Patent Publication Number: US-5829593-A

Title: Integral thermoplastic package for receiving an article

Description:
FIELD OF THE INVENTION 
     The invention relates generally to the field of packaging. More specifically, the invention relates to the packaging of articles, where the packaging is formed from an integral sheet of transparent thermoplastic material. 
     BACKGROUND OF THE INVENTION 
     It is well known practice to use transparent thermoplastic material in the packaging of articles such as digital camera flash cards (memory cards), which are sold in retail stores. Typically, such packaging incorporates a two piece packaging system, in which the article to be packaged is placed between the two piece package and then is sealed closed either through sonic welding or friction closures utilizing buttons or posts. For the distributor of the packaged article, the two piece packaging system is simple, inexpensive and provides for easy display for the consumer. However, this type of packaging system lends itself to easy pilferage. Often shoplifters are able to remove the contents of the package virtually unnoticed. The shoplifters are able to ply the package open at the point where the two pieces connect. 
     It has been found that an integral package composed of multiple sections would provide for more structural integrity. U.S. Pat. No. 5,595,300, entitled Apparatus for Holding and Dispensing Flat Articles, shows an integral package designed to allow both easy viewing and easy opening at one end for dispensing of flat articles. It would be useful to have an integral design which would discourage easy opening and consequential pilferage. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to overcoming one or more of the problems set forth above. Briefly summarized, the present invention provides a package which is easy to manufacture, but increases the level of difficulty of disassembly to prevent pilferage. 
     This object is achieved by an integral sheet formed of a thermoplastic material molded to form a package for an article, comprising: 
     three tray portions including a middle tray portion and first and second end tray portions; 
     the middle tray portion having a first receiving cavity and arranged to define first means for receiving the article wherein the first article receiving means is of a size less than the size of the first receiving cavity; 
     the first end tray portion having a mating surface and defining a second means for receiving the article wherein the second article receiving means is of a size less than the size of the mating surface, and a first hinge connected to the middle tray portion which permits the first end tray portion to be inserted into the first receiving cavity of the middle tray portion with the first and second article receiving means aligned to secure the article, the mating surface of the first end tray portion after being inserted into the first receiving cavity of the middle tray portion defining a second receiving cavity; and 
     the second end tray portion being at least half the length of the middle tray portion and having a second hinge connected to the middle tray portion which permits the second end tray portion to be inserted into the second receiving cavity, whereby a package for the article is formed. 
     A feature of the present invention is to hinge the first and second end tray portions to the middle tray portion to permit the first end tray portion to be inserted into the middle tray portion and the second end tray portion to be inserted into the cavity created by the insertion of the first end tray portion into the middle tray portion. 
     Another feature of the present invention is to provide a slot between the bases of the assembled end tray portions for the storage of flat paper articles to accompany the packaged article. 
     These and other aspects, objects, features and advantages of the present invention will be more clearly understood and appreciated from a review of the following detailed description of the preferred embodiments and appended claims, and by reference to the accompanying drawings. 
     ADVANTAGES 
     An advantage of the present invention is to provide a package, for receiving articles such as digital camera flash cards, which includes three integrally molded thermoplastic tray portions that can be readily assembled to receive an article but are relatively difficult to disassemble without drawing attention. 
     Another advantage of the present invention is that the tray portions are made of a material which is recyclable. The consumer is able to discard the packaging in recycle collection bins along with other household recyclable products. It is possible to use other materials, such as PVC and polystyrene, to manufacture this package, but these materials are negatively perceived by society because of their inability to be recycled. 
     A further advantage of the present invention is that the present invention is inexpensive to manufacture. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The aforementioned aspects of the present invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings showing a preferred embodiment wherein: 
     FIG. 1 is a top view showing an unassembled package in accordance with the present invention; 
     FIG. 2 is a sectional view taken along the line 2--2 of FIG. 1; 
     FIG. 3 is a view of unassembled package of FIG. 1; 
     FIG. 4 is a view of partially assembled package; 
     FIG. 5 is a view of the assembled package of FIG. 1; 
     FIG. 6 is a cross section taken along lines 6--6 of the partially assembled package shown in FIG. 4; and 
     FIG. 7 is a cross section taken along lines 7--7 of the assembled package shown in FIG. 5. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to FIG. 1, a package 10 is formed from an integral sheet 12 of a thermoforming material. For example, the thermoforming integral sheet 12 is made of a glycol modified polyethylene terphthalate material (known as PETG). It has been found preferable to have the thermoplastic material transparent and capable of being molded in a single injection molding operation. The PETG material is preferable because of its recycling ability. 
     The package 10 has three tray portions including a middle tray portion 14 and first and second end tray portions, 16 and 18 respectively. With reference to FIGS. 1 and 2, the middle tray portion 14 has a first base 20 formed with a first article receiving means, such as a recess 22, and first walls 24 a, b, c, d arranged with respect to the first base 20 to define a first receiving cavity 26. As shown, the first walls 24 a, b, c, d are arranged to form the sides of the first receiving cavity 26. 
     The first end tray portion 16 has a second base 28 formed with a second article receiving means, such as a recess 30. The first end tray portion 16 has second walls 32 a, b, c, d arranged with respect to the second base 28 to define a mating surface 34. As shown in FIG. 2, the first wall 24a and second wall 32d are connected to form a first hinge 36. As shown in FIGS. 3 and 4, and in cross section in FIG. 6, the first hinge permits the first end tray portion 16 to be folded according to the arrow 35 and inserted into the middle tray portion 14 with the first and second receiving recesses 22 and 30 aligned to secure an article 60. While the first hinge 36 may be a single hinge, the first hinge 36 is preferably made to form a double hinge as shown more clearly in FIG. 2 and FIG. 3. The double hinge is important because the PETG material is relatively thick and the double hinge allows the tray portions to bend 180 degrees and fold onto themselves. As shown in FIGS. 2 and 4, the opposite side of the mating surface 34 of the first end tray portion 16, particularly after being inserted into the first receiving cavity 26 of the middle tray portion 14, defines a second receiving cavity 48. 
     The second end tray portion 18 has a third base 38 and third walls 40 a, b, c, d arranged with respect to the third base 38 to form a third cavity 42. As shown in FIG. 5, lips 44 a, b, c are formed on three of the third walls 40 a, b, c. The third base 38 has a length less than the length of the second base 28. Preferably, this length is at least half the length of the first base 20 of the middle tray portion 14. Also shown in FIG. 5, it is also preferred to have the second end tray portion 18 to cover at least part of the aligned article receiving recesses 22 and 30. As shown in FIGS. 2 and 4, and in cross section in FIG. 7, the first wall 24d and the third wall 40d are connected to form a second hinge 46 which permits the second end tray portion 18 to be inserted into the second receiving cavity 48 according to the arrow 49. As in the case of the first hinge 36, the second hinge 46 is preferably a double hinge. 
     As shown in FIG. 5, when the package is assembled, the lips 44 a, b, c, engage the top of the second walls 32 c, b of the first end tray portion 16 forming a slot 50 between the second and third bases 28 and 38 of the first end tray portion and the second end tray portion respectively. A ledge 59 on the bottom of the third base 38 also helps to establish the slot 5D. As shown in FIG. 2, dimension d1 defining the thickness of the third cavity 42 is less than dimension d2 defining the thickness of the second receiving cavity 48, such that when the second end tray portion 18 is folded into the second receiving cavity 48, the difference between d1 and d2 creates the slot 50, which allows for the storage of the flat articles (such as instructions) to accompany the packaged article. 
     As shown in FIGS. 1 and 2, the middle tray portion 14 is molded with first post receiving recesses 52 and the first end tray portion 16 has first posts 54 corresponding to the first post receiving recesses 52. As shown in FIG. 3, when the mating surface 34 of the first end tray portion 16 is inserted into the first receiving cavity 26 of the middle tray portion 14 according to the arrow 35, the corresponding first posts 54 are inserted in the first post receiving recesses 52 to secure the first end tray portion 16 to the middle tray portion 14. As best shown in cross section in FIG. 6, one of the first posts 54 defines a one second post receiving recess 56. As shown in FIGS. 2 and 6, the second end tray portion 18 has a second post 58 positioned on a ledge 59 formed on the second end tray portion 18, corresponding to the second post receiving recess 56. As shown in FIG. 4, when the second end tray portion 18 is inserted into the second receiving cavity 48 according to the arrow 49, the second post 58 is inserted into the second post receiving recess 56 to secure the second end tray portion 18 to the first end tray portion 16 (as shown in FIG. 7). As shown in FIG. 5 this creates an assembled package 62, which secures and displays the packaged article 60 and the accompanying flat paper articles 64. As shown in the figures, the package is assembled and sealed using friction closures between posts and recesses, but sonic welding at appropriate points can also be used to seal the package. Sonic welding is achieved by emitting ultrasonic waves which create heat and melt the plastic. 
     Due to the interconnectivity of the three tray portions using the posts, recesses, and friction closures the assembled packaged curtails pilfering. The assembled package design comprising the tray portions being folded onto each other and then fastened together with posts causes the package to be sealed tighter. Thus, the tighter sealed integral package makes it more difficult for shoplifters to remove the article packaged within without completely disassembling the package and drawing attention to themselves. 
     The invention has been described with reference to a preferred embodiment. However, it will be appreciated that variations and modifications can be affected by a person of ordinary skill in the art without departing from the scope of the invention. 
     PARTS LIST 
     10 package 
     12 integral sheet 
     14 middle tray portion 
     16 first end tray portion 
     18 second end tray portion 
     20 first base 
     22 first article receiving recess 
     24a, b, c, d first walls 
     26 first receiving cavity 
     28 second base 
     30 second article receiving recess 
     32a, b, c, d second walls 
     34 mating surface 
     35 arrow 
     36 first hinge 
     38 third base 
     40a, b, c, d third walls 
     42 third cavity 
     44a, b, c lips 
     46 second hinge 
     48 second receiving cavity 
     49 arrow 
     50 slot 
     52 first post receiving recess 
     54 first posts 
     56 second post receiving recess 
     58 second posts 
     59 ledge 
     60 flat article 
     62 assembled package 
     64 accompanying paper articles