Current card board type display products for planar articles such as coins often consist of circular cavities within paper board, into which the coins can be inserted and snapped in place. Typically, the coins can only be viewed from one side. In addition, coins once in place, are not easily removed without damaging the coins or the circular cavities.
The present invention can provide a display for display articles, or planar articles such as coins or medallions, including a generally planar plastic sheet having one or more retaining structures for capturing one or more display or planar articles. The plastic sheet has opposite first and second generally planar sides. A first paper board sheet can be bonded to the first side of the plastic sheet, and a second paper board sheet can be bonded to the second side of the plastic sheet. The plastic sheet can have generally the same dimensions of at least one of the paper board sheets.
In particular embodiments, the one or more retaining structures can be integrally formed in the plastic sheet. The plastic sheet can be formed of polyethylene terephthalate-glycol-modified (PETG). The first and second paper board sheets can have grains that are aligned in different directions. At least one paper board sheet can have one or more openings aligned with the one or more retaining structures. The paper board sheets can be bonded to the plastic sheet with a heat and pressure activated adhesive. The one or more retaining structures each can include a resilient side wall protruding from one of the generally planar sides of the plastic sheet. Multiple retaining structures can be molded in the plastic sheet for capturing multiple display articles. The retaining structures can be configured to capture display articles such as coins or medallions. Each retaining structure can include a generally circular resilient side wall.
In some embodiments, one of the paper board sheets can have multiple openings, each corresponding to a retaining structure for allowing the resilient side wall of each retaining structure to extend through one of the paper board sheets. In other embodiments, the other paper board sheet can also have multiple openings, each corresponding to a retaining structure to provide viewing through the other paper board sheet. In further embodiments, the generally planar plastic sheet can be a first generally planar plastic sheet. The display can further include a second generally planar plastic sheet having one or more retaining structures for capturing one or more display articles. One of the paper board sheets can be sized to be bonded to both the first and the second generally planar plastic sheets with a fold line extending between the first and second generally planar plastic sheets to allow the display to be folded.
The present invention can also provide a display for display articles including a generally planar plastic sheet having multiple retaining structures for capturing multiple display articles. The plastic sheet has opposite first and second generally planar sides. Each retaining structure can be integrally molded in the plastic sheet and have a resilient side wall protruding from one of the planar sides of the plastic sheet. A first paper board sheet can be bonded to the first side of the plastic sheet, and a second paper board sheet can be bonded to the second side of the plastic sheet. The plastic sheet can have generally the same dimensions of at least one of the paper board sheets. The first and second paper board sheets can have grains that are aligned in different directions. At least one paper board sheet can have multiple openings, each aligned with a corresponding retaining structure for allowing the resilient side wall of each retaining structure to extend through the at least one paper board sheet.
The present invention can also provide a method of forming a display for display articles including providing a generally planar plastic sheet having one or more retaining structures for capturing one or more display articles. The plastic sheet can have opposite first and second generally planar sides. A first paper board sheet can be bonded to the first side of the plastic sheet, and a second paper board sheet can be bonded to the second side of the plastic sheet. The plastic sheet can have generally the same dimensions of at least one of the paper board sheets.
In particular embodiments, one or more retaining structures can be integrally formed in the plastic sheet. The plastic sheet can be formed of polyethylene terephthalate-glycol-modified (PETG). Grains of the first and second paper board sheets can be aligned in different directions. One or more retaining structures can be aligned with one or more openings in at least one paper board sheet. The paper board sheets can be bonded to the plastic sheet with a heat and pressure activated adhesive under heat and pressure. In some embodiments, the adhesive can be activated under heat and pressure in a first press. The first press can be removed, and the paper board sheets can be sealed to the plastic sheet under heat and pressure in a second press. In one embodiment, the adhesive can be activated under heat and pressure in a first press at about 276° F. for about 3 seconds. The first press can be removed, and the paper board sheets can be sealed to the plastic sheet under heat and pressure in a second press at about 276° F. for about 3 seconds. In another embodiment, the adhesive can be activated under heat and pressure in a first press at about 280° F. for about 4 seconds. The first press can be removed, and the paper board sheets can be sealed to the plastic sheet under heat and pressure in a second press at about 275° F. for about 3.75 seconds.
The one or more retaining structures can be formed, each with a resilient side wall protruding from one of the generally planar sides of the plastic sheet. Multiple retaining structures can be molded in the plastic sheet for capturing multiple display articles. The retaining structures can be formed for capturing display articles, such as coins and medallions. Each retaining structure can be formed with a generally circular side wall. In some embodiments, one of the paper board sheets can be provided with multiple openings, each corresponding to a retaining structure for allowing the resilient side wall of each retaining structure to extend through the one of the paper board sheets. In other embodiments, the other paper board sheet can also be provided with multiple openings, each corresponding to a retaining structure to provide viewing through the other paper board sheet. In further embodiments, the generally planar plastic sheet can be a first generally planar plastic sheet, and a second generally planar plastic sheet can be provided having one or more retaining structures for capturing one or more display articles. One of the paper board sheets can be sized and bonded to both the first and second generally planar plastic sheets with a fold line extending between the first and second generally planar plastic sheets to allow the display to be folded.
The foregoing will be apparent from the following more particular description of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention.
The present invention can provide a display device or product for display articles, which can be planar articles such as coins or medallions, in which the display articles may be snapped in and out of snap-in-snap-out mounts. Regions surrounding the snap-in-snap-out mount can be firmly sealed between two support or supporting material layers which can provide structural support. The display can comprise an integral mount sheet including one or more snap-in-snap-out mounts, which can be a semi-rigid, transparent plastic material, between two layers of support material, such as a rigid material, for example, paper board card stock, and which can be adhered together, for example, with adhesive. The snap-in-snap-out mounts can be aligned within an opening in the support layers so that the display article may be viewed or displayed either from one or both sides depending upon the embodiment. The support layers can have a high-gloss, heat-resistant coating applied.
The present invention can also provide a process for manufacturing the display. The display can consist of two support layers sealed to and sandwiching one inner layer made of plastic, all three of which in some embodiments, can be generally the same overall length and height. The snap-in-snap-out mount or mounts can be formed in and can be part of the plastic layer. The snap-in-snap-out mounts can be molded into plastic sheets, for example, ranging from about a 12 point (pt) thickness (about 0.012 inches) to about 13 pt thickness (about 0.013 inches). In other embodiments, the thickness can range from about 10 pt thickness (0.10 inches) to about 15 pt thickness (0.15 inches). The snap-in-snap-out mounts molded into the plastic sheet can hold their shape and firmly hold planar articles in place. When using 12 pt stock, sturdiness can be obtained to allow multiple display or planar articles to be displayed simultaneously without significant bending, folding, deforming or flexing.
Embodiments of the present invention display can allow users to protectively display or show articles (coins or medallions, such as United States Mint presidential golden dollars) so they are clearly visible and can be inserted and removed at will. The display can have added graphics and written information or text printed on the support layers to make a finished product. The display can be sold to users so they can place their display articles in the snap-in-snap-out mounts as they acquire them. Sealing two support layers of card stock to a plastic sheet can produce a more rigid overall product while still providing the flexibility needed for display articles to be snapped-in-snapped-out to the benefit of the user. In terms of product durability, the added stability of the solid plastic mount sheet of snap-in-snap-out mounts can provide a more functional and durable product. A given display can be of almost any size, and shape and contain one or multiple display articles on a single display mount sheet. The display can be sized correctly for displaying or storing multiple display articles such as coins for medallions on a single display. By sealing the support layer card stock over the plastic mount sheet, a more esthetically pleasing and rigid product can be produced offering a smooth surface while still providing the flexibility needed for display article insertion and removal on an “as-desired” basis. Once a display article has been inserted into a mount, it may be removed and inserted as often as the user desires without damaging the edges of the mount or other structural or cosmetic damage to the mount. A single, solid or integral plastic mount sheet can store and display more display or articles in a given space than individual mounts. The support layers may be formed with holes or openings, which can be die cut, on both sides to allow the display articles to be viewed on both sides.
In terms of productivity, a solid or integrally plastic mount sheet of snap-in-snap-out mounts can provide a dramatic labor savings during production. For example, an assembly of 24 separate individual mounts assembled together into a display can typically require about 18 employees for optimum quality. This could be reduced to 8 employees with a single mount sheet having multiple integrally formed snap-in-snap-out mounts sealed directly to support layers. This can result in more than a 50% reduction in labor cost. As a result, the present invention can result in superior product packaging, reduced labor costs, and quality display article presentation, use and storage.
In some embodiments, the back of the display articles 11 may also be revealed, such as shown in
Support layers, P1 and P2, can be about 16-point (about 0.016 inches) thick card stock coated with a clay coating (e.g. C2S Carolina Cover), and can be printed with a variety of graphic and text designs using inks R1a, R1b and R2, respectively. In some embodiments, the thickness of layers P1 and P2 can range between 13 pt (0.013 inches) and 19 pt (0.019 inches). After printing, support layers P1 and P2 can coated with a high-gloss heat-resistant transparent coating, U1 and U2, which can be a UV cured coating. The interior sides of the support layers P1 and P2, can be selectively coated with a heat and pressure-activated adhesive, A1 and A2, which can be, for instance, a Latiseal-brand adhesive, or other suitable adhesive or sealing material. The support layer P2 can be formed with one or more holes or openings 22, such as by die cutting, and which can be circular and approximately the same diameter as the outside diameter of the snap-in-snap-out mount G. In some embodiments, the support layer P1 may also be formed with one or more holes or openings 24, as seen in
During manufacture, a press 30 having a heat and pressure sealing plate, head, or member H, and a bed structure 32, can receive and seal the various display components. The bed 32 can comprise a support surface S and a bed W, which can include one or more holes 34 that is slightly larger than the outer perimeter or diameter of corresponding mounts G of mount sheet 10. The bed 32 can also be layered with a compressible blanket material B that can be substantially free of surface imperfections. The blanket B can be, for example, a ground surface compressible blanket such as commonly used for web offset, sheet-fed, and box board printing applications, which will not adhere to the coating U2 at the temperatures required for sealing the display 20. The sealing head H can include a smooth polished steel plate. The support layer P2 can be placed onto the bed 32 so that the each opening 22 aligns with a corresponding hole 34 in the bed 32. Next, the mount sheet 10 can be placed on top of support layer P2 and aligned so that each opening 22 in layer P2 is concentric with a corresponding snap-in-snap-out mount G that protrudes through the openings 22. Next, the printed, coated, and die-cut support layer P1 can be placed on top of mount sheet 10.
A protective layer of material M having suitable thickness, such as a plastic layer, for example, Mylar-brand PET film, can be placed over the support layer P1 to prevent the sealing head H from adhering to coating U1 of support layer P1. Typically, the protective film layer M will not melt or adhere to the sealing head H or to the coating U1 at the temperatures required for sealing the display 20. Heat and pressure are then applied by sealing head H, which causes the display 20 to be laminated together. The temperature of the sealing head H can range from about 250° F. to about 290° F., and the pressure applied can range from about 140 lbs/in2 to about 160 lbs/in2, for about 3-10 seconds. In one embodiment, the temperature at the surface of the sealing head H can be approximately 260° F., the pressure applied can be about 150 lbs/in2, and the dwell time (i.e. total amount of time that heat and pressure are applied) can be between about 3 and 8 seconds, for example, about 7 seconds.
In the manufacturing process, there can be a delicate balance between heat and dwell, for example, in some instances, as little as 5° F. can make a difference. Since the snap-in-snap-out mounts G are often manufactured through a heating process, the improper reapplication of heat can cause warping or distortion to the shape of the sheet area Ga and the individual mounts G. In some cases, the interior or exterior formation or dimensions of the mounts G can be changed. A “bubbling” air-pocket effect also can be created by the heating of the paper board support layers P1 and P2, and the plastic mount sheets 10 together with too much heat. The air-pocket effect between the paper board support layers P1 and P2, and plastic snap-in-snap-out mount sheets 10 can be eliminated by dropping the sealing temperature.
Referring to
Although particular temperatures and times have been described, these can be varied depending upon the situation at hand, for example, variations in the thicknesses and the materials used for display 20. The temperature can be increased or decreased, and the corresponding dwell time can be in some cases decreased or increased to compensate for the temperature change. In another embodiment, the temperature of the two separate presses can be about 280° F. for the first sealing head or press 30a, and about 275° F. for the second sealing head or press 30b, using about 150 lbs./in2 of pressure with a staggered dwell time of about 4 seconds for the first sealing head or press 30a, and about 3.75 seconds for the second sealing head or press 30b, and employing an index table 36 having a rotation speed of about 35 per minute. Although, presses 30a and 30b have been described to be employed with a rotary index table, in other embodiments, presses 30a and 30b can be sequentially or linearly inline, for operating with sequential or linear movement. In addition, the thicknesses and sizes of mount sheet 10, and support layers P1 and P2 can be varied as desired.
Referring to
While this invention has been particularly shown and described with references to example embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
Although the snap-in-snap-out mounts G have been shown in the figures as being generally round, it is understood that a number of different shapes can be used, depending on the shape of the article to be held, for example rectangular, oval, complex, etc., and that the sizes can vary, to accommodate different shaped and sized display articles 11. Openings 22 and 24 would also be shaped in a corresponding manner. In addition, although the snap-in-snap-out mounts G have been shown to be formed in an integral sheet of plastic 12, in other embodiments, individual mounts G can be secured to a sheet of plastic, or other suitable material, such as paper board. Furthermore, the mounts G can be made of other suitable materials or have other configurations. It is understood that the number of mounts and the size of the display can vary. For example, only one mount can be on any desired sized sheet, or 24 mounts can be on a 8.5 inch×11.5 inch sheet, four columns across the 8.5 inch width, and six rows down the 11.5 inch height. Embodiments of the display can be sturdy enough to withstand the weight of coins filling such a number and density of mounts G. The size and number of the mounts can be varied as desired. A special cutting die can be made to cut the snap-in-snap-out mount sheets 10 to allow for flush corners of paper stock and plastic on the finished display instead of cutting the sheets with round corners, which is usually the norm. Other embodiments of displays can include more than two mount sheets 10, and can be in a book configuration. In addition, in some embodiments, more than one mount sheet can be sandwiched between first and second support layers P1 and P2.
This application claims the benefit of U.S. Provisional Application No. 61/102,231, filed on Oct. 2, 2008 and U.S. Provisional Application No. 61/122,554, filed on Dec. 15, 2008. The entire teachings of the above applications are incorporated herein by reference.
Number | Date | Country | |
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61102231 | Oct 2008 | US | |
61122554 | Dec 2008 | US |