Title: Button cell battery pack with air access channel
Abstract: A battery pack suitable for use with button cell batteries. The battery pack includes a flexible card and a cover rotatably fixed relative to said flexible card. A backing is interposed between the card and said cover, and fixed relative to said card. The backing and cover define an enclosed space interposed between the cover and the backing for receiving batteries. Batteries disposed in the space are enclosed by the cover and backing. An air access channel formed in the backing diffuses air to the batteries.
Patent Number: 6,938,775 Issued on 09/06/2005 to Gaffney, et al.
| Inventors:
|
Gaffney; Robert C. (Sun Prairie, WI);
McKenzie; Rodney S. (Madison, WI);
Syvertsen; Marc L. (Madison, WI);
Schmoeger; Jeffrey W. (Deerfield, WI);
Johnstone; Michael J. (Madison, WI);
Reidl; Robert G. (Kendall, WI);
Poirier; Jeffrey A. (Madison, WI);
LaMasney; Robert G. (Cross Plains, WI);
Mack; Ross J. (Dane, WI)
|
| Assignee:
|
Rovcal, Inc. (Fresno, CA)
|
| Appl. No.:
|
614967 |
| Filed:
|
July 8, 2003 |
| Current U.S. Class: |
206/704; 206/471 |
| Intern'l Class: |
B65D 085/00 |
| Field of Search: |
206/703-705,528,530,538,539,533,461,471,806,464,465,477,486
|
References Cited [Referenced By]
U.S. Patent Documents
| 2899046 | Aug., 1959 | Cox, Jr.
| |
| 2971638 | Feb., 1961 | Allison et al.
| |
| 3433351 | Mar., 1969 | Zabornev.
| |
| 3995767 | Dec., 1976 | Brindley et al.
| |
| 4209091 | Jun., 1980 | Lieberman.
| |
| 4270659 | Jun., 1981 | Kuchenbecker.
| |
| 4860890 | Aug., 1989 | Cerny et al.
| |
| 4953700 | Sep., 1990 | DeDino.
| |
| 5033616 | Jul., 1991 | Wyser.
| |
| 5492675 | Feb., 1996 | Brizard.
| |
| 5795667 | Aug., 1998 | McKenzie et al.
| |
| 5839583 | Nov., 1998 | Pope et al.
| |
| 6039185 | Mar., 2000 | Pedracine et al.
| |
| D433629 | Nov., 2000 | Clarke et al.
| |
| 6830149 | Dec., 2004 | Merboth et al.
| |
Primary Examiner: Bui; Luan K.
Attorney, Agent or Firm: Quarles & Brady LLP
Parent Case Text
CROSS REFERENCES TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No.
10/079,357 filed on Feb. 20, 2002, now U.S. Pat. No. 6,659,281.
Claims
1. A battery pack suitable for use with button cell batteries, said battery pack comprising:
a flexible card;
a backing fixed to said card;
a platform extending from said backing away from said card for supporting the
batteries;
an air access channel formed in said platform for allowing air to diffuse to
the batteries supported by said platform;
a cover rotatably fixed to at least one of said backing and said card; and
a cavity formed in said cover and opening to said card, and said cavity receiving
said platform to inhibit access to a battery interposed between said cover and
said backing.
2. The battery pack as in claim 1, in which said cavity formed in said cover
is annular, and said platform formed in said backing is at least semi-annular,
wherein said semi-annular platform is received in said annular cavity, and sides
of said cavity overlap sides of said platform.
3. The battery pack as in claim 1, in which a plurality of receptacles are formed
in a wall of said cavity and open toward said backing, wherein each of said receptacles
are sized for receiving a single battery.
4. The battery pack as in claim 1, in which said air access channel is formed
by a groove formed in a top wall of said platform.
5. The battery pack as in claim 1, in which said air access channel is formed
by dimples formed in a top wall of said platform.
6. The battery pack as in claim 1, in which said air access channel is formed
by holes formed through a top wall of said platform.
7. The battery pack as in claim 1, in which a flap hingedly connected to said
backing extends radially from a center of said backing to provide access to a battery
interposed between said flap and said cover.
8. The battery pack as in claim 7, in which said flap includes a flap platform
for supporting a battery, and said flap platform includes an air access channel.
9. The battery pack as in claim 7, in which said flap pivots through an opening
formed in said card to provide access to the battery interposed between said flap
and aid cover.
10. The battery pack as in claim 1, in which a plurality of batteries engaging
said platform are interposed between said backing and said cover.
11. A battery pack suitable for use with button cell batteries, said battery
pack comprising:
a flexible card;
a backing fixed to said card;
a platform extending from said backing away from said card for supporting the
batteries, said platform having a top wall;
at least one structure extending from said platform top wall for engaging a battery
to form an air access channel beneath the battery for allowing air to diffuse to
the battery;
a cover rotatably fixed to at least one of said backing and said card over said
platform to sandwich a battery between said platform and cover.
12. The battery back as in claim 11 including a cavity formed in said cover and
opening to said card, and said cavity receiving said platform to inhibit access
to a battery interposed between said cover and said backing.
13. The battery pack as in claim 12, in which said cavity formed in said cover
is annular, and said platform formed in said backing is at least semi-annular,
wherein said semi-annular platform is received in said annular cavity, and sides
of said cavity overlap sides of said platform.
14. The battery pack as in claim 12, in which a plurality of receptacles are
formed in a wall of said cavity and open toward said backing, wherein each of said
receptacles are sized for receiving a single battery.
15. The battery pack as in claim 11, in which said structure is at least one
ridge extending from said platform top wall away from said card.
16. The battery pack as in claim 11, in which said structure includes dimples
formed in said platform top wall.
17. The battery pack as in claim 11, in which said structure includes holes formed
through said platform top wall.
18. The battery pack as in claim 11 in which a flap hingedly connected to said
backing extends radially from a center of said backing to provide access to a battery
interposed between said flap and said cover.
19. The battery pack as in claim 18, in which said flap includes a flap platform
for supporting a battery, and said flap platform includes structure forming air
access channel.
20. The battery pack as in claim 18, in which said flap pivots through an opening
formed in said card to provide access to the battery interposed between said flap
and aid cover.
21. The battery pack as in claim 11, in which a plurality of batteries engaging
said platform are interposed between said backing and said cover.
22. A battery pack suitable for use with button cell batteries, said battery
pack comprising:
a card;
a backing having a top and a bottom, said backing fixed to said card;
a platform extending from said backing top for supporting the batteries;
an air access channel formed in said platform for allowing air to diffuse to
the batteries supported by said platforms;
a cover rotatably fixed to at least one of said backing and said card, the cover
defining a cavity formed therein, the cavity opening to said card, and said cavity
receiving said platform to inhibit access to a battery interposed between said
cover and said backing.
23. The battery pack as in claim 22, in which a plurality of receptacles are
formed in a wall of said cavity and open toward said backing, wherein each of said
receptacles are sized for receiving a single battery.
24. The battery pack as in claim 22, in which said air access channel is formed
by a groove formed in a top wall of said platform.
25. The battery pack as in claim 22, in which said air access channel is formed
by dimples formed in a top wall of said platform.
26. The battery pack as in claim 22, in which said air access channel is formed
by holes formed through a top wall of said platform.
27. The battery pack as in claim 22, in which a plurality of batteries engaging
said platform are interposed between said backing and said cover.
Description
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not Applicable
BACKGROUND OF THE INVENTION
The present invention relates to packaging for button cell batteries, and more
particularly to button cell packs which inhibit pilfering.
Button cell batteries are typically used in hearing aids, and, are thus small
in size having a diameter which cam be less than half the width of a finger. Moreover,
the small battery size results in a limited power supply, and requires replacement
in a hearing aid at regular intervals. In order to accommodate frequent replacement
of these batteries, the batteries are typically sold in packages containing a plurality
of the batteries.
One known battery package disclosed in U.S. Pat. No. 5,839,583 encloses six button
cell batteries in a hard plastic case. The package is molded in one piece, and
includes a base hingedly connected to a cover. The base includes pockets which
receive the batteries. The pockets containing the batteries are covered by a sheet
of plastic material which is adhesively attached to the base and each battery.
The cover closes over the plastic covered batteries in the pockets. Absent wrapping
the package to prevent access by a pilferer by simply opening the cover, there
is no deterrent against pilfering. Additional wrapping is expensive, and increases
the cost of an already expensive package.
A less expensive package known in the art includes a plastic cover rotatably
mounted
to a card. The cover includes receptacles which open to the card. Each receptacle
receives a single battery which is accessed through a cutout formed in the card.
The cover is rotated to align a battery with the cutout, and the battery is popped
out of the receptacle through the cutout. The cutout is initially blocked by card
material to prevent pilfering prior to purchase. Once a purchaser has removed the
card material blocking the cutout, however, inadvertent rotation of the cover could
cause a battery to unintentionally fall out of the package. In addition, the flexible
card can be bent away from the cover to allow access to the batteries by a pilferer.
More secure packaging introduces an additional problem for batteries that require
the diffusion of air while packaged, such as tabbed zinc air cells. Restricting
air diffusion to the batteries can significantly reduce the effectiveness of the
battery. This problem is disclosed in U.S. Pat. No. 5,795,667 which is assigned
to the assignee of the present application. Accordingly, a need exists for a battery
package which can accommodate air diffusion to the batteries packaged therein.
SUMMARY OF THE INVENTION
The present invention provides a battery pack for batteries. The battery pack
includes a flexible card and a cover rotatably fixed relative to said flexible
card. A backing is interposed between the card and said cover, and fixed relative
to said card. The backing and cover define an enclosed space interposed between
the cover and the backing for receiving batteries. Batteries disposed in the space
are enclosed by the cover and backing. An air access channel formed in the backing
diffuses air to the batteries.
A general objective is to provide a battery pack for button cells which can diffuse
air to the batteries. This objective is accomplished by providing a backing having
an air access channel.
This and still other objects and advantages of the present invention will be
apparent from the description which follows. In the detailed description below,
preferred embodiments of the invention will be described in reference to the accompanying
drawings. These embodiments do not represent the full scope of the invention. Rather
the invention may be employed in other embodiments. Reference should therefore
be made to the claims herein for interpreting the breadth of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a battery pack incorporating the present invention;
FIG. 2 is an exploded perspective view of the pack of FIG. 1;
FIG. 3 is a cross sectional view along line 3—3 of FIG. 1;
FIG. 4 is a cross sectional view along line 4—4 of FIG. 1;
FIG. 5 is a detailed cross sectional view of the pack of FIG. 1 between a pair
of adjacent receptacles.
FIG. 6 is a rear view of the pack of FIG. 1;
FIG. 7 is a top view of the backing of FIG. 1;
FIG. 8 is a bottom view of the cover of FIG. 1;
FIG. 9 is a top view of the backing of FIG. 1 including an air access channel;
FIG. 10 is a cross sectional view along line 10—10 of FIG. 9;
FIG. 11
a is a top view of an alternative embodiment of the backing including
dimples to form the air access channel;
FIG. 11
b is a side cross sectional view along line 11
b-11
b
of FIG. 11
a; and
FIG. 12 is a top view of another alternative embodiment of the backing includes
holes to form the air access channel.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1-8, a battery pack
10 includes a flexible card
12, a clear plastic backing
14 fixed to the card
12, and a
clear plastic cover
16 rotatably fixed relative to the card
12 and
backing
14. The cover
16 and backing
14 have overlapping structure
which inhibits a pilferer from extracting one or more batteries
18, such
as tabbed zinc air cells, interposed between the backing
14 and the card
12.
The flexible card
12 is, preferably, a die cut paperboard card which can
carry identifying indicia and advertising thereon. A hanger slot
20 formed
through the card
12 can be provided to facilitate hanging the battery pack
10 for display to potential purchasers. A circular opening
22 interposed
between a pair of anchor holes
24 formed in the card
12 receives
a cover center post
26 extending from the cover
16 through a central
opening
28 in the backing
14. The anchor holes
24 receive
anchors
30 extending from the backing
14 to prevent rotation of the
backing
14 relative to the card
12. A rectangular flap cutout
32
formed in the card
12 between the circular opening
22 and hanger
slot
20 provides access to a flap
34 formed part of the backing
14.
The disc shaped cover
16 is rotatably fixed relative to the card
12,
and is preferably formed from a clear plastic which allows potential purchasers
to view the batteries
18 in the pack
10. The cover
16 includes
the center post
26 which is coaxial with a cover axis
36 of rotation.
The center post
26 has a distal end
38 which extends through the
central opening
28 of the backing
14 and through the circular opening
22 of the card
12. Preferably, the center post distal end
38
is thermally deformed, such that it is larger (shown in FIG. 5) than the card circular
opening
22 to rotatably fix the cover
16 relative to the card
12.
Although thermally deforming the center post distal end
38 is disclosed,
other methods can be used to rotatably fix the cover
16 relative to the
card
12, such as by using mechanical fasteners, a snap fit, and the like,
without departing from the scope of the present invention.
An annular cavity
40 formed in the cover
16 is coaxial with the
axis
36, and opens toward the card
12. The annular cavity
40
includes opposing sidewalls
42,
44 joined by a top wall
44.
As best shown in FIG. 5, the axially extending annular cavity sidewalls
42,
44 overlap sidewalls
48,
50 of a platform
52 extending
from the backing
14 to inhibit pilfering.
A plurality of battery receptacles
54 are formed in the annular cavity
top
wall
46, and open toward the card
12. The receptacles
54 are
spaced equidistantly from the axis
36, and are individually sized to receives
one of the disc shaped batteries
18. Although each receptacle
54
is shown to receive a single disc shaped battery
18, the receptacles can
be formed to receive more than one battery and batteries which are not disc shaped,
without departing from the scope of the invention.
A plurality of indents
56 is formed in the cover
16, and each indent
is equidistantly space about a diameter of the cover
16. Each indent
56
opens toward the backing
14, and is engageable with a protrusion
58
extending from the backing
14. Preferably, each indent
56 is radially
aligned with one of the battery receptacles
54 to index the receptacles
54 aligned with the flap
34 as the cover
16 rotates about
the axis
36. Although a plurality of indents
56 formed in the cover
16 which are engageable with the protrusion
58 extending from the
backing
14 is disclosed, other methods for indexing the rotation of the
cover can be used without departing from the scope of the invention, such as providing
a plurality of protrusions which engage one or more indents, forming the indents
in the backing and the protrusions on the cover, and the like.
The disc shaped backing
14 is sandwiched between the card
12 and
the cover
16, and is preferably formed from a clear plastic which allows
a potential purchaser to view at least one battery
18 through the flap cutout
32. Advantageously, the plastic backing
14 provides a low friction
surface on which the cover
16 rotates. Moreover, the backing
14 prevents
a pilferer from gaining access to the batteries
18 interposed between the
backing
14 and cover
16 by merely bending the card
12.
The pair of anchors
30 extending from the backing
14 through the
anchor holes
24 formed in the card
12 prevent rotation of the backing
14 relative to the card
14. Of course, the backing
14 can
be fixed to the card
12 using other methods, such as adhesives, mechanical
fasteners, and the like without departing from the scope of the invention.
The semi-annular platform
52 formed in the backing
14 extends away
from the card
12, and has a pair of opposing ends
60,
62 and
the sidewalls
48,
50 joined by a top wall
64. The platform
52 extends into the annular cavity
40 formed in the cover
16,
and the platform sidewalls
48,
50 overlap the annular cavity sidewalls
44,
46 to provide the overlapping structure which inhibits pilfering.
Advantageously, the platform
52 traps each battery
18 in one of the
receptacles
54 formed in the cover
16 to space the batteries
18
from the card
12, and further inhibit pilfering of the batteries
18.
The overlapping structure inhibits pilfering which occurs by a pilferer bending
the flexible card
12 away from the cover
16 to gain access to the
batteries
18. Although axially extending cover sidewalls
44,
46
overlapping the platform sidewalls
48,
50 to inhibit pilfering is
disclosed, other overlapping structure, such as an axially extending lip formed
at the circumference of the cover which extends past the circumferential edge of
the backing, can be provided to inhibit pilfering without departing from the scope
of the invention.
The height of the platform
52 is directly related to the effectiveness
of the overlapping structure to inhibit pilfering. In particular, the higher the
platform height, i.e. the further the platform
52 extends into the cover
annular cavity
40, the more effective the overlapping structure is for inhibiting
pilfering. The height is dependent upon several factors, such as battery size,
package size, formability of the material, and the like. Preferably, the platform
top wall
64 slidably engages the annular cavity top wall
46 to take
advantage of the full depth of the cover annular cavity
40.
Referring now to FIGS. 9 and 10, a groove
100 formed in the platform
top wall
64 defines a pair of radially spaced ridges
102 that engage
the batteries
18 to form an air access channel beneath the batteries
18.
The width of the groove
100 is dependent on the particular. battery size.
Preferably, the width of the groove
100 is not less than a circle defined
by the position of air holes in the battery side engaging the platform
52,
and the width of the groove
100 is not greater than the battery diameter.
The depth of the groove
100 is, preferably sufficient to allow air to enter
the groove
100, but shallow enough so as not to weaken the platform
52
or interfere with the rotation of the cover
16.
Although a groove
100 forming the air access channel is preferred,
other methods for providing an air access channel can be used without departing
from the scope of the invention. For example, raised structure extending above
the platform top wall
64, such as dimples
106 shown in FIGS. 11
a
and
11b can be provided which raise the batteries above the platform
top wall to provide a channel beneath the batteries, a single ridge formed along
a radial edge of the platform top wall can be provided to raise an edge of each
battery above the platform an form the channel beneath the batteries, and holes
108, such as shown in FIG. 12, formed in the platform top wall beneath the
batteries can formed the air access channel. Of course, other variations of the
preferred embodiment and above examples can be provided by one skilled in the art
without departing from the scope of the invention.
The air access channel allows the diffusion of air to the batteries
18
while the batteries are held securely between the platform
52 and cover
16. Advantageously, the air access channel provides unrestricted air to
the side of the batteries
18 engaging the ridges
102, and there is
no compression of a pressure sensitive adhesive
82 (shown in FIG. 2) over
the batteries' air access holes which could then be obstructed. Moreover, by forming
the air access channel in the platform
52, as the batteries
18 are
rotated for dispensing, the orientation of the air channel relative to the batteries
18 is maintained.
As shown in FIGS. 2 and 4, the protrusion
58 radially adjacent the platform
52 extends toward the cover
16, and is engageable with the indents
56 formed in the cover
16. The protrusion
58 and indents
56
allow the cover
16 to be indexed as the cover
16 rotates about the
axis
36. The indexing positions the cover
16, such that upon engagement
of the protrusion
58 with an indent
54, a battery
18 disposed
in one of the receptacles
18 is aligned with the flap cutout
32 for
access by a purchaser. Advantageously, the indexing also prevents inadvertent rotation
of the cover
16 which may align a battery
18 with the cutout
32
when the flap
34 is not in the closed position resulting in a battery
18
falling out of the pack
10.
The flap
34, shown in FIGS. 2,
4,
6, and
7, is formed
as an integral part of the backing
14, and has a top
66 and bottom
68 joined by side edges
70. The bottom
68 is hingedly connected
to the backing
14 by a living hinge
70. Pivoting the flap
34
away from the cover
16 through the flap cutout
32 to an open position
provides access to the battery
18 in the cover receptacle
54 aligned
with the flap
34 and cutout
32.
A flap platform
72 formed in the flap
34, and extending away from
the card
12, is interposed between the semi-annular platform ends
60,
62 formed in the backing
14 to fill the gap between the semi-annular
form ends
60,
62. The flap platform
72 prevents batteries
18 from lodging in the gap between the ends
60,
62 when the
cover
16 rotates about the cover axis
36 of rotation. Preferably,
a groove
104 is formed in the flap platform
72, such as shown in
FIGS. 9 and 10, to provide an air access channel for the battery
18 supported
by the flap platform
72.
As shown in FIG. 7, the flap edges
70 are initially fixed to the backing
14 by tack points
74 which join the edges
70 to the backing
14 to hold the flap
34 in a closed position. In order to access the
batteries
18, however, the tack points
74 are severed to allow the
flap
34 to pivot through the cutout
32 to the open position. Although
tack points are disclosed to initially hold the flap in the closed position, other
methods can be used, such as an adhesive strip covering the cutout, can be used
without departing from the scope of the invention.
Referring to FIGS. 6 and 7, once the tack points
74 are severed,
the flap
34 is held in the closed position by tabs
76 extending inwardly
into the card cutout
32 from the cutout edges
78. When moving the
flap
34 to the open position, the tabs
76 and/or the flap
34
deform to allow the flap
34 to pass through the cutout
32 past the
tabs
76 away from the cover
16. Similarly, when moving the flap
34
to the closed position, the tabs
76 and/or the flap
34 deform to
allow the flap
34 to pass through the cutout
32 past the tabs
76
toward the cover
16.
As shown in FIGS. 4,
6, and
7, the flap top
66 includes a
lip
80 which extends through the cutout
32. The lip
80 is
engageable by the user to pivot the flap
34 through the cutout
32
and gain access to a battery
18 aligned with the flap
34. Although
the lip
80 is preferred, any structure which allows a user to engage the
flap
34 through the cutout
32, such as a handle extending radially
and axially past the cover which allows pushing the flap through the cutout, and
the like, without departing from the scope of the invention. Moreover, the lip
can be eliminated without departing from the scope of the invention.
Referring now to FIG. 2, the batteries
18 are interposed between
the cover
16 and backing
14, and are urged into the receptacles
54
by the backing platform
64. The batteries
18 can be any battery known
in the art, such as a zinc air battery suitable for use as a hearing aid battery.
A self-adhesive tab
82 is fixed to each battery
18 to prevent premature
discharge of the zinc air battery by covering openings in the battery
18
which allows atmospheric oxygen to enter the battery
18. Advantageously,
the tab
82, as is known in the art, simplifies handling and positioning
the battery when inserting the battery
18 in a battery operated device.
Preferably, the free end
84 of each tab
82 is received in the indent
56 formed adjacent the receptacle
54 receiving the battery
18
fixed to the tab
82.
In use, with reference to FIGS. 1-8, the cover
16 is rotated about the
axis
36 of rotation until the protrusion
58 engages an indent
56
to align a receptacle
54 containing a battery
18 with the card cutout
32. A purchaser engages the flap lip
80 using a finger, and pulls
axially outwardly and radially inwardly to severe the tack points
74 joining
the flap edges
70 to the backing
14 to pivot the flap
34 past
the tabs
76 through the cutout
32 to expose the battery
18.
The purchaser then pops the battery
18 out of the receptacle
54 by
positioning the pack
10, such the receptacle
54 opens downwardly
through the cutout
32, and gravity urges the battery
18 out of the
receptacle
54 into the purchaser's hand.
The pack
10 is closed by pivoting the flap
34 back through the
cutout
32 past the tabs
76 toward the cover
16. The tabs
76
hold the flap
34 in the closed position until another battery
18
is desired, and the purchaser forces the flap
34 past the tabs
76
to the open position.
While there has been shown and described what are at present considered the
preferred embodiments of the invention, it will be obvious to those skilled in
the art that various changes and modifications can be made therein without departing
from the scope of the invention defined by the appended claims.
*
