Abstract:
A method and apparatus for packaging compact discs for portable storage. A walled enclosure is provided, the walled enclosure having a floor and a wall enclosing an extremity of the floor. A compact disc storage plate adaptable for holding a compact disc is also provided. The compact disc storage plate is pivotally mounted within the walled enclosure. The walled enclosure may have a floor with a floor recess adaptable for holding a first compact disc and a wall enclosing the extremity of the floor, the floor having hinge slots therethrough adjacent the wall. A compact disc storage plate may also be provided having a plate recess adaptable for holding a second compact disc and having hinge tabs at a plate end. The compact disc storage plate may then be pivotally mounted to the floor at the hinge slots by engaging the hinge tabs into the hinge slots.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S)  
       [0001]    The application claims priority to and the benefit of Application No. 60/350,210 filed on Jan. 18, 2002 in the United States Patent and Trademark Office. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The present invention relates to the field of compact disc (CD) packaging, and in particular, CD packaging having a multi-CD portable storage capacity.  
           [0003]    CDs have become a medium of choice for audio and data recordings. Conventional portable CD storage cases typically store a single CD. One prior art single CD storage case, the DiscPak (TM)CD package manufactured by CPU, Inc. of Arden, N.C., is seen in simplified perspective view in FIG. 1. CD package  10  includes bottom cover  12  having a recessed bottom cover floor  14 . Bottom cover floor  14  includes a further shallow recess  15  for receiving the CD therein, shown in more detail in FIG. 17. Top cover  16  is pivotally attached to bottom cover  12 . Rosette  18  having a plurality of radially extended flexible catch pawls is centered in shallow recess  15 . Rosette  18 , shown in more detail in FIGS. 15 a  and  15   b,  aligns a standard CD central hole such that the CD can be stored in the shallow recess. A stored CD is removed from the shallow recess by depressing the center of the radially extended flexible catch pawls to cause the catch pawls to retreat and release the CD. The marketing attractiveness of CD package  10  is its external appearance having a look/feel comparable to that of a book, whose top cover  16  is similar to that of a book front cover.  
           [0004]    As the capacity of content to be stored on CDs increase, multiple CDs are needed to capture the total content. Accordingly, a need for storage cases having a multi-CD storage capacity became needed. FIG. 2 depicts a prior art multi-CD storage case. CD case  20  includes an integrally formed foldable cover having a first section  22 , a second section  24  and a middle section  26 . A separation plate  28  is mounted into middle section  26 . First section  22  has a first rosette  30  formed at a center of an inner face thereof for releaseably holding a CD. Similar to the configuration of first section  22 , second section  24  has second rosette  32  formed at a center of an inner face thereof for releaseably holding another CD. Plate  28  has third rosette  34  and a fourth rosette (not shown) formed at a center of one face and on the other face thereof for holding a third and fourth CD respectively. Plate  28  has a plurality of slots  36  formed along one edge for engaging middle section  26 . Plate  28  is inserted into middle section  26  and engage catching elements (not shown) in middle section  26 . When the first cover and second cover are folded inwardly together about middle section  26 , a closed storage case if formed for the four CDs inserted on the respective rosettes. However, this multi-CD (four) storage case is limited to storing only up to four CDs. It also has limited marketing appeal, being close in appearance to that of the standard well-known “jewel” CD case.  
           [0005]    While the prior art may deal with a multi-CD storage case adapted for up to four CD storage, it does not address the need for a marketing attractive multi-CD storage package which can accommodate at least five CDs being stored therein and which can be included within a mailing wrapped package for mailing using 0.7501″ maximum thickness U.S. Postal Service mail rates. The invention as described herein provides a simple, cost effective, easy to install and use multi-CD storage package solution to meet such need.  
         SUMMARY OF THE INVENTION  
         [0006]    A method and apparatus packaging compact discs for portable storage is provided. A walled enclosure is provided, the walled enclosure having a floor and a wall enclosing an extremity of the floor. A compact disc storage plate adaptable for holding a compact disc is also provided. The compact disc storage plate is pivotally mounted within the walled enclosure.  
           [0007]    In accordance with an aspect of the present invention, a walled enclosure is provided, the walled enclosure having a floor with a floor recess adaptable for holding a first CD and a wall enclosing the extremity of the floor, the floor having hinge slots therethrough adjacent the wall. A CD storage plate is also provided having a plate recess adaptable for holding a second CD and having hinge tabs at a plate end. The CD storage plate is pivotally mounted to the floor at the hinge slots by engaging the hinge tabs into the hinge slots.  
           [0008]    Another aspect of the present invention includes providing a second CD storage plate having a second plate recess adaptable for holding a third CD and having second plate hinge tabs at a second plate end. Second hinge slots through the floor are also provided, the second hinge slots being located adjacent the wall. The second CD storage plate is pivotally mounted to the floor at the second hinge slots by engaging the second hinge tabs into the second hinge slots.  
           [0009]    In accordance with a further aspect of the present invention, the hinge slots each provide an access to a surface below the adjacent wall below the floor. The hinge tabs each include a hinge tab insert tip for guiding a hinge tab into a hinge slot. The hinge tab insert tip has an arc surface extending to a first shoulder. The arc surface upon hinge tab insertion flexes the adjacent wall from a relaxed wall position to an outwardly flexed wall position. The first shoulder engages the surface below the adjacent wall below the floor upon insertion of the first shoulder through the hinge slot and the adjacent wall returning from the outwardly flexed wall position to the relaxed wall position. Disengagement of the pivotally attached CD support plate from the floor is thereby prevented. The hinge tabs each further include a second arc surface extending from the first shoulder to a tapered second shoulder. The second arc surface, upon a moving of an inserted CD support plate to a position generally perpendicular to the floor, flexes the adjacent wall from a relaxed wall position to an outwardly flexed wall position. The tapered second shoulder engages the surface below the adjacent wall and below the floor upon the inserted CD support plate reaching the position generally perpendicular to the floor and the adjacent wall returning from the outwardly flexed wall position to the relaxed wall position. Disengagement of the CD support plate from the position generally perpendicular to the floor is semi-rigidly prevented in the absence of force applied to the CD support plate.  
           [0010]    In accordance with another aspect of the present invention, the CD storage plate includes a clearance slot therethrough positioned and dimensioned to allow clearance of an adjacent CD storage plate rosette when an inserted CD storage plate is layered upon an adjacent inserted CD storage plate or layered upon the floor.  
           [0011]    In accordance with a still further aspect of the present invention a plurality of compact disc storage plates are provided, each compact disc storage plate being adaptable for holding a compact disc. Each compact disc storage plate is pivotally mounted within the walled enclosure.  
           [0012]    In another further aspect of the present invention the walled enclosure has a floor with a floor recess adaptable for holding a first CD and a wall enclosing the extremity of the floor. The floor has a first hinge step adjacent the wall. The first hinge step has first hinge slots through the first hinge step. The floor also has second hinge slots on the floor adjacent the first hinge step. A first CD storage plate is provided having a first plate recess adaptable for holding a second CD and having first plate hinge tabs at a first plate end. A second CD storage plate is provided having a second plate recess adaptable for holding a third CD and having second plate hinge tabs at a second plate end. The first CD storage plate is pivotally mounted to the first hinge step by engaging the first plate hinge tabs into the first hinge slots. The second CD storage plate is pivotally mounted to the floor by engaging the second plate hinge tabs into the second hinge slots. A third CD storage plate is provided having a third plate recess adaptable for holding a fourth CD and having third plate hinge tabs at a third plate end. A fourth CD storage plate is provided having a fourth plate recess adaptable for holding a fifth CD and having fourth plate hinge tabs at a fourth plate end. A second hinge step is provided. The second hinge step has third hinge slots through the second hinge step. The third hinge slots are located adjacent the wall. Fourth hinge slots are provided on the floor adjacent the second hinge step. The third CD storage plate is pivotally mounted to the second hinge step by engaging the third plate hinge tabs into the third hinge slots. The fourth CD storage plate is pivotally mounted to the floor by engaging the fourth plate hinge tabs into the fourth hinge slots.  
           [0013]    As such, a book-like CD storage package is provided with means to add one or more additional CDs to a single book-like CD storage package, thus providing flexibility of packaging without the need to change a basic CD book-like packaging size or shape. The plate inserts are in essence a “snap in” design for easy (and perhaps automated) assembly and have a catch in the hinge area which keeps the inserts in the full open position while removing or replacing a CD beneath them. Once in place, the inserts are very difficult to remove and will not come loose during shipping and handling. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]    [0014]FIG. 1 shows a prior art portable CD storage case.  
         [0015]    [0015]FIG. 2 shows a prior art multi-CD storage case.  
         [0016]    [0016]FIG. 3 depicts a general concept of the present invention.  
         [0017]    [0017]FIGS. 4 a - 4   c  show a bottom view, top view and side view respectively of a CD storage plate in accordance with the present invention.  
         [0018]    [0018]FIG. 5 shows details of a hinge tab in accordance with the present invention.  
         [0019]    [0019]FIGS. 6 a - 6   c  show a bottom view, top view and side view respectively of a bottom cover in accordance with the present invention.  
         [0020]    [0020]FIG. 7 shows a simplified embodiment of the present invention having two CD storage plates.  
         [0021]    [0021]FIG. 8 shows details of a hinge slot area in accordance with the present invention.  
         [0022]    [0022]FIGS. 9 a - 9   c  show an assembly sequence of the insertion of a hinge tab into a hinge slot in accordance with the present invention.  
         [0023]    [0023]FIGS. 10 a - 10   c  show a pivoting sequence of a CD storage plate inserted in a hinge slot in accordance with the present invention.  
         [0024]    [0024]FIG. 11 shows another embodiment in accordance with the present invention.  
         [0025]    [0025]FIGS. 12 a - 12   c  show a bottom view, top view and side view respectively of a bottom cover in accordance with the present invention.  
         [0026]    [0026]FIG. 13 shows details of a pair of hinge slots area in accordance with the present invention.  
         [0027]    [0027]FIG. 14 shows a simplified view of multiple CD storage plates inserted and layered upon each other in accordance with the present invention.  
         [0028]    [0028]FIG. 15 shows details of a typical rosette in accordance with the present invention.  
         [0029]    [0029]FIG. 16 shows details of a typical CD ejector area in accordance with the present invention.  
         [0030]    [0030]FIG. 17 shows details of a typical bottom cover floor recess area in accordance with the present invention.  
         [0031]    [0031]FIG. 18 shows details of a typical CD storage place recess area in accordance with the present invention.  
         [0032]    [0032]FIG. 19 shows a simplified embodiment of an extended rectangular shape bottom cover with multiple CD support plates inserted therein in accordance with the present invention.  
         [0033]    [0033]FIG. 20 shows another embodiment in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0034]    Referring to FIG. 3, there is depicted the general concept of the present invention. Prior art CD package  10 , as seen in FIG. 1, is adapted to accept CD storage plate  40  which is configured to hold thereon CD  42 . CD storage plate  40  is pivotally hinged at end  44  through bottom cover floor  14  to allow it to swing through arc  46  spanning from a generally horizontal position adjacent to bottom cover floor  14  to a position generally perpendicular to bottom cover floor  14 .  
         [0035]    Referring to FIGS. 4 a - 4   c,  there is depicted a bottom view, top view and side view respectively of CD storage plate  40 . CD storage plate  40 , formed by typical ejection-molding a semi-flexible plastic, such as polystyrene, and dimensioned as shown in FIGS. 4 a - 4   c,  has a radial end  52  and an opposite straight end  54 . One surface, shown in FIG. 4 b,  has a recess area  48 , shown in more detail in FIG. 18, which is a section view C-C of FIG.  4   b,  and rosette  50 , which are comparable in function to recess  15  and rosette  18  depicted in FIG. 1, for accepting and holding in place a CD to be inserted onto CD storage plate  40  for storage within CD package  10  in addition to a CD which is storable in recess  15  of bottom cover floor  14 . CD storage plate  40  includes a pair of hinge tabs  56 , shown in more detail in FIG. 5. CD storage plate  40  also includes slotted through-hole  58  which is dimensioned and located to provide a clearance hole for an adjacent rosette when the storage plate is lowered to its generally horizontal position. This enables tighter layering of CD storage plates by avoiding interference between the CD storage plate and an adjacent layer&#39;s rosette or floor rosette. CD storage plate  40  also may include one or more typical CD ejector recesses  60 , shown in more detail in FIG. 16 to allow a finger grip of the edge of a stored CD to easier removal of the CD from the respective rosette and recess.  
         [0036]    Referring to area  62  of FIG. 4 c,  there is shown and dimensioned in FIG. 5 more detail of hinge tab  56 . Hinge tab  56  protrudes from straight end  54  at connection area  51  and includes insert tip  63 . Insert tip  63  is formed at a junction of insert taper surface  64  and insert arc surface  66 . Insert arc surface  66  ends at remove prevention edge stop  68 . Pivot facilitation arc surface  70  joins remove prevention edge stop  68  with vertical lock support taper surface  72 .  
         [0037]    Referring briefly to FIGS. 6 a - 6   c,  there is shown and dimensioned bottom cover  12 , as seen in FIGS. 1 and 3, adapted for accepting either one or two CD storage plates  40  into bottom cover floor  14 , e.g., one CD storage plate  40  being pivotally attachable at end  80 , and another CD storage plate  40  being pivotally attachable at end  82 . Slots “A”, two at end  80  and two at end  82 , accept hinge tabs  56  of a CD storage plate  40 . FIG. 7 shows the embodiment with two CD storage plates  40   a,    40   b  being pivotally attached, each holding a respective CD  42   a,    42   b,  each being able to swing through a respective arc  46   a,    46   b.  Bottom cover floor  14  holds CD  42   c  in the recess therein. When CD storage plate  40   b  is swung into a generally horizontal position relative to cover floor  14 , it lies upon and partially covers CD  42   c.  In turn, when CD storage plate  40   a  is swung into a generally horizontal position relative to cover floor  14 , it lies upon and partially covers CD  42   b.  In essence, a stacking of the CD support plates within the walls of bottom cover  12  occurs.  
         [0038]    Turning back to FIGS. 6 a - 6   c,  bottom cover floor  14  is formed by typical ejection-molding using a semi-flexible plastic, such as polystyrene, with support ribs  84  being formed on the side opposite recess  15 . Rosette  18  is situated within recess  15  for accepting a CD for storage thereon. A representative slot “A” area and dimensioning thereof are shown in more detail in FIG. 8, an enlargement of area  90  of end  82  seen in FIG. 6 c  and section A-A in FIG. 6 a.  Slot thru “A” is provided adjacent wall  94  in a tapered down 0.010″ thickness portion  96  of bottom cover floor  14 . Typical 13° taper  93  provides clearance for the hinge tab when CD storage plate is in a perpendicular lock position, as will be seen and described in conjunction with FIG. 10 c  below. Rib  84  provides support for bottom cover floor  14 . Wall  94  includes wall catch surface  98 , typically a 0.020″ minimum surface.  
         [0039]    Referring now to FIGS. 9 a - 9   c,  a depiction is provided of the assembly sequence, typically via automatic assembly-line manufacturing machine, of hinge tab  56  of CD storage plate  40  being inserted into slot “A” of bottom cover floor  14 . In FIG. 9 a,  hinge tab  56  is depicted just as insert tip  63  is progressing into slot A. In FIG. 9 b,  as insert tip  63  proceeds through slot A, insert arc surface  66  displaces flexible plastic wall  94  adjacent the slot A. In FIG. 9 c,  as the front portion of hinge tab  56  is fully inserted through slot A, remove prevention edge stop  68  catches on wall catch surface  98  when wall  94  returns back to its pre-flexed state. When a tandem pair of hinge tabs  56  are fully inserted CD storage plate  40  is secured at its end on bottom floor  14 .  
         [0040]    Referring now to FIGS. 10 a - 10   c,  the pivoting of a CD storage plate  40  from a generally horizontal position after insertion, e.g., a typical “CD stored” state, to a generally perpendicular state, to allow access to a lower stacked CD or cover floor stored CD, is depicted. FIG. 10 a  shows CD storage plate  40  fully inserted through slot A and resting on bottom floor  14  (comparable to a fully inserted state as depicted in FIG. 9 c ). In FIG. 10 b,  CD storage plate  40  is manually moved through arc  46  wherein pivot facilitation arc surface  70  forces wall  94  to flex. In FIG. 10 c,  CD storage plate  40  is locked into a perpendicular position when pivot facilitation arc surface  70  passes wall catch surface  98  such that vertical lock support taper surface  72  catches wall catch surface  98  when wall  94  returns back to its pre-flexed state. Vertical lock support taper surface  72  is tapered at 30° to provide a firm, semi-stiff but smooth locking—unlocking capability by manual force applied to CD support plate  40 , in lieu of a rigid locking 90° junction as is provided by remove prevention edge stop  68  for keeping CD storage plate  40  pivotally attached to bottom cover floor  14 . The locking of the CD storage plate at 90° allows it to stay in place and facilitate removal of a CD located in a lower layer CD storage plate, or bottom cover floor recess.  
         [0041]    Referring now to FIG. 11, another embodiment of the present invention is provided. Rather than having merely a single CD storage plate  40  for storably holding CD  42  and being pivotally hinged to swing through arc  46  at one end of bottom cover floor  14 , a second CD storage plate  100  is provided to pivotally swing through arc  102 . Bottom cover floor  14  has one end built up to provide hinge step  104  for engaging a second CD storage plate  100 . A comparable hinge step  106  is similarly built up at the opposite end of bottom cover floor  14  for comparably engaging a further CD storage plate (not shown), much like that seen in FIG. 7.  
         [0042]    Referring to FIGS. 12 a - 12   c,  there is shown and dimensioned bottom cover  12  as seen adapted in FIGS. 6 a - 6   c,  but further adapted to accommodate hinge steps  104 ,  106 . Walls  110 ,  112  are lengthened to accommodate the additional CD support plates to be inserted within bottom cover  12 . Rather than one pair of slots “A” being provided at each end as seen in FIGS. 6 a - 6   c,  two pairs of slots “B” are provided at each end as seen in FIGS. 12 a - 12   c.  A representative slot “B” area  114  and dimensioning thereof are shown in more detail in FIG. 13, an enlargement of area  114  seen in FIG. 12 c  and section B-B in FIG. 12 a.    
         [0043]    Referring to FIG. 14, there is shown in cutaway section view a depiction of the embodiment utilizing bottom cover  12  adapted to accommodate hinge steps wherein five CDs are stored utilizing a pair of CD storage plates inserted at each end of bottom cover  12 , only one of the comparable two ends being shown in the cutaway section view. First CD  120  is located in recess  15 . CD storage plate  122  has its hinge tab  124  inserted into a slot B in bottom cover floor  14 . CD storage plate  126  is inserted into a comparable slot B in bottom cover floor  14  at the end opposite (not shown) to that where hinge tab  124  is inserted, such that in its generally horizontal pivot position of CD storage plate  126  lies stacked upon CD storage plate  122 . CD storage plate  130  has its hinge tab  132  inserted into a slot B in hinge step  106  of bottom cover floor  14 . CD storage plate  134  is inserted into a comparable slot B in bottom cover floor at the end opposite (not shown) to that where hinge tab  132  is inserted, such that in the generally horizontal pivot position of CD storage plate  134  it lies stacked upon CD storage plate  130 . Accordingly, this embodiment provides for the pivotal stacking of five CDs in a 0.685 area. Therefore, with a top cover  16  (as seen in FIG. 1) typically of three thicknesses of 0.018″ card stock, utilized with the 0.685 wall thickness bottom cover floor adapted with hinge steps in addition to any such card stock applied to bottom cover  12 , a five-CD package can readily meet the 0.750″ maximum package size postal service mailing rate.  
         [0044]    Those skilled in the art can appreciate that, while several embodiments of the present invention has been described, various alternatives can be utilized to practice the invention. For example, while embodiments providing for up to four CD storage plates have been shown, the dimensions of the bottom cover floor can be expanded in length, width and height to accommodate further hinge steps allowing for further layering of CD storage plates within the bottom cover. Additional hinge steps could be built upon lower steps in a staircase fashion. While the slots and hinge steps have been shown at two opposing ends, slots and hinge steps could also be provided at one or both of the sides of the bottom floor. Various size slots and hinge tabs for insertion therein can be provided. While slots and tabs form the hinge in the embodiments described herein, other hinge mechanisms are possible. The material forming the CD storage plate and/or the bottom cover floor can be made from various semi-flexible plastics in addition to polystyrene described herein, such as polypropylene, polyethylene, or the like. Further, the embodiments described and shown herein include a generally rectangular CD package, simulating the appearance of a book. However, the CD package can be of other shapes, such as square or extended rectangle, provided the surface area within the shape is large enough to enclose one or more pivotally mountable CD storage plates shaped to accommodate a CD. FIG. 19 depicts in simplified form an extended rectangle walled enclosure  200 , wherein CD storage plates  202 ,  204 ,  206  are installed therein coupling their respective hinge tabs to the floor of walled enclosure  200 . As can be seen, CD storage plates are pivotally mounted along the long walls of rectangular enclosure  200 , while CD storage plate  206  is pivotally mounted along a short wall of rectangular enclosure  200 . FIG. 20 depicts another embodiment of the present invention wherein storage for five CDs are depicted, one being stored in the floor and four others being stored in respective storage plates, in addition to top cover  16  having the ability to have one or more cover panels, one panel  250  being shown as an example. The cover panel(s) can include additional text, graphics, photographs and the like for depicting the contents of the CDs being stored therein.