BOOKLET FORM PAPERBOARD PACKAGE FOR MEDIA DISKS

Abstract

A package for housing one or more items such as optical media discs is constructed from alternating layers of material such as paper and paperboard. The various layers are adhered together to form the package. The package has a book like form. The layers of paperboard have internal spaces for holding discs. The layers of paper are folded and the folds make up at least part of a binding. Projections into the internal spaces may be used to limit unintended movement of the items within the internal spaces.

Description

BACKGROUND OF THE INVENTION

The present invention relates generally to a closable storage package for a recording medium and, more particularly, to a package comprising a paper board book-like assembly for storing one or more discs.

Various types of planar discs are in use at the present time to record and store information which is to be retrieved by various means, such as by optical or magnetic means. Typical of such discs are compact discs in which information is digitally recorded by use of a laser beam and then read optically by a laser beam. Such discs are used to record audio information such as musical renditions, video information such as visual images and digital information for use as read only and other memories for use in various applications, such as computer applications. In most instances, at the present time, such discs are sold with information already recorded thereon. In other applications, such discs are sold in blank form and are used by the customer to record information thereon. In the latter case, for example, optical discs are sold for use as computer storage media and are used in hard disc storage systems. As used herein, the terms media disc, compact disc, CD or disc are intended to encompass all such discs, whatever their size, for all known or proposed uses.

Compact discs containing laser recorded information are typically packaged in injection molded plastic enclosures designed to hold one or more CDs for protecting the discs during storage and shipment. Enclosures commonly used at the present time, such as the well known “jewel box,” comprise a three piece assembly consisting of a base or bottom element, an insert or tray in the base/bottom element for positioning and supporting the disc in the base/bottom element, e.g., by a center projection (commonly referred to as a “rosette”) which engages the periphery of the aperture in the center of the disc, and a lid or cover which is hinged to the base/bottom element and is closed thereon after the disc is mounted therein on the tray. Other enclosures may support a disc or discs within booklet-like structure made partially or completely of paper or paperboard.

There remains a need for a simple, sturdy, environmentally friendly, attractive, and inexpensive to manufacture CD package that adequately protects the disc yet provides easy access thereto.

SUMMARY OF THE INVENTION

It is an object of the present disclosure to provide a package for holding discs that is easy to manufacture from paper board or similar suitable environmentally friendly and/or recyclable material and adhesive such that the finished package is sturdy and attractive.

The present disclosure is directed to a package for housing one or more discs in a booklet-like package including one or more pages comprising multiple plies some of whose material is partially cut away to provide a holding space for at least one disc. Variations of the illustrative embodiments are also within the contemplation of the present disclosure, including variations in the size, shape, material, and number of the pages, and the size, shape, number and location of the cutaway areas for holding discs.

It should be appreciated that the present invention can be implemented and utilized in numerous ways, including without limitation as a process, an apparatus, a system, a device, and a method for applications and from other suitable materials now known and later developed. These and other unique features of the system disclosed herein will become more readily apparent from the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those having ordinary skill in the art to which the disclosed system appertains will more readily understand how to make and use the same, reference may be had to the following drawings.

FIG. 1 shows an isometric view, prior to assembly, of a blank for forming part of a media package.

FIG. 2 shows an isometric view of the blank of FIG. 1, during a stage of its folding.

FIG. 3 shows an isometric view of additional parts as of FIG. 2, being assembled into a media package.

FIGS. 4A and 4B show top views of the media package.

FIG. 5 shows an isometric view of the media package of FIG. 3, holding optical media.

FIG. 6 shows an isometric view of the media package of FIG. 5, in a more open configuration.

FIG. 7 shows an isometric view of another variation on the media package.

FIG. 8 shows an isometric view of another variation on the media package.

FIG. 9A shows an isometric view of another embodiment of a part of a media package prior to assembly.

FIG. 9B shows a detail view of FIG. 9A.

FIG. 10 shows an isometric view prior to assembly of another blank for forming part of a media package.

FIG. 11 shows an isometric view after assembly of the part formed from the blank of FIG. 10.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present disclosure is for a book-like package for optical media or other items. The advantages, and other features of the package disclosed herein, will become more readily apparent to those having ordinary skill in the art from the following detailed description of certain exemplary embodiments taken in conjunction with the drawings which set forth representative embodiments of the present invention and wherein like reference numerals identify similar structural elements whenever possible.

All relative descriptions herein such as left, right, up, down, topside, underside and the like are with reference to the Figures, and not meant in a limiting sense. The illustrated embodiments can be understood as providing exemplary features of varying detail of certain embodiments, and therefore, unless otherwise specified, features, components, modules, elements, and/or aspects of the illustrations can be otherwise combined, interconnected, sequenced, separated, interchanged, positioned, and/or rearranged without materially departing from the disclosed systems or methods. Additionally, the shapes and sizes of components are also exemplary and unless otherwise specified, can be altered without materially affecting or limiting the disclosed technology to holding discs exclusively.

Exemplary embodiments of the present invention are illustrated in FIGS. 1-10, in which there are shown improved optical media packages made from paper and adhesive. In brief overview, the packages are made from folded sheets of (generally) a lighter weight sheet material (such as paper) with plies of a (generally) heavier weight sheet material (such as paperboard) sandwiched between. Cutout areas are provided in the heavier weight (paperboard) to receive optical media.

FIG. 1 shows certain parts the package prior to assembly. A first sheet of paper 10 is folded into panels 12A and 12B along a score line 14. A cutting line 18 may be provided, which is shown in dashed line in the drawing; this cutting line 18 may or may not be indicated by a visible marking. Beyond the cutting line 18 are trim panels 12C and 12D that may be removed in later trimming operations. A central aperture 16 may be provided in one or both panels 12A and 12B. A peripheral aperture 17 may also be provided in one or both panels 12A and 12B.

A second sheet 20 is folded into panels 22A and 22B along a score line 24. As with the first panel, cutting line 28, central aperture 26, and peripheral aperture 27 may be provided in the second sheet 20.

Shown between first sheet 10 and second sheet 20 is third sheet 30, which in the assembled configuration may hold optical media 50. The third sheet 30 may for example be formed of a paperboard, such as a paperboard having a thickness of about 0.036 inches. A cut line 34, shown as approximately “U” shaped, defines a removable region 32B that will ultimately be removed to make room for the optical media. However, at this point of the assembly, removable region 32B is still connected with the rest of third sheet 30, represented by permanent region 32A. A cutting line 38 is shown on third sheet 30.

FIG. 2 shows the parts of FIG. 1 having been brought together so that the third sheet 30 is sandwiched between the first and second sheets, forming an assembly 100. This may be done by applying adhesive to both sides of third sheet 30, excepting the removable region 32B, then placing the first sheet and second sheet on opposing surfaces of third sheet 30. The assembly as shown in FIG. 2 is an example of a stage in the construction of a multi-page booklet form package for holding one or more optical media. However, the assembly 100 as shown in FIG. 2 may be utilized as a package for a single disc, in which case central aperture 26 and peripheral aperture 27 may be omitted from the second sheet.

FIG. 3 shows a step in the assembly of a multi-page booklet-like package for holding one or more optical media. In this case additional pages 210 are provided within the package. Pages 210 each may comprise for example a first sheet (e.g. a lighter paper sheet as previously described) and a third sheet (e.g. a heavier paperboard sheet as previously described). The pages may be adhered together as explained in FIG. 2.

FIG. 4A shows a top view of the assembly as shown in FIG. 3, before adhering the parts together. It can be seen that the structure includes six of the third sheet 30, separated by five of first sheet 10, all between a “front cover” of first sheet 10 and a “rear cover” of second sheet 20. All of the facing surfaces of these sheets would be glued together as explained in FIG. 2, which then gives the package 200 as shown in top view in FIG. 4B, where the internal pages 210 are each shown as a unit.

After the component sheets have been glued together to form as many connected pages as desired, the package may be cut along cutting lines 18, 28, and 38, leaving package 200 appearing as shown in FIG. 5. The removable regions 32B are now free to be removed from the assembly, and their removal leaves internal spaces to receive optical media 50 (shown fully enclosed in the package) and optical media 51 (shown partly removed from the package). Removal from the package is facilitated by the peripheral apertures 17 which permit the disc edge 57 to be grasped, or by the central apertures 16 that permit the disc to be lifted by placing a finger in the disc hub opening 56.

Besides cutting the package along cutting lines 18, 28, and 38 as described, the other edges may also be trimmed or cut, excepting the joined edge that serves as the spine (e.g., along fold 14 and its counterparts). The removable region 32B may be recycled, or it may be used as feed stock for other uses. It may be pre-printed before assembly, to form promotional materials, coupons, cards, and other items useful to the purchaser or the manufacturer of the package.

FIG. 5 shows the appearance of the package 200 with only the front cover (represented by panel 12A) and the rear cover (represented by panel 42B, also showing its cutting line 48) opened outward. FIG. 6 shows another view of the package, with the pages 210 splayed somewhat apart to show a more typical use situation.

Since the facing surfaces at any “page” in the page in the package are made of a single continuous sheet of paper (such as facing surfaces 12A and 12B), a continuous graphic image may be printed without any disruptive discontinuities at the binding edge, which is merely the fold 14 between the facing panels.

FIG. 7 shows another embodiment as package 300 in which front pages 301, 302, 303, and 304 and back pages 317, 318, and 319 do not house optical discs. Such non-disc pages may occur in any desired number and may be located anywhere in the package, including interspersed between pages that house discs. Non-disc pages may include third sheet 30 if desired, but often would not include this thicker piece of material.

The package may contain one or more media discs, and each page may contain one or more discs. FIG. 8 shows another embodiment as package 400 wherein the pages each may hold two discs, for example discs 50 and 51 inward toward the “binding edge and discs 60 and 61 housed toward the outward edge of the package. In the embodiment of package 400, front pages 401, 402, 403, and 404 and back pages 417, 418, and 419 do not house optical discs.

The packages may contain items other than media discs. Although in some embodiments the packages may be made from paperboard having a thickness of about 0.036″, and paper of various thicknesses, other types and thicknesses of materials may be utilized as are known in the packaging arts. The third sheet 30 in particular may be formed of more than one ply or more than one material. For example, it may be bleached board, kraft board, dyed or otherwise colored board. The package may use multiple style covers, including for example a hard cover (for example, as used on case bound books, coffee table books or hard back novels) or thick paperboard may be used for the cover.

The removable region 32B may be rectangular as shown in the Figures, or it may have other shapes that are suitable to accommodate an optical disc or other item desired to be housed in the package. For example, the bottom periphery of removable region 32B may be semi-circular to fit the perimeter of a disc, or it may have a polyhedral shape. The shape of the removable region 32B may be simple (e.g. linear, curved) or complex. The shape and size of central aperture 16 may be varied, or it may be omitted. Likewise the shape and size of peripheral aperture 17 may be varied or it may be omitted. Either aperture may appear on one, both, or neither of the sheets of paper that are glued to third sheet 30.

FIG. 9A shows another embodiment of third sheet 530 (similar, for example, to third sheet 30 shown in FIG. 1), that may fit between the first sheet and second sheet and hold optical media 50. The third sheet 530 may for example be formed of paperboard, such as a paperboard having a thickness of about 0.036 inches. A cut line 534, only certain segments of which are labeled, is shown as approximately “U” shaped and defines a removable region 532B that will ultimately be removed to make room for the optical media. However, at initial stages of the assembly, removable region 532B is still connected with the rest of third sheet 530, represented by permanent region 532A. A cutting line 538 is shown on third sheet 530.

Third sheet 530 may have one or more notches 534A that protrude inwardly toward the region to be occupied by optical media 50. A detail view is shown in FIG. 9B. The notch or notches 532A create a slight constriction in the path of the optical media as it is slid out of (or into) the finished package. Such a constriction may help prevent unintended movement of the optical media out of the case, for example during shipping and handling. Notch 534A may be located between the storage position of optical media 50 (as shown in dotted line in FIG. 9B) and the opening through which the optical media will eventually be removed, that is, at the edge approximated by cutting line 538. As shown in FIG. 9B, notch 534A is positioned fairly near the storage position of optical media 50, although the notch may be further away if desired. Placement of the notch near the storage position of optical media 50 holds the disc almost completely within the package, until the customer pulls the optical media from the package. The notch however is able to yield slightly so that a slight tug is sufficient for pulling the optical media past the notch and out of the package.

It will be realized that notch 534A creates a constriction that may also resist pulling removable region 532B out of the package, once assembly, gluing, and trimming is accomplished. Therefore to facilitate removal of removable region 532B, relief cut 534B may be made in the removable region. The relief cut 534B may extend from the most inward point on notch 534A, and downward to the lower end of removable region 532B. Thus, a relief portion 532C is created below notch 534A. This relief portion 532C may be removed from third sheet 530 before assembly, for example, during a die cutting step when cut line 534 and relief cut 534B are made. Since removing relief portion 532C leaves a void during further assembly, the relief portion may comprise a relatively a small part of removable region 532B, so as to provide a rather solid stack of layers during subsequent processing steps. After assembly, when the package has been trimmed along cutting line 538, the central portion of the removable region 532B may be pulled out of the package as in the other examples. The package is thus ready to receive and hold optical media 50, with notch or notches 534A holding the optical media against inadvertently coming out of the package. However, the notches 534A are sufficiently yieldable to allow a customer to pull out the optical media from the package, or replace it into the package.

One or more notches 534A may be provided on one or both sides of each opening that receives optical media. The shapes of notches 534A and relief portions 534C may differ from those shown in the Figures.

FIG. 10 shows another embodiment by which an additional sheet may be attached into the package prior to assembly. FIG. 10 is in certain aspects similar to FIG. 1 and therefore not all elements will be described. First sheet of paper 610 may be folded into first extending panel 612A, panel 612B, and second extending panel 612C along score lines 614A, 614B. A cutting line 618 may be provided.

Additional sheet 640 with flange portion 642 may be attached into the structure by trapping the flange portion 642 between first extending panel 612A and second extending panel 612C as shown and fastening these flange portion 642, first extending panel 612A, and second extending panel 612C together for example by gluing. FIG. 11 shows an assembled structure with the additional sheet 640. The additional sheet 640 may be a transparent, translucent, or opaque sheet. It may be plastic, paper, or other sheet material. Instead of, or in addition to, providing additional sheet 640 held between first extending panel 612A and second extending panel 612C as in FIG. 10, another additional sheet (not shown) may be provided and held by its flange between panel 612B and an outward extension page (not shown, for example extended from edge 612D. Likewise one or more additional sheets may be attached to second sheet of paper 620 by a similar method.

As noted above, the packages can be formed using a variety of materials or substrates. For example, PRINTKOTE EAGLE®, which is composed of at least 10% post consumer recycled material, can be used. Moreover, a polymeric substrate such as calendered POLYLITH® GC-3 can be used. POLYLITH® substrate is manufactured by Nanya Plastics of Taiwan and is distributed in the U.S. by Granwell Products, Inc. POLYLITH® substrate is primarily formed using polypropylene resin and minerals comprising inert calcium carbonate and titanium dioxide and the resulting substrate is strengthened by calendaring.

While the invention has been described with respect to exemplary embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the invention without departing from the spirit or scope of the invention.

Claims

1. A package for holding an item, comprising: a first layer of sheet material,a second layer of sheet material,a third layer of sheet material adhered between the first and second layers, wherein the third layer has a first cutout area with a first opening to at least one edge of the third layer,wherein the first cutout area is sized to receive the item, and the first opening is large enough for the item to pass through the first opening.

2. The package of claim 1, further comprising a second cutout area in an edge of the first or second layer, wherein the second cutout area overlaps at least a portion of the first cutout area, and wherein the second cutout area is proximate to the first opening.

3. The package of claim 1, further comprising a third cutout area away from any edge of the first or second layer, wherein the third cutout area overlaps at least a portion of the first cutout area.

4. The package of claim 1, wherein the third layer has a thickness substantially equal to or greater than the thickness of the item.

5. The package of claim 1, wherein at least one of the first and second layer comprises a first extending portion hingedly attached thereto through a fold.

6. The package of claim 1, wherein the first cutout area comprises a yieldable constriction that resists movement of the item.

7. A package for holding an item, comprising: a plurality of folded sheets each comprising two panels connected by a fold between the two panels, each panel having an inward facing surface and an outward facing surface;at least one item-holding sheet, having a first face and a second face, wherein the first face is adhered to the outward facing surface of a first panel of one of the plurality of folded sheets, and the second face is adhered to the outward facing surface of a second panel of another of the plurality of folded sheets;wherein the item-holding sheet has a first cutout area with a first opening to at least one edge of the item-holding layer, wherein the first cutout area is sized to receive the item, and the first opening is large enough for the item to pass through the first opening.

8. The package of claim 7, further comprising a second cutout area in an edge of at least one of the first panel or the second panel, wherein the second cutout area overlaps at least a portion of the first cutout area, and wherein the second cutout area is proximate to the first opening.

9. The package of claim 7, further comprising a third cutout area in at least one of the first panel or the second panel, away from any edge of the first or second panel, wherein the third cutout area overlaps at least a portion of the first cutout area.

10. The package of claim 7, wherein the item-holding layer has a thickness substantially equal to or greater than the thickness of the item.

11. The package of claim 7, wherein the item-holding layer is made of one or more plies of sheet material.

12. The package of claim 7, wherein the first cutout area is sized to receive a disc.

13. The package of claim 7, wherein the first cutout area is rectangular in shape.

14. The package of claim 7, wherein the first cutout area has two sides and a bottom, and the bottom is rounded in shape.

15. The package of claim 8, wherein the second cutout area overlaps an edge of an item housed within the item-holding layer.

16. The package of claim 9, wherein the third cutout area overlaps a central region of an item housed within the item-holding layer.

17. The package of claim 7, wherein at least one pair of the plurality of folded sheets is adhered together with no item-holding layer between the pair.

18. The package of claim 7, wherein the item-holding layer holds more than one item.

19. The package of claim 7, the folded sheets and the item-holding sheets form pages of a booklet, with the folds at least in part forming a binding for the booklet.

20. The package of claim 7, wherein the inward-facing surfaces of the first and second panels form an uninterrupted surface for receiving a printed image or printed information.

21. The package of claim 7, wherein the first cutout area comprises a yieldable constriction to resist movement of the item.

22. The package of claim 21, wherein the yieldable constriction comprises one or more notches directed inward into the first cutout area.

23. The package of claim 5, further comprising a second extending portion extending from and hingedly attached to the first extending portion; andan additional sheet comprising a flange;wherein the second extending portion is folded upon the first extending portion, and the flange is held between the first extending portion and the second extending portion.

24. The package of claim 23, wherein the additional sheet comprises at least one of a transparent, translucent, and opaque material.

25. The package of claim 7, further comprising an additional sheet with a flange hingedly attached thereto; andan extending panel hingedly attached to the second panel of one of the plurality of sheets;wherein the extending panel is folded upon the second panel, holding the flange between the extending panel and the second panel.

26. The package of claim 25, wherein the additional sheet comprises at least one of a transparent, translucent, and opaque material.