WO2010011322A2

WO2010011322A2 - Merchandise storage container

Info

Publication number: WO2010011322A2
Application number: PCT/US2009/004274
Authority: WO
Inventors: Michael S. Jaeb; Mark E. Heuser; Jeffrey Sweatman; Charles G. Hoar; Vincent C.M. Leesberg
Original assignee: Nexpak Corporation
Priority date: 2008-07-24
Filing date: 2009-07-23
Publication date: 2010-01-28
Also published as: WO2010011322A3

Abstract

A recyclable merchandise storage container may be used in place of standard disc jewel cases. The invention provides a container that is entirely manufactured from a recyclable plastic material and labeled with recyclable plastic adhesive labels. The container may have a hollowed-out or cored out portion that is covered by a snap-in cover after the container is manufactured. This allows a label to extend over the cored-out portion when the container is used to provide a smooth uninterrupted outer surface. The container may have a literature tab that does not require an opening to be aligned with the literature tab. The literature tab may be molded outboard of the base of the container and then moved to an inboard position.

Description

MERCHANDISE STORAGE CONTAINER

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of United States provisional patent applications serial nos. 61/083,228 filed July 24, 2008; 61/091 ,391 filed August 24, 2008; 61/093,974 filed September 3, 2008; and 61/122,899 filed December 16, 2008; the disclosures of each are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Technical Field

The invention generally relates to merchandise storage containers and, more particularly, to media disc storage containers that are fabricated from recyclable plastic materials. The invention also relates to a method of packaging an item of merchandise such as a media disc.

2. Background Information

The jewel case is one of the standard packages for a media disc. Jewel cases have been extensively used for compact discs. Standard jewel cases include front and rear styrene covers that snap together at a hinge pin. A tray having a discholding hub is snapped to the rear cover to secure the media disc with the jewel case. A portion of the tray on the hinge end of the container protrudes up through the front cover to define a shelf. Paper inserts are used inside the front cover and between the tray and rear cover to provide the graphics and information for the container.

Automated jewel case loading apparatus are widely used by replicators and are based on the dimensions of the standard jewel case.

One drawback with a jewel case is they crack or shatter if dropped on a hard surface. Another drawback with standard jewel cases is the recyclability of their materials and its ability to pass so called "green" standards defined by large retailers.

Another type of media disc storage container that has been widely used in the art is a molded plastic container that is married to a transparent plastic sleeve that holds a printed literature page between the outer surface of the container and sleeve. US Patent 6,354,435 discloses one example of this type of container. These containers typically include literature tabs that hold a printed booklet. Typical literature tabs can be seen, for example, in FIGS. 1 , 13, and 20 of US Patent 6,354,435 identified by reference numeral 26. Literature tabs 26 of this type are molded in place and require an opening to be formed in the lid in alignment with the tab, reference numeral 14, for each tab 26. Such openings are undesirable in some applications for the containers.

SUMMARY OF THE INVENTION

The invention provides a "green" substitute for the standard jewel case that may be used with existing jewel case automated equipment with minimal modifications to the existing jewel case automated equipment.

The invention provides a container that is entirely manufactured from a recyclable plastic material and labeled with recyclable plastic adhesive labels.

The invention provides a container having a hollowed-out or cored out portion that is covered by a snap-in cover after the container is manufactured. This allows a label to extend over the cored-out portion when the container is used to provide a smooth uninterrupted outer surface.

The invention also provides a method for packaging a media disc wherein the graphics associated with the media disc are printed on demand and applied to the exterior of the container as the containers are within the automated process. The graphics are printed on recyclable labels with pressure sensitive adhesive that allows the labels to be adhered directly to the exterior of the container. In one configuration, the labels may be printed after they are adhered to the container.

The invention also provides a media storage container having a literature tab that does not requires an opening to be formed through an outer wall of the container so that the container will have an uninterrupted outer wall.

The invention provides a media storage container having at least one literature tab that is molded in a position outboard to the container. The tab is connected to the container with a hinge. After the container is molded, the literature tab is moved to an inboard position about the hinge where the tab may be used to retain printed literature that accompanies the media stored in the container.

Another configuration of the invention provides literature tabs that are separately molded from the container. These tabs are connected to the container where they function to hold literature booklets in the container.

In one configuration, the invention provides a merchandise storage container having a base and a lid; a literature clip connected to the lid and extending inside the lid; the literature clip being adapted to hold at least a sheet of printed literature inside the lid; and the lid being free of openings aligned with the literature clip.

In another configuration, the invention provides a merchandise storage container having a base and a lid; and a literature clip connected to the lid with a living hinge; the literature clip being disposed in an outboard position and movable about the living hinge to an inboard position.

In another configuration, the invention provides a merchandise storage container having a base and a lid; the base having a back wall that defines a portion of the rear surface of the container; the base having a structure with a cored-out area under the structure; a cover being pivotably connected to the base and movable from an open configuration to a closed configuration; the cover having a back wall; the cover disposed over the cored-out area when the cover is in the closed configuration; and the back wall of the cover being aligned with the back wall of the base to form a smooth rear surface for the container.

A further configuration of the invention provides a merchandise storage container that includes a base and a lid movable between open and closed configurations; the closed configuration of the base and lid defining a merchandise storage area between the base and lid; the base and lid having a plurality of outer surfaces; the base and lid being fabricated from a recyclable plastic; and at least one label connected to the an outer surface of the base and lid; the label being fabricated from a recyclable plastic.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary merchandise storage container having literature tabs that do not require an opening in the top wall of the lid.

FIG. 2 is a perspective view of the container of FIG. 1 showing the interior of the lid with the literature tabs in their inboard position. FIG. 3 is a perspective view of the container of FIG. 1 showing the outer surface of the container in an open condition.

FIG. 4 is a perspective view of a first configuration of a literature tab in an outboard position.

FIG. 5 is a perspective view of the first configuration of the literature tab in the inboard position.

FIG. 6 is a top plan view of the first configuration of the literature tab in the inboard position.

FIG. 7 is a section view taken along line 7-7 of FIG. 6.

FIG. 8 is a section view of the lock configuration for the first configuration of the literature tab taken along line 8-8 of FIG. 7.

FIG. 9 is a perspective view of a second configuration of a literature tab in an outboard position.

FIG. 10 is a perspective view of the second configuration of the literature tab in the inboard position.

FIG. 11 is a top plan view of the second configuration of the literature tab in the inboard position.

FIG. 12 is a section view taken along line 7-7 of FIG. 11.

FIG. 13 is a section view of the lock configuration for the second configuration of the literature tab taken along line 13-13 of FIG. 11.

FIG. 14 is a perspective view of a third configuration of the literature tab showing the tab disconnected from the container.

FIG. 15 is a perspective view of the third configuration of the literature tab showing the tab connected to the container.

FIG. 16 is a perspective view of a first configuration of a recyclable merchandise storage container.

FIG. 17 is an exploded perspective view of the first configuration of FIG. 16 with the recyclable label removed.

FIG. 18 is a perspective view of a second configuration of a recyclable merchandise storage container.

FIG. 19 is an exploded perspective view of the second configuration of FIG. 18 with the recyclable label removed.

FIG. 20 is a perspective view of the second configuration in a closed condition. FIG. 21 is a perspective view of a third configuration of a recyclable merchandise storage container.

FIG. 22 is an exploded perspective view of the third configuration of FIG. 21 with the recyclable labels removed.

FIG. 23 is a section view of the third configuration showing its relative size to a jewel case.

FIG. 24 is an exploded perspective view of the third configuration of the recyclable merchandise storage container.

FIG. 25 is a perspective view of the third configuration in a closed condition.

FIG. 26 is a perspective view of a fourth configuration of a recyclable merchandise storage container with the rear label removed and the snap-in cover in the open configuration.

FIG. 27 is a view similar to FIG. 26 with the snap-in cover closed.

FIG. 28 is a perspective view of the rear of the fourth configuration with the rear label adhered.

Similar numbers refer to similar parts through the specification.

DETAILED DESCRIPTION OF THE INVENTION

Different configurations of exemplary merchandise storage containers are indicated generally by the numeral 2 in the accompanying drawings. Containers 2 generally include a base 4, a spine 6, and a lid 8 that move between open (FIGS. 2 and 3) and closed (FIG. 1) conditions. The configurations of FIGS. 1-15 depict the literature tabs of the invention. These literature tabs also may be incorporated into the containers 2 of FIGS. 16-28. The elements of the different configurations may be combined to form additional configurations. Containers configured to be the same size as standard jewel cases may be molded to have a weight of about 50 to 52 grams. Containers 2 also may be sized to match a standard DVD case.

The configurations of containers 2 shown in FIGS. 1-15 include at least one literature tab 20 that does not require an opening to be defined by container 2 in alignment with tab 20 such as the openings that are typically defined in lid top walls. Literature tabs 20 may be formed integrally with a portion of container 2 and then moved into place. Literature tabs 20 also may be formed independently and connected to a portion of container 2. One configuration of literature tabs 20 are connected to lid 8 with a hinge 22 that allows tab 20 to move from an outboard position (FIGS. 4 and 9) to an inboard position (FIGS. 5-8 and 10-13). Tab 20 is molded in the outboard position and is then moved to the inboard position for use.

FIGS. 4-8 depict a first lock configuration wherein angled lock fingers 30 carried by tab 20 snap over catches 32 defined by lid 8. In the first configuration, both members 30 and 32 may be angled. FIGS. 9-13 depict a second lock configuration wherein angled lock fingers 40 are defined by lid 8. These lock fingers 40 receive a portion of tab 20 where they snap over the upper surface of tab 20 which functions as a catch surface 42. A stop wall 44 limits the movement of tab 20. Both lock configurations may be designed to be one-way; meaning that significant effort must be made to unlatch the elements and return tab 20 to its outboard position. In both configurations, the lock fingers and the catch surface may be reversed.

Each configuration includes walls 50 that limit access to the underside of tab 20.

The third configuration of is depicted in FIGS. 14-15 and includes at least one literature tab 20 that does not require an opening to be defined by container 2 in alignment with tab 20 such as the openings that are typically defined in lid top walls. Literature tabs 20 may be formed independently from a portion of container 2 and then connected to container 2. In the exemplary configuration of FIGS. 14 and 15, the outboard position is depicted in FIG. 14 and the inboard position is depicted in FIG. 15.

FIGS. 14 and 15 depict a third lock configuration wherein at least one centrally-disposed angled lock finger 30 snaps over a catch wall 32. In one configuration, both members 30 and 32 may be angled. Lock finger 30 and catch 32 may be designed to be one-way as described above. The position of the lock finger and the catch surface may be reversed.

In the third configuration, tab 20 includes a five-sided box 50 that snaps over a raised finger that projects up from the inner surface of the lid. Additional lock fingers 30 may be provided to secure tab 20 in place.

These configurations provide literature tabs 20 in traditional locations at the front wall of lid 8 without formed openings in lid 8. A solid, uninterrupted top wall for lid 8 is desired for smooth graphics or for an uninterrupted view when lid 8 is clear. Each of containers 2 may be configured to have the same footprint as the standard styrene jewel case used to receive compact discs or the same size as a Standard DVD case. Each container 2 may be configured to run on existing automated jewel case packaging apparatus with minimal retrofitting. Each container 2 uses less material than a standard styrene, three-piece jewel case. The container configurations are fully recyclable when used with one or more polypropylene labels 60 that may connected to base 4, spine 6, and lid 8 (as needed) with an adhesive such as a pressure sensitive adhesive. Each container configuration is more impact resistant than the standard styrene jewel case. The graphics for the container may be printed on an adhesive label 60 that may be applied to the exterior of the body of the container. Containers 2 also may be configured with an outer sleeve that receives a graphics sheet that is slid between the sleeve and the body of container 2 so that the sheet is exposed on the exterior of the container like a DVD container.

The replicator may incorporate an on-demand, in-line, serialized digitally printed film printing step into the automated container 2 loading apparatus so that the graphics may be printed "on demand" for the item of merchandise that is being loaded into container 2. The replicator may use a digital printer (such as an Indigo ® 6000) that prints the graphics label 60 for container 2 as container 2 is ready for the labels 60. Labels 60 may be a polypropylene-based material so that the labels 60 do not need to be removed prior to recycling container 2. Labels 60 may be configured to be applied automatically during the automated loading process. This method eliminates overruns and reduces waste paper and ink. In another configuration, the graphics may be printed directly onto the surfaces of container 2.

FIGS. 16 and 17 depict a first configuration of recyclable container 2 wherein container 2 includes a base 4 and a lid 8 connected to the base 4 with a snap fit hinge 70. Base 4 includes a perimeter sidewall 72 that is integral to the bottom wall 74 and the tapered nest wall 76. When container 2 is used for media discs, a disc hub 78 projects up from bottom wall 74 at the center of tapered nest wall 76. Perimeter sidewall 72 defines gaps 80 at the 12 o'clock and 6 o'clock positions relative to nest wall 76 to allow access to the item of merchandise held in container 2.

Base 4 includes a pair of spaced corner shoulders 82. The inwardly facing surfaces (that face each other) of shoulders 82 define a portion of hinge 70 that connects lid 8 to base 4. The other portion of hinge 40 is defined by a pair of ears 84 that project substantially perpendicular to the top wall 86 of lid 8.

Lid 8 has a top wall 86 with a full perimeter sidewall 88 that defines rounded corners 90. Perimeter sidewall 88 of lid 8 is disposed on the outside of base sidewall 72 when lid 8 is closed. Literature booklet holding clips 92 project inwardly from lid perimeter sidewall 88 so that a literature booklet may be held inside lid 8. The literature clips described above may be used with lid 8 in this configuration. The front portions of the lid sidewalls 88 define recessed finger grips 94 that allow a user to firmly grasp lid 8 to open container 2.

Lid 8 defines a front surface 96 and a front outer spine surface 98 that receives a folded polypropylene substrate, adhesive-backed label 60 that displays the graphics associated with container 2 and the merchandise held within container 2. Label 60 may be slit 100 at the corners so that there are no gaps between label and surfaces 96 and 98 after label 60 is applied.

FIGS. 18-20 depict a second configuration of the recyclable container 2 wherein the container includes base 4 and lid 8 connected to base 4 with a snap fit hinge 70. Base 4 includes perimeter sidewall 72 that is integral to bottom wall 74 and tapered nest wall 76. The central front wall portion 102 of perimeter sidewall 72 is bowed inwardly to expose a portion of bottom wall 74 to define a finger grip for container 2.

Base 4 includes a pair of spaced corner shoulders 82 and an inner back wall 83. The inwardly facing surfaces (that face each other) of shoulders 82 and back wall 83 define portions of hinges 70 that connect lid 8 to base 4. The other portions of the hinges 70 are defined by the two pairs of ears 84 that project substantially perpendicular to top wall 86 of lid 8.

Lid 8 has a top wall 86 with a full perimeter sidewall 88 that defines rounded corners 90. Perimeter sidewall 88 of the lid is disposed on the outside of base sidewall 72 when lid 8 is closed. The front wall is inwardly curved 104 to match the curve of the front portion 102 of base wall 72. Literature booklet holding clips 92 project inwardly from lid perimeter sidewall 88 so that a literature booklet may be held inside lid 8. The literature clips described above may be used with lid 8 in this configuration. The front portions of the lid sidewalls define recessed finger grips 94 that allow a user to firmly grasp lid 8 to open container 2.

Lid defines a front surface that receives a flat polypropylene substrate, adhesive-backed label 60 that displays the graphics associated with container 2 and the merchandise held within container 2. Base 4 defines a rear surface 106 and a rear spine 108 that receive a folded polypropylene substrate, adhesive-backed label 60 that displays the graphics associated with container 2 and the merchandise held within container 2.

FIGS. 21-23 depict a third configuration of recyclable container 2 wherein container 2 includes base 4 and lid 8 connected to base 4 with a pair of living hinges 110 separated by spine 6. Base 4 includes perimeter sidewall 72 that is integral to bottom wall 74 and tapered nest wall 76. The front of base 4 defines a structure such as a shelf or ledge 112 that extends from sidewall to sidewall with a recess 114 defined so that the user may access the edge 116 of lid 8 to lift lid 8 from the closed position.

Lid 8 defines a front surface that receives a flat polypropylene substrate, adhesive-backed label 60 that displays the graphics associated with the container and the item of merchandise held within the container. Spine 6 defines a second surface that receives a flat polypropylene substrate, adhesive-backed label 60 that displays the graphics associated with the container and the item of merchandise held within container 2. Base 4 defines a third surface (on the outer surface of bottom wall 74) that receives a flat polypropylene substrate, adhesive-backed label 60 that displays the graphics associated with the container and media disc held within the container. In this configuration, a single label 60 may extend across all three surfaces. This continuous label may define slits 100 to prevent wrinkling at living hinges 110.

FIG. 23 shows the relationship between one configuration and a standard jewel case. When manufactured to this size, the total weight of container 2 may be reduced to about 50 to 52 grams

FIG. 25 shows the back wall of this configuration wherein a cored-out or hollowed-out portion 120 is used to create structure 112 at the front of container 2. FIG. 25 shows that label 60 does not extend over this cored-out area120.

FIGS. 26-28 depict a solution to cored-out area 120 of the container of FIGS. 21-25. In the FIGS. 26-28 configuration, a snap-in cover 130 is hinged to the back corner 132 of the front wall 134 of base 4. When molded, snap-in cover 120 is disposed in an open configuration as shown in FIG. 26 which allows cored-out portion 120 to be formed in the mold. After container 2 is removed from the mold, snap-in cover 130 is moved to its closed configuration as shown in FIG. 27 and is held in place with one-way snap fit locking fingers. Cover 130 is configured to form a smooth rear surface 136 for container 2 with its back wall flush with the back wall of base 4. This allows label 60 to extend over the entire back wall 136 of container 2 as shown in FIG. 28.

In the above configurations, nest wall 76 and hub 78 may be replaced with a structure configured to interact with the item of merchandise being held in container 2.

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. Throughout the description and claims of this specification the word "comprise" and variations of that word, such as "comprises" and "comprising," are not intended to exclude additives, components, integers, or steps.

Claims

1. A merchandise storage container comprising: a base and a lid; a literature clip connected to the lid and extending inside the lid; the literature clip being adapted to hold at least a sheet of printed literature inside the lid; and the lid being free of openings aligned with the literature clip.

2. The container of claim 1 , wherein the literature clip is connected to the lid with a living hinge; the literature clip having been molded in an outboard position and moved about the living hinge to an inboard position.

3. The container of claim 2, wherein the literature clip is connected to the lid with a snap fit in the inboard position.

4. The container of claim 2, wherein the lid has a front wall; the front wall having an upper edge and a lower edge.

5. The container of claim 4, wherein the living hinge is disposed at the upper edge of the front wall.

6. The container of claim 4, wherein the living hinge is disposed intermediate the upper and lower edges of the front wall.

7. The container of claim 4, wherein the literature clip includes a pair of lock fingers and the lid defines a catch surface aligned with each of the lock fingers; each of the lock fingers snap fitting over one of the catches when the clip is in the inboard position.

8. The container of claim 1 , wherein the literature clip is connected to the clip with a snap fit connection.

9. A merchandise storage container comprising: a base and a lid; and a literature clip connected to the lid with a living hinge; the literature clip being disposed in an outboard position and movable about the living hinge to an inboard position.

10. The container of claim 9, wherein the literature clip is connected to the lid with a snap fit in the inboard position.

11. A merchandise storage container comprising: a base and a lid; the base having a back wall that defines a portion of the rear surface of the container; the base having a structure with a cored-out area under the structure; a cover being pivotably connected to the base and movable from an open configuration to a closed configuration; the cover having a back wall; the cover disposed over the cored-out area when the cover is in the closed configuration; and the back wall of the cover being aligned with the back wall of the base to form a smooth rear surface for the container.

12. The container of claim 11 , wherein the cover is held in the closed configuration with one-way snap fit locking fingers.

13. The container of claim 12, wherein the base has a front wall that defines a back corner; the cover being connected to the base with a living hinge disposed at the back corner of the front wall.

14. A merchandise storage container comprising: a base and a lid movable between open and closed configurations; the closed configuration of the base and lid defining a merchandise storage area between the base and lid; the base and lid having a plurality of outer surfaces; the base and lid being fabricated from a recyclable plastic; and at least one label connected to the an outer surface of the base and lid; the label being fabricated from a recyclable plastic.

15. The container of claim 14, wherein the label is slit at the location where it is bent around a corner.

16. A method for packaging a media disc comprising the steps of: printing graphic labels on demand as the media discs associated with the labels are loaded into storage containers; and adhesively connecting the printed labels to the loaded storage container