US20230030821A1

US20230030821A1 - Container assembly with releasable substrate

Info

Publication number: US20230030821A1
Application number: US17/537,159
Authority: US
Inventors: James Chu; Philippe HOLTHUIZEN; George Douglas IRWIN; Eric Wong
Original assignee: Kacepack Ltd
Current assignee: Kacepack Ltd
Priority date: 2021-07-30
Filing date: 2021-11-29
Publication date: 2023-02-02

Abstract

A container is disclosed that includes an outer shell with an opening. A receptacle can be insertable through the opening of the outer shell, the receptacle configured to receive contents of the container. A flexible substrate can be releasably sealed to the receptacle. The flexible substrate can include a first edge, a second edge opposite the first edge, and one or more anchors positioned on or adjacent the second edge. Each of the one or more anchors are configured, upon unpeeling an inner side of the flexible substrate from the receptacle, to remain adhered to the receptacle

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part (CIP) of U.S. Design patent application No. 29/788,824, filed Jul. 30, 2021, which is incorporated by reference in its entirety, for all purposes, herein.

FIELD

Embodiments of the present disclosure relate generally to small containers and more specifically containers with child-resistant features, and related methods of use thereof.

BACKGROUND

Portable, child-resistant containers may be useful for a variety of applications. For example, such containers may be used to store contents, such as medications, tobacco products, cannabis products, or other products and substances that may be hazardous to children. Such containers may ideally be lightweight, easily opened and closed to keep the contents fresh, and include a mechanism suitable for preventing children from accessing the contents. Existing containers may lack some or all of these desirable features and may further be constructed in a manner that is inefficient for mass production. Accordingly, existing containers may not be suitable for retail distribution of the aforementioned products that may be stored in such containers.
As such, there exists a need for improved child-resistant containers and methods of using the same to provide users with the desirable features described herein previously via a container that can be manufactured in a low-cost and efficient manner.
The present disclosure is directed to addressing the above-referenced challenges. The background description provided herein is for the purpose of generally presenting the context of the disclosure. Unless otherwise indicated herein, the materials described in this section are not prior art to the claims in this application and are not admitted to be prior art, or suggestions of the prior art, by inclusion in this section.

SUMMARY

In accordance with certain embodiments of the present disclosure, a container is disclosed that includes an outer shell with an opening. A receptacle can be insertable through the opening of the outer shell, the receptacle configured to receive contents of the container. A flexible substrate can be releasably sealed to the receptacle. The flexible substrate can include a first edge, a second edge opposite the first edge, and one or more anchors positioned on or adjacent the second edge. Each of the one or more anchors are configured, upon unpeeling an inner side of the flexible substrate from the receptacle, to remain adhered to the receptacle
In some examples, the outer shell is a sleeve with an opening through which the receptacle can be inserted.
In some aspects, the outer shell can include an open upper end. A cover can be releasably connected to the open upper end to form an enclosure between the cover and the outer shell.
In some aspects, the first edge can be included with a pull tab.
In some aspects, the inner side includes an adhesive that can be selectively positioned and configured to removably seal the inner side to an upper planar surface of the receptacle.
In some aspects, the one or more anchors is integrally formed with the inner side and extending from one or more cutouts located adjacent the second edge, wherein the one or more anchors include a fixed end positioned on or adjacent the second edge and an elongate portion extended away from the second edge within the one or more cutouts.
In some aspects, the outer shell includes a closed lower end and a cavity defined between the closed lower end and the open upper end.
In some aspects, one or more walls are extended from the closed lower end to the open upper end of the outer shell, the one or more walls including one or more receivers configured to securely engage with a locking mechanism of the receptacle once the receptacle is nested within the outer shell.
In some aspects, the one or more receivers include a latch inwardly extended from the one or more walls to which the locking mechanism couples when the receptacle is nested within the outer shell.
In some aspects, the receptacle can be a locking blister including one or more recesses configured to receive the contents.
In some aspects, the one or more recesses can include at least three spaced apart recesses contiguous with a planar upper surface of the receptacle, each of the at least three spaced apart recesses configured to separately receive a portion of the contents.
In some aspects, the receptacle can include a planar upper surface adjacent the one or more recesses. A locking mechanism can extend from at least one of the planar upper surface and a wall of the receptacle to securely engage the receptacle with one or more receivers of the outer shell.
In some aspects, the receptacle can be an integrally formed plastic structure.
In some aspects, the locking mechanism can be contiguously formed with the at least one of the planar upper surface and the wall of the receptacle, the locking mechanism including a locking panel hingedly articulating away from a first edge of the receptacle.
In some aspects, the locking mechanism can include a first locking panel extended from a wall positioned on a first edge of the planar upper surface and a second locking panel extended away from a wall positioned on a second edge of the planar upper surface, the first edge being opposite the second edge.
In some aspects, a flexible substrate is disclosed, which can include an inner side configured to be adhered to an opening of a container. A first edge can be included with a pull tab. A second edge can be opposite the first edge. One or more anchors can be positioned on or adjacent the second edge. Each of the one or more anchors are configured, upon unpeeling the inner side from the container, to remain adhered to the opening of the container.
In some aspects, the one or more anchors can include a paddle-like shape with an elongate portion having a constant width and a fixed end proximally extended from the elongate portion having a width less than the constant width of the elongate portion.
In some aspects, the one or more cutouts include a pair of rounded portions curved into a centralmost portion of the fixed end. In some aspects, the centralmost portion is be thinnest portion of the fixed end whereas proximal and distal portions of the fixed end outward from the centralmost portion.
In some aspects, the one or more anchors can be integrally formed with the inner side and extending from one or more cutouts located adjacent the second edge.
In some aspects, the one or more anchors can include a fixed end positioned on or adjacent the second edge and an elongate portion extended away from the second edge within the one or more cutouts.
In some aspects, each elongated portion is configured, upon unpeeling the substrate from the container by the first edge toward the second edge, to remain adhered to the opening of the container.
In some aspects, the inner side is unpeeled by the first edge toward the second edge from the container by grasping the pull tab.
In some aspects, a method is disclosed for assembling a container that includes an outer shell or a sleeve comprising an opening and a receptacle insertable through the opening and configured to receive contents of the container. The method can include adhering an inner side of a flexible substrate to at least one of the opening and an upper surface of the receptacle. The flexible substrate can include a first edge and a second edge opposite the first edge, and one or more anchors positioned on or adjacent the second edge. The one or more anchors can be integrally formed with the inner side and extend from one or more cutouts of the flexible substrate adjacent the second edge. The one or more anchors can include a paddle-like shape with an elongate portion having a constant width. The method can include unpeeling, from the first edge, the inner side of the flexible substrate from the at least one of the opening and the upper surface of the receptacle such that, upon unpeeling the inner side of the flexible substrate to expose the contents, one or more anchors of the flexible substrate opposite the first edge remain adhered to the at least one of the opening and the upper surface of the receptacle.
In some aspects, the method can include extending a fixed end portion of the one or more anchors from the elongate portion, the fixed end comprising a width less than the constant width of the elongate portion.
In some aspects, the method can include sealing, from the first edge, the inner side of the flexible substrate back to the at least one of the opening and the upper surface of the receptacle.
In some aspects, the method can end after some or all of these steps. In other aspects, additional steps according to the examples described herein can be performed.
To the accomplishment of the foregoing and related ends, certain illustrative aspects are described herein in connection with the following description and the appended drawings. These aspects are indicative, however, of but a few of the various ways in which the principles of the claimed subject matter may be employed and the claimed subject matter is intended to include all such aspects and their equivalents. Other advantages and novel features may become apparent from the following detailed description when considered in conjunction with the drawings

BRIEF DESCRIPTION OF THE FIGURES

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various exemplary aspects of the disclosure, and together with the description serve to explain the principles of the present disclosure.

FIG. 1A shows an upper isometric view of an assembled container system, according to certain aspects of this disclosure.

FIG. 1B shows a lower isometric view of the assembled container system of FIG. 1A.

FIG. 2A shows an isometric view of the assembled container system of FIG. 1 .

FIG. 2B shows an exploded view of the assembled container system of FIG. 1 .

FIG. 3 shows a lower isometric view of an insert of the container system of FIG. 1 .

FIG. 4A shows an upper isometric view of the assembled container system of FIG. 1 with a substrate in an opened state.

FIG. 4B shows a top plan view of the assembled container system of FIG. 4A with the substrate in the opened state.

FIG. 5A shows a close-up upper isometric view of section 5A-5A of FIG. 2B.

FIG. 5B shows a close-up upper isometric view of section 5B-5B of FIG. 2B.

FIG. 6A shows an upper isometric view of a partially exploded container system in a first configuration, according to certain aspects of this disclosure.

FIG. 6B shows a lower isometric view of the assembled container system of FIG. 6A in a second configuration.

FIG. 7A shows an upper isometric view of a partially exploded container system in a first configuration, according to certain aspects of this disclosure.

FIG. 7B shows an upper isometric view of an assembled container system with a substrate partially shown in an opened state.

FIG. 7C shows an upper isometric view of an example receptacle.

FIG. 8 depicts a flow diagram of a method of assembling a container system according to certain aspects of this disclosure.

DETAILED DESCRIPTION

Particular aspects of the present disclosure are described in greater detail below. The terms and definitions provided herein control, if in conflict with terms and/or definitions incorporated by reference. The Figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the disclosed subject matter.
Particular aspects of the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity, and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Different embodiments may have different advantages, and no particular advantage is necessarily required of any embodiment.
As used herein, the terms “comprises,” “comprising,” or any other variation thereof are intended to cover a non-exclusive inclusion, such that a process, method, composition, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such process, method, composition, article, or apparatus. The term “exemplary” is used in the sense of “example” rather than “ideal.”
As used herein, the singular forms “a,” “an,” and “the” include plural reference unless the context dictates otherwise.
As used herein, “approximately” and “about” refer to being nearly the same as a referenced number or value. As used herein, the terms “approximately” and “about” should be understood to encompass ±10% of a specified amount or value (e.g., “about 90%” can refer to the range of values from 81% to 99%).
As used herein, when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, if an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present.
In general, the present disclosure is directed to improved containers and methods for using the same. The devices and methods according to the present disclosure offer significant technical benefits which will become apparent. Portable, child-resistant containers may be useful for storing medications, tobacco products, cannabis products, or other products and substances that may be hazardous to children. As one example, such containers may be used to store contents, such as pre-rolled tobacco or cannabis cigarettes. In such an application, child-resistant containers may serve multiple functions, such as protecting the contents from physical damage during shipment, maintaining the freshness of the contents, providing a means for an end user to safely and easily transport the contents, and preventing access by children to whom the contents may be hazardous or toxic.
It may be desirable for child-resistant containers to be sufficiently rigid to protect the contents during shipment, for example, to a retail location or to an end user. If the contents of a container include pre-rolled cigarettes, for example, the container may protect the cigarettes from physical damage during shipment. The container may further be suitable for being packed in large quantities with other similar containers without buckling or flattening.
It may also be desirable for child-resistant containers to be easily opened and resealed such that the contents need not be removed from the container all at once. For example, a user may wish to open such a container to remove contents (e.g., one of multiple cigarettes for immediate use and reseal the remaining cigarettes in the container). However, the user may save the remaining contents for later use in the container, thereby preventing the contents, such as cigarettes or other perishable product(s), from becoming stale and also preventing access of the remaining contents by children. The container may further allow the user to easily transport the remaining cigarettes in a pocket, for example, without risking crushing, tearing, or other physical damage to the cigarettes.
It may further be desirable for child-resistant containers to include a mechanism suitable for preventing children from accessing the contents of the containers while simultaneously being easily operable by the intended user. An easily operable mechanism may be operated manually, requiring minimal force and not requiring tools. An easily operable mechanism may also be sufficiently complex so as to inhibit a child from opening the container, but not so complex that an adult could not readily open the container.
Additionally, it may be desirable for child-resistant containers incorporating one or more of the foregoing features to be formed of a simple construction to enable efficient and low-cost manufacturing. Therefore, such containers may be used in high-volume packaging applications without significantly contributing to a cost of the end product.
Accordingly, a need exists for improved child-resistant containers and methods of using the same to provide users with the desirable features described herein previously via a container that can be manufactured in a low-cost and efficient manner. Embodiments of the present disclosure offer technical solutions to address the foregoing needs, as well as other needs.
Turning to the drawings, FIG. 1A is an upper isometric view of a container system 100 in a first configuration, according to certain aspects of this disclosure. In the first configuration, container system 100 can be partially or completely assembled. FIG. 1B shows a lower isometric view of container system 100 in the first, assembled configuration. Container system 100 can include a cover 110 that is releasably connected to the open upper end 132 of an outer shell 130 to form an enclosure therebetween configured to store contents. Cover 110 and/or outer shell 130 can be can be formed, for example, of folded paper materials such as paperboard, cardboard, or the like. In some embodiments, cover 110 and/or outer shell 130 may alternatively be formed of molded plastic materials such as polyethylene terephthalate (PET), high-density polyethylene (HDPE), polyvinyl chloride (PVC), low-density polyethylene (LDPE), polypropylene (PP) or polystyrene. In some embodiments, cover 110 and/or outer shell 130 may formed of a stamped metal material such as aluminum, tin, or the like. It is understood that the term, “contents”, can include any consumable material such as medications, pre-rolled cigarettes, edible products, or any other item (e.g., a solid, liquid, gel, or any other form) suitable for storage.
To access the contents of container system 100, a user can begin with the assembled container system 100 of FIGS. 1A and 1B, then remove cover 110. As shown in FIG. 2A, cover 110 can be substantially rectangular and include a first edge 118 parallel and opposite a second edge 116. A third edge 119 can be orthogonal to either or both of edges 116, 118. A fourth edge 115 can be opposite and parallel to edge 119. While cover 110 is shown with four edges in a substantially rectangular shape, other shapes of cover 110 are possible, as needed or required. Cover 110 can also include a protective outer surface 111. Cover 110 can include one or more receivers 113 to securely engage with one or more corresponding couplers 133 of outer shell 130 in the assembled state. In some aspects, receiver 113 can be a cutout or aperture sized to securely receive corresponding coupler 133 of outer shell 130. For example, one or more receivers 113 can include a cutout in edge 115 and the one or more corresponding couplers 133 can include a latch or protrusion configured for insertion into one or more receivers 113 in the assembled state. In some aspects, when assembling outer shell 130 to cover 110, one or more corresponding couplers 133 can be configured to flex inwardly until being sufficiently coupled with one or more receivers 113 as outer shell 130 is assembled with cover 110. To disengage the one or more couplers 133 from the corresponding receivers 113, an externally positioned marking 134 can be provided. In some aspects, an end user may disengage couplers 133 from receivers 113 by feeling the outer surface of outer shell 130 until sensing marking 134 and then squeezing outer shell 130, thereby causing couplers 133 to disengage from receivers 113.
With cover 110 removed, as in FIG. 2A, substrate 150 can be seen covering receptacle 170 in the first configuration, which is shown nested in outer shell 130. In some aspects, it is contemplated that contents can be sealed (e.g., hermetically sealed) in one or more recesses 171 a of receptacle 170 when flexible substrate 150 is removably sealed thereover. Substrate 150 can be transparent, opaque, semi-transparent, or any combination thereof.
Exemplary structure of receptacle 170 is shown and further discussed in FIG. 3 and FIG. 4A. Substrate 150 can be at least one of a flexible membrane, film, sheet, surface, or other flexible member(s) configured to be attached in a manner so as to create a fluid impermeable seal and re-seal contents in receptacle 170 and/or outer shell 130. Non-limiting examples of fluid-impermeable materials contemplated to construct substrate 150 can include natural and synthetic rubbers, polyvinyl chloride, ethylene-vinyl acetate copolymers, polyurethanes, acrylic ester polymers, polyamides and the like. Other examples of flexible substrates are contemplated to include polyethylene terephthalate (PET), oriented polypropylene (OPP), biaxially oriented polypropylene (BOPP), Polyvinyl Chloride (PVC), art paper (wood-based), Coated Art paper (laminated with polypropylene), wood free paper, polycarbonates (PC), PET plated aluminum and/or gold, aluminum foil, nylon, and/or a holographic material, as needed or required.
Receptacle 170 can be insertable through open upper end 132 of outer shell 130. Receptacle 170 can be a locking blister that is integrally formed (e.g., a molded plastic structure) and can include one or more recesses 171 a to receive the contents (see FIGS. 3 and 4A). Receptacle 170 can be formed from plastic material(s) such as PET, HDPE, PVC, LDPE, PP or polystyrene. As shown in FIG. 3 , which is a lower isometric view of receptacle 170 when disassembled from container system 100, the one or more recesses 171 a can include at least three spaced apart and aligned recesses contiguous with a planar upper surface 171 b surrounding the recesses. Each of the depicted recesses 171 a is configured to separately receive all or a portion of the contents of container system 100. FIG. 3 shows three aligned recesses 171 a with axes of adjacent recesses 171 a aligned in parallel. However, the solution of this disclosure is not so limited and it is contemplated that fewer (e.g., two recesses, only one recess, etc.) or greater (e.g., more than three recesses) number of recesses 171 a can be included in receptacle 170. For example, referring to FIGS. 7B and 7C, an example embodiment of modified receptacle 370 is shown, with similar structure to receptacle 170, except with more than three recesses 371 a. In FIG. 7B, receptacle 370 is nested, assembled with outer shell 330 while FIG. 7C shows receptacle 370 alone. Receptacle 370 as illustrated can include four recesses 371 a, though fewer or greater number of recesses 371 a can be included. Recesses 371 a can each include respective axis 371 b aligned in a non-parallel orientation relative to an axis 371 b of an immediately adjacent recess 371 a. As used herein, the term “non-parallel” can refer to any orientation defined by an angle formed between one axis 371 b relative to an immediately adjacent axis 371 b that less than or greater than 180 degrees but never 180 degrees (e.g., 15 degrees, 30 degrees, 45 degrees, 90 degrees, etc.). In some aspects, recesses 371 a can each be formed with different and/or the same non-parallel orientations than immediately an adjacent recess 371 a. In some aspects, some of the recesses 371 a can each be formed with non-parallel orientations while other recesses 371 a can be oriented parallel. As shown in the example embodiments of FIGS. 7B-7C, the recesses 371 a may be arranged in a fan-like configuration. That is, proximal ends of recesses 371 a may be disposed closer to one another than the respective distal ends of recesses 371 a.
Turning back to FIG. 3 , the one or more recesses 171 a of receptacle 170 can be arranged as a matrix or grid of separate recesses integral with planar surface 171 b. Moreover, recesses 171 a may include any suitable shape and/or configuration. Referring to substrate 150, it can include an outer surface 151 opposite inner surface 153 (inner surface 153 is shown in FIGS. 4A and 4B where substrate 150 is being unpeeled). Inner surface 153 can include adhesive A selectively positioned thereon so as to facilitate sealing and re-sealing with corresponding surfaces of receptacle 170 and outer shell 130. In some aspects, adhesive A can be any suitable adhesive (e.g., glue) provided directly and/or indirectly in contact with a suitable substrate (e.g., any of the herein described substrates), such as a pressure sensitive adhesive. In some aspects, adhesive A can be selectively positioned in one or more regions of inner surface 153 so as to seal and re-seal with planar surface 171 b of receptacle 170, whereas other of the remaining regions of inner surface 153 can lack adhesive A, so as to avoid inadvertent sticking or otherwise damaging contents disposed within corresponding recesses 171 a. Adhesive A can be selectively positioned in one more adhering strips sized and positioned relative to corresponding planar surfaces 171 b and to avoid corresponding recesses 171 a.
In some aspects, adhesive A can be applied only along the perimeter of substrate 150 or otherwise selectively positioned so substrate 150 can sufficiently seal with corresponding surfaces of receptacle 170 and/or shell 130. While substrate 150 is shown as a seal-on/peel off cover through use of an adhesive, it is contemplated that substrate 150 can include other seal/re-seal approaches, including being a substrate that snaps-on or is press-fit to open and close and hinge about one or more anchors 152. In some aspects, a rubber gasket can be included (e.g., along an inner perimeter surface of open upper end 132 or along an outer perimeter surface of receptacle 170). For example, substrate 150 can include one or more mechanical connectors to facilitate sufficient sealing between substrate 150 and receptacle 170 and/or open upper end 132, including but not limited to one or more magnetic connectors, an openable seal along the perimeter of receptacle 170 and/or open upper end 132, a slider seal substrate 150 to receptacle 170 and/or open upper end 132, as well as other coupling mechanisms to effect a proper seal between substrate 150 and receptacle 170 and/or open upper end 132.
In some aspects, substrate 150 can be unpeeled (e.g., by grasping a pull tab 154 (shown in FIG. 2B) that is extended away from edge 156). Once grasped, tab 154 can be peeled back causing substrate 150 to unpeel from a receptacle 170 and/or outer shell 130. Container system 100 can include an outer shell 130 with an open upper end 132 and a closed lower end 131. A cavity can be defined between the open upper end 132 and closed lower end 131 in which contents or other components can be stored. One or more walls 135, 136, 138, 139 can extend from closed lower end 131 up to open upper end 132 end.
In some aspects, flexible substrate 150 can be releasably sealed to at least one of receptacle 170 or open upper end 132 (e.g., the upper perimeter of walls 135,136 138, 139) so that upon unpeeling, an inner side of the flexible substrate 150 from receptacle 170 and/or open upper end 132, at least a portion of the flexible substrate 150 remains adhered to at least one of the receptacle 170 and the open upper end 132.
Substrate 150 can be substantially rectangular and include a first edge 156 parallel and opposite a second edge 158. A third edge 159 can be orthogonal to either or both of edges 156, 158. A fourth edge 155 can be opposite and parallel edge 159. While substrate 150 is shown with four edges in a substantially rectangular shape, other shapes of substrate 150 are possible, as needed or required. In some aspects, first edge 156 can include a pull tab 154. Pull tab 154 can be detachable from the remainder of substrate 150 or can be integrally formed therewith (e.g., extended outward and/or away from edge 156 so as to be graspable by a user). One or more anchors 152 can be positioned on or adjacent edge 158, preferably opposite pull tab 154. The one or more anchors 152 can be configured, upon unpeeling the inner side 153 from receptacle 170 and/or open upper end 132, to remain adhered via adhesive A. In this respect, being fixedly adhered allows one or more anchors 152 to permit substrate 150 to rotate about anchors 152 in a hinge-like manner to render accessible contents of receptacle 170.
The one or more anchors 152 can be integrally formed with inner surface 153 and outer surface 151 of substrate 150, as shown in FIG. 5A which is a close-up of section 5A-5A of FIG. 2B. One or more anchors 152 can include a paddle-like shape and extend from one or more cutouts 152 b located adjacent edge 158. A fixed end 152 c of anchor 152 can be relatively short and thin relative to a wider, longer elongate portion 152 a. An outer edge of the one or more cutouts 152 b can be substantially elongate with a constant width and relatively flattened and/or blunt distal edge, opposite fixed end 152 c. A ratio can be defined between the length and the width of the one or more cutouts 152 b. For example, in certain aspects the ratio of the length and the width of one or more cutouts 152 b can vary from 1.5:1 to 6:1, and in the preferred embodiment can vary between 4:1 and 5:1. Preferably, the length of cutout 152 b can be approximately 22 mm and the width of the cutout 152 b can be about 5 mm. However, these dimensions are merely exemplary and not intended to be limiting, as other lengths and widths of cutout 152 b are contemplated, as needed or required.
A proximal end of the one or more cutouts 152 b can include a pair of rounded portions 152 d positioned around a thinned portion of fixed end 152 c. Portions 152 d can be relatively circular or elliptical so that fixed end 152 c can have a centralmost portion to be thinnest whereas proximal and distal portions of end 152 c can taper outward. For example, end 152 c can taper from a thinnest portion in its centralmost portion to the relatively constant width that commences at a proximal end of an elongate portion 152 a. In certain aspects, portions 152 d will extend no further than the constant width of cutout 152 b thereby limiting a maximum radius of portion 152 d. A ratio can be defined between the radius of portions 152 d and the width of the thinnest portion of end 152 c, which can vary from 1:1 to 5:1, and in the preferred embodiment is between 1:1 and 2:1. Preferably, the width of end 152 c can be about 1 mm and the radius of portions 152 b can be about 1 mm. However, these dimensions are merely exemplary and not intended to be limiting, as other dimensions are contemplated, as needed or required.
In certain aspects, elongate portion 152 a can be configured to fit within corresponding cutout 152 b but include a width greater than fixed end 152 c. Similar to the distal edge of corresponding cutout 152 b, a distal edge of elongate portion 152 a can be relatively flat or otherwise blunt with a relatively constant width or radius throughout its length. Elongate portion 152 a can similarly include the same or similar width—length ratio as corresponding cutout 152 b except for being slightly offset from corresponding cutout 152 b so as to permit the rest of substrate 150 to move between configurations, as needed or required.
Elongate portion 152 a can be configured so that, upon unpeeling substrate 150 from the container by urging edge 156 toward edge 158, elongate portion 152 a will remain fixedly adhered. In some aspects, one or more anchors 152 can be fixedly adhered by thermal or ultrasonic welding, adhesives, or any other suitable means. For example, anchor 152 can include an adhesive different (e.g., with a different tack) from the adhesive A of the remainder of substrate 150, so that anchor 152 can remain fixedly attached while the remainder of substrate 150 via adhesive A is capable of sealing and resealing between uses. In some aspects, the one or more anchors 152 can be fixedly adhered by thermal or ultrasonic welding or any other suitable means
As shown in FIG. 5A, in certain aspects elongate portion 152 a can be releasably and fixedly adhered to planar surface 171 b. For example, one or more anchors 152 can include a relatively thin, fixed end 152 c from which elongate portion 152 a extends along and adhered to planar surface 171 b. Elongate portion 152 a can be wider than fixed end 152 c. Elongate portion 152 a can be configured so that, upon unpeeling substrate 150 from the container by edge 156 toward edge 158, elongate portion 152 a will remain adhered. In some aspects, one or more anchors 152 can be fixedly attached by thermal or ultrasonic welding, adhesives, or any other suitable means.
As shown in FIG. 5B, which is a close-up of section 5B-5B of FIG. 2B, at least one of walls 135, 136, 138, 139 can include one or more receivers 137 a, 137 b configured to securely engage with a locking mechanism 177 of receptacle 170 once receptacle 170 is nested within outer shell 130. Locking mechanisms 177 may interact with corresponding receivers 137 a, 137 b, to prevent unintentional withdrawal of receptacle 170 from outer shell 130. For example, the interaction between locking mechanisms 177 and receivers 137 a, 137 b may counteract an upward force exerted on receptacle 170 when substrate 150 is unpeeled. Receivers 137 a, 137 b of outer shell 130 can include a latch inwardly extended from the one or more walls 135, 136, 138, 139 to which the locking mechanism 177 can rotatably, pivotally, or otherwise hingedly couple when receptacle 170 is nested within outer shell 130. In FIG. 5B, while marking 134 is shown along the inner surface of wall 139, marking 134 in FIG. 5B is intended to illustrate marking 134 as it forms an outward extended indentation that can be touched or sensed by an end user along the opposite, outer surface of wall 139.
An example locking mechanism 177 of receptacle 170 can be seen in FIG. 3 and FIG. 5A, which is a close-up of section 5A-5A of FIG. 2B. Locking mechanism 177 in some aspects can be contiguously formed with the at least one of planar upper surface 171 b and/or one or more of walls 175, 176, 178, 179 of receptacle 170. For example, in FIG. 5 A locking mechanism 177 is shown with a locking panel 177 b extended away from a bottom portion of wall 175 and coupled thereto by hinge 177 a. Panel 177 b can be, for example, one or more depressible tabs, depressible buttons, or any other suitable mechanism for selectively engaging with receivers 137 a, 137 b. In some examples, locking panel 177 b can be folded upward toward planar surface 171 b so that upon folding of locking panel 177 b upward toward planar surface 171 b, a natural resiliency of a hinge-like surface formed by the folding of locking panel 177 b can cause receptacle 170 to be biased outwardly, away from the wall or edge from which it extends. Accordingly, locking panel 177 b can be selectively depressed inwardly by the user.
In some aspects, locking panel 177 b can be in the same plane as a lower surface of corresponding portion of receptacle 170 (e.g., one or more of walls 175, 176, 178, 179). Mechanism 177 can be configured so that panel 177 b naturally is biased inward so that pressing against corresponding inner wall(s) of outer shell 130 causes a friction fit between mechanism 177 and outer shell 130, including any corresponding receiver (s) 137 a, 137 b. In some aspects, locking mechanism 177 b can be folded upward from hinge 177 a. While an integrally formed hinge 177 a is shown in FIG. 5A, other mechanisms to induce a biased pivot or rotation type movement are contemplated for use with system 100. Similar features of mechanism 177 are included in the opposite wall 179 of receptacle 170, as shown in FIG. 3 .
In this example, locking mechanism 177 can catch between the latch of corresponding receiver 137 a, 137 b to induce secure engagement between receptacle 170 and outer shell 130. Optionally, locking panel 177 b and hinge 177 a can be sized such that at the full extent of the permitted travel of locking panel 177 b, an outer tip of locking panel 177 b can abut or contact corresponding one or more receivers 137 a, 137 b.
FIG. 6A depicts an upper isometric, exploded view of a container system 200, in the form of a sleeve-and-drawer style container with example receptacle 270 and substrate 250 withdrawn, just prior to being advanced in opening 218 of sleeve 210. Sleeve 210 can be formed, for example, of folded paper materials such as paperboard, cardboard, or the like. In some embodiments, sleeve 210 may alternatively be formed of molded plastic materials such as PET, HDPE, PVC, LDPE, PP or polystyrene. In some embodiments, sleeve 210 may be formed of a stamped metal material such as aluminum, tin, or the like. FIG. 6B depicts receptacle 270 partially advanced through opening 218 with substrate 250 being opened about anchors 252, which are positioned at least partially in sleeve 210. Substrate 250 can be opened, similar to substrate 150, and therefore does not need to be positioned within sleeve 210 at all in order to be opened, as shown in FIG. 6B.
Substrate 250 can be largely similar to previous substrate 150, inclusive of positioning and structure of example anchors 252 with respect to sleeve 210 and/or receptacle 270. Anchors 252 may be substantially similar to anchors 152 described above. Sleeve 210 can be a unitary structure that includes an enclosure with opening 218 opposite a closed distal edge 216. Edge 276 of receptacle 270 (e.g., its distal end) can be advanced through opening 218. One or more foldable tabs 218 a can be positioned on opposite sides of opening 218. In FIG. 6A, each of tabs 218 a are depicted relatively open whereas in FIG. 6 B tabs 218 are folded inward so as to be aligned or otherwise parallel with side walls 215, 219 of sleeve 210. Receptacle 270 can include one or more recesses 271 a and planar surface 271 b, which in FIG. 6B is depicted as along an upper perimetral surface of walls 275, 276, 278, 279. While only a single recess 271 a is shown in FIG. 6B, more than one recesses 271 a is contemplated, similar to recesses 171 a.
FIG. 7A depicts an upper isometric, exploded view of system 200 with modified substrate 250′. Substrate 250′ here can include one or more portions 257 capable of being separately unpeeled from receptacle 270 (e.g., from around an upper perimetral surface of a recess 271 a) and/or substrate 250. The one or more portions 257 can be can be opened (e.g., unpeeled), similar to substrates 150 and 250.
Container system 200 can include a pair of opposite locking mechanisms 277, with hinge 277 a and panel 277 b. Panel 277 b may include for example, depressible tabs, depressible buttons, or any other suitable mechanism for selectively engaging locking ports 213. In some aspects, panel 277 b may be hinged tabs extending from and attached to hinge 277 a. Locking mechanisms 277 may be integrally formed with wall 275, such that they may be folded upward. Upon folding of locking mechanisms 277 upward toward the upper surface of receptacle 270, a resiliency of the hinges may cause the locking mechanisms 277 to be biased outwardly, away from respective side wall of receptacle 270. Locking mechanism 270, as described herein, may further include one or more of the features described in U.S. application Ser. No. 17/454,084, the entirety of which is incorporated by reference in its entirety as if set forth verbatim.
Mechanisms 277 can be optionally localized at or adjacent edge 276 so as to securely engage with corresponding tabs 218 a when tabs 218 are folded inwardly, as in FIG. 6B. Mechanism 277 can prevent receptacle 270 from becoming fully separated or detached from sleeve 210, as shown in FIG. 6B when receptacle 270 is at least partially assembled with sleeve 210. Mechanisms 277 may further serve to make container system 200 child resistant. For example, one or more locking ports 213 can be provided on sleeve 210 with which mechanisms 277 may selectively engage. An end user may disengage mechanisms 277 from locking ports 213 by depressing mechanisms 277 inwardly, thereby allowing receptacle 270 to slide relative to sleeve 210 to make the contents accessible. Container system 200, as described herein, may further include one or more of the features described in U.S. application Ser. No. 17/454,084 as well as subject matter of U.S. application Ser. No. 29/788,824 filed Jul. 30, 2021, the entirety of which is incorporated by reference in its entirety as if set forth verbatim.
FIG. 8 depicts a method 800 of assembling any of the herein disclosed container systems. Step 810 of method 800 can include adhering an inner side of a flexible substrate to an opening and/or an upper surface of the receptacle. The flexible substrate can be any of this disclosure, including one with a first edge and a second edge opposite the first edge, and one or more anchors positioned on or adjacent the second edge. The one or more anchors can be integrally formed with the inner side and extend from one or more cutouts of the flexible substrate adjacent the second edge. The one or more anchors can include a paddle-like shape with an elongate portion having a constant width. Step 820 of method 800 can include unpeeling, from the first edge, the inner side of the flexible substrate from the opening and/or the upper surface of the receptacle such that, upon unpeeling the inner side of the flexible substrate to expose the contents, one or more anchors of the flexible substrate opposite the first edge remain adhered to the opening and/or the upper surface of the receptacle. Method 800 can end after step 820. In other embodiments, additional steps according to the examples described above can be performed.
The systems and methods of this disclosure are beneficial by for providing content-dispensing container systems that can be repeatedly opened, re-closed many times without failure, with optimized container size relative to the size of its contents to minimize materials and reduce associated container shipping containers, with costs as low as possible, and also maintaining durable structural integrity. And although the exemplary embodiments described above have been disclosed in connection with a child-resistant container, those skilled in the art will understand that the principles set out above can be applied to any container and can be implemented in different ways without departing from the scope of the disclosure as defined by the claims. In particular, construction details, including manufacturing techniques and materials, are well within the understanding of those of skill in the art and have not been set out in detail here. These and other modifications and variations are well within the scope of the present disclosure and can be envisioned and implemented by those of skill in the art.
While certain features of the present disclosure are discussed within the context of exemplary procedures, systems, and methods may be used according to the general principles disclosed. The presently disclosed embodiments, therefore, are considered in all respects to be illustrative and not restrictive. It will therefore be apparent from the foregoing that while particular forms of the disclosure have been illustrated and described, various modifications can be made without departing from the spirit and scope of the disclosure and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the present disclosure being indicated by the following claims.

Claims

What is claimed is:

1. A container, comprising:

an outer shell comprising an opening;

a receptacle insertable through the opening of the outer shell, the receptacle configured to receive contents of the container; and

a flexible substrate releasably sealed to the receptacle, the flexible substrate comprising a first edge, a second edge opposite the first edge, and one or more anchors positioned on or adjacent the second edge,

wherein each of the one or more anchors are configured, upon unpeeling an inner side of the flexible substrate from the receptacle, to remain adhered to the receptacle.

2. The container of claim 1, wherein the outer shell includes an open upper end, and further comprising a cover releasably connected to the open upper end to form an enclosure between the cover and the outer shell.

3. The container of claim 1, wherein the first edge comprises a pull tab.

4. The container of claim 3, wherein the inner side comprises an adhesive configured to removably seal the inner side to an upper planar surface of the receptacle.

5. The container of claim 3, wherein the one or more anchors is integrally formed with the inner side and extending from one or more cutouts located adjacent the second edge, wherein the one or more anchors comprise a fixed end positioned on or adjacent the second edge and an elongate portion extended away from the second edge within the one or more cutouts.

6. The container of claim 1, wherein the outer shell comprises a closed lower end and a cavity defined between the closed lower end and the open upper end.

7. The container of claim 6, wherein one or more walls are extended from the closed lower end to the open upper end of the outer shell, the one or more walls comprising one or more receivers configured to securely engage with a locking mechanism of the receptacle once the receptacle is nested within the outer shell.

8. The container of claim 7, wherein the one or more receivers comprise a latch inwardly extended from the one or more walls to which the locking mechanism couples when the receptacle is nested within the outer shell.

9. The container of claim 1, wherein the receptacle is a locking blister comprising one or more recesses configured to receive the contents.

10. The container of claim 9, wherein the one or more recesses comprise at least three spaced apart recesses contiguous with a planar upper surface of the receptacle, each of the at least three spaced apart recesses configured to separately receive a portion of the contents.

11. The container of claim 9, wherein the receptacle includes:

a planar upper surface adjacent the one or more recesses; and

a locking mechanism extended from at least one of the planar upper surface and a wall of the receptacle to securely engage the receptacle with one or more receivers of the outer shell.

12. The container of claim 11, wherein the receptacle is an integrally formed plastic structure.

13. The container of claim 11, wherein the locking mechanism is contiguously formed with the at least one of the planar upper surface and the wall of the receptacle, the locking mechanism comprising a locking panel hingedly articulating away from a first edge of the receptacle.

14. The container of claim 11, wherein the locking mechanism includes a first locking panel extended from a wall positioned on a first edge of the planar upper surface and a second locking panel extended away from a wall positioned on a second edge of the planar upper surface, the first edge being opposite the second edge.

15. A flexible substrate, comprising:

an inner side configured to be adhered to an opening of a container;

a first edge comprising a pull tab;

a second edge opposite the first edge; and

one or more anchors positioned on or adjacent the second edge, the one or more anchors being integrally formed with the inner side and extending from one or more cutouts located adjacent the second edge;

wherein each of the one or more anchors are configured, upon unpeeling the inner side from the container, to remain adhered to the opening of the container.

16. The substrate of claim 15, wherein the one or more anchors comprise a paddle-like shape with an elongate portion comprising a constant width and a fixed end proximally extended from the elongate portion comprising a width less than the constant width of the elongate portion.

17. The substrate of claim 16, wherein the one or more cutouts comprise a pair of rounded portions curved into a centralmost portion of the fixed end.

18. The substrate of claim 15, wherein each elongated portion is configured, upon unpeeling the substrate from the container by the first edge toward the second edge, to remain adhered to the opening of the container.

19. The substrate of claim 15, wherein the inner side is unpeeled by the first edge toward the second edge from the container by grasping the pull tab.

20. A method of assembling a container comprising an outer shell or a sleeve comprising an opening and a receptacle insertable through the opening and configured to receive contents of the container, the method comprising:

adhering an inner side of a flexible substrate to at least one of the opening and an upper surface of the receptacle, the flexible substrate comprising a first edge and a second edge opposite the first edge, and one or more anchors positioned on or adjacent the second edge, the one or more anchors being integrally formed with the inner side and extending from one or more cutouts of the flexible substrate adjacent the second edge, the one or more anchors comprising a paddle-like shape with an elongate portion comprising a constant width; and

unpeeling, from the first edge, the inner side of the flexible substrate from the at least one of the opening and the upper surface of the receptacle such that, upon unpeeling the inner side of the flexible substrate to expose the contents, one or more anchors of the flexible substrate opposite the first edge remain adhered to the at least one of the opening and the upper surface of the receptacle.

21. The method of claim 20, further comprising: extending a fixed end portion of the one or more anchors from the elongate portion, the fixed end comprising a width less than the constant width of the elongate portion.

22. The method of claim 20, further comprising: sealing, from the first edge, the inner side of the flexible substrate back to the at least one of the opening and the upper surface of the receptacle.