WO2014085625A1

WO2014085625A1 - Packaging system, part-formed structure and blank therefor

Info

Publication number: WO2014085625A1
Application number: PCT/US2013/072294
Authority: WO
Inventors: Rodney D. Dixon; Steven P. Jones; Thomas R. Grinnan
Original assignee: Meadwestvaco Corporation
Priority date: 2012-11-30
Filing date: 2013-11-27
Publication date: 2014-06-05

Abstract

A container is disclosed for housing an article such as a tray or blister pack and an information leaflet. A wall of the container includes a window through which the information leaflet may be withdrawn once the blister pack is removed.

Description

PACKAGING SYSTEM, PART- FORM ED STRUCTURE AND BLANK THEREFOR

REFERENCE TO RELATED APPLICATIONS

[0001 ] This application claims the benefit of priority under 35 U.S.C. §1 19(e) of United States provisional applications serial number 61/731 ,968 filed on November 30, 2012, and serial number 61/767,832 filed on February 22, 2013, both of which are hereby incorporated by reference in their respective entireties.

FIELD OF THE INVENTION

[0002] The present invention relates to a container and more particularly, but not

exclusively, to a container for housing an article such as a tray or blister pack and an information leaflet. It also relates to a blank for forming the container and a part-formed substantially flat part-formed structure that can be shipped and then erected to form the container.

BACKGROUND OF THE INVENTION

[0003] Personal or healthcare items, for example medication in the form of pills, tablets, caplets and other pharmaceutical preparations, are often housed or contained in blister packs or other suitable primary packages or wrappers. These primary packages, for example blister packs, often contain an array of pills or course of medication. Other objects may accompany the healthcare items, or be held in containers on their own. Such objects may include medical devices, for example syringes, where the syringes may be held in thermoformed trays or tray structures made of paperboard.

[0004] Commonly the primary package, including the healthcare items and any ancillary objects, is enclosed in a secondary package which serves to protect and group the primary package and any other ancillary objects. Some secondary packages additionally have features to make them tamper evident, child resistant, senior friendly, able to withstand repeated use and/or reclosable.

[0005] In WO 2010/014396 to the present applicant, a book-style secondary packaging container is disclosed. Referring to Figures 10 and 17 of WO 2010/014396 in particular, the container includes an outer sleeve that houses a blister pack (primary package) and a cover integrally formed therewith that hinges about a spine panel or hinge panel to create a book-style package with a cover attached to the lowest panel of the outer sleeve. The blister pack can be repeatedly withdrawn and reinserted into the sleeve, and a cutout area or window provided on the sleeve enables a user to assist the withdrawal of the blister pack from the sleeve. An indexing tab that is dependable inwardly from part of the sleeve proximate the window is used to control the withdrawal of the blister pack and to prevent its inadvertent egress from the sleeve. The cover is used to close the sleeve, and is disposed over the window in the closed position so that the blister pack is protected and securely disposed within the container.

[0006] For patients required to carry medication about their person, it is desirable that the secondary package is portable, discreet, easy to open, easy to close, securely reclosable and/or sufficiently strong to withstand repeated use and transportation without becoming crushed and damaged. The aesthetic appeal of the primary package is also a concern to some patients, especially where they may be required to administer their medication in a work or social environment. It is also desirable for the secondary package to be informative, which may include the provision of information printed directly onto the secondary package and/or the housing of one or more leaflets. Where leaflets are provided, they need to be readily accessible to encourage patients and other users to refer to them frequently. Additionally, however, consideration needs to be given to the automated packaging process, and the loading of a leaflet into a secondary package needs to be quickly and repeatedly executable by a packaging machine. Managing loose leaflets in conjunction with high-speed machinery can present difficulties, for example, mis-loading of leaflets and/or leaflets being caught in the machinery components can cause down time. [0007] It is against this background that the present invention has been conceived. Embodiments of the invention seek to provide an improvement in the field of personal and/or healthcare packaging. It is a consideration of the present invention to provide improved packaging that is compatible with existing automated packaging machinery in order to avoid the high costs involved in substantial modification or replacement of packaging machinery.

[0008] For simplicity in this disclosure, a blister pack is often used as an example of an article or structure that may be housed in the disclosed container or containers;

however, in other embodiments, trays or tray-like structures or other articles may be housed in the container as well and, as used herein, the term "blister pack" should be read synonymously with "article" as appropriate.

SUMMARY OF INVENTION

[0009] The present disclosure relates to a secondary packaging container for housing one or more articles, for example blister packs. The container is preferably formed from a unitary blank of foldable sheet material and includes: a base portion; a cover portion (which may also be referred to as a lid portion); and a hinge that connects an interior panel of the base portion to the cover portion. The cover portion and the base portion are moveable relative to one another between an open configuration and a closed configuration. In the closed configuration, the lid or cover portion overlies the base portion. The base portion is a sleeve-style structure configured to accommodate one or more articles in an interior housing. The base portion is tubular in structure, such that the interior housing it provides is sized sufficiently to accommodate an article such as a blister pack. The sleeve provided by the base portion can slidably receive one or more articles, and has a reclosable outlet through which one or more articles can be withdrawn, such that the blister pack can be moved from a storage position and into one or more dispensing positions.

[00010] Beneficially, the sleeve may further include a cutout area (also called a window) configured to allow a user to access an article stored within the sleeve of the base portion, and to assist in the withdrawal and/or re-insertion of an article therethrough. Advantageously, a leaflet can be loaded with the blister pack into the sleeve of the base and, further advantageously, the window is configured to permit withdrawal of the leaflet stowed within the sleeve. In this way, the loading of the leaflet into the sleeve can be carried out easily by packaging machinery and in conjunction with the loading of the blister pack into the sleeve. Indeed, the leaflet can be folded about a leading edge of the blister pack such that, when the blister pack is first loaded into the sleeve, the leaflet is also loaded into the sleeve of the base portion. The provision of the window enables a user to clearly see the presence of the leaflet. This is an important benefit because, in other known medication packages where blister packs are stowed into fully enclosed sleeves or packages in a similar manner, the leaflet is pushed to the bottom of the sleeve and often a patient or user of the secondary package may not know that the leaflet is even present. Furthermore, the provision of the window enables a user to easily extract the leaflet from the sleeve. This is a further important benefit because, in known packages where the leaflet is pushed to the bottom of the sleeve, it can be difficult to get it out again. The folded leaflet is typically forced against the bottom and sides of the known packages, and the slim form of the sleeve makes it awkward for a user to reach in with their fingers. When the folded leaflet has been loaded, it relaxes due to the natural resilience of the paper material from which it is formed and it adopts a position wherein it is tucked tightly against the interior surfaces of the sides of the sleeve and it can be very difficult to grasp. 1 1] Another improvement offered by the present disclosure, that may be taken alone or in conjunction with any of the aforementioned features, is the provision of a three sided pocket within the cover portion. The cover portion is thereby configured such that it can securely hold, store or house a leaflet, pamphlet or other booklet-type article. In the alternative, the cover portion is also a sleeve-style structure, but may not be tubular in structure as such. Once a user has extracted a leaflet from the sleeve structure of the base portion, the leaflet can conveniently be relocated within the pocket provided by the cover portion, so that a user can easily refer to the information in the leaflet and may be reminded to do so. In other embodiments, the leaflet may be held in part on the cover portion and held in part within the cover portion. The prominent presence of the leaflet when mounted to the inside surface of the cover portion may be beneficial. This is because during the course of a medical treatment, a patient may be reminded to refer to the information leaflet due to its prominent position (and it not being lost) and this may remind them of details that could be critical to the effectiveness of their treatment. By placing the information leaflet such that it is easy to access, not lost, easy refer to and/or such that its prominent positioning serves as a reminder of the information when the package is used, is advantageous and may improve the effectiveness of a patient's treatment.

[00012] Another improvement offered by the present disclosure, that may be taken alone or in conjunction with any of the aforementioned features, is the provision of one or more tamper evident features. The tamper evident feature may include a flap that is contiguously formed with the base portion and that is frangibly connected thereto. The flap is adhesively attached to the cover portion and may beneficially is used to adhesively seal one end of the cover portion of the sleeve closed. In this way, the cover and base portions are affixed together, and the cover cannot be moved into its open position without first breaking the frangible connection between the flap and the base portion. If a user is provided with the package and the frangible connection has been broken, this will be apparent due to the slightly rough un-cut edge that breaking a perforation causes.

[00013] Another improvement offered by the present disclosure, that may be taken alone or in conjunction with any of the aforementioned features, is a reclosing feature. More specifically, whereas it is known to provide locking tabs, which provide a releasable mechanical lock with a complementary slit for locking secondary packages closed once they have been opened (for example, in WO 2010/014396 an engaging tab (769) is struck from the inner cover panel (763) and is hingedly connected to the outer cover panel (760) along a fold line (764) - see Figure 1 herein which repeats Figure 17 of WO

'396), such locking tabs can present a problem during the automated manipulation and assembly of containers from blanks. This is because, once struck out from an inner cover panel, the engaging tab is loose and "hanging free". In such a condition, the engaging tab may catch on static or moving guides, and other parts of the automated packaging machinery. If a blank is caught on the machinery, it can cause processing delays and can even result in the downtime of the packaging line. To prevent this, the present invention provides for an engaging tab that is struck from an inner panel of the cover portion, and which is held in a stable condition therewith by means of a frangible connection and which is only separated therefrom by a user first requiring to use that engaging tab. In this way, the engaging tab is "tied" to the blank and to the container during assembly of a part-formed container from the blank (on In-Plant-Equipment (IPE)) and during opening and loading of the container to form a finished package at a converting plant (on Out-Plant-Equipment (OPE)).

[00014] Another improvement offered by the present disclosure, that may be taken alone or in conjunction with any of the aforementioned features, is the provision of two different types of end closure mechanism. One end of the container may be closed by an adhesively bonded wall, whereas the other end of the container may be closed by a tuck-style end closure wall. This arrangement allows for the blank to be part-assembled into a flat-form, open-ended container that can be shipped in a substantially flat form to a converting plant, where the open-ended container is erected, loaded with a blister pack and leaflet, and closed. Due to the format and arrangement of currently available manufacturing equipment, closing both ends of the container by means of an adhesive bond would require substantial modification and re-working of the machinery. This would not only increase cost, but the added complexity of handling hot-melt adhesive at both ends of a moving container could result in a loss in processing speed and therefore an increase in cost. In the alternative, in other embodiments, a tuck-style end closure is provided at both ends so that the part-assembled flat-form, open-ended container can be shipped in a substantially flat form to a converting plant.

[00015] The base portion of the container may include a restricting feature for yieldably restricting movement of one or more articles. This restricting feature may take the form of an indexing tab.

[00016] According to one aspect of the invention, for which protection is sought, there is provided a secondary packaging container including a cover portion and a base portion, the base portion having wall panels defining a housing in which at least one article can be held and the cover portion being hinged to the base portion and thereby being moveable relative to the base portion between a closed configuration in which the cover portion is disposed in overlying relationship with an interior wall panel of the base portion and an open configuration in which the cover portion does not overlie the interior wall panel of the base portion, wherein the cover portion and base portion are each provided with a respective part of a mechanical locking mechanism for locking the secondary package in a closed configuration, the mechanical locking mechanism including a tab hingedly connected to the cover portion and a slit formed within the base portion, the tab and slit being structured and arranged such that the tab is locatable in the slit for locking the cover portion to the base portion and wherein before being used as a locking tab, the tab is temporarily and frangibly connected to the cover portion such that the tab is retained within the plane of a wall panel of the cover portion during assembly of the secondary package.

[00017] In the alternative, the cover portion includes two wall panels: an inner panel and an outer panel, the inner panel and outer panel being hinged directly to one another along a fold line and wherein the tab is hinged to the cover portion along the same fold line and wherein the tab is struck from material that would otherwise form part of the inner panel of the cover portion and is defined at least in part by a cut line.

[00018] In the alternative, the tab is temporarily and frangibly connected to the inner cover panel by one or more connecting portions that interrupt said cut line.

[00019] Additionally or alternatively, one or more apertures is provided adjacent to the tab such that one or more free edges of the tab are available for grasping and for facilitating moving the tab for breaking the temporary and frangible connection such that the tab can be moved out of the plane of the inner panel used as a locking tab locatable in the slit.

[00020] Preferably, the secondary packaging container is formed from a single blank of foldable sheet material and wherein each of the panels forming the base portion structure and the cover portion are hinged one to the next in series.

[00021] According to a second aspect of the invention for which protection is sought, there is provided a secondary packaging container including a cover portion and a base portion, the base portion having wall panels including: a primary base panel, a first side panel, an interior wall panel and a second side panel, which together define a housing in which at least one article can be held, the cover portion being hinged to the base portion and thereby being moveable relative to the base portion between a closed configuration in which the cover portion is disposed in overlying relationship with the interior wall panel of the base portion and an open configuration in which the cover portion does not overlie the interior wall panel of the base portion, the interior wall panel including a window such that an article held in the housing is visible through the window when the cover portion is in the open configuration and the window being structured and arranged such that a leaflet held within the housing can be withdrawn from the housing though the window.

[00022] In the alternative, the leaflet is initially folded at least partially about an article held in the housing.

[00023] According to a third aspect of the invention for which protection is sought, there is provided a packaging system including a secondary packaging container as described in the preceding paragraphs; a blister pack; and a leaflet, wherein the leaflet is folded about part of the blister pack and the blister pack and leaflet are both disposed within the housing such that at least part of the leaflet is visible through the window and such that the leaflet can be withdrawn from the housing though the window.

[00024] In the alternative, the blister pack is moveable out of the housing through an outlet disposed at the top of the base portion in order to release the leaflet so that it may be withdrawn though the window.

[00025] Additionally or alternatively, the cover portion includes two wall panels: an inner panel and an outer panel which form a pocket therebetween that is closed along three side edges and has at least one opening through which said leaflet can be inserted.

[00026] According to a fourth aspect of the invention for which protection is sought, there is provided a secondary packaging container including a cover portion and a base portion, the base portion having wall panels including: a primary base panel, a first side panel, an interior wall panel and a second side panel, which together define a housing in which at least one article can be held, the cover portion being hinged to the base portion and thereby being moveable relative to the base portion between a closed configuration in which the cover portion is disposed in overlying relationship with the interior wall panel of the base portion and an open configuration in which the cover portion does not overlie the interior wall panel of the base portion, the cover portion including two wall panels: an inner panel and an outer panel which form a pocket therebetween that is closed along three side edges and has at least one opening.

[00027] In the alternative, a first side edge of the pocket is closed by virtue of a hinge connection between the inner panel and the outer panel, wherein a second side edge is closed by virtue of a glue flap hinged to the outer panel and affixed inside the pocket to an inside surface of the inner panel, and wherein a bottom side edge of the pocket is closed by virtue of an adhesive connection between the inner panel and the outer panel.

[00028] Further In the alternative, the adhesive connection between the inner panel and the outer panel is formed using a lower end closure panel that is disposed between the inner and outer panels and which is adhesively affixed on one side to an inside surface the inner panel and which is adhesively affixed on the other side to an inside surface of the outer panel.

[00029] Preferably, said lower end closure panel is frangibly coupled to the interior wall panel of the base portion in an initial sealed and closed configuration of the secondary packaging container.

[00030] In the alternative, the base portion further includes a first upper closure flap

frangibly connected to the primary base panel and the cover portion further includes a second upper closure flap hingedly connected to the outer panel, wherein the second upper closure flap is disposed on top of and is affixed to the first upper closure flap and wherein the first and second upper closure flaps close an upper outlet of the housing of the base portion and close an uppermost opening of said at least one openings of the pocket.

[00031] According to a fifth aspect of the invention for which protection is sought, there is provided a secondary packaging container including a cover portion and a base portion, the base portion having wall panels including: a primary base panel, a first side panel, an interior wall panel and a second side panel, which together define a housing in which at least one article can be held, the cover portion being hinged to the base portion and thereby being moveable relative to the base portion between a closed configuration in which the cover portion is disposed in overlying relationship with the interior wall panel of the base portion and an open configuration in which the cover portion does not overlie the interior wall panel of the base portion, the cover portion including two wall panels: an inner panel and an outer panel and wherein a lower end closure panel is frangibly connected to the interior wall panel of the base portion and is affixed between the inner panel and the outer panel of the cover portion to provide a connection between the cover portion and the base portion in an initial sealed and closed configuration of the secondary packaging container.

[00032] In the alternative, the frangible connection between the lower end closure panel and the interior wall panel must be broken in order to move the cover portion from its closed configuration into its open configuration and thereby the lower end closure panel provides a tamper evident feature.

[00033] According to yet a further aspect of the invention for which protection is sought, there is provided a blank for forming a secondary packaging container, the blank including: an outer panel and an inner panel for forming a cover portion which inner and outer panels are hinged together; an interior wall panel, a first side panel, a primary base panel and a second side panel hinged together in series for forming a base portion, the inner panel of the cover portion and interior panel of the base portion being hinged together and thereby, once the blank is constructed into a secondary packaging container a cover portion formed from the inner and outer panels is moveable relative to a base portion formed from the primary base panel, first side panel, interior wall panel and second side panel, wherein the blank includes a mechanical locking mechanism including a tab hingedly connected to the outer panel of the cover portion and a slit formed co-linearly with a fold line between the interior panel and the first side panel of the base portion, and wherein the tab is temporarily and frangibly connected to the inner panel of the cover portion such that the tab is retained within the plane of the inner panel of the cover portion during assembly of the secondary package. [00034] In the alternative, the tab is struck from material that would otherwise form part of the inner panel of the cover portion and is defined at least in part by a cut line.

[00035] Preferably, the tab is temporarily and frangibly connected to the inner cover panel by one or more connecting portions that interrupt said cut line.

[00036] According to an even further aspect of the invention for which protection is

sought, there is provided a blank for forming a secondary packaging container, the blank including: an outer panel and an inner panel for forming a cover portion which inner and outer panels are hinged together; an interior wall panel, a first side panel, a primary base panel and a second side panel hinged together in series for forming a base portion, the inner panel of the cover portion and interior panel of the base portion being hinged together and thereby, once the blank is constructed into a secondary packaging container a cover portion formed from the inner and outer panels is moveable relative to a base portion formed from the primary base panel, first side panel, interior wall panel and second side panel, wherein the blank further includes a first glue flap for affixing the inner and outer panels of the cover portion together, which glue flap is hinged to the outer panel and a second glue flap for affixing the second side panel to the interior panel for forming a housing of the base portion and wherein a first upper closure flap is frangibly connected to the primary base panel and a second upper closure flap is hingedly connected to the outer panel, wherein the second upper closure flap is foldable on top of and is affixable to the first upper closure flap for closing an upper outlet of the housing of the base portion and for closing an uppermost opening of said at least one openings of the pocket when the blank is formed into a secondary packaging container.

[00037] According to yet an even further aspect of the invention for which protection is sought, there is provided a secondary packaging container including a cover portion and a base portion, the cover portion including only two panels: an inner panel and an outer panel, the base portion having: an interior wall panel, a first side wall panel, a primary base wall panel and a second side wall panel which define a housing in which at least one article can be held, the inner panel of the cover portion being hinged to the interior wall panel of the base portion such that the cover portion is moveable relative to the base portion between a closed configuration in which the cover portion is disposed in overlying relationship with the interior wall panel of the base portion and an open configuration in which the cover portion does not overlie the interior wall panel of the base portion, wherein the cover portion and base portion are each provided with a respective part of a mechanical locking mechanism for locking the secondary package in a closed configuration, the mechanical locking mechanism including a tab hingedly connected to the cover portion and a slit formed within the interior wall panel of the base portion, the tab and slit being structured and arranged such that the tab is locatable in the slit for locking the cover portion to the base portion and wherein before being used as a locking tab, the tab is temporarily and frangibly connected to the inner panel of the cover portion such that the tab is retained within the plane of the inner wall panel of the cover portion during assembly of the secondary package.

[00038] In the alternative, one or more apertures is provided adjacent to the tab such that one or more free edges of the tab is available for grasping the tab and for facilitating breaking the temporary and frangible connection such that the tab can be moved out of the plane of the inner panel and used as a locking tab locatable in the slit.

[00039] In the alternative, the secondary packaging container is formed from a single blank of foldable sheet material and wherein each of the panels forming the base portion structure and the cover portion are hinged one to the next in series.

[00040] In the alternative, there further is included a window in the interior wall panel structured and arranged such that an article held in the housing is visible through the window when the cover portion is in the open configuration and the window being structured and arranged such that a leaflet disposed within the housing can be withdrawn from the housing though the window. Additionally, an indexing tab may be hinged to the interior panel of the base portion and moveable below the plane of the interior panel for selectively restricting the withdrawal of an article including perturbations out of the housing provided by the base portion.

[00041] In the alternative, the base portion includes first and second tuck-style end

closure structures each for closing an end of the housing provided by the base portion. Additionally, the first tuck style closure structure may include a side end closure flap hinged to the first side panel of the base portion; a side end closure flap hinged to the second side panel of the base portion; an upper closure flap hinged to the primary base panel; and a tuck flap partially hinged to the upper closure flap and partially separated therefrom by cut lines which each provide a free edge of the tuck flap and upper closure panels. Additionally or alternatively, the second tuck style closure structure may include a side end closure flap hinged to the first side panel of the base portion; a side end closure flap hinged to the second side panel of the base portion; a lower closure flap hinged to the primary base panel; and a tuck flap partially hinged to the lower closure flap and partially separated therefrom by cut lines which each provide a free edge of the tuck flap and lower closure panels

[00042] Within the scope of this application it is to be understood that the various

aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings may be taken independently or in any combination thereof. For example, features described in connection with one embodiment are applicable to all embodiments unless there is incompatibility of features.

BRIEF DESCRIPTION OF THE DRAWINGS

[00043] Exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which:

[00044] FIGURE 1 is a reproduction of Figure 17 of WO 2010/014396, which Figure is a plan view from above of a blank for forming a secondary packaging container;

[00045] FIGURE 2 is a plan view from above of a blank for forming a secondary

packaging container according to a first embodiment of the invention;

[00046] FIGURE 3 is a plan view from above of a blank for forming a secondary

packaging container according to a second embodiment of the invention; [00047] FIGURE 4A is a perspective view from above of a part-formed "flat"-folded container made from the blank of Figure 2 and looking at a base portion of the container;

[00048] FIGURE 4B is a perspective view from above of a part-formed "flat"-folded

container made from the blank of Figure 2 and looking at a cover portion of the container;

[00049] FIGURE 5 is a perspective view from above of a blister pack that could be

contained in the container;

[00050] FIGURE 6 is a perspective view from a bottom closed end of the container being formed from the structure of Figures 4A and 4B, wherein the bottom end has not yet been closed fully;

[00051] FIGURE 7 is a perspective view from above of the container of Figure 6, standing on the bottom closed end and shown in an open configuration wherein the cover portion is not disposed over the base portion;

[00052] FIGURE 8 is a perspective view from above of two containers, each formed from the blank of Figure 3, loaded with articles and affixed into a first closed condition. The container on the left-hand side shows a bottom closed end of the container, and the container on the right-hand side of the Figure is rotated to show a top-closed end;

[00053] FIGURE 9A is a perspective view from above of the container of Figure 8 being loaded with an article and leaflet;

[00054] FIGURE 9B is a perspective view from above of the container of Figure 9A in an open configuration having been loaded with an article and leaflet, wherein the cover portion is not disposed over the base portion;

[00055] FIGURE 9C is a perspective view from above of the container of Figure 9B in an closed configuration having been loaded with an article and leaflet, wherein the cover portion is disposed over the base portion and the top closure flaps are closed; [00056] FIGURE 9D is a perspective view from above of the container of Figure 9C after opening, wherein the cover portion is not disposed over the base portion;

[00057] FIGURE 10A is a plan view of a blank for forming a container according to

another embodiment of the disclosure;

[00058] FIGURE 10B is a plan view of an alternative blank for forming a container

according to another embodiment of the disclosure; and

[00059] FIGURE 1 1 is a plan view of a blank for forming a container according to a

further embodiment of the disclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE PRESENT INVENTION

[00060] Detailed descriptions of specific embodiments of the package, blanks and

cartons are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be

implemented, and do not represent an exhaustive list of all of the ways the invention may be embodied. As used herein, the word "exemplary" is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. Indeed, it will be understood that the packages, blanks and cartons described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale, and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. 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 invention.

[00061] In the Figures, certain features are identified by numerals, or occasionally by letters. In most cases numbers differing by 100, 200, etc may identify similar features, for example a fold line is shown in the Figures as 755, 55, 155, 255, and 355. However, similar features may not always be described every time they appear. For example if 155 is not explicitly identified as a fold line, it may be understood to be a fold line from the description of its counterparts 755, 55 etc.

[00062] Referring to Figure 1 , the blank 710 shown therein is a copy of the blank 710 shown in Figure 17 of WO 2010/014396. The blank 710 is now described by way of introductory background to the present invention. The blank 710 is a unitary blank 710 formed from a foldable sheet of paperboard and includes a base portion 71 1 , a cover portion 712, a hinge portion 713 and a shell portion 740. The shell portion 740 is affixable to the base portion 71 1 to create a void therebetween.

[00063] The base portion 71 1 includes a primary base panel 773, a first upper closure flap 774 and a first lower closure flap 775. The upper and lower closure flaps 774, 775 are hingedly connected to the primary base panel 773 along a tear line 776 and a fold line respectively.

[00064] The shell portion 740 includes a first shell side panel 741 , a primary shell panel 742, a second shell side panel 743, and a glue flap 750. The first shell side panel 741 is hingedly connected to the primary base panel 773 along a fold line 753. The primary shell panel 742 is hingedly connected to the first side panel 741 along a fold line 754. The second shell side panel 743 is hingedly connected to the primary shell panel 742 along a fold line 755. The glue flap 750 is hingedly connected to the second shell side panel 743 along a fold line 756. Attached to the lower edge of the primary shell panel 742 is a second lower closure flap 752. The shell portion 740 is designed to be folded inwardly along the fold lines 753, 754, 755, 756 and to be attached to the primary base panel 773 by means of the glue flap 750, so that a sheath for holding contents is provided by the shell portion 740 and the base portion 71 1 . The glue flap 750 may be secured to the inside surface of the primary base panel 773 by any adhesive, tape or mechanical securing means such as staples. The upper edge of the shell portion 740 defines a shell outlet 744. [00065] The cover portion 712 includes inner and outer cover panels 763, 760 that are hinged directly to one another along a fold line 765. A second upper closure flap 767 is hingedly connected to the upper edge of the inner cover panel 763 along a tear line 768. An engaging tab 769 is struck from the inner cover panel 763 and hingedly connected to the outer cover panel 760 along a fold line 764. The fold line 764 of the engaging tab 769 is slightly offset from the fold line 765 along which the inner and outer cover panels 763, 760 are hingedly connected. The engaging tab 769 provides part of an engaging mechanism and is designed to cooperate with an engaging slit 749 to retain the cover portion 712 in a closed position.

[00066] The engaging slit 749 serves as the other part of the engaging mechanism for retaining the tab 769 struck from the cover portion 712 in the closed position. The engaging slit 749 is formed substantially in a primary shell panel 742 in such a manner that the fold line 754 is interrupted by the engaging slit 749.

[00067] The primary shell panel 742 has a shell window area 746 for access to the

interior of the shell. Shell window area 746 may be large enough for a finger to be inserted therethrough to move the contents (such as a blister pack) of the shell. The window area 746 is provided with an indexing element in the form of an indexing tab 747. The indexing tab 747 serves to resiliency engage the blisters of a blister pack as they pass the indexing tab 747, so as to provide an indexing function whereby the blister pack is releasably held in a plurality of dispensing positions as it is withdrawn from the shell.

[00068] The indexing tab 747 is connected to an edge of the shell window area 746 along a fold line. The indexing tab 747 is struck from the primary shell panel 742 and extends into the shell window area 746. When a container is erected from the blank 710, the indexing tab 747 is folded inwardly of the sheath to be disposed between two adjacent rows of the blisters of a blister pack received in the shell, so as to interfere with movement of the blister pack. However, the indexing tab 747 is designed to be flexible enough to yield to an applied force, such as pressure from a finger inserted through window area 746, such that the indexing tab 747 allows movement of the blister pack in or out of the shell through the outlet 744. When the blister pack is pulled inwardly, or pushed outwardly, of the sheath, the indexing tab 747 flexes to allow itself to be moved from a location, for example, between the first and second blister rows to a location between the second and third blister rows. This allows the blister pack to be moved in a shuttle fashion in and out of the sheath by a predetermined distance at a time, the distance being generally equal to the pitch of the blister rows.

[00069] The blank 710 may be erected into a container as follows: glue is applied to the inside surface of either the inner or outer cover panel 763 or 760; the inner cover panel 763 is folded about the fold line 765 onto the inside surface the outer cover panel 760; the secured cover portion 712 is brought to the closed position over the primary shell panel 742 of an erected shell portion 740. The cover portion 712 is locked in the closed position by the slit-and-tab 769/749 engaging mechanism described above. To activate the engaging mechanism, the engaging tab 769 is inserted into the slit 749 so that it is retained in the slit by friction. A product such as a blister pack is loaded into such a container through the outlet 744. The upper closure flaps 767, 774 are then folded and secured together in a flat face contacting relationship. The loaded container may be opened by tearing the secured closure flaps 767/774 along the tear lines 768, 776. The product in the sheath is then pushed out of the sheath through the outlet 744 by accessing the product through the shell window area 746.

[00070] In the embodiments of the present application detailed herein, the terms carton, carrier, container, secondary packaging container and packaging container refer, for the non-limiting purpose of illustrating the various features of the invention, to a container for engaging, carrying, and/or dispensing articles, such as blister packs. However, it is contemplated that the teachings of the invention can be applied to various containers, which may or may not be planar, lidded (covered) and/or substantially rectangular.

Other exemplary articles include lozenges, cigarettes, chewing gum, cigarette replacement items, personal items, tablets, pouches, packets and the like. [00071] Referring now to Figures 2, 3 and 10, the blanks 10, 1 10, 210 shown therein are each formed from a sheet of suitable substrate. It is to be understood that, as used herein, the term "suitable substrate" includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be recognized that one or other numbers of blanks may be employed, for example, to provide the carrier structure described in more detail below. More than one type of material may be used to form a single or multiple-piece blank.

[00072] Referring to Figure 2, the blank 10 is a unitary blank 10 formed from paperboard and includes a base portion 40 and a cover portion 12.

[00073] The base portion 40 includes: an interior wall panel 42 (also referred to as a shell panel 42), a first side panel 41 , a primary base panel 73, a second side panel 43 and a glue flap 50. The shell panel 42, first side panel 41 , base panel 73, second side panel 43 and glue flap 50 are hinged together in a linear series by fold lines 51 , 53, 55 and 56 respectively. When the blank 10 is formed into a secondary packaging container 90 (such as that shown in figure 7), the glue flap 50 is affixed to part of the inside surface of the shell panel 42. Once erected, a void or housing H or internal volume is provided between the shell panel 42, primary base panel 73 and the first and second side panels 41 , 43.

[00074] The primary base panel 73 includes a first upper closure flap 74, connected to the primary panel 73 along a frangible line 76, which may preferably be a perforated tear line 76. The first upper closure flap 74 is used in conjunction with a second upper closure flap 67 to close an end of the housing between the shell panel 42, primary base panel 73 as well as a pocket that is provided in the cover portion 12 (described below). The upper edge of the base portion 40 defines a first container outlet 44.

[00075] A tuck-style end closure structure 75a/75b/75c/75d is provided at the opposite end of the primary base panel 73 and includes: a first lower closure flap 75a hinged directly to the primary base panel 73 along fold line 16; a tuck-flap 75b hinged to the first lower closure flap 75a along a fold line 83; and a pair of side end closure flaps 75c, 75d that are hinged to the first and second side panels 41 , 43 by fold lines 81 and 82 respectively. The fold line 83 between the first lower closure flap 75a and the tuck-flap 75b is not co-extensive with the first lower closure flap 75a or the tuck-flap 75b, but rather terminates in cut lines 84a, 84b. The provision of cut lines 84a, 84b allows for a portion of the tuck-flap 75b adjacent to each cut line 84a, 84b to be positioned between the first lower closure flap 75a and a side end closure flap 75c, 75d to create a mechanical lock for the tuck-style end closure structure. A user deliberately intending to do so can pull on the tuck-flap 75b and move it past the first lower closure flap 75a to release the engagement of edge portions of the tuck-flap 75b on the first lower closure flap 75a.

[00076] The shell panel 42 preferably includes a second lower end closure panel 52 that is connected to a bottom end of the shell panel 42 by means of a frangible connection 14. In the alternative, the frangible connection 14 may include two substantially parallel lines of perforations or tear lines. The second lower end closure panel 52 is provided to: seal closed a bottom end of a pocket formed in the cover portion 12 (described further below); temporarily attach the cover portion 12 to the base portion 40; and provide a tamper evident feature. The full operation of the second lower end closure panel 52 is further described below, in the context of the assembly of a secondary packaging container 90 and the opening of the secondary packaging container 90 (see also Figures 6 and 7).

[00077] The shell panel 42 has a window 72 or cutout area 72 defined by a cut line 46.

The window 72 is at least partly open and provides access to the interior of the housing

H between shell panel 42 and the primary base panel 73. Window 72 may preferably be large enough for a user's finger to be inserted therethrough to move the contents (such as a blister pack) to assist with the withdrawal of an article from the housing. Additionally beneficially, the window 72 is sized, shaped, structured and/or otherwise arranged such that a product information leaflet (PIL) or other leaflet 'L' (see Figure 9D) can be withdrawn through the window 72 and out of the internal housing. The window area 72 may preferably be provided with an indexing element in the form of an indexing tab 47.

The indexing tab 47 serves to resiliency engage an upstanding or protruding portion of an article housed within the secondary packaging container 90, such as for example, the blisters 84 of a blister pack 80 (see Figure 5) as they pass the indexing tab 47. In this way an indexing function or ratchet is provided, whereby the article (blister pack) 80 is releasably held in a plurality of dispensing positions as it is withdrawn from the sheath.

[00078] The indexing tab 47 is connected to the shell panel 42 by a fold line 70 provided along a portion of the edge of the window 72. The indexing tab 47 is struck from material of the shell panel 42 that would otherwise have been removed to form the window 72. In other embodiments, the tab 47 is omitted. In the present arrangement, however, when a container is erected from the blank 10, the indexing tab 47 is folded inwardly of the housing to be disposed between two adjacent rows of the blisters 84 of a blister pack 80 received in the housing so as to interfere with free movement of the blister pack 80. However, the indexing tab 47 is designed to be flexible enough to yield to an applied force, such as pressure from a finger inserted through the window area 72, such that the indexing tab 47 allows movement of the blister pack 80 in or out of the housing through the outlet 44. When the blister pack 80 is pulled inwardly, or pushed outwardly, of the housing, the indexing tab 47 flexes to allow itself to be moved from a location, for example, between first and second blister rows, to a location between second and third blister rows. This allows the blister pack 80 to be moved in a step-wise or shuttle fashion in and out of the housing, which may be by a predetermined distance per withdrawal, which predetermined distance is generally equal to the pitch of the blister rows 84. A recess 34 is provided depending inwardly from the upper edge of the shell panel 42 to assist a user grasping an edge of an article for facilitating its withdrawal.

[00079] An engaging slit 49 is provided on the base portion 40 for receiving a tab 69

(described below). The engaging slit 49 is formed substantially in the shell panel 42 in such a manner that the fold line 51 is interrupted by the engaging slit 749.

[00080] The cover portion 12 is hingedly connected directly to the shell panel 42 of the base portion 40 along fold line 13. The cover portion 12 includes: inner and outer panels

60, 63 respectively that are hinged directly to one another along a fold line 65, and a second glue flap 54 that is hinged directly to the outer panel 63 by means of a fold line

58. During construction of a secondary packaging container 90 from the blank 10, the cover portion 12 is constructed. This, in part, involves the second glue flap 54, which is folded about hinge connection 58 and into face contacting relationship with an underside surface (In the alternative the underside surface is the non-printed and/or non-coated side) of the outer panel 63. Adhesive may be applied to either the glue flap 54 and/or to the underside surface of the inner panel 60. References G1 and G2 illustrate alternative locations for the application of adhesive that is used to affix the second lower end closure panel 52 to each of the underside surfaces of the inner panel 60 and outer panel 63. The construction of the blank 10 is described in a full sequence below and during this sequence, the second lower end closure panel 52 is affixed by adhesive G1 , G2 to each of the inner and outer panels 60, 63. When the outer panel 63 is folded to overlay the inner panel 60, the glue flap 54 and the second lower end closure panel 52 are each sandwiched therebetween and affix the inner and outer panels 60, 63 together. The glue flap 54 is sized, shaped and dimensioned such that it does not interfere with the operation of the pocket P that is thereby formed between the inner and outer panels 60, 63. The second lower end closure panel 52 seals the bottom end between bottom edges 18, 20 of the inner and outer panels 60, 63 respectively. The pocket is sealed or closed on three sides. Two sealed sides are provided by the fold line 65 and the fold line 58/glue flap 54. A bottom sealed end of the pocket is provided by the second lower end closure panel 52.

[00081] Preferably, the width of each of the inner and outer panels 60, 63 is exactly the same, to encourage the inner panel 60 to, very slightly, bow outwardly away from the outer panel 63 which thereby opens an upper outlet 36 of the pocket for use. The pocket can be used by a patient or consumer to hold the leaflet 'L' once it has been extracted from the housing in the base portion 40 of the secondary packaging container 90, which may be done via withdrawal through the window 72. To assist in the location and withdrawal of leaflet 'L' in the pocket between the inner panel 60 and outer panel 63, a recess 61 is provided in one of the inner or outer panels 60, 63. In the alternative, the inner panel 60 may, in other embodiments, have a slightly smaller or larger width.

[00082] A second upper closure flap 67 is hingedly connected to an upper edge of the outer cover panel 63 along a fold line or frangible line 68. Together with the first upper closure flap 74, the second upper closure flap 67 forms a composite closure wall that seals closed both the open outlet 44 of the housing of the base portion 40 and the open outlet 36 of the pocket formed in the cover portion 12. [00083] An engaging tab 69 is struck from the inner panel 60 and is hingedly connected to the outer panel 63 along a fold line 64. The fold line 64 of the engaging tab 69 is substantially co-linear with the fold line 65 along which the inner and outer panels 60, 63 are hingedly connected. The engaging tab 69 provides a further part of a two part engaging mechanism, and is designed to cooperate with the engaging slit 49 to retain the cover portion 12 in a closed position. The engaging tab 69 is frangibly tied or connected to the inner panel 60 by means of one or more connecting portions 28 that interrupt a cut line 26 formed in the inner panel 60. The cut line 26 may preferably be shaped and positioned relative to the engaging tab 69 such that at least one aperture 32, 30 (in this embodiment two apertures 32, 30) are formed adjacent the engaging tab 69. The one or more connecting portions 28 provide a temporary and frangible connection, which beneficially maintains the engaging tab 69 in the plane of the inner panel 60 until such time as a user requires the engaging tab 69 to be deployed for mechanically locking or closing the cover portion 12 to the base portion 40 for securing the secondary packaging container 90 in its closed configuration. At that time, the one or more apertures 32, 30 provide an access point so that a user can grasp an edge of the engaging tab 69 and break it free of direct attachment to the inner panel 60 by breaking the one or more frangible connections 28.

[00084] The blank 10 may be folded, glued and formed into a part-formed, substantially flat-folded structure 21 as shown in Figures 4A and 4B. The first stage in the assembly of the blank 10 into the part-formed, substantially flat-folded structure 21 is likely to be carried out on in-plant equipment (IPE). The flat form of the structure 21 is therefore beneficial because, in that form, it can be shipped at minimum cost. Furthermore, if erected, but empty, secondary packaging containers 90 are shipped, not only is the shipping cost greater because the empty erected container has a larger capacity and fewer units can be transported per shipping container, the empty secondary packaging containers may be more vulnerable to damage, for example, by crushing.

[00085] Turning to the construction of the part-formed, substantially flat-folded structure 21 illustrated in Figures 4A and 4B from the blank 10, the part-formed, substantially flat- folded structure 21 can be formed by a series of sequential folding operations in a straight line machine so that the part-formed, substantially flat folded structure 21 is not required to be rotated or inverted unnecessarily to complete its construction. The folding process is not limited to that described below and may be altered according to particular manufacturing requirements.

[00086] The outer surface (the outer surface may be the coated and/or printed side of the paperboard blank 10) of the inner panel 60 of the cover portion 12 may be folded about fold line 13 to bring it into face contacting relationship with the outer surface of the shell panel 42. The glue flap 54 may then be folded into face contacting relationship with the inner surface of the outer panel 63 of the cover portion 12. Adhesive may be applied to the glue flap 54 and to locations generally denoted as G1 , G2 (which are not restricted to being singular locations or circular) on the inner surfaces of each of the inner and outer panels 60, 63. The second lower end closure panel 52 may be folded about frangible line 14 to bring it into flat face contact with the inner surface of the inner panel 60 and into contact with adhesive at region G2. By folding the outer panel 63, together with the glue flap 54 about the fold line 65, the outer panel 63 is laid on top of the inner panel 60 and affixed thereto by means of glue flap 54, and by means of glue G1 and the second lower end closure panel 52. During this construction process, the engaging tab 69 remains neatly within the plane of inner panel 60 and problems associated with the loose engaging tab 769 of the blank 710 are avoided.

[00087] The blank 10 may then be flipped, inverted or otherwise manipulated so that the outer panel 63 is face down and such that the inside surfaces of the shell panel 42, first side panel 41 , primary base panel 73, second side panel 43 and glue flap 50 are facing outwards. The glue flap 50 together with the second side panel 43, may then be folded about fold line 55 so that they are brought into flat face contact with a portion of the inside surface of primary base panel 73. Adhesive may then be applied to the glue flap

50, or a portion of the inside surface of the shell panel 42. Then, the shell panel 42

(together with the second lower end closure panel 52 and outer panel 63 affixed thereto) is folded about fold line 51 and placed on top of the primary base panel 73 and into face contacting relationship with the glue flap 50, such that the shell panel 42 is affixed thereto. The part-formed, substantially flat-folded structure 21 is then completed. This structure is shown in Figures 4A and 4B. In Figure 4A the primary base panel 73 is disposed outermost. In Figure 4B, the outer panel 63 of the cover portion 12 is disposed outermost. The tuck-style end closure 75a/75b/75c/75d, first upper closure flap 74 and second upper closure flap 67 remain unfolded.

[00088] After transportation, the part-formed, substantially flat folded structure 21 is then opened into a tubular structure, for example by pushing the first and second side panel 41 , 43 towards one another and/or by relative separation of the primary base panel 73 and the shell panel 42. The housing thereby created between the primary base panel 73 and the shell panel 42 can then be loaded through one or both ends with one or more articles. In a preferred application, the articles include a blister pack 80 (see Figure 5) including one or more blisters 84 and tablets 86 and a product-information-leaflet 'L' that is folded about a leading end of the blister pack 80. The leading end is then pushed into the housing from the outlet 44 leading with the leaflet 'L' toward the tuck-style end closure structure 75a/75b/75c/75d. Before or after loading, the tuck-style end closure structure 75a/75b/75c/75d is folded and erected to create a bottom end wall of the secondary packaging container 90. The other "top" end of the secondary packaging container 90 is then affixedly sealed closed by first folding the first upper closure flap 74 about fold line 76 and then folding the second upper end closure flap 67 about fold line 68. Adhesive is used to affix the second upper end closure flap 67 (which is disposed outermost) to the first upper closure flap 74. The construction of the secondary packaging container 90 is thereby completed and, by having one tuck-style end closure and one adhesively sealed end closure, existing machinery can be utilised to complete the package, and the complexities associated with the modification of In-Plant- Equipment to facilitate adhesive closing of both ends are avoided. Nevertheless, it will be understood that in the alternative, both ends may be adhesively closed.

[00089] In this initial closed position (shown in Figure 6), the upper end of the secondary packaging container 90 is adhesively sealed; the upper outlet 36 of the pocket in the cover portion 12 is adhesively sealed (by second upper end closure flap 67) and the cover portion 12 is affixed to the base portion 40 by means of second lower end closure panel 52. It is therefore evident that the secondary packaging container 90 has been securely closed and, when presented to a patient or consumer in this condition, the consumer, patient or other user will have a high level of confidence in the integrity and quality of the contents. Conversely, if the secondary packaging carton has been tampered with, this would be evident by one or both of: the tear line 14 being broken, or, the tear line 76 being broken.

[00090] To open the secondary packaging container 90 for the first time, the second

upper end closure flap 67 and the first upper end closure flap 74 are together displaced. Conveniently, the rounded open corners at the upper end of the second upper end closure flap 67 provide a point of ingress for a user's finger for grasping an end of the second upper end closure flap 67 and the first upper end closure flap 74, and for pulling and peeling them away from the primary base panel 73 by breaking the frangible line 76. In the alternative, and preferably, the first upper end closure flap 74 may be detached from the outer panel 63 by breaking the frangible connection 68. Alternatively, the second upper end closure flap 67 and the first upper end closure flap 74 may at least temporarily remain attached to the secondary packaging container 90. Thereafter, the cover portion 12 can be moved relative to the base portion 40 by breaking the frangible connection 14. Figure 7 illustrates the opened package wherein the broken lines 76, 68, 14 can be seen. Reference is made to Figures 9A-9D, which shows a secondary packaging container according to a second embodiment which is further described below. Therein it can be seen that the blister pack 80 and a leaflet 'L' are disposed within housing. Once the secondary packaging container 90 has been opened (as shown in Figure 7), the leaflet 'L' can be withdrawn though the window 72. To do this, a user may need to at least partially withdraw the blister pack 80 to release the leaflet 'L'. A user can then position the leaflet in the convenient pocket provided in the cover portion 12, as shown in Figure 7.

[00091] The engaging tab 69 can then be broken free of its connection with the inner panel 60 as described above, so that a user of the secondary packaging container 90 can reclose the secondary packaging container 90, by locating the engaging tab 69 in slit 49.

[00092] Referring now to Figures 3, 8, 9, 10 and 1 1 , there are shown alternative

embodiments of the present invention. In the second, third and fourth illustrated embodiments, like numerals have, where possible, been used to denote like parts, albeit with the addition of the prefix "100", "200" and "300" to indicate that these features belong to the second, third and fourth embodiments respectively. The alternative embodiments share many common features with the first embodiment and therefore only the differences from the embodiment illustrated in Figures 2 and 4 to 7 will be described in any greater detail.

[00093] Referring to Figures 3, 8 and 9 which show the second embodiment of the

invention, the blank 1 10 does not necessarily include a three-sided pocket in the cover portion 1 12, but additionally or alternatively, includes a slit 'S' that may be disposed diagonally across the inner panel 160 of the cover portion 1 12. The slit 'S' may terminate in arcuate ends, which may serve to mitigate against undesirable propagation of the slit 'S'. In embodiments where a slit 'S' is provided, this may be used in conjunction with a three-sided pocket formed as described above and having three closed edges (165, 158/154 and 1 14/152). The slit 'S' may beneficially provide a larger opening into which a leaflet can be inserted. An aperture 186 may assist a user in accessing the slit 'S' and/or in accessing a leaflet caught at least partially in the slit 'S'. In the alternative, an additional adhesive bond G5 may be provided to attach the inner panel 160 to the outer panel 163 of the cover portion. In this way, the outlet 136 of the top of the pocket is additionally closed by an adhesive bond as well as by the second upper closure flap 167. The diagonally formed slit 'S' may make it easier for a user of the secondary carton package to insert and/or remove a leaflet 'L' into and/or out of the pocket formed between the inner panel 160 and the outer panel 163.

[00094] Referring to Figure 9A, an article such as a blister pack 80 may be inserted into housing portion H of the secondary packaging container. A leaflet 'L' may be folded about or otherwise placed on the leading edge of blister pack 80 as it is inserted into the housing H. Thus the blister pack 80 may be used as a tool to push the leaflet 'L' into the housing. As seen in Figure 9B, after the blister pack 80 and leaflet 'L' have been inserted into the housing H, the leaflet 'L' and blister pack 80 may be visible through window 172.

[00095] Thus the blister pack 80 is sandwiched between interior wall panel 142 and

primary base panel 173. The leaflet 'L" may be disposed covering at least part of the blister pack 80 to hide it from partly view through window 172, and the leaflet 'L' may be visible at least in part from outside of the base or housing portion through window 172. The leaflet 'L' may thus be disposed in part between blister pack 80 and interior wall panel 142, and also at least part of the leaflet may be disposed between the blister pack 80 and the primary base panel 173. Window 172 may be structured and arranged such that leaflet 'L' disposed at least partially within housing H can be withdrawn from housing H through window 172.

[00096] Window 172 may be dimensioned and configured such that leaflet 'L' is

manipulate to exit housing H through the window 172, and blister pack 80 may be received in housing H and disposed in engagement with leaflet 'L' such that leaflet 'L' is prevented from exiting housing H through window 172 until removal of the leaflet is desired, for example when a user has opened the secondary packaging system as in Figure 9D.

[00097] As shown in Figure 9C, the cover portion (e.g. inner panel 160 and outer panel 163) may be closed over the housing H and may be secured closed by first upper closure flap 174 and second upper closure flap 167, which may be sealed or adhered together or otherwise fastened together. The secondary packaging container may be shipped or stored in this condition until ready for use.

[00098] As shown in Figure 9D, the first upper closure flap 174 and second upper closure flap 167 may be torn away, for example along frangible lines 176, 168 respectively, to allow the secondary packaging container to be opened. The blister pack 80, which may previously have held leaflet 'L' in the housing, may now be withdrawn at least partly from the secondary packaging container, releasing leaflet 'L' sufficiently that leaflet 'L' may be withdrawn through window 172, or through the open upper end of the container. The leaflet may be stored in the cover portion (e.g. between inner panel 160 and outer panel 163) by passing the leaflet through the open upper end of the cover, or through recess 161 , or through a slit (see for example slit 262 in Figure 10B) provided in the inner panel 160. [00099] Thus, as shown in Figures 9A-9D, the secondary packaging system may include a housing H in which at least one article 80 may be held, along with a leaflet 'L'. A window 172 may be provided in wall panel 142, the window being structured and arranged such that leaflet 'L' when disposed at least partially within housing H is at least partly visible through window 172, and when article 80 is disposed within housing H the article 80 may retain the leaflet 'L' within housing H. The window 172 may be structured and arranged such that a when the article 80 is at least partly removed from housing H, the leaflet 'L' within housing H can be withdrawn from housing H through the window 172. The secondary packaging system may further include a cover portion (e.g. panels 160, 163) that may be hinged to the housing H and moveable relative to the housing H between a closed position in which the cover portion overlies window 172 and an open configuration in which the cover portion does not overlie the window 172. The leaflet 'L' may be initially folded at least partially about article 80, and article 80 may be held at least in part in the housing. When both the article 80 and leaflet 'L' and disposed within the housing H, at least part of the leaflet 'L' is visible through window 172. In order to remove leaflet 'L' through window 172, the article 80 may first be at least partly removed from the housing.

[000100] Referring to Figure 10A that shows the third embodiment of the invention, the blank 210 includes a base portion 240 and a cover portion 212. The base portion 240 includes: an interior wall panel 242 (also referred to as a shell panel 242), a first side panel 241 , a primary base panel 273, a second side panel 243 and a glue flap 250. The shell panel 242, first side panel 241 , primary base panel 273, second side panel 243 and glue flap 250 are hinged together in a linear series by fold lines 254, 253, 255 and 256 respectively. When the blank 210 is formed into a secondary packaging container (not shown), the glue flap 250 is affixed to part of the inside surface of the shell panel 242. Once opened and erected, a void or housing or internal volume is provided between the shell panel 242, primary base panel 273 and the first and second side panels 241 , 243.

[000101 ] The primary base panel 273 includes a first tuck-style end closure structure

277a/277b/277c/277d at an upper end of the primary base panel 273. The first tuck-style end closure structure includes: an upper closure flap 277a hinged directly to the primary base panel 273 along fold line 276; a first tuck-flap 277b hinged to the upper closure flap 277a along a fold line 279; and a pair of side end closure flaps 277c, 277d that are hinged to the first and second side panels 241 , 243 by fold lines 287 and 285

respectively. The fold line 279 between the upper closure flap 277a and the first tuck-flap 277b is not co-extensive with the upper closure flap 277a or the first tuck-flap 277b, but rather terminates in cut lines 261 a, 261 b. The provision of cut lines 261 a, 261 b allows for a portion of the first tuck-flap 277b, adjacent to each cut line 261 a, 261 b, to be positioned between the first upper closure flap 277a and a side end closure flap 277c, 277d to create a mechanical lock for the first tuck-style end closure structure. A user deliberately intending to do so can pull on the tuck-flap 277a and move it past the first lower closure flap 277a to release the engagement of edge portions of the tuck-flap 277b on the first lower closure flap 277a.

[000102] In the alternative, the shell panel 242 may not include a second lower end

closure panel or structure and the bottom edge of the shell panel 242 may be a free edge.

[000103] The shell panel 242 has a window 272 or cutout area 272 defined by a cut line 246. As before, the window 272 provides access to the interior of the housing between shell panel 242 and the primary base panel 273. Window 272 is may preferably be large enough for a user's finger to be inserted therethrough to move the contents (such as a blister pack) to assist the withdrawal of an article from the housing. Additionally, the window 272 is sized, shaped, structured and/or otherwise arranged such that a product information leaflet (PIL) or other leaflet 'L' can be withdrawn through the window 272 and out of the internal housing. The window area 272 may preferably be provided with an indexing element in the form of an indexing tab 247. The indexing tab 247 serves to resiliency engage an upstanding or protruding portion of an article housed within the container formed from the blank 210. In this way an indexing function or ratchet is provided, whereby an article (blister pack) is releasably held in a plurality of dispensing positions as it is withdrawn from the shell. The indexing tab 247 is connected to the shell panel 242 by a fold line 270 provided along a portion of the edge of the window 272. In other embodiments, the tab 247 is omitted. [000104] In the present arrangement, however, when a container is erected from the blank 210, the indexing tab 247 is folded inwardly of the housing to be disposed between two adjacent rows of the blisters as described above.

[000105] An engaging slit 249 is provided on the base portion 240 for receiving a tab 269 (similar to that as described above). The engaging slit 249 is formed substantially in the shell panel 242 in such a manner that the fold line 254 is interrupted by the engaging slit 249 and such that the engaging slit 249 is off-set from the fold line 254.

[000106] A second tuck-style end closure structure 275a/275b/275c/275d is provided at the opposite end of the shell panel 242 to the end of the base panel 273 that is closed by the first tuck-style end closure structure 277a/277b/277c/277d. The second tuck-style end closure structure 275a/275b/275c/275d includes: a lower closure flap 275a hinged directly to the primary base panel 273 along fold line 216; a second tuck-flap 275b hinged to the first lower closure flap 275a along a fold line 283; and a pair of side end closure flaps 275c, 275d that are hinged to the first and second side panels 241 , 243 by fold lines 281 and 282 respectively. The fold line 283 between the lower closure flap 275a and the second tuck-flap 275b is not co-extensive with the lower closure flap 275a or the tuck-flap 275b, but rather terminates in cut lines 284a, 284b. The provision of cut lines 284a, 284b allows for a portion of the second tuck-flap 275b adjacent to each cut line 284a, 284b to be positioned between the lower closure flap 275a and a side end closure flap 275c, 275d to create a mechanical lock for the second tuck-style end closure structure. A user deliberately intending to do so can pull on the second tuck-flap 275b and move it past the first lower closure flap 275a to release the engagement of edge portions of the tuck-flap 275b on the first lower closure flap 275a.

[000107] The cover portion 212 again includes: inner and outer panels 260, 263

respectively that are hinged directly to one another along a fold line 265. No second upper end closure flap is provided and the upper edges of each of the inner and outer panels 260, 263 are free edges. Unlike the first embodiment, no second glue flap is provided and in this arrangement, the outer panel 263 is affixed, for example by adhesive, directly to the inner panel 260. In this arrangement no second lower end closure panel (52) is provided and each edge 220, 218 of the outer and inner panels 260, 263 may be free edges. The construction of the blank 210 is described in a full sequence below and during this sequence, the inner and outer panels 260, 263 are affixed together along an edge opposite to the fold line 265 and along the bottom edges 220/218 thereof. In this way a pocket is formed between the inner and outer panels 260, 263 that is closed on three sides.

[000108] Preferably, the width of each of the inner and outer panels 260, 263 is exactly the same, to encourage the inner panel 260 to, very slightly, bow outwardly away from the outer panel 263 which thereby opens an upper outlet of the pocket for use. The pocket may be used by a patient or consumer to hold the leaflet 'U, once it has been extracted from the housing in the base portion 240, which may be done via withdrawal through the window 272, or through the opened upper end of the container. To assist in the location and withdrawal of leaflet 'L' in the pocket between the inner panel 260 and outer panel 263, a recess 261 is provided in one of the inner or outer panels 260, 263. In the alternative, the inner panel 260 may, in other embodiments, have a slightly smaller or larger width. In another alternative, as shown in Figure 10B, the inner panel 260 may have a slit or slot 262 sized to receive leaflet 'L', instead of or in addition to recess 261 .

[000109] An engaging tab 269 is struck from the inner panel 260 and is hingedly

connected to the outer panel 263 along a fold line 265. The fold line 265 of the engaging tab 269 is substantially co-linear with the fold line 265 along which the inner and outer panels 260, 263 are hingedly connected. In other embodiments, the engaging tab 269 is hinged along a line that is slightly off-set from the fold line 265. The engaging tab 269 again provides a further part of a two part engaging mechanism, and is designed to cooperate with the engaging slit 249 as described above to retain the cover portion 212 in a closed position. The engaging tab 269 is frangibly tied or connected to the inner panel 260 by means of one or more connecting portions 228 that interrupt a cut line 226 formed in the inner panel 260. The cut line 226 may be shaped and positioned relative to the engaging tab 269 such that at least one aperture 232 (in this embodiment one aperture 232) is formed adjacent the engaging tab 269. The one or more connecting portions 228 provide a temporary and frangible connection, which beneficially maintains the engaging tab 269 in the plane of the inner panel 260 until such time as a user requires the engaging tab 269 to be deployed for mechanically locking or closing the cover portion 212 to the base portion 240 for securing the container in its closed configuration. At that time, the one or more apertures 232, provide an access point so that a user can grasp an edge of the engaging tab 269 and break-it free of direct attachment to the inner panel 260 by breaking the one or more frangible connections 228.

[0001 10] The blank 210 may be folded, glued and formed into a part-formed, substantially flat-folded structure (not shown). The first stage in the assembly of the blank 210 into the part-formed, substantially flat-folded structure is again, likely to be carried out on in-plant equipment (IPE). The flat form of the structure is again beneficial because, in that form, it can be shipped at minimum cost and do not suffer the vulnerability to damage (by crushing) associated with shipping erected, but empty secondary packaging containers.

[0001 1 1 ] Turning to the construction of the part-formed, substantially flat-folded structure, the part-formed, substantially flat-folded structure may be formed by a series of sequential folding operations in a straight line machine so that the part-formed, substantially flat folded structure is not required to be rotated or inverted unnecessarily to complete its construction. The folding process is not limited to that described below and may be altered according to particular manufacturing requirements.

[0001 12] Figure 10A shows the outside surface of the blank 210. The inside surface may be the coated and/or printed side of the paperboard blank 210. The inside surface (the inside surface may be the non-coated and/or non-printed side of the paperboard blank 210) of the outer panel 263 of the cover portion 212 may be folded about fold line 265 to bring it into face contacting relationship with the inside surface of the inner panel 260. Adhesive, such as hot melt glue, or other affixing agent may be applied to one or both of the inside surfaces of the outer and inner panels 263, 260 so that after folding (about fold line 265), the outer panel and inner panel 263, 260 are selectively affixed together such that a pocket is formed between the two panels that is at least substantially closed at three sides and open only at one end, in the region of the recess 261 . During this stage in the construction process, the engaging tab 269 remains affixed to and neatly within the plane of inner panel 260 and problems associated with the loose engaging tab 769 of the blank 710 are avoided. 1 13] At this stage, the blank 210 will be disposed with its outside surface generally facing a viewer of Figure 10A except the outer cover panel 263 the inside surface of which is facing the viewer. In this configuration, stated differently, the outside surfaces of the shell panel 242, first side panel 241 , primary base panel 273, second side panel 243 and glue flap 250 are facing up toward the viewer of Figure 10; and the inside surface of the outer panel 263 is facing up and is disposed under, and affixed to, the inner panel

260. To form the sheath or sleeve, the glue flap 250 and the second side panel 243 may be folded about fold line 255 so that their inside surfaces are brought into flat face contact with a portion of the inside surface of the base panel 273. Adhesive may then be applied to a portion of the outside surface of the glue flap 250, and/or to a portion of the inside surface of the shell panel 242. Then, the base panel 273 and the first side panel

241 (together with the second side panel 243 and glue flap 250) are folded about fold line 254 and placed behind the shell panel 242. In this way, the glue flap 250 is disposed in face contacting relationship with a portion of the inside surface of the shell panel 242 and is affixed thereto. The part-formed, substantially flat-folded structure is then completed. The first and second tuck-style end closures 277a/277b/277c/277d,

275a/275b/275c/275d may remain unfolded and substantially flat. The cover portion 212 may then be affixed to the shell panel 242. In the alternative, in this embodiment, the cover portion 212 is adhered to the shell panel 242 at one or more specific and weakened locations A1 , A2. In Figure 10A, it can be seen that two substantially circular weakened locations A1 , A2 are provided. The weakened locations may be circular and may be formed as a half-depth cuts into the material forming the shell panel 242.

Adhesive applied to the shell panel 242 at the weakened locations A1 , A2 and/or to the inner panel 260 of the cover portion 212 at corresponding locations is used to selectively affix the cover portion 212 to the base portion 240. Beneficially, such an arrangement for affixing the cover portion 212 to the base portion 240 enables a user to more cleanly and controllably separate the two adhered panels 260, 242. This is because the material, such as paperboard, at the weakened locations A1 , A2, will tear out, approximately to the depth of the half-depth cut. This prevents untidy tearing of the outer surface of the inner panel 260 so that the integrity of the package and the appearance of the package is substantially maintained after the first opening. This may be beneficial where the secondary packaging container is intended for repeated use, for example, where a patient repeatedly opens and closes the secondary packaging container to access and then store a blister pack of medication over the course of the medication.

[0001 14] After transportation, the part-formed, substantially flat folded structure is then opened into a tubular structure, for example by pushing the first and second side panels 241 , 243 towards one another and/or by relative separation of the primary base panel 273 from the shell panel 242. The housing thereby created between the primary base panel 273 and the shell panel 242 can then be loaded through one or both ends with one or more articles. In a preferred application, the articles include a blister pack including one or more blisters and tablets and a product-information-leaflet 'L' that is folded about a leading end of the blister pack and the leading end is pushed into the housing from the outlet leading with the leaflet 'L' toward the second tuck-style end closure structure 275a/275b/275c/275d. Before or after loading, the second tuck-style end closure structure 275a/275b/275c/275d is folded and erected to create a bottom end wall of the secondary packaging container. The other "top" end of the secondary packaging container is then closed. The second tuck-style end closure structure

277a/277b/277c/277d is folded and erected to create a top end wall of the secondary packaging container. The construction of the secondary packaging container is thereby completed and, by providing tuck-style end closures at both ends, existing machinery can be utilised to complete the package, and the complexities associated with the modification of In-Plant-Equipment to facilitate adhesive closing of both ends are avoided. However, it will be understood that one or both ends may be adhesively closed in other embodiments.

[0001 15] In this initial closed position, the top end of the secondary packaging container is closed; the upper outlet of the pocket in the cover portion 212 is open and the cover portion 212 is affixed to the base portion 240. It is therefore reasonably evident that the secondary packaging container has been securely closed for the first time and, when presented to a patient or consumer in this condition, the consumer, patient or other user will have a high level of confidence in the integrity and quality of the contents.

[0001 16] To open the secondary packaging container for the first time, a user may

typically, separate the cover portion 212 from the base portion 240 by pulling or peeling the inner panel 260 away from the shell panel 242, the window 272, leaflet and articles will then be visible to the user. The user may then remove the product information leaflet (PIL) by withdrawing it through the window and may then stow the product-information- leaflet in the pocket provided by the cover portion 212. The user may then open the first tuck style end closure structure 277a/277b/277c/277d and by inserting their finger into the window 272 can push the article out of the open top end of the secondary packaging container. The indexing tab 247 operates to selectively restrict the withdrawal of the article, such as a blister pack. Once a user has finished the current use of the package, the secondary packaging container can then be re-closed to keep it in a compact, tidy and discreet format. To do this, the engaging tab 269 can then be broken free of its connection with the inner panel 260 as described above, so that a user of the secondary packaging container can reclose the cover portion 212 over the base portion 240 by locating the engaging tab 269 in slit 249.

[0001 17] Advantageously, in the blank 210, the inner panel 260 of the cover portion 212 is hinged directly to the shell panel 242. In this way the size of the blank 210 can be reduced and less material used compared to the arrangement of Figure 1 wherein the cover portion 712 is hingedly connected to the base portion 71 1 through an additional spine panel (hinge panel) 713 that is hinged directly to the primary base panel 773 of the base portion 71 1. The minimum end-to-end length of the blank 210 is shorter than the minimum end-to-end length of the blank 710 when the blanks 710, 210 have been configured to house the same size of article. The construction of the blank 210 may also be simplified by having the cover portion 212 hinged directly to the shell panel 242 since the blank 210 is not required to be flipped from an inside surface to an outside surface during its construction.

[0001 18] Referring to Figure 1 1 that illustrates the fourth embodiment of the invention, the blank 310 includes a base portion 340, a hinge portion 313 and a cover portion 312. The cover portion 312 is hingedly connected to the base portion 340 through the hinge portion 313. The base portion 340 includes: an interior wall panel 342 (also referred to as a shell panel 342), a first side panel 341 , a primary base panel 373, a second side panel 343 and a glue flap 350. The primary base panel 373, first side panel 341 , interior wall panel 342, second side panel 343 and glue flap 350 are hinged together in a linear series by fold lines 353, 354, 355 and 356 respectively. When the blank 310 is formed into a secondary packaging container (not shown), the glue flap 350 is affixed to part of the inside surface of the base panel 373. Once erected and opened, a void or housing or internal volume of the container is provided between the shell panel 342, primary base panel 373 and the first and second side panels 341 , 343.

[0001 19] The base panel 373 is provided with a first upper closure flap 374 and a first lower closure flap 375. The upper and lower closure flaps 374, 375 are hingedly connected to the primary base panel 373 along a tear line 376 and a fold line 377 respectively.

[000120] The first side panel 341 is hingedly connected to the primary base panel 373 along a fold line 353. The shell panel 342 is hingedly connected to the first side panel 341 along a fold line 354. The second side panel 343 is hingedly connected to the shell panel 342 along a fold line 355. The glue flap 350 is hingedly connected to the second side panel 343 along a fold line 356. Attached to the lower edge of the shell panel 342 along a fold line 357 is a second lower closure flap 352. The panels 341 , 342, 343, 350 are designed to be folded inwardly along the fold lines 353, 354, 355, 356. The glue flap 350 is then attached to the primary base panel 373 so that a sheath for holding one or more contents is provided by the base portion 340. The glue flap 750 may be secured to the inside surface of the primary base panel 373 by any adhesive, tape or mechanical securing means such as staples. The upper edge of the tubular base portion 340 defines a sheath outlet 344.

[000121 ] The cover portion 312 includes inner and outer cover panels 360, 363 that are hinged directly to one another along a fold line 365. A second upper closure flap 367 is hingedly connected to the upper edge of the outer cover panel 363 along a tear line 368. An engaging tab 369 is struck from the inner cover panel 360 and hingedly connected to the outer cover panel 363 along a fold line 364. The fold line 364 of the engaging tab 369 is substantially co-linear with the fold line 365 along which the inner and outer cover panels 360, 363 are hingedly connected. The engaging tab 369 provides part of an engaging mechanism and is designed to cooperate with an engaging slit 349 in the shell panel 342 to retain the cover portion 312 in a closed position with respect to the base portion 340.

[000122] The shell panel 342 has a window 372 defined by a window periphery 346. As before, the window 372 provides access to the interior of the housing or sheath between shell panel 342 and the primary base panel 373. Window 372 may preferably be large enough for a user's finger to be inserted therethrough to move the contents (such as a blister pack) to assist the withdrawal of an article from the housing. Additionally, the window 372 is sized, shaped, structured and/or otherwise arranged such that a product information leaflet (PIL) or other leaflet 'L' (see Figure 9D) can be withdrawn through the window 372 and out of the internal housing or sheath. The window 372 may preferably be provided with an indexing or ratchet element in the form of an indexing tab 347. The indexing tab 347 serves to resiliency engage an upstanding or protruding portion of an article housed within the container formed from the blank 310. In this way, an indexing function or ratchet is provided, whereby an article (e.g., a blister pack) is releasably held in a plurality of dispensing positions as it is withdrawn from the shell. The indexing tab 347 is connected to the shell panel 342 by a fold line 370 provided along a portion of the periphery of the window 372. In preferred embodiment, the length "W1 " of the indexing tab 347 is substantially less than either the distance between the shell panel 342 and the base panel 373 or the width "W2" of the first or second side panel 341 or 343 so that the tab 347 can yield and thereby swing toward the outlet 344 when force is applied thereto by the article or content during the withdrawing or exiting movement of the article. In other embodiments, the indexing tab 347 may be omitted.

[000123] An engaging slit 349 is provided on the base portion 340 for receiving a tab 369.

The engaging slit 349 is formed substantially in the shell panel 342 in such a manner that the fold line 354 is interrupted by the engaging slit 349 and such that the engaging slit 349 is slightly off-set from the fold line 354 toward the window 372.

[000124] Referring further to Figure 1 1 and particularly to the cover portion 312, no upper or lower end closure panel is provided on the inner cover panel 360 and thus both the upper and lower edges of the inner panel 360 are fee of hinged connection to any other part of the blank 310. The lower edge 318 of the outer cover panel 363 also is a free edge which is not hingedly connected to any other part of the blank 310. The

construction of the blank 310 is described in a full sequence below and during this sequence, the inner and outer panels 360, 363 are affixed together along an edge opposite to the fold line 365 and along the bottom edges 320/318 thereof. In this way a pocket is formed between the inner and outer panels 360, 363 that is closed on three sides. The open end of the pocket is closed, when the container is erected, by the first and second upper closure flaps 374 and 367 which also close the outlet or upper end 344 of the sheath.

[000125] The pocket defined between the inner and outer panels 360, 363 may be used by a patient or consumer to hold the leaflet 'L' (see Figure 9D), once it has been extracted from the housing in the base portion 340, which may be done, for example via withdrawal through the window 372. To assist in the location and withdrawal of leaflet 'L' in the pocket, a recess 361 is provided in one of the inner and outer panels 360, 363.

[000126] The engaging tab 369 is struck from the inner panel 360 and is hingedly

connected to the outer panel 363 along a fold line 364. The engaging tab 369, stated differently, is defined by a cut line 326 and a semi-circular aperture 332. The engaging tab 369 is frangibly or detachably tied or connected to the inner panel 360 by means of one or more nick or connecting portions 328 that interrupt the cut line 326. The cut line 326 may be shaped and positioned relative to the engaging tab 369 such that the one or more apertures 332 (in this embodiment one aperture 332) is formed adjacent the engaging tab 369. The aperture 332 in the illustrated example also interrupts the cut line 326. The one or more connecting portions 328 provide a temporary and frangible connection, which beneficially maintains the engaging tab 369 in the plane of the inner panel 360 until such time as a user requires the engaging tab 369 to be deployed for mechanically locking or closing the cover portion 312 to the base portion 340 for securing the container in its closed configuration.

[000127] The blank 310 may be folded, glued and formed into a part-formed, substantially flat-folded structure (not shown). The first stage in the assembly of the blank 310 into the part-formed, substantially flat-folded structure is again, likely to be carried out on in-plant equipment (IPE).

[000128] Turning to the construction of the part-formed, substantially flat-folded structure, the part-formed, substantially flat-folded structure may be formed by a series of sequential folding operations in a straight line machine so that the part-formed, substantially flat folded structure is not required to be rotated or inverted unnecessarily to complete its construction. The folding process is not limited to that described below and may be altered according to particular manufacturing requirements.

[000129] Figure 1 1 shows the inside surface of the blank 310. The inside surface may be the non-coated and/or non-printed side of the paperboard blank 310. The inner cover panel 363 may be folded about fold lines 365 and 364 to bring it into face contacting relationship with the inside surface of the outer panel 363. Adhesive, such as hot melt glue, or other affixing agent may be applied to one or both of the inside surfaces of the outer and inner panels 360, 363 so that after folding about fold lines 365 and 364, the inner panel 360 and outer panel 363 are selectively affixed together such that a pocket is formed between the two panels that is at least substantially closed at three sides and open only at one end, in the region of the recess 361 . During this stage in the construction process, the engaging tab 369 remains affixed to and neatly within the plane of inner panel 360.

[000130] At this stage, the blank 310 will be disposed with its inside surface generally facing up toward a viewer of Figure 1 1 . In this configuration, more specifically, the inside surfaces of the hinge portion 313, base panel 373, first side panel 341 , shell panel 342, second side panel 343 and glue flap 350 are facing up toward the viewer; and the outer surface of the inner panel 360 is facing up toward the viewer and is disposed on top of and affixed to the inside surface of the outer panel 363. To form the sheath or sleeve, the glue flap 350 and the second side panel 343 may be folded about fold line 355 so that they are brought into flat face contact with a portion of the inside surface of the shell panel 242. Adhesive may then be applied to at least a portion of the outside surface of the glue flap 350, and/or to a portion of the inside surface of the base panel 373. Then, the shell panel 342 and first side panel 341 (together with the second side panel 343 and glue flap 350) are folded about fold line 353 and placed on top of the base panel 373 and the hinge portion 313. In this way, the glue flap 350 is disposed in face contacting relationship with a portion of the inside surface of the base panel 373 and is affixed thereto. The part-formed, substantially flat-folded structure is then completed. The upper and lower closure flaps 367, 374; 375, 352 may remain unfolded and substantially flat in the plane of their respective adjacent panels 360, 373 and 342. The cover portion 312 may then be affixed to the shell panel 342. In the alternative, in this embodiment, the cover portion 312 is adhered to the shell panel 342 at one or more specific and weakened locations similar to the locations A1 , A2 shown in Figure 10. In Figure 10, it can be seen that two substantially circular weakened locations A1 , A2 are provided.

[000131 ] After transportation, the part-formed, substantially flat folded structure is then opened into a tubular structure, for example by pushing the first and second side panels 341 , 343 towards one another and/or by relative separation of the primary base panel 373 from the shell panel 342. The housing thereby created between the primary base panel 373 and the shell panel 342 can then be loaded through one or both ends with one or more articles. In a preferred application, the articles include a blister pack including one or more blisters and tablets and a product-information-leaflet 'L' (see Figure 9D) that is folded about a leading end of the blister pack and the leading end is pushed into the housing from, for example, the outlet 344 leading with the leaflet 'L' toward the lower closure flaps 375, 352. Before or after loading, the lower closure flaps 375, 352 are folded and glued together to create a bottom end closure wall of a secondary packaging container. After the loading, the upper closure flaps 367,374 are also folded and glued together. They provide a top end closure wall of the container. The construction of the secondary packaging container is thereby completed

[000132] The container formed from the blank 310 may be opened in a similar way to that formed from the blank 210 of Figure 10. The way to use the engaging tab 369 is also similar to that to use the tab 269 shown in Figure 10.

[000133] It can be appreciated that various changes may be made within the scope of the present invention, for example, the size and shape of the panels and apertures may be adjusted to accommodate articles of differing size or shape. In other embodiments of the invention, the specific arrangement of panels used to form the walls of the secondary carton package may be reordered in the blank.

[000134] It will be recognised that as used herein, directional references such as "top", "bottom", "front", "back", "end", "side", "inner", "outer", "upper" and "lower" do not limit the respective panels to such orientation, but merely serve to distinguish these panels from one another.

[000135] As used herein, the terms "hinged connection" and "fold line" refers to all manner of lines that define hinge features of the blank, facilitate folding portions of the blank with respect to one another, or otherwise indicate optimal panel folding locations for the blank. A fold line is typically a scored line, an embossed line, or a debossed line. Any reference to hinged connection or fold line should not be construed as necessarily referring to a single fold line only; indeed it is understood that hinged connection can be formed from any one or more of the following, a short slit, a frangible line or a fold line without departing from the scope of the invention.

[000136] As used herein, the term "severance line" refers to all manner of lines that

facilitate separating portions of the substrate from one another or that indicate optimal separation locations. Severance lines may be frangible or otherwise weakened lines, tear lines, cut lines, or slits.

[000137] It should be understood that hinged connection, severance lines and fold lines can each include elements that are formed in the substrate of the blank including perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half- cut, a cut line, an interrupted cut line, slits, scores, any combination thereof, and the like. The elements can be dimensioned and arranged to provide the desired functionality. For example, a line of perforations can be dimensioned or designed with degrees of weakness to define a fold line and/or a severance line. The line of perforations can be designed to facilitate folding and resist breaking, to facilitate folding and facilitate breaking with more effort, or to facilitate breaking with little effort.

ADDITIONAL EMBODIMENTS [000138] Additional embodiments are described below.

[000139] In one embodiment a secondary packaging container comprises: a cover portion comprising an inner panel and an outer panel defining a pocket therebetween, a base portion comprising an interior wall panel, a first side wall panel, a primary base wall panel and a second side wall panel which define a housing in which at least one article can be held, the cover portion being hinged to the base portion such that the cover portion is moveable relative to the base portion between a closed configuration in which the cover portion is disposed in overlying relationship with the interior wall panel of the base portion and an open configuration in which the cover portion does not overlie the interior wall panel of the base portion, wherein the base portion further comprises a first upper closure flap frangibly connected to the primary base panel and the cover portion further comprises a second upper closure flap hingedly connected to the outer panel, wherein the second upper closure flap is affixed to the first upper closure flap and wherein the first and second upper closure flaps close an upper outlet of the housing of the base portion and close an uppermost opening of said at least one openings of the pocket.

[000140] In another embodiment, A blank for forming a secondary packaging container, comprises: an outer panel and an inner panel for forming a cover portion which inner and outer panels are hinged together; an interior wall panel, a first side panel, a primary base panel and a second side panel hinged together in series for forming a base portion; the cover portion and the base portion being hinged together and thereby, once the blank is constructed into a secondary packaging container a cover portion formed from the inner and outer panels is moveable relative to the base portion; wherein the blank further comprises a first glue flap for affixing the inner and outer panels of the cover portion together to form a pocket between the inner and outer panels of the cover portion, which first glue flap is hinged to the outer panel, the pocket having at least one opening; a second glue flap for affixing the second side panel to the interior panel for forming a housing of the base portion; a first upper closure flap hingedly connected to the primary base panel; a second upper closure flap hingedly connected to the outer panel; wherein the second upper closure flap is affixable to the first upper closure flap for closing an upper outlet of the housing of the base portion and for closing an uppermost opening of said at least one openings of the pocket when the blank is formed into a secondary packaging container.

[000141 ] In certain embodiments of the blank, the inner panel of the cover portion and the interior panel of the base portion are hinged together.

[000142] In certain embodiments of the blank according one of the first and second upper closure flaps is foldable on top of the other, and at least one of the hinged connections of the first and second upper closure flaps is a frangible connection.

[000143] In another embodiment, a secondary packaging container comprises: a base portion having wall panels defining a housing in which at least one article can be held; a cover portion hinged to the base portion and thereby being moveable relative to the base portion between a closed configuration in which the cover portion is disposed in overlying relationship with an interior wall panel of the base portion and an open configuration in which the cover portion does not overlie the interior wall panel of the base portion; wherein the cover portion and base portion are each provided with a respective part of a mechanical locking mechanism for locking the secondary package in a closed configuration, the mechanical locking mechanism comprising a tab hingedly connected to the cover portion and a slit formed within the base portion, the tab and slit being structured and arranged such that the tab is locatable in the slit for locking the cover portion to the base portion and wherein before being used as a locking tab, the tab is temporarily and frangibly connected to the cover portion such that the tab is retained within the plane of a wall panel of the cover portion during assembly of the secondary package.

[000144] In certain embodiments of the secondary packaging container the cover portion comprises two wall panels: an inner panel and an outer panel, the inner panel and outer panel being hinged directly to one another along a fold line and wherein the tab is hinged to the cover portion along said fold line and wherein the tab is struck from material that would otherwise form part of the inner panel of the cover portion and is defined at least in part by a cut line. [000145] In certain embodiments of the secondary packaging container the tab is temporarily and frangibly connected to the inner cover panel by one or more connecting portions that interrupt said cut line.

[000146] In certain embodiments of the secondary packaging container one or more

apertures is provided adjacent to the tab such that one or more free edges of the tab are available for grasping the tab and for facilitating moving the tab for breaking the temporary and frangible connection such that the tab can be moved out of the plane of the inner panel and used as a locking tab locatable in the slit.

[000147] In certain embodiments of the secondary packaging container, the secondary packaging container is formed from a single blank of foldable sheet material and wherein each of the panels forming the base portion structure and the cover portion are hinged one to the next in series.

[000148] In an another embodiment, a blank for forming a secondary packaging container, comprises: an outer panel and an inner panel for forming a cover portion which inner and outer panels are hinged together; an interior wall panel, a first side panel, a primary base panel and a second side panel hinged together in series for forming a base portion; the cover portion and the base portion being hinged together and thereby, once the blank is constructed into a secondary packaging container, a cover portion formed from the inner and outer panels is moveable relative to the base portion, wherein the blank comprises a mechanical locking mechanism comprising a tab hingedly connected to the outer panel of the cover portion and a slit formed co-linearly with a fold line between the interior panel and the first side panel of the base forming portion, and wherein the tab is temporarily and frangibly connected to the inner panel of the cover portion such that the tab is retained within the plane of the inner panel of the cover portion during assembly of the secondary package.

[000149] In certain embodiments of the blank, the inner panel of the cover portion and the interior panel of the base portion are hinged together. [000150] In certain embodiments of the blank, the tab is struck from material that would otherwise form part of the inner panel of the cover portion and is defined at least in part by a cut line.

[000151 ] In certain embodiments of the blank, the tab is temporarily and frangibly

connected to the inner cover panel by one or more connecting portions that interrupt said cut line.

[000152] In another embodiment, a part-formed substantially flat-folded structure is made from the blank.

[000153] In an additional embodiment, a secondary packaging container comprises: a cover portion comprising an inner panel and an outer panel defining a pocket

therebetween, a base portion comprising an interior wall panel, a first side wall panel, a primary base wall panel and a second side wall panel which define a housing in which at least one article can be held, the cover portion being hinged to the base portion such that the cover portion is moveable relative to the base portion between a closed configuration in which the cover portion is disposed in overlying relationship with the interior wall panel of the base portion and an open configuration in which the cover portion does not overlie the interior wall panel of the base portion, wherein an adhesive connection between the inner panel and the outer panel is formed using a lower end closure panel that is disposed between the inner and outer panels and which is adhesively affixed on one side to an inside surface of the inner panel and which is adhesively affixed on the other side to an inside surface of the outer panel.

[000154] In certain embodiments of the secondary packaging container, said lower end closure panel is frangibly coupled to the interior wall panel of the base portion in an initial sealed and closed configuration of the secondary packaging container.

[000155] In certain embodiments of the secondary packaging container, said lower end closure panel provides a connection between the cover portion and the base portion in an initial sealed and closed configuration of the secondary packaging container. [000156] In certain embodiments of the secondary packaging container the frangible connection between the lower end closure panel and the interior wall panel must be broken in order to move the cover portion from its closed configuration into its open configuration and thereby the lower end closure panel provides a tamper evident feature.

[000157] In certain embodiments of the secondary packaging container, the base portion comprises first and second tuck-style end closure structures each for closing an end of the housing provided by the base portion.

[000158] In certain embodiments of the secondary packaging container the first tuck style closure structure comprises a side end closure flap hinged to the first side panel of the base portion; a side end closure flap hinged to the second side panel of the base portion; an upper closure flap hinged to the primary base panel; and a tuck flap partially hinged to the upper closure flap and partially separated therefrom by cut lines which each provide a free edge of the tuck flap and upper closure panels.

[000159] In certain embodiments of the secondary packaging container the second tuck style closure structure comprises a side end closure flap hinged to the first side panel of the base portion; a side end closure flap hinged to the second side panel of the base portion; a lower closure flap hinged to the primary base panel; and a tuck flap partially hinged to the lower closure flap and partially separated therefrom by cut lines which each provide a free edge of the tuck flap and lower closure panels.

Claims

1. A packaging system, comprising:

a base portion having wall panels which together define a housing, the base portion having a window defined in at least one of the wall panels;

at least one article received in the housing;

a leaflet received in the housing such that the leaflet is disposed covering at least part of the at least one article to hide it from view through the window and such that the leaflet is visible at least in part from outside of the base portion through the window.

2. The packaging system of claim 1 , wherein the leaflet is disposed in part between the at least one article and the at least one of the wall panels.

3. The packaging system of claim 1 or 2, wherein the wall panels include a pair of first and second opposed walls disposed sandwiching the at least one article, the at least one of the wall panels comprises the first wall, and at least part of the leaflet is disposed between the second wall and the at least one article.

4. The packaging system of claim 1 , the window being structured and arranged such that a leaflet disposed at least partially within the housing can be withdrawn from the housing through the window.

5. The packaging system of claim 1 , further comprising a cover portion.

6. The packaging system of claim 5, wherein the cover portion is hinged to the base portion and thereby being moveable relative to the base portion between a closed position in which the cover portion overlies the window and an open configuration in which the cover portion does not overlie the window.

7. A packaging system comprising a secondary packaging container according to claim 1 , wherein the leaflet is initially folded at least partially about the article and the article is held at least in part in the housing.

8. A packaging system according to claim 7, wherein the article is a blister pack, wherein the leaflet is folded about part of the blister pack and the blister pack and leaflet are both disposed within the housing such that at least part of the leaflet is visible through the window and such that the leaflet can be withdrawn from the housing through the window.

9. A packaging system according to claim 8, wherein the blister pack is moveable out of the housing through an outlet disposed at the top of the base portion in order to release the leaflet so that it may be withdrawn though the window.

10. A packaging system according to claim 8 or 9, further comprising a cover portion that comprises two wall panels: an inner panel and an outer panel which form a pocket therebetween that is closed along three side edges and has at least one opening through which said leaflet can be inserted.

1 1 . A packaging system according to claim 10, wherein a first side edge of the pocket is closed by virtue of a hinge connection between the inner panel and the outer panel, wherein a second side edge is closed by virtue of a glue flap hinged to the outer panel and affixed inside the pocket to an inside surface of the inner panel, and wherein a bottom side edge of the pocket is closed by virtue of an adhesive connection between the inner panel and the outer panel.

12. A packaging system according to any of claims 5, 6, 10, or 1 1 , wherein the cover portion and base portion are each provided with a respective part of a mechanical locking mechanism for locking the cover in a closed position, the mechanical locking mechanism comprising a tab hingedly connected to the cover portion and a slit formed within the base portion, the tab and slit being structured and arranged such that the tab is locatable in the slit for locking the cover portion to the base portion and wherein before being used as a locking tab, the tab is temporarily and frangibly connected to the cover portion such that the tab is retained within the plane of a wall panel of the cover portion during assembly of the secondary package.

13. A packaging system according to claim 12, wherein the cover portion comprises an inner panel and outer panel hinged directly to one another along a fold line and wherein the tab is hinged to the cover portion along said fold line and wherein the tab is struck from material that would otherwise form part of the inner panel of the cover portion and is defined at least in part by a cut line.

14. A packaging system according to claim 13, wherein the tab is temporarily and frangibly connected to the inner cover panel by one or more connecting portions that interrupt said cut line.

15. A packaging system according to claim 13 or 14, wherein one or more apertures is provided adjacent to the tab such that one or more free edges of the tab are available for grasping the tab and for facilitating moving the tab for breaking the temporary and frangible connection such that the tab can be moved out of the plane of the inner panel and used as a locking tab locatable in the slit.

16. A packaging system according to claim 10 or 1 1 wherein the base portion further comprises a first upper closure flap frangibly connected to base portion and the cover portion further comprises a second upper closure flap hingedly connected to the outer panel, wherein the second upper closure flap is affixed to the first upper closure flap and wherein the first and second upper closure flaps close an upper outlet of the housing of the base portion and close an uppermost opening of said at least one openings of the pocket.

17. A packaging system according to any preceding claim, wherein the base portion is formed from a single blank of foldable sheet material and herein each of the panels forming the base portion are hinged one to the next in series.

18. A packaging system according to any of claims 5, 6, or 10 through 17, wherein the base portion and cover portion are formed from a single blank of foldable sheet material and wherein each of the panels forming the base portion structure and cover portion are hinged one to the next in series.

19. A packaging system, comprising:

a base portion having a plurality of wall panels which together define a housing, the base portion having a window defined in at least one of the wall panels; a leaflet received in the housing such that at least part of the leaflet is visible from outside of the base portion through the window; the window being dimensioned and configured such that the leaflet is manipulable to exit the housing through the window; and

at least one article received in the housing and disposed in engagement with the leaflet such that the leaflet is prevented from exiting the housing through the window until removal of the leaflet is desired.

20. The packaging system of claim 19, the window being structured and arranged such that when the article at least partly removed from the housing, the leaflet within the housing can be withdrawn from the housing through the window.

21 . The packaging system of claim 19 or 20, further comprising a cover portion.

22. The packaging system of claim 21 , wherein the cover portion is hinged to the base portion and thereby being moveable relative to the base portion between a closed position in which the cover portion overlies the window and an open configuration in which the cover portion does not overlie the window.

23. A packaging system according to claim 19, wherein the leaflet is initially folded at least partially about the article and the article is held at least in part in the housing.

24. A packaging system according to claim 23 wherein the article is a blister pack, wherein the leaflet is folded about part of the blister pack and the blister pack and leaflet are both disposed within the housing such that at least part of the leaflet is visible through the window and such that the leaflet can be withdrawn from the housing through the window.

25. A packaging system according to claim 19 wherein at least part of the leaflet is disposed between the at least one article and the at least one of the wall panels.

26. A packaging system according to claim 19 or 25 wherein the wall panels include a pair of first and second opposed walls disposed sandwiching the at least one article, the at least one of the wall panels comprises the first wall, and at least part of the leaflet is disposed between the second wall and the at least one article.

27. A method of forming a packaging system, the method comprising:

providing a housing having at least one open end;

providing a window in the housing;

providing an article;

providing a leaflet;

inserting the article and the leaflet into the housing

positioning the leaflet such that at least a part of the leaflet is visible through the window.

28. A method according to claim 27, further comprising folding said leaflet about a lower edge of said article before inserting the article and leaflet into the housing.

29. A method according to claim 27, wherein the leaflet and article are inserted into the housing through the open end.

30. A method according to claim 29, wherein the leaflet enters the housing before the article.

31 . A method according to claim 27, wherein the article held in the housing is at least partly visible through the window.

32. A method according to claim 27, wherein a cover portion is provided which is hingedly attached to the housing and moveable relative to the housing between a closed configuration in which the cover portion overlies the window and an open configuration in which the cover portion does not overlie the window.

33. A method according to claim 32, wherein the cover portion comprises two panels with a pocket formed therebetween into which the leaflet may be inserted.

34. A method according to claim 32 or 33, wherein the cover portion and base portion are each provided with a respective part of a mechanical locking mechanism for locking the secondary package in a closed configuration, the mechanical locking mechanism comprising a tab hingedly connected to the cover portion and a slit formed within the base portion, the tab and slit being structured and arranged such that the tab is locatable in the slit for locking the cover portion to the base portion and wherein before being used as a locking tab, the tab is temporarily and frangibly connected to the cover portion such that the tab is retained within the plane of a wall panel of the cover portion during assembly of the secondary package.

35. A method according to claim 34 wherein cover portion comprises an inner panel and outer panel hinged directly to one another along a fold line and wherein the tab is hinged to the cover portion along said fold line and wherein the tab is struck from material that would otherwise form part of the inner panel of the cover portion and is defined at least in part by a cut line.

36. A method according to claim 35 wherein the tab is temporarily and frangibly connected to the inner cover panel by one or more connecting portions that interrupt said cut line.

37. A method according to any of claims 27 to 36 wherein the article is a blister pack.