Note: Descriptions are shown in the official language in which they were submitted.
CA 02372480 2002-02-15
PROTECTIVE PACKAGING ENCLOSURE
FOR SHOCK SENSITIVE PRODUCTS
FIELD OF TIHE INVENTION:
[0001] This invention relates to protective packaging enclosures, and
particularly to
protective packaging enclosures for shock sensitive products. The protective
packaging enclosures
of the present invention are formed as clamshells, which fit together to
conipletely enclose the shock
sensitive product to be protected.
BACKGROUND OF THE INVENTION:
[0002] Shock is a major concern for manufacturers of many high tech products.
In
particular, shock is a major concern for the components of computers and the
like, which are
manufactured by one of several major component manufacturers for delivery to
hundreds, if not
thousands, for computer manufacturers and assemblers.
[0003] Particularly, shock sensitive products include hard drives, CD and DVD
drives, as
well as motherboards, cards, floppy disk drives, and unmounted CPUs.
[0004] Indeed, even fully assembled products may be shock sensitive. They may
include
lap-top and hand-held computers, personal digital assistants, and the like;
and more particularly,
shock sensitive products may include boards and cards therefor that are
intended to be rack-mounted
in broadcast and computer networking, web support services, and the like.
[0005] However, the greatest concern of manufacturers of shock sensitive
products is in
respect of hard drives and CD and DVD drives, before they are properly mounted
into a computer
case. It is to such shock sensitive products as hard drives for computers, CD
and DVD drives, and
the like, that the following discussion is particularly directed.
[0006] A hard drive for a computer may have a mass of several hundred grams,
in a
relatively compact configuration. Thus, hard drives may have relatively high
density. Needless to
say, a computer hard drive or the like is a very sensitive, highly designed
product, with extremely
critical alignment of track reading heads, laser elements in the case of CL)
or DVD drives, and the
like.
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[0007] While the manufacturers of such devices go to extreme lengths to shock
proof their
products, or to design them so that in the event that they are dropped they
will not be damaged or
misaligned, such efforts eventually reach a stage where they are not cost
effective, or where the size
of the shock sensitive product is to be compromised.
[0008] Accordingly, protective packaging is required for these products -
especially newly
manufactured, unmounted, shock sensitive devices. What is surprising is the
fact that the shock
sensitive products are most likely to be dropped only a very short distance -
say, six inches - and
manufacturers of such shock sensitive products are establishing acceptance
criteria to be applied to
protective packaging enclosures therefor. Those criteria will differ from
manufacturer to
manufacturer and from product category to product category, but nonetheless
they seek to reduce
shock being transmitted to their manufactured shock sensitive products to less
than about 50 Gs or,
at most, 75 Gs. Indeed, less than 30 Gs is a criterion which manufacturers of
hard drives, in
particular, would be happy to achieve.
[0009] An unprotected shock sensitive product, even if dropped a clistance of
six inches onto
a hard surface, may experience deceleration of certain of its components, in
the range of 100 Gs or
more. Almost certainly, the shock sensitive product will have been damaged in
such circumstances.
[0010] Accordingly, a protective packaging enclosure is required for the shock
sensitive
products, so that immediately upon their final assembly they may be placed
into their protective
packaging enclosure for further handling. That is a stage when most damage may
occur, by the
shock sensitive products being dropped by individuals who are handling them
for purposes of
packaging them into outer packaging containers for quantity shipments.
[0011] Typically, after its manufacture, a shock sensitive product such as a
hard drive may
be shipped in quantities of ten or twenty to a customer. However, not only
must each of the shock
sensitive products in the quantity package be protected in the event that
t.hat: package is dropped, they
must be protected in the event that an individual shock sensitive product is
dropped on its way to the
package in which it will be placed. Other danger to the shock sensitive
products, of course, occurs
when they are being unpackaged from the quantity packaging in which they have
been shipped,
typically by unskilled or semi-skilled workers who are employed in the
receiving room of a
computer manufacturer or the like.
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[0012] It will be appreciated that most shock sensitive products of the sort
as particularly
contemplated herein have generally rectilinear configuration. It will also be
appreciated that the
most common kind of drop for such products is for them to be dropped onto one
of the corners of
the product. That is to say, shock forces are more typically transmitted to
components of the shock
sensitive product when it is dropped on a corner than when it is dropped on a
side, end, bottom, or
top surface.
[0013] However, various shock sensitive products of the sort contemplated
herein may have
specific dimensions of thickness, length, and width, which differ from product
to product and which
most certainly differ from manufacturer to manufacturer - particularly, length
and thickness. On the
other hand, the protective packaging enclosures of the present invention are
provided for the specific
and known dimensions of thickness, length, and width for any one such product
or family of
similarly sized products. It is recognized, of course, that in quantities of
thousands, hundreds of
thousands, or millions, of such protective packaging enclosures as are taught
by the present
invention, the per unit cost is minimal; and the incremental cost for making
new molds for shock
sensitive products having differing dimensions of thickness, length, and -
width are also minimal.
SUMMARY OF THE INVENTION:
[0014] In accordance with one aspect of the present invention, there is
provided a protective
packaging enclosure for a shock sensitive product, where the product is
substantially rectilinear in
overall configuration, and has known dimensions of thickness, length, and
width.
[0015] The protective packaging enclosure comprises a clamshell configuration
having a first
half clamshell and a second half clamshell, where the half clamshells are j
oined together by a hinge
element.
[0016] The first half clamshell, the second half clamshell, and the hinge
element are all
molded from a plastics material as a unitary body.
[0017] The protective packaging enclosure, when closed, has a substantially
rectilinear
configuration, but its dimensions of thickness, length, and width are greater
than the known
dimensions of thickness, length, and width of the shock sensitive product to
be protected.
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[0018] Each of the first and second half clamshells has a major base wall, a
pair of opposed
side walls, and a pair of opposed end walls.
[0019] Each one of the pair of opposed side walls, and each one of the pair of
opposed end
walls is convoluted. The convolutions are such that there are at least two
inwardly directed
convolutions formed in each one of the pairs of opposed side walls and end
walls.
[0020] Each one of the at least two inwardly directed convolutions in each of
the pair of
opposed side walls and the pair of opposed end walls has a product contacting
surface.
[0021] The product contacting surfaces of the inwardly directed convolutions
of each side
wall and each end wall are in a respective plane; and wherein the distance
between the contacting
surface planes of the pair of opposed side walls is substantially equal to the
known dimension of
width of the shock sensitive product. Also, the distance between the
contacting surface planes of
the pair of opposed end walls is substantially equal to the known dimension of
length of the shock
sensitive product.
[0022] Each of the first half clamshell and the second half clamshell is
formed having a
peripheral lip, and each such lip has a down-turned outer lip surface and an
inner lip surface.
[0023] The hinge element is formed between a pair of down-turned outer lip
surfaces in an
end wall or a side wall of each of the half clamshells.
[0024] The peripheral lips of the first and second half clamshelis are formed
so as to
comprise a mating pair of male and female lips. Thus, the outer peripheral
surfaces of the male lips
are received in and retained by the inner peripheral surfaces of the female
lips.
[0025] At least one inwardly directed dimple is formed in each rriajor base
wall of each of
the first and second half clamshells.
[0026] Each of those dimples has an inwardly directed height w:hich is such
that, when a
shock sensitive product is enclosed in the protective packaging enclosure, and
the protective
packaging enclosure is closed with the male and female lips in mating
configuration, then each of
the inwardly directed dimples in the major base walls contacts the shock
sensitive product.
[0027] Alternatively, each of the product contacting surfaces in each of the
pair of opposed
side walls and the pair of opposed end walls is opposed to, and faces, a
product contacting surface
in the opposed side wall or the opposed end wall, respectively.
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[0028] Typically, each ofthe convolutions in each of the pair of opposed side
walls, and each
of the pair of opposed end walls, is curved away from the respective product
contacting surface of
each.
[0029] The plastics material from which the protective packaging enclosure may
be molded
can be such as to have electrical conductive properties. If so, then the shock
sensitive product when
enclosed therein, is electrically shielded.
[0030] At least a major portion of each of the pair of opposed side walls, the
pair of opposed
end walls, and the major base walls of the first and second half clamshells
may be textured so as to
at least partially obscure visibility therethrough.
[0031] However, at least a portion of at least one dimple on one of'the major
base walls may
be molded so as to be planar, whereby a label on the shock sensitive produict
when enclosed therein,
is visible for reading or scanning.
[0032] Typically, there are at least three inwardly directed convolutions
formed in each of
the at least one pair of opposed side walls or the pair of opposed end walls.
[0033] A pair of inwardly directed posts may be formed in the major base walls
of at least
one of the first and second half clamshells, in a region other than where the
dimple is formed, so as
to function as nesting locators for the protective packaging enclosure during
handling thereof.
[0034] In some cases, the distance between the contacting surface planes of
the pair of
opposed side walls is slightly greater than the known dimension of width of
the shock sensitive
product; and the distance between the contacting surface planes of the pair of
opposed end walls is
slightly greater than the known dimension of length of the shock sensitive
product.
BRIEF DESCRIPTION OF THE DRAWINGS:
[0035] The novel features which are believed to be characteristic of the
present invention,
as to its structure, organization, use and method of operation, together with
further objectives and
advantages thereof, will be better understood from the following drawings in
which a presently
preferred embodiment of the invention will now be illustrated by way of
example. It is expressly
understood, however, that the drawings are for the purpose of illustration and
description only and
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CA 02372480 2002-02-15
are not intended as a definition of the limits of the invention. Embodiments
of this invention will
now be described by way of example in association with the accompanying
drawings in which:
[0036] Figure 1 is a perspective view from the outside surfaces of a first
embodiment of
protective packaging enclosure in keeping with the present invention;
[0037] Figure 2 is a perspective view of the embodiment of Figure 1, looking
at the inside
surfaces thereof;
[0038] Figure 3 is a perspective view of a second embodiment of protective
packaging
enclosure in keeping with the present invention, looking at the inside
surfaces thereof;
[0039] Figure 4 is a is a view similar to that shown in Figure 1of a third
embodiment of
protective packaging enclosure in keeping with the present invention, viewed
from the outside
surfaces thereof;
[0040] Figure S is a perspective view ofthe embodiment ofFigure 4, viewed from
the inside
surfaces thereof;
[0041] Figure 6 is a set of traces of acceleration forces imparted to a shock
sensitive product
when packaged in a proprietary packaging enclosure for the manufacturer of
that shock sensitive
product; and
[0042] Figure 7 is a set of traces similar to those of Figure 6 and to the
same scale, showing
an identical drop test using the protective packaging enclosure of the preSent
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS:
[0043] The novel features which are believed to be characteristic of the
present invention,
as to its structure, organization, use and method of operation, together wi:th
further objectives and
advantages thereof, will be better understood from the following discussion.
[0044] The principal features of the present invention are easily understood
from a review
of Figures 1 and 2, to which reference is now made. However, the same
reference numerals are used
throughout the following discussion of any of Figures 1 through 5, for the
same elements as they are
found in the various embodiments of those Figures.
[0045] Referring now to Figures 1 and 2, a protective packaging enclosure 10
is shown,
being configured to protect a shock sensitive product which has a
substantially rectilinear overall
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CA 02372480 2002-02-15
configuration. Needless to say, the shock sensitive product to be protected
has known dimensions
of thickness, length, and width.
[0046] The protective packaging enclosure 10 comprises a clamshell
configuration, having
a first half clamshell 12, a second half clamshell 14, and a hinge element 16
joining the first and
second half clamshells 12, 14 together.
[0047] Any embodiment of the present invention is such that the first and
second half
clamshells, and the hinge element, 12, 14, 16, respectively, are molded fi~om
a plastics material as
a unitary body. Typically, the protective packaging enclosures of the present
invention are vacuum
molded, using complex articulated molds, but they may be injection molded or
by other suitable
molding techniques as are well known to those skilled in the art.
[0048] It will be understood that when the protective packaging is closed, it
has a
substantially rectilinear configuration. It will also be understood that
wher.i the protective packaging
enclosure 10 is closed, its substantially rectilinear configuration has
dimensions of thickness, length,
and width, each of which are greater than the known dimensions of thickness,
length, and width, of
the shock sensitive product to be protected. Each of the first and second half
clamshells 12, 14, has
a respective major base wall 18, 20. Each has a pair of opposed side walls 22,
22, and 24, 24,
respectively; and each of the first and second half clamshells has a pair of
opposed end walls, 26,
26 and 28, 28, respectively.
[0049] Each of the pair of opposed side walls 22, 22 and 24, 24 and each of
the pair of
opposed end walls 26, 26, and 28, 28, respectively, is convoluted. There are
at least two inwardly
directed convolutions 30 formed in each of the respective side walls and end
walls.
[0050] Each of the at least two inwardly directed convolutions 30 has a
product contacting
surface 32. It will be seen in Figure 2 that, typically, each of the product
contacting surfaces 32 in
each of the pair of opposed side walls 22, 22 and 24, 24, and in each of the
pairs of opposed end
walls 26, 26 and 28, 28, respectively, is opposed to, and faces, a product
contacting surface in the
opposed side wall or end wall, respectively.
[0051] The distance between the opposed product contacting surfaces 32 in the
side walls
is typically substantially equal to the known width of the shock sensitive!
product to be protected.
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Likewise, the distance between the opposed product contacting surfaces 32 in
the end walls, is
typically substantially equal to the known length of the shock sensitive
product to be protected.
[0052] However, it will also be understood that the product contacting
surfaces 32 of each
one of the convolutions 30 formed in each one of the pair of opposed side
walls and in each one of
the pair of opposed end walls, are in a respective plane. Thus it is not
necessary that the
convolutions 30 in the opposed side walls are opposed to and face each other,
so long as the distance
between the respective planes in the side walls is substantially equal to the
]mown width of the shock
sensitive product, and the distance between the respective planes in the end
walls is substantially
equal to the known length of the shock sensitive product.
[0053] Moreover, it must be noted that by the term "substantially equal" as it
is used herein,
Applicant means that the respective distances and lengths being spoken of' are
the same as or nearly
the same as, the distance or length to which the comparison is being macie.
This is because some
manufacturers of shock sensitive products such as hard drives, or CD or DVD
drives, in particular,
require that there be some tolerance for placing the shock sensitive product
into its protective
packaging enclosure; whereas other manufacturers want zero tolerance, or even
a slightly less
distance between the planes of the product contacting surfaces, than the
vvidth and/or length of the
shock sensitive product, so that the product must be slightly forced into
place in the protective
packaging enclosure.
[0054] It is seen in Figures 1 and 2 that each of the first half clamshells 12
and 14 is formed
having a peripheral lip; and each of the peripheral lips has a down-turned
outer lip surfaces 36, and
inner lip surface 38. It will also be seen from Figures 1 and 2 that the hinge
element 16 is formed
between the pair of down-turned outer lip surfaces 36; and it will be
understood from a comparison
of Figures 3, 4, and 5, with Figures 1 and 2, that the hinge element may be
formed between a pair
of end walls, or a pair of side walls, one of each of the respective half
clamshells.
[0055] It will be particularly understood from Figures 1 and 2 that the
peripheral lips of the
first and second half clamshells are formed so as to be configured as a mating
pair of male and
female lips 40,42, respectively. It will be understood that the outer
peripheral surface 36 of the male
lips are received in and retained by the inner peripheral surfaces 38 of the
female lips 40 when the
half clamshells 12 and 14 are closed with respect of one to the other.
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[0056] There is at least one inwardly directed dimple 42 which is formed in
each major base
wall 18, 20, of the first and second half clamshells 12, 14, respectively.
[0057] The inwardly directed height of each of the dimples 44 is such that,
when a shock
sensitive product has been enclosed in the protective packaging enclosure 10,
and the protective
packaging enclosure is closed with the male and female lips 40, 42 in mating
configuration, then
each of the inwardly directed dimples will contact the shock sensitive product
on the top and bottom
surface thereof, respectively.
[0058] Figure 3 illustrates a further embodiment of the protective packaging
enclosure of the
present invention which is virtually identical with that of the Figure 1,
except that the two half
clamshells 12, 14, are joined together by a hinge element 16 formed at the
sides thereof, rather than
the ends thereof.
[0059] It will be seen in any of the Figures that each of the convolutions 30
in each of the
side walls and end walls is formed so as to be curved away from the respective
product contacting
surface 32 thereof. That configuration, of course, provides for additional
shock absorption
characteristics apart from those which will be demonstrated by the plastics
material per se.
[0060] It is also noted in each of the Figures 1 through 5 that, typically,
there are at least
three inwardly directed convolutions 30 formed in each of the side walls and
end walls of each of
the half clamshells 12, 14.
[0061] Typically, the plastics material from which the protective packaging
enclosures 10,
50, 60, as illustrated, are molded, is such as to have electrical conductive
properties. Thus, when a
shock sensitive product is enclosed in any of the protective packaging
enclosures of the present
invention, it will be electrically shielded. Accordingly, the protective
packaged shock sensitive
products may be handled by workers without risk of damage to electronic
components within the
shock sensitive products.
[0062] Typically, so as to provide a surface which may be more easily gripped
by a human
hand, or an appropriate piece of handling machinery, and so as to at least
partially obscure visibility
through the protective packaging enclosure of the present invention, at least
a major portion of each
of the pairs of opposed side walls and end walls, and the major base walls, of
each of the first and
second half clamshells is textured.
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[0063] However, as seen in Figures 4 and 5, a dimple 62 may be formed in one
of the major
base walls of either of the half clamshells in such a manner as to be planar
and translucent. Thus,
a label which is placed on the shock sensitive product when it is enclosed in
the protective packaging
enclosure 60 is visible through the planar dimple 62, in such a manner that it
may be read or scanned.
As an example, machine reading of the serial numbers of the shock sensitive
products being
packaged, for purposes of shipping manifests and the like, may be easily
accommodated.
[0064] A pair of inwardly directed posts 48 may be formed in a major base wall
of at least
one of the first and second half clamshells 12, 14. These posts function as
nesting locators for the
protective packaging enclosure during handling thereof. That is, as the
protective packaging
enclosure is being handled towards a location where it will be taken froni a
stock thereof, one at a
time, so as to have a shock sensitive product placed therein, the nesting
locators will co-operate with
a pair of machine fingers at each assembly or packaging station.
[0065] Figures 6 and 7 are drop test traces of a typical computer hard drive
manufactured by
one of the world's leading manufacturers thereof. The same equipment was used
to produce each
of Figures 6 and 7, but the manufacturer's own proprietary protective
packaging enclosure was
employed in the tests illustrated in Figure 6 whereas a protective packaging
enclosure in keeping
with the present invention was employed in the tests of Figure 7.
[0066] In each test, a computer hard drive was placed into the respective
proprietary or
subject protective packaging enclosure, and dropped from a distance of six
inches so as to land on
a corner 46, as shown in the drawings.
[0067] Acceleration was measured in each of three mutually perpendicular axis,
identified
as the X-Axis, the Y-Axis, and the Z-Axis, with traces 70, 72, and 74,
respectively.
[0068] It will be seen in Figure 6 that the maximum G forces imparted to the
computer hard
drive, when dropped from six inches in the proprietary protective packaging
enclosure of the
computer hard drive manufacturer, reached 68 Gs.
[0069] On the other hand, the maximum forces imparted to the same computer
hard drive
when dropped from six inches onto its corner when enclosed in the protective
packaging enclosure
of the present invention, was 25.4 Gs.
CA 02372480 2002-02-15
[0070] Moreover, it is seen in Figure 6 that there was significant chatter, at
least in the Z-
Axis; whereas the protective packaging enclosure of the present invention had
reasonably well
settled down by the time that 40 milliseconds had elapsed.
[0071] Figures 6 and 7 provide graphic evidence of the ability of'the
protective packaging
enclosure of the present invention to withstand shock loading, so that
considerably less shock is
transmitted to the shock sensitive product which is enclosed therein. The
configuration of the
protective packaging enclosure of the present invention, with pairs of opposed
product contacting
surfaces in each of the six major claims which define the substantially
rectangular configuration of
the shock sensitive product - two sides, two ends, top, and bottom - so as to
immediately take up
shock loading after the protective packaging enclosure has contacted the clrop
surface but the shock
sensitive product continues to move according to its own inertia. Such a
configuration is unknown
previously, but is significant as to the shock protection for shock sensitive
products.
[0072] There has been described protective packaging enclosures for shock
sensitive
products, with several representative embodiments being illustrated. Other
embodiments and
configurations may, of course, be derived from the above teachings, without
departing from the spirit
and scope of the appended claims.
[0073] Other modifications and alterations may be used in the desiam and
manufacture of the
apparatus of the present invention without departing from the spirit and scope
of the accompanying
claims.
[0074] Throughout this specification and the claims which follow, imless the
context requires
otherwise, the word "comprise", and variations such as "comprises" or
"comprising", will be
understood to imply the inclusion of a stated integer or step or group of
ir.itegers or steps but not to
the exclusion of any other integer or step or group of integers or steps.
[0075] Moreover, the word "substantially" when used with an adjective or
adverb is intended
to enhance the scope of the particular characteristic; e.g., substantially
rectilinear is intended to mean
having a generally rectilinear configuration with definable top and bottoni
surfaces, definable side
edges, and defmable ends.
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