Abstract:
A package for housing a disc is provided, including a cover forming an elongated spine panel with first and second opposing panels extending therefrom such that the opposing panels selectively rotate between open and closed positions and a tray attached to one of the opposing panels. The tray has a planar surface and first and second opposing angular surfaces extending from the planar surface. Each angular surface has a slot for receiving an edge of the disc to support the disc above the planar surface, wherein at least one of the angular surfaces can be deflected to facilitate removal and insertion of the disc.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 60/922,124, filed Apr. 6, 2007 and U.S. Provisional Patent Application Ser. No. 60/965,875, filed Aug. 23, 2007, the disclosures of which are herein incorporated by reference in their entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to a reclosable storage package for recording media and, more particularly, to a package having securing ledges for storing a media disc. 
         [0004]    2. Description of the Prior Art 
         [0005]    Various types of planar discs are in use at the present time to record and store information which is to be retrieved by various means, such as by optical or magnetic means. Typical of such discs are compact discs (CDs) or digital video discs (DVDs) in which information is digitally recorded by use of a laser beam and then read optically by a laser beam. Such discs are used to record audio information (e.g., musical renditions), video information (e.g., visual images and digital information) for use as read only and other memories for use in various applications, such as computer applications. 
         [0006]    In most instances, at the present time, such discs are sold with information already recorded thereon. In other applications, such discs are sold in blank form and are used by the customer to record information thereon. In the latter case, for example, optical discs are sold for use as computer storage media and are used in hard disc storage systems. As used herein, the terms media disc, compact disc, CD or disc are intended to encompass all such discs, whatever their size, for all known or proposed uses. 
         [0007]    Compact discs containing laser recorded information are typically packaged in injection molded plastic enclosures designed to hold one or more CDs for protecting the discs during storage and shipment. Enclosures commonly used at the present time, such as the well known “jewel box,” comprise a three piece assembly consisting of a base or bottom element, an insert or tray in the base/bottom element for positioning and supporting the disc in the base/bottom element, e.g., by a center projection (commonly referred to as a “rosette”) which engages the periphery of the aperture in the center of the disc, and a lid or cover which is hinged to the base/bottom element and is closed thereon after the disc is mounted therein on the tray. Other enclosures utilize only two pieces, omit the tray, and position and support the disc via the center projection directly on the base/bottom element. The enclosure is, typically, at least partially transparent and graphics relating to the disc and containing trademark and sales promotional information are usually inserted in such a manner as to be visible through the enclosure. 
         [0008]    Except for the printed matter inserted therein, the “jewel box” is entirely plastic. For this reason, as well as because the typical jewel box requires three separately injection molded elements which must be manually assembled, the use of this type of enclosure is relatively expensive. Moreover, the use of such an enclosure is believed to be ecologically unacceptable by many because the plastic is non-biodegradable and, in view of the huge volume of such enclosures in use today, the disposal of these enclosures poses either a real or potential environmental problem. Still further, polymeric jewel boxes are relatively heavy and therefore, are not well suited for applications in which the CDs or DVDs are shipped through the mail. The weight of the plastic case adds significantly to the postal cost of the shipment. 
         [0009]    One solution to these problems has been the development of hybrid packages comprising both paperboard and plastic components. These hybrid packages provide a CD package which is suitable and attractive for display, sale and storage of compact discs, yet which is both simple and inexpensive to manufacture. 
         [0010]    For example, U.S. Pat. No. 4,709,812 to Kosterka, which is incorporated herein by reference, discloses a compact disc package formed from a pre-scored, preprinted unitary blank and at least one injection molded plastic compact disc holder or tray adhesively adhered to one segment of the blank, the blank being adapted to fold along fold lines to position a blank segment over the top of the disc holder to sandwich it, in book style, between the segment to which it is adhered and the overlying segment. The problem with this type of arrangement is that the book frequently opens and provides little protection for the disc there within. Moreover, this type of package still includes a relatively heavy plastic components. 
         [0011]    It should be apparent, therefore, that efforts to date directed at hybrid packaging containing multiple discs suffer from one or more shortcomings which make the resulting CD packaging unsatisfactory or require unduly complex manufacturing. Accordingly, there remains a need for a simple, environmentally friendly, inexpensive to manufacture and lightweight package for media discs that adequately protects the disc yet provides easy access thereto. 
       SUMMARY OF THE INVENTION 
       [0012]    It is an object of the subject disclosure to provide a package for holding discs that is easy to manufacture, lightweight and may be made from environmentally friendly materials. 
         [0013]    The present disclosure is directed to a package for housing a disc including a cover forming an elongated spine panel with first and second opposing panels extending therefrom such that the opposing panels selectively rotate between open and closed positions and a tray attached to one of the opposing panels. In the illustrative embodiment, the tray has a planar surface and first and second opposing angular surfaces extending from the planar surface. Each angular surface has a slot for receiving an edge of the disc to support the disc above the planar surface, wherein at least one of the angular surfaces can be deflected to facilitate removal and insertion of the disc. 
         [0014]    The present invention is also directed to a tray for a disc package that includes a planar surface; and first and second opposing angular surfaces extending upwardly from the planar surface. Each angular surface defines a slot for receiving an edge of a disc to support the disc above the planar surface, wherein at least one of the angular surfaces can be deflected in a radially outward direction to facilitate removal and insertion of the disc. 
         [0015]    In certain embodiments, the tray further includes a tension member secured to an underside of the tray member for structurally reinforcing the tray member. Preferably, the tension member is stiffer than the tray member. Still further, it is envisioned that in certain embodiments, the tray member and the tension member are fabricated from materials selected from paper, plastic and combinations thereof. 
         [0016]    The present invention is also directed to a package for housing a disc that includes, inter alia, a cover and a tray assembly. The cover formes an elongated spine panel with first and second opposing panels extending therefrom such that the opposing panels selectively rotate between open and closed positions. The tray assembly is attached to one of the opposing panels and includes a tray member and a tension member. The tray member has a planar surface, and angular surfaces extending from the planar surface, each angular surface defining a slot for receiving an edge of a disc to support the disc above the planar surface. The tension member is secured to the underside of the tray member for structurally reinforcing the tray member. 
         [0017]    The present disclosure is further directed to a tray assembly for retaining a disc that includes, inter alia, a tray member including a planar surface; two landings extending above the planar surface, each landing defining a slot for receiving an edge of the disc to support the disc above the planar surface; and a central landing for affirmatively engaging an aperture of the disc. 
         [0018]    It is envisioned that the tray assembly can further include a tension member secured to the tray member for structurally reinforcing the tray member. Moreover, in certain constructions, it is preferred that the central landing has a first level adjacent the planar surface to support the disc above the planar surface and a second level extending above the first level. Preferably, the central landing defines a slot for capturing the disc. The shape of the slot can be selected from the group consisting of arcuate, straight, Y-shaped and combinations thereof. 
         [0019]    The present invention is also directed to a method for creating a tray for storing a media disc that includes the steps of: vacuum forming plastic into a planar, disc-shaped recess having opposing angled wall portions extending from the recess; and forming opposing undercuts in the opposing angled wall portions. In certain embodiments, the method of the present invention includes the step of affixing the tray to a cover, the cover having an elongated spine panel with first and second opposing panels extending therefrom such that the opposing panels selectively rotate between open and closed positions. Preferably, the method also includes the step of forming a raised boss substantially centrally located in the disc-shaped recess. In certain constructions, graphics are applied directly to the cover. Additionally, the method may also include the step of forming overhangs above the undercuts, wherein the overhangs are deflectable. 
         [0020]    The present disclosure is a method for creating a tray for storing a media disc that includes the steps of: forming a blank into a planar, disc-shaped recess having opposing angled wall portions extending from the recess; and forming opposing undercuts in the opposing angled wall portions. Preferably the step of forming is stamping. Alternatively the forming step is vacuum forming. 
         [0021]    In certain constructions the inventive method further includes the steps of: forming the blank with die cut slots; placing the blank into a forming mold; and applying pressure to the blank to result in a three-dimensional shape. further comprising the step of applying heat during the applying pressure step. Preferably, the die cut slots become the opposing undercuts during the applying pressure step. 
         [0022]    The present invention is also direct to a blank for creating tray member comprising a flat board defining first and second opposing slots, and a third central slot. Preferably, the first and second slots are arcuate shaped with a v-shape on a first end and an angled portion on a second end, and the central slot is linear with an arcuate portion on one end, the arcuate portion having angled portions on each end. 
         [0023]    Variations of the illustrative embodiment, including variations in the shape of the angular surfaces of the tray and variations in the shape, size and location of the ledge lock and/or slit lock for receiving an edge of the disc, are also within the contemplation of the present invention as is further described below. 
         [0024]    It should be appreciated that the present invention can be implemented and utilized in numerous ways, including without limitation as a process, an apparatus, a system, a device, and a method for applications and from other suitable materials now known and later developed. These and other unique features of the system disclosed herein will become more readily apparent from the following description and the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]    So that those having ordinary skill in the art to which the disclosed system appertains will more readily understand how to make and use the same, reference may be had to the following drawings. 
           [0026]      FIG. 1  is a perspective view of a package in accordance with the subject disclosure, wherein the package has a plastic tray. 
           [0027]      FIG. 2  is an isolated view of the tray of the package of  FIG. 1 . 
           [0028]      FIG. 3  is an isolated view of a paper tray for a package in accordance with the subject disclosure. 
           [0029]      FIG. 4  is a of view of another package in accordance with the subject disclosure, wherein a disc is being loaded thereon. 
           [0030]      FIG. 5  is a view of the package of  FIG. 4  with the disc being removed therefrom. 
           [0031]      FIG. 6  is a perspective view of another the package in accordance with the subject disclosure. 
           [0032]      FIG. 7  is a perspective view of the tray prior to affixing on the cover of the package of  FIG. 6 . 
           [0033]      FIG. 8  is an isolated view of another paper tray for a package in accordance with the subject disclosure. 
           [0034]      FIGS. 9-11  are perspective views of a disc being mounted in another tray assembly in accordance with the subject disclosure. 
           [0035]      FIG. 12  is a top view of the tray assembly of  FIGS. 9-11  with the disc mounted thereon. 
           [0036]      FIG. 13  is a side view of the tray assembly of  FIGS. 9-11  showing a disc mounted thereon. 
           [0037]      FIG. 14  is a perspective view of still another tray assembly in accordance with the subject disclosure. 
           [0038]      FIG. 15  is a top view of the tray assembly of  FIG. 14 . 
           [0039]      FIG. 16  is a partial side view of the tray assembly of  FIG. 14 . 
           [0040]      FIG. 17  is a perspective view of a disc being mounted in another tray assembly in accordance with the subject disclosure. 
           [0041]      FIG. 18  is a perspective view of a disc being mounted in yet another tray assembly in accordance with the subject disclosure. 
           [0042]      FIG. 19  is a perspective view of a disc being mounted in still another tray assembly in accordance with the subject disclosure. 
           [0043]      FIGS. 20   a - c  are perspective views of still another tray member in accordance with the subject disclosure. 
           [0044]      FIG. 21  is a top view of the tray member of  FIGS. 20   a - c.    
           [0045]      FIG. 22  is a partial side view of the tray member of  FIGS. 20   a - c.    
           [0046]      FIG. 23  illustrates a blank for forming the tray member of  FIGS. 20   a - c.    
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0047]    The present invention overcomes many of the problems associated with prior art media disc packages. The advantages, and other features of the packages disclosed herein, will become more readily apparent to those having ordinary skill in the art from the following detailed description of certain preferred embodiments taken in conjunction with the drawings which set forth representative embodiments of the present invention and wherein like reference numerals identify similar structural elements whenever possible. 
         [0048]    All relative descriptions herein such as left, right, up, down, topside, underside and the like are with reference to the Figures, and not meant in a limiting sense. The illustrated embodiments can be understood as providing exemplary features of varying detail of certain embodiments, and therefore, unless otherwise specified, features, components, modules, elements, and/or aspects of the illustrations can be otherwise combined, interconnected, sequenced, separated, interchanged, positioned, and/or rearranged without materially departing from the disclosed systems or methods. Additionally, the shapes and sizes of components are also exemplary and unless otherwise specified, can be altered without materially affecting or limiting the disclosed technology to holding discs exclusively. 
         [0049]    An exemplary embodiment of the present invention is illustrated in  FIGS. 1 and 2 , in which there is shown an improved media disc package  10  made from a plastic tray  12  and a paperboard cover  14 . The tray  12  is vacuum formed plastic and glued, hot melted or otherwise affixed to the cover  14 . The tray  12  is sized and shaped to fit on the bottom of the cover  14 . The tray  12  has angled walls  15  extending from a substantially disc-shaped recess  17 . The angled walls  15  define two opposing undercuts  16  or slots to support a disc  20  about the outer diameter of the disc  20 . 
         [0050]    Landings  21  are formed above each undercut  16  such that upon depressing one or both of the landings  21 , the respective angled wall  15  flexes to separate the undercuts  16  and facilitate insertion and removal of the disc  20 . Alternatively, when the angled walls  15  are not flexed, the disc  20  is securely held within the undercuts  16 . The landings  21  also form overhanging portions  25  above each undercut  16 . The overhanging portions  25  can also simply deflect, with or without deflection of the angled walls  15 , to release the disc  20  from the tray. 
         [0051]    The tray  12  could also be configured with three, four or even more undercuts to provide further support. The undercuts are preferably evenly spaced about the recess  17 . The angled walls  15  do not completely surround the recess  17  such that finger recesses  19  are formed. A simple raised boss or rosette (not shown) could also be centrally located in the recess  17  to help retain and/or position the disc  20  and provide additional protection against damage to the disc  20 . 
         [0052]    The cover  14  includes a spine that interconnects a top  26  and a bottom to which the tray  12  is attached. The top  26  may have a feature to create friction with the tray  12  to retain the package  10  closed. The tray  12  may also have a complimentary feature that interacts with the top  26 . Such features could include detents, slots, protrusions, hollows, lips, ridges and the like. 
         [0053]    Another preferred embodiment of the present invention is illustrated in  FIG. 3 , in which there is shown an improved media disc tray  112 . The tray  112  is made from paper board and glued or otherwise affixed to a cover (not shown). The tray  112  is sized and shaped to fit on the bottom of the cover. The tray  112  also has angled walls  115  extending from a substantially flat surface  117 . The angled walls  115  define two opposing undercuts  116  to support a disc  20  about the outer diameter of the disc  20 . Folded sidewalls  119  extend between the opposing angled walls  115 . Preferably, the angled walls  115  are formed by stamping or creasing paperboard, however the angled walls  115  could also be formed by folding and other techniques. As before, the disc  20  can be inserted in or removed from the tray by flexing angled walls  115  outwardly, thereby increasing the distance between the opposing undercuts  116 . 
         [0054]    Referring now to  FIGS. 4 and 5 , there is shown another package  210  that is constructed in accordance with the subject disclosure, wherein a disc  20  is being loaded thereon. The package  210  also has a tray  212  stamped/formed from paper board and affixed to a cover. The stamping creates angled walls  215 A,  215 B extending from a substantially flat surface  217 . The angled wall  215 A defines a slot or ledge lock that captures an outer diameter of the disc  20 . The angled wall  215 B defines a hollow  230  which supports the outer diameter of the disc  20  so that the disc  20  rests above the flat surface when stored therein. The angled wall  215 A is part of a step  231 . A portion of the step  231  is adhered to the spine such that upon opening the package  210 , the angled wall  215 A flexes away from the opposing angled wall  215 B and, in turn, the disc  20  is easily inserted and removed from the package  210 . Folded or stamped sidewalls  219  extend between the opposing angled walls  215 A,  215 B. The sidewalls  219  can be stamped as part of the tray  212  or cover, or formed by folding and other techniques.  FIG. 5  is a view of the package of  FIG. 4  with the disc being removed therefrom. 
         [0055]    Referring now to  FIG. 6 , there is shown another package  310  in accordance with the subject disclosure, wherein a disc  20  is loaded thereon. Referring to  FIG. 7  as well, the tray  312  and the cover  314  of the package  310  is shown. The package  310  also has a tray  312  stamped from paper board and affixed to a cover  314 . The tray  312  has side walls  315 A,  315 B extending from a substantially flat surface  317 . The side wall  315 A defines a ledge lock  329  that captures an outer diameter of the disc  20 . The opposing side wall  315 B also defines a slot  330  which supports the outer diameter of the disc  20  so that the disc  20  rests above the flat surface  317  when stored therein. Sidewalls  319  extend between the opposing angled walls  315 A,  315 B. The angled wall  315 A is part of a step  331 . A portion of the step  331  is adhered to the spine of the cover  314  such that upon opening the package  310 , the angled wall  315 A flexes away from the opposing angled wall  315 B and, in turn, the disc  20  is easily inserted and removed from the package  310 . 
         [0056]    Referring now to  FIG. 8 , an isolated view of another paper tray  412  for holding a disc  20  in a package in accordance with the subject disclosure is shown. As can be seen, tray  412  includes four angled sidewalls  415  extending up from a flat surface  417 . Three of the sidewalls (shown as the left side, top and bottom)  415  define a ledge lock/ 416  to support the disc  20 . Tray  412  can be adhered to a cover, such as cover  314  shown in  FIG. 6 . In such a construction, when the cover is opened, the disc  20  is disengaged from left side ledge lock/slot  416 , but remains engaged with the top and bottom ledge locks  416 . That way, the disc does not fall out when the package is opened and can only be removed when the top and bottom sidewalls are forced in an outward direction. 
         [0057]    Referring now to  FIGS. 9-13 , perspective views of a disc  20  being mounted in another tray assembly  500  in accordance with the subject technology are shown.  FIGS. 12 and 13 , which show a disc  20  mounted on the tray assembly  500  in top and side view, respectively, are also referred to in the following description. As will be appreciated by those of ordinary skill in the pertinent art, the tray assembly  500  utilizes similar elements to those described above. The following description is directed primarily to the alternative features of the embodiment described with respect to tray assembly  500 . 
         [0058]    The tray assembly  500  includes a tray member  510  having a tension member  512  adhered thereto for structurally reinforcing the tray member  510 . The tray member  510  and tension member  512  may be formed from paper, plastic or combinations thereof or any other suitable material now known or later developed. In the described embodiment, both are formed from paper and the tension member  512  is a relatively thicker and stiffer paperboard. Stamping, vacuum forming and other manufacturing techniques now known and later developed may be used to form the tray member  510  into the desired shape. 
         [0059]    The tray member  510  has a planar surface  514  with a central land  518  and two outer lands  520  extending upwards therefrom. The central land  518  is circular to engage, align and/or support the central opening  22  of the disc  20 . The outer lands  520  engage, align and/or support a periphery  24  of the disc  20 . Each outer land  520  has an angular surface  524  defining a slot  526  for receiving the periphery or edge  24 . Each outer land  520  also has an arcuate section  525  to further engage, align and/or support the disc  20 . Moreover, in the embodiment shown in  FIGS. 9-13 , the angled surfaces  524  each include a protuberance  528  positioned diametrically opposite of a corresponding slot  526  to assist in urging and retaining the disc  20  within the slot  526 . 
         [0060]    As noted above, stamping, vacuum forming and other manufacturing techniques now known or later developed may be used to form the tray member  510  into the desired shape. In an exemplary method in accordance with the invention, a blank is formed with die cut slots and placed into a forming mold. Pressure with or without heat is applied, and the blank is pressed into a three-dimensional shape. The two-dimensional blank may be shaped such that the pressed and formed three-dimensional product has specific dimensions and shape. As the board blank is being formed in the mold, the pre-cut slits create additional structural elements during the forming process. In particular, the die-cut slits in the blank are formed into undercuts, ledges, and other elements in the formed tray. For example, the slits formed in the two-dimensional blank creates a more three-dimensional gap or slot  526  in the formed tray for receiving the periphery or edge of a disk  24 . It can be appreciated that by providing such two-dimensional features in the blank and controlling the forming process as described above, three-dimensional structural elements are created in the formed tray by the forming process, and it becomes unnecessary to form such elements in the tray in a secondary step. 
         [0061]    The tray member  510  is secured, by gluing, heat sealing or other suitable method to the substantially flat tension member  512 . As a result, the lands  518 ,  520  are structurally reinforced more than would be expected, providing the tray member  510  with significantly greater structural integrity than the tray member  510  would have alone. The flat tension member  512  may be a separate flat sheet, as described, or may define a portion of a cover (not shown), to which the tray member  510  may be directly secured or adhered. Although deflection can still occur to allow removal and replacement of the disc  20 , the robustness and firmness of the action of the tray member  510  is improved. Once assembled, the tray assembly  500  can be mounted to an additional cover. 
         [0062]      FIGS. 14-16  are views of still another tray assembly constructed in accordance with the subject disclosure and designated as reference numeral  500 A. The tray assembly  500 A includes a tray member  510 A having a tension member  512 A adhered thereto for structurally reinforcing the tray member  510 A. The tray member  510 A and tension member  512 A may be formed from paper, plastic or combinations thereof or any other suitable material now known or later developed. In the described embodiment, both are formed from paper and the tension member  512 A is a relatively thicker and stiffer paperboard. Like before, stamping, vacuum forming and other manufacturing techniques now known and later developed may be used to form the tray member  510 A into the desired shape. 
         [0063]    The tray member  510 A has a planar surface  514 A with a central land or rosette  518 A and two outer lands  520 A extending upwards therefrom. The outer lands  520 A engage, align and/or support a periphery  24  of a disc  20  (shown in  FIG. 9 ). Each outer land  520 A has an angular surface  524 A for supporting the periphery or edge  24  of the disc  20 . As can be seen, the rosette  518 A or central landing is configured with several arcuate sections formed in its periphery  519 A. As shown in  FIG. 16 , a slit  521  A may be formed in the outer periphery  519 A of rosette  518 A in order to engage inner periphery of the disc. Additionally, the outer landings/angular surfaces  524 A may also include slots/slits to engage the outer periphery of the disk. 
         [0064]    Referring now to  FIG. 17 , a perspective view of a disc  20  being mounted in another tray assembly  600  in accordance with the subject technology is shown. As will be appreciated by those of ordinary skill in the pertinent art, the tray assembly  600  utilizes similar principles to tray  500  described above. The following description is directed primarily to certain differences of the tray assembly  600  therefrom. 
         [0065]    The tray assembly  600  may or may not have a supporting flat tension member  612 . The primary difference is the central land  618  that has a lower level portion  620  and an upper level portion  622 . The upper level portion  622  extends from the lower level portion  620  and is sized and configured to fit within the aperture  22  of the disc  20 . To further secure the disc  20  in place, a partial slit  624  is formed in the side wall of the upper portion  622 . As a result, the aperture  22  of the disc  20  is affirmatively captured. In a preferred embodiment, the slit  624  is arcuate shaped, faces the slots formed in the angled surfaces, and extends about 70 degrees. 
         [0066]    Referring now to  FIGS. 18 and 19 , additional variations of the tray  600  are shown. Each variation modifies the central land  618  so that the aperture  22  of the disc  20  may more easily be removed or properly positioned for retention.  FIG. 18  uses an additional slit  626  across the upper level portion  622 , whereas  FIG. 19  uses an additional Y-shaped slit  628  across the upper level portion  622 . 
         [0067]    Referring now to  FIGS. 20   a - c ,  21  and  22 , still another tray member in accordance with the subject disclosure is shown and referred to generally by the reference numeral  700 . As will be appreciated by those of ordinary skill in the pertinent art, the tray member  700  utilizes similar principles to the trays described above. The following description is directed primarily to the differences of the tray member  700  therefrom. 
         [0068]    The tray member  700  has a rosette  716  that has a lower level circular portion  720  and an upper level circular portion  722  to retain a disc (not shown). The upper level portion  722  is sized and configured to fit within the central aperture of the disc. The upper level portion  722  may be domed or beveled to provide an angular surface  726  to engage the central aperture of the disc. 
         [0069]    The upper level portion  722  forms a roughly T-shaped slit  724  so that the upper level portion  722  may be compressed to facilitate placement and removal of the disc. Additionally, the upper level portion  722  exerts an outward force on the central aperture of the disc to help retain the disc. The rosette  716  is created when forming the tray member  700  from the blank  750  shown in  FIG. 23 . 
         [0070]    The tray member  700  also includes two outer lands  720  with stop surfaces  740 . The stop surfaces  740  along with the rosette  720  form a three-point support surface for the disc. The outer lands  720  also have angular surfaces  724  defining slots  726  for receiving the periphery or edge of the disc. The slots  726  form upper ledges  728 . The outer lands  720 , including the stop surfaces  740  and ledges  728 , are also created when forming the tray member  700  from the blank  750 . When the disc is in the retained position, the disc is secured by the rosette  720  in combination with ledges formed by the slots  726 . 
         [0071]    Referring now to  FIG. 23 , a blank  750  for creating tray member  700  is shown. The blank  750  has slots  752   a ,  752   c  that are arcuate shaped with a v-shape  754   a ,  754   c  on a first end and an angled portion  756   a ,  756   c  on a second end. The blank  750  also has a central slot  752   b  that is linear with an arcuate portion  758  on one end, the arcuate portion having angled portions on each end. 
         [0072]    To form the blank  750  into the tray member  700 , stamping, vacuum forming and other manufacturing techniques now known or later developed may be used. In an exemplary method, the blank  750  has slots  752   a - c  die cut. Then, the blank  750  is placed into a forming mold (not shown). Pressure with or without heat is applied, and the blank  750  is pressed into a three-dimensional shape. The two-dimensional blank  750  may be shaped such that the pressed and formed three-dimensional product has specific dimensions and shape. As the board blank  750  is being formed in the mold, the pre-cut slits  752   a - c  create additional structural elements during the forming process. In particular, the die-cut slits  752   a - c  in the blank are formed into undercuts, ledges, and other elements in the formed tray. It can be appreciated that by providing such two-dimensional features in the blank and controlling the forming process as described above, three-dimensional structural elements are created in the formed tray by the forming process, and it becomes unnecessary to form such elements in the tray in a secondary step. 
         [0073]    While the invention has been described with respect to preferred embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the invention without departing from the spirit or scope of the invention.