wherein the button is formed in the outer sleeve, and wherein the button is configured to contact the locking tab to move the locking tab away from the tab engaging protrusion when the button is depressed.

14. The container of claim 11, wherein the outer sleeve extends between a first end and a second end, wherein the outer sleeve substantially defines a rectangular prism, and wherein a separation prevention tab is located at the second end of the outer sleeve.

15. The container of claim 11, further comprising a product retaining insert located in the product receiving area.

16. A method for forming a child resistant container, comprising:

folding a first portion of material to form an outer sleeve having an interior cavity, wherein an internal surface of the outer sleeve has a tab engaging protrusion;

providing a second portion of material, wherein the second portion of material includes a locking tab integrally formed with the second portion of material;

mechanically folding the second portion of material to form an inner drawer, wherein the inner drawer extends between a first end and a second end;

folding the locking tab outwardly from the first end; and

inserting the first end of the inner drawer through an opening in the outer sleeve and into the interior cavity.

17. The method of claim 16, wherein providing the second portion of material further comprises die cutting the second portion of material from a material feedstock, wherein the second portion of material is a unitary die cut, and further comprising foldably forming the inner drawer, the locking tab, and a product receiving area from the unitary die cut.

18. The method of claim 16, further comprising adhering the tab engaging protrusion to the internal surface of the outer sleeve, wherein the tab engaging protrusion is configured to engage a distal end of the locking tab, and wherein sliding movement of the inner drawer relative the outer sleeve is restricted when the distal end of the locking tab is engaged by the tab engaging protrusion.

19. The method of claim 16, further comprising:

die cutting the first portion of material from a material feedstock, wherein a release button is die cut into the outer sleeve; and

wherein the release button, when depressed, is configured to act upon the locking tab to prevent the tab engaging protrusion from engaging the locking tab to enable sliding movement of the inner drawer relative the outer sleeve.

20. The method of claim 16, wherein providing a second portion of material further comprises die cutting the second portion of material from a sheet of solid bleached sulphate board.