Abstract:
A media storage container has at least one media storage tray connected to a flexible cover with a mechanical connection. One embodiment of the media storage container includes two media storage trays connected together with a mechanical connection that traps an inner cover member between the media storage trays to connect the cover to the trays. Embodiments are provided wherein the inner cover member is connected to one outer cover member and two outer cover members.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims priority from U.S. provisional application Ser. No. 60/337,518 filed Dec. 3, 2001; the disclosures of which are incorporated herein by reference. 

   BACKGROUND OF THE INVENTION 
   1. Technical Field 
   The present invention generally relates to media storage containers and, more particularly, to media storage containers that include elements fabricated from paperboard and plastic. Specifically, the present invention relates to a media storage container having plastic media holding trays connected to paperboard cover members without adhesives. 
   2. Background Information 
   Various types of paperboard media storage containers are known in the art. Some of these containers utilize plastic media-holding trays connected to the paperboard cover members. Although some of the devices use connecting arrangements that secure the paperboard to the plastic media holding tray without adhesive, most of the containers known in the art use an adhesive to connect the two elements together. The known media storage containers that form the connection without adhesive leave room for improvement. The art desires that these connections securely hold the rigid media storage trays to the paperboard cover members while being simple to manufacture and assemble. The art also desires this type of media storage container to hold multiple items of recorded media in a single container. 
   BRIEF SUMMARY OF THE INVENTION 
   The invention provides a media storage container that having at least one rigid media storage tray connected to a flexible cover with a mechanical connection. In one embodiment, the invention provides two media holding trays that include elements that snap together to trap a portion of the flexible cover between the trays to hold the cover to the trays. 
   The invention provides one embodiment of the media storage container wherein the spine is split in another embodiment wherein the spine is whole. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       FIG. 1  is a perspective view of the first embodiment of the invention showing the media storage container in its closed configuration. 
       FIG. 2  is a perspective view showing the split spine of the first embodiment of the invention. 
       FIG. 3  is a top plan view of the cover of the first embodiment in an unfolded configuration. 
       FIG. 4  is an end view showing the cover folded to receive the media holding trays. 
       FIG. 5  is a view similar to  FIG. 4  showing the media holding trays connected to the cover. 
       FIG. 6  is a front view of one of the locking fingers taken along line  6 — 6  of  FIG. 5 . 
       FIG. 7  is a section view taken along line  7 — 7  of  FIG. 6 . 
       FIG. 8  is a view similar to  FIG. 5  showing the cover being closed on the media holding trays. 
       FIG. 9  is a perspective view of the second embodiment of the invention showing the spine. 
       FIG. 10  is a top plan view of the cover of the second embodiment of the invention in an unfolded condition. 
       FIG. 11  is an end view of the second embodiment of the cover with the panels being initially folded upon each other. 
       FIG. 12  is an end view of the second embodiment of the invention with the cover folded together and the disc-holding trays being aligned with the cover so that they may be connected together. 
       FIG. 13  is a view similar to  FIG. 12  showing the media holding trays connected to the cover. 
       FIG. 14  is a elevation view taken along line  14 — 14  showing one of the locking fingers of the media holding trays. 
       FIG. 15  is a section view taken along line  15 — 15  of  FIG. 14 . 
       FIG. 16  is a view similar to  FIG. 13  showing the cover in a closed condition. 
   

   Similar numbers refer to similar parts throughout the specification. 
   DETAILED DESCRIPTION OF THE INVENTION 
   The first embodiment of the media storage container is indicated generally by the numeral  10  in  FIGS. 1–8 . Media storage container  10  generally includes a cover  12  and at least one but preferably two media storage trays  14 . Cover  12  is fabricated from a relatively flexible material and may be preferably fabricated from a paper-based material such as paperboard. The paperboard may include smooth outer surfaces with a layer disposed between the smooth outer surfaces. The smooth outer surfaces are useful for displaying printed information about the contents of the media stored by trays  14 . Media storage trays  14  are preferably fabricated from a relatively rigid material such as a plastic. In other embodiments, trays  14  may be fabricated from a paper-based material, a metal, wood, or a variety of other materials known to those skilled in the art. In accordance with one of the objectives of the invention, trays  14  are connected to cover  12  without the use of adhesive. Trays  14  are thus connected to cover  12  with a mechanical connection that forms an interference fit between trays  14  and cover  12 . 
   Cover  12  is fabricated from a single piece of material that is divided into a plurality of panels by living hinges. Cover  12  includes first  20  and second  22  inner cover panels that are configured to fold together in a back-to-back configuration when trays  14  are attached to cover  12 . First panel  20  is connected to second panel  22  with a first living hinge  24 . Living hinge  24  may be formed by scoring the material of cover  12 , may be formed by embossing a line across cover  12 , or by other methods known to those skilled in the art. First and second inner cover panels  20  and  22  each have a height (measured in the direction of reference arrow  26  in  FIG. 3 ) and a width (in the direction of reference arrow  28  in  FIG. 3 ). Height  26  and width  28  are varied as media storage container  10  is designed to hold different types of recorded media. For instance, height  26  and width  28  are equal to one set of dimensions when media storage container  10  is used to hold CDs and dimensions  26  and  28  are equal to a different set of dimensions when media storage container  10  is used to hold DVDs. Media storage container  10  may also be configured to hold VHS tapes, cassette tapes, memory chips, mini discs, and other types of items of recorded media known in the art. 
   First and second inner cover panels  20  and  22  define openings  30  that align with one another when cover panels  20  and  22  are in the back-to-back configuration depicted in  FIG. 4 . In the embodiment of the invention depicted in the drawings, each panel  20  and  22  defines four openings  30  with each opening  30  being disposed adjacent one of the corners of one of panels  20  and  22 . 
   A front outer cover  40  is connected to first inner cover panel  20 . A first spine panel is disposed between front cover panel  40  and first inner cover panel  20 . First spine panel  42  is connected to first inner cover panel  20  with a second living hinge  44 . First spine panel  42  is connected to front cover panel  40  with a third living hinge  46 . First spine panel  42  has a width slightly larger than the thickness of tray  14  so that front cover panel  40  is disposed against the front surface  48  when front cover panel  40  is closed as depicted in  FIG. 8 . 
   Cover  12  also includes a rear cover panel  50  that is connected to second inner cover panel  22 . A second spine panel  52  is disposed between rear cover panel  50  and second inner cover panel  22 . Second spine panel  52  is connected to second inner cover panel  22  with a fourth living hinge  54 . Second spine panel  52  is connected to rear cover panel  50  with a fifth living hinge  56 . Second spine panel  52  has a width substantially equal to first spine panel  42  such that rear cover panel  50  lies against front surface  48  of media storage tray  14  when cover  12  is closed as depicted in  FIG. 8 . 
   Trays  14  are connected to cover  12  with mechanical connections that create an interference fit between trays  14  and cover  12  such that trays  14  are locked to cover  12  once the mechanical connection is created. In the exemplary embodiment, each tray  14  includes a pair of locking fingers  60 . Locking fingers  60  are positioned on trays  14  such that they are aligned with openings  30  as depicted in  FIGS. 4 and 6 . Locking fingers  60  are disposed at opposite corners disposed diagonally across tray  14  such that there are locking fingers  60  disposed at all four corners when two trays  14  are disposed back-to-back as depicted in  FIG. 4 . In this configuration, the tray on the left includes two locking fingers  60  and the tray on the right includes two locking fingers  60 . Both trays.  14  have the same configuration. Each tray  14  also defines a locking ledge  62  as depicted in  FIGS. 6 and 7  that is adapted to receive locking finger  60  in a one-way snap fit connection as depicted in  FIG. 7 . To facilitate this type of locking connection, each locking finger  60  includes an angled surface  64  and a locking surface  66 . Locking surface  66  is disposed substantially perpendicular to the longitudinal direction of locking fingers  60 . 
   Container  10  is thus formed by folding cover  12  into the configuration depicted in  FIG. 4  by folding cover panels  20  and  22  against each other about living hinge  24 . Front cover panel  40  and rear cover panel  50  are then moved to the open position as depicted in  FIG. 4 . Trays  14  are then aligned in a back-to-back configuration with locking fingers  60  extending toward each other. Locking fingers  60  are aligned with openings  30  and trays  14  are brought together with locking finger  60  disposed through openings  30  as depicted in  FIG. 5 . Locking fingers  60  are locked into place as depicted in  FIGS. 6 and 7 . Covers  40  and  50  are then closed to form the container as depicted in  FIG. 8 . As described above, each tray  14  may be configured to receive and hold a CD, a DVD, a VHS tape, a cassette tape, a microchip, or any other type of item of recorded media known now in the art or developed in the future. When container  10  is formed in this manner, its rear spine is split by first living hinge  24  as depicted in  FIG. 2 . Container  10  includes the advantage that the user of container  10  may print material on the inside and outside surfaces of covers  40  and  50  as well as on both spine panels  42  and  52 . 
   Another advantage presented by container  10  is that trays  14  are substantially identical thus allowing a single part to be used for both pieces. If desired, one tray  14  may include all of locking fingers  60  with the other tray including all locking ledges  62 . In other embodiments of the invention, container  10  may be formed with a single tray  14  and locking fingers  60  may be snap-fit into retaining elements that simply hold the position of tray  14  with respect to cover  12 . In a further embodiment of the invention, first and second inner cover panels  20  and  22  may have corners similar to the corners of the inner cover panels described below with respect to the second embodiment of the invention. 
   The second embodiment of the media storage container of the present invention is indicated generally by the numeral  110  in  FIGS. 9–16 . Media storage container  110  is designed to have the same advantages as media storage container  10  described above and is configured to use a mechanical, interlocking connection to lock the cover  112  to the media storage trays  114 . 
   Cover  112  includes a plurality of panels connected together with living hinges. The living hinges may be formed by any method known in the art including any of the methods described above. Cover  112  includes first and second inner cover panels  120  and  122 . Inner cover panel  120  is connected to inner cover panel  122  with a first living hinge  124 . As shown in  FIGS. 10 and 14 , the corners of inner cover panels  120  and  122  are cut away such that each inner cover panel  120  and  122  is octagonal. When each corner is cut away, a corner wall  132  is formed. Corner wall  132  may be substantially shorter than the width and height of panels  120  and  122 . 
   Second inner cover panel  122  is connected to an inner spine panel  134  with a second living hinge  136 . A third living hinge  138  connects inner spine panel  134  to the inner panel  139  of rear cover panel  140 . As shown in  FIG. 13 , inner spine panel  134  has a width that is slightly larger than the thickness of one tray  114  such that inner panel  139  lies directly against the outer surface of tray  114  when cover  112  is closed as depicted in  FIG. 16 . 
   In addition to inner panel  139 , rear cover panel  140  includes an outer panel  141  that is connected to inner panel  139  with a fourth living hinge  142 . 
   Outer panel  141  is connected to the outer spine panel  144  with a fifth living hinge  146 . Outer spine panel  144  has a width that is slightly larger than the thickness of both trays  114  and panels  120  and  122  as depicted in  FIG. 16 . When cover  112  is folded together, fifth living hinge  146  is disposed immediately adjacent third living hinge  138  as depicted in  FIGS. 13 and 16 . If desired, inner panel  139  and outer panel  141  may be connected together with an adhesive so that they do not fall open when container  110  is in use. 
   An outer panel  151  of a front cover panel  150  is connected to outer spine panel  144  with a sixth living hinge  152 . Front cover panel  150  also includes an inner panel  153  that is connected to outer panel  151  with a seventh living hinge  154 . Panels  151  and  153  may be connected together with an adhesive so that front cover  150  does not open unintentionally. 
   Trays  114  are connected to cover  112  in the manner described above. As such, each tray  114  includes a pair of locking fingers  160  that snap fit onto locking ledges  162 . Each locking finger  160  includes the same elements described above with respect to locking fingers  60 . The difference between this embodiment and the first embodiment described above is that locking fingers  160  do not pass through openings in inner cover panels  120  and  122 . Inner cover panels  120  and  122  is locked between the four locking fingers  160  because locking fingers  160  are disposed in the cut away corners. Covers  120  and  122  thus cannot move laterally or vertically out from between trays  114  once locking fingers  160  are snapped into position. If desired, inner cover panels  120  and  122  may be formed with openings  30  as described above. 
   An advantage to media storage container  110  is that spine  144  is unbroken as depicted in  FIG. 9  so that standard printing may be used on spine  144 . The standard-sized spine  144  will thus accept large titles so that the contents of media storage container  110  may be readily discerned by the consumer. 
   In both of the embodiments described above, the exemplary embodiment uses trays  14  and  114  that are designed to hold a single item of recorded media. The inventors contemplate that each tray  14  and  114  may be configured to hold multiple items of recorded media such that each container  10  and  110  may be configured to hold one, two, three, four, five, six, or other numbers of items of recorded media. In still other embodiments, the inventors contemplate that covers  12  and  112  may include additional panels and additional hinges so that additional trays  14  and  114  may be held in a book-like manner. 
   In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. 
   Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described.