Patent Publication Number: US-2005126937-A1

Title: Multiple pocket perforated print sheets

Description:
This application is a Continuation-In-Part of Ser. No. 10/046,833 filed on Jan. 15, 2002, which claims priority to provisional application Ser. No. 10/046,833 filed Jan. 23, 2001. These and all other extrinsic materials referenced herein are incorporated in their entireties by reference. 
    
    
     BACKGROUND  
      U.S. Pat. No. 6,117,061 to Popat et al. (September 2000) describes the production of three-dimensional printed objects using a desktop printer and special paper having perforations and fold lines. Using a single sheet Popat et al. contemplate only “simple” objects, which term is used in this application to mean that the objects have only a single cavity, or objects that have no operational closures or other features. Popat et al. do apparently suggest production of complicated three-dimensional objects, but most of those suggestions are not enabled in the patent, and in any event, all of Popat et al.&#39;s complex three-dimensional objects are apparently produced by combining multiple such sheets (col. 6, line 63-col. 7, line 62).  
      In contrast, the present inventor has discovered how to produce “complex three-dimensional objects” from a single sheet. As distinct from simple objects, the term “complex objects” is used herein to mean those objects that have multiple cavities, or a single cavity having an operational closure.  
      In the parent application, the present inventor described a sliding panel assembly comprising front and rear panels, each bearing a different image or photograph, and each divided into a plurality of parallel strips. The strips of the front panel are arranged as slidable interleaves between the strips of the rear panel, such that the strips of the front panel are movable between a first position, in which the strips of the rear panel are completely covered by the strips of the front panel, and a second position, in which the strips of the front panel are completely hidden behind the strips of the rear panel. Thus, in the first position, only the image on the front panel is visible, while in the second position, only the image on the rear panel is visible.  
      What is still needed, however, is a generalized conception of producing complex three-dimensional objects using perforated sheets with fold lines, where the sheets are printed using a desktop printer.  
     SUMMARY OF THE INVENTION  
      The present invention provides apparatus, systems and methods in which a single template sheet having perforations and fold lines is used to produce a three-dimensional object that has at least one of: (a) separated first and second cavities; and (b) a functionally operating tab or flap.  
      In an exemplary embodiment the perforations and fold lines are arranged such that the first and second images form a sliding panel display. In another exemplary embodiment the first cavity is sized and dimensioned to hold a CD or DVD, and the flap closes an opening to the cavity. In yet another exemplary embodiment each of the first and second cavities is sized and dimensioned to hold a CD or DVD, and the cavities fold together in a tri-fold.  
      Numerous options are contemplated for the template sheet material, including especially card stock. Preferred papers have a thickness of at least {fraction (4/1000)}″. The template preferably has a gloss or semi-gloss printing area that produces a high quality image. Printing can take place on any suitable desktop printer, including for example a laser printer, a bubble-jet printer, and an ink-jet printer.  
      Kits can advantageously include one or more templates, as well as instructions. These materials can advantageously be shrink wrapped together.  
      Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING  
       FIG. 1  is a perspective view of the photographic card of the present invention, the view showing a first panel displaying an image.  
       FIG. 2  is a plan view of the photographic card of the present invention, the view showing a first panel displaying an image.  
       FIG. 3  is a plan view of the photographic card of the present invention, the view showing a second panel displaying a different image.  
       FIG. 4  is a plan view of a die-perforated first sheet before any image is printed thereon.  
       FIG. 5A  is a plan view of a die-perforated second sheet before removal of any excess material.  
       FIG. 5B  is a plan view of the die-perforated second sheet after removal of excess material.  
       FIG. 6  is a plan view of the die-perforated first sheet after first and second images are printed thereon.  
       FIG. 7A  is a plan view of a part of a rear panel after removal from the left side of the front sheet.  
       FIG. 7B  is a plan view of another part of the rear panel after removal from the left side of the front sheet.  
       FIG. 7C  is a part of a front panel after removal from the right side of the front sheet.  
       FIG. 7D  is another part of a front panel after removal from the right side of the front sheet.  
       FIG. 8A  shows the manner of interleaving the two parts of the front panel.  
       FIG. 8B  is a plan view of the front panel interleaved from the two parts.  
       FIG. 8C  is a cross-sectional view taken on lines  8 C, 8 C of  FIG. 8B .  
       FIG. 9A  is a plan view showing the manner of interleaving the two parts of the rear panel.  
       FIG. 9B  is a plan view of the rear panel interleaved from the two parts.  
       FIG. 9C  is a cross-sectional view taken on lines  9 C, 9 C of  FIG. 9B .  
       FIG. 10  is a plan view showing the assembly of the front and rear panels.  
       FIG. 11  is a cross-sectional view taken on lines  11 , 11  of  FIG. 10 .  
       FIGS. 12A-12D  are rear perspective views, respectively showing the steps of assembling the front and rear panels and the second sheet from which excess material has been removed, to form the photographic card of the present invention.  
       FIG. 13  is a cross sectional view taken on lines  13 , 13  of  FIG. 2 .  
       FIG. 14  is a cross sectional view taken on lines  14 , 14  of  FIG. 3 .  
       FIG. 15  is a cross sectional view taken on lines  15 , 15  of  FIG. 1 .  
       FIG. 16  is a plan view of the first sheet of the invention showing the precise areas where images are printed on the first sheet in the preferred embodiment.  
       FIG. 17  is a plan view of a template for making a single sleeve CD/DVD holder.  
       FIG. 18A  is plan view of a template for making a double sleeve CD/DVD holder.  
       FIG. 18B  is perspective view of a three-panel side-load CD/DVD holder.  
       FIG. 18C  is perspective view of a three-panel top-load CD/DVD holder. 
    
    
     DETAILED DESCRIPTION  
      Sliding Image Assembly  
      In  FIGS. 1-3  a sliding image assembly  20  generally comprises: a first panel  22  that displays an image, which for the sake of precision in the description is hereinafter termed the first image; and a second panel  24  that carries an image, which is hereinafter termed the second image. In  FIGS. 1 and 2  the sliding image assembly  20  hides the second panel  24  behind the first panel  22 . In  FIG. 3  the first panel  22  is hidden behind the second panel  24 , and therefore the second image is displayed.  
      Movement of the panels  22 ,  24  is effected by movement of a tab  28 , which in this particular embodiment is essentially flush with the lower edge  30  of assembly  20  when the first panel  22  displaying the first image is exposed for view. The tab  28  is pulled out, as shown in  FIG. 3  when the second panel  24  displaying the second image is exposed for view. The tab  28  can also be folded to occupy a position substantially parallel with a support surface (not shown).  
      Substantially any images can be displayed in the first  22  and second  24  panels, including for example, pictures, photographs, or text, drawings, or any combination of same. The images can also be placed on the first  22  and second panels  24  in any suitable manner, and using any suitable technology. For example the images could be drawn, painted, or silk-screened. In preferred embodiments, the images are deposited on the first  22  and second  24  panels by a desktop (non-offset) printer such as a laser, bubble jet or ink-jet type printer, under the control of one or more computer programs.  
      In  FIG. 4 , a die-perforated (or otherwise pre-cut) first sheet  32  preferably comprises high quality paper, and more preferably the kind of glossy or semi-gloss photographic quality paper upon which it is customary to print photographs under the control of a computer (not shown) with the assistance of an image printing program. The first sheet  32  is die-cut in such a manner that a picture or image can be printed onto its right side in 4 strips or sections, and another picture or image can be printed, also in 4 strips or sections on its left side. The picture or image printed on the right side of the sheet  32  corresponds to the first image carried by the first panel  22  in the assembled card  20 , and the picture or image printed on the left side of the sheet corresponds to the second picture or image carried by the second panel  24 .  FIG. 4  discloses the first sheet  32  before pictures or images are printed thereon.  
      The printing of the photographs or other images on the first sheet is performed by printing each image in 4 parts on the left and right sides of the underlying sheet, respectively, which after separation of the die-cut lines, become strips  36  to be assembled into the respective panels  22  and  24 . Glue carrying areas  38  are provided on the first sheet  32  in the areas shown in  FIGS. 4 and 6 . Alternatively, the areas  38  can just be marked for external glue (not shown) to be deposited thereon by a user (not shown). The printing of the pictures desired to be displayed in the sliding image assembly  20  (the first picture on the right side of the sheet  32 , and the second on the left side) can advantageously be accomplished using the software-program-controlled printer in accordance with the parameters provided for the first preferred embodiment. There, the sheet  32  can have any suitable dimensions, but preferably the American standard 8.5 by 11 inches in size. These parameters are expressed in inches, as indicated in  FIG. 16 , and counted from the respective edges  39  of the sheet  32 .  
       FIG. 6  illustrates the first sheet  32  of the invention, after both the first and second images have been printed thereon.  FIG. 5A  shows a second sheet  40 , which need not be printed at all. Rather, the second sheet  40  serves to form a frame and support onto which the image carrying first  22  and second  24  panels are assembled. Second sheet  40  is also preferably 8.5 by 11 inches in size, and has sufficient rigidity that it can serve for receiving the mounted panels  22  and  24  and to support them in an up-right position standing on a support surface (not shown). The second sheet  40  also contains perforations or die cutting, to delimit areas or parts, which are to be removed and not used for preparing the sliding image assembly  20 .  FIG. 5B  illustrates the second sheet  40  after the unnecessary or excess material has been removed from it.  
       FIGS. 7A and 7B  illustrate two pieces  42  and  44  obtained from the left side of the first sheet  32 , by separating the first sheet  32  into the pieces  42  and  44  along the die-cut or pre-perforated lines. The second image has been printed onto the two pieces  42  and  44  in 4 strips  36 , and each piece includes slotted areas or slots  46 . Similarly,  FIGS. 7C and 7D  illustrate two other pieces  48  and  50  obtained from the right side of the first sheet  32 , by separating the first sheet  32  into the pieces  48  and  50  along the die-cut or pre-perforated lines. The first image has been printed into the two pieces  48  and  50  in 4 strips  36 , and each piece includes slotted areas or slots  46 . The numerals 1, 2, 3, and 4, respectively printed on the edge of the pieces  42 ,  44 ,  48  and  50 , as applicable, refer to the segment or portion of the image, which is printed on the respective strip  36 , and facilitates the process of printing and assembling.  
       FIG. 8A  shows how the two pieces  48  and  50  are assembled to one another, by placing the tab  28  of piece  50  into the slot  46  of the piece  48 , and gluing the glued area to the paper above it.  FIG. 8B  illustrates the first panel  22  assembled or interleaved from the two pieces  48  and  50 . Similarly,  FIG. 9A  shows how the two pieces  42  and  44  are assembled to one another by insertion and gluing of the glue carrying areas  38 , and  FIG. 9B  illustrates the second panel assembled or interleaved from the two pieces  42  and  44 .  FIGS. 8C and 9C  show the assembled or interleaved first  22  and second  24  panels in cross-section, respectively.  
       FIGS. 10 and 11  illustrate how the first panel  22  bearing the first image is assembled or interleaved to the second panel  24  bearing the second image. This is done so that the panels  24  are disposed in the positions shown in  FIG. 11 . Then the two panels  22  and  24  are slid together completely.  FIG. 11  illustrates the interleaved first  22  and second  24  panels in cross section, and shows their relationship.  
       FIGS. 12A through 12D  illustrate the steps of forming an ear or easel flap  26 , which can be folded out from the rear of the sliding image assembly  20 , and which can be used to support the sliding image assembly  20  in an upright standing position on a support surface (not shown), such as a table (not shown).  FIGS. 1 and 2  of the drawings disclose the sliding image assembly  20  from the assembled or interleaved first  22  and second  24  panels, illustrated in  FIGS. 10 and 11 , and from the second sheet  40 , from which the excess material has been removed, illustrated in  FIG. 5B . Thus, referring now to  FIGS. 12A through 12D  which illustrate the process from a rear view, the assembled panels  22  and  24  are placed into the open window  51 , with the image bearing side facing forwards, centered and with the top of the assembled panels  22  and  24  flush with the top of the second sheet  40 . This is shown in  FIG. 12A . In subsequent steps flaps  52  of the second sheet are folded up over and on top of the assembled panels  22  and  24 . Some glue (not shown) is applied to the flaps  52  and to the top of the back side of the assembled panels  22  and  24 . Then the large flap or back cover  54  is folded over the flaps  52 . During this operation care must be taken not to remove the assembled panels  22  and  24  from their correct positions. Glue (not shown) is then applied to an elongated gluing area  38  forming a narrow strip  58 , shown in  FIG. 12C , which is thereafter folded back and glued to the back cover  54 .  
      On the backside of assembly  20 , an ear or easel flap  26  can be provided that supports the sliding image assembly  20  in an upright standing position on a support surface (not shown), such as a table (not shown).  
      A significant aspect of sliding image assembly  20  is that it is functional, not merely ornamental. As used herein, the concept of functionality means that the fully constructed three-dimensional object has at least two different configurations, and that the object includes a mechanism that reconfigures the object from one configuration to another. Note that this definition excludes the calendar of the Popat et al. because there is only one usable configuration of the fully constructed calendar. Yes, it is possible to flatten the calendar, but the flattened calendar is not fully constructed. It is also true that the Popat et al. calendar can be turned around and even upside down to emphasize different faces. But those are merely different orientations, rather than different configurations. There is also no mechanism, as part of the object that reconfigures the object from one configuration to another.  
      In the example above, the assembly  20  clearly has two different configurations, one that displays the first image and one that displays the second image. Assembly  20  also has a tab  28  that reconfigures the assembly  20  from one configuration to another.  
      There are, of course, innumerable possible objects that can be made from perforated templates having fold lines, and that also have a functionally operating mechanism. Below are two examples of such objects. The first is a single CD/DVD sleeve having a fold-over flap mechanism. The second is a double CD/DVD sleeve having a common closing fold panel mechanism. In each case the mechanisms serve to reconfigure between an open configuration and a closed configuration.  
      Single CD Sleeve  
      In  FIG. 17 a  template for a single sleeve CD/DVD generally includes a sheet  100  having perforations  110  and a vertical fold line  120 . Those skilled in the art will appreciate that the term vertical as used herein is merely a relational designation and has nothing to do with actual orientation of the object.  
      The material of template  100  is contemplated to be any relatively thick paper or cardstock. At least a portion of at least one side of the template is preferably coated with a high quality coating such as a gloss or semi-glass, either of which is adapted to receive and reproduce a photograph or other high quality image. Such materials are described above, as well as in the Popat et al. patent. Standard dimensions are advantageous because they would fix readily into most printers. Especially preferred dimensions are the American standard letter (8.5 inches by 11 inches), the American standard legal (8.5 inches by 14 inches), and the European standard A4 (8.27 by 11.69 inches).  
      The printer is contemplated to be any desktop type printer, including for example a laser printer, bubble-jet printer, or ink-jet printer. Color printers are preferred, but not required.  
      Portions of the template can advantageously carry a water-soluble dry adhesive, press-on adhesive, and so forth. Alternatives are also described above, and in the Popat et al. patent.  
      The perforations can have any suitable characteristics, so long as they provide a relatively simple mechanism for a user to conveniently produce a desired edge. Perforations can be even such that the template needs to be cut with scissors or other device rather than being ripped by the user.  
      The fold lines correspond to the lines of weakness contemplated in the Popat et al. patent. Fold lines can be produced in any suitable manner, which usually means impressing lines upon the template  100 .  
      Production of the CD/DVD sleeve is straightforward. First, the user optionally inserts template  100  into his printer, and directs the printer to apply an image on at least a portion of the template  100 . The portion used is preferably that which will be displayed on the outside of the constructed sleeve. Next, the user removes the working portion  102  from the throwaway portion  104 . The term “throw-away” portion is, of course, merely a euphemism that distinguishes the working portion. The user can throw away portion  104 , or not, as desired. Next the user folds the working portion  102  at the various fold lines. This can be done in many different orders, such as folding horizontal fold line  120  to produce panels  106  and  107  first and then making additional folds as needed. Finally, the user applies, uncovers or otherwise activates the adhesive on the reverse side of panels  106  and  107  and sticks them together. This forms a cavity at the opening of panels  106  and  107 , which opening can be accessed or closed by unfolding or folding of a panel that extends over the opening (not shown).  
      Double Sleeve  
      In  FIG. 18A  a template for a double sleeve CD/DVD generally includes a sheet  200  having perforations  210 , and fold lines  220 A and  220 B.  
      The material of template  200  is contemplated to have the thickness, coating materials, and dimension characteristics of template  100 . Preferred printers, adhesives, perforations, and fold lines can also advantageously be the same as that of template  100 .  
      Production of the CD/DVD sleeve is more complicated than that of the single sleeve CD/DVD holder, but is still relatively straightforward. First, the user optionally inserts template  200  into his printer, and directs the printer to apply an image on at least a portion of the template  200 . The portion used is preferably that which will be displayed on the outside of the constructed sleeve. Next, the user removes the working portion  202  from the throwaway portion  204 . Next the user folds the working portion  202  at the various fold lines. This can be done in many different orders, such as folding along horizontal fold line  220 A first then folding along vertical fold lines  220 B. Finally, the user applies, uncovers or otherwise activates adhesive and sticks opposing panels together. This forms cavities below panels  230 ,  240 , and  250  for insertion of CD/DVDs show in  FIG. 18B . It should be pointed out that the openings to the cavities are along sides  235  and  255  so that the CD/DVDs will be protected from falling out when the case is closed.  
      Drawing your attention to  FIG. 18C , a three-panel top-load CD/DVD holder  260  is shown partially folded. It should be appreciated that although this embodiment is described as a “top-load”, the middle panel  270  is side loaded as can be observed.  
      Thus, specific embodiments and applications of templates for complex three-dimensional, desktop printed, objects have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps can be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.