Patent Application
20060042995
This invention relates to suspension packages that suspend an article within upper and lower holding members, held in place by resilient suspension films.
For the transportation of valuable surface-sensitive objects that are relatively non-breakable (e.g., prisms, lenses, coins, jewelry, orthodontics, semiconductor wafers, and the like), it is often desirable to immobilize the objects within an outer packaging container. Suspension packages of a general type that suspend the article between upper and lower covers and hold the article in place by resilient films are particularly well suited for such applications.
U.S. Pat. No. 5,988,387 (assigned to the assignee of the present invention) describes suspension packages of this type. As best shown by
The scope of the present invention is defined solely by the appended claims, and is not affected to any degree by the statements within this summary.
By way of introduction, a first suspension package embodying features of the present invention includes: (a) a first holding member; (b) a second holding member pivotably connected to the first holding member along a living hinge, such that the first and second holding members are configured to pivot between open and closed positions; (c) a first mounting ring detachably connectable to the first holding member, wherein the first mounting ring comprises a first film-mounting surface; (d) a second mounting ring detachably connectable to the second holding member, wherein the second mounting ring comprises a second film-mounting surface; (e) a first suspension film mounted to the first film-mounting surface; and (f) a second suspension film mounted to the second film-mounting. The first suspension film is configured to be recessed with respect to an upper peripheral surface of the first holding member, and the second suspension film is configured to protrude beyond an upper peripheral surface of the second holding member.
A second suspension package embodying features of the present invention includes: (a) a first cover defining a first product-receiving well; (b) a second cover defining a second product-receiving well, wherein the second cover is pivotably connected to the first cover along a living hinge, such that the first and second covers are configured to pivot between open and closed positions; (c) a first mounting ring detachably connectable to the first cover, wherein the first mounting ring comprises a first film-mounting surface; (d) a second mounting ring detachably connectable to the second cover, wherein the second mounting ring comprises a second film-mounting surface; (e) a first suspension film mounted to the first film-mounting surface and configured to extend over at least a portion of the first product-receiving well; and (f) a second suspension film mounted to the second film-mounting surface and configured to extend over at least a portion of the second product-receiving well. The first suspension film is configured to be recessed with respect to an upper peripheral surface of the first product-receiving well, and the second suspension film is configured to protrude beyond an upper peripheral surface of the second product-receiving well.
A third suspension package embodying features of the present invention includes: (a) a first mounting ring comprising a first film-mounting surface; (b) a second mounting ring comprising a second film-mounting surface, wherein the second mounting ring is pivotably connected to the first mounting ring along a living hinge, such that the first and second mounting rings are configured to pivot between open and closed positions; (c) a first suspension film mounted to the first film-mounting surface; and (d) a second suspension film mounted to the second film-mounting surface.
Suspension packages of a type that suspend an article within upper and lower holding members, held in place by resilient suspension films, have been discovered and are described hereinbelow. In presently preferred configurations described below, all portions of the suspension package other than the detachable mounting rings may be desirably formed from a single material in a single manufacturing operation. As further described below, portions that may be thus formed (i.e., from one material in one operation) include but are not limited to the first holding member or cover, the second holding member or cover, the living hinge, the first locking member, and the second locking member. The manufacture of suspension packages embodying features of the present invention is simpler, less expensive, and less time-consuming than that of previous designs. For example, separate manufacturing and subsequent assembly of the hinging mechanisms and closure or locking mechanism may be avoided. In addition, these suspension packages are less susceptible to hinge and/or closure malfunction and breakage, and provide enhanced performance reliability. Moreover, these suspension packages have sleek and streamlined designs that provide an aesthetic appeal.
Throughout this description and in the appended claims, the following definitions are to be understood:
The phrase “living hinge” refers to a hinge in a substantially continuous piece of material. By way of example, the living hinge may be a molded unit in which two pivotable portions (e.g., the first and second holding members of a suspension package, which are pivotable with respect to one another) are disposed on either side of the hinge.
The phrase “locking member” refers to one element of a locking mechanism that is configured to engage detachably with a second element of the locking mechanism having a complementary structure, such that the two elements are configured to remain joined until disengaged.
The term “complementary” is used to describe a structural element that has the requisite geometry to engage with a second structural element to provide a detachable connection between the two elements. By way of example, this detachable connection may be achieved by virtue of a friction or snug-type fit, a snap fit, a pressure fit or the like.
The phrase “fully open” refers to an open configuration of the first and second holding members of a suspension package that is sufficient to allow product insertion within. As used herein, a suspension package described as being “fully open” (e.g., the suspension package shown in FIG. 2) may still allow for additional unfolding beyond that needed for product insertion.
Presently preferred embodiments in accordance with the present invention will now be described in reference to the appended drawings. It is to be understood that elements and features of the various representative embodiments described below may be combined in different ways to produce new embodiments that likewise fall within the scope of the present invention. Accordingly, the description provided below, when provided in reference to one or more specific figures, is to be understood as being likewise applicable to other embodiments, including but not limited to those that are shown in other drawing figures that may not have been specifically referenced.
As best shown by
In presently preferred configurations, as best shown by
As best shown by
In a presently preferred configuration, the ledge surfaces 30 on second cover 8 are substantially flush with the upper peripheral surface 32, whereas the ledge surfaces 26 on first cover 4 are slightly recessed below the upper peripheral surface 28, as shown in
As shown in
In presently preferred embodiments described herein, the mechanism for detachably connecting mounting rings to the covers of a suspension package include one or a plurality of mounting legs and one or a plurality of complementary sockets. Although mounting legs and sockets are presently preferred mounting mechanisms for use in accordance with the present invention, the present invention is not limited thereto. All manner of alternative means for mounting, and all equivalents thereto, may also be employed. Representative alternative means for mounting include but are not limited to adhesives, tongue and groove assemblies, stud and socket assemblies, magnets, VELCRO hook and loop fabric fasteners, and the like, and combinations thereof.
In presently preferred configurations, first cover 4 includes a first locking member, and second cover 8 includes a complementary second locking member. Although all manner of locking mechanisms whereby first cover 4 and second cover 8 may be held in a closed position are contemplated for use in accordance with the present invention, a presently preferred configuration is shown in FIGS. 14 and is best shown by
In presently preferred embodiments described herein, the mechanism for detachably locking the covers of a suspension package in the closed position include a protruding element and a gripping element, such as described above. Although protruding elements and complementary gripping elements are presently preferred locking mechanisms for use in accordance with the present invention, the present invention is not limited thereto. All manner of alternative means for locking, and all equivalents thereto, may also be employed. Representative alternative means for locking include but are not limited to stud and socket assemblies, tab and slot assemblies, magnets, hook and loop assemblies, adhesives, VELCRO hook and loop fabric fasteners, screw and screwhole assemblies, and the like, and combinations thereof.
All manner of regular and irregular geometric shapes, including those based on specific shapes of products to be retained, are contemplated for the design of first cover 4, second cover 8, first product-receiving well 6, and second product-receiving well 10. However, the geometric shapes of first mounting ring 14 and second mounting ring 18 should preferably be chosen to substantially match the geometry of first and second covers, 4 and 8, respectively, at least at the portions adjacent to upper peripheral surfaces 28 and 32, respectively.
In a presently preferred configuration, shown in
As shown in
In accordance with the present invention, all manner of materials (e.g., polymeric materials such as plastics, sheet metal, wood, and the like) are contemplated for use in the manufacture of first cover 4 and second cover 8. It is presently preferred, however, that first cover 4 and second cover 8 comprise a contiguous sheet of material (i.e., an integral, continuous piece of material, such as may be formed in a single molding operation). Presently desirable materials are polymeric materials, such as polyethylene, polypropylene, polyurethane, and the like. Moreover, it is presently preferred that the contiguous piece of material used to form first cover 4 and second cover 8 be clear rather than opaque to enable a user to observe the contents of the suspension package 2 without opening it.
Furthermore, it is presently preferred that each of first cover 4, second cover 8, the first locking member (e.g., protruding element 34), and the complementary second locking member (e.g., gripping element 36) comprise a contiguous sheet of polymeric material, such as polyethylene, polypropylene, polyurethane or the like. Thus, all portions of the suspension package 2 other than the first and second mounting rings, 14 and 18, respectively, may be formed in a single molding operation, thereby minimizing the material, labor, and time costs of individually manufacturing and then assembling top and bottom covers and a closure mechanism.
The above-described one-piece units containing a built-in living hinge and a built-in closure mechanism are preferably manufactured by injection molding or thermoforming, with injection molding, which enables the introduction of different thicknesses throughout the unit, being particularly desirable at present. Assembly of the complete suspension package 2 is accomplished by mounting first and second suspension films, 22 and 24, respectively, to first and second film-mounting surfaces, 16 and 20 respectively, for example using heat and/or adhesives and/or sonic welding and/or RF welding techniques. Then, each of first and second mounting rings, 14 and 18, respectively, is mounted to a respective cover 4 or 8 by pushing the mounting legs 38 into sockets 40. The mounting legs 38 are dimensioned to hold the mounting rings 14 and 18 in place by a friction fit. Since the first and second mounting rings, 14 and 18, respectively, are held in place in the first and second covers, 4 and 8, respectively, with a friction fit rather than a latch mechanism, the sockets 40 may be simply molded in a conventional molding operation in which the mold parts move in only a single direction as the mold is open or closed. This further reduces manufacturing costs.
Since the first locking member (e.g., protruding element 34) and the complementary second locking member (e.g., gripping element 36) are formed in the mold, no additional manufacture or assembly is needed. In the closed position shown in
In the first series of suspension packages shown in
As described above in connection with the first series of suspension packages embodying features of the present invention, it is presently preferable that first mounting ring 56 is recessed with respect to an upper peripheral surface 70 of the first holding member 50 in which it is fitted, and second mounting ring 62 is raised with respect to an upper peripheral surface 74 of the second holding member 52 in which it is fitted or vice versa. Preferably, the amount that one mounting ring is raised is substantially equal to the amount that the other mounting ring is recessed. Preferably, this amount corresponds to the thickness of the mounting rings, such that when suspension package 48 is in the fully closed position, the first and second suspension films, 58 and 64, respectively, will be in close proximity and/or in contact along at least a portion of the interface therebetween. Representative structures for providing the recessing and raising of the mounting rings are described below. Alternative mechanisms, including but not limited to those described above, may likewise be used.
As shown in
In a presently preferred configuration, the ledge surfaces 72 on second holding member 52 are substantially flush with the upper peripheral surface 74, whereas the ledge surfaces 68 on first holding member 50 are slightly recessed below the upper peripheral surface 70, as shown in
In presently preferred configurations, first holding member 50 includes a first locking member, and second holding member 52 includes a complementary second locking member. Although all manner of locking mechanisms whereby first holding member 50 and second holding member 52 may be held in a closed position are contemplated for use in accordance with the present invention, including but not limited to those described above, a presently preferred configuration is analogous to that described above in reference to
As shown in
Suspension packages of the type shown in
All manner of geometric shapes are contemplated for the first and second mounting rings, 86 and 90, respectively, shown in
Suspension packages of the type shown and described herein may be used for a variety of applications, including for packaging articles, such as electronics, optics, medical products, surgical implements, and the like, which are to be maintained in a clean and/or sterile container until their moment of use. In such instances, the suspension package may be cleaned and/or sterilized prior to product insertion and, once the product is in place, may optionally be sterilized. The preferred one-piece assemblies described herein, wherein all elements of the suspension package except for the mounting rings are formed from a substantially continuous piece of a single material, may be readily cleaned and/or sterilized by procedures well known to those of ordinary skill in the art. Such cleaning and sterilization procedures may be easier, less expensive, and more effective than analogous procedures used for the cleaning and/or sterilization of multi-piece suspension packages that lack built-in hinging and/or locking mechanisms in accordance with the present invention.
All manner of dimensions are contemplated for suspension packages embodying features of the present invention. As will be appreciated by those skilled in the art, package dimensions may be determined in view of the size of article to be package. Solely by way of illustration, representative dimensions and construction details are provided below, although it is to be understood that these details are merely illustrative and are not intended to limit the scope of the appended claims or their equivalents.
In an exemplary design, a suspension package 2 in the fully closed position is about 2.64 inches in height measured from the exterior surfaces of first and second covers, 4 and 8, respectively. Each of the first and second product-receiving wells, 6 and 10, respectively, is about 1.25 inches in depth measured from an interior bottom surface of the wells to first and second suspension films, 22 and 24, respectively. The length of the living hinge 12 is about 4.00 inches measured from end to end. The width of living hinge 12 is about 0.23 inches. The length of first and second covers, 4 and 8, respectively, is about 6.95 inches measured from one exterior end surface to the other. The width of first and second covers, 4 and 8, respectively, is about 5.04 inches measured from one exterior side surface to the point at which the other exterior side surface is attached to living hinge 12. The length of first and second mounting rings, 14 and 18, respectively, is about 6.76 inches measured from one exterior end surface to the other. The width of first and second mounting rings, 14 and 18, respectively, is about 4.85 inches measured from one exterior side surface to the other. The wall thickness of first and second covers, 4 and 8, respectively, is about 0.07 inches measured from an interior surface to an exterior surface.
In some embodiments, the first and second mounting rings, 14 and 18, respectively, may be formed from any polymeric materials, with polyurethanes being a presently preferred example (e.g., Dow 302EZ PUR). In some embodiments, the first cover 4, second cover 8, protruding element 34, and gripping element 36 may be formed (e.g., via injection molding) from any polymeric material, with a styrene-butadiene copolymer such as that sold under the tradename K-resin® (Chevron Phillips Chemical Company LLC) being a presently preferred example. PCTG (e.g., Eastman PCTG) is another representative material that may be used. In some embodiments, the first and second suspension films, 22 and 24, respectively, may be formed of any polymeric material, with polyurethane being a presently preferred example. All manner of film thicknesses are contemplated for use in accordance with the present invention, with film thicknesses between about 2 and about 4 mils being presently preferred. It is presently preferred that the material used to form first and second mounting rings, 14 and 18, respectively, and the material used to form first and second suspension films, 22 and 24, respectively, be compatible to ensure proper a seal. In some embodiments, each of these elements is formed from a polyurethane material.
In the suspension package 2, the first and second suspension films, 22 and 24, respectively, are preferably tensioned on and then sealed to the first and second mounting rings, 14 and 18, respectively, before the mounting rings are installed in place on the first and second covers, 4 and 8, respectively. This may generally be achieved by stretching the first and second suspension films, 22 and 24, respectively, with a holding fixture as the films are secured in place to the first and second mounting rings 14 and 18—for example, by heating, sonic welding, RF welding, or the like. Excess film may be trimmed from the outer periphery of the mounting rings after the film has been secured thereto. For example, the holding fixture for the film may hold enough film for one to six or more rings, which all may be secured to the film in a single bonding operation.
Of course, numerous changes and modifications may be made to the embodiments described herein, as will be appreciated by those skilled in the art. For example, the various walls have been illustrated as plates, and they can be formed with or without ribs and as curved or flat sections. If desired, the suspension films may be mounted directly to the respective covers rather than to mounting rings that are in turn mounted to the covers. Furthermore, dimensions, proportions and other geometrical considerations may all be modified as appropriate for a particular application.
The foregoing detailed description and accompanying drawings have been provided by way of explanation and illustration, and are not intended to limit the scope of the appended claims. Many variations in the presently preferred embodiments illustrated herein will be obvious to one of ordinary skill in the art, and remain within the scope of the appended claims and their equivalents.
