Abstract:
A form for a package for holding consumer articles including optically-based media. The form is a base sheet with a central section and a series of foldable adjoining flaps extending from the central section in alternate first and second directions. The flaps are adapted to be folded over the central section and then secured to the central section for mounting one or more holders, such as one or more trays for digital video disks. The invention includes the package made from the form and a method of making the form from a blank sheet of paperboard material.

Description:
BACKGROUND 
   The use of die-cut paperboard for packaging a variety of consumer goods is increasingly popular given paperboard&#39;s versatility, light weight and relatively low cost. Further, it is beneficial for a packaging manufacturer to produce a number of package styles which are producible from a common form, yet appear to be different when finished. 
   Optically-based media used for the storage of digital information is a type of packaged consumer good that is increasingly popular because it is economical. Optically-based media are used for the recording and distribution of computer programs, music, and video programs. In the context of digital video disks (“DVDs”), it is often desired to produce and sell DVDs in multi-disk sets. Examples of such sets are collections of several motion pictures, collections of television programs having a common featured actor or subject matter or collections of several episodes of a popular television series. 
   It has become common to market DVD&#39;s as a collection in a package which opens and closes in a book-like manner. The package includes an individual plastic tray for each DVD in the set with the trays being mounted to different “pages” of a paperboard element which is foldable on itself into a compact closed form. The paperboard stock commonly used in the manufacture of such a package is relatively light in weight and is preferred because of its low cost per unit area. 
   Conventional paperboard stock packages described as useful for packaging compact discs have inherent shortcomings. For example, U.S. Pat. No. 4,709,812 describes a compact disc (“CD”) package and method of making same that is limited to a rectangular sheet configuration. This conventional rectangular configuration limits the ability to creatively package a multi-disk CD collection. In addition, the rectangular sheet configuration has a medial fold which allows for one weak edge when the sections are folded. Over years of repeated use, this weak edge on the folded-up package may tear along the medial fold line. 
   The paperboard packaging material is most economically obtained from large sheets of stock paperboard material. It is desirable that as many package units as possible be obtained from a single blank sheet of the stock. Therefore, it is desirable that the outlines of multiple package forms nest in close relation on the sheet, thereby to minimize waste of the stock material and to enable efficient printing on one side of the sheet before the sheet is die cut to create individual forms. Thus, there is a need for an improved form for a package and there is a need for an improved method of making the form from a sheet of stock paperboard material. 
   SUMMARY 
   The present invention is an improvement over conventional prior art packaging and methods of making forms for packages. The present invention enables the manufacture of packages of different styles based upon a basic form. The invention is preferably implemented by use of lightweight paperboard which can bear high quality printing on at least one surface. 
   The present invention has an advantage over conventional packages because the fold-over flaps are folded from alternating directions over a central portion to create a strong structural package. In one version, the form has a base having a surface with a top, a bottom, and opposing first and second sides, the base comprising a series of central portion sections extending between the bottom and the top which are separated from each adjoining section by one or more fold lines. The form has a series of adjoining flaps which are adapted to be folded over the corresponding adjoining central section from the opposite] sides. 
   The version can include an end flap adjacent to the top. The version may include additional sections and can include additional sections and adjoining flaps. In one version, the holders comprise trays for digital video disks. 
   The present invention includes a method of making a package from the inventive form. In this method, the adjoining flaps are folded over and secured onto each of their corresponding adjoining central sections by an adhesive or other conventional methods. One or more holders are secured onto one or more of the combination of the sections and the secured flaps. This assembly can be folded into a book-like package and later opened when desired to remove the article(s) in the package. The holders can be used for holding a variety of consumer goods. In one version, the method is for a package with holders for digital video disks. 
   The present invention includes a method of making the form from a nested arrangement on the paperboard stock. This advantageously allows for easier stripping of the forms from the stock material and from each other. In one version, the form is manufactured by die cutting at least two of the forms from a sheet of paperboard, wherein the forms nest on the paperboard sheet. 

   
     DRAWINGS 
       FIG. 1  is a plan view of a preferred version of a form for packaging according to the present invention; 
       FIG. 2  is a perspective view of the version of  FIG. 1 , with the printed side flipped over from  FIG. 1 , showing the folding of the adjoining flaps and the folding of the end flap; 
       FIG. 3  is a perspective view of the version of  FIG. 1  showing the possible placement of a holder; 
       FIG. 4  is another perspective view showing the version of  FIG. 1  with multiple holders secured to the folded-up form; 
       FIG. 4   a  shows a preferred version of  FIG. 4  folded-up into a package; and 
       FIG. 5  is a plan view showing a preferred method of making multiple forms according to the present invention simultaneously. 
   

   DESCRIPTION 
   The present invention is an improvement over conventional forms and an improvement over conventional packages and methods of making the package forms. Referring to the Figures, a preferred form  10  according to the present invention is shown in FIG.  1 . The form  10  comprises a base  12  having adjacent sections  20 ,  22 ,  24  and  26  which span between the bottom  27   a  to the top  27   b  of the form  10  as shown in FIG.  1 . Preferably, the sections  20 ,  22 ,  24  and  26  are substantially rectangularly shaped as shown in FIG.  1 . The sections  20 ,  22 ,  24  and  26  are separated by one or more parallel fold lines  28  as shown in FIG.  1 . The sections are arranged in a row in a central portion of the form  10 , and so can be referred to as central sections of the form  10 . The form  10  is preferably made of paperboard. Where two adjacent central sections are separated by plural fold lines, those fold lines are separated from each other by hinge areas of the form. 
   The form  10  comprises side flaps  30 ,  32 ,  34  and  36  which adjoin sections  20 ,  22 ,  24  and  26 , respectively. As shown in  FIG. 1 , these flaps  30 ,  32 ,  34  and  36  alternate between a side  37   a  and a second side  37   b  of the row of central sections of form  10 . For example, the flap  30  adjoins the section  20  and extends from the first side  37   a  of the form  10 , flap  32  adjoins the section  22  extending from the second side  37   b  of form  10 , the flap  34  adjoins the section  24  extending from the first side  37   a  of the form  10 , while the flap  36  adjoins the section  26  and extends from the second side  37   b  of form  10 . That is, side flaps  30  and  34  are located in a first side row of the base to one side of the row of central sections, and side flaps  32  and  36  are located in a second side row to the other side of the row of central sections. 
   The side flaps  30  and  34  on the first side  37   a  adjoin their corresponding sections along the preferably aligned fold lines  38   a.  The side flaps  32  and  36  on the second side  37   b  adjoin their corresponding sections along fold lines  38   b.  Preferably, the form  10  has an end flap  40  with adjacent tabs  40   a  and  40   b  to hold promotional materials by folding the end flap  40  over section  26  along the fold line  28 , folding the adjacent tabs  40   a  and  40   b  as shown in FIG.  2  and adhering the tabs  40   a  and  40   b  to the underside of the end flap  40 , as folded over section  26 , by an adhesive, glue or other conventional techniques. Each side flap preferably has a height in a direction parallel to the length of the row of central sections which is not greater than the height of the corresponding central section, and is so positioned relative to the corresponding central section that when the side flaps are folded into overlying relation to their corresponding central section no portion of the side flaps overlies a fold line  28  bounding that central section. 
     FIG. 2  shows (by arrows) folding of the side flaps  30 ,  32 ,  34  and  36  into overlying relation onto their corresponding central sections along the respective fold lines  38   a  and  38   b.  The form  10  is shown with the printed side down in FIG.  2 . Each side flap may be affixed to its corresponding central section by conventional methods such as adhesives, glue or other techniques well known to persons skilled in the art. 
   One or more holders, such as trays  50 , may be attached to one or more of the folded over side flaps  30 ,  32 ,  34  and  36  as shown in FIG.  3 . The trays  50  may be affixed to this arrangement, comprised of two layers of base material as a result of adherence of the side flaps to the central sections, by conventional methods such as adhesives, glue or other techniques well known to persons skilled in the art.  FIG. 4  illustrates one version of the present invention showing multiple trays  50  secured onto the flaps  30 ,  32  and  34  as folded over onto and adhered to the corresponding central sections  20 ,  22  and  24 . 
     FIG. 4   a  shows a version of a book-like package  52  folded up from the version in FIG.  4 . Preferably, the outermost surface  52   a  of package  52  is pre-printed with a design or other information to reflect the contents of the package  52 . Preferably package  52  is housed in a slipcase or sleeve, not shown. 
     FIG. 5  illustrates a preferred method of making multiple forms  10  by printing the forms  10  onto a sheet of stock paperboard material  60 . As shown in  FIG. 5 , the preferred method minimizes waste from stock material  60  by nesting one form  10  within the unused portion of stock material  60  between flaps, for example, by nesting or interdigitating side flaps  32  and  36  of one form  10  with or between flaps  30  and  34  of an adjacent form  10 , so that the overall width on the stock material  60  of the nested forms is significantly less than the sum of the widths of the individual forms. 
   Thus, an improved form with fold-over flaps for added strength for use in a book-like package is shown and described. An improved method of making the form to minimize waste materials from a sheet of stock paperboard material is also shown and described. 
   Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. For example, additional sections may be included or additional sections with adjoining flaps may be utilized. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. All features disclosed in the specification, including the claims, abstract, and drawings, and all the steps in any method or process disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive or inconsistent or incompatible with each other. Each feature disclosed in the specification, including the claims, abstract, and drawings, can be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. 
   Also, any element in a claim that does not explicitly state “means for” performing a specified function or “step for” performing a specified function, should not be interpreted as a “means” or “step” clause as specified in 35 U.S.C. § 112.