Binder
A system configured to hold a plurality of discs comprises a plurality of disc holders. The plurality of disc holders have a region with a snap-fit structure that is configured to receive a disc. The plurality of disc holders also have a plurality of hinges with protruding portions positioned along a disc holder binding edge. The plurality of disc holders comprise polystyrene. The system further comprises a flexible binder having a plurality of slots formed therein. The slots are positioned over the protruding portions on the disc holder binding edges. The flexible binder comprises at least polypropylene. The flexible binder is bonded to the plurality of disc holders using a heat treatment technique.
This application claims the benefit of U.S. Provisional Patent Application 60/842,335 (filed 5 Sep. 2006), the entire disclosure of which is hereby incorporated by reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENTNot Applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENTNot Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISCNot Applicable
BACKGROUND OF THE INVENTIONThe present invention relates generally to plastics manufacturing, and relates more specifically to a device capable of binding a plurality of plastic items together.
Plastic holders are often used in the packaging and storage of items such as compact discs (CDs), digital video discs (DVDs), memory cards, magnetic cards, radiofrequency identification cards and other items. For example, the jewel case is a common type of plastic holder that is used to package CDs and DVDs in a way that provides protection from dust, scratches and other types of damage. For applications where several items are to be packaged together, packaging systems have been developed to bind multiple plastic holders together. Such packaging systems are useful because they allow consumers to easily turn from one plastic holder to another while viewing the packaged items, much like the pages of a book are turned and viewed. To provide a specific example, a set of DVDs will often be packaged together, wherein each DVD in the set contains episodes from a different season of a television show. Providing the DVDs in plastic holders that are bound together like pages of a book allows a consumer to quickly turn the plastic holders and view the available DVDs.
BRIEF SUMMARY OF THE INVENTIONWhile conventional packaging systems allow multiple plastic holders to be bound together, such systems tend to include complex and/or fragile structures that do not provide adequate durability. For example, in a configuration wherein multiple plastic holders are coupled together using a snap-fit hinge, it is common for the plastic holders to break away or otherwise become separated from the snap-fit hinge. Likewise, plastic holders that are glued, taped, or are otherwise adhered to a binding element also suffer from limited durability, particularly since adhesives (a) tend not to bond well to many of the commonly-used plastics, and (b) tend to lose their adhesiveness over time and with repeated use. The durability of packaging systems is important, since one purpose of such systems is to provide continued protection for the packaged items even if the holder is handled roughly, and even after prolonged and repeated use. Based on the foregoing, Applicant has developed an improved durable binding system that is capable of holding multiple plastic holders together.
In one embodiment, a system configured to hold a plurality of discs comprises a plurality of disc holders. The plurality of disc holders have a region with a snap-fit structure that is configured to receive a disc. The plurality of disc holders also have a plurality of hinges with protruding portions positioned along a disc holder binding edge. The plurality of disc holders comprise polystyrene. The system further comprises a flexible binder having a plurality of slots formed therein. The slots are positioned over the protruding portions on the disc holder binding edges. The flexible binder comprises at least polypropylene. The flexible binder is bonded to the plurality of disc holders using a heat treatment technique.
In another embodiment, an apparatus comprises a plurality of trays. The plurality of trays have a region that is shaped to removably hold a packaged item therein. The plurality of trays also have a side. The plurality of trays are stacked such that the sides of the plurality of trays are positioned adjacent to each other. The plurality of trays also have a protruding portion positioned along and extending from the side. The apparatus further comprises a binder that is bonded to the sides of the plurality of trays. The binder has a plurality of openings formed therein. The plurality of openings receive the protruding portions from the plurality of trays.
In another embodiment, a method for manufacturing an apparatus capable of holding a plurality of media discs comprises positioning a first holding tray adjacent to a second holding tray. A binding edge of the first holding tray is positioned adjacent to a binding edge of the second holding tray. The first and second holding trays each include a plurality of protruding portions extending from the respective binding edges of the first and second holding trays. The first and second holding trays comprise a first material. The method further comprises placing a binder on the first and second holding trays. The binder includes a plurality of openings that are configured to receive the plurality of protruding portions extending from the binding edges of the first and second holding trays. The binder comprises a second material. The method further comprises performing a heat treatment technique, so as to secure the binder to the first and second holding trays.
In another embodiment, an apparatus comprises a disc holder having a region with a snap-fit structure that is configured to removably receive a disc therein. The disc holder comprises a first material. The apparatus further comprises a plurality of protruding portions positioned along a binding edge of the disc holder. The protruding portions include a riveted tab portion. The protruding portions comprise the first material. The apparatus further comprises a flexible binder having a plurality of openings formed therein. The flexible binder is comprised of a second material that is different than the first material. The flexible binder is positioned onto the disc holder such that the protruding portions are at least partially within the openings, and such that the riveted tab portions at least partially extend over an exterior surface of the flexible binder.
Example embodiments of the binding systems disclosed herein are illustrated in the accompanying drawings, which are for illustrative purposes only. The drawings comprise the following figures, in which like numerals indicate like parts.
In accordance with the foregoing, packaging systems have been developed to bind multiple plastic holders together. Several example embodiments of such binding systems are disclosed herein. These systems are generally useful for applications where a plurality of holders are to be held together in a way that allows users to easily turn from one holder to another while viewing items held in the holders. While the binding systems disclosed herein are particularly useful for binding together plastic trays used to hold digital media such as CDs and DVDs, such systems are also useful for binding together (a) plastic trays configured to hold other items, such as rare coins, photographic slides or silverware, and (b) types of holding apparatuses other than plastic trays, such as holders comprising materials other than plastic, and plastic apparatuses other than trays.
In view of the foregoing, the terms “holder” and “holders” are used generically herein to refer to both (a) apparatuses conventionally described as “holders” or “trays” and (b) other apparatus that are capable of holding items, and that are typically kept together using a binder. Likewise, the terms “packaged item” and “packaged items” are used herein to refer generally to items held using a “holder”, and are not limited to digital and/or optical media such as CDs and DVDs.
The holder 100 includes a central region 102 configured to hold a packaged item, such as a CD or a DVD. The details of the means used to secure the packaged item in the central region 102 are not illustrated for the purposes of clarity, and because the binding systems disclosed herein are independent of such details. For example, the holder 100 optionally includes recessed areas and/or protrusions that are used to removably snap items, such as optical media, thereon.
Still referring to
In an example embodiment, a plurality of holders, such as the four holders 100 illustrated in
In certain embodiments, the binder 116 comprises a plastic material having an increased flexibility as compared to the material used to form the holders 100. For example, in one embodiment the binder 116 comprises a polystyrene-based material or a polypropylene-based material having increased flexibility as compared to the holder 100, although other materials are used in other embodiments and optionally in the present embodiment. Optionally, the binder 116 and the holder 100 have the same or similar melting points.
As indicated, in an example embodiment the binder 116 is configured to be mounted into the recessed hinges 104, such that the protruding portions 108 fit into the slots 118. For example,
In an example embodiment, the binder 116 is snap-fit into the recessed hinges 104, for example by fitting the binder 116 around, and seating the binder 116 into, the tabs 114 on the protruding portion 108. Optionally, holders 100 that are bound together with a binder 116 are further exposed to a heat treatment process that is sufficient to slightly or significantly melt or soften the material comprising the protruding portions 108 of the holders. In such embodiments, the thermally affected protruding portions 108 deform to slightly or significantly spread over the exterior surface 120 of the binder 116, thereby making it more difficult for the binder 116 to be later removed from the recessed hinges 104 and/or the protruding portions 108. Optionally, a compressive force is applied to the protruding portions 108 during the heat treatment process, thereby further facilitating their physical deformation over the exterior surface 120 of the underlying binder 116. In this example process, the material comprising the holder 100 and the material comprising the binder 116 are not intermixed.
One example heat treatment process is an ultrasonic welding technique, wherein focused ultrasonic energy is used to generate a region of elevated temperature. Other heat treatment processes are used in addition or instead; example heat treatment processes include, but are not limited to, plastic welding, hot-plate welding, spin welding, and vibration welding, and laser welding. In an example embodiment, the heat treatment process is applied only to a localized portion of the holder 100, such as only to the protruding portions 108, thereby reducing the likelihood of causing thermal damage to other portions of the holder 100.
In an example heat treatment process, the protruding portions 108 are subjected to a compressive force and are exposed to a temperature that is preferably between about 190° C. and about 250° C., that is more preferably between about 200° C. and about 240° C., and that is most preferably between about 210° C. and about 230° C. The period of temperature exposure is preferably between about 0.5 second and about 5 seconds, is more preferably between about 1 second and about 4 seconds and is most preferably between about 1.5 seconds and about 3 seconds. In an example embodiment, the protruding portions 108 are subjected to a compressive force and are exposed to an elevated temperature more than once, such as two times, three times, or four or more times. The protruding portions 108 are subjected to a compressive force that is preferably between about 25 N and about 55 N, that is more preferably between about 30 N and about 50 N, and that is most preferably between about 34 N and about 44 N. Other parameters (for example, thermal energy sources, temperatures, exposure times, compressive forces) are used in other embodiments.
Optionally, in addition or instead, the binder 116 is secured in the recessed hinges 104 using a plastic welding technique, which is one example type of heat treatment process. Plastic welding techniques are particularly useful for forming a strong bond between components comprised of similar or identical materials. Use of such a technique advantageously helps secure the binder 116 to the holder 100, thereby increasing the durability of the finished assembly, and decreasing the ease at which the binder 116 can be removed from the recessed hinge 104. Specifically, use of a plastic welding technique creates a chemical intermixing of the material comprising the holder 110 and the material comprising the binder 116. Example plastic welding techniques that are usable to bond the binder 116 to the holder 100 include, but are not limited to, ultrasonic welding, hot-plate welding, spin welding, and vibration welding, and laser welding. Regardless of the particular technique used, plastic welding can advantageously provide a bond between the binder 116 and the holder 110 that is significantly more durable than the bond provided by a simple snap-fit configuration or an adhesive joint.
In an example binding process, the plurality of holders 100 to be bound are held together in a clamp. A binder 116 is then placed in the corresponding recessed hinge 104 on the bound edge 106 of the holder 100. As disclosed herein, in certain embodiments one binder 116 is fitted into one recessed hinge 104, while in other embodiments multiple binders 116 are fitted into multiple recessed hinges 104. A heat treatment process is then used to cause the protruding portions 108 to slightly or significantly deform/change shape and overlay or spread over some or all of the exterior surface 120 of the binder 116. Optionally, in addition or instead, a plastic welding technique is used to heat, soften and/or melt the binder 116. Depending of the type of heat treatment process used, thermal energy is generated ultrasonically, using infrared light, using a laser, using a hot plate, using a solvent, using a combination of these techniques, or otherwise. The thermal energy causes the binder 116 to become welded onto and optionally insolubly connected to the holder 100. Optionally, the holder 100 is also heated, softened, and/or melted during the heat treatment process. Optionally, pressure is applied to the binder 116 during the heat treatment process to press the binder 116 into the recessed hinge 104. In an example embodiment, after the heat treatment process or processes are complete, the holder 100 is fixedly bound to the binder 116. Yet, owing to the flexibility of the binder 116, it, is still possible to open and turn the bound holders 100 like the pages of a book, as similarly described herein. This configuration advantageously allows a user to quickly and easily turn the holders 100 and view packaged items held therein.
One example machine suitable for conducting the heat treatment processes described herein is GuoLin Model GL-8000KTC, available from Foshan Nanhai GuoLin Mechanics & Electrics High-Frequency Equipment Factory (Foshan City, Guangdon Province, China), although other machines are used in other embodiments. In an example heat treatment process using this particular machine, the components to be bonded together are pressed together and are exposed to a temperature that is preferably between about 190° C. and about 250° C., that is more preferably between about 200° C. and about 240° C., and that is most preferably between about 210° C. and about 230° C. The period of temperature exposure is preferably between about 0.5 second and about 5 seconds, is more preferably between about 1 second and about 4 seconds and is most preferably between about 1.5 seconds and about 3 seconds. In an example embodiment, the components to be bound are pressed together and are exposed to an elevated temperature more than once, such as two times, three times, or four or more times. The components are pressed together using a force that is preferably between about 25 N and about 55 N, that is more preferably between about 30 N and about 50 N, and that is most preferably between about 34 N and about 44 N. Other parameters (for example, thermal energy sources, temperatures, exposure times, forces) are used in other embodiments.
Optionally, a cover (for example, comprising paper stock, plastic, and/or other material) is glued, taped, or otherwise fixed over all or a portion of the hinged side and/or over all or portions of the two end holders (for example, the top and bottom holders illustrated in
In modified embodiments, the holder does not include a recessed hinge, in which case the binder is affixed directly to the edge of the holder 100. An example embodiment using such a configuration is illustrated in
The modified embodiment illustrated in
The binding system illustrated in
The holders 100 illustrated in
Specifically,
Still referring to the example embodiment illustrated in
The structure of the binder 316 also advantageously imparts additional flexibility to the binder 316. For example, the presence of the slots 318 increases the flexibility of the binder 316. Furthermore, by varying the relative thickness of the binder 316 and the slots 318, it is possible to further increase the flexibility of the binder 316. For example,
In an example embodiment, the slots 318 have a varying width, with a narrower portion 324 located adjacent to an interior surface 326 of the binder 316, the interior surface 326 being configured to be positioned adjacent to the recessed shelf 310 of the holder 300. A wider portion 328 of the slots 318 is located adjacent to an exterior surface 330 of the binder 316, the exterior surface 330 located opposite the interior surface 326. This shape facilitates mating of the relatively narrow protruding portion 308 into the narrower portion 324 of the slot 318, and the relatively wide riveted tab 314 into the wider portion 328 of the slot 318. However, in other embodiments the slots 318 have a substantially constant width, such that the walls of the slots 318 and substantially linear, and form substantially right angles with the interior surface 326 and the exterior surface 330 of the binder 316.
Regardless of the particular configuration of the binder 316 and the riveted tabs 314 that extend from the protruding portions 308 of the hinges 304, in one embodiment the binder 316 is dimensioned to sit completely within the recessed hinge 304. In this configuration, the exterior surface 330 of the binder 316 is flush with the bound edge 306 of the holder 300. This configuration advantageously allows the dimensions of the holder 300 to be substantially unaffected by the presence of the binder 316. In other embodiments, the binder 116 is dimensioned to be recessed with respect to the bound edge 306, or is dimensioned to protrude from the bound edge 306. Likewise, the riveted tabs 314 are configured to extend out of the slots 318 in certain embodiments, while in other embodiments the riveted tabs 314 are configured to be flush with the binder exterior surface 330. The particular relative dimensions and shapes of the binder and the hinges are selected to provide a secure connection between the binder and the plurality of holders; this connection is optionally further secured by using a plastic welding technique.
In certain embodiments, the riveted tabs 314 extend out of the slots 318 formed in the binder 316. This configuration advantageously facilitates the deformation of the material comprising the riveted tabs 314 during a heat treatment process, such as one of the heat treatment processes disclosed herein. Specifically, the presence of the protruding riveted tab 314 provides additional plastic material to flow over and mechanically secure the binder 316, thus providing a particularly strong and durable bond between the holders 300 and the binder 316.
For example,
As set forth herein, the number of slots, or paired slots, provided in the binder depends on the number of holders which the binder is configured to bind together. For example,
A cover is optionally affixed to one or more of the holders. For example,
While the foregoing detailed description discloses several embodiments of the present invention, it should be understood that this disclosure is illustrative only and is not limiting of the present invention. It should be appreciated that the specific configurations and operations disclosed can differ from those described above, and that the methods described herein can be used in contexts other than binding multiple trays together in a way that allows the trays to be turned like the pages of a book.
Claims
1. A system configured to hold a plurality of discs, the system comprising:
- a plurality of disc holders having a region with a snap-fit structure that is configured to receive a disc, the plurality of disc holders also having a plurality of hinges with protruding portions positioned along a disc holder binding edge, wherein the plurality of disc holders comprise polystyrene; and
- a flexible binder having a plurality of slots formed therein, the slots being positioned over the protruding portions on the disc holder binding edges, wherein the flexible binder comprises at least polypropylene, and wherein the flexible binder is bonded to the plurality of disc holders using a heat treatment technique.
2. The system of claim 1, wherein the heat treatment technique is an ultrasonic welding technique that causes a portion of the protruding portions to extend over an exterior surface of the flexible binder.
3. The system of claim 1, wherein the polystyrene has a greater flexibility than the polypropylene.
4. The system of claim 1, wherein each of the plurality of disc holders includes two hinges, the two hinges being positioned on opposite sides of the snap-fit structure.
5. The system of claim 1, wherein the snap-fit structure is configured to receive at least one of a compact disc or a digital video disc.
6. The system of claim 1, wherein each of the plurality of hinges includes a plurality of protruding portions.
7. The system of claim 1, wherein the protruding portions extend from a recessed shelf formed along the disc holder binding edge, such that the protruding portions do not extend beyond the disc holder binding edge.
8. The system of claim 1, wherein:
- the protruding portions extend from a recessed shelf formed along the disc holder binding edge, such that the protruding portions do not extend beyond the disc holder binding edge; and
- the flexible binder has a thickness less than or equal to a depth of the recessed shelf, such that the flexible binder does not extend beyond the disc holder binding edge when the flexible binder is bonded to the plurality of disc holders.
9. The system of claim 1, wherein the flexible binder includes a hinge portion located between adjacent slots, wherein the hinge portion has an increased flexibility as compared to other portions of the flexible binder.
10. The system of claim 1, further comprising a cover affixed to at least the binding edges of the plurality of holders.
11. The system of claim 1, further comprising a multi-panel cover that includes a first panel that is not directly affixed to any of the plurality of holders, and that includes a second panel that is coupled to at least one of the plurality of holders.
12. The system of claim 1, further comprising a multi-panel cover, wherein a selected one of the plurality of holders has a plurality of panels coupled thereto.
13. The system of claim 1, further comprising a cover affixed to at least one of the plurality of holders.
14. An apparatus comprising:
- a plurality of trays, the plurality of trays having: a region that is shaped to removably hold a packaged item therein, a side, wherein the plurality of trays are stacked such that the sides of the plurality of trays are positioned adjacent to each other, and a protruding portion positioned along and extending from the side; and
- a binder that is coupled to the sides of the plurality of trays, the binder having a plurality of openings formed therein, wherein the plurality of openings receive the protruding portions from the plurality of trays.
15. The apparatus of claim 14, wherein the side is a binding edge.
16. The apparatus of claim 14, wherein the binder is bonded to the sides of the plurality of trays by intermixing a material comprising the plurality of trays and a material comprising the binder.
17. The apparatus of claim 14, wherein the binder is bonded to the sides of the plurality of trays by deforming the protruding portion such that the protruding portion at least partially extends over an exterior surface of the binder.
18. The apparatus of claim 14, wherein the binder has sufficient flexibility so as to allow a selected one of the plurality of trays to be rotated by at least about 90° with respect to an adjacent tray.
19. The apparatus of claim 14, further comprising a tab that extends in multiple dimensions from the protruding portion.
20. The apparatus of claim 14, further comprising a head that extends in at least one direction from the protruding portion.
21. The apparatus of claim 14, further comprising a head that extends in multiple dimensions from the protruding portion, wherein the plurality of openings have a wider portion configured to receive the head, and a narrower portion configured to receive the protruding portion.
22. The apparatus of claim 14, wherein the plurality of trays comprise a first material, and the binder comprises a second material that has a greater flexibility than the first material.
23. The apparatus of claim 14, wherein the plurality of trays comprise at least polystyrene, and wherein the binder comprises at least polypropylene.
24. The apparatus of claim 14, wherein:
- the plurality of trays comprise a first material; and
- the binder comprises a second material that has a greater flexibility than the first material.
25. The apparatus of claim 14, wherein at least one of the plurality of openings is a slot.
26. The apparatus of claim 14, further comprising a cover affixed to the sides of the plurality of trays.
27. The apparatus of claim 14, further comprising a cover affixed to at least one of the plurality of trays.
28. The apparatus of claim 14, wherein the apparatus includes at least two spaced apart binders.
29. The apparatus of claim 14, wherein the apparatus includes at least three spaced apart binders.
30. A method for manufacturing an apparatus capable of holding a plurality of media discs, the method comprising:
- positioning a first holding tray adjacent to a second holding tray, wherein a binding edge of the first holding tray is positioned adjacent to a binding edge of the second holding tray, wherein the first and second holding trays each include a plurality of protruding portions extending from the respective binding edges of the first and second holding trays, and wherein the first and second holding trays comprise a first material;
- placing a binder on the first and second holding trays, wherein the binder includes a plurality of openings that are configured to receive the plurality of protruding portions extending from the binding edges of the first and second holding trays, and wherein the binder comprises a second material; and
- performing a heat treatment technique, so as to secure the binder to the first and second holding trays.
31. The method of claim 30, wherein:
- the first material and the second material are the same; and
- the heat treatment technique causes intermixing of the first and second materials.
32. The method of claim 30, wherein:
- the first material is polystyrene;
- the second material is polyethylene; and
- the heat treatment technique at least partially deforms the plurality of protruding portions, such that the plurality of protruding portions at least partially extend over an exterior surface of the binder.
33. The method of claim 30, wherein the heat treatment technique is an ultrasonic welding technique.
34. The method of claim 30, wherein the heat treatment technique further comprises heating the first material and the second material to a temperature between about 200° C. and about 240° C. while pressing the first material and the second material together.
35. The method of claim 30, wherein each of the plurality of protruding portions includes a riveted tab that extends in multiple dimensions from the protruding portion.
36. The method of claim 30, wherein the second material has a flexibility that is greater than a flexibility of the first material.
37. The method of claim 30, wherein the binder includes a hinge portion positioned between adjacent openings of the plurality of openings, wherein the hinge portion has an increased flexibility as compared to other portions of the binder.
38. The method of claim 30, wherein at least one opening is a slot.
39. The method of claim 30, the method further comprising affixing a cover to at least one binding edge.
40. The method of claim 30, the method further comprising affixing a cover to at least one of the first and second holding trays.
41. An apparatus comprising:
- a disc holder having a region with a structure that is configured to removably receive a disc therein, the disc holder comprising a first material;
- a plurality of protruding portions positioned along a binding edge of the disc holder, wherein the protruding portions include a riveted tab portion, and wherein the protruding portions comprise the first material; and
- a flexible binder having a plurality of openings formed therein and being comprised of a second material that is different than the first material, the flexible binder being positioned onto the disc holder such that the protruding portions are at least partially within the openings, and such that the riveted tab portions at least partially extend over an exterior surface of the flexible binder.
42. The apparatus of claim 41, wherein the first material is polystyrene and the second material is polypropylene.
43. The apparatus of claim 41, further comprising a cover that is affixed to the disc holder.
44. The apparatus of claim 41, further comprising a cover that is affixed to at least two side of the disc holder.
45. The apparatus of claim 41, wherein the first material has a lower melting temperature than the second material.
46. The apparatus of claim 41, further comprising a plurality of disc holders having protruding portions that are coupled to the flexible binder.
47. The apparatus of claim 41, wherein the snap-fit structure is configured to receive at least one of a compact disc and a digital video disc.
48. The apparatus of claim 41, wherein the protruding portions extend from a recessed shelf formed along the disc holder binding edge.
Type: Application
Filed: Nov 10, 2006
Publication Date: Mar 6, 2008
Inventor: Ara Alan Sarkis Sabounjian (Stevenson Ranch, CA)
Application Number: 11/598,217
International Classification: B65D 85/57 (20060101); B65D 85/00 (20060101);