Abstract:
A container to hold optical disk media is described, incorporating disc locking arms to loosely retain discs when the container is open, and securely retain discs when the container is closed.

Description:
BACKGROUND 
       [0001]    Various packaging structures have been used for containing optical media such as CDs and DVDs. Packaging may include paper or paperboard boxes, injection molded cases, and combinations thereof. Often it is desired to hold multiple discs in a single package, and in some cases to overlap the discs to save frontal space of the package. One example of such a package, where the discs are held in an overlapping geometry, is U.S. Pat. No. 5,743,390 which discloses a case holding multiple levels of disks in planes parallel to a major surface of the case, and having optional swing-out structures to hold disks. Another example is U.S. Pat. No. 5,595,308 which discloses a device for holding multiple disks or disk cases in planes parallel to each other but at an angle to a major surface of the device. 
         [0002]    Optical disc packages sometimes utilize hubs that retain the disc by gripping the internal circumference of the disc (the center hole), either by friction alone or by a detent mechanism overcome by slight force on the disc or on the detent mechanism. Other packages may simply use gravity or friction to retain the disc, for example sleeve devices such as disclosed in U.S. Pat. No. 5,762,246. 
         [0003]    As the data storage density of optical discs continues to increase, it becomes more important to protect the discs from surface wear, warpage, and delamination. 
       SUMMARY 
       [0004]    This invention provides for holding two or more discs in a package or tray element that is combined with other elements to form a package. The package holds multiple optical disc media in an overlapping orientation that permits the user to view all discs, and provides disc locking arms that retain the discs in place. The locking arms each retain a peripheral point on a respective disc and prevent unintended movement of the disc from the package. When the package is in an open configuration, the locking arms each provide a light retaining force on their respective disc, allowing a single disc to be removed or replaced at will while other discs remain secured. When the package is in a closed configuration, the locking arms each provide a strong retaining force on their respective disc, holding the disc in place despite any movement of the package. The discs are held at a minimum number of peripheral points, and are allowed to teeter slightly to protect against damage during handling. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]      FIG. 1  illustrates a perspective view of a tray in an embodiment according to the invention; 
           [0006]      FIG. 2  illustrates a perspective view of a tray containing discs in an embodiment according to the invention; 
           [0007]      FIG. 3  illustrates a detail view of flexing arms in the side of a tray according to the invention; 
           [0008]      FIG. 4  illustrates a detail view showing the flexing arms in a retaining position according to the invention; 
           [0009]      FIG. 5  illustrates a detail view showing the flexing arms in a releasing position according to the invention; 
           [0010]      FIG. 6  illustrates a cross section view of a tray according to the invention; 
           [0011]      FIG. 7  illustrates a perspective view of a container incorporating the tray according to the invention, in an open configuration; 
           [0012]      FIG. 8  illustrates a perspective view of a container incorporating the tray according to the invention, in a partially closed configuration. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]      FIG. 1  illustrates a perspective view of a tray or base  100  in an embodiment according to the invention. The tray is preferably molded from a plastic material. A first nominal resting surface  111  is provided for a first disk  210  (shown in  FIG. 2 , a perspective view of a tray containing discs). Nominal resting surface  111  is generally planar and at an angle to the major plane of the tray. The shape of nominal resting surface  111  may be an approximately circular outline of varying width as shown. A a depressed central region  110 , not part of the nominal resting surface, is at least slightly below the plane of the nominal resting surface, and which may be as low as the back or bottom surface of the tray. 
         [0014]    A second nominal resting surface  112  is provided for a second disk  220  (shown in  FIG. 2 ). Nominal resting surface  112  is generally planar and at an angle to the major plane of the tray. The nominal resting surface  112  may have a crescent shape as shown. 
         [0015]    Rather than having discs  210  and  220  rest directly upon nominal resting surfaces  111  and  112  respectively, it may be preferred to minimize contact between the discs and the nominal resting surfaces so as to protect the data surface of the discs. Therefore supporting detents  118  may be provided to support selected points along the periphery of the discs, for example, by providing supporting detents  118  at each side of the tray, located approximately the horizontal centerline of each disc. When the tray  100  is laying flat (as shown in  FIGS. 1 and 2 ), the periphery of disc  210  may rest on a pair of detents  118  and upon point  121  on nominal resting surface  111 . The periphery of disc  220  may likewise rest on a pair of detents, and upon resting point  122  on nominal resting surface  112 . However, each disc may teeter slightly as represented by teeter leeway  125  shown for disc  220 . The teeter leeway makes it easier to remove and replace disc  220 , for example to grasp its edge, or slide it from and into the tray. A lifting recess  115  is also provided in tray  100  to facilitate grasping disc  210 . 
         [0016]    To help retain the discs in tray  100 , overhanging ledges  120  may be provided. As shown in  FIG. 2 , an overhanging ledge  120  is provided to retain each side of each disk. Once a disc has been slid into the tray, the overhanging ledge retains the disc so that it cannot be removed in the direction normal to the tray (that is, upward from the tray as shown in  FIG. 2 ). 
         [0017]    Side flexing arms  151  and  152  may be provided to help retain discs  210  and  220  respectively in the tray  100 . The side flexing arms may be provided in a side wall  140  of tray  100 . 
         [0018]    With this design, the discs are positioned at an angle to the major planes of the tray, and are positioned in the tray such that all discs can be viewed. The discs slide into and out of their independent positions within the tray, and are retained in the tray by overhanging ledges  120 , supporting detents  118 , and locking ribs  161 ,  162  (described below) that are positioned on flexing side arms  151 ,  152  respectively that are extensions of the side wall  140  of the tray. 
         [0019]    Discs can be inserted and removed independently of each other and without having to remove the other discs from the tray. The locking elements of the tray work in relationship to corresponding elements of the package such as other trays and the inner surface panels of a multi panel outer cover or molded case as described below. The discs each rest on a set of supporting detents  118  that allow the disc to pivot or teeter on the axis between the detents. Allowing the disc to move/pivot on this axis facilitates the insertion and removal of disc from the package without having to remove co-packaged discs located in the tray. 
         [0020]      FIG. 3  illustrates a detail view of side flexing arms  151 ,  152  in the side of a tray according to the invention. The side flexing arms are preferably part of tray side wall  140 , and may be formed for example by providing separation lines or gaps  170 ,  171 , and  172  that permit the side flexing arm  152  to flex in the general plane of the tray. The side flexing arms are part of a disc retaining and locking system. Side flexing arms  151 ,  152  are situated slightly outward (in the direction of disc removal) from the at-rest horizontal center axes  211 ,  221  of discs  210 ,  220  respectively. The side flexing arms provide enough force to hold locking ribs  161 ,  162  inward, retaining the discs in the tray  100 . Thus peripheral points  215 ,  225  representing the largest width of the disc are not able to slide past locking ribs  161 ,  162  unless the side flexing arms  151 ,  152  are able to flex outward. The side flexing arms are able to flex outward to allow the user to slide the disc(s) from or into the tray, unless the flexing arms are restrained, as when an outer cover of a package is closed around tray  100 , as described later. The design provides for a passive locking/unlocking of the disc(s) held in the tray. A consumer does not have to actively manipulate any element or part of the disc package or tray to lock and unlock the discs. An advantage of this design is the insertion and removal of a disc into or out of the tray without having to remove to remove other discs from the package. The invention allows each disc to be inserted and removed from the package without grossly disturbing the other disc(s). 
         [0021]      FIGS. 4 and 5  illustrate detail views showing a side flexing arm  152  in the retaining and releasing positions respectively. In  FIG. 4 , disc  220  is in the retained or ‘storage’ position, where it would be located after having been slid into the tray. The disc is retained from moving up from the general plane of the tray by overhanging ledge  120  (one on the near side of the disc as shown, and one also on the diametrically opposed edge of the disc, not shown). Flexing side arm  152  with its locking rib  162  contacts the periphery of the disc, slightly forward from the disc&#39;s maximum width at its horizontal centerline  221 . The locking rib  162  thus prevents sliding movement of the disc  220  within the general plane of the tray. 
         [0022]    In  FIG. 5 , disc  220  has been moved by sliding it slightly toward the removal position. As the centerline  221  of the disk reaches locking rib  162 , it pushes the rib outward against the force of flexing side arm  152 . This sliding movement of disc  220  also brings it out from underneath overhanging ledge  120 . The disc is then free to be removed from the tray either by sliding outward in the general plane of the disc, or by tilting upward and lifting it out of the plane of the tray. Note that as the locking rib  162  is pushed outward by disc  220 , the flexing side arm  152  bends temporarily out of line with the side wall  140  of the tray as shown by gap  180 . This out-of-line bending by flexing side arm  152  is only possible when nothing obstructs the side wall  140 . 
         [0023]      FIG. 6  illustrates a cross section view of a tray according to the invention. The discs  210 ,  220  are tilted at an angle to the major plane of the tray. Although disc  210  appears to rests on nominal resting plane  111  (only partially visible in  FIG. 6 ), there is actually a slight separation, due to disc  210  being supported by supporting detents  118  (not shown in  FIG. 6 ). This prevents the disc from resting in direct contact with the surfaces of the tray, such as surface  111  that may otherwise contact large areas of disc  210 . Likewise, although disc  220  appears to rests on nominal resting plane  112 , there is actually a slight separation, due to disc  220  being supported by supporting detents  118  (not shown). This prevents the disc from resting in direct contact with the surfaces of the tray, such as surface  112  that may otherwise contact large areas of disc  220 . Keeping the disc away from these surfaces of the tray prevents scuffing and scratching from insertion and removal of the discs, and during handling of the package. When a disc is in its storage position, it is partly supporting by a detent  118  on each side. Particularly, if the case tray  100  is in a lay-flat orientation, the periphery of the discs will also be supported by the tray at contact points  121  and  122 . The detents  118  and the contact points  121 ,  122  do not contact the central, data-bearing surfaces of the discs. Furthermore, the discs may teeter on the detents  118 , so that if the tray is flexed during shipping, handling, or storage, the discs are able pivot slightly and minimize the chance of their warping or delaminating. Thus exposure to intermittent or even continuous minor distortions of the tray will not damage the discs. 
         [0024]      FIG. 7  illustrates a perspective view of a container  300  incorporating the tray, in an open configuration. In this example, the tray is used with a casing, which may have a front panel  310 , a spine or side panel  320 , and aback panel  330 . These parts may be formed separately or together with the tray  100 . The flexing side arms  151 ,  152  are free to move, since no part of the casing obstructs their movement. Thus the discs  210 ,  220  may be removed from the tray as described previously. The flexing side arms  151 ,  152  flex outward as discs are slid in and out of the tray. 
         [0025]      FIG. 8  illustrates a perspective view of a container incorporating the tray, in a partially closed configuration. The flexing side arms are obstructed from free movement by an inner surface portion of an side panel  320  as, in closing the container, the side panel  320  folds toward the flexing side arms. In the closed position the flexing side arms  151 ,  152  cannot flex and thus they lock the discs  210 ,  220  in place. 
         [0026]    Methods of making and using the disc container in accordance with the invention should be readily apparent from the mere description as provided herein. No further discussion or illustration of such products or methods, therefore, is deemed necessary. 
         [0027]    While preferred embodiments of the invention have been described and illustrated, it should be apparent that many modifications to the embodiments and implementations of the invention can be made without departing from the spirit or scope of the invention. Although the preferred embodiments illustrated herein have been described in connection with an injection molded plastic structure, these embodiments may easily be implemented in accordance with the invention in other structures or materials. Although the example given is for two a tray containing two discs, the design can be readily extended to trays containing more than two discs. 
         [0028]    It is to be understood therefore that the invention is not limited to the particular embodiments disclosed (or apparent from the disclosure) herein, but only limited by the claims appended hereto. 
       LIST OF ITEMS 
       [0000]    
       
           100  Tray 
           110  lower plane of tray (typical) 
           111 ,  112  nominal resting planes of disc(s) 
           115  Lifting recess 
           118  Supporting detents (side resting points of disc(s) 
           120  overhanging ledges 
           121 , 122  resting points of disc(s) 
           125  teeter leeway (typical) 
           140  side wall of tray 
           151 ,  152  side flexing arms 
           161 ,  162  locking ribs 
           170 ,  171 ,  172  openings defining side flexing arm 
           180  gap representative of side flexing arm in “open” position 
           210 ,  220  discs 
           215 ,  225  side periphery of disc(s) 
           211 ,  221  horizontal centerline of disc 
           300  disc container 
           310  package front panel 
           320  package spine 
           330  package back panel