Package Assembly for Separately Packaging, Displaying, and Dispensing a Plurality of Articles

This application generally relates to packaging, and is specifically concerned with a packaging assembly formed from two releasably connectable package modules for separately packaging, displaying, and dispensing a plurality of articles, such as the cutting inserts used in metalworking machinery.

Various types of packaging for metalcutting inserts are known in the prior art. However, before the specialized nature of such packaging can be fully appreciated, some brief background is necessary concerning both the physical characteristics of the inserts, as well as the environment in which they are used.

Metalcutting inserts are used to cut and shape metal machine components in metalworking machinery such as lathes, drills, routers, and threading machines. Despite the large amounts of metal that each insert typically cuts in its lifetime, the actual dimensions of most inserts are quite small (i.e., less that one inch across). In use, such inserts are clamped or otherwise secured in a toolholder in the metalworking machine, which manipulates and forcefully engages a cutting edge of the insert against the metal being machined. Because they are formed from very hard sintered tungsten carbide, ceramic or cermet compositions, the cutting edges of such inserts are brittle, and are prone to chipping if bumped against another insert or otherwise exposed to significant shock. Additionally, because the cutting edges of a typical insert may only have a life expectancy of about an hour of hard machining, the machinist must unclamp a spent, dull insert from his cutting tool several times a day and replace it with a fresh insert from an insert package.

As a consequence of their brittle nature, the packaging for such inserts must protect the inserts from outside shock and prevent the cutting edges of adjacently packaged inserts from bumping against each other and chipping during transit from the insert manufacturer to the machinist. To this end, most prior art packaging arrangements provide a protective, plastic wall of material, individually around each insert. To facilitate the frequent need to replace a dull insert with a new one, some prior art packages have a sliding lid designed to dispense the new inserts contained inside.

In addition to these basic features, the applicants have noted a number of other features that would be highly desirable in such packaging. For example, the packaging should readily and immediately inform the machinist as to the precise type of inserts being stored therein so that the machinist can easily confirm that the packaged inserts are the type needed for a particular job. Additionally, while most insert packages presently in the industry are designed to contain ten cutting inserts, the lengthening lifetimes of such inserts due to advances in material sciences, along with the proliferation of small-volume machining operations, have led the applicants to conclude that it would be highly desirable for an insert package to optionally accommodate either five or ten inserts. Such optional accommodation of fewer inserts should occur without compromising the integrity of the package or the protection afforded the inserts. The packaging should further allow the machinist to quickly and positively dispense the inserts contained therein in order to minimize the time spent replacing dull inserts with new ones in the lathe or other machine tool where the inserts are being used. Moreover, the packaging should allow the inserts to be individually dispensed. If more than one insert is dispensed into the hand of a machinist at one time, the edges of the inserts might bump against each other, or one or more of the inserts might be dropped. In either case, unwanted chipping of the brittle insert edges might occur.

It would also be desirable if the packaging were compatible with automatic loading machinery, so that the packages could be quickly and efficiently loaded with inserts without the need for human labor. Further, if the packaging were stackable and laterally unitizable, space could be conserved during shipping and storing operations, the taking of inventory would be facilitated, and the shock-absorption capabilities of the resulting array of packages would be maximized. Finally, such packaging should be reusable over a long life span, like deposit soft drink bottles, to reduce the overall expense associated with the packaging, and formed from recyclable plastics or other materials so that new packaging can be fabricated from worn-out packaging.

Presently, the applicants are not aware of any insert packaging that completely fulfills all of the aforementioned criteria. Clearly, there is a need for such packaging.

Generally speaking, the invention is a package assembly that fulfills all of the aforementioned criteria. The new package assembly is formed from two detachably connectable package modules, each of which separately packages, displays, and dispenses a plurality of articles, such as cutting inserts, wherein each module is substantially structurally identical to the other.

Moreover, each of the package modules comprises an elongated tray having a top portion, a bottom wall, sidewalls, and a plurality of spaced-apart interior walls traversing its longitudinal axes for defining a plurality of article holding chambers, a lid for retaining, displaying, and sequentially dispensing the articles disposed in the chambers of the tray, and a cantilevered lip for detachably interconnecting the sidewalls of the trays of two different package modules such that the bottom wall of the tray of one module and the lid of the other module face the same direction.

The outer surface of the bottom wall of the tray may include a labeling film for displaying written information concerning the nature of the articles packaged in the assembly, such that once a user picks up a particular package assembly, he simultaneously sees not only the articles themselves through the lid of one module, but also the written information concerning the articles printed on the outer surface of the bottom wall of the other module. This is advantageous when the package assembly is used to package inserts used by machinists, as the machinist can easily and immediately identify the particular kind of insert packaged by the assembly by merely glancing at it. Additionally, the fact that the package modules forming the assembly can be easily detached from one another allows the consumer of the articles packaged therein to buy fewer of the articles, if desired, without compromising the integrity of the packaging structure that surrounds and protects the articles.

Each package module preferably includes a means for detachably connecting the bottom wall of the tray of one module with the top portion of the tray of another module to render the modules vertically stackable and vertically unitized. In the preferred embodiment, such detachable connecting means includes a pair of parallel ribs protruding from the bottom wall of the tray of one module that resiliently engage the top edges of the tray of another module. This feature, in combination with cantilevered lips that allow two modules to be releasably interconnected along their sidewalls, provides both a horizontal and vertical unitizing capability. Hence the individual modules can be joined in a fashion which not only facilitates the storing and shipping of the articles contained within the modules, but the taking of an inventory of the articles as well.

Each package module may further include a detent means for stopping the slidable movement of the lid in the tray whenever the lid completely uncovers one of the article chambers. In one embodiment, the detent means is formed from a pair of opposing recesses in the lid which catch onto opposing beads integrally molded into the tray. The beads are received within the recesses whenever the lid is slid to a position uncovering another one of the chambers in the tray.

A similar arrangement may be incorporated between the tapered ends of the parallel flanges of one tray and the parallel ribs protruding from the bottom wall of another tray such that the sliding motion between unitized trays may be stopped.

The lid may include a finger-receiving recess for facilitating the gripping and sliding thereof by the user. A magnifying lens may be integrally molded into the transparent plastic or other material forming the lid to provide a magnified image of the article being held within the module.

The tray and lid of each module is preferably formed from a recyclable plastic material, in order to render each module not only reusable, but completely recyclable as well. Finally, the elongated shape of the tray and the sliding connection between the top portion of the tray and the lid not only allow each module of the assembly to sequentially and individually dispense an article, but also render the module of the invention compatible with article loading machinery.

FIG. 1 is a perspective view of the package module of the invention;

FIG. 2 is a side view of the module illustrated in FIG. 1 along the line 2--2;

FIG. 3 is a cross-sectional side view of the module illustrated in FIG. 1 along the line 3--3 with the lid removed from the tray of the module;

FIGS. 4A, 4B and 4C are a plan view, cross-sectional side view, and end view of the lid of the packaging module, respectively;

FIG. 5 is a plan view of two modules releasably interconnected together to form the package assembly of the invention, and

FIG. 6 is an end view of a vertically unitized stack of the packaging assemblies of the invention.

With reference now to FIGS. 1, 2, and 3 wherein like numerals designate like components throughout all the several figures, the package module 1 of the invention generally comprises an elongated tray 3 over which a transparent lid 5 is slidably mounted. A cantilevered lip 7 extends from one of the sidewalls of the tray 3 in order to render the module 1 releasably interconnectable with the cantilevered lip 7 of another package module 1' to form the package assembly 55 illustrated in FIG. 5. A pair of opposing, parallel ribs 9a,b extend out from the bottom of the elongated tray 3 in order to render the module 1 vertically stackable with another such module, as will be described in more detail hereinafter.

With reference to FIG. 3, the tray 3 of the module 1 includes a top portion 13 having a pair of opposing, parallel slots 15a,b best seen in FIG. 3. Two pairs of opposing, bead-like detents 17a-d (of which only 17a,b are shown) are disposed along the parallel slots 15a,b at either end of the tray 3 for a purpose which will become evident shortly. Disposed above the parallel slots 15 are a pair of parallel flanges 19a,b, each of which terminates in a tapered end 21 as shown. The detents 17c,d are located along the parallel slots and are distanced from the side wall 25b approximately the same amount as detents 17a,b are distanced from the side wall 25d.

In an alternative embodiment, bead-like detents may be disposed along one of the parallel slots 15a,b on only a single side of the tray. Furthermore, while the detents 17a-d shown in FIG. 3 are on a horizontal surface of the slots 15a,b, the detents may alternatively be on a vertical surface of the slots 15a,b.

With reference now to FIGS. 2, 3, and 5, the elongated tray 3 of the package module 1 further includes a bottom wall 23. The outer surface of the bottom wall 23 may include a label film 24 (shown in phantom in FIG. 5) which is specifically designed to carry and display written information concerning the contents of the module 1. However, such a label film may also be placed on the top surface of the transparent lid 5. Sidewalls 25a-d interconnect the bottom wall 23 with the previously described top portion 13. These walls interconnect one another by means of rounded joints 27. Such rounded joints 27 are preferred over the sharply angular joints associated with the prior art, as the arcuate contours of such joints are less apt to rupture blister packing or tear through envelope packaging when the package module 1 is used as a shipping container. Located in the interior of the elongated tray 3 are four interior walls 29a-d which are disposed orthogonally with respect to the longitudinal axis of the tray 3. These interior walls 29a-d define five article-holding chambers 31a-e which, in the preferred embodiment, are shaped like flattened cubes. The flattened cube shape of each of the chambers 31a-e maximizes the number of types of cutting inserts (or other objects) that a particular module 1 can safely contain and protect. As an optional feature, a shallow, concave indentation 33 may be provided on the floor of each of the article holding chambers 31a-e. These concave indentations 33 help to center the article contained within the chambers 31a-e when the bottom wall 23 is oriented downwardly as shown in FIGS. 1, 2, and 3. In the preferred embodiment, the elongated tray 3 is preferably formed from a recyclable plastic material, such a polystyrene.

With reference now to FIGS. 4A, 4B, and 4C, the lid 5 of the module 1 is preferably transparent and likewise formed from a recyclable plastic material, such as K-Resin.RTM. copolymer. K-Resin.RTM. is a trademark of the Phillips Petroleum Company to describe a series of styrene-butadiene copolymers. The lid 5 includes a pair of opposing side rails 36a,b which are slidably movable within the previously described parallel slots 15a,b located on the top portion 13 of the elongated tray 3. The side rails 36a,b include five opposing pairs of detent-receiving notches 38a-e and 39a-e, respectively. Each opposing pair of notches is engagable with one of the two pairs of detents 17a,b and 17c,d located within the slots 15a,b on the top portion 13 of tray 3. The relative longitudinal spacing of the notches 38a-e and 39a-e with the pairs of detents 17a,b and 17c,d on the top portion 13 of the tray 3 is such that whenever one or both of the pairs of detents 17a,b or 17c,d is snapped into registry with one of the pairs of notches 38a-e and 39a-e, the lid 5 has completely uncovered one of the article holding chambers 31a-e. This feature greatly aides the dispensing function of the module 1, as the user knows that whenever the detents 17a,b and 17c,d snap into the opposing pairs of notches 38a-e and 39a-e on the lid 5, that the lid 5 has completely cleared another one of the chambers 31a-e, whereupon the article in the chamber may be freely removed. As is indicated in phantom is FIG. 4A, a magnifying lens 42 may be integrally molded into the transparent plastic material forming the lid 5, if desired. The lid 5 may also include a finger-receiving recess 40 for facilitating the gripping and sliding of the lid 5. Finally, as is best seen in FIGS. 4A and 4B, transverse reinforcing ribs 44a-d may be integrally formed on the underside of the lid 5 for strengthening purposes. These reinforcing ribs 44a-d are spaced apart the same distance as the interior walls 29a-d in the tray 3 so that they will not interfere with the view of the inside of the article-holding chambers 31a-e.

An alternative embodiment for the bead-like detents along the parallel slots 15a,b of the tray 3 was previously discussed in which the detents were disposed on a vertical surface within one or both of the slots 15a,b. Consistent with that, an alternative embodiment of the lid 5 involves positioning the notches 38a-e within the side rails 36a,b such that they engage the detents on the vertical surface of the slots 15a,b. While not shown, the plan view of FIG. 4A would have horizontal indentations where items 38a-e and 39a-e now appear.

With reference in particular to FIGS. 3, 5, and 6, the cantilevered lip 7 of the package module 1 includes a rounded section 47 which orients the underside of the lip 7 parallel with sidewall 25a of the tray 3. The lip 7 further terminates in a retention bead 49 as shown. The spacing of the underside of the lip 7 from the sidewall 25a and the dimensions of the retention bead 49 are such that the cantilevered lip 7 of one module 1 can releasably capture the cantilevered lip 7' of another module 1' as is shown in FIG. 6. When two such modules 1 and 1' are releasably and horizontally interconnected via their cantilevered lips 7 and 7', they form the package assembly 55 illustrated in FIG. 5. Such a packaging assembly 55 can advantageously be broken back down into two individual package modules 1 and 1' by sliding the cantilevered lips 7 and 7' out of engagement from one another. Additionally, because the transparent lid of one module 1 and the bottom wall 23 of the other module 1' always face the same direction, the user of the articles contained within the package assembly 55 can see a label with written information describing the articles, whether the label is on the lid 7 or the bottom wall 23 of a module. However, a label having transparent portions should be used when the label is on the lid 5 so that the tray contents may still be seen.

While not shown in the figures, a small protrusion may be extended from the tray wall 25a beyond each end of the cantilevered lip 7 so that when two modules are horizontally coupled, the tendency for the modules to shift within the engaged cantilevered lips 7 and 7' will be minimized.

FIG. 6 illustrates how a plurality of package assemblies 55 may be detachably connected in the vertical direction to form a unitized stack 59. Specifically, because the distance between the tapered ends 21 of the parallel flanges 19a,b on the top portion 13 of each module 1 is slightly less than the distance between the retention feet 53 disposed OD the outside of the parallel ribs 9a,b, these retention feet 53 may be snap-fitted within the tapered ends 21 of the flanges 19 as is seen in FIG. 6. Additionally, to enhance the bond with the tapered ends 21 of the flanges 19, the retention feet 53 may be slightly angled toward the module side walls 25a,c as illustrated in FIGS. 2 and 3. With such an arrangement, there exists contact between mating retention feet 53 and flanges 19a,b and any tendency for sliding between these elements would be resisted by friction as a result of the contact between them. However, to further counter any tendency for these elements to slide relative to one another, while not shown in the figures, it is possible to provide a pair of beads extending outwardly from one or both of the feet 53 with a distance between each pair greater than the length of the tapered ends 21 of flanges 19a,b. In this manner, when modules are vertically engaged through resilient contact between retention feet 53 and tapered ends 21, the beads on the retention feet 53 may be positioned to restrain horizontal movement of the feet 53 with respect to the tapered ends 21 of the flanges 19a,b.

While FIG. 6 specifically shows how packaging assemblies 55 formed from two horizontally interconnected modules 1, 1' may be vertically stacked together, it is also possible to vertically stack individual package modules 1 which are not horizontally interconnected to another module 1' if desired.

While the invention has been described with reference to a specific embodiment thereof, various modifications, additions, and improvements, will be apparent to a person having ordinary skill in the packaging arts. All such modifications, additions, and improvements are intended to be encompassing within this invention, which is limited only by the claims appended hereto.