Patent Application
20090308522
The present invention generally relates to systems, methods and apparatuses for sealing materials without the use of glue, and, more particularly, sealing materials via a heated die press system to form heat-seals created by aqueous coatings on the materials.
Die press systems to seal materials can be used in a wide variety of industries for a wide variety of applications. Additionally, glue is often used in conjunction with the die press system to create the seal between the material pieces. However, these glue-based seals can often be disadvantageous for many reasons, including aesthetics, durability and strength, just to name a few.
Additionally, the use of discs such as CD-ROMs (compact disc-read only memory) and DVDs (digital versatile disc) has become increasingly common. In order to expose as many potential customers as possible to their products, providers would like to mail the CD-ROMs and DVDs to a great many potential customers as well as provide the discs in association with other items such as books and manuals.
There is therefore a need for an improved die press system to heat-seal materials without the use of glue, as well as improved disc packages. The present disclosure is directed toward systems which meet these needs.
In certain embodiments, an apparatus comprises a first sheet of paper having a coating, a second piece of material, and a disc positioned between the first sheet and the second piece of material. The coating includes at least one polymer capable of being heated to its softening point using radio frequency energy. The apparatus includes a die-formed heat-seal fusing the first sheet and the second piece of material, and forming a pocket containing the disc, the disc being substantially surrounded by the heat-seal. The heat-seal includes the coating of the first sheet melted and sealed to the second piece of material. The apparatus may further include access means formed in the first sheet and positioned over the pocket to access the disc.
In certain embodiments, a system comprises first and second material pieces. The first material piece is a sheet of paper having a coating. The coating includes at least one polymer capable of being heated to its softening point using radio frequency energy. The system includes a disc positionable between the first and second material pieces. Additionally, the system includes a die press having top and bottom press components operable to create a heat-seal between the first and second material pieces to fuse the first and second material pieces together around the disc. Accordingly, the disc is substantially surrounded by the heat-seal. To create the heat-seal, at least one of the die process components is heated via radio frequency energy to melt a portion of the coating of the first material piece to the second material piece.
In certain embodiments, a method comprises providing first and second paper material pieces to be heat sealed, with the first material piece being paper material having a coating, and providing a disc and positioning the disc between the first and second pieces. The coating includes at least one polymer capable of being heated to its softening point using radio frequency energy. The method includes forming a heat-seal with a die press fusing the first and second pieces together. In forming the heat-seal, part of the coating of the first piece is melted via radio frequency energy and sealed to the second piece. The material pieces form a space or pocket therebetween where the disc resides, the disc being substantially surrounded by the first heat-seal. In certain embodiments, at least one the first and second material pieces includes access means therein positioned over the space to access the disc.
For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended, and alterations and modifications in the illustrated systems, and further applications of the principles of the disclosure as illustrated therein are herein contemplated as would normally occur to one skilled in the art to which the disclosure relates.
The present disclosure is directed to apparatuses, systems and methods for sealing materials without the use of glue and the products produced thereby. At least one material piece to be sealed includes an aqueous coating. A die press using radio frequency (RF) heating can be used to create a heat-seal between the material pieces. In certain embodiments, the die press includes top and bottom press components and at least one of the components is heated. The die press components are pressed together with the material pieces positioned therebetween, thereby melting part of the coating to create the heat-seal between the material pieces. In certain embodiments, an object such as a disc may be positioned between the pieces and be captured therebetween after the heat-seal is formed. Additionally, access means may be included in at least one of the pieces to enable access to the disc. In certain embodiments, one or more of the material pieces may be heat-sealed to a book cover, providing a package of a book along with a disc.
Referring generally to
Die press 12 includes top die press component 14 and bottom die press component 16. The die press components, in some embodiments, may be metal die press components. In certain embodiments, components 14 and 16 include matching die press patterns 18 and 20, respectively. In the illustrated embodiment, die press patterns 18 and 20 are circular; however, it should be appreciated that patterns 18 and 20 could be shaped and sized differently but still include matching configurations. Patterns 18 and 20 include diameters DD, substantially equal in size. Top component 14 includes top plate 15 and bottom component 16 includes bottom plate 17. Components 14 and 16 are configured to be pressed together via a force exerted on plates 15 and 17 to create a heat-seal between sheets of paper 22 and 24, thereby forming an enclosed pocket or space in which an object, such as disc 26, may reside. In such embodiments, the heat-seal between sheets of paper 22 and 24 is in substantially the same shape and size as patterns 18 and 20 and substantially surrounds disc 26.
In the illustrated embodiment, sheets of paper 22 and 24 are circular in shape, having substantially equal diameters DP, and disc 26 is circular in shape, having a diameter DO. As illustrated, diameters DP of sheets 22 and 24 are at least substantially equal to or larger than diameters DD of die press patterns 18 and 20, so that the die press components are able to create seals within the dimensions of the sheets of paper. It should be appreciated that sheets 22 and 24 could be shaped differently than as illustrated and include other appropriate dimensions, as desired. Additionally, sheets 22 and 24 may be at least partially transparent and include first surfaces 22a and 24a, respectively, and opposite second surfaces 22b and 24b, respectively. In the illustrated embodiment, second surface 22b and first surface 24a substantially face each other and create the space containing disc 26. As will be discussed further below, at lest one of sheets of paper 22 and 24 includes an aqueous coating able to create the heat-seal upon application of heated die press 12.
In the illustrated embodiment, sheet of paper 22 is also heat-sealed to a book 28 using die press 12. As illustrated, book 28 includes a cover 30 having an outside surface 30a, an inside surface 30b and a hole 32 extending therethrough, with hole 32 having a diameter DH.
The heat-seals created by die press 12 may be of sufficient strength as to make access to disc 26 difficult without the use of sharp instruments. In order to alleviate this problem, one or more of sheets of paper 22 and 24 may include access means to access disc 26 contained between the sheets of paper after the sheets of paper have been heat-sealed together. In certain embodiments, both sheets of paper 22 and 24 include a mechanism capable to access disc 26. In certain other embodiments, only one of sheets of paper 22 and 24 includes such an access mechanism. In even certain other embodiments, neither of sheets of paper 22 and 24 include access means, requiring that a sharp instrument be used and/or that the heat-seal between the sheets of paper be at least partially compromised to access or remove disc 26.
In the illustrated embodiment, the access means include preferential tear strips 40 and 42 to allow a user to create an opening in the respective sheet of paper via the tear strips to access the object contained within the space between the heat-sealed sheets of paper. In such embodiments, a user may grasp the material adjacent tear strip 40 and/or 42 and pull the material in a direction away from disc 26, causing the tear strip to tear, opening a gap in the particular sheet allowing access to disc 26. Tear strips 40 and 42 may include perforations or other areas of weakened material that will direct a tear along a predetermined path.
As illustrated, tear strips 40 and 42 may be arcuate in shape; however, tear strips 40 and 42 may be shaped and sized differently than as illustrated. More specifically, in the illustrated embodiment, tear strips 40 and 42 are half-circular in shape and include substantially equal diameters DA, the diameters DA being the diameter of the part imaginary circles formed in part by arcuate tear strips 40 and 42. In such embodiments, the diameters DA of tear strips 40 and 42 are necessarily substantially equal to or slightly larger than the diameter DO of disc 26 in order to access and remove disc 26 from the space created between the heat-sealed sheets of paper.
In embodiments in which disc 26 can be accessed by a user through outside surface 30a of cover 30 of book 28, the diameter DH of hole 32 is necessarily substantially equal to or slightly larger than the diameter DA of tear strip 40. However, it should be appreciated that in certain other embodiments, the diameter DH of hole 32 is smaller than the diameter DO of disc 26, such that disc 26 is visible through outside surface 30a of cover 30, but yet cannot be accessed through outside surface 30a. In such embodiments, access means in sheet 22 such as tear strip 40 may be absent from system 10, with disc 26 being accessible through access means in sheet 24. It is contemplated that other access means could be used with system 10 to access disc 26 through one or more sheets of paper 22 and 24, such as zippers, flaps, buttons and various other access mechanisms.
In certain embodiments, system 10 may include a sound clip 50 to store digital sound information and play when activated. As illustrated, sound clip 50 may be positioned on inside surface 30b of cover 30 of book 28. However, it should be appreciated that sound clip 50 can be positioned elsewhere as desired. In certain embodiments, sound clip 50 may store digital sound recordings associated with the subject matter of disc 26. Sound clip 50 may be configured to play the stored digital sound recording upon a user opening book 28. In other embodiments, the sound recording on sound clip 50 may only play when activated by a user, such as by depressing a switch.
It is contemplated that the die press systems of the present disclosure can be used to heat-seal together various material pieces at various positions and orientations. The configuration shown in
Referring to
Additionally, in such embodiments, sheet of paper 24 may include access means, such as tear strip 40 as an example, to access disc 26. Due to the orientation of sheets of paper 22 and 24 containing disc 26 sealed to outside surface 130a of cover 130, access means in sheet of paper 22 may be absent. In certain embodiments, cover 130 is the front cover of book 128; however, in certain other embodiments cover 130 may be the back cover of book 128.
Referring to
Referring generally to
As illustrated, top component 314 includes top plate 315 and bottom component 316 includes bottom plate 317. Components 314 and 316 are configured to be pressed together via plates 315 and 317 to create a heat-seal between sheet of paper 324 and inside surface 330a of center portion 330 of disc holder 328, thereby forming an enclosed pocket or space in which an object such as disc 26 may reside. In such embodiments, the heat-seal between sheet 324 and center portion 330 is substantially the same shape and size as patterns 318 and 320, and substantially surrounds disc 26.
In the illustrated embodiment, sheet 324 is substantially square shaped and includes a width WP. As illustrated, width WP of sheet 324 is at least substantially equal to or larger than width WD of die press patterns 318 and 320, so that the die press components are able to create a seal within the dimensions of the sheet of paper. However, it should be appreciated that sheet 324 can be shaped differently and include other appropriate dimensions. Additionally, sheet 324 may be at least partially transparent and include a first surface 324a and an opposing second surface 324b. In the illustrated embodiment, second surface 324b and inside surface 330b of center portion 330 substantially face each other and create the space containing disc 26.
Similar to systems 10, 110 and 210, the heat-seal created by die press 312 may be of sufficient strength as to make access to disc 26 difficult without the use of sharp instruments. To address this, sheet of paper 324 may include access means to access disc 26 contained between sheet of paper 324 and disc holder 328 after the heat-seal has been formed. In certain embodiments, sheet of paper 324 may include access means to access and retrieve disc 26 contained between the sheet of paper and the center portion of the disc holder after the sheet of paper has been heat-sealed to the disc holder.
In the illustrated embodiment, access means in sheet of paper 324 includes a tear strip 340 to allow a user to create an opening in the sheet of paper to access disc 26. Tear strip 340 may include perforations or other areas of weakened material that will direct a tear along a predetermined path. As illustrated, tear strip 340 may be arcuate in shape; however, it should be appreciated that the tear strip may be shaped and sized differently than as illustrated. In the illustrated embodiment, tear strip 340 is half-circular in shape and includes a diameter DA3 extending between the ends of the tear strip. In such embodiments, the diameter DA3 of tear strip 340 is substantially equal to or slightly larger than the diameter DO of disc 26, in order to access and remove disc 26 from the space created between sheet of paper 324 and disc holder 328. It is contemplated that other access means could be used with system 310 to access disc 26 through sheet of paper 324, such as zippers, flaps, buttons and various other access mechanisms. Additionally, in certain other embodiments, the access mechanism through sheet of paper 324 is absent and disc 26 is retrieved by the use of sharp objects, compromising the heat-seal and/or removing sheet of paper 324 from disc holder 328.
Referring generally to
According to the present disclosure, at least one of the pieces of material positioned between the die press components to form part of the seal is a sheet of paper having a coating applied thereon. The coating may be applied to one or both sides of the sheet of paper, and may be applied to the entire side of the sheet of paper or only applied to select regions. Additionally, the coating may remain on the surface of the sheet of paper or may partially or completely soak into the sheet of paper.
In preferred embodiments, the coating includes at least one polymer capable of being heated to its softening point using RF energy. The at least one polymer may be one or more copolymers, one or more homopolymers, or mixtures thereof. In certain embodiments, the polymer used in the coating has a softening point in the range of 150 to 190 degrees Fahrenheit. Additionally, in certain embodiments the coating may be a water-based coating. In such cases, the water-based coating may be either an aqueous solution or an aqueous emulsion. In a particular embodiment, the polymer used in the coating is an acrylic copolymer, with the coating including at least 20% acrylic copolymer. In other embodiments, the coating contains one or more other polymers capable of sealing the materials together via RF heating. As examples, the alternative polymer used within the coating could be ethyl vinyl alcohol (EVA) polymer, nylon, polyester glycol (PETG), or polyester polyal.
The coating at least partially melts upon application of the heated die press components, thereby creating a seal between the sheet of paper having the coating and at least one other piece of material. As illustrated, an object, such as a disc, may be placed between the material pieces to be sealed. Accordingly, the seal between the pieces creates a space containing the disc which can then be accessed as desired by a user through access means included in at least one of the material pieces. In such embodiments, a package for distribution containing a disc, such as a DVD or CD-ROM, created.
It is contemplated that books 28 and 128 could include mechanical bound books, soft cover books, saddle-stitch books or other types of books capable of having one or more sheets of paper heat-sealed thereto. Moreover, it is contemplated that the sheets of paper described above may be heat-sealed to other items, such as manuals, booklets, pamphlets and binders as examples, in addition to or in lieu books 28 and 128.
While the disclosure has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only certain embodiments have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected.
