US20080245687A1

US20080245687A1 - Disc package with securing ledges

Info

Publication number: US20080245687A1
Application number: US12/080,859
Authority: US
Inventors: John A. Gelardi
Original assignee: Gelardi John A
Current assignee: WestRock MWV LLC; Atlas AGI Holdings LLC
Priority date: 2007-04-06
Filing date: 2008-04-07
Publication date: 2008-10-09
Also published as: EP2150476A1; EP2150476A4; WO2008124115A1

Abstract

A package for housing a disc is provided, including a cover forming an elongated spine panel with first and second opposing panels extending therefrom such that the opposing panels selectively rotate between open and closed positions and a tray attached to one of the opposing panels. The tray has a planar surface and first and second opposing angular surfaces extending from the planar surface. Each angular surface has a slot for receiving an edge of the disc to support the disc above the planar surface, wherein at least one of the angular surfaces can be deflected to facilitate removal and insertion of the disc.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 60/922,124, filed Apr. 6, 2007 and U.S. Provisional Patent Application Ser. No. 60/965,875, filed Aug. 23, 2007, the disclosures of which are herein incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention relates generally to a reclosable storage package for recording media and, more particularly, to a package having securing ledges for storing a media disc.
2. Description of the Prior Art
Various types of planar discs are in use at the present time to record and store information which is to be retrieved by various means, such as by optical or magnetic means. Typical of such discs are compact discs (CDs) or digital video discs (DVDs) in which information is digitally recorded by use of a laser beam and then read optically by a laser beam. Such discs are used to record audio information (e.g., musical renditions), video information (e.g., visual images and digital information) for use as read only and other memories for use in various applications, such as computer applications.
In most instances, at the present time, such discs are sold with information already recorded thereon. In other applications, such discs are sold in blank form and are used by the customer to record information thereon. In the latter case, for example, optical discs are sold for use as computer storage media and are used in hard disc storage systems. As used herein, the terms media disc, compact disc, CD or disc are intended to encompass all such discs, whatever their size, for all known or proposed uses.
Compact discs containing laser recorded information are typically packaged in injection molded plastic enclosures designed to hold one or more CDs for protecting the discs during storage and shipment. Enclosures commonly used at the present time, such as the well known “jewel box,” comprise a three piece assembly consisting of a base or bottom element, an insert or tray in the base/bottom element for positioning and supporting the disc in the base/bottom element, e.g., by a center projection (commonly referred to as a “rosette”) which engages the periphery of the aperture in the center of the disc, and a lid or cover which is hinged to the base/bottom element and is closed thereon after the disc is mounted therein on the tray. Other enclosures utilize only two pieces, omit the tray, and position and support the disc via the center projection directly on the base/bottom element. The enclosure is, typically, at least partially transparent and graphics relating to the disc and containing trademark and sales promotional information are usually inserted in such a manner as to be visible through the enclosure.
Except for the printed matter inserted therein, the “jewel box” is entirely plastic. For this reason, as well as because the typical jewel box requires three separately injection molded elements which must be manually assembled, the use of this type of enclosure is relatively expensive. Moreover, the use of such an enclosure is believed to be ecologically unacceptable by many because the plastic is non-biodegradable and, in view of the huge volume of such enclosures in use today, the disposal of these enclosures poses either a real or potential environmental problem. Still further, polymeric jewel boxes are relatively heavy and therefore, are not well suited for applications in which the CDs or DVDs are shipped through the mail. The weight of the plastic case adds significantly to the postal cost of the shipment.
One solution to these problems has been the development of hybrid packages comprising both paperboard and plastic components. These hybrid packages provide a CD package which is suitable and attractive for display, sale and storage of compact discs, yet which is both simple and inexpensive to manufacture.
For example, U.S. Pat. No. 4,709,812 to Kosterka, which is incorporated herein by reference, discloses a compact disc package formed from a pre-scored, preprinted unitary blank and at least one injection molded plastic compact disc holder or tray adhesively adhered to one segment of the blank, the blank being adapted to fold along fold lines to position a blank segment over the top of the disc holder to sandwich it, in book style, between the segment to which it is adhered and the overlying segment. The problem with this type of arrangement is that the book frequently opens and provides little protection for the disc there within. Moreover, this type of package still includes a relatively heavy plastic components.
It should be apparent, therefore, that efforts to date directed at hybrid packaging containing multiple discs suffer from one or more shortcomings which make the resulting CD packaging unsatisfactory or require unduly complex manufacturing. Accordingly, there remains a need for a simple, environmentally friendly, inexpensive to manufacture and lightweight package for media discs that adequately protects the disc yet provides easy access thereto.

SUMMARY OF THE INVENTION

It is an object of the subject disclosure to provide a package for holding discs that is easy to manufacture, lightweight and may be made from environmentally friendly materials.
The present disclosure is directed to a package for housing a disc including a cover forming an elongated spine panel with first and second opposing panels extending therefrom such that the opposing panels selectively rotate between open and closed positions and a tray attached to one of the opposing panels. In the illustrative embodiment, the tray has a planar surface and first and second opposing angular surfaces extending from the planar surface. Each angular surface has a slot for receiving an edge of the disc to support the disc above the planar surface, wherein at least one of the angular surfaces can be deflected to facilitate removal and insertion of the disc.
The present invention is also directed to a tray for a disc package that includes a planar surface; and first and second opposing angular surfaces extending upwardly from the planar surface. Each angular surface defines a slot for receiving an edge of a disc to support the disc above the planar surface, wherein at least one of the angular surfaces can be deflected in a radially outward direction to facilitate removal and insertion of the disc.
In certain embodiments, the tray further includes a tension member secured to an underside of the tray member for structurally reinforcing the tray member. Preferably, the tension member is stiffer than the tray member. Still further, it is envisioned that in certain embodiments, the tray member and the tension member are fabricated from materials selected from paper, plastic and combinations thereof.
The present invention is also directed to a package for housing a disc that includes, inter alia, a cover and a tray assembly. The cover formes an elongated spine panel with first and second opposing panels extending therefrom such that the opposing panels selectively rotate between open and closed positions. The tray assembly is attached to one of the opposing panels and includes a tray member and a tension member. The tray member has a planar surface, and angular surfaces extending from the planar surface, each angular surface defining a slot for receiving an edge of a disc to support the disc above the planar surface. The tension member is secured to the underside of the tray member for structurally reinforcing the tray member.
The present disclosure is further directed to a tray assembly for retaining a disc that includes, inter alia, a tray member including a planar surface; two landings extending above the planar surface, each landing defining a slot for receiving an edge of the disc to support the disc above the planar surface; and a central landing for affirmatively engaging an aperture of the disc.
It is envisioned that the tray assembly can further include a tension member secured to the tray member for structurally reinforcing the tray member. Moreover, in certain constructions, it is preferred that the central landing has a first level adjacent the planar surface to support the disc above the planar surface and a second level extending above the first level. Preferably, the central landing defines a slot for capturing the disc. The shape of the slot can be selected from the group consisting of arcuate, straight, Y-shaped and combinations thereof.
The present invention is also directed to a method for creating a tray for storing a media disc that includes the steps of: vacuum forming plastic into a planar, disc-shaped recess having opposing angled wall portions extending from the recess; and forming opposing undercuts in the opposing angled wall portions. In certain embodiments, the method of the present invention includes the step of affixing the tray to a cover, the cover having an elongated spine panel with first and second opposing panels extending therefrom such that the opposing panels selectively rotate between open and closed positions. Preferably, the method also includes the step of forming a raised boss substantially centrally located in the disc-shaped recess. In certain constructions, graphics are applied directly to the cover. Additionally, the method may also include the step of forming overhangs above the undercuts, wherein the overhangs are deflectable.
The present disclosure is a method for creating a tray for storing a media disc that includes the steps of: forming a blank into a planar, disc-shaped recess having opposing angled wall portions extending from the recess; and forming opposing undercuts in the opposing angled wall portions. Preferably the step of forming is stamping. Alternatively the forming step is vacuum forming.
In certain constructions the inventive method further includes the steps of: forming the blank with die cut slots; placing the blank into a forming mold; and applying pressure to the blank to result in a three-dimensional shape. further comprising the step of applying heat during the applying pressure step. Preferably, the die cut slots become the opposing undercuts during the applying pressure step.
The present invention is also direct to a blank for creating tray member comprising a flat board defining first and second opposing slots, and a third central slot. Preferably, the first and second slots are arcuate shaped with a v-shape on a first end and an angled portion on a second end, and the central slot is linear with an arcuate portion on one end, the arcuate portion having angled portions on each end.
Variations of the illustrative embodiment, including variations in the shape of the angular surfaces of the tray and variations in the shape, size and location of the ledge lock and/or slit lock for receiving an edge of the disc, are also within the contemplation of the present invention as is further described below.
It should be appreciated that the present invention can be implemented and utilized in numerous ways, including without limitation as a process, an apparatus, a system, a device, and a method for applications and from other suitable materials now known and later developed. These and other unique features of the system disclosed herein will become more readily apparent from the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those having ordinary skill in the art to which the disclosed system appertains will more readily understand how to make and use the same, reference may be had to the following drawings.

FIG. 1 is a perspective view of a package in accordance with the subject disclosure, wherein the package has a plastic tray.

FIG. 2 is an isolated view of the tray of the package of FIG. 1.

FIG. 3 is an isolated view of a paper tray for a package in accordance with the subject disclosure.

FIG. 4 is a of view of another package in accordance with the subject disclosure, wherein a disc is being loaded thereon.

FIG. 5 is a view of the package of FIG. 4 with the disc being removed therefrom.

FIG. 6 is a perspective view of another the package in accordance with the subject disclosure.

FIG. 7 is a perspective view of the tray prior to affixing on the cover of the package of FIG. 6.

FIG. 8 is an isolated view of another paper tray for a package in accordance with the subject disclosure.

FIGS. 9-11 are perspective views of a disc being mounted in another tray assembly in accordance with the subject disclosure.

FIG. 12 is a top view of the tray assembly of FIGS. 9-11 with the disc mounted thereon.

FIG. 13 is a side view of the tray assembly of FIGS. 9-11 showing a disc mounted thereon.

FIG. 14 is a perspective view of still another tray assembly in accordance with the subject disclosure.

FIG. 15 is a top view of the tray assembly of FIG. 14.

FIG. 16 is a partial side view of the tray assembly of FIG. 14.

FIG. 17 is a perspective view of a disc being mounted in another tray assembly in accordance with the subject disclosure.

FIG. 18 is a perspective view of a disc being mounted in yet another tray assembly in accordance with the subject disclosure.

FIG. 19 is a perspective view of a disc being mounted in still another tray assembly in accordance with the subject disclosure.

FIGS. 20 a-c are perspective views of still another tray member in accordance with the subject disclosure.

FIG. 21 is a top view of the tray member of FIGS. 20 a-c.

FIG. 22 is a partial side view of the tray member of FIGS. 20 a-c.

FIG. 23 illustrates a blank for forming the tray member of FIGS. 20 a-c.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention overcomes many of the problems associated with prior art media disc packages. The advantages, and other features of the packages disclosed herein, will become more readily apparent to those having ordinary skill in the art from the following detailed description of certain preferred embodiments taken in conjunction with the drawings which set forth representative embodiments of the present invention and wherein like reference numerals identify similar structural elements whenever possible.
All relative descriptions herein such as left, right, up, down, topside, underside and the like are with reference to the Figures, and not meant in a limiting sense. The illustrated embodiments can be understood as providing exemplary features of varying detail of certain embodiments, and therefore, unless otherwise specified, features, components, modules, elements, and/or aspects of the illustrations can be otherwise combined, interconnected, sequenced, separated, interchanged, positioned, and/or rearranged without materially departing from the disclosed systems or methods. Additionally, the shapes and sizes of components are also exemplary and unless otherwise specified, can be altered without materially affecting or limiting the disclosed technology to holding discs exclusively.
An exemplary embodiment of the present invention is illustrated in FIGS. 1 and 2, in which there is shown an improved media disc package 10 made from a plastic tray 12 and a paperboard cover 14. The tray 12 is vacuum formed plastic and glued, hot melted or otherwise affixed to the cover 14. The tray 12 is sized and shaped to fit on the bottom of the cover 14. The tray 12 has angled walls 15 extending from a substantially disc-shaped recess 17. The angled walls 15 define two opposing undercuts 16 or slots to support a disc 20 about the outer diameter of the disc 20.
Landings 21 are formed above each undercut 16 such that upon depressing one or both of the landings 21, the respective angled wall 15 flexes to separate the undercuts 16 and facilitate insertion and removal of the disc 20. Alternatively, when the angled walls 15 are not flexed, the disc 20 is securely held within the undercuts 16. The landings 21 also form overhanging portions 25 above each undercut 16. The overhanging portions 25 can also simply deflect, with or without deflection of the angled walls 15, to release the disc 20 from the tray.
The tray 12 could also be configured with three, four or even more undercuts to provide further support. The undercuts are preferably evenly spaced about the recess 17. The angled walls 15 do not completely surround the recess 17 such that finger recesses 19 are formed. A simple raised boss or rosette (not shown) could also be centrally located in the recess 17 to help retain and/or position the disc 20 and provide additional protection against damage to the disc 20.
The cover 14 includes a spine that interconnects a top 26 and a bottom to which the tray 12 is attached. The top 26 may have a feature to create friction with the tray 12 to retain the package 10 closed. The tray 12 may also have a complimentary feature that interacts with the top 26. Such features could include detents, slots, protrusions, hollows, lips, ridges and the like.
Another preferred embodiment of the present invention is illustrated in FIG. 3, in which there is shown an improved media disc tray 112. The tray 112 is made from paper board and glued or otherwise affixed to a cover (not shown). The tray 112 is sized and shaped to fit on the bottom of the cover. The tray 112 also has angled walls 115 extending from a substantially flat surface 117. The angled walls 115 define two opposing undercuts 116 to support a disc 20 about the outer diameter of the disc 20. Folded sidewalls 119 extend between the opposing angled walls 115. Preferably, the angled walls 115 are formed by stamping or creasing paperboard, however the angled walls 115 could also be formed by folding and other techniques. As before, the disc 20 can be inserted in or removed from the tray by flexing angled walls 115 outwardly, thereby increasing the distance between the opposing undercuts 116.
Referring now to FIGS. 4 and 5, there is shown another package 210 that is constructed in accordance with the subject disclosure, wherein a disc 20 is being loaded thereon. The package 210 also has a tray 212 stamped/formed from paper board and affixed to a cover. The stamping creates angled walls 215A, 215B extending from a substantially flat surface 217. The angled wall 215A defines a slot or ledge lock that captures an outer diameter of the disc 20. The angled wall 215B defines a hollow 230 which supports the outer diameter of the disc 20 so that the disc 20 rests above the flat surface when stored therein. The angled wall 215A is part of a step 231. A portion of the step 231 is adhered to the spine such that upon opening the package 210, the angled wall 215A flexes away from the opposing angled wall 215B and, in turn, the disc 20 is easily inserted and removed from the package 210. Folded or stamped sidewalls 219 extend between the opposing angled walls 215A, 215B. The sidewalls 219 can be stamped as part of the tray 212 or cover, or formed by folding and other techniques. FIG. 5 is a view of the package of FIG. 4 with the disc being removed therefrom.
Referring now to FIG. 6, there is shown another package 310 in accordance with the subject disclosure, wherein a disc 20 is loaded thereon. Referring to FIG. 7 as well, the tray 312 and the cover 314 of the package 310 is shown. The package 310 also has a tray 312 stamped from paper board and affixed to a cover 314. The tray 312 has side walls 315A, 315B extending from a substantially flat surface 317. The side wall 315A defines a ledge lock 329 that captures an outer diameter of the disc 20. The opposing side wall 315B also defines a slot 330 which supports the outer diameter of the disc 20 so that the disc 20 rests above the flat surface 317 when stored therein. Sidewalls 319 extend between the opposing angled walls 315A, 315B. The angled wall 315A is part of a step 331. A portion of the step 331 is adhered to the spine of the cover 314 such that upon opening the package 310, the angled wall 315A flexes away from the opposing angled wall 315B and, in turn, the disc 20 is easily inserted and removed from the package 310.
Referring now to FIG. 8, an isolated view of another paper tray 412 for holding a disc 20 in a package in accordance with the subject disclosure is shown. As can be seen, tray 412 includes four angled sidewalls 415 extending up from a flat surface 417. Three of the sidewalls (shown as the left side, top and bottom) 415 define a ledge lock/416 to support the disc 20. Tray 412 can be adhered to a cover, such as cover 314 shown in FIG. 6. In such a construction, when the cover is opened, the disc 20 is disengaged from left side ledge lock/slot 416, but remains engaged with the top and bottom ledge locks 416. That way, the disc does not fall out when the package is opened and can only be removed when the top and bottom sidewalls are forced in an outward direction.
Referring now to FIGS. 9-13, perspective views of a disc 20 being mounted in another tray assembly 500 in accordance with the subject technology are shown. FIGS. 12 and 13, which show a disc 20 mounted on the tray assembly 500 in top and side view, respectively, are also referred to in the following description. As will be appreciated by those of ordinary skill in the pertinent art, the tray assembly 500 utilizes similar elements to those described above. The following description is directed primarily to the alternative features of the embodiment described with respect to tray assembly 500.
The tray assembly 500 includes a tray member 510 having a tension member 512 adhered thereto for structurally reinforcing the tray member 510. The tray member 510 and tension member 512 may be formed from paper, plastic or combinations thereof or any other suitable material now known or later developed. In the described embodiment, both are formed from paper and the tension member 512 is a relatively thicker and stiffer paperboard. Stamping, vacuum forming and other manufacturing techniques now known and later developed may be used to form the tray member 510 into the desired shape.
The tray member 510 has a planar surface 514 with a central land 518 and two outer lands 520 extending upwards therefrom. The central land 518 is circular to engage, align and/or support the central opening 22 of the disc 20. The outer lands 520 engage, align and/or support a periphery 24 of the disc 20. Each outer land 520 has an angular surface 524 defining a slot 526 for receiving the periphery or edge 24. Each outer land 520 also has an arcuate section 525 to further engage, align and/or support the disc 20. Moreover, in the embodiment shown in FIGS. 9-13, the angled surfaces 524 each include a protuberance 528 positioned diametrically opposite of a corresponding slot 526 to assist in urging and retaining the disc 20 within the slot 526.
As noted above, stamping, vacuum forming and other manufacturing techniques now known or later developed may be used to form the tray member 510 into the desired shape. In an exemplary method in accordance with the invention, a blank is formed with die cut slots and placed into a forming mold. Pressure with or without heat is applied, and the blank is pressed into a three-dimensional shape. The two-dimensional blank may be shaped such that the pressed and formed three-dimensional product has specific dimensions and shape. As the board blank is being formed in the mold, the pre-cut slits create additional structural elements during the forming process. In particular, the die-cut slits in the blank are formed into undercuts, ledges, and other elements in the formed tray. For example, the slits formed in the two-dimensional blank creates a more three-dimensional gap or slot 526 in the formed tray for receiving the periphery or edge of a disk 24. It can be appreciated that by providing such two-dimensional features in the blank and controlling the forming process as described above, three-dimensional structural elements are created in the formed tray by the forming process, and it becomes unnecessary to form such elements in the tray in a secondary step.
The tray member 510 is secured, by gluing, heat sealing or other suitable method to the substantially flat tension member 512. As a result, the lands 518, 520 are structurally reinforced more than would be expected, providing the tray member 510 with significantly greater structural integrity than the tray member 510 would have alone. The flat tension member 512 may be a separate flat sheet, as described, or may define a portion of a cover (not shown), to which the tray member 510 may be directly secured or adhered. Although deflection can still occur to allow removal and replacement of the disc 20, the robustness and firmness of the action of the tray member 510 is improved. Once assembled, the tray assembly 500 can be mounted to an additional cover.
FIGS. 14-16 are views of still another tray assembly constructed in accordance with the subject disclosure and designated as reference numeral 500A. The tray assembly 500A includes a tray member 510A having a tension member 512A adhered thereto for structurally reinforcing the tray member 510A. The tray member 510A and tension member 512A may be formed from paper, plastic or combinations thereof or any other suitable material now known or later developed. In the described embodiment, both are formed from paper and the tension member 512A is a relatively thicker and stiffer paperboard. Like before, stamping, vacuum forming and other manufacturing techniques now known and later developed may be used to form the tray member 510A into the desired shape.
The tray member 510A has a planar surface 514A with a central land or rosette 518A and two outer lands 520A extending upwards therefrom. The outer lands 520A engage, align and/or support a periphery 24 of a disc 20 (shown in FIG. 9). Each outer land 520A has an angular surface 524A for supporting the periphery or edge 24 of the disc 20. As can be seen, the rosette 518A or central landing is configured with several arcuate sections formed in its periphery 519A. As shown in FIG. 16, a slit 521 A may be formed in the outer periphery 519A of rosette 518A in order to engage inner periphery of the disc. Additionally, the outer landings/angular surfaces 524A may also include slots/slits to engage the outer periphery of the disk.
Referring now to FIG. 17, a perspective view of a disc 20 being mounted in another tray assembly 600 in accordance with the subject technology is shown. As will be appreciated by those of ordinary skill in the pertinent art, the tray assembly 600 utilizes similar principles to tray 500 described above. The following description is directed primarily to certain differences of the tray assembly 600 therefrom.
The tray assembly 600 may or may not have a supporting flat tension member 612. The primary difference is the central land 618 that has a lower level portion 620 and an upper level portion 622. The upper level portion 622 extends from the lower level portion 620 and is sized and configured to fit within the aperture 22 of the disc 20. To further secure the disc 20 in place, a partial slit 624 is formed in the side wall of the upper portion 622. As a result, the aperture 22 of the disc 20 is affirmatively captured. In a preferred embodiment, the slit 624 is arcuate shaped, faces the slots formed in the angled surfaces, and extends about 70 degrees.
Referring now to FIGS. 18 and 19, additional variations of the tray 600 are shown. Each variation modifies the central land 618 so that the aperture 22 of the disc 20 may more easily be removed or properly positioned for retention. FIG. 18 uses an additional slit 626 across the upper level portion 622, whereas FIG. 19 uses an additional Y-shaped slit 628 across the upper level portion 622.
Referring now to FIGS. 20 a-c, 21 and 22, still another tray member in accordance with the subject disclosure is shown and referred to generally by the reference numeral 700. As will be appreciated by those of ordinary skill in the pertinent art, the tray member 700 utilizes similar principles to the trays described above. The following description is directed primarily to the differences of the tray member 700 therefrom.
The tray member 700 has a rosette 716 that has a lower level circular portion 720 and an upper level circular portion 722 to retain a disc (not shown). The upper level portion 722 is sized and configured to fit within the central aperture of the disc. The upper level portion 722 may be domed or beveled to provide an angular surface 726 to engage the central aperture of the disc.
The upper level portion 722 forms a roughly T-shaped slit 724 so that the upper level portion 722 may be compressed to facilitate placement and removal of the disc. Additionally, the upper level portion 722 exerts an outward force on the central aperture of the disc to help retain the disc. The rosette 716 is created when forming the tray member 700 from the blank 750 shown in FIG. 23.
The tray member 700 also includes two outer lands 720 with stop surfaces 740. The stop surfaces 740 along with the rosette 720 form a three-point support surface for the disc. The outer lands 720 also have angular surfaces 724 defining slots 726 for receiving the periphery or edge of the disc. The slots 726 form upper ledges 728. The outer lands 720, including the stop surfaces 740 and ledges 728, are also created when forming the tray member 700 from the blank 750. When the disc is in the retained position, the disc is secured by the rosette 720 in combination with ledges formed by the slots 726.
Referring now to FIG. 23, a blank 750 for creating tray member 700 is shown. The blank 750 has slots 752 a, 752 c that are arcuate shaped with a v- shape 754 a, 754 c on a first end and an angled portion 756 a, 756 c on a second end. The blank 750 also has a central slot 752 b that is linear with an arcuate portion 758 on one end, the arcuate portion having angled portions on each end.
To form the blank 750 into the tray member 700, stamping, vacuum forming and other manufacturing techniques now known or later developed may be used. In an exemplary method, the blank 750 has slots 752 a-c die cut. Then, the blank 750 is placed into a forming mold (not shown). Pressure with or without heat is applied, and the blank 750 is pressed into a three-dimensional shape. The two-dimensional blank 750 may be shaped such that the pressed and formed three-dimensional product has specific dimensions and shape. As the board blank 750 is being formed in the mold, the pre-cut slits 752 a-c create additional structural elements during the forming process. In particular, the die-cut slits 752 a-c in the blank are formed into undercuts, ledges, and other elements in the formed tray. It can be appreciated that by providing such two-dimensional features in the blank and controlling the forming process as described above, three-dimensional structural elements are created in the formed tray by the forming process, and it becomes unnecessary to form such elements in the tray in a secondary step.
While the invention has been described with respect to preferred embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the invention without departing from the spirit or scope of the invention.

Claims

1. A tray for a disc package comprising:

a planar surface; and

first and second opposing angular surfaces extending upwardly from the planar surface, each angular surface defining a slot for receiving an edge of a disc to support the disc above the planar surface, wherein at least one of the angular surfaces can be deflected in a radially outward direction to facilitate removal and insertion of the disc.

2. A tray as recited in claim 1, further comprising a tension member secured to an underside of the tray member for structurally reinforcing the tray member.

3. A tray assembly as recited in claim 2,wherein the tension member is stiffer than the tray member.

4. A tray assembly as recited in claim 2,wherein the tray member and the tension member are fabricated from materials selected from paper, plastic and combinations thereof.

5. A package for housing a disc comprising:

a cover forming an elongated spine panel with first and second opposing panels extending therefrom such that the opposing panels selectively rotate between open and closed positions; and

a tray assembly attached to one of the opposing panels, wherein the tray assembly includes:

(a) a tray member including a planar surface, and angular surfaces extending from the planar surface, each angular surface defining a slot for receiving an edge of a disc to support the disc above the planar surface, and

(b) a tension member secured to the tray member for structurally reinforcing the tray member.

6. A tray assembly for retaining a disc comprising:

a tray member including a planar surface;

two landings extending above the planar surface, each landing defining a slot for receiving an edge of the disc to support the disc above the planar surface; and a central landing for affirmatively engaging an aperture of the disc.

7. A tray assembly as recited in claim 6, further comprising a tension member secured to the tray member for structurally reinforcing the tray member.

8. A tray assembly as recited in claim 6, wherein the central landing has a first level adjacent the planar surface to support the disc above the planar surface and a second level extending above the first level.

9. A tray assembly as recited in claim 6, wherein the central landing defines a slot for capturing the disc.

10. A tray assembly as recited in claim 9, wherein a shape of the slot is selected from the group consisting of arcuate, straight, Y-shaped and combinations thereof.

11. A method for creating a tray for storing a media disc comprising the steps of:

vacuum forming plastic into a planar, disc-shaped recess having opposing angled wall portions extending from the recess; and

forming opposing undercuts in the opposing angled wall portions.

12. A method as recited in claim 11, wherein the angled wall portions are deflectable.

13. A method as recited in claim 11, further comprising the step of affixing the tray to a cover, the cover having an elongated spine panel with first and second opposing panels extending therefrom such that the opposing panels selectively rotate between open and closed positions.

14. A method as recited in claim 11, wherein the angled wall portions define a third undercut.

15. A method as recited in claim 14, wherein the angled wall portions define a fourth undercut.

16. A method as recited in claim 11, further comprising the step of forming a raised boss substantially centrally located in the disc-shaped recess.

17. A method as recited in claim 11, wherein the cover is paper board.

18. A method as recited in claim 11, further comprising the step of applying graphics directly to the cover.

19. A method as recited in claim 11, further comprising the step of forming overhangs above the undercuts, wherein the overhangs are deflectable.

20. A package for housing a disc comprising:

a tray attached to one of the opposing panels,

wherein the tray has a planar surface and first and second opposing angular surfaces extending from the planar surface, each angular surface having a slot for receiving an edge of the disc to support the disc above the planar surface, wherein at least one of the angular surfaces can be deflected to facilitate removal and insertion of the disc.

21. A method for creating a tray for storing a media disc comprising the steps of:

forming a blank into a planar, disc-shaped recess having opposing angled wall portions extending from the recess; and

forming opposing undercuts in the opposing angled wall portions.

22. A method as recited in claim 21, wherein the angled wall portions are deflectable.

23. A method as recited in claim 21, wherein the forming step is stamping.

24. A method as recited in claim 21, wherein the forming step is vacuum forming.

25. A method as recited in claim 21, further comprising the steps of:

forming the blank with die cut slots;

placing the blank into a forming mold; and

applying pressure to the blank to result in a three-dimensional shape.

26. A method as recited in claim 25, further comprising the step of applying heat during the applying pressure step.

27. A method as recited in claim 21, wherein the die cut slots become the opposing undercuts during the applying pressure step.

28. A blank for creating tray member comprising a flat board defining first and second opposing slots, and a third central slot.

29. A blank as recited in claim 28, wherein

the first and second slots are arcuate shaped with a v-shape on a first end and an angled portion on a second end, and

the central slot is linear with an arcuate portion on one end, the arcuate portion having angled portions on each end.