Abstract:
A one-piece, injection molded intended for display by positioning it upright includes a spine, a front cover coupled to the spine via a first living hinge, and a back cover coupled to the spine via a second living hinge. When in a closed configuration, the case has generally semi-cylindrical sidewalls which intersect in generally quarter-spherical corners. The case incorporates a flexible, polymeric sleeve that wraps around the spine sidewall, is bonded to the front and back covers near the edges of the closure sidewall.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. application Ser. No. 11/268,205, titled INJECTION MOLDED CASE FOR OPTICAL STORAGE DISCS, which was filed on Nov. 7, 2005, the entire contents of which is incorporated by reference herein. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates to cases for optical storage discs such as compact discs and digital video discs and, more particularly, to injection molded cases having a wrap around flexible sleeve. 
       BACKGROUND OF THE INVENTION 
       [0003]    Cases for storing optical storage discs, such as compact discs (CDs) and digital video discs (DVDs) CDs and digital video discs (DVDs), when not being used, have been manufactured for about twenty years. The typical case is a square-cornered box having a center hub for receiving the central mounting aperture of the disk. There are significant differences between so-called “jewel cases” used to store CDs and the taller cases used to store DVDs. The first significant difference is that conventional jewel cases are typically injection molded from polystyrene plastic. As the use of this material precludes the use of a “live” hinge, the cases covers are formed in two pieces—a front cover and a back cover—that use snap-together hinges. A third piece, which is internal to the case, snaps into the back cover and holds the back information sheet in place. The second significant difference is that the mechanism used to hold CDs is generally a spring plastic assembly that requires that CDs be pried therefrom. DVD cases, on the other hand, are typically injection molded as a single piece from polyolefins, such as polyethylene and polypropylene, and rely on live hinges to interconnect a front cover, a spine and a back cover. In addition, as DVDs are considered to be more fragile than CDs, DVD case specifications require a disc retaining mechanism (usually called a hub) having a push-button release. Although some CD cases have been injection molded from polyolefins such as polyethylene and polypropylene and have used disc attachment mechanisms that do not require the CD to be pried therefrom, they constituted a tiny minority of CD cases in use. 
         [0004]    U.S. Pat. No. D459,935 S discloses a typical injection-molded DVD case. It has a spine connected to both a front cover and a back cover via live hinges. Live hinges are ultra-thin and, hence, involve ultra-flexible strips of polyolefin material formed between spine and covers during the injection molding process. The case of the present invention, like nearly all of those produced by the DVD packaging industry, is a shallow, medially split rectangular box with rounded edges and corners. Such boxes are not particularly good as self-standing items. In other words, they are unstable when one attempts to stand them on the lower sidewall. The instability is related to the relatively narrow band of flat surface thereon and typical slight misalignment of the front and back covers. 
         [0005]    What is needed is a new injection molded DVD case that can be used as a display item by standing it upright. In addition, since the DVD case is intended as a display item, a new more aesthetically pleasing case design is also needed. The new design should be at least as structurally strong, if not stronger, than the conventional genre of DVD cases and would, ideally, use less polyolefin material in its manufacture. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention provides a new DVD case that answers the heretofore express need for a new one-piece, injection molded DVD case that can be used as a display item by standing it upright. As with conventional DVD cases, it also includes a spine, a front cover coupled to the spine via a first living hinge, and a back cover coupled to the spine via a second living hinge. However, for a preferred embodiment of the invention, the new DVD case, when in a closed configuration, has generally semi-cylindrical sidewalls, including upper and lower sidewalls, a spine sidewall, and a closure sidewall, which intersect in generally quarter-spherical corners. So that the front cover, the back cover and the spine may lie in a common plane when in an open configuration, it was found necessary to position the first live hinge at a first quarter position along the spine sidewall, and the second live hinge at a third quarter position along the spine sidewall. In other words, the front cover incorporates about one-fourth of the spine sidewall, the spine incorporates about one-half of the spine sidewall, and the back cover incorporates the remaining about one-fourth of the spine sidewall. This configuration has an added advantage in that, when the case is open, it occupies less table space than does a DVD case having the same thickness and a flat spine that is perpendicular to the front and back covers when the case is closed. In addition, the new DVD case has a pair of spaced-apart feet positioned along the lower sidewall of the case, each of the feet being medially split into first and second halves, the first half being integral with the front cover and the second half being integral with the back cover. In the event of slight misalignment caused by an imperfectly made mold or slight shrinkage, the feet can be easily trimmed so that the bottom of the first half of each foot is flush with its mating second half. 
         [0007]    Not only is the new DVD case unique and more aesthetically pleasing than current designs, it also features enhanced structural rigidity and requires slightly less polyolefin material for its manufacture. The new DVD case may also incorporate a flexible, polymeric sleeve that wraps around the spine sidewall and is bonded to an edge of the closure sidewall on an outer surface of the front cover and to an edge of the closure sidewall on an outer surface of the back cover. 
         [0008]    For aesthetic reasons, the flexible, polymeric sleeve may be displaced from the upper and lower semi-cylindrical sidewalls by at least an amount equal to the diameter of the case sidewalls. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Further features and advantages of the preferred embodiments of the present invention will be described by reference to the following detailed description of the preferred embodiments taken in conjunction with the attached drawings in which: 
           [0010]      FIG. 1  is a plan view of the outer major surfaces of the injection molded DVD case in a full open configuration; 
           [0011]      FIG. 2  is a plan view of the inner major surfaces of the injection molded DVD case in a full open configuration; 
           [0012]      FIG. 3  is an elevational view of the top edge of the injection molded DVD case in a full open configuration; 
           [0013]      FIG. 4  is an elevational view of the bottom edge of the injection molded DVD case in a full open configuration; 
           [0014]      FIG. 5  is an elevational view of the open injection molded DVD case, as seen from the closure edge of the back cover; 
           [0015]      FIG. 6  is an elevational view of the open injection molded DVD case, as seen from the closure edge of the front cover; 
           [0016]      FIG. 7  is a cross-sectional view of the open injection molded DVD case, than through section line  7 - 7  of  FIG. 2 ; 
           [0017]      FIG. 8  is a cross-sectional view of the open injection molded DVD case, taken through section line  8 - 8  of  FIG. 2 ; 
           [0018]      FIG. 9  is a cross-sectional view of the open injection molded DVD case, taken through section line  9 - 9  of  FIG. 2 : 
           [0019]      FIG. 10  is an isometric view of the open injection molded DVD case, showing the top edge of the front and back covers, the closure edge of the front cover, and the inner surfaces for the front and back covers; 
           [0020]      FIG. 11  is an isometric view of the open injection molded DVD case, showing the bottom edge of the front and back covers, the closure edge of the back cover, and the outer surfaces for the front and back covers; 
           [0021]      FIG. 12  is a plan view of the front cover of the injection molded DVD case in a closed configuration; 
           [0022]      FIG. 13  is a plan view of the back cover of the injection molded DVD case in a closed configuration; 
           [0023]      FIG. 14  is an elevational view of the bottom of the injection molded DVD case in a closed configuration; 
           [0024]      FIG. 15  is an elevational view of the top of the injection molded DVD case in a closed configuration; 
           [0025]      FIG. 16  is an elevational view of the closure edges of the injection molded DVD case in a closed configuration; and 
           [0026]      FIG. 17  is an elevational view of the spine of the injection molded DVD case in a closed configuration. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0027]    Referring now to  FIG. 1 , the DVD case  100  has a spine  101 , a front cover  102  coupled to the spine  101  via a first living hinge  103 , and a back cover  104  coupled to the spine  101  via a second living hinge  105 . The front cover  102  has a quarter round (i.e., quartercylindrical) upper edge  106 U, a quarter round lower edge  106 L and a quarter round closure edge  106 C. The upper edge  106 U and the lower edge  106 L each intersect the closure edge  106 C to form a rounded, octospherical corner  107 U and  107 L, respectively. Likewise, the back cover  104  has a quarter round upper edge  108 U, a quarter round lower edge  108 L and a quarter round closure edge  108 C. The upper edge  108 U and the lower edge  108 L each intersect the closure edge  108 C to form a rounded, octospherical corner  109 U and  109 L, respectively. A pair of half feet  110 A and  110 B, which are unitary with the lower edge  107 L of the front cover  102 , align with a pair of half feet  111 A and  111 B, which are unitary with the lower edge  108 L of the back cover  104 , when the case  100  is in a closed configuration. The hinged edges  106 H and  108 H of the front cover  102  and back cover  104 , respectively, are each rounded to have about an octocylindrical shape. The spine  101  is also rounded and has about a quarter cylindrical shape. As will be seen in subsequent drawing figures, when the case  100  is in a closed configuration, the rounded hinged edges  106 H and  108 H and the spine  101  form a generally semicylindrical shape having quarterspherical corners. For a preferred embodiment of the invention, the DVD case  100  also incorporates a flexible, polymeric sleeve  115 , that wraps around the spine  101  and is bonded adjacent the rounded closure edges  106 C and  108 C of the front and back covers, respectively. In conformity with industry practice, a printed paper insert (not shown) containing descriptive information relating to the enclosed DVD can be slipped beneath the flexible, polymeric sleeve  115 . For such an application, the flexible, polymeric sleeve  115  would be transparent. Alternatively, information can be printed directly on the flexible, polymeric sleeve  115 . 
         [0028]    Referring now to  FIG. 2 , two clips  201 A and  201 B, which are integral with the front cover  102 , are provided to hold information booklets. A disc attachment hub  202  and upper and lower disc support shelves  203 U and  203 L are provided inside the back cover  104 . 
         [0029]    Referring now to  FIG. 3 , the lower edges  106 L and  108 L of the front and back covers  102  and  104 , respectively are visible, as is the flexible, polymeric sleeve  115  and the semicylindrical profile of the spine  101 . Half feet  110 A and  110 B on the lower edge  106 L of the front cover  102  and half feet  111 A and  111 B, which are on the lower edge  108 L of the back cover  104 , are also visible, as is a lower closure clasp  301 L, which maintains the case locked when in a closed configuration. 
         [0030]    Referring now to  FIG. 4 , the upper edges  106 U and  108 U of the front and back covers  102  and  104 , respectively are visible in this view, as is the flexible, polymeric sleeve  115  and the upper closure clasp  301 U. 
         [0031]    Referring now to  FIG. 5 , the closure edge  108 C of the back cover  104  is shown. Also visible in this view is the back cover half  501 B of a longitudinally and medially split oblong recess  501 , that provides opposed grips for opening the case  100  when closed. The flexible polymeric sleeve  115  is also visible in this view, as is half foot  111 B. 
         [0032]    Referring now to  FIG. 6 , the closure edge  106 C of the front cover  102  is shown. Also visible in this view is the front cover half  501 F of the longitudinally and medially split oblong recess  501 , that provides opposed grips for opening the case  100  when closed. The flexible polymeric sleeve  115  is also visible in this view, as is half foot  110 B. 
         [0033]    Referring now to  FIG. 7 , this cross-sectional view shows the clip  201 B, the disc attachment hub  202 , the lower disc support shelf  203 L, and the lower closure clasp  301 L. The flexible, polymeric sleeve  115  is also visible in this view. 
         [0034]    Referring now to  FIG. 8 , this cross-sectional view shows the clips  201 A and  201 B, as well as upper and lower closure projections  801 U and  801 L, which engage upper and lower closure clasps  301 U and  301 L, respectively. The flexible, polymeric sleeve  115  is also visible in this view. 
         [0035]    Referring now to  FIG. 9 , this cross-section view shows the back side of upper and lower closure clasps  301 U and  301 L, the upper and lower disc support shelves  203 U and  203 L and the disc attachment hub  202 . 
         [0036]    Referring now to  FIG. 10 , this isometric view of primarily the interior of the DVD case  100  shows many of the heretofore described features from a different, and in many cases, clearer perspective. 
         [0037]    Referring now to  FIG. 11 , this isometric view of primarily the exterior of the DVD case  100  shows many of the heretofore described features from a different, and in many cases, clearer perspective. 
         [0038]    Referring now to  FIG. 12 , the front of the case  100  is shown in a closed configuration. The noteworthy feature of this drawing figure is the manner in which the spine  101  fits together with the front cover  102 . It will be noted that the top and bottom portions  112 U and  112 L, respectively, of the spine  101  curve into the upper and lower edges  110 U and  110 L of the front cover  102 . 
         [0039]    Referring now to  FIG. 13 , the back of the case  100  is shown in a closed configuration. The noteworthy feature of this drawing figure is the manner in which the spine  101  fits together with the back cover  104 . It will be noted that the top and bottom portions  112 U and  112 L, respectively, of the spine  101  curve into the upper and lower edges  111 U and  111 L of the back cover  104 . 
         [0040]    Referring now to  FIG. 14 , the case  100  has been closed to show the bottom sidewall  1401 . The bottom sidewall  1401  is a combination of the quarter-round lower edges  106 L and  108 L of the front and back covers  102  and  104 , respectively. With the case  100  closed, the half feet  110 A and  111 A form a first unified oblong foot  1402 A. Likewise, the half feet  110 B and  111 B form a second unified oblong foot  1402 B. 
         [0041]    Referring now to  FIG. 15 , the case  100  in a closed configuration shows the top sidewall  1501 , which is a combination of the quarter-round upper edges  106 U and  108 U of the front and back covers  102  and  104 , respectively. 
         [0042]    Referring now to  FIG. 16 , the case  100  in a closed configuration shows the closure sidewall  1601 , which is a combination of the quarter-round closure edges  106 C and  108 C of the front and back covers  102  and  104 , respectively. It will be noted that the front cover half  501 F and the back cover half  501 B of the longitudinally and medially split oblong recess  501  are now adjacent. It can be clearly seen in this view how the oblong recess  501  provides opposed upper and lower grips for opening the case  100  when closed. 
         [0043]    Referring now to  FIG. 17 , the case  100  in a closed configuration shows the spine sidewall  1701 , which is a combination of the quarter-cylindrical spine  101  and the eighth-cylindrical rounded hinged edges  106 H and  108 H of the front and back covers  102  and  104 , respectively. 
         [0044]    Referring now collectively to  FIG. 14 through 17 , it will be noted that the bottom sidewall  1401  intersects with the closure sidewall  1601  and the spine sidewall  1701  to form first and second generally quarter-spherical corners  1702 A and  1702 B. Likewise, the top sidewall  1501  intersects with the closure sidewall  1601  and the spine sidewall  1701  to form second and third generally quarter-spherical corners  1702 C and  1702 D. So that the front cover  102 , the back cover  104  and the spine  101  may lie in a common plane when in an open configuration, it was found necessary to position the first live hinge  103  at a first quarter position along the spine sidewall  1701 , and the second live hinge  105  at a third quarter position along the spine sidewall  1701 . In other words, the front cover  102  incorporates about one-fourth of the spine sidewall  1701 , the spine  101  incorporates about one-half of the spine sidewall  1701 , and the back cover  104  incorporates the remaining about one-fourth of the spine sidewall  1701 . This configuration has an added advantage in that, when the case is open, it occupies less table space than does a DVD case having the same thickness and a flat spine that is perpendicular to the front and back covers when the case is closed. 
         [0045]    Although only several embodiments of the invention has been shown and described, it will be obvious to those having ordinary skill in the art that changes and modifications may be made thereto without departing from the scope and the spirit of the invention as hereinafter claimed.