Abstract:
A book format data package that utilizes dovetail shaped clips to attach trays together and to a book-like cover. The clips have internal living hinges molded between each segment. The book-like cover has a cover, spine made of flexible material, back panel and openings on the spine that are smaller than the resting length of the clips. These openings are a set of two parallel mounting recesses that leave a center strip. This center strip is used to lock the trays and book together. To attach the trays to the cover, the clips are folded to a size less than the size of the openings on the cover. There may be one or more locations to attach clips on the cover&#39;s spine. After passing through the opening on the cover and over the center strip of flexible material, the clips are pressed forward and returned to their original configuration. A locking rib is molded into the center of each female dovetail shaped pocket. Each clip has a groove down its centerline that the locking rib fits into.

Description:
[0001]     This application claims the benefit of U.S. Provisional Application No. 60/446,554, filed Feb. 12, 2003. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     Data storage devices are delicate devices that are easily damaged by scratches, dirt and other consequences of handling. As such, there is a need for carrying cases and other storage mechanisms that protect compact discs, DVDs and other digital and analog media devices during transport and between uses.  
         [0003]     Additionally, data storage devices are often used as advertising mechanisms to sell contents. Data storage devices are often displayed directly on shelves in retail stores. Attractive packaging designs provide benefits in sales.  
         [0004]     Most storage mechanisms for digital media and other devices are capable of storing only one or two discs at a time. A common media storage device is a jewel case for storing compact discs. In a jewel case, a disc fits into a plastic tray and a hinged cover snaps onto the tray to close the jewel case. Two discs may be held in a jewel case if a double-sided tray is used inside the case. However, jewel cases are not visually appealing, are difficult to open and often break. Similar problems exist with packaging for DVDs.  
         [0005]     Methods for carrying and storage of multiple digital discs are also unsatisfactory. Multiple disc carriers often involve bulky and hard to use cases that allow the user to carry multiple discs at once. Most of these devices are not user-friendly and are not visually appealing.  
         [0006]     Needs exist for improved methods for storing, protecting and displaying data storage devices in a less expensive and more visually appealing manner.  
       SUMMARY OF THE INVENTION  
       [0007]     The present invention is a method of attaching rigid pages to each other and to a book-like cover to form a package for holding, protecting and displaying data storage devices. Flexible plastic strips, preferably dovetail shaped clips, are used to secure trays to one another and to the book-like cover. The clips may have a trapezoidal shape with a triangular recess that allows them to bend along a central, longitudinal living hinge axis. If multiple trays are being used, multiple tray holder clips can be strung together with living hinges that allow the user to flip thought the trays of the novel package without damaging the clips. The living hinges slightly raise the next adjacent tray while the user is flipping to make the package easier to use. Anti-tear hinges prevent the living hinges from ripping.  
         [0008]     The tray holder clips have tray engagement sides with end connectors for fitting into one or more spaced complementary mounting recesses in the edges of the trays. Each end connector has split aligning projection receivers at the extremities for receiving complementary aligning projections in the mounting recesses. The tray holder clips also have openings for receiving securing projections in the tray edge mounting recesses. The securing projections include projections with enlarged detent ends for fitting inside the openings. They cooperate with the internal shapes of the openings. The securing projections and the detents cooperate with holes and the snaps for locking the holder slips inward and for holding the receivers laterally outward for engaging the aligning projections. The openings have internal snaps for cooperating with the end connectors and receivers extending outward.  
         [0009]     The individual trays may have at least one depression with a central rosette for holding a digital media disc. There may also be finger holds along the depression to make extracting the digital media disc easier. There is also a rim the trays and lugs around the rim for holding a graphic card on a side of the tray opposite the depression. An individual tray may also have opposite depressions with opposite rosettes for holding two media discs on opposite sides of the tray.  
         [0010]     Preferably, both the tray holder clips and the mounting recesses are dovetail shaped. The mounting recesses are narrower at the connecting edge and wider further toward the center of the tray.  
         [0011]     Additionally, there may be at least one end tray with mounting recesses on a mounting edge. Preferably, there may be two opposite end trays. One or more of the end trays may be deep trays with similar connection mechanisms to the central or end trays. The end tray may be used to hold pamphlets, booklets, literature or other materials. The end tray or other trays may have inward extending literature clips near an edge opposite the mounting edge to hold any extra materials.  
         [0012]     The free edges of plural trays may have aligned fastener recesses. A flexible fastener strip has two ends, one with a first connector. The first tray in a stack of trays has a flap with a second connector. The flexible fastener strip lies within the aligned fastener recesses when first and second complementary connectors are connected. The end of the flexible fastener strip without the connector is attached to the bottom tray. The second end of the flexible fastener strip has a hook that engages one of a series of holes on the base of the bottom tray. This flexible fastener strip may be used with a book cover.  
         [0013]     The book-like cover can be of a various thickness or have graphics imprinted upon it. The cover wraps around stacked plastic trays or pages. The plastic trays hold compact discs, DVDs, descriptive booklets and other materials on the front, back or both surfaces. Both the front and back of the trays can hold media devices or booklets and the trays fit front to back to avoid movement relative to one another. A locking rib on the trays fits tightly with a locking groove on the clips.  
         [0014]     The package of the present invention can be made as large or small as needed by simply adding additional trays and increasing the width of a flexible spine material. The flexible material is located between the front and back panel of the package cover and is the place where the trays are attached to the cover. Two parallel strips are cut in the flexible spine material to allow bent, dovetail shaped clips to pass through the flexible material and into corresponding dovetail shaped mounting recesses on the trays. The clips trap the flexible spine material between the locked clips and the trays. One or more sets of dovetail shaped clips are used to hold trays to the cover.  
         [0015]     To create a package, a stack of trays is formed. Each tray has end flanges and recessed edges for receiving the flanges of a next adjacent tray in order to avoid sliding movement of the trays relative to one another. Then, the cover and flexible spine material is overlaid so that the cutout openings are over the dovetail shaped mounting recesses on the trays. The clips are then bent and passed through the flexible spine material. Pressure is applied to the bent clips and the clips return to their original configuration and lock into the dovetail shaped mounting recesses. Thus, the trays are attached securely to the book-like cover.  
         [0016]     These and further and other objects and features of the invention are apparent in the disclosure, which includes the above and ongoing written specification, with the drawings.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]      FIG. 1  shows a single dovetail shaped clip.  
         [0018]      FIG. 2  shows multiple dovetail shaped clips and the corresponding female dovetail shaped mounting recesses on trays.  
         [0019]      FIG. 3  shows the dovetail shaped clip bent prior to insertion into the mounting recess.  
         [0020]      FIG. 4  shows the locking ribs on the trays and the corresponding groove on the clip.  
         [0021]      FIG. 5  shows the end of the package showing a clip attached to a tray in the open position.  
         [0022]      FIG. 6  shows the top of the package showing a clip attached to a tray in the open position.  
         [0023]      FIG. 7  shows the side of the package showing a clip fully inserted into a mounting recess.  
         [0024]      FIG. 8  shows a stack of trays with mounting recesses.  
         [0025]      FIG. 9  shows the front and back cover and the flexible spine material with cutouts.  
         [0026]      FIG. 10  shows a stack of trays with the flexible spine material about to be overlaid and clips in position.  
         [0027]      FIG. 11  shows the bending of the clips to fit within the cutouts in the flexible spine material.  
         [0028]      FIG. 12  shows the installed clips with the spine material trapped between the clip and tray.  
         [0029]      FIG. 13  shows a media holder set and a book cover.  
         [0030]      FIG. 14  shows a media holder set in a book cover.  
         [0031]      FIG. 15  shows a book with a deep tray.  
         [0032]      FIG. 16A  is a top perspective view of a tray holding clip.  
         [0033]      FIG. 16B  is a top view of a tray holding clip.  
         [0034]      FIG. 17A  is a bottom perspective view of a tray holding clip.  
         [0035]      FIG. 17B  is a bottom view of a tray holding clip.  
         [0036]      FIG. 18  is a front view of a tray.  
         [0037]      FIG. 19  is a perspective view of the tray showing the connecting edge.  
         [0038]      FIG. 20  is a perspective detail of the tray connecting edge.  
         [0039]      FIG. 21  is a perspective detail of the tray free edge.  
         [0040]      FIG. 22  is a front view of a tray with a graphics card.  
         [0041]      FIG. 23  is a rear view of a tray with a graphic card.  
         [0042]      FIG. 24  is a front perspective view of a tray combination in a carrying case.  
         [0043]      FIG. 25  is a rear perspective view of a tray combination in a carrying case.  
         [0044]      FIG. 26  is a rear detail of hinged clips holding the elements of the carrying case.  
         [0045]      FIG. 27  is a detail of a fastener strip.  
         [0046]      FIG. 28  is a detail of a handle.  
         [0047]      FIG. 29  shows a handle inserted in the deep tray of the carrying case.  
         [0048]      FIG. 30  is a perspective front view of a double-sided rosette used with a double-sided holder tray.  
         [0049]      FIG. 31  is a perspective rear view of a double-sided rosette used with a double-sided holder tray.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0050]     The present invention is a book format package for holding compact discs, DVDs, booklets and other data storage devices and a method for attaching plastic trays to one another and attaching the trays to a book-like cover.  
         [0051]      FIG. 1  shows a strip of plastic having a central longitudinal living hinge. Preferably, the strip of plastic is a dovetail shaped clip  11 . The clip  11  is basically trapezoidal in shape, with two angled sides  25 ,  27 , a top surface  23  and a bottom surface  29 . The clip  11  also has a roughly triangular shape  13  removed from the side surface  31 . The clip  11  is molded from plastic or another suitably strong and flexible material. The triangular recess  13  allows the clip  11  to bend along a top surface  23  at the peak  15  of the triangular shape  13  when pressure is applied to the ends  17 ,  19  of the clip  11 . The clip  11  also has a locking groove  21  molded into the bottom surface  29  of the clip  11 . The locking groove  21  may be triangular or another shape.  
         [0052]      FIG. 2  shows two dovetail shaped clips  11  and corresponding dovetail shaped mounting recesses  33  on trays  35  or pages that make up a package. The mounting recesses  33  are located on an edge  37  of the trays  35 . The trays of the package book are plastic trays  35  that hold data storage devices such as compact discs, DVDs or other devices. The front  39 , back  41  or both surfaces of each tray  35  are capable of holding a data storage device.  
         [0053]     A completed package can accommodate from one to an infinite number of trays  35 . The use of multiple trays  35  in a package requires multiple clips  11 . Multiple clips are connected together by living hinges  45 . These living hinges  45  allow a user of the package to flip through the trays  35  without separating or breaking the clips  11  apart. As an additional precaution, anti-tear hinge ribs  47  may be molded into the clips  11  and hinges  45  of the present invention. The anti-tear hinge ribs  47  reinforce the living hinges  45  to allow for more extensive bending of the hinges  45 . The living hinges  45  are molded during molding of the clips  11  to ensure a solid connection. The clips  11  ensure that the trays  35  do not move relative to one another. With each additional tray  35  added to a stack  43  of trays  35 , a corresponding clip  11  is needed to attach the new tray  35  to the package. Individual clips  11  are separated by a space  49  between each clip  11 .  
         [0054]      FIG. 3  shows a dovetail clip  11  in a bent position, ready to be inserted into a dovetail shaped mounting recess  33  of a tray  35 . Pressure  51  is applied to the ends  25 ,  27  of the clip  11  and the clip  11  bends  53  along the peak  15  of the triangular cutout  13 . In order to fit the clip  11  into the opening  33 , the largest width of the clip  11  must be compressed to a size less than the smallest size of the mounting recess  33  on the outside edge  37  of the tray  35 . This allows the clip  11  to pass through top edges  55 ,  57  of the mounting recess  33  and into the wider opening  59  further into the tray  35 .  
         [0055]      FIG. 4  is a view from the end of the package showing multiple clips  11  attached to multiple trays  35 . Each dovetail shaped mounting recess  33  may have a locking rib  61  that fits into the locking groove  21  of each clip  11 . When the clip  11  is fully inserted into the tray  35 , the locking rib  61  of the tray  35  fits snuggly into the locking groove  21  of the corresponding clip  11 . The locking ribs  61  can be seen fit into the locking grooves  21  of the clips  11 .  
         [0056]      FIG. 5  shows a view from the end of the package with two clips  11  in a fully opened position. The living hinge  45  is completely flexed.  
         [0057]      FIG. 6  shows a view from the top of a package showing two clips  11  in a fully opened position. The living hinge  45  is completely flexed. The individual trays  35  may have ridges  63  on one or more edges  65  of each tray  35  that allow for easy alignment of the trays  35  into a stack  43 .  
         [0058]      FIG. 7  shows a view from the top of the package with a clip  11  locked into the dovetail shaped mounting recess  33 .  
         [0059]      FIG. 8  shows a stack of trays  43  with dovetail shaped mounting recesses  33 . The openings  33  are at identical locations on each tray  35 . When stacked, the top  39  of each tray  35  fits tightly with the bottom  41  of the tray  35  on top. This repeats for as many trays  35  as needed. Each tray has flanges and recessed edges. The recessed edges receive the flanges of the next adjacent tray. This prevents sliding of the trays  35  with respect to one another during production, shipment or use.  
         [0060]      FIG. 9  shows a front cover  65 , back cover  67 , flexible spine material  69  and two sets cutout openings  71  on the spine material  69 . One or more sets of clips  11  can be used to attach the covers  65 ,  67  to one or more trays  35 . The flexible spine material  69  is attached between the front  65  and back  67  covers, forming a spine of the package. The front  65  and back covers  67  of the package are formed from paper, cardboard, binder&#39;s board or other suitable materials. The covers  65 ,  67  are made from at least one layer of material. Adding additional layers of material, or folding the covers  65 ,  67  to increase the number of layers can achieve different thickness. Pockets for pamphlets, booklets or other informational materials may be folded into or attached to the covers  65 ,  67 . The flexible spine material  69  is adhered to the covers  65 ,  67  or is sandwiched between layers of the front  65  and back  67  covers. The front  65 , back  67  or both covers of the package may be printed with graphics. The front  65  and back  67  covers may also be made of preprinted graphic materials.  
         [0061]     To form a completed package, the covers  65 ,  67  are folded around the stack  43  of trays  35 . Increasing the number of individual trays  35  and the size of the flexible spine material  69  increases the size of the package. During the folding process, the spine material  69  that abuts one edge  37  of the stack  43  of trays  35 .  
         [0062]     The flexible spine material  69  has cutout openings  71  to allow the covers  65 ,  67  to be connected to the trays  35 . The cutout openings  71  consist of two parallel slits for each clip  11  that is to be used. The openings  71  are spaced such that the bent clips  11  pass through the openings  71 . When the bent clips  11  pass through the openings  71 , they engage the thin strip  73  of flexible binding material  69  that is between the parallel openings  71 . Once the clips  11  are locked into the mounting recesses  33 , the thin strip  73  is trapped between the clip  11  and the tray  35 . This secures the book-like cover  75  to the stack  43  of trays  35 .  
         [0063]      FIG. 10  shows a stack  43  of trays  35  with the flexible spine material  69  overlaid and the clips  11  preparing to lock the spine material  69  to the trays  35 .  
         [0064]      FIG. 11  shows the process of attaching the trays  35  to the front  65  and back  67  panels of the cover  75 , as well as the flexible spine material  69 . The clip  11  begins in a relaxed, non-flexed state  77 . The clip  11  is then bent  79  far enough to allow passage of the ends  17 ,  19  through the top edges  55 ,  57  of the mounting recess  33 . The clip  11  is then passed through the flexible spine material  69  by means of the cutout openings  71 . The narrow strip  73  of flexible spine material  69  between the cutout openings  71  is pinned between the clip  11  and the tray  35 . When the bent clip  11  reaches the mounting recess  33 , pressure is applied to the top  23  of the clip  11 . This causes the clip  11  to straighten out and the clip  11  becomes locked into the mounting recess  33 .  
         [0065]      FIG. 12  shows the final, locked position of the clip device  11 . The narrow strip  73  of flexible binding material  69  is trapped between the tray  35  and the clip  11 . This ensures that the trays  35  are securely attached to the cover  75  and that the package can be operated in a book-like manner.  
         [0066]     The trays  35  can be leafed through like the pages of books. As each individual tray  35  is flipped, the next tray  35  partially rises due to the resistance of the living hinges  45 . This movement allows the user to more easily grasp the next tray  35  without having to try and separate trays  35  manually. This process is repeated as the user continues through the entire package. Through this process, the user can easily see the data storage devices in the book and quickly flip through the entire book to find the appropriate tray.  
         [0067]      FIGS. 13 and 14  show a book cover  120  with a spine  121  interconnecting cover  117  and back  119 .  
         [0068]     A holder set  130  includes trays  109  hinged together at connecting edges  131 . First and second end trays  133  and  135  have flat outer surfaces  134  which are bonded respectively to inner surfaces of cover  117  and back  119 , completing the book  140 . Free edges  137  of the trays  109  have fastener recesses  139 . A first connector  141  on flap  143  from first end tray  133  engages a second connector  145  on a second, free end  147  of flexible fastener strip  149  to hold book  140  closed. The fasteners and fastener recesses  139  may be omitted.  
         [0069]      FIG. 15  shows a book with a deep tray  150  as the second end tray that is attached to rear cover panel  119 .  
         [0070]     The trays  109  have rearward extending rims  151  and depressions  153 . Edge recesses or bevels on front edges receive rear edges of the rims to resist sliding of the trays when the book is closed. Depressions  153  hold media discs on central rosettes. Finger holes  155  aid in removal of discs. Literature clips  157  hold booklets inside the first end tray  133 . Snaps or micro hook and loop straps  159  are used to hold the book  140  closed.  
         [0071]      FIGS. 16A, 16B ,  17 A and  17 B show strips  161  of tray holder clips  11  that are connected together by living hinges  113 . A central living hinge  163  extends along the strip  161  to separate each of the clips  11  into identical sides  165 . The dovetail shaped clips  11  have divided ends  167  which form receivers  169  for aligning projections  171  in dovetail shaped mounting recesses  170  in the mounting edges  131  of trays  109 , as shown in  FIGS. 18-20 . The divided ends  167  of the sides  165  fit in the corners  173  of the mounting recesses  170 . Sloping sidewalls  195  of sides  165  have inverted V-shaped grooves  196  to receive the complementary V-shaped sidewalls  197  of the sloping sides  198  of the mounting recesses  170 . The mounting recesses have central securing projections  175  with extended enlarged securing detents  177 .  
         [0072]     The sides  165  of the clips  11  have openings  181  into which the securing projections  175  fit. The detents  177  are engaged by inward-extending snaps  183  in the small openings  185  to retain the clips in the recess. Sloping walls  189  of the holes  181  are engaged by the sloping edges  179  of the securing projections  175  to hold the sides  165  of the clips  11  outward, with the ends  167  in the corners  173  and the aligning projections  171  securely in the receivers  169  and the complementary V-shaped grooves  196 . Edges  166  of the ends  167  are tapered inward to guide the receivers  169  into alignment with the aligning projection  171 , which occurs in the initial assembly.  
         [0073]     To assemble the clips  11  on the trays  109 , the clips  11  are bent inward along longitudinal living hinge  163 . After receivers  169  are positioned on alignment projections  171 , further inward pressing on the back  162  of the strip  161  engages the snaps  183  on the detents  177 , holding the clips straightened with ends  167  outward. Enlarged rounded feet  168  on ends  167  ensure that the clips  11  may be pressed inward sufficiently to snap the snaps  183  over the detents  177  and to provide over-the-center clamping.  
         [0074]     When assembling the holder sets, preferably the trays  109 , mounting edges  131  and recesses  170  are aligned. The strip  161  is bent along living hinge  163 , and all clips  11  are connected to the aligned trays  109  at one time.  
         [0075]     As shown in  FIGS. 16A and 16B , tear-preventing ribs  164  are positioned at ends of living hinges  113  to resist tearing of the living hinges.  
         [0076]      FIG. 21  is a detail of a tray  109  showing a fastener recess  139  in its free edge  137 .  
         [0077]      FIGS. 22 and 23  show a transparent tray  190  having lugs  191  extending inward from edges of rim  151  to hold a graphics card  193 , which is visible through the tray.  
         [0078]      FIGS. 24-29  show a carrying case  200  made with several trays  109 , including a first end tray  133  and a deep tray  150  as the second end tray  135 , and plural two-sided holder trays  201 . The two-sided holder trays  201  are used on the books  140  as well as cases  200 . The holder trays  201  have a standard rim  151  and a small inner rim  203  interrupted by finger openings  205  to surround a media disc held on the second side of a two-sided central rosette  207 .  
         [0079]     The second media disc is held within the thickness of the tray that is established by the rim  151 . Reinforcements  209  extend inward from the rim around the first end tray  133 .  
         [0080]     A handle assembly  210  is added to the deep tray  150 . The flexible fastener strap  149  fits within fastener recesses  139  in free edges  137  of the trays. The strip  161  of clips  11  is attached along the connecting edges  131  of the trays, as shown in  FIG. 25 .  
         [0081]     A hook  221  is provided on the first end  223  of flexible adjustable fastener strap  149 . Hook  221  selectively engages one hole in the array of holes  225  in the central depression  227  on the outer surface of the deep tray  150 . Tabs  229  shown in  FIG. 29  hold the flexible fastener strap in the depression  227 .  
         [0082]      FIG. 26  is a detail of the flexible strip  161  of tray holder clips  11  engaging the trays in the case  200 .  
         [0083]      FIG. 27  is a detail of the fastener strap  149  with the hook  221  on the first end  223  and a connector  145  on the second end  147 . Grooves  228  allow bending of the strap  149  around the front corner of the deep tray at an appropriate position according to the number of trays assembled in the carrier  200  or book  140 . The deep tray  150  may be replaced with a second end tray  135  shown in  FIGS. 13 and 14 , which also has the same outer surface depression  227  and array of holes  225  for engaging the hook  221  according to the total number and height of the stacked trays  109 .  
         [0084]      FIG. 28  shows the handle assembly  210  with bases  211  having sloping side walls  213  which slide into and engage the handle recesses  215  shown in  FIG. 24 . The handle assembly has spacers  217  mounted on the basis and living hinges  218  which connect ends  219  of the handle  212  to the spacers.  
         [0085]      FIGS. 30 and 31  show the front and back of two-sided rosettes  207  used on two-sided trays. The front shown in  FIG. 30  has a central push button  231  that is connected to legs  233  to flex bases  235  downward and legs  233  and holding lips  234  inward when the button is depressed. Raised surfaces  237  on guides  239  hold a central opening in a disc centered on the rosette.  
         [0086]     The rear of rosette  207  is shown in  FIG. 31 . A central cylinder  241  acts as a push button and, when depressed, draws inward legs  243  connected by radial arms  244  to the cylinder  241 . The inward movement of the cylinder flexes bases  235  to which the legs  243  are connected and draws lips  244  inward, releasing the disc. Raised surfaces  247  on guides  249  center the disc. The guides  239  and  249  extend through the tray.  
         [0087]     Rounded outer surfaces on the holding lips  234  and  244  allow the discs to be shaped onto the rosette.  
         [0088]     While the invention has been described with reference to specific embodiments, modifications and variations of the invention may be constructed without departing from the scope of the invention.