Graphics insertion method and apparatus in an optical disc package

Abstract: A method capable of manufacturing an optical disc package such as a DVD (100) efficiently and properly, and a method of and apparatus for inserting graphics (105) inside a cover sheet (104) attached to the surface of a box (101) efficiently and properly. A method of inserting graphics (105) inside a cover sheet (104) attached to the surface of the box (101) in an optical disc package so as to mount the graphics (105) on the box (101), which method comprises a step of developing a box (101), contracting the developing length of the box (101), and moving the cover sheet (104) attached to the surface of the box (101) away from the surface of the box (101), a step of inserting the graphics (105), which are formed and held so as to be narrowed in width, in a space (108) defined between the surface of the box (101) and the cover sheet (104), and positioning the graphics (105) in the space (108) at a given position, a step of inserting and holding the graphics (105) into the space (108) certainly while the graphics (105) is widened in width in the space (108), and a step of feeding the box (101) in which graphics (105) is inserted and held.

Description: The invention relates to a method of and an apparatus for inserting graphics (graphic pieces) inside a cover sheet to be mounted thereon attached to the surface of a box so as to mount the graphics on the box in an optical disc package for storing an optical disc such as a digital video disc (DVD) and the like. A DVD has been recently drawn the attention as a storage medium of a large capacity of image information, and it has become widespread quickly. The DVD is normally stored in a box and sold as a DVD package. When the DVD is play backed by a playback system, and the like, a cover of a storage box is opened to pick up the DVD from the box and is used. Fig. 10 shows an example of the construction of a DVD package. As shown in Fig. 10, a DVD 100 is generally stored in a box 101 comprising a box body 101a and a cover body 101b wherein the box body 101a is closable by way of a hinge section 101c. A reception section 102 protrudes from the box body 101a, and a center hole 100a of the DVD 100 is engaged in the reception section 102. Retaining pawls or retaining pieces 103a, 103b are provided on both the box body 101a and cover body 101b and they are retained by each other, so that the box 101 can be locked in a closable state. A transparent vinyl cover sheet 104 is attached to the outer surfaces of the box body 101a and cover body 101b. The cover sheet 104 has opposite two sides which are in parallel with the hinge section 101c and it is fixed to end portions of the box body 101a and cover body 101b. Other two sides of the cover sheet 104 are not connected to the box body 101a and cover body 101b. Graphics 105, which is a piece of paper to which photograph, patterns and the like are applied, is inserted inside the cover sheet 104. A booklet 106 is mounted on the inner part of the cover body 101b. The booklet 106 is held and fixed by a pair of press pieces 107 attached to the cover body 101b. The DVD package is made of the combination of a material which is relatively thin in thickness and a bending sheet of paper. Accordingly, a DVD package has been manufactured manually or partly automatically. The manufacture of such a DVD package is not efficient because it requires much labor and much time, and hence it largely influences upon a manufacturing cost. Particularly, since the graphics 105 is flexible thin piece of paper, it lacks in correctness and very troublesome to enter or incorporate the graphics 105 inside the cover sheet 104 attached to the surface of the box. EP-A-0 894 725 discloses a method of inserting graphics inside a cover sheet attached to the surface of a video cassette container so as to mount the graphics on said container, said method comprising: a step of developing a container, contracting the developing length of the container, and moving the cover sheet attached to the surface of the container away from the surface of the container; a step of inserting the graphics, which are formed and held so as to be narrowed in width, in a space defined between the surface of the container and the cover sheet and positioning the graphics in the space at a given position; a step of inserting and holding the graphics into the space certainly while the graphics is widened in width in the space; and a step of feeding the container in which the graphics is inserted and held. GB-A-2 246 549 discloses an apparatus according to the preamble of claim 8. The invention has been made under such a circumstances. That is, it is an object of the invention to provide a method of and an apparatus for manufacturing an optical disc package such as a DVD and the like efficiently and properly. It is another object of the invention to provide a method of and apparatus for inserting graphics inside a cover sheet attached to the surface the box efficiently and properly. The inventors have endeavored themselves to study such problems, and have found that to incorporate the graphics automatically into a cover sheet by dividing an insertion operation step utilizing shapes and characteristics of elements or components, and they completed the invention based on this finding. These objects are achieved by a method according to claim 1. A second aspect of the invention is the method of inserting graphics wherein the box comprises a box body and a cover body which are interrelatedly closable by way of a hinge section. A third aspect of the invention is the method of inserting graphics wherein the graphics is inserted into the space by moving the box when the graphics is inserted into the space. A fourth aspect of the invention is the method of inserting graphics wherein the graphics has substantially S shape and is formed narrow in width. A fifth aspect of the invention is the method of inserting graphics wherein a portion close to the center of the cover sheet is sucked downward while the cover sheet is positioned at the lower side when the cover sheet is moved away from the surface of the box A sixth aspect of the invention is the method of inserting graphics wherein an insertion opening of the space through which the graphics is inserted is formed substantially diamondwise. A seventh aspect of the invention is the method of inserting graphics wherein the step of inserting the graphics, which are formed and held so as to be narrowed in width, in a space defined between the surface of the box and the cover sheet, and positioning the graphics in the space at a given position, the step of inserting and holding the graphics into the space certainly so as to mount the graphics on the box are effected on a turntable which is intermittently turned. Furthermore, these objects are achieved by an apparatus aecording to claim 8. A ninth aspect of the invention is the apparatus for inserting the graphics characterized in further comprising a formation mechanism for forming and holding the graphics in substantially an S-shape so as to be narrowed in advance. A tenth aspect of the invention is the apparatus for inserting the graphics characterized in that the formation mechanism is intermittently turned by a turntable. According to the invention, the cover body is opened to develop the box and the cover sheet attached to the surface of the box is moved away from the surface of the box, then graphics (a piece of paper) is inserted into a space defined between the surface of the box and the cover sheet. In this case, the graphics is formed and held substantially in an S-shape so that it becomes narrower in advance while the cover sheet is positioned at the lower side to develop and hold the box substantially horizontally, and a portion close to the center of the cover sheet is sucked downward. The S-shaped graphics which becomes narrower in width is smoothly inserted through an insertion opening of the space which is expanded diamondwise. Since these steps are all automatically effected, graphics can be inserted into and mounted on the space very efficiently and properly. Fig. 1 is a perspective view showing the entire construction of a DVD package manufacturing apparatus according to a preferred embodiment of the invention; Fig. 2 is a perspective view showing a step of inserting graphics according to the preferred embodiment of the invention; Figs. 3 (A), (B), (C) are views showing essential components of a box development section and its basic operation in sequence according to the preferred embodiment of the invention; Fig. 4 (A) and (B) are side view and front view showing a construction of a main part of a graphic insertion section according to the preferred embodiment of the invention; Fig. 5 is a plan view showing the construction of essential components of the graphics insertion section according to the preferred embodiment of the invention; Fig. 6 (A) and (B) are views showing an operation of a graphics insertion section at a graphics reception position according to the preferred embodiment of the invention; Fig. 7 is a view showing an operation of the graphics insertion section at a box reception position according to the preferred embodiment of the invention; Fig. 8 is a view showing an operation of a graphics insertion section at graphics insertion and hold position according to the preferred embodiment of the invention; Fig. 9 is a view showing an operation of the graphics insertion section at a box take out position according to the preferred embodiment of the invention; and Fig. 10 is an exploded perspective view showing an example of the construction of a DVD package. A method of and an apparatus for inserting graphics in an optical disc package according to a preferred embodiment of the invention are described with reference to the attached drawings. Components which are substantially the same as or corresponding to the components of the conventional method and apparatus are depicted by the same reference numerals. According to the preferred embodiment of the invention, the DVD package as shown in Fig. 10 is assembled, particularly the invention relates to the method of and apparatus for inserting the graphics into a box and mounting thereon. The DVD package comprises, as described before, a DVD 100, a box 101 comprising a box body 101a and cover body 101b which is closable by way of a hinge section 101c, a cover sheet 104 which is attached to the outer surface of the box body 101a and the cover body 101b, graphics 105 inserted inside the cover sheet 104, and a booklet 106 mounted on the inner part of the cover body 101b, and hence the construction of the DVD package is substantially the same as the DVD package as shown in Fig. 10. Fig. 1 schematically shows a DVD package manufacturing apparatus or entire construction of a system according to the invention. The apparatus has a conveyor 1 which intermittently carries the DVD package at a given pitch in the direction of a production line L, wherein a box development section 10, a graphics insertion section 20, a disc mount section 30, a booklet mount section 40, and a cover body close section 50 are disposed in this order along the line L. The components of the package are supplied and transported along each of these sections and they are assembled sequentially. A method of the invention is described next sequentially in the order of essential steps. First of all, the boxes 101 are sequentially moved from a box stocker 11 in which the boxes are stocked to the conveyor 1 in the box development section 10. In this case, each box 101 is placed in the direction of the line L in the manner that the hinge section 101c directs downward. Thereafter, each box 101 is horizontally opened double by an opener, not shown. Further, the box body 101a and the cover body 101b are biased to be warped moderately from a horizontal state so that they rise and fall about a central hinge section 101c. At this time, the cover sheet 104 attached to the outer surfaces of the box body 101a and cover body 101b is sucked from namely, in a thickness direction lower side at the same time. As a result, a space 108 is defined between the surface of the box and the cover sheet 104. Meanwhile, the graphics insertion section 20 has a turntable 21 which is intermittently turned at a given pitch and which moves each box 101 to four positions 1 ○ to 4 ○ in this order. Each graphics 105 is supplied to the position1 ○ from a graphics stoker 22 in which many graphics 105 are stocked and piled up vertically. Then, the graphics 105 is inserted into the space 108 defined between the surface of the box 101 and the cover sheet 104 at the position 2 ○. The graphics 105 inserted into the space 108 reaches the position 3 ○ and it is certainly mounted and held at the position 3 ○. The box 101 in which the graphics 105 is inserted and held is moved again on the conveyor 1 from the turntable at the position 4 ○, In the disc mount section 30, each DVD 100 is sequentially moved and supplied to each box 101 on the conveyor 1 through the disc stocker 31 and the intermediate table 32 by a moving and placing unit, not shown. In this case, the DVD 100 is once temporarily placed on the reception section 102 (see Fig. 10) of the box 101, then it is pressed again so that it can be mounted on and fixed to the reception section 102. In such two stage steps, the center hole 100a of the DVD 100 can be completely engaged in the reception section 102 of the box 101. In the booklet mount section 40, the booklet 106 is moved and supplied from the booklet stocker 41 to the box 101 on the conveyor 1 by the moving and placing unit, not shown. In this case, although the booklet 106 is fixed by the press pieces 107 of the cover body 101b, when the booklet 106 is mouthed, the press pieces 107 (see Fig. 10) are warped and lifted from the cover body 101b by pawl members, not shown, to produce a gap so as to be easily mounted on the cover body 101b. In the cover body close section 50 of the cover body 101b, when the cover body 101b is superimposed on the box body 101a, it is once temporarily closed on the box body 101a, then it is completely closed. The retaining pieces 103a of the box body 101a and cover body 101b are interrelatedly retained or engaged with one another when the cover body 101b is completely closed so as to lock the box 101 while the box 101 is covered so as to completely close the cover body 101b. When the components of the DVD package are sequentially assembled along the line L where respective step sections are arranged, the DVD packages are manufactured efficiently. One of the main characteristics of the invention resides in that the graphics 105 is narrowed in width in the graphics insertion section 20 and inserted into the space 108. Thereafter, the graphics 105 is widened in width to be rendered in a state where the graphics 105 is inserted and held by the box 101. Fig 2 shows the graphics insertion section 20, wherein when the graphics 105 is supplied at the position 1 ○, both ends of the graphics 105 are gripped by chucks, not shown, on the turntable 21 side so that each graphics 105 is delivered from the graphics stoker 22 to the graphics insertion section 20. Then, the interval between the chucks is narrowed so as to guide and control the graphics 105 in comma-shaped heraldic design, thereby rendering the graphics 105 substantially in S-shape. The graphics 105 which is formed in S-shape is made narrower than the space 108 in width, and hence it can be inserted into the space 108 smoothly and properly at the position 2 ○. Thereafter, when the graphics 105 is moved to the position 3 ○, the interval between the chucks are widened gradually, namely, graphics is made wider, so that each graphics 105 can be inserted into and mounted on the space between the box body 101a, the cover body 101b and the cover sheet 104 with assurance. Then, the box 101 in which each graphics 105 is inserted and held is carried to the disc mount section 30 on the conveyor. A method of and apparatus for inserting graphics according to the preferred embodiment of the invention is described in detail Figs. 3 (A) to (C) show the construction of main components of the box development section 10 and its basic operations in order. In these figures, support arms 111 are pivotally provided on both sides of a base table 110 which is disposed along the line L, and they can operate in the manner that the upper portions thereof are narrowed, namely, they can swing. A pair of guides 112 are attached to upper portions of the support arms 111 and a suction pad 113 is provided under the hinge section 101c to be movable up and down and supported by the base table 110. Pushers 114 can push up the box body 101a and the cover body 101b at appropriate portions thereof. In Fig. 3 (A), the box 101 which is horizontally opened double by an opener, not shown, is developed horizontally and held by the guides 112 while the cover sheet 104 is positioned downward. In Fig. 3 (B), the box 101 is slightly pushed up by the suction pad 113 and the pushers 114 so that the box 101 is moderately warped while the box body 101a and the cover body 101b are restricted from both sides by the guides 112 which are narrowed by the support arms 111, (at this time, the developing length of the box is contracted). At the same time, the suction of the cover sheet 104 is started by the suction pad 113. In Fig. 3 (C), the developing length of the box is further contracted by the guides 112 which are further narrowed in width by the support arms support arms 111, and the suction pad 113 is lowered while the box 101 is restricted. As a result, the space 108 is defined between the surface of the box and the cover sheet 104. The insertion opening 108a of the space 108 through which the graphics 105 is inserted is formed substantially diamondwise. The box 101 having the space which is widened diamondwise is carried to the graphics insertion section 20 on a next turntable. Figs. 4 (A) and (B) and Fig. 5 show main components of the graphics insertion section 20. In these figures, there is provided a formation mechanism 120 for forming and holding the graphics 105 in the manner that it renders the graphics 105 substantially in S-shape to be narrowed every positions 1 ○ to 4 ○ where the graphics 105 is moved by the turntable 21 which is intermittently turned. The formation mechanism 120 comprises a pair of chucks 121 for gripping both ends of the graphics 105, formation shafts 122 which are turnably supported at the inner central portion of the chucks 121, and box guides 123 which are disposed outside the chucks 121. The formation mechanism 120, namely, the chucks 121, the formation shafts 122, the box guides 123 and the like are controlled to be driven by a cam unit, not shown, so that they effect predetermined operations at the positions 1 ○ to 4 ○. The outer width dimensions W1 to W4 of the chucks 121 are changed when the chucks 121, the formation shafts 122, and the box guides 123 move to the graphics reception position 1 ○, the box reception position 2 ○, graphics insertion and hold position 3 ○, and the box take out position 4 ○ in this order. More in detail, the outer width dimensions are set at as follows. W1 = 237 mm, W2 = 180mm, W3 =232 mm and W4 = 232 mm. Described next is basic operations of components at respective positions 1 ○ to 4 ○ with reference to Figs. 6 (A) and (B). In the graphics reception position 1 ○, the chucks 121 are opened when the graphics 105 is supplied as shown in Fig. 6 (A), through which the graphics 105 is supplied. After the graphics 105 is supplied, the chucks 121 are closed to as shown in Fig. 6 (B), to grip both ends of the graphics 105. The outer width dimensions of the chucks 121 becomes W1. Then, although the graphics 105 moves to the box reception position 2 ○, the chucks 121 are narrowed in interval as the graphics 105 moves from the position 1 ○ to the position 2 ○ and the outer dimension of the chucks 121 becomes W2 = 180 mm. As the graphics 105 moves from the position 1 ○ to the position 2 ○, the formation shafts 122 turn rightward in Fig. 7 to guide and control the graphics 105 in comma-shaped heraldic design so that the graphics 105 is formed substantially in S-shape. When the box 101 is moved in parallel with the graphics 105 by a feed member, not shown, from the box development section 10, it is supplied relative to the graphics 105 which is held in S-shape by the formation shafts 122. At this time, since the space 108 is expanded in diamondwise, when the box 101 is moved in parallel with the graphics 105 so as to feed the graphics 105 to the position 2 ○ on the turntable so that the graphics 105 can be received accurately in the space 108. That is, the box 101 which is not placed on the turntable is moved to encapsulate the graphics 105 placed on the turntable. Thereafter, when the graphics 105 is moved from the position 2 ○ to the graphic insertion hold position 3 ○, the interval between the chucks 121 is gradually widened, namely, graphics is made wider, so that the outer width dimensions W3 becomes 232 mm as shown in Fig. 8. As a result, the graphics 105 can be inserted into and held by the space between the box body 101a, the cover body 101b and the cover sheet 104 with assurance. At this time, the formation shafts 122 turn leftward in Fig. 8 so as to return the graphics 105 to the original state. As the graphics 105 is moved from the position 2 ○ to the position 3 ○, it is possible to obtain a state where the graphics 105 can be stably inserted and held not to come out from the space. Then, at the box take out position 4 ○, the chucks 121 are opened to release the graphics 105. In a state shown in Fig. 9, the box 101 in which the graphics 105 is inserted and held is taken out to the disc mount section 30 (see Fig. 1). The operations of the formation shafts 122 and the chucks 121 are accurately effected by a cam unit, not shown, built in the turntable of the formation mechanism. Respective steps are effected along the line L at the disc mount section 30, the booklet mount section 40 and the cover body close section 50. Although the invention has been described with reference to the preferred embodiment, the invention is not limited to this preferred embodiment, and hence various modifications can be made within the object of the invention. For example, although concrete numerals are exemplified in the preferred embodiment, these numerals can be appropriately changed. As described in detail above, according to the invention, the graphics can be inserted into and mounted on the box with very efficiently and properly by automating troublesome steps in an optical disc package in this type. When the components can be efficiently assembled by the automation, there is an advantage to realize the reduction of manufacturing and product costs.

Claims: A method of inserting graphics (105) inside a cover sheet (104) attached to the surface of the box (101) in an optical disc package so as to mount the graphics (105) on the box (101), said method comprising: a step of developing a box (101), contracting the developing length of the box (101), and moving the cover sheet (104) attached to the surface of the box (101) away from the surface of the box (101); a step of inserting the graphics (105), which are formed and held so as to be narrowed in width, in a space (108) defined between the surface of the box (101) and the cover sheet (104), and positioning the graphics (105) in the space (108) at a given position, wherein the narrowed sheet of graphics (105) is securely held at its lateral margins by a pair of chucks (121) while being widened up to its final width and until the developed box (101) is stretched in width to a position where the sheet of graphics (105) is firmly secured by cooperation of the cover sheet (104) and the surface of the box (101); and a step of feeding the box (101) in which graphics (105) is inserted and held. The method of inserting graphics (105) according to claim 1, wherein the box (101) comprises a box (101) body (101a) and a cover body (101b) which are interrelatedly closable by way of a hinge section (101c). The method of inserting graphics (105) according to claim 1 or 2, wherein the graphics (105) is inserted into the space (108) by moving the box (101) when the graphics (105) is inserted into the space (108). The method of inserting graphics (105) according to claim 3, wherein the graphics (105) has substantially S shape and is formed narrow in width. The method of inserting graphics (105) according to any of claims 1 to 4, wherein a portion close to the center of the cover sheet (104) is sucked downward while the cover sheet (104) is positioned at the lower side when the cover sheet (104) is moved away from the surface of the box (101) The method of inserting graphics (105) according to claim 5, wherein an insertion opening of the space (108) through which the graphics (105) is inserted is formed substantially diamondwise. The method of inserting graphics (105) according to claim 1, wherein the step of inserting the graphics (105), which are formed and held so as to be narrowed in width, in a space (108) defined between the surface of the box (101) and the cover sheet (104), and positioning the graphics (105) in the space (108) at a given position, the step of inserting and holding the graphics (105) into the space (108) certainly while the graphics (105) is widened in width in the space (108), and the step of feeding the box (101) in which graphics (105) is inserted and held are effected on a turntable which is intermittently turned. An apparatus for inserting graphics (105) inside a cover sheet (104) attached to the surface of the box (101) in an optical disc package so as to mount the graphics (105) on the box (101), said apparatus comprising: a box (101) development section for developing a box (101), contracting the developing length of the box (101), and moving the cover sheet (104) attached to the surface of the box (101) away from the surface of the box (101); a graphic insertion section for inserting the graphics (105) in a space (108) defined between the surface of the box (101) and the cover sheet (104), and positioning the graphics (105) in the space (108) at a given position; characterized in a pair of chucks (121) for holding the graphics (105) at its lateral margins while being widened up again. The apparatus for inserting the graphics (105) according to claim 8, further comprising a formation mechanism for forming and holding the graphics (105) in substantially an S-shape so as to be narrowed in advance. The apparatus for inserting the graphics (105) according to claim 9, wherein the formation mechanism is intermittently turned by a turntable.

Inventors: KITANO RYOKO, NISHINO TAKAFUMI, SHINOHARA TOSHINORI, KITANO, RYOKO, NISHINO, TAKAFUMI, SHINOHARA, TOSHINORI, Kitano, Ryoko, c/o Kitano Engineering Co., Ltd., Nishino, Takafumi, c/o Kitano Engineering Co., Ltd, Shinohara, Toshinori, c/oKitano Engineering Co.Ltd
Applicants: KITANO ENG CO LTD, KITANO ENGINEERING CO., LTD.
Application year: 2001
Main classification: B65B61
IPC codes: B65B61