Product packaging with releasable fastener

This application is a continuation of non-provisional application Ser. No. 12/906,413, entitled “Product Packaging with Releasable Fastener” and filed on 18 Oct. 2010, which is a continuation of non-provisional application Ser. No. 12/249,235, entitled “Product Packaging with Releasable Fastener” and filed on 10 Oct. 2008. The disclosure of each of the above applications is hereby incorporated by reference in its entirety.

The present invention is directed toward product packaging and, in particular, to toy product packing including a releasable, reusable product fastener.

Products such as toys are generally placed in packaging that provides protection to the toy, as well as and provides a means to easily display the toy. The toys are often held within the packaging by wire tie elements, which surround the toy and are twisted together to hold the toy in place in the packaging. This design works for small toys; however, large toys require a significant amount of wire and, because of the shape of the toys, it may not be practical to place the wire around the toy to retain it in its packaging. In addition, removal of such a large amount and number of wire tie elements is tedious and time-consuming. Thus, it is desirable to create a fastening system that secures a product within its packaging, but is easily manipulated by a user to remove the product therefrom.

A fastener system for product packaging is disclosed. The system includes a product, a support platform, and a plug that engages a keyhole formed into the product. The plug includes a base and a key extending from the base. The support platform includes a through-hole that permits the passage of the key into the packaging. In operation, a product is oriented on one side of the support platform, and the plug is oriented on an opposite side of the support platform. The key is inserted though the packaging (via the through-hole), and into the keyhole formed in the product. The key is then rotated to misalign its fingers with the openings in the keyhole, preventing the key's exit from the keyhole. Biasing members located on the base of the plug draw the key toward the product to create a secure connection. With this configuration, a product may be secured within packaging without the use of wire tie fasteners.

FIG. 1 illustrates an exploded view of a product fastening system in accordance with an embodiment of the present invention.

FIGS. 2A and 2B illustrate a plug in accordance with an embodiment of the present invention. Specifically, FIG. 2A illustrates an isolated, top perspective view of a plug component of the fastening system in accordance with an embodiment of the present invention. FIG. 2B illustrates a bottom perspective view of the plug of FIG. 2A .

FIG. 3 illustrates a support platform in isolation, showing a close-up of the through-holes.

FIGS. 4A and 4B illustrate a portion of a wall forming the product if FIG. 1 . Specifically, FIG. 4A illustrates a side view of the product wall, while FIG. 4B illustrates an interior view of the product wall of FIG. 4A .

FIG. 5A illustrates an interior view of the product, showing the plug/key oriented in an unlocked position.

FIG. 5B illustrates an interior view of the product, showing the plug/key oriented in a locked position.

FIG. 6A illustrates a cross-sectional view of the product, showing the insertion of the key into the keyhole of the product.

FIG. 6B illustrates a rear perspective view of the support platform, showing orientation of the plug in locked/unlocked positions.

FIGS. 7A and 7B illustrate a plug/key in accordance with another embodiment of the present invention.

FIG. 8 illustrates a side perspective view of a key/plug in accordance with the present invention, indicating the application of shear forces thereon.

Like reference numerals have been used to identify like elements throughout this disclosure.

FIG. 1 illustrates and exploded view of a product fastening system in accordance with an embodiment of the invention. As illustrated, the system 100 includes a key or plug, a product support or platform 120 , and a product 130 . By way of example the system 100 may include one or more plugs 110 A, 110 B, 110 C, each having a stem of a predetermined length. The plugs 110 A- 110 C are configured to selectively secure the product 130 to the product support 120 . Referring to FIGS. 2A and 2B (showing top and bottom views, respectively), the plug 110 A includes a base 200 and a shaft or stem 210 extending distally from the base 200 . The base 200 may be in the form of a plate or disk having a first or top surface 220 and a second or bottom surface 230 . The shaft 210 may be disposed coaxially with the central axis of the base 200 . The distal end 240 of the shaft may further include a first finger 250 A and a second finger 250 B collectively defining a keyed end of the shaft 210 . The base 200 may further include one or more cut-out sections 260 configured to permit gripping of the base utilizing a users fingers. By way of example, the base 200 may include a pair of opposed, curved, cut-out sections 260 formed into the periphery of the base.

The plug 110 A may further include one or more biasing members. In the embodiment of FIGS. 2A and 2B , the plug 110 A may have a first spring 270 A and a second spring 270 B formed into the base 200 . The springs 270 A, 270 B may be positioned along the base periphery such that the first spring 270 A is oriented opposite the second spring 270 B. The biasing members 270 A, 270 B apply a force to the product support 120 and/or the product 130 to increase the tension between the plug 110 A-C and the product 130 (discussed in greater detail below). While a particular configuration spring is illustrated as the biasing member 270 A, 270 B, it should be understood other forms of the biasing member could be utilized such as a flat springs, coil springs, cantilevered springs, leaf springs, etc.

The product support or platform 120 provides a surface to which the product 130 may be secured. The product support 120 typically comprises a portion of product packaging, e.g., a wall or a display platform, to which the product 130 is secured. Referring to FIG. 3 , the product platform 120 may be a generally planar element having a first or outer surface 310 and a second or inner surface 320 . The planar member may include one or more key ports 330 configured to receive the keyed end of a respective plug 110 A- 110 C. That is, the key port 330 possesses a shape and has dimensions suitable to permit the passage of the distal/keyed end 240 of the plug shaft 210 , while preventing the passage of the base 200 therethrough. As illustrated, the port 330 may possess a generally circular shape having a diameter slightly larger than the diameter of the fingers 250 A, 250 B, to permit the fingers to pass therethrough.

The product support 120 may further include one or more receptacles or guide tracks configured to receive and/or orient the biasing members 270 A, 270 B on the plug 110 A-C. By way of example, the product support 120 may include a first guide track 340 A and a second guide track 340 B oriented opposite the first guide track 340 A, across the port 330 (i.e., each biasing member 270 A, 270 B may include an associate track 340 A, 340 B with which it mates). The structure of the guide track 340 A, 340 B may be any suitable for its described purpose. In the illustrated embodiment, the guide tracks 340 A, 340 B are each defined by a generally rectangular opening that permits a biasing member 270 A, 270 B to extend through or into the platform 120 . Each guide track 340 A, 340 B is positioned and sized to receive a corresponding biasing member 270 A, 270 B, indicating the orientation of the plug 110 A-C in either a locked or unlocked position (discussed in greater detail below). The product support 120 may be formed from any conventional packaging materials including, but not limited to, plastic, cardboard, wood, etc.

The product 130 , e.g., a toy, is configured to selectively mate with the plugs 110 A-C. Referring to FIGS. 4A and 4B , showing exterior and interior views the product 130 , the product 130 includes a wall 400 having a first or exterior side 410 and a second or interior side 420 . The wall 400 includes one or more keyholes 430 possessing a shape complimentary to that of the distal end 240 of each of the plugs 110 A-C. In the embodiment illustrated in FIGS. 4A and 4B , the keyhole 430 is a generally elongated slot that receives the fingers 250 A, 250 B of the plug 110 A-C when properly aligned with the slot. The keyhole 430 may be formed on a pedestal 440 extending distally from the interior surface 420 of the product wall 400 .

The pedestal 440 may form a corresponding recessed area 450 along the exterior surface 410 of the product wall 400 . The height of the pedestal 440 is not particularly limited, but is typically is sized to correspond with the length of the stem 210 extending form the base 200 of the plug (taking into account the thickness of the product wall 400 as well as the product support 130 ). By way of example, the pedestal 440 may have a height corresponding to the stem of plug 110 A, or may have a height corresponding to the stem of plug 110 B ( FIG. 1 ). Alternatively or addition, no pedestal 440 may be formed into the product wall 400 to permit the keyhole 430 to be generally flush with the product wall 400 . Note that for exemplary purposes, all three examples are shown in FIGS. 1 , 4 A, and 4 B.

With this configuration, plug 110 A-C selectively engages the keyhole 430 to secure the product 130 to the support 120 . Referring to FIGS. 5A and 5B , the stem 210 of the plug 110 A-C may be axially inserted into the port 330 of product support 120 and through the keyhole 430 formed in the product 130 . The plug 110 A-C may then be selectively rotated from a first (unlocked) position ( FIG. 5A ), in which the fingers 250 A, 250 B of the plug generally align with the keyhole 430 , to a second (locked) position ( FIG. 5B ), in which the fingers 250 A, 250 B of the plug 110 A-C are not aligned with the keyhole 430 . In the locked position of FIG. 5B , the plug 110 A-C is secured to the product 130 . To unlock the plug 110 A-C and remove it from the keyhole 430 , the plug 110 A-C is simply rotated in the reverse direction until the fingers 250 A, 250 B of the plug 110 A-C once again align with the slot of keyhole 430 . The stem 210 of the plug 110 A-C is then axially removed from the product 130 .

The operation of a fastening system in accordance with the present invention is explained with reference to FIGS. 6A and 6B . FIG. 6A illustrates a cross-sectional view of the system in accordance with an embodiment of the invention. The product 130 is positioned on the second side 320 of the support platform 120 , and the plug 110 A-C is positioned on the first side 310 of the support platform. The port 330 of the support platform 120 is generally aligned with a keyhole 430 of the product 130 , and the plug 110 A-C is axially inserted through the port 330 of the support platform 120 and into the keyhole 430 of the product 130 . The plug 110 A-C may then be rotated to move the plug 110 A-C (by gripping the cut-out sections 260 ) from the unlocked position to the locked position as described above.

Referring to FIG. 6B , illustrating a rear perspective view of the system, the plug 110 A-C may be rotated utilizing finger cut-out sections 260 until the biasing members 270 A, 270 B align with the guide tracks 340 A, 340 B formed into the product support 120 . The biasing members 270 A, 270 B and guide tracks 340 A, 340 B may be oriented such that mating of the biasing members with the guide tracks indicates the fingers 250 A, 250 B of the plug 110 are oriented in their misaligned/locked position with respect to the keyhole 430 of the product 130 . The biasing members 270 A, 270 B apply a downward pressure (from the perspective of FIG. 6A ) to the plug stem 210 , drawing the distal end 240 of the stem downward, toward the interior surface 420 of the product wall 400 . This, in turn, increases the frictional forces between the fingers of the plug 110 A-C and the product 130 , improving the connection of the product 130 to the product support 120 . The biasing members 270 A, 270 B further function as shock absorbers, adjusting to movement of the packaging during transport and stabilizing the product 130 .

To release the product 130 from the product support 120 , the plug 110 is rotated to displace the biasing members 270 A, 270 B from the guide tracks 340 A, 340 B until the fingers 250 A, 250 B are once again axially aligned with the keyhole 430 of the product 130 as described above. The plug 110 A-C may then be removed from the product 130 , which, in turn, may be removed from the support platform 120 .

FIGS. 7A and 7B illustrate a fastening system in accordance with another embodiment of the present invention. As illustrated, the pedestal 440 may include one or more stops to prevent over rotation of the plug 110 A-C, as well as to signal to the user that the plug 110 A-C is in its locked position. Referring to FIG. 7A , the pedestal 440 may include a first boss 710 and a second boss 720 opposed from the first boss across the keyhole 430 . In operation, as shown in FIG. 7B , the plug 110 A-C may be inserted into the keyhole 430 and rotated until the fingers 250 A, 250 B of the plug 110 A-C contact the bosses 710 , 720 . The bosses 710 , 720 , then, prevent over rotation of the plug 110 A-C.

The shaft 210 and fingers 250 A, 250 B of the plug 110 A-C may also configured to prevent the formation of small parts. A “small part” is any object that fits completely into a specially designed test cylinder (2.25 inches long by 1.25 inches wide) that approximates the size of the fully expanded throat of a child under three years old. This specialized definition applies to (1) a whole toy or article, (2) a separate part of a toy, game, or other article, or (3) a piece of a toy or article that breaks off during testing that simulates use or abuse by children. If a “small part” fits completely into the specially designed test cylinder, and the toy or product from which it came is intended for use by children under three years of age, the toy or product is banned because the small part presents a choking hazard.

Thus, toys and products intended for use by children less than three years of age must not release pieces that fit completely into the small parts cylinder after impact, flexure, torque, tension and compression testing. These tests simulate the forces that toys and products can/may experience during normal use and abuse by children less than three years of age. If these forces cause parts to break off that fit in the small parts cylinder, those parts are deemed to present a risk of choking, aspiration, or ingestion to children less than three years of age.

For this reason, the fingers 250 A, 250 B of the plug 110 A-C are configured to plastically deform when a pressure of at least about 48-56 lbs. is applied to the plug 110 A-C. That is, referring to FIG. 8 , the fingers 250 A, 250 B of the plug 110 A-C are resilient, thus they tend to flex whenever a downward force is applied to the plug 110 A-C (as indicated by arrows F). As a result, should the plug 110 A-C be oriented in its locked position when a user attempts to draw the plug out of the keyhole 430 with a force of at least about 48-56 lbs., the fingers 250 A, 250 B will plastically deform upward (in a direction D which is opposite to the force F) and remain intact (i.e., the fingers 250 A, 250 B plastically deform to permit removal of the plug 110 A-C from the keyhole 430 , but do not do not break off of the shaft 210 ), preventing the potential for formation of small parts as explained above. Many different materials may be utilized to form the shaft 210 and the fingers 250 A, 250 B of the plug 110 A-C, such as different kinds of plastic and thermoplastics (such as ABS (acrylonitrile butadiene styrene), PPR (polypropylene resin), styrene, nylon, etc.). However in one preferred embodiment, the shaft 210 and the fingers 250 A, 250 B of the plug 110 A-C are formed from PPR and shaped such that when a user attempts to draw a locked plug 110 A-C out of the keyhole 430 with a force of at least about 48-56 lbs., the fingers 250 A, 250 B will plastically deform upward (in a direction D which is opposite to the force F) and remain intact.

While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. For example the base 200 may possess any shape and have any suitable dimensions. Though a generally circular, disc-shaped base 200 is illustrated, other shapes may be utilized, including but not limited to polygons. The biasing members 270 A, 270 B may be any suitable for their described purpose. The support platform 120 may be formed of any suitable materials, possess any suitable dimensions, and have any suitable shape. Similarly, the port 330 and the guide tracks 340 A, 340 B may possess any shape of have any dimensions suitable for their described purposed. For example, while a guide track is shown in the figures to be an opening (a pass-through), a guide track may also be defined by a recessed area or notch formed into the support platform 120 . The pedestal 440 may possess any suitable shape and have any suitable dimensions. Specifically, the height of the pedestal 440 may be any suitable for its described purpose.

Thus, it is intended that the present invention cover the modifications and variations of this invention that come within the scope of the appended claims and their equivalents. It is to be understood that terms such as “left”, “right” “top”, “bottom”, “front”, “rear”, “side”, “height”, “length”, “width”, “upper”, “lower”, “interior”, “exterior”, “inner”, “outer” and the like as may be used herein, merely describe points of reference and do not limit the present invention to any particular orientation or configuration.