Abstract:
A container with double-walled construction eliminates problems encountered with a conventional jewel box; the container comprises a rectangular shell and a cartridge non-removably held within the shell, the cartridge in turn holding a disc; the disc is ejectable from one side with an ejection button; the cartridge is sheathed in the shell so as to have only one open side; the container allows printed material to completely obscure a disc held within the cartridge; yet the container allows one to determine visually whether a disc is stored within the cartridge from the position of the ejection button. The roof of the cartridge is provided with a detent in which the central aperture of the disc is held, and while so held, the disc is supported in the cartridge only at its opposed peripheral edges.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to an improved storage container for a thin flexible laminar disc having a central aperture, such disc being used to store data electronically on one surface thereof. The disc, generally referred to as a compact disc or CD-ROM, is typically stored in a container referred to in the art as a “jewel box” (or “jewel case”). A currently popular ubiquitously marketed jewel box is hand-held to open it, and to remove a disc stored therein by lifting it in a direction normal (typically vertically) from its horizontal position within a storage insert or “tray” securely held in the lower wall or “floor” of the box. The box is opened by rotating the upper wall or “cover” of the box from its horizontal position. The cover is pivotable on a pair of opposed pivot pins which are journalled in a sidewall of the box, specifically the left sidewall, as the cover is designed to be opened with one&#39;s left hand. The box is closed by returning the cover to its horizontal position. The cover is provided with two pairs of oppositely disposed projecting ears spaced apart from its inside surface sufficiently to allow a booklet of lyrics or “libretto” to be slidably inserted along the inside surface of the cover, so that it is held by the ears. Currently marketed jewel boxes are made of a substantially transparent synthetic resinous material (“plastic”), typically polystyrene, so that the printed matter on the booklet may be read. 
     The problem is that the construction of a conventional jewel box is such that with the libretto held in the cover, a person cannot know whether the disc is in its tray, so that, to find out, it is necessary to open the box to check. Removing the disc from its tray subjects the disc to an unpredictable amount of flexural force, depending upon the size and strength of the hand removing it, and whether it is being removed in a hurry. Re-inserting the disc requires centering it in the tray; a substantial misalignment results in the lower recorded surface of the disc being abraded against the tray. The close tolerance required between the surface of a libretto and the spacing of the plastic ears from the inside surface of the cover, not only subjects the ears to breakage but also makes it difficult to re-insert the libretto, particularly if the libretto is handled many times and becomes somewhat dog-eared. Further, repeatedly opening and closing the cover results in the plastic pivot pins being broken off. The foregoing disadvantages of a jewel box are accepted because of its overwhelming economic advantage—it requires a minimum quantity of plastic and is easy to manufacture so that it is inexpensive. 
     Recognizing the foregoing problems, several attempts have been made to provide a container in which the disc is inserted and removed from one side, and to avoid using a pivotable cover. Such containers are disclosed in U.S. Pat. Nos. 5,676,246; 5,799,783; 5,944,180 and others. None suggests using a container with a double-walled construction. 
     SUMMARY OF THE INVENTION 
     It is a general object of this invention to provide a container with double-walled construction which eliminates problems encountered with a conventional jewel box; the container comprises a rectangular shell and a cartridge non-removably held within the shell, the cartridge in turn holding a disc; the disc is ejectable from one side with an ejection button; the cartridge is sheathed in the shell so as to have only one open side; the container allows printed material to completely obscure a disc held within the cartridge; yet the container allows one to determine visually whether a disc is stored within the cartridge from the position of the ejection button. 
     It is a specific object of this invention to provide a container comprising a rectangular paralleled piped shell within which is secured, preferably non-removably, a cartridge of generally similar rectangular shape, the cartridge having one open side, opposed guide rails, each with an inclined ramp over a portion of its length along each opposed sidewall of the cartridge, and an arcuate projection or “rounded detent” disposed between the rails, the detent projecting downward from the cartridge&#39;s upper wall or “cartridge roof”; the detent, preferably rounded, is dimensioned so as to be insertable within the central aperture of the disc when the aperture is urged into position by the flexure of the disc in contact with the ramps&#39; upper surfaces; the inclination of the ramps, which are in mirror-image relationship with each other, is adapted to engage the rounded detent in the central aperture of the disc, and such inclination need extend along less than about one-half of the length (along the x-axis) of the cartridge, provided the ramps have a sufficient angle of inclination to force the central portion of the disc against the rounded detent until it is inserted in the central aperture. When an ejection button in one side of the shell is pressed inwards, it pushes against the disc stored in the cartridge and ejects the disc from the open side of the cartridge. The cartridge is secured within the shell with a predetermined spacing between the cartridge&#39;s floor and roof and the corresponding floor and roof of the shell, so as to allow printed matter to be inserted in the spaces therebetween. 
     It is also a specific object of this invention to provide a shaped laminar imprinted insert for the shell of the container. 
     It is another specific object of this invention to provide a simple and effective means for locking an article within another, wherein each article has resilient, parallel opposed sides. 
     Specific advantages of the double-walled container are that it provides: 
     (a) visual indication of the absence of a disc without having to handle the container; 
     (b) space between the respective roofs and floors of the cartridge and shell tailored to accept the amount of printed material to be included with the container; 
     (c) display of printed material on the roof, floor and three sides of the shell, which is more than can be conveniently displayed on a conventional jewel box; 
     (d) each of the foregoing without fragile pivot pins or hinges, using minimal space so as to be economical despite the additional synthetic resinous material required for the cartridge used to provide its double-walled construction. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     The foregoing and additional objects and advantages of the invention will best be understood by reference to the following detailed description, accompanied with schematic illustrations of preferred embodiments of the invention, in which illustrations like reference numerals refer to like elements, and in which: 
     FIG. 1 is an exploded perspective view of a container showing an outer shell, a cartridge fitted therein and an ejection mechanism in one side of the shell. 
     FIG. 2 is a top plan view of the assembled container showing in phantom outline, a disc stored therein. 
     FIG. 3 is a perspective view of the shell lying in the horizontal (x-y) plane showing the one open side (right hand side) of the shell, through which open side a cartridge is inserted. 
     FIG. 4 is a perspective view of the cartridge lying in the horizontal (x-y) plane with portions broken away, showing the one open side (right hand side) of the shell, through which open side a disc is inserted. 
     FIG. 5 is a top plan view of the shell only, showing a recessed slideway for the ejection button. 
     FIG. 6 is a perspective view of the ejection button lying in the horizontal (x-y) plane. 
     FIG. 7 is a cross-sectional view taken along the line  7 — 7  in FIG. 2, with a disc engaged by a central detent, enlarged and not to scale, to show the structural relationship of the rails and inclined ramps in the cartridge, and ejection button in the shell. 
     FIG. 8 is a side elevational view of the shell shown in FIG.  5 . 
     FIG. 9 is an enlarged detail view schematically illustrating the geometry of one of the guide rails to show the coaction of its inclined ramp and the rounded detent. 
     FIG. 10 is a perspective view, with a portion broken away, of one sidewall of the shell; on the inner surface of each sidewall locking ramps are provided which are adapted to receive self-locking detents matingly inserted therein. 
     FIG. 11 is a plan view of a printed document insert, typically relating to data carried on a compact disc, which document is to be folded along the fold lines shown when it is inserted in the shell. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The container may be adapted for storage of any compact audio or video discs which has a central aperture. The description herebelow is specifically directed to a commercial CD-ROM about 12 cm in diameter and less than 1 mm thick with a central aperture having a diameter of about 16 mm. 
     Referring to FIG. 1, there is schematically illustrated a container referred to generally by reference numeral  10 , comprising a shell  20  and a cartridge  30  dimensioned to be insertable within the shell in the direction of the arrow. The function of the cartridge is to store the disc and hold it securely in a central position within the cartridge; the shell protects the disc and cartridge within which the disc is held. The cartridge is preferably made from a synthetic resinous material of lesser cross-section than the shell, so that the cartridge uses far less material and is more flexible. The shell  20 , shown lying flat in a horizontal x-y plane, is a rectangular paralleled piped having an upper wall or roof (“shell roof”)  21  and a lower wall or (“shell floor”)  22  spaced apart by opposed sidewalls  23 ,  24  and an end-wall  25  which is interrupted at its center to provide a recessed rectangular slideway indicated generally by  26 , for an ejection button  40 . The roof  21  and floor  22  are provided with cut-outs  27 ,  28  for finger access to the edge of a disc which is ejected. 
     Cartridge  30  is a smaller rectangular paralleled piped than the shell  20 , the thickness (in the z direction) of which cartridge is such as to provide a predetermined rectangular space above and beneath its floor and roof respectively, when the cartridge is confined within the shell. The interior dimensions of the cartridge are essentially fixed by the structural requirements which effectively capture the central aperture  51  of disc  50  by a central “rounded” detent  35 , on the underside of the cartridge roof  31 . The cartridge floor  32  is spaced apart from the cartridge roof  31  by opposed sidewalls  33 ,  34  and end-wall  35 . The end-wall  35  is interrupted to provide a rectangular recess  36  for access by the ejection button  40 . 
     The top plan view of the assembled container shown in FIG. 2 shows the cartridge  30  held within the shell  20  and disc  50  in phantom outline after the disc has been slidably inserted against end  41  of the ejector button  40 . This causes the disc to be secured by the detent  35  in the roof  31  of cartridge  30 . Guide-splines  42  and  43  in opposed faces of the slideway  26  allow ejection button  40  with a flange  72  to be reciprocably translated in the x-direction. The thickness (z-direction) of the ejection button is such that, to eject a disc, it is thrust between the roof  21  and floor  22  of the shell  20  until upper and lower portions of a flange  72  abut the roof  21  and floor  22  of the shell, thus ejecting the disc. The position of the ejection button  40  with its flange  72  against the inner edge  16  of slideway  26  shell, leaves a rectangular recess (which is the slideway  26  )in the end-wall  25  of the shell, visually indicating that the disc has been ejected. The under surface of the roof  21  of the shell  20  is preferably provided with retainer means such as bars  29  to retain a libretto inserted between the roofs  31  and  21  of the cartridge and shell respectively. 
     In the perspective view of the shell  20  illustrated in FIG. 3 there is shown in greater detail, the slideway  26  which is provided with opposed guide-splines  42 ,  43  which capture the ejection button  40  in the shell. In the sidewalls  23  and  24  are provided locking means to non-removably lock cartridge  30  within shell  20 . The type of locking means is not narrowly critical and may be any locking means known in the art which will effectively fasten cartridge  30  in shell  20  so as to leave an annular zone around the cartridge. A convenient locking means is provided by locking ramps  46 ,  47  in the sidewalls of the shell, in which locking ramps are matingly received self-locking locking bars  37  on the outer surfaces of sidewalls  33 ,  34  of the cartridge  30 ; alternatively, wedge-shaped projections may be provided on adjacent faces of the shell and cartridge, the projections on one being angulated in a direction opposite from the other; still another alternative is to provide a recess in the shell wall and a mating locking bar on the cartridge which locking bar would be matingly held in the recess. 
     Referring to FIG. 4, the perspective view of cartridge  30 , with portions broken away, shows one of two guide rails  38 ,  39  (only the end near the opening is shown) each with an inclined ramp  61 . The width of each guide rail (y direction) is about as wide as the unused space (not used to store data) near the circumference of the disc and is preferably in the range from about 2 to 3 mm wide to avoid contact with data stored on the disc. The guide rail  38  in the near half of the cartridge has an essentially horizontal upper surface  62  lying in the x-y plane; further along the guide rail, as it approaches the central area between the walls  33 ,  34  of the cartridge, the upper surface of the guide rail rises upward at  61 , as more clearly seen in the detail illustration of FIG. 9 in which the dimensions are exaggerated for clarity. At a location aligned with the central y-axis of the rounded detent, it is critical that the thickness of the inclined ramp (z direction) be such as to allow the bottom of the rounded detent to deflect a disc pushed up the ramp downwards. Thereafter the upper surface at  63  of the guide rail  38  is horizontal for a distance sufficient to provide support of the disc at a diametrically opposed location through the rounded detent. The horizontal portion  63  presents a surface in the x-y plane, vertically spaced apart from the horizontal surface  62  of the guide rail so that substantially no portion of the data-storage lower surface of the disc is in contact with the supporting guide rails. The disc  50  is supported at its opposed peripheral edges on the tops of surfaces  63  only, upper and lower surfaces are both spaced apart from the cartridge roof  31  and the cartridge floor  32  respectively, and the disc&#39;s lower surface is spaced apart from the remaining portion of the guide rail  38 . 
     Referring to FIG. 7 there is schematically illustrated the position of the disc  50  in its “home” position with the disc&#39;s periphery in contact or near-contact with the thrusting end of the ejection button  40 , the disc being supported only near its center, and neither the upper or lower surface of the disc being in contact with any other surface. Thus, when the inserted disc is held in place, the only contact between the disc and the cartridge are (i) the periphery of the detent, and (ii) the centrally aligned opposed surfaces  63 ,  64  under diametrically opposite edges of the disc. A libretto or album cover (not shown) is typically inserted in the space between the lower surface of shell roof  21  and the upper surface of cartridge roof  31 . 
     It will now be seen that as disc  50  is urged upward along the ramped surface  61 , the disc&#39;s upper surface is biased against the rounded detent  35  and is deformed thereby until the central aperture  51  of the disc is presented under the detent  35 , whereupon the disc is securely held though the disc is only supported on the surface  63  and the corresponding surface  64  (not shown) of guide rail  39 . 
     FIG. 5 is a top plan view of the shell showing guide-splines  42 ,  43  in the recessed slideway  26 , and four self-locking locking ramps  46 ,  47 , two locking ramps  46  on the inner surface of shell sidewall  24 , and two locking ramps  47  on the inner surface of the opposite shell sidewall  23 ; locking ramps  46  are oppositely located near the opposed ends of sidewall  24 , and locking ramps  47  are oppositely located near the opposed ends of sidewall  23 . The function of the locking ramps  46 ,  47  is to matingly lock self-locking detents such as locking bars  37  on cartridge  30  when the cartridge is inserted in the direction of the arrow, behind the locking ramps  47 ; the cartridge is then non-removably secured in the shell  20  and closely sheathed therewithin. The shape of a locking bar is not narrowly critical; vertical bars integrally formed on the outer surfaces of sidewalls  33 ,  34  provide adequate purchase behind locking ramps  47 . 
     The side elevational view shown in FIG. 8 locates internal locking ramps  46  near the opposed ends of sidewalls  24  of the shell so as to permit display of the maximum area of printed matter behind each sidewall. 
     Referring to FIG. 10, there is illustrated shell sidewall  24  with one of two spaced-apart locking ramps  47  shown as an immovable substantially wedge-shaped projection, one locking ramp near each respective end of the sidewall  24 . The ramp  47  is integrally formed in the sidewall  24 ; hypotenuse  48  of the wedge-shaped projection is inclined inwardly (towards the longitudinal central axis of the shell) from the interior surface of the sidewall  24 , in a direction in which the cartridge is to be inserted, at an acute angle sufficient to provide a locking function without obstructing insertion of the cartridge. An acute angle in the range from about 1° to 45° allows the opposite side of the wedge-shaped projection, that is opposite the acute angle, to provide a locking surface  49 . The hypotenuse  48  extends for a sufficient distance to allow a locking bar  37  to be locked against the locking surface  49  after a cartridge is inserted into the shell  20  in the direction of the arrow, when the locking bars  37  are urged over the inclined surface  48 . Locking ramps  46  are in mirror-image relationship to locking ramps  47 . It will now be evident that there must be sufficient relative movement between the shell sidewall  24  and the cartridge sidewall  33  to allow the cartridge to be thrust far enough so that the locking bars go past the inclined surfaces of the wedge-shaped projections. To provide such relative movement the shell and cartridge are constructed from plastic sufficiently resilient to do so. In a typical container for a CD-ROM sufficient resilience is provided by a relative movement, in a direction normal to the sidewalls, in the range from about 0.0254 mm (0.001″) to about 0.508 mm (0.020″). 
     An alternative means for locking the cartridge in the shell is to a known locking means which provides locking recesses in the sidewalls  23 ,  24  and wedge-shaped projections on the cartridge sidewalls  33 ,  34  with the inclined surface flaring away from the central longitudinal axis, so that once the hypotenuse of a wedge travelled past the edge of a recess, it would be captured in the recess. Still another alternative means for non-removably securing the cartridge in the shell is to adhesively secure opposed inner and outer surfaces of the shell and cartridge respectively, or to provide a sonic weld therebetween. 
     FIG. 6 is a perspective view of the ejection button  40  which is preferably a rectangular body  71  having a thickness (z direction) slightly less than the space between the opposed inner surfaces of the shell&#39;s floor  22  and roof  21  respectively, and a flange  72  which extends vertically a short distance above and below the upper and lower surfaces of the body  71 , so as to abut the roof  21  and floor  22  respectively, of the shell  20 . A groove  73 , one in each opposed wall of the body  71 , extends laterally (x direction) about mid-way in the body  71 , and through the side edges of flange  72  so as to enable the ejection button to be slidably reciprocated on the grooves  73  in which guide splines  42 ,  43  are slidably inserted. Each groove  73  terminates just before the far end of the body  71  which end is distally disposed relative to the flange  72 . The length (x direction) of the body  71  is such that, when the ejection button is in its “home” location, that is when the disc  50  is held in rounded detent  35  and the outer surface of flange  72  is flush with the outer surface of endwall  25  of the shell, the distal end  41  of the body  71  is in contact with the periphery of the disc  50 . 
     To locate the ejection button  40  in its “home” position, and to prevent the button to fall out, grooves  73  terminate a short distance from end  41  so that the termination of the each groove  73  provides a bumper stop  75  which abuts the end of each guide-spline  42 ,  43  and stops the face of flange  72  from moving beyond the vertical plane of the outer surface of endwall  25 . The height (z direction) of flange  72  preferably corresponds to the overall height of the shell  20 . It will now be evident that the length of the guide-splines  42 ,  43  and grooves  73  is such as to allow the ejection button  40  sufficient travel to push the central aperture  51  of disc  50  past the rounded detent  35  and to a location between the finger cut-outs  27 ,  28 . 
     The guide-splines  42 ,  43  are fitted in the grooves  73  of ejection button  40  preferably before securing the shell roof  21  to the sidewalls  23 ,  24  and endwall  25 . Grooves  73  extend through the sides of the flange  72 . The ejection button  40  is inserted by thrusting the flange  72  over the inner edge  16  of the slideway recess  26  and pressing downwards until the guide-splines are inserted in the grooves  73  on either side of the flange, and continuing to push the ejection button  40  in the direction of the arrow in FIG. 5, until the end  41  of the button clears the inner edge  16  of the recess  26 . 
     Referring to FIG. 11 there is shown a laminar sheet of paper  80  or other imprintable material on which the dotted lines adjacent solid lines indicate fold lines when the sheet  80  is to include the last page of an album cover which is to be printed, so that each rectangular portion  81 ,  82 ,  83 ,  84 ,  85 ,  86 ,  87  presents information about the contents of the album or its performers, drawings, photographs and the like, a corner of one portion typically being devoted to a bar code. The dimensions of portion  81  correspond substantially to the inner area of the shell floor  22  so that when folded along its margins, indicated by the dotted lines for portions  86  and  87 , each portion fits behind each of the sidewalls  24 ,  23  respectively; when folded along its margins indicated by dotted lines for portions  83 ,  85 , and folded again along margins indicated by dotted lines between portions  82 ,  83  and  84 ,  85 , portions  83  and  85  fits behind endwall  25 , on either side of ejector button  40 ; and portions  82  and  84  are secured between the roofs of the cartridge and shell when the sheet  80 , folded as indicated and having the cartridge inserted therein, is inserted in the shell. The visible outer surfaces of each of the above-identified portions is available for printing. 
     Having thus provided a general discussion, described the double-walled container in detail and illustrated the invention with specific examples of the best mode of making and using it, it will be evident that the invention has provided an effective solution to a difficult and old problem. It is therefore to be understood that no undue restrictions are to be imposed by reason of the specific embodiments illustrated and discussed, and particularly that the invention is not restricted to a slavish adherence to the details set forth herein.