Patent Abstract:
A fastener system includes a toy product, a support platform, and a plug that engages a keyhole formed into the product. The plug includes a base and a pronged key extending from the base. The support platform includes a through-hole that permits the passage of the key into the packaging. One or more integrally-formed biasing members are located on the base of the plug to draw the key toward the product and create a secure connection. The pronged key may be formed from a plastic material and configured such that it plastically deforms but remains attached to the key when and predetermined force is applied to the key to pull the key from a misaligned position with respect to the key hole.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of non-provisional application Ser. No. 12/906,413, entitled “Product Packaging with Releasable Fastener” and filed on 18 Oct. 2010, which is a continuation of non-provisional application Ser. No. 12/249,235, entitled “Product Packaging with Releasable Fastener” and filed on 10 Oct. 2008. The disclosure of each of the above applications is hereby incorporated by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention is directed toward product packaging and, in particular, to toy product packing including a releasable, reusable product fastener. 
     BACKGROUND OF THE INVENTION 
     Products such as toys are generally placed in packaging that provides protection to the toy, as well as and provides a means to easily display the toy. The toys are often held within the packaging by wire tie elements, which surround the toy and are twisted together to hold the toy in place in the packaging. This design works for small toys; however, large toys require a significant amount of wire and, because of the shape of the toys, it may not be practical to place the wire around the toy to retain it in its packaging. In addition, removal of such a large amount and number of wire tie elements is tedious and time-consuming. Thus, it is desirable to create a fastening system that secures a product within its packaging, but is easily manipulated by a user to remove the product therefrom. 
     SUMMARY OF THE INVENTION 
     A fastener system for product packaging is disclosed. The system includes a product, a support platform, and a plug that engages a keyhole formed into the product. The plug includes a base and a key extending from the base. The support platform includes a through-hole that permits the passage of the key into the packaging. In operation, a product is oriented on one side of the support platform, and the plug is oriented on an opposite side of the support platform. The key is inserted though the packaging (via the through-hole), and into the keyhole formed in the product. The key is then rotated to misalign its fingers with the openings in the keyhole, preventing the key&#39;s exit from the keyhole. Biasing members located on the base of the plug draw the key toward the product to create a secure connection. With this configuration, a product may be secured within packaging without the use of wire tie fasteners. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an exploded view of a product fastening system in accordance with an embodiment of the present invention. 
         FIGS. 2A and 2B  illustrate a plug in accordance with an embodiment of the present invention. Specifically,  FIG. 2A  illustrates an isolated, top perspective view of a plug component of the fastening system in accordance with an embodiment of the present invention.  FIG. 2B  illustrates a bottom perspective view of the plug of  FIG. 2A . 
         FIG. 3  illustrates a support platform in isolation, showing a close-up of the through-holes. 
         FIGS. 4A and 4B  illustrate a portion of a wall forming the product if  FIG. 1 . Specifically,  FIG. 4A  illustrates a side view of the product wall, while  FIG. 4B  illustrates an interior view of the product wall of  FIG. 4A . 
         FIG. 5A  illustrates an interior view of the product, showing the plug/key oriented in an unlocked position. 
         FIG. 5B  illustrates an interior view of the product, showing the plug/key oriented in a locked position. 
         FIG. 6A  illustrates a cross-sectional view of the product, showing the insertion of the key into the keyhole of the product. 
         FIG. 6B  illustrates a rear perspective view of the support platform, showing orientation of the plug in locked/unlocked positions. 
         FIGS. 7A and 7B  illustrate a plug/key in accordance with another embodiment of the present invention. 
         FIG. 8  illustrates a side perspective view of a key/plug in accordance with the present invention, indicating the application of shear forces thereon. 
     
    
    
     Like reference numerals have been used to identify like elements throughout this disclosure. 
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  illustrates and exploded view of a product fastening system in accordance with an embodiment of the invention. As illustrated, the system  100  includes a key or plug, a product support or platform  120 , and a product  130 . By way of example the system  100  may include one or more plugs  110 A,  110 B,  110 C, each having a stem of a predetermined length. The plugs  110 A- 110 C are configured to selectively secure the product  130  to the product support  120 . Referring to  FIGS. 2A and 2B  (showing top and bottom views, respectively), the plug  110 A includes a base  200  and a shaft or stem  210  extending distally from the base  200 . The base  200  may be in the form of a plate or disk having a first or top surface  220  and a second or bottom surface  230 . The shaft  210  may be disposed coaxially with the central axis of the base  200 . The distal end  240  of the shaft may further include a first finger  250 A and a second finger  250 B collectively defining a keyed end of the shaft  210 . The base  200  may further include one or more cut-out sections  260  configured to permit gripping of the base utilizing a users fingers. By way of example, the base  200  may include a pair of opposed, curved, cut-out sections  260  formed into the periphery of the base. 
     The plug  110 A may further include one or more biasing members. In the embodiment of  FIGS. 2A and 2B , the plug  110 A may have a first spring  270 A and a second spring  270 B formed into the base  200 . The springs  270 A,  270 B may be positioned along the base periphery such that the first spring  270 A is oriented opposite the second spring  270 B. The biasing members  270 A,  270 B apply a force to the product support  120  and/or the product  130  to increase the tension between the plug  110 A-C and the product  130  (discussed in greater detail below). While a particular configuration spring is illustrated as the biasing member  270 A,  270 B, it should be understood other forms of the biasing member could be utilized such as a flat springs, coil springs, cantilevered springs, leaf springs, etc. 
     The product support or platform  120  provides a surface to which the product  130  may be secured. The product support  120  typically comprises a portion of product packaging, e.g., a wall or a display platform, to which the product  130  is secured. Referring to  FIG. 3 , the product platform  120  may be a generally planar element having a first or outer surface  310  and a second or inner surface  320 . The planar member may include one or more key ports  330  configured to receive the keyed end of a respective plug  110 A- 110 C. That is, the key port  330  possesses a shape and has dimensions suitable to permit the passage of the distal/keyed end  240  of the plug shaft  210 , while preventing the passage of the base  200  therethrough. As illustrated, the port  330  may possess a generally circular shape having a diameter slightly larger than the diameter of the fingers  250 A,  250 B, to permit the fingers to pass therethrough. 
     The product support  120  may further include one or more receptacles or guide tracks configured to receive and/or orient the biasing members  270 A,  270 B on the plug  110 A-C. By way of example, the product support  120  may include a first guide track  340 A and a second guide track  340 B oriented opposite the first guide track  340 A, across the port  330  (i.e., each biasing member  270 A,  270 B may include an associate track  340 A,  340 B with which it mates). The structure of the guide track  340 A,  340 B may be any suitable for its described purpose. In the illustrated embodiment, the guide tracks  340 A,  340 B are each defined by a generally rectangular opening that permits a biasing member  270 A,  270 B to extend through or into the platform  120 . Each guide track  340 A,  340 B is positioned and sized to receive a corresponding biasing member  270 A,  270 B, indicating the orientation of the plug  110 A-C in either a locked or unlocked position (discussed in greater detail below). The product support  120  may be formed from any conventional packaging materials including, but not limited to, plastic, cardboard, wood, etc. 
     The product  130 , e.g., a toy, is configured to selectively mate with the plugs  110 A-C. Referring to  FIGS. 4A and 4B , showing exterior and interior views the product  130 , the product  130  includes a wall  400  having a first or exterior side  410  and a second or interior side  420 . The wall  400  includes one or more keyholes  430  possessing a shape complimentary to that of the distal end  240  of each of the plugs  110 A-C. In the embodiment illustrated in  FIGS. 4A and 4B , the keyhole  430  is a generally elongated slot that receives the fingers  250 A,  250 B of the plug  110 A-C when properly aligned with the slot. The keyhole  430  may be formed on a pedestal  440  extending distally from the interior surface  420  of the product wall  400 . 
     The pedestal  440  may form a corresponding recessed area  450  along the exterior surface  410  of the product wall  400 . The height of the pedestal  440  is not particularly limited, but is typically is sized to correspond with the length of the stem  210  extending form the base  200  of the plug (taking into account the thickness of the product wall  400  as well as the product support  130 ). By way of example, the pedestal  440  may have a height corresponding to the stem of plug  110 A, or may have a height corresponding to the stem of plug  110 B ( FIG. 1 ). Alternatively or addition, no pedestal  440  may be formed into the product wall  400  to permit the keyhole  430  to be generally flush with the product wall  400 . Note that for exemplary purposes, all three examples are shown in  FIGS. 1 ,  4 A, and  4 B. 
     With this configuration, plug  110 A-C selectively engages the keyhole  430  to secure the product  130  to the support  120 . Referring to  FIGS. 5A and 5B , the stem  210  of the plug  110 A-C may be axially inserted into the port  330  of product support  120  and through the keyhole  430  formed in the product  130 . The plug  110 A-C may then be selectively rotated from a first (unlocked) position ( FIG. 5A ), in which the fingers  250 A,  250 B of the plug generally align with the keyhole  430 , to a second (locked) position ( FIG. 5B ), in which the fingers  250 A,  250 B of the plug  110 A-C are not aligned with the keyhole  430 . In the locked position of  FIG. 5B , the plug  110 A-C is secured to the product  130 . To unlock the plug  110 A-C and remove it from the keyhole  430 , the plug  110 A-C is simply rotated in the reverse direction until the fingers  250 A,  250 B of the plug  110 A-C once again align with the slot of keyhole  430 . The stem  210  of the plug  110 A-C is then axially removed from the product  130 . 
     The operation of a fastening system in accordance with the present invention is explained with reference to  FIGS. 6A and 6B .  FIG. 6A  illustrates a cross-sectional view of the system in accordance with an embodiment of the invention. The product  130  is positioned on the second side  320  of the support platform  120 , and the plug  110 A-C is positioned on the first side  310  of the support platform. The port  330  of the support platform  120  is generally aligned with a keyhole  430  of the product  130 , and the plug  110 A-C is axially inserted through the port  330  of the support platform  120  and into the keyhole  430  of the product  130 . The plug  110 A-C may then be rotated to move the plug  110 A-C (by gripping the cut-out sections  260 ) from the unlocked position to the locked position as described above. 
     Referring to  FIG. 6B , illustrating a rear perspective view of the system, the plug  110 A-C may be rotated utilizing finger cut-out sections  260  until the biasing members  270 A,  270 B align with the guide tracks  340 A,  340 B formed into the product support  120 . The biasing members  270 A,  270 B and guide tracks  340 A,  340 B may be oriented such that mating of the biasing members with the guide tracks indicates the fingers  250 A,  250 B of the plug  110  are oriented in their misaligned/locked position with respect to the keyhole  430  of the product  130 . The biasing members  270 A,  270 B apply a downward pressure (from the perspective of  FIG. 6A ) to the plug stem  210 , drawing the distal end  240  of the stem downward, toward the interior surface  420  of the product wall  400 . This, in turn, increases the frictional forces between the fingers of the plug  110 A-C and the product  130 , improving the connection of the product  130  to the product support  120 . The biasing members  270 A,  270 B further function as shock absorbers, adjusting to movement of the packaging during transport and stabilizing the product  130 . 
     To release the product  130  from the product support  120 , the plug  110  is rotated to displace the biasing members  270 A,  270 B from the guide tracks  340 A,  340 B until the fingers  250 A,  250 B are once again axially aligned with the keyhole  430  of the product  130  as described above. The plug  110 A-C may then be removed from the product  130 , which, in turn, may be removed from the support platform  120 . 
       FIGS. 7A and 7B  illustrate a fastening system in accordance with another embodiment of the present invention. As illustrated, the pedestal  440  may include one or more stops to prevent over rotation of the plug  110 A-C, as well as to signal to the user that the plug  110 A-C is in its locked position. Referring to  FIG. 7A , the pedestal  440  may include a first boss  710  and a second boss  720  opposed from the first boss across the keyhole  430 . In operation, as shown in  FIG. 7B , the plug  110 A-C may be inserted into the keyhole  430  and rotated until the fingers  250 A,  250 B of the plug  110 A-C contact the bosses  710 ,  720 . The bosses  710 ,  720 , then, prevent over rotation of the plug  110 A-C. 
     The shaft  210  and fingers  250 A,  250 B of the plug  110 A-C may also configured to prevent the formation of small parts. A “small part” is any object that fits completely into a specially designed test cylinder (2.25 inches long by 1.25 inches wide) that approximates the size of the fully expanded throat of a child under three years old. This specialized definition applies to (1) a whole toy or article, (2) a separate part of a toy, game, or other article, or (3) a piece of a toy or article that breaks off during testing that simulates use or abuse by children. If a “small part” fits completely into the specially designed test cylinder, and the toy or product from which it came is intended for use by children under three years of age, the toy or product is banned because the small part presents a choking hazard. 
     Thus, toys and products intended for use by children less than three years of age must not release pieces that fit completely into the small parts cylinder after impact, flexure, torque, tension and compression testing. These tests simulate the forces that toys and products can/may experience during normal use and abuse by children less than three years of age. If these forces cause parts to break off that fit in the small parts cylinder, those parts are deemed to present a risk of choking, aspiration, or ingestion to children less than three years of age. 
     For this reason, the fingers  250 A,  250 B of the plug  110 A-C are configured to plastically deform when a pressure of at least about 48-56 lbs. is applied to the plug  110 A-C. That is, referring to  FIG. 8 , the fingers  250 A,  250 B of the plug  110 A-C are resilient, thus they tend to flex whenever a downward force is applied to the plug  110 A-C (as indicated by arrows F). As a result, should the plug  110 A-C be oriented in its locked position when a user attempts to draw the plug out of the keyhole  430  with a force of at least about 48-56 lbs., the fingers  250 A,  250 B will plastically deform upward (in a direction D which is opposite to the force F) and remain intact (i.e., the fingers  250 A,  250 B plastically deform to permit removal of the plug  110 A-C from the keyhole  430 , but do not do not break off of the shaft  210 ), preventing the potential for formation of small parts as explained above. Many different materials may be utilized to form the shaft  210  and the fingers  250 A,  250 B of the plug  110 A-C, such as different kinds of plastic and thermoplastics (such as ABS (acrylonitrile butadiene styrene), PPR (polypropylene resin), styrene, nylon, etc.). However in one preferred embodiment, the shaft  210  and the fingers  250 A,  250 B of the plug  110 A-C are formed from PPR and shaped such that when a user attempts to draw a locked plug  110 A-C out of the keyhole  430  with a force of at least about 48-56 lbs., the fingers  250 A,  250 B will plastically deform upward (in a direction D which is opposite to the force F) and remain intact. 
     While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. For example the base  200  may possess any shape and have any suitable dimensions. Though a generally circular, disc-shaped base  200  is illustrated, other shapes may be utilized, including but not limited to polygons. The biasing members  270 A,  270 B may be any suitable for their described purpose. The support platform  120  may be formed of any suitable materials, possess any suitable dimensions, and have any suitable shape. Similarly, the port  330  and the guide tracks  340 A,  340 B may possess any shape of have any dimensions suitable for their described purposed. For example, while a guide track is shown in the figures to be an opening (a pass-through), a guide track may also be defined by a recessed area or notch formed into the support platform  120 . The pedestal  440  may possess any suitable shape and have any suitable dimensions. Specifically, the height of the pedestal  440  may be any suitable for its described purpose. 
     Thus, it is intended that the present invention cover the modifications and variations of this invention that come within the scope of the appended claims and their equivalents. It is to be understood that terms such as “left”, “right” “top”, “bottom”, “front”, “rear”, “side”, “height”, “length”, “width”, “upper”, “lower”, “interior”, “exterior”, “inner”, “outer” and the like as may be used herein, merely describe points of reference and do not limit the present invention to any particular orientation or configuration.

Technology Classification (CPC): 1