Abstract:
A manufacturing line for making DVD assemblies includes a conveyor belt or similar apparatus for providing continuously DVD packages, holding tray for providing a plurality of shells, each shell defining a cavity adapted to receive one of said DVD packages; and an encasing position adapted to receive each DVD package, encase it into a respective shell and then seal the shell to form a DVD assembly.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    A. Field of Invention  
           [0002]    This invention pertains to a method and apparatus for packaging audio-visual media, such as DVDs, and more particularly to an apparatus and method that is particularly suited to be integrated to a manufacturing line to apply a sealed blister-pack type package.  
           [0003]    B. Description of the Prior Art  
           [0004]    DVDs are becoming popular media for distributing various audio-video content. While DVDs have essentially the same dimensions as CDs and, hence, DVDs could be packaged using containers similar to CD packages, such as jewel cases. However, several criteria must be considered when designing DVD packages. First, unlike CDs, DVDs are double-sided, and are more prone to damage when bent or warped. Second, DVDs are more susceptible to physical damage caused, for example, by scratches when they contact with other surfaces.  
           [0005]    Most DVDs are presently available in one of two packages: the “amaray” package and the “snapper” package. The amaray package is very popular and it consists of a plastic box with a push-button locking tray hub for easy disc release, and clamps for multi-page booklets.  
           [0006]    Another type of package, referred to as the “Snapper” consists of printed paperboard coupled to a plastic tray and outfitted with “click-closure” spines molded in the bottom and top of the tray.  
           [0007]    One problem with these types of packages is that they do not deter theft. Manufacturers have attempted to rectify this problem by various means. For example, frequently, DVD packages contain electronic surveillance (EAS) devices that are detected when the packages are removed from the premises. However, these devices must be incorporated in the package itself, and hence are ineffective if when a disc is removed from the package. Other attempts used various means designed to seal the package so that a disc is difficult to remove. These latter means include special adhesive labels and other locking mechanisms. However, these means are expensive, esthetically objectionable, inconvenient to use.  
         OBJECTIVES AND SUMMARY OF THE INVENTION  
         [0008]    It is an objective of the present invention to provide a means of packaging DVDs that has improved anti-theft characteristics over the known packages.  
           [0009]    A further objective is to provide an improved package that makes use of existing, well known types of packages.  
           [0010]    A further objective is to provide an esthetically pleasing DVD package.  
           [0011]    Yet another objective is to provide a method of making a novel package by making relatively minor changes to an existing manufacturing line.  
           [0012]    Other objectives and advantages of the invention will become apparent from the following description. A manufacturing line for making DVD assemblies in a continuous process in accordance with this invention includes means for providing a plurality of shells, each shell defining a cavity adapted to receive one of the DVD packages; and an encasing position adapted to receive each DVD package, encase it into a respective shell and then seal the shell to form a DVD assembly. Preferably the shell is made of two segments having a depression and a surrounding lip. The segments are joined by a live hinge and are constructed and arranged so that when they are closed about the live hinge, their lips are superimposed and the depressions define a cavity which has the same size and shape as a DVD package. The shells are preferably molded of a transparent plastic made, for example, of PET.  
           [0013]    Each shell is loaded by placing a DVD package on one segment. The loaded shell is then closed by pivoting the other segment. The closed shell is then sealed by bonding or fusing the lips together to form a closed and hermetically sealed DVD assembly.  
           [0014]    Optionally, a hologram sheet is also enclosed in the DVD assembly as a decoration, and/or to provide a means of authenticating the DVD assembly. The sheet can be attached to an inner surface of the shell or on the DVD package.  
           [0015]    In order to perform these steps, the manufacturing line includes a holding tray that holds several shells and an insertion station adapted to load each DVD package into a shell from said tray. 3 . The manufacturing line further includes a closing station adapted to close each loaded shell, and a sealing station adapted to seal each closed shell.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]    [0016]FIG. 1 shows an orthogonal view of a prior art DVD package;  
         [0017]    [0017]FIG. 2 shows the DVD package of FIG. 1 with a security label attached thereto;  
         [0018]    [0018]FIG. 3 shows an orthogonal view of a DVD packaging shell constructed in accordance with this invention;  
         [0019]    [0019]FIG. 4 shows an orthogonal view of another embodiment of the shell;  
         [0020]    [0020]FIG. 5 shows a somewhat diagrammatic view of a DVD package manufacturing line constructed in accordance with this invention;  
         [0021]    [0021]FIG. 6 shows the DVD assembly obtained from the manufacturing line of FIG. 5; and  
         [0022]    [0022]FIG. 7 shows an embodiment of the DVD assembly incorporating a hologram sheet. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0023]    [0023]FIG. 1 shows an orthogonal view of a so-called “snapper” package  10  designed to hold a DVD  13 . The package  10  has the shape of a box and includes a flap  12  that can be opened to gain access to the DVD  13 . The flap is sealed in order to insure that the DVD is not stolen. FIG. 2 shows the package  10  being sealed by a tape  14  made of a plastic material. As can be seen in the figure, the sealed package does not look esthetically pleasing. Moreover many customers, especially elderly customers, have difficulty opening the package by hand. If a sharp object, such as a knife is used, the DVD may get damaged.  
         [0024]    [0024]FIG. 3 shows an orthogonal view of a packaging shell  20  composed of two segments  22 ,  24  joined by a live hinge  26 . The segments  22 ,  24  can be substantially identical, and are formed with depressions  28 ,  30  surrounded by a lip  32  having a uniform width. The shell  20  is preferably molded from a transparent or, at least translucent sheet material made of PET, or other similar plastic compounds.  
         [0025]    In the embodiment of FIG. 3, the segments  22 ,  24  are generally rectangular and are joined by hinge  26  along a respective long edge  34 ,  36 . FIG. 4 shows an embodiment of the invention wherein a shell  20 A is provided with rectangular segments  22 A,  24 A joined by a live hinge  26 A along respective short sides  34 A,  36 A.  
         [0026]    The shells  20 ,  20 A are arranged and constructed so that when their segments  22 ,  24 ,  22 A,  24 A are pivoted from the open positions shown in FIGS. 3 and 4 to a closed position along respective live hinges  26 ,  26 A, the depressions thereon form a cavity which matches the size and shape of a predetermined DVD package, such as the DVD package  10  shown in FIG. 1. In this position the lips of the two segments come in contact with each other and the shell can then be closed and sealed by bonding, by fusing the lips together, or by joining the lips using an adhesive material.  
         [0027]    [0027]FIG. 5 shows a diagrammatic view of a manufacturing line  40  used to encase DVD packages  10  received on a conveyor belt  42  into shells  20  from a holding tray  48 . For this purpose, the manufacturing line  40  includes an encasing position  44  which includes several stations that are constructed and arranged to insert each DVD package  10  into a respective shell  20  and then close and seal the shell. As seen in FIG. 5, the encasing position  44  includes a package loading station  46 , an insertion station  52 , a closure station  54  and a sealing station  56 .  
         [0028]    The holding tray  48  is used to keep the several shells  20  from a chute  50 . The package loading station  46  and the insertion station  52  cooperate so as each package  10  is received from belt  42 , it is inserted into a respective shell  20 . Next, at the closure station  54  each loaded shell  20  is closed by pivoting segment  28  to fit over the segment  30 . At the sealing station  56  the lips  32  of the segments are bonded or fused together by applying heat, and/or an adhesive thereto. Various known intermediate conveyor mechanisms are used to move the DVD packages  10  and shells  20  between the stations. These mechanisms have been omitted from FIG. 5 since they are well known in the art.  
         [0029]    The final DVD assembly  60  is shown in FIG. 6 and consists of a DVD package  10  enclosed and sealed in a shell  20 . The manufacturing line  40  performs this encasing process in a continuous manner. Hence, it can be provided independently, and used to encase a plurality of DVD packages received from another source. Alternatively, the manufacturing line  40  can be easily incorporated into an automated process for making DVD packages. Moreover, a fully integrated line may also be constructed in which DVDs are made, inserted into a package, and the package is then encased in a shell.  
         [0030]    [0030]FIG. 7 shows an alternate embodiment of the invention wherein an embossed hologram sheet  62  is incorporated into the DVD assembly  60 . The sheet  62  may be provide as a means of decorating the assembly. In addition, the sheet  62  may be provided as a means of authenticating the assembly  60  since it is very hard to make unauthorized copies of such embossed hologram sheets. The holographic sheet  62  can be attached either to the DVD package  10  or on the inner surface of shell  20 . Preferably, the holographic sheet  62  is attached at the casing position  42 , for example, by the insertion station  52 .  
         [0031]    Obviously numerous modifications may be made to this invention without departing from its scope, as defined in the appended claims.