Abstract:
A package for housing an item is provided, including a rectangular enclosure having an access opening in which to receive one or more items such as media discs, and a wrapper at least partly surrounding said items and closely fitting into said access opening.

Description:
REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of priority under 35 U.S.C. §119(e) of provisional application Ser. Nos. 61/078,672 and 61/078,689, both filed on Jul. 7, 2008, both of which are hereby incorporated by reference in their entireties 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to a storage package for recording media and, more particularly, to a package comprising a paper board assembly for storing one or more discs. 
         [0004]    2. Description of the Prior Art 
         [0005]    Various types of planar discs are in use at the present time to record and store information which is to be retrieved by various means, such as by optical or magnetic means. Typical of such discs are compact discs in which information is digitally recorded by use of a laser beam and then read optically by a laser beam. Such discs are used to record audio information, such as musical renditions, video information such as visual images and digital information for use as read only and other memories for use in various applications, such as computer applications. In most instances, at the present time, such discs are sold with information already recorded thereon. In other applications, such discs are sold in blank form and are used by the customer to record information thereon. In the latter case, for example, optical discs are sold for use as computer storage media and are used in hard disc storage systems. As used herein, the terms media disc, compact disc, CD or disc are intended to encompass all such discs, whatever their size, for all known or proposed uses. 
         [0006]    Compact discs containing laser recorded information are typically packaged in injection molded plastic enclosures designed to hold one or more CDs for protecting the discs during storage and shipment. Enclosures commonly used at the present time, such as the well known “jewel box,” comprise a three piece assembly consisting of a base or bottom element, an insert or tray in the base/bottom element for positioning and supporting the disc in the base/bottom element, e.g., by a center projection (commonly referred to as a “rosette”) which engages the periphery of the aperture in the center of the disc, and a lid or cover which is hinged to the base/bottom element and is closed thereon after the disc is mounted therein on the tray. Other enclosures utilize only two pieces, omit the tray, and position and support the disc via the center projection directly on the base/bottom element. The enclosure is, typically, at least partially transparent and graphics relating to the disc and containing trademark and sales promotional information are usually inserted in such a manner as to be visible through the enclosure. 
         [0007]    Except for the printed matter inserted therein, the “jewel box” is entirely plastic. For this reason, as well as because the typical jewel box requires three separately injection molded elements which must be manually assembled, the use of this type of enclosure is relatively expensive. Moreover, the use of such an enclosure is believed to be ecologically unacceptable by many because the plastic is non-biodegradable and, in view of the huge volume of such enclosures in use today, the disposal of these enclosures poses either a real or potential environmental problem. One solution to both of these problems has been the development of hybrid packages comprising both paperboard and plastic components. These hybrid packages provide a CD package which is suitable and attractive for display, sale and storage of compact discs, yet which is both simple and inexpensive to manufacture. 
         [0008]    For example, U.S. Pat. No. 4,709,812 to Kosterka, which is incorporated herein by reference, discloses a compact disc package formed from a pre-scored, preprinted unitary blank and at least one injection molded plastic compact disc holder or tray adhesively adhered to one segment of the blank, the blank being adapted to fold along fold lines to position a blank segment over the top of the disc holder to sandwich it, in book style, between the segment to which it is adhered and the overlying segment. The problem with this type of arrangement is that the book frequently opens and provides little protection for the disc there within. 
         [0009]    It should be apparent, therefore, that efforts to date directed at hybrid packaging containing multiple discs suffer from one or more shortcomings which make the resulting CD packaging unsatisfactory. Among these shortcomings are that prior art hybrid packaging is typically either uneconomical to manufacture and may be expensive to transport, store and display in retail stores. Further, the plastic materials are not ecologically friendly. Accordingly, there remains a need for a simple, environmentally friendly, inexpensive to manufacture CD package that adequately protects the disc yet provides easy access thereto. 
       SUMMARY 
       [0010]    It is an object of the subject disclosure to provide a package for holding discs that is easy to manufacture from paper board or similar suitable environmentally friendly and/or recyclable material and adhesive such that promotional graphics and other necessary information like UPC codes can be printed directly on the package blank. 
         [0011]    In one embodiment, the present disclosure is directed to a package for housing a disc including an enclosure with an elongated panel having an access opening through which one or more discs may be received into or removed from the package. The package may have internal supports or abutments to securely receive the one or more discs. The discs may be wrapped in a fold-around wrapper or “taco” together and graphics may be printed on the taco and extend onto the spine of the taco, where they may form a contiguous portion of additional graphics printed on the outside of the enclosure. Variations of the illustrative embodiment, including variations in the size and shape of the taco, variations in the size and shape of the access opening, and variations in the size and shape of the internal supports or abutments, are also within the contemplation of the present invention and are further described below. In certain embodiments the enclosure may be made from a single blank of material. In certain embodiments the enclosure may be made from more than one blank of material. In certain embodiments items other than discs may be housed within the package. 
         [0012]    In another embodiment, the present disclosure is directed to a booklet-style package for housing a disc, including a hinged cover over an enclosure in which one or more discs may be received. The package may have internal supports or abutments for strength and to more securely receive the one or more discs. Graphics may be printed on all exterior surfaces (and at least some interior surfaces) and may extend onto all four spines of the package. Variations of the illustrative embodiment, including variations in the size and shape of the internal supports or abutments, are also within the contemplation of the present invention and are further described below. In certain embodiments the enclosure may be made from a single blank of material. In certain embodiments the enclosure may be made from more than one blank of material. In certain embodiments items other than discs may be housed within the package. 
         [0013]    It should be appreciated that the present invention can be implemented and utilized in numerous ways, including without limitation as a process, an apparatus, a system, a device, and a method for applications and from other suitable materials now known and later developed. These and other unique features of the system disclosed herein will become more readily apparent from the following description and the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    So that those having ordinary skill in the art to which the disclosed system appertains will more readily understand how to make and use the same, reference may be had to the following drawings. 
           [0015]      FIG. 1  is a view of a blank for forming a package enclosure; 
           [0016]      FIG. 2  is a perspective view of the blank of  FIG. 1 ; 
           [0017]      FIG. 3  is a perspective view of a step in the fabrication of a package enclosure from the blank of  FIG. 2 ; 
           [0018]      FIG. 4  is a perspective view of a further step in the fabrication of a package enclosure from the blank of  FIG. 2 ; 
           [0019]      FIG. 5A  is a perspective view of a another step in the fabrication of a package enclosure from the blank of  FIG. 2 ; 
           [0020]      FIG. 5B  is a perspective view of a final step in the fabrication of a package enclosure from the blank of  FIG. 2 ; 
           [0021]      FIG. 6A and 6B  are perspective views of the finished package enclosure made from the blank of  FIG. 2 ; 
           [0022]      FIG. 7A  is a view of a blank for forming a wrapper; 
           [0023]      FIG. 7B  is a perspective view of the wrapper blank of  FIG. 7A ; 
           [0024]      FIG. 8A  is a perspective view of a step in the folding of the wrapper, showing items to be held by the wrapper; 
           [0025]      FIG. 8B  is a perspective view of the folded wrapper, showing items held by the wrapper; 
           [0026]      FIG. 9A  is a perspective view of the folded wrapper, partly inserted into the package enclosure; 
           [0027]      FIG. 9B  is a perspective view of the folded wrapper, further inserted into the package enclosure; 
           [0028]      FIG. 10A  is a perspective view of the folded wrapper, entirely inserted into the package enclosure; 
           [0029]      FIG. 10B  is a perspective view of two folded wrappers partly inserted into the package enclosure; 
           [0030]      FIG. 11  is a view of a blank for forming a package; 
           [0031]      FIG. 12  is a perspective view of the blank of  FIG. 11 ; 
           [0032]      FIGS. 13-16  are perspective views of steps in the fabrication of a package from the blank of  FIG. 12 ; 
           [0033]      FIG. 17  is a perspective view of a finished package made from the blank of  FIG. 12 ; 
           [0034]      FIG. 18  is a perspective view of the finished package holding items therein; and 
           [0035]      FIG. 19  is a perspective view of the closed package. 
       
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0036]    The present invention overcomes many of the prior art problems associated with CD packages. The advantages, and other features of the package disclosed herein, will become more readily apparent to those having ordinary skill in the art from the following detailed description of certain preferred embodiments taken in conjunction with the drawings which set forth representative embodiments of the present invention and wherein like reference numerals identify similar structural elements whenever possible. 
         [0037]    All relative descriptions herein such as left, right, up, down, topside, underside and the like are with reference to the Figures, and not meant in a limiting sense. The illustrated embodiments can be understood as providing exemplary features of varying detail of certain embodiments, and therefore, unless otherwise specified, features, components, modules, elements, and/or aspects of the illustrations can be otherwise combined, interconnected, sequenced, separated, interchanged, positioned, and/or rearranged without materially departing from the disclosed systems or methods. Additionally, the shapes and sizes of components are also exemplary and unless otherwise specified, can be altered without materially affecting or limiting the disclosed technology to holding discs exclusively. 
         [0038]      FIG. 1  shows a package blank  100  for forming an exemplary package enclosure  102 . Package blank  100  may be formed by, for example, cutting a board substrate with a die. Various board thicknesses and materials are acceptable. The stock board may be paper, plastic and/or the like. The stock board may be single ply although, in some instances, it may be desirable for blank  100  to be two or multiple ply. Once blank  100  is formed, it is folded and glued into the package  102  described below. In the description, certain steps are used which help describe the structure of the package  102 , but the assembly process may use steps other than these, or in a different order. For example, as described herein, initial assembly may comprise a limited number of folding steps that create a “flattened” tubular structure, which later (and possibly with some folds now made for the first time) is assembled into a “opened” tubular structure. 
         [0039]    Certain parts of blank  100  will now be described. The major panels include back panel  110 , open spine  120 , front panel  130 , closed spine  140 , and innercell  150 . Back panel  110  may comprise a thumb aperture  112 . Open spine  120  comprises an aperture that may be partly bounded by support flaps  122 . Innercell  150  may comprise an inward stopper wall  152 , outward buttress walls  154 , floor  156 , side beams  157  and top beam  158 . Additionally the blank  100  may comprise end panels  134 , closure flaps  136 , and closure tabs  138 . 
         [0040]    Package blank  100  may be formed by, for example, cutting a board substrate with a die. Various board thicknesses and materials are acceptable. The stock board may be paper, plastic and/or the like. The stock board may be single ply although, in some instances, it may be desirable for blank  100  to be two or multiple ply. Once blank  100  is formed, it is folded and glued into the package  102  described below. 
         [0041]      FIG. 2  shows package blank  100  in an isometric view.  FIG. 3  shows a step in the forming of blank  100  into a package enclosure  102 , for example by a sequence of folding and gluing operations. The sequence shown here is by example only. There may be other sequences also suitable for forming the package enclosure. In  FIG. 3 , closed spine  140  and innercell  150  have been folded forward relative to front panel  130 , and portions of the innercell have been glued to front panel  130 . For example, a significant portion of innercell  150 , including floor  156 , have by folding been brought into parallel contact with front panel  130  to which they may be attached with an adhesive. Other portions including inward stopper wall  152  and outward buttress walls  154  have by folding been made perpendicular to front panel  130 , and along with closed spine  140 , provide support for side beams  157  and top beam  158 , which are now parallel to and spaced apart from front panel  130 . 
         [0042]      FIG. 4  shows another step in forming the package enclosure, where open spine  120  has been folded upward and is now shown perpendicular to the plane of front panel  130  and innercell  150 . 
         [0043]      FIG. 5A  shows another step in forming the package enclosure, where back panel  110  is folded over upon the package (as denoted by arrow “X”) so that the inside of back panel  110  will rest upon side beams  157  and top beam  158 . The back panel  110  is shown partway folded so that the internal structure of the package is still clear. After folding, the inside of back panel  110  may be attached to top beam  158 , or side beam  157 , or both, for example by use of an adhesive such as glue. The package enclosure thus forms a tubular shape. This tubular shape may be collapsed flat, due in part to end panels  134 , closure flaps  136 , and closure tabs  138  not yet being folded. In an alternate assembly process, the package enclosure may be formed to a flattened tubular shape by folding only along fold lines Y 1  and Z 1  (see  FIG. 1  and  FIG. 5A ) and applying adhesive as previously discussed. (Or, by folding only along lines Y 2  and Z 2 ) and applying adhesive as previously discussed. Such an assembly (flattened) allows the package to be shipped or handled in a flattened configuration. 
         [0044]      FIG. 5B  shows a the package in a final assembly step when the tubular assembly (if flattened) is opened into an open tube, the closure tabs  138  (not shown) are folded inward, the end panels  134  have been or are being folded upward, and closure flaps  136  have been or are being folded inward and placed inside the package. Also shown in dotted lines are support flaps  122  being folded inward into the package, where they may form support or guide surfaces for items being inserted into the package. Support flaps  122  may also provide strength to the package. By folding inward support flaps  122 , an access opening  125  is created along open spine  120 . 
         [0045]      FIG. 6A  shows a finished package enclosure.  FIG. 6B  shows another view of the finished package enclosure  102 , with the access opening  125  visible in open spine  120 . Items may be inserted into package enclosure  102  through the access opening  125 . For example, such items may include disc media. 
         [0046]      FIG. 7A  shows a wrapper blank  180  for forming an exemplary wrapper  182  or “taco” to enclose items, such as disc media, to be held in package enclosure  102 . Wrapper blank  180  may comprise a wrapper front panel  184 , wrapper spine panel  185 , and wrapper back panel  187 .  FIG. 7B  shows wrapper blank  180  in an isometric view. 
         [0047]      FIG. 8A  shows a partly folded wrapper  182  formed from wrapper blank  180 . The wrapper  182  may wrap items such as mini-jackets  190 , for example containing disc media. In one embodiment, mini-jackets  190  may be formed of sheet material such as paperboard. In  FIG. 8A , three mini-jackets are shown, although the number may be more or less. 
         [0048]      FIG. 8B  shows a fully folded wrapper  182  partly enclosing mini-jackets  190 , which for clarity are shown displaced laterally within the folded wrapper  182 . In typical use, the mini-jackets  190  would be aligned within wrapper  182  so that one edge of the mini-jackets is more or less abutted against the inside of wrapper spine panel  185 , as shown by the dashed line. 
         [0049]    In the remaining FIGURES, mini-jackets  190  are not shown but are understood to be contained within wrapper  182  which is placed within package enclosure  102 .  FIG. 9A  shows wrapper  182  inserted about 30% into package enclosure  102 , with a hidden portion of the wrapper shown in a dashed line.  FIG. 9B  shows wrapper  182  inserted about 80% into package enclosure  102 , and  FIG. 10A  shows wrapper  182  completely inserted into package enclosure  102 . Thumb aperture  112  in the package enclosure may be used to provide a grasping point by which to remove wrapper  182  from the package enclosure  102 . 
         [0050]    Although a single wrapper  182  is shown in the preceding examples, more than one wrapper may be used, for example two wrappers  183  as shown in  FIG. 10B . The number of wrappers used may be suitably sized to nest neatly and snugly within package enclosure  102 . 
         [0051]    In order that the assembled package fit together neatly, the various panels may be suitably sized and shaped. Package blanks  100  and wrapper blank  180  may typically be produced with printing on at least one side. Since these blanks form package enclosure  102  and wrapper  182 , respectively, which fit together to form a finished package, blank  180  may be printed so that the graphics on wrapper  182  form a continuous image with the graphics on package enclosure  102  (which were printed on package blank  100 ). 
         [0052]      FIG. 11  shows a package blank  200  for forming another exemplary package  202 . Package blank  200  may be formed by, for example, cutting a board substrate with a die. Various board thicknesses and materials are acceptable. The stock board may be paper, plastic and/or the like. The stock board may be single ply although, in some instances, it may be desirable for blank  200  to be two or multiple ply. Once blank  200  is formed, it is folded and glued into the package  202  described below. 
         [0053]    Certain parts of blank  200  will now be described. Portions of blank  200  are symmetric with respect to the horizontal axis of  FIG. 11 , and where a given part has been labeled, its mirror-image counterpart is not necessarily labeled. The major panels include front outside panel  210 , front inside panel  220 , back panel  230 , and floor  240 . Between the front outside panel  210  and back panel  230  is spine  238 . Between front outside panel  210  and front inside panel  220  are outer side panel  212  and inner side panel  222 . At each end of front outside panel  210  are an outer end panel  216  and an inner end panel  218 . In the flattened blank  200  as shown in  FIG. 11 , outer end panel  216  is perpendicular to outer side panel  212 , with a gusseted dustflap  214  between the juncture of outer end panel  216  and outer side panel  212 . 
         [0054]    Portions of the blank will form channels  258  as shown later. These portions include channel outer wall  250 , channel top wall  252 , and channel inner wall  254 . The channel inner wall  254  may be connected to back panel  230  by an adhesive attachment through channel foot  241  or floor  240 . A semicircular tab  256  may be attached to channel top wall  252 . Dust flaps  251  and  255  may are attached to channel outer wall  250  and channel inner wall  254  respectively. 
         [0055]    On the side of back panel  230 , opposite from spine  238 , is outer side wall  232 , inner side wall  234 , and side wall foot  236 . Package blank  200  may be formed by, for example, cutting a board substrate with a die. Various board thicknesses and materials are acceptable. The stock board may be paper, plastic and/or the like. The stock board may be single ply although, in some instances, it may be desirable for blank  200  to be two or multiple ply. Once blank  200  is formed, it is folded and glued into the package  202  described below. For example, the package may be assembled as described herein by the illustrated folding steps, and with blank  200  as viewed in  FIG. 11 , having adhesive applied to parts or all of inner end panels  218 , front inside panel  220 , floor  240 , and channel foot  241 . 
         [0056]      FIG. 12  shows package blank  200  in an isometric view.  FIG. 13  shows a step in the forming of blank  200  into a package  202 , for example by a sequence of folding and gluing operations. The sequence shown here is by example only. There may be other sequences also suitable for forming the package. In  FIG. 13 , outer end panels  216  have been folded upward from front outside panel  210 , and then inner end panels  218  folded downward relative to outer end panels  216 , and adhered thereto, forming upstanding end walls. The gusseted dustflaps  214  will then be folded and tucked between outer side panel  212  and inner side panel  222  in the next step, shown in  FIG. 14 , where outer side panel  212  is first folded upward relative to front outside panel  210 . Inner side panel  222  is then folded back upon outer side panel  212 , trapping gusseted dustflaps  214  therebetween as shown by dotted line. Then front inside panel  220  is folded flush onto and adhered to front outside panel  210 . This creates a front cover (made of front outside panel  210  and front inside panel  220 ) bounded by walls on three sides and by spine  238  on the fourth side. 
         [0057]      FIG. 15  shows a further step in the forming of the package, where channels  258  are formed, first by folding channel outer wall  250  upward from back panel  230 , then folding channel top wall  252  inward, then folding channel inner wall  254  inward and back toward back panel  230 . Attached to channel inner wall  254  on one of the channels  258  is channel foot  241  that may be folded relative to channel inner wall  254  and then glued to back panel  230  as shown in final glued position. Attached to channel inner wall  254  on the other of channels  258  is floor  240  that may be folded relative to channel inner wall  254  (this folding process is shown in  FIG. 15 ) and then glued to back panel  230 , where it may overlap channel foot  241 . On channels  258  thus formed, semicircular tabs  256  protrude inward from channel top walls  252 . A dust flap  251  is attached to one end of each channel inner wall  254 , and a dust flap  255  is attached to one end of each channel outer wall  250 . In the next step, these dust flaps  251  are each folded inward as shown in  FIG. 16 . Then, from the side of back panel  230  opposite from spine  238 , outer side wall  232  may be folded upward from back panel  230 . Next, inner side wall  234  may be folded inward from outer side wall  232 , trapping dust flaps  251 ,  255  between outer side wall  232  and inner side wall  234 . Finally, side wall foot  236  folded related to inner side wall  234  may be placed in proximity with back panel  230  into a space not covered by floor  240 . At least a portion of the end  253  of channel top wall  252  may slightly overlap the tops of the dust flaps  251 ,  255  which may provide strength to the structure. The folded outer side wall  232  thus fits snugly against the dust flaps  251 ,  255  and the ends of channels  258 , while the folded inner side wall  234  and side wall foot  236  fit snugly between the channels  258 . 
         [0058]    Package blank  200  may be formed by, for example, cutting a board substrate with a die. Various board thicknesses and materials are acceptable. The stock board m 
         [0059]      FIG. 17  shows a finished package  202 . Floor  240  may have a cutaway area  242 . If the glue pattern under floor  240  (holding to back panel  230 ) is only around the periphery of floor  240  (and not adjacent cutaway area  242 , then materials such as a leaflet (not shown) may be inserted between floor  240  and back panel  230 . 
         [0060]    The finished package  202  may be considered to comprise a cover (generally made up of front outside panel  210 , front inside panel  220 , and their associated inner and outer end and side panels) and a base (generally made up of back panel  230 , floor  240 , channels  258 , and the associated outer side wall  232  and inner side wall  234 ). The cover and base are hingedly connected by the spine  238 . 
         [0061]      FIG. 18  shows how items  290  may be contained within package  202 , between channel  258  and retained by semicircular tabs  256 . For example, such items may include slipcases or mini-jackets containing disc media. The items  290  may be placed or slid into package  202 , and would normally be positioned with an edge ends abutting inner side wall  234 . The items  290  may be closely received between channel inner walls  254 . While two items  290  are shown, more or fewer may be held in package  202 . 
         [0062]    In order that the assembled package fit together neatly, the various panels may be suitably sized and shaped. Package blank  200  may typically be produced with printing on at least one side. Usually the exterior surface of package  202  would be printed. By printing a single surface of blank  200 , graphics may be provided on all exterior surfaces of package  202  (that is the major surfaces of front outside panel  210 , back panel  230 , spine  238 , outer side panel  212 , and outer end panels  216 ). By printing the same single surface of blank  200 , graphics may also be provided on the inner surfaces of the cover (that is, inside front panel  220 , inner side panel  222 , and inner end panels  218 ), as well as the exposed surfaces of channels  258 . outer side wall  232  and inner side wall  234 , and floor  240 . Thus substantially all of the external surfaces of package  202  are printed, and nearly all (even 90% or more) of surfaces internal surfaces that are visible inside an open package are also printed (in the case of package  202 , the inside of spine  238  may not be printed. However, by modifying blank  200 , even the inside of spine  238  could be printed, for example if an additional narrow panel was provided at the left end (as viewed in  FIG. 11 ) of front inside panel  220 . 
         [0063]    The package examples shown here are particularly suitable for forming a package sized as is common for a “DVD package,” that is, a package with a major face having one dimensional substantially larger than the other, or a somewhat elongated rectangle as opposed to a generally square shape. The content items as shown by example here have a generally square aspect, as would seen with “mini-jacket” holders for disc media. It will be understood that other blanks may be produced according to the principles of blanks  100  and  180 , and blank  200 , but with appropriate dimensions to form packages of other sizes and shapes. 
         [0064]    The packages disclosed herein may contain one or more items, such as one or more sleeves or mini-jackets containing media discs. For example, the packages may contain from one to 25, or even more, mini-jackets. The term sleeves or mini-jackets is meant to include other forms of thin envelope-type enclosures, such as dust-jackets, sleeves, and the like. The package may contain items other than media discs. In some embodiments the package may be made from paperboard having a thickness of about 0.018″, other types and thicknesses of materials may be utilized as are known in the packaging arts. 
         [0065]    The packages can be formed using a variety of materials or substrates. For example, PRINTKOTE EAGLE®, which is composed of at least 10% post consumer recycled material, can be used. Moreover, a polymeric substrate such as calendered POLYLITH® GC-3 can be used. POLYLITH® substrate is manufactured by Nanya Plastics of Taiwan and is distributed in the U.S. by Granwell Products, Inc. POLYLITH® substrate is primarily formed using polypropylene resin and minerals comprising inert calcium carbonate and titanium dioxide and the resulting substrate is strengthened by calendaring. 
         [0066]    While the invention has been described with respect to preferred embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the invention without departing from the spirit or scope of the invention.