WO1996035628A1

WO1996035628A1 - Composite package for compact discs

Info

Publication number: WO1996035628A1
Application number: PCT/US1996/006397
Authority: WO
Inventors: Edwin C. Mclaren
Original assignee: Mclaren Edwin C
Priority date: 1995-05-08
Filing date: 1996-05-07
Publication date: 1996-11-14
Also published as: AU5729496A

Abstract

A composite package (8) for use in storing a laser or optically readable disc in either video or audio format. The package includes a lightweight frame (10) for storing the disc. The frame is encompassed by a sheath (12) which is securely bonded to an exterior surface of the frame. Graphics for the package are printed directly on the inside and/or outside of the sheath.

Description

DESCRIPTION COMPOSITE PACKAGE FOR COMPACT DISCS

RELATED APPLICATIONS This application is a continuation-in-part of co-pending application

08/436,706 filed May 8, 1995 which a continuation-in-part of Serial No. 08/188,209, filed January 27,1994 now U.S. Patent No. 5,414,582, which is a continuation-in-part of Serial No. 07/897,233, filed June 1 1 , 1992, now U.S. Patent No. 5,31 1 ,388. The subject matter of the '582 and '388 patents and the '706 application are expressly incorporated herein in their entirety.

BACKGROUND OF THE INVENTION The invention relates to an improved package for optically read media such as digital video display (DVD) packages, compact disc (CD) packages (commonly called "jewel boxes"), floppy discs, ROMs and other such items intended for use with video or audio technology. Specifically, the invention provides a package intended to be primarily utilized in the prerecorded market for both the video and audio markets. For instance, the video market (DVD's) is a new and growing area for the movie retail and rental market while other markets are already well- established such as for audio compact discs (CD's), computer discs for ROM applications and the like. Such packages, in the audio industry alone, are now the major medium for selling music (now surpassing vinyl albums and audio tapes).

The jewel boxes which are commonly available are all plastic packages which are constructed of new or virgin plastic components. A label and a graphic paperboard insert usually placed inside the jewel.

It is desirable to display eye-catching or consumer pleasing graphics with the packaged item. In order to have any graphics visible through the lid of the plastic jewel box, it has been necessary to use clear plastic materials. However, such clear plastic materials are made of new or non-recycled materials and are expensive and time consuming to manufacture. Further, such clear plastic materials are rigid and tend to crack or break during use. in addition, the assembly of the packaged item involves placing the label adjacent the clear plastic lid, and placing the disc and any written materials within the jewel box. Such assembly is labor intensive and not easily automated; therefore, the costs of producing these jewel boxes is high.

The use of such jewel boxes provides for an end quality product which is sometimes much greater than that necessary for the intended life span of the disc contained therein. As a result, there is a demand for less expensive and more-environmentally conscious boxes. Jewel box designers, primarily those in the audio industry, have attempted to meet this demand and provide a lower cost box better suited for use in the industry. Examples of such boxes are shown, for instance, in United States Patent Nos. 5,332,089, 5,310,053, 5,284,242, 5,188,229, 5,188,230, 5,205,405, 5,219,417, 5,236,081 and 4,709,812 which disclose a multi-ply folded bendable material such as paperboard, and United States Patent Nos. 5,279,097, 5,259,498, 5,209,409 and 5,263,582 which disclose plastic containers or boxes. Such boxes, however, require the use of large amounts of paper and/or plastic materials. This use of extra materials is an added cost to the manufacturer in terms of time to assemble the multi-layer folded materials, extra costs of the materials themselves, and in shipping costs associated with the extra weight of the multiple layered boxes.

Further, there are increasing environmental concerns about the wasted packaging materials which are often not recyclable. Still, the manufactures want the package to appeal to the consumer and be able to readily display the visual graphics and written information about the material on the disc or floppy disc package itself. Therefore, there remains a demand for a composite package both audio and video, that is better suited for use in the market than the currently available jewel boxes.

It is an object of this invention to provide a composite compact disc package which is lightweight and offers high quality graphics displayed to the consumer.

Another object of this invention is to reduce the per unit manufacturing cost of a compact disc package by increasing the production rate and decreasing the cost per unit manufactured.

A further object of this invention is to provide a compact disc package having a lower per unit postage weight and cost for mailing and shipping than the industry "standard" package.

Another object of this invention is to provide a lightweight and less expensive compact disc package by reducing the amount of plastic and paper required in the structure of the package. Yet another object of the invention is to provide a compact disc package that eliminates the need for the outer plastic covers.

Yet a further object of the invention is to provide the capability for applying high quality graphics directly to the compact disc package, thus further eliminating the need and the cost for printed labels or other materials that must be reproduced and inserted into the package.

A further object of the present invention is to provide graphics, applied directly to the compact disc package, that have a print/gloss quality comparable to that of a vinyl album jacket.

SUMMARY OF THE INVENTION

This invention achieves the above-noted objectives by providing a compact disc package, either audio or video, which is composed of a lightweight frame having structural integra . on with a sheath.

The package of the present invention can be manufactured at higher speeds and at lower costs per unit than prior art packages. The package of the present invention is a light weight and less expensive package which requires much less plastic and paper than prior art packages.

The package of the present invention comprises a frame and a sheath. The frame is provided to enhance the structural integrity and durability of the package. According to one aspect of the present invention, where structure of the frame is unnecessary for the structural integrity and strength of the package, any such structure is either reduced in thickness or eliminated altogether. The frame is covered with a sheath which provides a light weight material for the package construction. The use of the sheath further provides the ability to apply overall graphics directly onto the an outside surface of the sheath, thereby creating an attractive and marketable package shell. In addition, the structure and shape of the frame, now make it possible to have graphics also visible on an inside surface of the sheath through open cut- out areas of the frame.

The package of the present invention can be made using recyclable or recycled materials which are less expensive and more-environmentally conscious than the currently used clear plastic materials. Further, the package of the present invention can be made with materials which are more flexible (or less rigid) than the currently used clear plastic materials. In a preferred embodiment, the package comprises a frame made of a lightweight recycled plastic material and a sheath made of a paperboard material. The plastic material and the paper material are at least somewhat flexible and allow the package to withstand the bending and manipulation that occurs when removing or replacing the packaged item. However, in certain embodiments, it is contemplated that the sheath can comprise a suitable flexible plastic type material, such as a plastic sheet which can readily accept printed and/or graphic information.

The unit cost of each package constructed in accordance with this invention is greatly reduced by limiting the amount of plastic and paperboard materials used in the construction of the package. The cost is further reduced by eliminating the need for an outer carton with graphics printed thereon and the need for clear plastic flip-top box with graphics visible therethrough.

In addition, the package of the present invention does not require complicated manufacturing processes. The present invention eliminates the need to have multi-step plastic molding operations, and in certain embodiments, eliminates the step of inserting additional printed material into the package.

Rather, the package of the present invention can be readily and automatically manufactured and assembled. The sheath, with the identifying material already printed thereon, is quickly and easily secured to the outside surface of the frame.

The present invention, incorporating the plastic frame and sheath with graphics preapplied, provides a strong, lightweight package having overall high quality graphic capability. The present invention, provides a strong, yet lightweight package having enhanced durability.

The present invention can be readily understood upon analysis of the following detailed description of the preferred embodiments with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is an exploded perspective view showing a package of the present invention, with the frame separated from the sheath.

Fig. 1 A is a partial perspective view of one corner of an alternative embodiment of the sheath on a frame as shown in Fig. 1.

Fig. 2 is a perspective view of the bottom of the frame of Fig. 1.

Fig. 2A is a partial perspective view of the bottom of a corner of a top support member of an alternative embodiment of the frame shown in Fig. 1. Fig. 2B is a cross-sectional view taken along the line 2B-2B in Fig.

2A. Fig. 3 is a perspective view of the package of Fig. 1 with the sheath bonded to the frame shown in a closed position.

Fig. 4 is an exploded perspective view showing a package of the present invention with the frame separated from the sheath. Fig. 4A is a partial perspective view of one corner of the package shown in Fig. 4.

Fig. 4B is a cross-sectional view taken along the line 4B-4B in Fig. 4A.

Fig. 5 is an exploded perspective view of another embodiment showing a package of the present invention with the frame separated from the sheath.

Fig. 5 A is a partial perspective view showing an alternative embodiment of a sheath showing an area skived or removed from one end of the sheath.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The present invention provides a composite package, composed of a frame having a shell or sheath suitably adhered an outer surface of the frame. The frame is designed to enhance the structural integrity of the package, while still allowing the package to be lightweight. The package of the present invention is intended for use in either video or audio format; the features of the invention remain the same.

Referring now to the figures, a package intended for use as an audio or video compact disc package 8 is shown in detail. The package 8 shown is designed to store a standard CD or DVD; however, it should be understood that video and/or ROM compact discs of any format can be used with the subject of the present invention. The package 8 shown in the figures includes a frame member 10. in a preferred embodiment the frame 10 is comprised of at least one recyclable or recycled material such as a durable lightweight thermoplastic material. The frame 10 is encased by a lightweight flexible sheath member 12, which is adhered to the frame 10 to form the package shown in Fig. 3. In preferred embodimer , the sheath 12 is composed of a single layer of a material which readily accepts printed or graphic materials, in especially preferred embodiments, the material composing the sheath is of a high quality paperboard material.

The frame 10 of the package 8 of the present invention is constructed to have a first or top support member 1 1 and a second or bottom support member 13. The top support member 1 1 has an outside surface 1 1a (as seen in Fig. 2) and an inside surface 1 1 b (as seen in Fig. 1 ) and the bottom support member 13 has an outside surface 13a (as seen in Fig. 2) and an inside surface 13b (as seen in Fig. 1 ). In certain preferred embodiments, the support members 1 1 and 13 have the standard outside dimensions designed for use storage of a standard CD or DVD. The frame 10 includes a plurality of open cut-out areas 14 extending through the top support member 11 and the bottom support member 13. The cut-out areas 14 are designed to eliminate as much material from the package as possible, without negatively affecting the structural rigidity of the frame 10. The cut-out areas 14 in the bottom support member 13 define a structural support or retaining means 20 comprised of a plurality of radially extending tab members 21. As can be seen from the figures, the retaining means 20 is supported by at least one cross member 22 extending through the cut-out areas 14 generally in the plane of the bottom support member 13. While the embodiment shown has a plurality of the cross members 22 which extend in a generally perpendicular manner, it is to be understood that either fewer or more cross members 22 can provide the support for the retaining means 20.

The bottom support member 13 defines raised areas 16 having a general shape that is complementary to the disc being stored. The bottom support member 13 further defines lower areas 18 adjacent the raised areas 16 which have a general shape of the disc being stored. In certain embodiments, the raised areas 16, the lower areas 18 and the cross members 22 have about the same thickness.

The top support member 11 has a perimeter defined by parallel extending sides 24 which are connected by corners 26 to a parallel extending inner edge 27 and an outer edge 28.

In certain embodiments, it is desired that the frame 10 be provided with at least two distinct thicknesses. This embodiment is partially shown in Fig. 2A where longitudinally extending sides 24a, corners 26a and edges 28a can have a first cross-sectional area or a thickness of material that is comparable to that found in the "standard" commercial package. The second thickness or cross-sectional area of material of the remaining frame structure is designed to be thinner than the first thickness. In certain embodiments, it is contemplated that the second thickness can be about .014 to .018 mils thinner than the first thickness. The sides 24a, corners 26a and bottom edges 28a, which have the first thickness, are designed to have a thicker structure or cross-sectional area in order to provide the necessary strength, integrity and durability to the frame 10. In certain preferred embodiments, the difference in thickness between the sides 24a, corners 26a, bottom edges 28a, and the remainder or second thickness of the frame 10 is approximately equivalent to the thickness of the sheath 12 which encompasses the frame 10. The sheath 12 is bonded to the thinner first thicknesses or areas of the sides 24, corners 26 and edges 27 and 28 of the top support member 1 1 and is bonded to the lower areas 18 of the bottom support member 13. Thus, after the sheath 12 is bonded to the frame 10, there will be no exposed edges of the sheath 12 which could be subject to damage.

In certain embodiments, it is also desired that the frame 10 be provided with a third, still thinner thickness or cross-sectional areas than the second thickness. This embodiment is partially shown in Figs. 2A and 2B where the parallel extending sides 24 and/or the longitudinally edges 27 and/or 28 of the top support member 1 1 can define at least one or more reduced cross-sectional areas, generally designed as 24b, 27b and/or 28b. The third, thinner thickness can be present on either the outside surface 11 a or the inside surface 11 b of the frame 10. In the embodiment shown in Figs. 2A and 2B, the third, thinner thickness is shown as being on the outside surface 1 1a of the frame 10 such that, when the package 8 is assembled, the sheath 12 substantially covers the third thicknesses and the aesthetics of the package 8 remain pleasing and acceptable. However, it should be understood that in certain other embodiments, the third thicknesses can be formed on both the inside and outside surfaces or only on the inside surface of the frame 10.

The presence of third, thinner thicknesses or areas in certain embodiments, allows the frame 10 to be made with less material, thereby reducing both the manufacturing costs and the weight of the frame. The frame of the present invention can have one or more, and in certain embodiments, a plurality of, reduced cross-sectional areas (for example, 24b, 27b and/or 28b) without degrading the appearance or the diminishing the strength of the package 8. While not shown, it is to be understood that the bottom support member 13 can also have at least one or more third, thinner thicknesses or cross-sectional areas in, for example, the retaining means 20 and/or cross members 22.

It is to be further understood that the cross-sectional thickness or area of such thinner, third thicknesses can be as much as, in certain preferred embodiments, about one half or less the thickness of the remaining, first and/or second thicknesses of the frame 10.

In certain embodiments located about the periphery or perimeter of the thin portions of the frame 10 are a plurality of up-raised energy director beads or areas 29 which are formed from the same thermoplastic material as the frame 10. The energy director beads 29 are also utilized to add structural integrity to the frame 10 and to provide additional surface area in which to bond the sheath 12 to the frame 10. In certain embodiments, the sheath 12 is coated on an interior surface 37 with a styrene film coating material or other product known to be compatible with the material of the frame 10. In one method of production, the sheath 12 is positioned over the frame 10 and ultrasonic vibrations are applied to the composite frame 10 and sheath 12. The ultrasonic vibrations "melt" or adhere the sides 24, corners 26, edges 27 and 28, and lower areas 18 (and in certain embodiments, the energy beads 29 and/or sides 24a, corners 26a and edge 28a) and causes the material of the frame 10 to blend with the coating material on the interior surface 37 of the sheath 12. The sheath 12 is bonded or welded to the frame 10 as the molten blend solidifies. Of course, other methods of adhering or bonding, such as adhesives, two-faced tape, hot melt gluing, or other means may be used in place of energy director beads 29 and the ultrasonic weld technique and such methods are within the contemplated scope of the present invention.

In preferred embodiments, the sheath 12 is made of one layer of a suitably thick paperboard material which provides protection to the frame 10 and enhances the structural rigidity of the package 8. It has been surprisingly found that only one layer of a suitable thickness of the sheath material is needed to form a package 8 which meets both industry and consumer expectations.

The sheath 12 of the present invention includes a top flap 30, a bottom flap 32, and a middle or center portion 34. The sheath 12 is patterned to fit on the frame 10 (as defined by the sides 24, corners 26 and edges 27 and 28 of the top support member 11 and the perimeter of the raised area 16 of the bottom support member 13 of the frame 10) . The top flap 30 and the bottom flap 32 are preferably composed of solid material.

Graphics may be applied to both an exterior surface 36 and the interior surface 37 of the sheath 12 prior to application and bonding of the sheath .12 to the frame 10. It is to be understood that, due to the shape of the cutout areas 14 of the frame 10, it is possible to display printed material and/or graphics on the interior surface 37 of the sheath 12. This visible portion of the interior surface 37 provides a greatly expanded surface area in which the manufacturer can provide additional information, and in certain situations, allow the manufacturer to dispense with providing any additional printed materiε, with the package. In various embodiments, the exterior surface 36 provides an impermeable barrier for protection from extreme environmental conditions, such as heat, humidity or physical stresses. Thus, after application and bonding of the sheath 12 to the frame 10, as shown in Fig. 2, a composite package having graphics applied thereto is provided.

In preferred embodiments, the exterior surface 36 and/or interior surface 37 of the middle portion 34 are relatively flat so that the printed material can be readily displayed thereon. In the embodiment shown, the middle portion 34 of the sheath 12 acts as a spine and is defined by at least one, and preferably, at least two parallel extending folds or score lines 38 which allow the sheath 12 to conform to the frame 10. The folds 38 are in at least adjacent, and preferably at substantially, the middle portion 34 of the sheath 12. The area adjacent the fold 38 (or the area between the folds 38 when two folds are present) defines a closed or hinged end 39 of the package 8. However, it is to be understood that, in preferred embodiments, the folds 38 are slightly off center since, in preferred embodiments, one support member is slightly larger than the opposing support member, such that the opposing support members can be brought into mating engagement, as described in detail below.

Referring now to Fig. 1A, it is to be understand that, in certain embodiments, at least one end 32' of the bottom flap 32 on the sheath 12 can extend beyond an end of the bottom support member 13 of the frame 10. The end 32' defines at least one fold or score line 31 which is in a spaced apart relationship from the end 32'. The end 32' is bent or folded at the fold 31 such that an inner surface 33 of the end 32' is adjacent the end of the bottom support member 13. Any suitable graphic materials can be printed on an exterior surface 35 of the end 32'. It should be noted that, in preferred embodiments, the frame 10 includes the top support member 1 1 and the bottom support member 13 which are connected together by a hinge means 40. In especially preferred embodiments of the present invention, the top support member 1 1 and bottom support member 13 can be designed to be connected together by a hinge means 40 comprising at least one, and in the embodiment, shown a plurality of hinge members 40a, 40b and 40c which define openings 42a and 42b therebetween. However, it is to be understood that in certain embodiments, the top support member 11 and the bottom support member 13 can be operatively connected by other suitable joining means.

In certain embodiments, for example, the top support member 11 and the bottom support member 12 can be secured to the sheath 12 without any hinging means, as shown in detail in Figs. 4-5 below. That is, the middle portion 34 of the sheath 12 can act as a hinging means without compromising the integrity of the package 8. This elimination of the need for movable parts such as the plastic hinging means, serves to eliminate the cost of the parts, the assembly or molding time required to make the parts, as well as the weight of the parts.

In certain preferred embodiments, the hinge members 40a, 40b and/or 40c act as a spine and have at least one, and preferably at least 2 parallel extending folds 44 which allow the top support member 11 to be rotated about the hinge members 40a, 40b and 40c in a direction toward the bottom support member 13 such that the top support member 11 mating engages the bottom support member 13.

The package 8 constructed in accordance with the present invention usually is designed to have laterally extending edges or side walls 50 which extend from the top support member 11 in a direction toward the bottom support member 13 when the package 8 is in a closed position. The sidewalls 50 are generally constructed of a plastic material and in preferred embodiments are formed as an integral part of the frame member 10. in certain embodiments, the sidewalls 50 can include at least one inwardly projecting tab member 52. It is to be understood that the frame 10 can be manufactured such that the tab members 52 can be easily molded whereby there are corresponding openings 52' (as shown in Fig. 2) on the outside surface 11a of the frame 10. The present invention provides for easy manufacturing of the package since less complicated molding processes are required to form the tabs 52 with the adjacent openings 52'. The openings 52' are not visible when the frame 10 is covered by the sheath 12. In the embodiment shown in Figs. 1 and 2 the tab members 52 designed to mate with a corresponding indentation 54 located on the bottom support member 13 of the frame 10. The mating of the tab members 52 with the indentations 54 allows the top support member 1 1 to be brought into a parallel relationship with the bottom support member 13 when the package 8 is in a closed position.

The tab members 52 are in a spaced apart relationship from the plane of the top support member 11 such that optional printed information (not shown) can be inserted and removably held in place between the tab members 52 and the top support member 11.

In certain embodiments, the bottom support member 13 has an inner edge 60 and an outer edge 62 which are in a substantially parallel and spaced apart relationship to the hinge means 40. The outer edge 62 extends from the bottom support member 13 in a direction toward the top support member 1 1 when the package 8 is in a closed position. The outer edge 60 defines an attaching means 64 at opposing ends or corners 65 of the edge 62 such that the bottom support member 13 is πraiingly secured to the top support member 1 1. It is to be understood that various types of attaching means 64 are useful with the present invention to prevent unwanted opening of the package 8. For example, many compact disc packages are opened by simultaneously squeezing or applying pressure or compression to the opposing corners 65 of the package 8 while lifting or rotating the top support member 11 about the hinge means 40 in a direction away from the bottom support member 13. in one preferred embodiment, the attaching means 64 can comprise a latching means 66 on one support member for engaging a receiving means 68 on the opposing support means, such as, for example, a post and hole friction fit. Fig. 3 shows the package 8 in a closed position.

Another embodiment of a package intended for use as an audio or video compact disc package 108 is shown in Fig. 4 in detail. The package 108 shown is designed to store a standard CD or DVD; however, it should be understood that video and/or ROM compact discs of any format can be used with the subject of the present invention. The package 108 shown in the figures includes a frame member 110. In a preferred embodiment the frame 1 10 is comprised of at least one recyclable or recycled material such as a durable lightweight thermoplastic material. The frame 1 10 is encased by a lightweight flexible sheath member 1 12, which is adhered to the frame 1 10 to form the package, in preferred embodiments, the sheath 112 is composed of a single layer of a material which readily accepts printed or graphic materials. In especially preferred embodiments, the material composing the sheath is of a high quality paperboard material.

The frame 1 10 of the package 108 of the present invention comprises a first or top support member 111 and a second or bottom support member 113. The top support member 111 has an outside surface 1 1 1 a and an inside surface 1 1 1 b (as best seen in Fig. 4b) and the bottom member 1 13 has an outside surface 1 13a and an inside surface 1 13b (as best seen in Fig. 4). In certain embodiments, the support members 11 1 and 113 have the standard outside dimensions designed for use storage of a standard audio or video CD or DVD. The frame 1 10 includes a plurality of open cut-out areas 1 14 which extend through the bottom support member 1 13. At least one open cut-out area

1 15 extends through the top support member 111. The cut-out areas 114 and 115 are designed to eliminate as much material from the package as possible, without negatively affecting the structural rigidity of the frame 110. The cut-out areas 114 in the bottom support member 113 define a structural support or retaining means 120 comprised of at least one, and preferably a plurality of radially extending tab members 121. As can be seen from the figures, the retaining means 120 is supported by at least one cross member 122 extending through the cut- out areas 114 generally in the plane of the bottom support member 1 13. While the embodiment shown has a plurality of the cross members 122 which extend in a generally perpendicular manner, it is to be understood that either fewer or more cross members 122 can provide the support for the retaining means 120. The bottom support member 113 defines raised areas or ridges

1 16 having a general shape that is complementary to the disc being stored. The bottom support member 113 further defines lower areas 1 18 adjacent the ridges 1 16 which have a general shape of the disc being stored. In certain embodiments, the ridges 1 16, the lower areas 1 18 and the cross members 122 have about the same thickness.

The top support member 111 has a perimeter defined by parallel extending sides 124 which are connected by corners 126 to a parallel extending inner edge 127 and an outer edge 128.

In certain embodiments, it is desired that the frame 1 10 be provided with at least two distinct thicknesses. This embodiment is partially shown in Fig. 4A where longitudinally extending sides 124a, corners 126a and edges 128a can have a first cross-sectional area or thickness of material that is comparable to that found in the "standard" commercial package. The second thickness or cross-sectional area of material of the remaining frame structure is designed to be thinner than the first thickness. In certain embodiments, it is contemplated that the second thickness can be about .014 to .018 mils thinner than the first thickness. The sides 124a, corners 126a and bottom edges 128a, which have the first thickness, are designed to have a thicker structure or cross-sectional area in order to provide the necessary strength, integrity and durability to the frame 1 10. In certain preferred embodiments, the difference in thickness between the sides 124a, corners 126a, bottom edges 128a, and the remainder or second thickness of the frame is approximately equivalent to the thickness of the sheath 1 12 which encompasses the frame member 1 10. The sheath 112 is bonded to the outer surfaces of the thinner first thicknesses or areas of the sides 124, corners 126 and edges 127 and 128 of the top support member 1 1 1. The sheath 112 is bonded to the outer surface of the lower areas 1 18 of the bottom support member 113. Thus, after the sheath 1 12 is bonded to the frame 1 10, there will be no exposed edges of the sheath 1 12 which could be subject to damage.

In certain embodiments, it is also desired that the frame 1 10 be provided with a third, still thinner thickness or cross-sectional areas than the second thickness. This embodiment is partially shown in Fig. 4B where the edge 128 is shown as an example of the thinner thicknesses of cross-sectional areas. It is to be understood that the parallel extending sides 124 and/or the longitudinally extend edges 127 and/or 128 of the top support member can define at least one or more reduced cross- sectional areas, generally designated as 128b in Fig. 4B. The third, thinner thickness can be present on either the outside surface 111a or the inside surface wall 1 1 1 b of the frame 1 10. In the embodiment shown in Fig. 4B, the third, inner thickness is shown as being on the outside surface 1 1 1a of the frame 1 10 such that, when the package 8 is assembled, the sheath 12 substantially covers the third thicknesses and the aesthetics of the package 108 remain pleasing and acceptable. However, it should be understood that in certain other embodiments, the third thicknesses can be formed on both the inside and outside surfaces or only on the inside surface of the frame 110.

The presence of the third, thinner thickness or areas, in certain embodiments, allows the frame 110 to be made with less material, thereby reducing both the manufacturing costs and the weight of the frame. The frame of the present invention could have one or more, and in certain embodiments, a plurality of reduced cross-sectional areas without degrading the appearance or diminishing the strength of the package 108. While not shown, it is to be understood that the bottom support member 113 can also have at least one or more third, thinner thicknesses or cross-sectional areas in, for example, the retaining means 120 and/or cross members 122.

It is to be further understood that the cross-sectional thickness or area of such thinner, third thicknesses can be as much as, in certain preferred embodiments, about one-half or less the thickness of the remaining, first and/or second thicknesses of the frame 110.

It is to be understood that, in certain embodiments, located about the periphery or perimeter of the thin portions of the frame (not shown) can be a plurality of up-raised energy director beads or areas (not shown) which are formed from the same thermoplastic material as the frame. The energy director beads are also utilized to add structural integrity to the frame and to provide additional surface area in which to bond the sheath to the frame, as described above.

In certain embodiments, the sheath 112 is coated on an interior surface 137 with a styrene film coating material or other product known to be compatible with the material of the frame 1 10. In one method of production, the sheath 1 12 is positioned over the frame 1 10 and ultrasonic vibrations are applied to the composite frame 110 and sheath 1 12. The ultrasonic vibrations "melt" or adhere the sides 124, corners 126, edges 127 and 128, and lower areas 1 18 (and in certain embodiments, the energy beads and/or sides 124a, corners 126a and edge 128a) and causes the material of the frame to blend with the coating material on the interior surface 137 of the sheath 112. The sheath 112 is bonded or welded to the outside surface of the frame 1 10 as the molten blend solidifies. Of course, other methods of adhering or bonding, such as adhesives, two-faced tape, hot melt gluing, or other means may be used in place of energy director beads and the ultrasonic weld technique and such methods are within the contemplated scope of the present invention.

In preferred embodiments, the sheath 1 12 is made of one layer of a suitably thick paperboard material which provides protection to the frame 1 10 and enhances the structural rigidity of the package 108. It has been surprisingly found that only one layer of a suitable thickness of the sheath material is needed to form a package 108 which meets both industry and consumer expectations. The sheath 112 of the present invention includes a top flap 130, a bottom flap 132, and a middle or center portion 134. The sheath 112 is patterned to fit on the frame member 110. The top flap 130 and the bottom flap 132 are preferably composed of solid material.

Graphics may be applied to both an exterior surface 136 and the interior surface 137 of the sheath 1 12 prior to application and bonding of the sheath 112 to the frame 1 10. It is to be understood that, due to the shape of the cut-out areas 114 and 1 15 of the frame 1 10, it is possible to display a printed material and/or graphics on the interior surface 137 of the sheath 1 12. This visible portion of the interior surface 137 provides a greatly expanded surface area in which the manufacturer can provide additional information, and in certain situations, allow the manufacturer to dispense with providing any printed material with the package. In various embodiments, the exterior surface 136 provides an impermeable barrier for protection from extreme environmental conditions, such as heat, humidity or physical stresses. Thus, after application and bonding of the sheath 112 to the frame 1 10, a composite package having graphics applied thereto is provided.

In preferred embodiments, the exterior surface 136 and/or interior surface 137 of the middle portion 134 are relatively flat so that the pri. d material can be readily displayed thereon. In the embodiment shown, the middle portion 134 of the sheath 112 acts as a spine and is defined by at least one fold or score line 138, and preferably, at least two parallel extending folds 138a and 138b which allow the sheath 1 12 to conform to the frame 1 10. The folds 138a and 138b are in at least adjacent, and preferably at substantially, the middle portion 134 of the sheath 1 12. The area adjacent the fold 138 (or an area between the folds 138a and 138b when two folds are present) defines a closed or hinged end 139 of the package 108. However, it is to be understood that, in preferred embodiments, the folds 138 are slightly off center since, in preferred embodiments, one support member is slightly larger than the opposing support member, such that the opposing support members can be brought into mating engagement, as described in detail below.

In certain embodiments, at least one end 132' of the bottom flap 132 on the sheath 1 12 can extend beyond an end of the bottom support member 113 of the frame 110. The end 132' defines at least one fold or score line 131 which is in a spaced apart relationship from end 132'. The end 132' is bent or folded at the fold 131 such that an inner surface 133 of the end 132' is adjacent the end of the bottom support member 113. Any suitable graphic materials can be printed on an exterior surface 135 of the end 132'.

It should be noted that, in preferred embodiments, the frame 1 10 includes the top support member 111 and the bottom support member 13 which are unconnected to each other. For example, the top support member 1 11 and the bottom support member 1 12 can be secured to the sheath 1 12 without any hinging means. That is, the middle portion 134 of the sheath 112 can act as a hinging means without compromising the integrity of the package 108. This elimination of the need for movable parts such as any plastic hinging means, reduces or eliminates the cost of the parts, the assembly or molding time required to make the parts, as well as the weight of the parts.

The package 108 constructed in accordance with the present invention usually is designed to have laterally extending edges or side walls 150 which extend from the top support member 1 11 in a direction toward the bottom support member 113 when the package 108 is in a closed position. The sidewalls 150 are generally constructed of a plastic material and in preferred embodiments are formed as an integral part of the frame 1 10. In certain embodiments, the sidewalls 150 can include at least one inwardly projecting tab member 152. It is to be understood that the frame 1 10 can be manufactured such that the tab members 152 can be easily molded whereby there are corresponding openings 152' on the outside surface 111a of the frame 110. The present invention provides for easy manufacturing of the package 108 since less complicated molding processes are required to form the tabs 152 with the adjacent openings 152'. The openings 152' are not visible when the frame 110 is covered by the sheath 112. In the embodiment shown in Fig. 4, the tab members 152 do not need to mate with any corresponding indentation located on the bottom support member 1 13 of the frame 110 since the thickness of the bottom support member 1 13 is sufficiently thin. There is no need for the tab member 152 to be brought into any mating engagement in order for the top support member 11 1 to be brought into a parallel relationship with the bottom support member 113 when the package 108 is in a closed position.

The tab members 152 are in a spaced apart relationship from the plane of the top support member 1 1 1 such that optional printed information (not shown) can be inserted and removably held in place between the tab members 152 and the top support member 11 1. In certain embodiments, the bottom support member 113 has an inner edge 160 and an outer edge 162 which are in a substantially parallel and spaced apart relationship. The outer edge 162 extends from the bottom support member 1 13 in a direction toward the top support member 11 1 when the package 108 is in a closed position. The outer edge 160 defines an attaching means 164 at opposing ends or corners 165 of the edge 162. The bottom support member 113 is matingly secured to the top support member 111 when the package 108 is in a closed position. It is to be understood that various types of attaching means 164 are useful with the present invention to prevent unwanted opening of the package 108. For example, many compact disc packages are opened by simultaneously squeezing or applying pressure or compression to the opposing corners 165 of the package 108 while lifting or rotating the top support member 1 1 1 about the hinge area 139 in a direction away from the bottom support member 113.

In one preferred embodiment the attaching means 164 can comprise a latching means 166 on one support member for engaging a receiving means 168 on the opposing support means, such as, for example, a post and hole friction fit. Referring now to the Fig. 5, another embodiment of a package intended for use as a compact disc package 208 is shown in detail. The package 208 shown is designed to store a standard CD or DVD; however, it should be understood that video and/or ROM compact discs of any format can be used with the subject of the present invention. The package 208 shown in the figures includes a frame member 210. In a preferred embodiment the frame 10 is comprised of at least one recyclable or recycled material such as a durable lightweight thermoplastic material. The frame 210 is encased by a lightweight flexible sheath member 212, which is adhered to the frame 210 to form the package. In preferred embodiments, the sheath 212 is composed of a single layer of a material which readily accepts printed or graphic materials. In especially preferred embodiments, the material composing the sheath is of a high quality paperboard material.

The frame 210 of the package 208 of the present invention comprises a first or top support member 21 1 and a second or bottom support member 213. The top support member 21 1 has an outside surface 211a and an inside surface 21 1 b and the bottom support member 213 has an outside surface 213a and an inside surface 213b. The frame 210 includes a plurality of open cut-out areas 214 extend through the bottom support member 213. At least one open cut-out area 215 extends through the top support member 21 1. The cut-out areas 214 and 215 are designed to eliminate as much material from the package as possible, without negatively affecting the structural rigidity of the frame 210. The cut-out areas 214 in the bottom support member 213 define a structural support or retaining means 220 comprised of at least one, and preferably a plurality of radially extending tab members 221. As can be seen from the figures, the retaining means 220 is supported by at least one support cross member 222 extending through the cut-out areas 214 generally in the plane of the bottom support member 213. While the embodiment shown has a plurality of the cross members 222 which extend in a generally perpendicular manner, it is to be understood that either fewer or more cross members 222 can provide the support for the retaining means 220.

The bottom support member 213 defines raised areas or ridges 216 having a general shape that is complementary to the disc being stored. The bottom support member 213 further defines lower areas 218 adjacent the raised ridge 216 which have a general shape of the disc being stored. In certain embodiments, the raised ridge 216, the lower areas 218 and the cross members 222 have about the same thickness.

The top support member 21 1 has a perimeter defined by parallel extending sides 224 which are connected by corners 226 to a parallel extending inner edge 227 and an outer edge 228. In the embodiment shown in Fig. 5, the frame 210 extends beyond the diameter of the disc to be stored, as defined by the raised areas or ridges 216. The bottom support member defines at least one or more additional cut-out areas 214' which extend through the bottom support member 213. The cut-out areas 214' are designed to eliminate as much material from the package as possible without negatively effecting the structural rigidity of the frame 210, while still allowing the package to have an increased length. The increased length allows the package 208 to readily be inserted into existing displays at the retail level. Further, the increased size in packaging allows additional graphic or other information to be provided to the end user. In the embodiment shown, the bottom portion 213 has at least one cross member 222' which extends through the cut out areas 214' generally in the plane of the bottom support member 213. While the embodiment shown depicts the cross-member 222' which extends in a generally perpendicular manner, is to be understood that either fewer or more cross-members 222' can provide support for the retaining means 220 and the bottom support member 213.

In certain embodiments, it is desired that the frame member 210 be provided with at least three distinct thicknesses, as discussed above with respect to Figs. 2A-2B and 4A-4B.

The sheath 212 is bonded to the thinner areas of the sides 224, corners 226 and edges 227 and 228 of the top support member 21 1. The sheath 212 is bonded to the outer surface of the lower areas 218 of the bottom support member 213. Thus, after the sheath 212 is bonded to the outer surfaces of the frame 210, there will be no exposed edges of the sheath 212 which could be subject to damage.

It is to be understood that the embodiment shown in Fig. 5 can also have located about the periphery or perimeter of the thin portions of the frame 210, a plurality of up-raised energy director beads or areas (not shown) which - ^re formed from the same thermoplastic material as the frame 210. The energy director beads are also utilized to add structural integrity to the frame and to provide additional surface area in which to bond the sheath to the frame, as described above.

In certain embodiments, the sheath 212 is coated on an interior surface 237 with a styrene film coating material or other product known to be compatible with the material of the frame 210, as discussed in detail above with respect to the other embodiments of the present invention.

In preferred embodiments, the sheath 212 is made of one layer of a suitably thick paperboard material which provides protection to the frame 210 and enhances the structural rigidity of the package 208. It has been surprisingly found that only one layer of a suitable thickness of sheath material is needed to form a package 208 which meets both industry and consumer expectations. The sheath 212 of the present invention includes a top flap 230, a bottom flap 232, and a middle or center portion 234. The sheath 212 is patterned to fit on the frame 210. The top flap 230 and the bottom flap 232 are preferably composed of solid material.

Graphics may be applied to both an exterior surface 236 and the interior surface 237 of the sheath 212 prior to application and bonding of the sheath 212 to the frame 210. It is to be understood that, due to the shape of the cut-out areas 214, 214' and 215 of the frame 210, it is possible to display printed material and/or graphics on the interior surface 234 of the sheath 212. The visible portion of the interior surface 237 provides a greatly expanded surface area which the manufacturer can provide additional information, and in certain situations, allow the manufacturer to dispense with providing any additional printed material with the package. In various embodiments, the exterior surface 236 provides an impermeable barrier for protection from extreme environmental conditions, such as heat, humidity or physical stresses. Thus, after application and bonding of the sheath 212 to the frame 210, a composite package having graphics applied thereto is provided.

In preferred embodiments, the exterior surface 236 and/or interior surface 237 of the middle portion 234 are relatively flat so that the printed material can be readily displayed thereon. In the embodiment shown, the middle portion 234 of the sheath 212 acts as a spine and is defined by at least one fold or score line 238, and preferably, at least two parallel extending folds 238a and 238b which allow the sheath 212 to conform to the frame 210. The folds 238 are in at least adjacent, and preferably at substantially, the middle portion 234 of the sheath 212. The area adjacent the fold 238 (or an area 239 between the folds 238a and 238b when two folds are present) defines a closed or hinged end 239 of the package 208. However, it is to be understood that, in preferred embodiments, the folds 238 are slightly off center since, in preferred embodiments, one support member is slightly larger than the opposing support member, such that the opposing support members can be brought into mating engagement, as described in detail below. in certain embodiments, at least one end 232 of the sheath 212 can extend beyond an end of the bottom support member 213 of the frame 210. The end 232' defines at least one fold or score line 231 which is in a spaced apart relationship from end 232'. The end 232' is bent or folded at the fold 231 such that an inner surface 233 of the end 232' is adjacent an end 213' of the bottom support member 213. Any suitable graphic or printed materials can be printed on an exterior surface 235 of the end 232'.

In certain embodiments, as shown in Figs. 5A and 5B, it is desired that an end 332' adjacent a fold 331 on a bottom flap 332 of a sheath 312 have a cross-sectional thickness that is less than the cross-sectional thickness of the remaining portion of the bottom flap 332. The end 332' can be skived or thinned to, in certain preferred embodiments, about one- half or less the thickness of the remaining portions of the bottom flap 332. The thinner area of the skived end 332' allows the end 332' to be readily bent or folded at the fold 331 and securely adhered to the end 213' of the frame 210 without creating any undesirable bulges or wrinkles. It is to be understood that the sheaths described in all embodiments can have skived ends to readily fold around the end of the frame.

It should be noted that, in preferred embodiments, the frame 210 includes the top support member 21 1 and the bottom support member 213 which are unconnected. For example, the top support member 211 and the bottom support member 212 can be secured to the sheath 212 without any hinging means. That is, the middle portion 234 of the sheath 212 can act as a hinging means without compromising the integrity of the package 208. This elimination of the need for movable parts such as any plastic hinging means, reduces or eliminates the cost of the parts, the assembly or molding time required to make the parts, as well as the weight of the parts.

The package 208 constructed in accordance with the present invention usually is designed to have laterally extending edges or side walls 250 which extend from the top support member 211 in a direction toward the bottom support member 213 when the package 208 is in a closed position. The sidewalls 250 are generally constructed of a plastic material and in preferred embodiments are formed as an integral part of the frame 210. In certain embodiments, the sidewalls 250 can include at least one inwardly projecting tab member 252 and opening 252', as described above with respect to the other embodiments.

The tab members 252 are in a spaced apart relationship from the plane of the top support member 211 such that optional printed information (not shown) can be inserted and removably held in place between the tab members 252 and the top support member 21 1. The bottom support member 213 has an inner edge 260 and an outer edge 262 which are in a substantially parallel and spaced apart relationship. The outer edge 262 extends from the bottom support member 213 in a direction toward the top support member 211 when the package 208 is in a closed position. The outer edge 260 defines an attaching means 264 at opposing ends or corners 265 of the edge 262. The Jttom support member 213 is matingly secured to the top support member 21 1 when the package 208 is in the closed position. It is to be understood that various types of attaching means 264 are useful with the present invention to prevent unwanted opening of the package 208. For example, many compact disc packages are opened by simultaneously squeezing or applying pressure or compression to the opposing corners 265 of the package 208 while lifting or rotating the top support member 21 1 about the hinge area 239 in a direction away from the bottom support member 213.

In one preferred embodiment the attaching means 264 can comprise a latching means 266 on one support member for engaging a receiving means 268 on the opposing support means, such as, for example, a post and hole friction fit.

The above descriptions of the video and audio package version of the present invention are meant to be illustrative in nature and are not intended to be solely limiting upon the scope and content of the following claims.

Claims

I CLAIM:

1. A composite package for storing an optically readable disc comprising, in combination: a frame member defining the shape of the disc, the disc being retained between a pair of opposed first and second support members, the support members defining a first area of thickness of material and defining a second area of thickness of material, the first area of thickness of material being greater than the second area of thickness of material, the first area of thickness of material providing the desired rigidity and durability for the package; and, a sheath member suitably adhered an outside surface of the frame member to encompass the first and second support members.

2. The package of claim 1 , wherein the sheath member comprises a single layer of a suitable flexible material.

3. The package of claim 2, wherein the sheath member comprises a paperboard material.

4. The package of claim 2, wherein the sheath member has graphics on at least one of an interior surface or an exterior surface of the sheath member.

5. The package of claim 1 , wherein the frame member comprises a thermoplastic material.

6. The package of claim 1 , wherein the sheath member is of a thickness that, when bonded to the second area of thickness of material of the frame member, provides a composite thickness of material that is substantially equivalent to the first thickness of material, whereby the sheath member is protected from premature wear.

7. The package of claim 1 , wherein the sheath member further includes at least a first fold adjacent a middle portion of the sheath member, wherein the fold defines a hinged end of the package.

8. The package of claim 6, wherein the sheath member has a first end and a second end, the sheath member defining at least a second fold adjacent the first end of the sheath member, the sheath member being bent or folded at the second fold whereby a portion of the first end of the sheath member is adjacent at least one end of the frame member.

9. The package of claim 8, wherein the portion of the first end of the sheath adjacent the end of the frame member has a cross-sectional area less than a cross-sectional area of a remaining portion of the sheath.

10. The package of claim 1 , wherein the sheath member has a surface area slightly smaller than a surface area of the frame member, wherein the sheath member is bonded to the frame member.

1 1. The package of claim 1 , wherein the support members each provide substantially one-half of the frame member.

12. The package of claim 1 , wherein the support members each provide substantially one-half of the frame member and extend beyond a diameter of the disc to be stored in the package.

13. The package of claims 11 , wherein a first end of the first support member is operatively connected to a first end of the second support member by at least one hinge means.

14. The package of claim 1 , wherein the first area of thickness includes at least one upraised bead sensitive to the application of ultrasound, wherein the upraised bead acts to bond the sheath member to the first area of thickness upon exposure to ultrasound.

15. The package of claim 1 , wherein the sheath member is bonded to the second area of thickness of the frame member by a solvent adhesive, by a heat application designed to adhere the sheath member to the frame member, or through exposure of the sheath member and the frame member to ultrasound waves.

16. The package of claim 1 , further including a means for removably attaching a second end of the first support member to a second end of the second support member.

17. The package of claim 16, wherein the attaching means includes a latching member on one support member for engaging a receiving member on the opposing support member to prevent unwanted opening of the package.

18. The package of claim 1 , wherein the material comprising the second area of thickness of at least one of the support members of the frame member defines at least one cut-out area where in the material is removed.

19. The package of claim 18, wherein the second area of thickness provides at least one planar surface having at least one third area of thickness which is less than the second area of thickness.

i 20. The package of claim 18, wherein at least one support member includes at least one cross member which extends across the cut out area to retain and support the disc on the frame member.