Packaging case for a windshield wiper blade

A packaging case for a windshield wiper blade includes an elongated wiper blade receiving section including a perimeter wall defining a blade-retaining channel. The perimeter wall includes inner and outer wall segments. At least one aperture is formed within the outer wall segment of the perimeter wall. An elongated cover section is pivotally coupled to wiper blade receiving section and configured to pivot between an open state and a closed state. The elongated cover section includes first and second lateral walls and first and second end walls defining a cover compartment that fits over the elongated wiper blade receiving section. At least one projection is formed on an inner surface of the first lateral wall for engaging the at least one aperture formed within the outer wall segment of the contoured wall, thereby retaining the cover section over the wiper blade receiving section.

FIELD OF THE INVENTION

The present invention relates to a packaging case for a windshield wiper blade used to wipe rain or dirt from a windscreen of automobiles, and more particularly to a packaging case that is easily secured in a closed position.

BRIEF SUMMARY OF THE INVENTION

A packaging case for a windshield wiper blade includes an elongated wiper blade receiving section including a contoured perimeter wall defining a blade-retaining channel. The perimeter wall has inner and outer wall segments. Retaining elements are formed within the inner wall segment of the perimeter wall for holding the wiper blade within the blade-retaining channel. At least one aperture is formed within the outer wall segment of the perimeter wall.

An elongated cover section is pivotally coupled to wiper blade receiving section and configured to pivot between an open state and a closed state. The elongated cover section includes first and second lateral walls and first and second end walls defining a cover compartment that fits over the elongated wiper blade receiving section. At least one projection is formed on an inner surface of the first lateral wall for engaging the at least one aperture formed within the outer wall segment of the perimeter wall, thereby retaining the cover section over the wiper blade receiving section.

DETAILED DESCRIPTION

In general, a wiper blade (not shown) includes a wiper strip to make close contact with a windshield, a frame configured to mount the wiper strip thereon, and a connector coupled to the frame so as to be coupled to a wiper arm of the automobile. Such a wiper blade is provided as a replaceable component and is commonly available from automobile specialty shops, large distribution and discount stores, etc. Typically, a wiper blade can be sold in a separate packaging case for identification and protection of the products. The packaging case prevents damage of the wiper blade accommodated therein and enables the wiper blades to be maintained in an optimal state. The wiper blade may be a 24″ wiper blade by Trico.

In accordance with the present embodiments of a packaging case for a windshield wiper,FIG. 1illustrates a perspective view of a packaging case10for a windshield wiper blade, in which packaging case10is opened to accommodate the wiper blade.FIG. 2is a top view of packaging case10in an open position.FIG. 3is an end view of packaging case10of a windshield wiper blade, in which packaging case10is opened to accommodate the wiper blade.FIGS. 4 and 5are perspective and cross-sectional views of packaging case10in a closed position.

Packaging case10includes an elongated wiper blade receiving section20having a blade retaining-channel or accommodating pocket25defined by a perimeter wall having a first elongated wall30having a spaced-apart inner wall segment30aand an outer wall segment30badjoined by a top ledge30c. Perimeter wall also includes a second elongated wall31having spaced-apart inner wall segment31aand an outer wall segment31badjoined by a top ledge31c. A plurality of retaining elements, one of which is indicated at35, is formed within inner wall segments30aand31afor holding a wiper blade securely within blade accommodating pocket25.

Each retaining element35is formed to have a predetermined elasticity, so that, when a wiper blade is positioned within blade accommodating pocket25, the wiper blade is securely held in position by retaining elements35. Retaining elements35may take on a variety of forms. For example, retaining elements35may be symmetrically or asymmetrically shaped. Furthermore, retaining elements35may be disposed in a staggered pattern on inner wall segments30aand31a, so that the wiper blade can be more easily inserted or taken out of blade accommodating pocket25. In the embodiment shown, blade-accommodating pocket25is contoured to accommodate the shape of a wiper blade in order to more securely retain the wiper blade.

In order to facilitate a secure closure of packaging case10, outer wall segment30bof first elongated wall30includes a plurality of depressions, generally indicated at40. An aperture42is formed within each depression40for engaging a projection formed on an elongated cover section, as will be discussed in detail below. An additional plurality of apertures43(seeFIG. 5), which align with apertures42, may also be formed within inner wall segment30aof first elongated wall30. First elongated wall30also includes notches44formed therein. A flange45extends from a perimeter of blade receiving section20.

Packaging case10also includes an elongated cover section50pivotally coupled to wiper blade receiving section at a hinge52. Elongated cover section50is configured to pivot about hinge52between an open state and a closed state. In particular, cover section50includes first and second lateral walls55,57and first and second end walls58,59defining a cover compartment60that fits over elongated wiper blade receiving section20. First lateral wall55includes a plurality of inwardly protruding sections65shaped to correspond with depressions40formed within outer wall segment30bof first elongated wall30. In addition, a post67projects from each inwardly protruding section65. Each post67is adapted to engage a corresponding aperture42. Tabs68are also formed within and project inward from first lateral wall55. Tabs68are positioned such that they engage notches44with packaging case10in a closed position. A flange70extends horizontally from a perimeter elongated cover section50such that when packaging case10is in a closed position flange70abuts flange45of blade receiving section20.

Each of flanges45and70includes a hanger opening72a,72bformed at one side such that the packaging case10can be hung on and kept in a display rack used for storage or selling of wiper blades encased in packaging case10. When packaging case10is in a closed position hanger openings72aand72balign with one another. Hanger openings72aand72bare formed by a circular hole, a linear groove, or a combination such that packaging case10can be hung on any display rack having a circular rack rod or a thin plate-shaped rack rod. Thus, packaging case10can be suspended from a display rack through hanger openings72aand72b.

FIG. 4is a perspective view of the packaging case of a windshield wiper blade, in which the packaging case is closed andFIG. 5is a cross-sectional view of the packaging case in a closed position. In the embodiment illustrated, elongated wiper blade receiving section20and elongated cover section50are an integral component and are pivotally connected to each other via hinge52.

Hereinafter, a process of manufacturing the packaging case according to an embodiment of the present invention is described. Packaging case10may be formed completely or partially of a transparent material to allow a user to see the interior of the packaging case. In particular, packaging case10is manufactured using a thermoforming process. In order produce a projection, such as post67, or other shaped projection in a vertical or nearly vertical sidewall of a thermoformed package, retractable tooling features are incorporated into a tool, which forms the package. These features can be of a variety of shapes and sizes.

Packaging case10is formed from a preheated sheet of thermoplastic material that is drawn into, or over a mold to create the desired shape of the end product. After the material has reached a stable set point, where upon it is rigid enough to be removed from the mold without loosing the shape of the mold upon which it was formed, the sheet is withdrawn in the opposite direction from which it entered the mold. Typically the sheet enters the mold and is removed from the mold in a vertical fashion. Posts67are formed utilizing retractable features, such as a round post, or pin. When the heated plastic sheet is drawn into the mold the post is in an extended position. The plastic forms around the post, adopting its shape. The post is then retracted until the face of the post is flush with the sidewall of the mold. Thus, the post is out of the way such that the plastic product can be removed from the mold. The actual mechanization of the post, or feature can be accomplished in a number of ways. Mechanical linkages and drive mechanisms may be used. Alternately, magnetics, pneumatic cylinders or the like may be employed. The timing of the projection of the feature outbound from the sidewall of the mold may be fine tuned by being in the fully extended position prior to the heated material entering the mold and being activated just after the material has entered the mold, but prior to the material cooling beyond the point where it will be able to form around the feature.

Apertures42are formed within outer wall segment30bof wall30, which is a vertical or nearly vertical surface. A punch and die mechanism is utilized to form apertures42and43. The punch and die may mimic the profile of the formed post67, but with a slightly larger profile to allow for clearance and ease of insertion of the formed posts67within apertures43and43. Alternatively, the cutout may take a shape that is different from the formed projection. For example, the formed projection could be a simple post, but the cutout could be oval in shape. The function of projections or posts67and cutouts or apertures42,43is to prevent the vertical opening of cover section50of packaging case10. Similarly, apertures42,43may be round and projections may be star, octagonal, or the like, in shape. Apertures42and43are formed after the forming of packaging case10. Thus, the plastic has formed into the mold, the plastic has been demolded and then the apertures are cutout. In high volume production the cutting of the hole feature occurs at a station between a forming station and a die cutting station. It is in the die cutting station that the planer surfaces of the plastic container are trimmed from the surrounding web of material so that the container can be removed from a leftover perimeter sheet.

Apertures42and43may also be formed following a die cutting step, i.e. after the formed and die cut plastic part has been removed from the surrounding left over plastic sheet. Thus, the last step in the process is to place the formed and die cut package into a mechanical device, which then punches out the holes. The holes may be formed by a manually actuated device punching one hole at a time or by a fully automated system punching all the holes in a package at once, with automated load and unload of the package into the punching mechanism. The holes may also be cut in the same station as where the planer die cut of the perimeter plastic occurs.

In use, a wiper blade is positioned within blade accommodating pocket25of elongated wiper blade-receiving section20. Retaining elements35are adapted to hold a wiper blade in position within blade accommodating pocket25. Cover section50is then rotated to cover wiper blade receiving section20. At this time, posts67and inwardly protruding sections65engage depressions40and corresponding apertures42. In particular, posts67of cover section50penetrate apertures42of blade receiving section20, thereby securing cover section20to blade receiving section20. As shown inFIG. 5, post67includes an angled edge67aand a top edge67b. Each post67penetrates a corresponding aperture42to prevent cover50from being pivoted open. In order to open packaging case10, post67and first lateral wall55must be deflected laterally such that post67disengages from a corresponding aperture42. A plurality of apertures43are also provided in inner wall segment30aof first elongated wall30such that posts67may penetrate apertures43if first lateral wall55is pushed inward. Thus, inward deflection of lateral wall55will not cause posts67to become disengaged from apertures42.

In general, the posts and apertures engage to form a locking feature that uses the shear strength of a post engaged against the wall of material through which the aperture is formed. The force required to separate the posts from the apertures is a function of the shear strength of the formed post, and or the tear strength of the punched hole, rather than the function of friction.

The downward force of closing elongated cover section50over blade receiving section20drives post67having beveled edge67adown across the outer wall segment30bdescending the wall of the package until the post “snaps” into the hole. Since the posts and apertures are formed on vertical walls at 90 degrees, no additional material is required to form a secure closure of packaging case10.

Although the present invention has been described with reference to the embodiments and the accompanying drawings, it is not limited to the embodiments and the drawings. It should be understood that various modifications and changes can be made by those skilled in the art without departing from the spirit and scope of the present invention defined by the accompanying claims.