Abstract:
A system for removing covers from shipping cassettes that are used to ship computer disk media unlatches the covers and separates them from the cassette in a single fixture position. A movable fork unlatches a top cover from a bottom cover while the cassette is rotated off of the bottom cover. This action unlatches and separates the two covers allowing the removal of the bottom cover from the cassette in one motion. The top cover is then easily lifted off of the bottom cover.

Description:
BACKGROUND OF THE INVENTION 
   1. Technical Field 
   The present invention relates in general to efficiently handling the packaging of products and, in particular, to an improved system, method, and apparatus for removing the covers from shipping containers of computer disk media. 
   2. Description of the Related Art 
   Referring to  FIGS. 1 and 2 , a typical shipping container or cassette  11  for holding a plurality of workpieces  12  (e.g., computer disk media) is shown. The cassette  11  has a main body  13  that engages and supports the workpieces  12  therein. The cassette  11  has open upper and lower ends that are covered by upper and lower lids or covers  15 ,  17 , respectively. The upper and lower covers  15 ,  17  wrap around the body  13  to engage each other via interlocking tabs  19  and flexible clasps  21 . One paired set of the tabs  19  and clasps  21  are located on each end of the cassette  11 . When the three pieces of cassette  11  are mounted together (i.e., the body  13  and two covers  15 ,  17 ), the workpieces  12  located therein are protected from damage during shipping. The tabs  19  engage small slots in the clasps  21  to capture the body  13  therebetween. A small recess  23  is located between each clasp  21  and the end wall of the lower cover  17 . In addition, the cassette  11  has pockets  25  located to the left and right of each of the clasps  21 . 
   The three components that form cassette  11  are disassembled by bending the two clasps  21  outward or away from tabs  19 , and then lifting upper cover  15  and (optionally) lowering lower cover  17  away from body  13 . The workpieces  12  are then physically exposed while seated in the body  13  and ready for removal therefrom via the open upper end of the body  13 . 
   Historically, the covers  15 ,  17  have been manually removed from the body  13 . However, manual removal of the covers  15 ,  17  on a large volume basis is a probable source of repetitive motion injury to the operators.  FIG. 14  depicts a prior art fixture  31  for removing the covers  15 ,  17  from body  13 . This fixture  31  requires the cassette  11  to be mounted at a first position  33  to unlatch the tabs  19  from the clasps  21 , and then moved to a second position  35  to remove the lower cover  17  from body  13 . Unfortunately, this prior art design is a potential source of cover breakage (e.g., tabs  19  and clasps  21 ) and requires multiple hand motions to unlatch the covers before they are removed from the cassettes. Moreover, the end features on fixture  31  tend to force clasps  21  to reengage the tabs  19  and thereby prevent efficient disassembly of the components. Although this solution is workable, an improved solution would be desirable. For example, a reduction in the amount of hand motion would reduce operator fatigue. In addition, means for ensuring that the tab  19  is bent outward away from clasp  21  before the lower cover  17  is removed would prevent breakage of the tab  19 . 
   SUMMARY OF THE INVENTION 
   One embodiment of a system, method, and apparatus for easily and quickly removing covers from shipping cassettes that are used to ship computer disk media is disclosed. This solution unlatches the covers and separates them from the cassette in a single fixture position with fewer motions and with less breakage. The present invention uses a movable fork to unlatch one end of the top cover from the bottom cover while the cassette is rotated off of the other end of the bottom cover. This action unlatches and separates the two covers to remove the bottom cover from the cassette in one motion. The top cover is then easily lifted off of the bottom cover. The advantage of this tool is that the unlatching and cover removal can be done in one motion on a single fixture position instead of having to move the cassette between two separate positions on a fixture. It also reduces the number of broken covers by ensuring that the covers are unlatched prior to separating and removing them. 
   To use the tool, the cassette is placed between the side walls, either on top of a pair of guide rails (e.g., for a 95 mm, 84 mm, or 70 mm cassette), or in a slot between the guide rails (e.g., 65 mm cassette). The cassette is moved forward until it contacts the front of the catch and is then rocked down on top of the fork. As the covers move down on the fork, the slope of the fork pulls the top cover forward and unlatches it from the bottom cover. The fork is mounted to a spring-loaded slide, so that the now-unlatched cover and the cassette are slid forward. This slides the bottom cover under the catch. The cassette is then rocked backward over the inner guide rails and the bottom cover is pried off of the cassette. The cassette is pulled off the tool toward the rear and operator catches the loose bottom cover and removes it from the latch on the other end of the cassette. The top cover is then easily lifted off and the contents of the cassette made accessible. 
   The foregoing and other objects and advantages of the present invention will be apparent to those skilled in the art, in view of the following detailed description of the present invention, taken in conjunction with the appended claims and the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     So that the manner in which the features and advantages of the invention, as well as others which will become apparent are attained and can be understood in more detail, more particular description of the invention briefly summarized above may be had by reference to the embodiment thereof which is illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the drawings illustrate only an embodiment of the invention and therefore are not to be considered limiting of its scope as the invention may admit to other equally effective embodiments. 
       FIG. 1  is a bottom isometric view of a conventional shipping container or cassette; 
       FIG. 2  is an exploded top isometric view of the conventional cassette of  FIG. 1 ; 
       FIG. 3  is a top isometric view of one embodiment of a fixture for disassembling the cassette of  FIGS. 1 and 2  and is constructed in accordance with the present invention; 
       FIG. 4  is a side view of the fixture of  FIG. 3  and is constructed in accordance with the present invention; 
       FIG. 5  is a side view of the fixture of  FIG. 3  during an initial step of operation and is constructed in accordance with the present invention; 
       FIG. 6  is a side view of the fixture of  FIG. 3  during a step of operation subsequent to  FIG. 5  and is constructed in accordance with the present invention; 
       FIG. 7  is a side view of the fixture of  FIG. 3  during a step of operation subsequent to  FIG. 6  and is constructed in accordance with the present invention; 
       FIG. 8  is an enlarged sectional side view of the fixture of  FIG. 3  during a step of operation subsequent to  FIG. 7  and is constructed in accordance with the present invention; 
       FIG. 9  is a side view of the fixture of  FIG. 3  during a step of operation subsequent to  FIG. 8  and is constructed in accordance with the present invention; 
       FIG. 10  is an enlarged sectional side view of the fixture of  FIG. 3  during a step of operation subsequent to  FIG. 9 , and is constructed in accordance with the present invention; 
       FIG. 11  is a side view of the fixture of  FIG. 3  during a step of operation subsequent to  FIG. 10 , and is constructed in accordance with the present invention; 
       FIG. 12  is an enlarged isometric view of a fork on the fixture of  FIG. 3  and is constructed in accordance with the present invention; 
       FIG. 13  is a high level flow diagram of one embodiment of a method constructed in accordance with the present invention; and 
       FIG. 14  is a top isometric view of a prior art fixture for disassembling the cassette of  FIGS. 1 and 2 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring to  FIGS. 3-13 , one embodiment of a system, apparatus, and method for removing a cover from a shipping container is disclosed. The apparatus comprises a fixture  41  ( FIGS. 3 and 4 ) having a base  43  with a longitudinal axis  45 , a lateral axis  47  orthogonal to the longitudinal axis  45 , and a transverse (i.e., vertical) axis  49  orthogonal to both the longitudinal and lateral axes  45 ,  47 . A surface  50  extends in a plane defined by the longitudinal and lateral axes  45 ,  47 . Side walls  51  extend transversely (i.e., vertically) from the surface  50 , and a slot  53  is defined longitudinally between the side walls  51  and extends along the surface  50  for supporting the cassette or shipping container  11 . 
   In one embodiment, a pivot guide  55  is mounted to the surface  50  and extends laterally between the side walls  51 . The pivot guide  55  guides the shipping container  11  and acts as a fulcrum for pivoting of the shipping container  11  during cover removal. A catch  57  is mounted to the surface  50  and is longitudinally spaced apart from the pivot guide  55 . The catch  57  has a lip  59  extending longitudinally that is transversely spaced apart from the surface  50  to define a slit  61  for receiving a portion  63  ( FIGS. 1 and 2 ) of the cover (e.g., the bottom cover  17 ). The lip  59  engages the bottom cover  17  during its removal from the shipping container  11  in a longitudinally deeper position ( FIGS. 9-11 ). 
   In the illustrated embodiment, the catch  57  is mounted adjacent a longitudinal end  65  of the base  43  and is laterally centered between the side walls  51 . The pivot guide  55  is mounted longitudinally closer to the catch  57  than to an opposite longitudinal end  67  of the base  43 . The pivot guide  55  has a pivot guide surface  69  transversely spaced apart from and parallel to the surface  50 . Rails  71  extend transversely from the pivot guide surface  69  parallel to and abutting the side walls  51 . In one embodiment, the side walls  51  are taller in the transverse direction than the rails  71 . A pivot guide slot  73  is defined longitudinally between the rails  71  and extends along the pivot guide surface  69 . 
   The fixture  41  is designed to remove covers from shipping containers  11  of different sizes. The pivot guide  55  guides shipping containers of a larger size on top of the rails  71  but between side walls  51 , rather than between the rails  71  (as shown for a small container  11 ). This design improves the guiding and handling of larger containers  11  when they rest on top of rails  71 . 
   In one embodiment, a fork  75  ( FIGS. 3 and 12 ) is mounted to the base  43  adjacent the catch  57  and extends transversely above the surface  50  as shown. The fork  75  is longitudinally movable relative to the base  43 , the pivot guide  55 , and the catch  57  (compare  FIGS. 8 and 10 ). The fork  75  engages the covers  15 ,  17  and moves longitudinally during disassembly of shipping container  11 . In the embodiment shown, the lips  59  on the catch  57  have a central longitudinal recess  77  for accommodating the fork  75  and the clasp  21  on cover  15 . 
   In the embodiment shown, the fork  75  comprises a pair of tines  81  ( FIG. 12 ) extending transversely from the surface  50 . Each of the tines  81  has an orthogonal surface  83  facing the pivot guide  55  and an inclined surface  85  opposite the orthogonal surface  83  that tapers from a maximum longitudinal dimension  87  adjacent the surface  50  to a lateral edge  89  that is transversely spaced apart from the surface  50 . 
   In operation ( FIGS. 5-11 ), the shipping container  11  is placed in the slot  53  and pivot guide  55 , pushed longitudinally into contact with the catch  57 , pivoted transversely about the pivot guide  55  toward the fork  75  such that the fork  75  deflects a portion of the cover from the shipping container (i.e., the fork  75  separates one of the clasps  21  from an associated one of the tabs  19 ), pushed longitudinally deeper into the slit  61  of the catch  57  to longitudinally move the fork  75 , and then pulled transversely away from the fork  75  such that the lip  59  pulls the lower cover  17  from body  13  and top cover  15 . 
   When the shipping container  11  is pushed longitudinally into contact with the catch  57 , there is a transverse clearance  91  ( FIG. 6 ) between the top edges  89  of the fork  75  and a bottom of the clasp  21 . Prior to longitudinal movement of the fork  75  ( FIG. 6-8 ), the fork  75  is longitudinally closer to the pivot guide  55  than the lip  59  on the catch  57 . After longitudinal movement of the fork  75  ( FIGS. 9-11 ), the fork  75  is longitudinally flush with the lip  59  on the catch  57 . 
   Referring now to  FIG. 13 , the present invention also comprises a method of removing covers from shipping containers of various sizes. One embodiment of the method starts as indicated at step  131 , and comprises providing a fixture (step  133 ) having a slot, a pivot guide and a catch mounted in the slot, and a fork located between the pivot guide and the catch; placing a shipping container in the slot and on the pivot guide (step  135 ), the shipping container having a cover; pushing the shipping container and cover along the slot such that the pivot guide guides the shipping container into contact with the catch (step  137 ); pivoting one end of the shipping container and the cover about the pivot guide toward the fork (step  139 ); deflecting a portion of the cover from the shipping container with the fork (step  141 ); pushing the shipping container deeper into the catch and displacing the fork toward the catch (step  143 ); and then retaining the cover with the catch by pulling the shipping container away from the cover to remove the cover from the shipping container (step  145 ), before ending as indicated at step  147 . 
   An alternate embodiment of the method of the present invention comprises mounting the catch adjacent an end of the fixture and mounting the pivot guide closer to the catch than to an opposite end of the fixture. When the shipping container is of a relatively small size, another alternate embodiment of the method comprises placing the shipping container in a slot formed in the pivot guide between rails. When the shipping container is of a relatively large size, the shipping container is placed on top of the rails. Yet another alternate embodiment of the method comprises forming lips on the catch and a recess therebetween for accommodating the fork and the portion of the cover. 
   The present invention has several advantages, including the ability to unlatch and remove cassette covers in one motion on a single fixture instead of having to move the cassette between two fixtures mounted on one plate. It also reduces the number of broken covers by ensuring that the covers are unlatched prior to separating and removing them. 
   While the invention has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention.