WO2002085751A1

WO2002085751A1 - Package

Info

Publication number: WO2002085751A1
Application number: PCT/AU2002/000503
Authority: WO
Inventors: Andrew Morris
Original assignee: Hampton Corporation Pty Limited
Priority date: 2001-04-20
Filing date: 2002-04-22
Publication date: 2002-10-31
Also published as: NZ529680A; AUPR451901A0; AU2002248992B2

Abstract

In a moulded package (100), first and second package components are coupable to each other to define an interior spae for the package. An internal wall (118) extends from one component to the other in a package closed position to define, in conjunction with those components, an enclosed inner space in which items can be located for protection. A package component and a method of manufacture thereof are disclosed wherein a fastener (20) can be moulded in the component such that the component can be removed from a die as a unitary structure incorporating the fastener and then used without detaching the fastener therefrom. In addition, a package component is disclosed which includes a frangible line (110/112) therein whereby separation along the line enables access to the package interior.

Description

PACKAGE

FIELD OF THE INVENTION

The present invention relates to a moulded package and a method for moulding the package, for example, a unitary moulded package. The invention has been developed primarily for use as a mailing package for boxed or cassette items such as CDs, DVDs, video cassettes, tapes etc and will be described hereafter with reference to this application. However, it will be appreciated that the invention is not limited to this field of use.

DESCRIPTION OF THE PRIOR ART

Packaging for storing or mailing relatively fragile items such as compact discs (CDs) , digital video discs

(DVDs), video cassettes, tapes, wine bottles, etc includes stiff cardboard envelopes, padded bags, cardboard boxes and so on. This packaging is not always suitable for protecting the items which are packed inside them against impact. For example, cardboard boxes are used for mailing cased CDs. During the mail sorting process carried out by postal authorities, the package is passed through rollers. Because of the shape of the cardboard box and its low impact resistance, the rollers often crack the CD case when the box is passed therethough.

SUMMARY OF THE INVENTION

In a first aspect the present invention provides a moulded package including : - first and second package portions that, in a package closed position, are couplable to each other to define an interior space for the package; and an internal wall which extends from an inner surface of the first package portion to an inner surface of the second package portion, the internal wall being arranged such that, in the package closed position, it cooperates with the first and second package portion inner surfaces to define an enclosed inner space, within the interior space, into which item(s) can be located.

This enclosed inner space can be used for the storage of fragile-to-mail items such as CDs and CD cases, DVDs and DVD cases, video cassettes, audio tapes and cases, etc. In addition, the cooperation between the internal wall and the inner surfaces of the first and second package portions results in a package which is structurally quite resistant to deformation under impact, or when inserted through rollers of mail sorting machines etc. This further protects the contents of the package. Preferably, the internal wall is integral with the first package portion whereas an edge of the internal wall abuts with the second package portion inner surface in the package closed position. Whilst preferably the internal wall extends from a flat first inner surface to a second opposing flat inner surface, in the closed position it may alternatively abut an embossment or protrusion extending from the second package portion inner surface.

Preferably, in addition to the internal wall, a second internal wall projects from the second package portion inner surface towards the first package portion inner surface such that, in the package closed position, the second internal wall surrounds the first package portion internal wall. The second internal wall is typically located in a close facing relationship with the first internal wall in the package closed position, and this further strengthens and adds to the overall integrity and impact resistance of the package. Typically, the first internal wall has four sides, as essentially may the second internal wall. In this regard, in plan view, typically the four sides define a rectangle that is sized for storage of one or more CD, DVD or tape cases, or video cassettes (e.g. in stacked relationship) .

To further enhance the structural integrity of the package, preferably the first and second package portion inner surfaces are each reinforced with moulded ridges.

In a most preferred orientation, the first and second package portions are hinged to each other for pivoting movement between the package closed position and a package open position. In the package open position, item(s) (e.g. a disc) can be located in the package and, once closed, the package may in affect be permanently closed until e.g. a tear strip is removed therefrom (described below) to reveal and allow access to and removal of the package contents .

Preferably, the first and second package portions are coupled to each other in the closed position by a fastening mechanism which can include one or more spigots extending from the first or second package portion inner surface for fastening receipt in corresponding recesses located at the second or first package portion inner surface respectively. In this regard, in the package closed position, an end of each spigot can include a catch which can latch with a latch portion formed inside its respective recess. Alternatively, each spigot can be sized to be received interferingly in its respective recess. When the spigot includes a catch which latches in its recess, such an arrangement can, in affect, provide a type of permanent locking of the package so that package access is then only facilitated by e.g. severance along a frangible line such as removal of a tear strip (described in greater detail below) .

When the spigot is sized to be received interferingly, this arrangement is typically employed when the primary function of the spigot is to facilitate alignment between the first and second package portions in the package closed position, rather than providing for permanent closure. In other words, the spigots and recesses can act as looking and/or locator mechanisms. With this latter spigot configuration, the locking of the package in the closed position can be facilitated by a separate fastener.

Preferably each recess is defined as part of an upstanding projection from the second or first package portion inner surface, such that, in the package closed position, the respective spigot extends into the upstanding projection.

The fastening mechanism may further include one or more fasteners for externally fastening the first and second package portions together in the package closed position. In this regard, each fastener can be moulded integrally with one of the first or second package portions, or it can be moulded separately. In either case, each fastener can, in the package closed position, be either: (a) inserted through aligned externally located fastener holes in the first and second package portions; or

(b) moulded as part of one of the first or second package portions for insertion through an aligned externally located fastener hole in the second or first package portion respectively.

Each package portion typically has a laterally projecting lip extending around its periphery, which lips align and abut in the package closed position.

In the package closed position, and as viewed in side elevation, each package portion preferably comprises a flat wall that overlies the enclosed inner space. Beyond the inner space that wall then curves inwardly with respect to the package, and then bends back out with respect to the package, to terminate at the lip. Such a lip arrangement facilitates more smooth insertion of the package through mail sorting and rolling apparatus, without abrupt edges being defined in the package. This further prevents abrupt impact on the package in the mail handling process to protect the contents thereof.

With such lip arrangements, preferably the fastener holes for (a) are defined in both of the lips of the first and second package portions, and for (b) are defined in one of the lips of the first or second package portions. In this regard, for (b) the fastener is preferably incorporated into the other of the lips of the second or first package portions respectively. Again, in this regard, the fastener is preferably formed in a tab hingedly connected to the package portion, the tab being incorporated into said other of the lips. Thus, when the package is closed, the fastener tab can be pivoted downwardly to introduce the fastener through its respective hole to then lock closed the package.

As described above, the package preferably includes a frangible line, such as a tear strip in one of the first or second package portions and positioned such that, when the line is severed therealong, items located in the inner space can be accessed.

Preferably, the frangible line is a tear strip that commences adjacent to a hinge between the first and second package portions and that extends adjacent to a periphery of the package portion in which it is located such that, when the tear strip is removed, at least a part of the package portion can be pivoted away from the package to enable item(s) to be removed therefrom. Preferably, one or both ends of the tear strip are connected to a respective tab moulded integrally with one of the package portions, the or each tab facilitating gripping and initiation of tear strip removal. In this regard, the tab(s) can be located adjacent to a hinge between the first and second package portions, with a given tab at one package portion being positionable in a cut-out region of the other package portion when in the package closed position. Such an arrangement means that the overall dimensions of the package in the closed position need not be compromised by the provision of the tabs (in other words, the tabs need not protrude out beyond the periphery of the package in the closed position) . However, the tabs may protrude slightly to indicate their presence. Packages may be fastened closed in a variety of ways. For example, prior art packages such as cardboard boxes may be fastened closed by using adhesive packaging tape to seal the lid of the box. This method of fastening the box closed is clumsy and inefficient. In a second aspect the present invention provides a unitary moulded component for a package including: a package portion; and a fastener connected to the package portion for fastening engagement with a receiver; wherein, when the package component is moulded, the fastener is positioned with respect to the package portion such that the package component can be removed from a die in which it is formed as a unitary structure and such that the fastener can then be used without detaching it from the package portion.

Preferably, the fastener projects from and is optionally hingedly connected to the package portion. Preferably in this regard, the fastener is either a spigot which latches into a recess in the receiver, or is a hinge plate having a male portion projecting therefrom, the male portion being adapted for snap locking engagement with the receiver. Preferably, the package portion of the second aspect is the second package portion of the first aspect. In this regard the second package portion can be connected (e.g. hingedly) to the first package portion, and the receiver can be defined at the first package portion. In this regard, the receiver can be the recess or holes as defined in the first aspect.

In a third aspect the present invention provides a process for moulding in a two part die the unitary package component of the second aspect, the process including the steps of: introducing a mouldable material into the die and allowing the mouldable material to cure; and removing the resultant package component from the die in a manner such that it is maintained as unitary, and such that the fastener can be used without detaching it from the package portion.

Preferably, the process is an injection moulding process and the mouldable material is a polymer such as polypropylene or polyethylene. Preferably, the step of removing the package component from the die includes employing a first knock out rod to dislodge the fastener from the die by causing the fastener to rotate about a hinge axis therefore; and employing a second knock out rod to dislodge the package component from the die .

Evidence of tampering of packages is becoming increasingly important in the international context. Tamper proof and tamper evident packaging is thus taking increased significance, especially where manufacturers wish to preserve the integrity or safety of their packaged products .

In a fourth aspect the present invention provides a moulded package portion for use as a component of a package, the package portion being connectable to another package portion to define the package and to define an interior therefore, the package portion including a frangible line therein such that one part of the package portion can be separated along the line relative to another part of the package portion to provide access to the package interior.

Thus, where the package portion is fastened to another package portion in a closed form of the package, access to the package interior may only occur when the frangible line is severed, such severance being a ready indication of tampering.

Preferably, the frangible line is defined by a tear strip, a line or perforation, a line of weakness in the package portion or a line of reduced wall thickness in the package portion.

Preferably, the package portion is one of the first or second package portions of the first aspect, and preferably said another package portion is respectively the other of the second or first package portions of the first aspect of the invention. In this regard, preferably separation along the frangible line enables item(s) to be accessed and/or removed from the package. Typically it is only separation along the frangible line which enables such access and removal .

Alternatively, the package portion of the fourth aspect can constitute the package portion of the second aspect, or may be manufactured by a process as defined in the third aspect.

Preferably, the frangible line extends around a periphery of the package portion such that separation therealong enables said one part of the package portion to be either removed or pivoted away from the package to thus provide access to the package interior.

BRIEF DESCRIPTION OF THE DRAWINGS

Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

Figure 1 shows a perspective view of a top side of a closed package embodiment in accordance with the invention;

Figure 2 shows an underside perspective view of the package of Figure 1 ;

Figure 3 shows a perspective view of the outside of the package of Figure 1 in an open position;

Figure 4 shows a perspective view of the inside of the package of Figure 1 in an open position;

Figures 5 to 8 show a detailed views of parts of the package of Figures 1 to 4 ; Figures 9 to 12 show similar perspective views to

Figures 1 to 4 , but of an alternative package embodiment in accordance with the present invention;

Figures 13 and 14 show perspective views of another package embodiment in accordance with the invention in open and closed positions respectively;

Figure 15 shows a perspective view of another package embodiment in accordance with the invention in an open configuration;

Figure 16 is a detail sectional view of the package of Figure 15, taken from the direction of A;

Figure 17 is a detailed sectional view of Figure 16 taken on line 17-17; Figure 18 is a simplified fully open plan view of the embodiment of the invention illustrated in Figure 15;

Figure 19 shows a plan view of another embodiment of a package component in accordance with the invention; Figure 20 shows a detail in cross sectional side elevation of a two part die construction; and

Figure 21 is a detail view of the die illustrated in Figure 20, not showing knock-out rods.

MODES FOR CARRYING OUT THE INVENTION Referring firstly to Figures 1 to 4, a package in accordance with the invention is shown in the form of moulded box 100. The box includes a lid 102 hingedly coupled to a base 104 along a plastic hinge 106.

The lid and base are each provided with a respective peripheral lip 107, 108 which align and abut when the box is in the closed position. The aligned, abutting lips prevent access to the box interior in the closed position.

In accordance with the invention, a frangible line in the form of a tear strip 110 is defined in the lid 102 of the box. The tear strip is defined by lines of perforation 112 which extend in parallel around the periphery of the lid as best shown in Figure 1. Opposing ends of the tear strip are connected to tear tabs 114, which facilitate gripping and then removal of the tear strip from the box. A cut away recess 116 is moulded on opposite sides of the base 104, to each accommodate a respective tear tab in the box closed position. In use, a user grips one of the tear tabs, pulls it upwardly, and causes the tear strip to sever from the remainder of the lid along the lines of perforation, typically until the entire tear strip is removed therefrom. This then defines a central flap (C) , being part of the lid 102, which can now pivot upwardly and away from the remainder of the box in the closed position. The remainder of the lid is fastened to the base (in a manner as described below) , and the pivoting of flap (c) thus exposes the box interior, to enable the removal of any items therein (as described below) .

Referring now particularly to Figure 4, in accordance with the invention, an internal rectangular wall 118 is defined in the base 104, the wall being moulded integrally with the base and extending upwardly therefrom. The wall is shaped and sized such that rectangular cased products such as CDs, DVDs, tapes or video cassettes can fit typically snugly therewithin. The wall also has a height such that, when the lid is pivoted about hinge 106 to the box closed position, the wall abuts or engages at the lid underside 120 to thus support the upper side of the lid against impact and weight thereon (e.g. from mail rollers etc) and to enhance the dimensional and structural integrity of the box in the closed position. The wall also laterally protects any items stored therewithin. In the closed position, the wall cooperates with the lid underside and the base upperside to define an enclosed space into which items can be stored and protected. Typically the wall has a height sufficient to accommodate multiple flat storage cases such as CD cases.

Projecting from the lid underside is a second wall 122. Typically that wall is sized to fit snugly around the outside of wall 118. It will also be seen that the second wall is only three sided, the second wall terminating adjacent to the tear tabs 114. Again, the provision of the second wall enhances the structural integrity and dimensional stability of the box in the closed position. Projecting from the lid underside are five discrete locking spigots 124. One such spigot is shown in greater detail in Figure 5. Each spigot has a sloping catch 126 formed adjacent to its free end, the function of which is described below. Projecting upwardly from the base 104 are five complimentary cylindrical receivers 128. Each receiver is hollow, with an opening 130 extending from its upper end right through to the base underside (as shown in Figure 2 and 3) . One such receiver is shown in greater detail in Figure 6. This receiver configuration enables the whole package to be moulded in one die (ie. as a sliding core can be used to define each receiver) .

Referring specifically to Figure 7, when the lid 102 is closed on the base 104, locking spigot 124 is caused to be introduced through opening 130 of receiver 128. The interior of receiver 128 is provided with a deflectable latch 132 which is deflected out of the way by action thereon of the sloping catch 126 as the spigot extends into the receiver. The catch and latch are so positioned such that when the lid and based are closed along their respective peripheral lips, the catch 126 has just passed latch 132, and the latch now springs back to locate behind catch 126, thereby locking the spigot in the receiver. The spigot and receiver are arranged such that it is now not possible to open the box without damaging or destroying the structural integrity thereof, thereby indicating to a user that the box has been tampered with.

As stated above, one advantage of the arrangement depicted in Figure 7 is that the spigot and receiver can be moulded integrally with the remainder of the box, to define a unitary moulded box. A suitable moulding process is described with reference to the embodiment of Figures 20 and 21, and will not be described again here.

It will also be seen that the inside faces of the lid and base are each reinforced with a grid of rib mouldings 134. These rib mouldings increase the strength and deflection resistance, particularly of the flat portions of each of the lid and base, and again enhance its impact resistance, overall strength and dimensional stability, thereby protecting any items held within the box. Referring now to Figures 9 to 12, where like reference numerals are used to denote similar or like parts, a moulded box 100 is shown which is similar in most respects to the moulded box 100 of Figures 1 to 8. However, instead of employing a tear strip 110, a central flap F in the lid 102 can be detached from the remainder of the lid along lines of perforation 136. The lines of perforation 136 terminate at either end thereof at a hinge axis 138, defined towards a forward part of the lid. On the opposite side of the lid, and connected to the central flap F is a lifting tab 140. The tab 140 includes an integrally moulded finger grip bar 141 to facilitate better grip during lifting. As best seen in Figure 11, the line of perforation 136 extends around the side periphery of the lid and terminates on either side of lifting tab 140. Lifting tab 140 is otherwise located adjacent to the hinge 106.

As shown in Figure 10, a cut-away recess 142 is moulded into the base to provide clear access to tab 140. A similar cut-away recess 143 is provided in the lid.

Thus, when the box is in the closed position, the user can insert their fingers under tab 140, lift that tab and cause severance along the lines of perforation 136, causing central flap F to pivot up and away from the box, thereby exposing the interior of the box. This enables items within the box to be accessed.

To facilitate access to the articles when the box is in its closed configuration, a further cut-away portion 144 can be defined in wall 118, so that a user may easily remove articles (especially flat articles, such CD cases etc) from the box interior. Where such a cut-away portion, to some extent, compromises the overall structural integrity of the box, instead one or more finger holes or slots can also be defined in the wall 118 so that its continuity and structural integrity is preserved.

As will also be seen in Figure 12, a pair of upstanding spigots 146 can be provided within the base, inside wall 118, to snugly accommodate smaller sized rectangular packages, such as cardboard cases for CD ROM discs (which have a smaller dimension than standard CD cases) . However, if a CD case is to be packaged in the box 100, the spigots are adapted to be snapped off and discarded. Referring now to Figures 13 to 18, two other embodiments of the invention are depicted. Figures 13 and 14 show one embodiment and Figures 15 to 18 show another embodiment of a moulded package. In these drawings, like reference numerals are used to denote similar or like parts. Also, in these drawings the moulded package component is shown as part of a box 10 which includes one package portion in the form of a lid 12 and another package portion in the form of a base 14. The box 10 has also been developed primarily as a box for mailing items such as CDs, DVDs, tape cassettes and video cassettes.

In this regard, a wall 15 is configured to receive and support either one, two, or a double CD or DVD case within the box. However, the box according to the invention can be altered for packing other items, such as books, audio cassettes, wine bottles, etc. The wall 15 is discussed in more detail below.

Typically, the lid 12 and base 14 are hingedly connected about hinge axis 16, although in alternative embodiments (and in the embodiments of Figures 1 to 12) they may be formed and joined separately.

In the embodiment of Figures 15 to 18, an integral fastener 17 is provided that includes a hinge plate 18 and a male portion in the form of a pin 20 (with two such fasteners being provided in the box 10 of Figure 15) . The hinge plate 18 is hingedly connected to the lid to pivot about hinge plate axis 22. The pin 20 is arranged to be inserted through a receiver in the form of a hole 24, when the lid 12 is closed upon the base 14. The fasteners 17 are thus used to secure the lid to the base. Each hole 24 is formed in a respective flange 29 on the base 14.

As best shown in Figures 16 and 17, the pin 20 is mushroom shaped, having a split head 25 and neck 26, wherein the diameter of the widest part 27 of the head 25 is slightly larger than the hole 24. The split 28 of the head 25 allows the head 25 to contract radially inwardly aiding the widest part 27 of the head 25 to move through the hole 24. Once through, the head 25, being resilient, springs back to its original shape. The widest part 26 of the head 25 moves past the flange 29 in which the hole 24 is situated. The neck 26 then rests within the hole 24. Thus fastener 17 effectively locks the lid 12 to base 14. In the embodiment of Figures 13 and 14, a flange 30 is provided for registration with flange 29 in the box closed position (as shown in Figure 14) . The flange 30 also has holes 24 therethrough which align with holes 24 of flange 29 in the closed position. Because flange 29 has a cut-away portion 29A, a user is able to insert their fingers under flange 30 in the closed position to urge open lid 12. The box of Figure 14 can be locked closed by inserting locking pins (not shown, but similar to pins 20 except that they have a double head 25 connected by a neck 26) through aligned holes 24 in the closed position.

The box 10 is typically made from a resilient material, such as polypropylene for example. The box is moulded to include a grid of strengthening ribs 31 to increase the torsional stiffness and impact resistance of the box. Also, spigots in the form of locator pins- 32 and their corresponding receiving portions in the form of cylinder projections 34 are provided. The pins and projections aid in the correct positioning of the lid 12 upon the base 14, but can also be provided with locking latches as described above.

The box 10 is preferably formed as a unitary structure with no need for additional components to be subsequently formed and added to or be used with the box 10 in order for the box to function as desired. However, the pins can be separately formed and then used in the embodiment of Figures 13 and 14.

The box is closed by rotating the lid 12 with respect to the base 14 about the hinge axis 16. The locator pins 32 are then received in their corresponding projections 34. In the closed position, a peripheral lip 38 of lid 12 is brought into alignment with and abuts corresponding peripheral lip 38A of base 14. The wall 15 is then enclosed within the space defined between the lid 12 and the base 14. In a most preferred embodiment of the invention, the lid 12 rests upon the upper edge 39 of the wall 15 when the box 10 is closed. The wall 15 thus acts to support the lid 12 against impact resistance and thereby protects the contents within the inner space, bounded by the wall 15, the lid 12 and the base 14, when the box is closed.

Also, as shown in Figure 14, the lid 12 and base 14 include curved 40 external surfaces and 40A such that, when the box is closed, the edges of the closed box 10 are generally wedge shaped. This is useful when e.g. the box is fed through twin rollers, such as in a postal service sorting system. In this regard, in a postal service sorting system, typically a conveyer belt transports articles of mail to twin rollers. The twin rollers start in a position where the rollers are in close, parallel relation to each other. When an article of mail is passed through them, the rollers are forced apart by the mail article, and re- converge once the article has passed between the rollers. A standard cardboard box carrying a CD, for example, is in the form of a rectangular prism. Therefore, when the leading edge of the box is presented to the rollers, the rollers are quickly forced apart such that they initially lose contact with the standard box. When the rollers re- converge, they impact the box, often damaging the box's contents. If the contents of the standard box is a cased CD, the CD case may be cracked.

Due to the general wedge shaped edge of the closed box 10 of the present invention, when the box 10 is presented to the rollers, the rollers are progressively/gradually urged apart in such a way that they maintain contact with the box. Therefore, there is no impact of re-converging rollers on the box 10 to damage its contents. In addition, the wall 15, the strengthening lips 30 and the locator pins 32, and their corresponding receiving portions 34 aid in maintaining box dimensional stability and strengthen the box, thereby protecting its contents .

Once the lid flange 38 is brought into abutment with the base flange 38A, the box is fastened closed by either rotating the fastener 17 about the hinge plate axis 23, to move the head 25 of the pin 20 through the hole 24 and into a fastened position (Figure 15) , or by inserting pins through the aligned holes (Figure 14) .

An alternative component for use in a box according to the invention is illustrated in Figure 19, where like reference numerals refer to similar or like parts. The component of this embodiment can be used as a base 14 in a box similar to that illustrated in Figures 13 to 15, by being hinged, for example, along edge 38A. The hinge axis 16 then extends along edge 38A. The wall 15 of this embodiment has an extended wall region 15A.

Some CD sleeves or cases are formed from cardboard, especially those used to house computer CDs (e.g. CD ROM discs) . These sleeves can be of different length and width proportions to standard plastic CD cases. The extended wall portion therefore allows the wall 15 to accommodate either a standard CD case within the wall 15, or CD sleeves of the type described above, within the wall 15 and extended wall region 15A.

In the embodiments of the invention illustrated in Figures 13 to 19, two fasteners and their corresponding holes 24 are employed. However, in alternative embodiments, more fasteners and holes may be employed. For example, if the lid 12 is provided separately to the base 14, several fasteners may be employed around the periphery of the lid, with corresponding holes 24 around the edge of the lid and/or base 14. Referring now to Figures 20 and 21, a moulding process for forming a box according to Figures 15 to 18 in an injection moulding process will now be described. Figures 20 and 21 illustrate cross-sectional views of a portion of a die D used to mould form the box 10. The die includes an upper component 41 and lower component 42. The die has been designed such that the box 10 can be moulded as a unitary, ready to use package. For this reason, the fastener 17 is moulded in a position such that the axis 43 of the pin 20 lies on a plane P between the components 41 and 42 of the die and dividing the two.

This makes it possible to remove the box blank from the die without damaging the pin 20, otherwise due to the mushroom shape of the pin head 25, the die would necessarily at least partially enclose the head 25 in such a manner as to capture the head 25.

The box blank is removed from the die in a process including at least three steps as described below. Firstly, the components 41 and 42 of the die are separated. While the upper component 41 is lifted from lower component 42, a first knock-out rod 46 is moved downwardly causing the fastener 17 to rotate about hinge plate axis 23, knocking the fastener 17 from the upper component 41. The blank remains on the lower component 42. A series of knock-out rods 48 are then moved in an upward direction to knock the blank from the lower component 42 of the die. The blank is therefore removed from the die as a ready to use, unitary structure. Now that preferred embodiments of the invention have been described, it will be apparent to those skilled in the art that the package component has at least the following advantages :

1. The shape and configuration of the package aids in preventing damage of the box's contents.

2. The package can be moulded as a unitary component, requiring no removal from the component of any parts, such as a fastener, or the addition of any parts, for its intended use. 3. Since there is no need to remove the fastener from the component to secure the lid to the base, the hinge lines can be more securely moulded, such that the fastener will not be accidentally detached from the component prior to its intended use. 4. The provision of a tear strip or equivalent provides a tamper evident package, thus preventing swapping or fouling of package contents.

Although the invention has been described with reference to particular examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms .

It is to be understood that, if any prior art is referred to herein, such reference does not constitute an admission that the prior art forms a part of the common general knowledge in the art, in Australia or any other country.

Claims

1. A moulded package including: first and second package portions that, in a package closed position, are couplable to each other to define an interior space for the package; and an internal wall which extends from an inner surface of the first package portion to an inner surface of the second package portion, the internal wall being arranged such that, in the package closed position, it cooperates with the first and second package portion inner surfaces to define an enclosed inner space, within the interior space, into which item(s) can be located.

2. A package as claimed in claim 1 wherein the internal wall is integral with the first package portion whereas an edge of the internal wall abuts with the second package portion inner surface in the package closed position.

3. A package as claimed in claim 2 wherein, a second internal wall projects from the second package portion inner surface towards the first package portion inner surface such that, in the package closed position, the second internal wall surrounds the first package portion internal wall.

4. A package as claimed in any one of the preceding claim wherein the first package portion internal wall has four sides.

5. A package as claimed in claim 4 wherein, in plan view, the four sides define a rectangle that is sized for storage of one or more CD, DVD or tape cases, or video cassettes.

6. A package as claimed in any one of the preceding claims wherein the first and second package portion inner surfaces are each reinforced with moulded ridges.

7. A package as claimed in any one of the preceding claims wherein the first and second package portions are hinged to each other for pivoting movement between the package closed position and a package open position.

8. A package as claimed in any one of the preceding claims wherein the first and second package portions are couplable to each other in the closed position by a fastening mechanism which includes one or more spigots extending from the first or second package portion inner surface for fastening receipt in corresponding recesses located at the second or first packaged portion inner surface respectively.

9. A package as claimed in claim 8 wherein, in the package closed position, an end of each spigot includes a catch which can latch with a latch portion formed inside its respective recess, or wherein each spigot is sized to be received interferingly in its respective recess.

10. A package as claimed in claim 8 or 9 wherein each recess is defined as part of an upstanding projection from the second or first package portion inner surface respectively, such that, in the package closed position, the respective spigot extends into the upstanding projection.

11. A package as claimed in any one of claims 8 to 10 wherein the fastening mechanism further includes one or more fasteners for externally fastening the first and second package portions together in the package closed position.

12. A package as claimed in claim 11 wherein each fastener is, in the package closed position, either:

(a) inserted through aligned externally located fastener holes in the first and second package portions; or (b) moulded as part of one of the first or second package portions for insertion through an aligned externally located fastener hole in the second or first package portion respectively.

13. A package as claimed in any one of the preceding claims wherein each package portion has a laterally projecting lip extending around its periphery, which lips align and abut in the package closed position.

14. A package as claimed in claim 13 wherein, in the package closed position, and as viewed in side elevation, each package portion has a flat wall that overlies the enclosed inner space, which beyond the inner space curves inwardly with respect to the package, and which then bends back out with respect to the package, to terminate at the lip.

15. A package as claimed in claim 13 or 14 when dependent on claim 12 wherein the fastener holes for (a) are defined in both of the lips of the first and second package portions, and for (b) are defined in one of the lips of the first or second package portion.

16. A package as claimed in claim 15 wherein for (b) the fastener is incorporated into the other of the lips of the second or first package portions respectively.

17. A package as claimed in claim 16 wherein the fastener is formed in a tab hingedly connected to the package portion and incorporated in said other of the lips.

18. A package as claimed in any one of the preceding claims including a frangible line in one of the first or second package portions and positioned such that, when the line is severed therealong, item(s) located in the inner space can be accessed.

19. A package as claimed in claim 18 wherein the frangible line is a tear strip that commences adjacent to a hinge between the first and second package portions, the tear strip extending adjacent to a periphery of the package portion in which it is located such that, when the tear strip is removed, at least a part of the package portion can be pivoted away from the package to enable item(s) to be removed therefrom.

20. A package as claimed in claim 18 or 19 wherein one or both ends of the tear strip are connected to a respective tear tab moulded integrally with one of the package portions, the or each tab facilitating gripping and initiation of tear strip removal.

21. A package as claimed in claim 20 wherein the tab(s) is/are located adjacent to a hinge between the first and second package portions, with a given tab of one package portion being positionable in a cut-out region of the other package portion when in the package closed position.

22. A unitary moulded component for a package including: a package portion; and a fastener connected to the package portion for fastening engagement with a receiver; wherein, when the package component is moulded, the fastener is positioned with respect to the package portion such that the package component can be removed from a die in which it is formed as a unitary structure and such that the fastener can then be used without detaching it from the package portion.

23. A component as claimed in claim 22 wherein the fastener projects from and is optionally hingedly connected to the package portion.

24. A component as claimed in claim 22 or 23 wherein the fastener is either a spigot which latches into a recess in the receiver, or is a hinge plate having a male portion projecting therefrom, the male portion being adapted for snap locking engagement with the receiver.

25. A component as claimed in one of claims 22 to 24 wherein the package portion is the second package portion as defined in any one of claims 1 to 22, and the receiver is respectively the recess or holes as defined in any one of claims 8 to 10, or 12 and 15.

26. A component as claimed in claim 25 wherein the package portion is hingedly connected to the first package portion for pivoting between package closed and open positions.

27. A process for moulding in a two part die the unitary package component of any one of claims 22 to 26, the process including the steps of : introducing a mouldable material into the die and allowing the mouldable material to cure; and removing the resultant package component from the die in a manner such that it is maintained as unitary, and such that the fastener can be used without detaching it from the package portion.

28. A process as claimed in claim 27 that is an injection moulding process wherein the mouldable material is a polymer.

29. A process as claimed in claim 28 wherein the polymer is polypropylene or polyethylene.

30. A process as claimed in any one of claims 27 to 29 wherein the step of removing the package component from the die includes : employing a first knock out rod to dislodge the fastener from the die by causing the fastener to rotate about a hinge axis therefore; and employing a second knock out rod to dislodge the package component from the die .

31. A moulded package portion for use as a component of a package, the package portion being connectable to another package portion to define the package and an interior therefore, the package portion including a frangible line therein such that one part of the package portion can be separated along the line relative to another part of the package portion to provide access to the package interior.

32. A portion as claimed in claim 31 wherein the frangible line is defined by a tear strip, a line of perforation, a line of weakness in the package portion or a line of reduced thickness in the package portion.

33. A portion as claimed in claim 31 or 32 that is one of the first or second package portions, and said another package portion is respectively the other of the second or first package portions, as defined in any one of claims 1 to 21, 25 or 26.

34. A portion as claimed in claim 33 wherein separation along the frangible line enables item(s) to be accessed and/or removed from the package .

35. A portion as claimed in claim 31 or 32 that is the package portion as defined in any one of claims 22 to 26, or is manufactured by a processes defined in any one of claims 27 to 30.

36. A portion as claimed in any one of claims 31 to 35 wherein the frangible line extends around a periphery of the package portion such that separation therealong enables said one part of the package portion to be either removed or pivoted away from the package to thus provide access to the package interior.