Abstract: The invention provides a vacuum formed cassette album having front and rear covers connected by a spine. The covers and spine are formed from a stiff, self-supporting thermoformed tray sheet extending the height and breadth of both the front and rear covers and across the spine area. A soft cover sheet, formed for example from supple plastic, is sealed to the tray sheet along its edges. A pair of parallel, vertically disposed, laterally spaced apart vacuum formed channel-form hinges are provided in the tray sheet at the edges of the spine and extending to the top and bottom edges of the tray sheet to define fold lines between the spine and the covers. The channel-form hinges are substantially uncompressed and are of uniform thickness throughout. Between the channels in the spine area is an elevated rectangular plateau defining a box-like frame to help keep the spine flat. One cover has tabs that extend into recesses within the other cover.

Abstract: A two-ply, book-style album comprises an inside tray sheet (12) and an outside cover sheet (14). The sheets (12, 14) are preferably formed from high-density polyethylene, and are thermally heat sealed together via a peripheral seal (34) and spine rules (36). The spine rules are formed into the front or obverse surface of the inside tray sheet (12) to define living hinges. An apparatus (70) and method for automatically manufacturing the albums (10) is also disclosed.

Abstract: A composite thermoformed cassette album or cover is described in the style of a book having a front and rear cover with a connecting spine between them. The album is formed from a base or backing sheet of relatively stiff material which extends throughout the width and breadth of the front and rear covers and through the spine area. It includes a thermoformed tray on the rear cover to hold the cassette. Soft vinyl sheet material is laminated over the outside surface of the stiff plastic sheet. A soft front cover liner laminated to the inside of the front cover includes a medial spine extension that extends throught the spine area. The soft plastic encapsulates the ridged plastic in a 3 layer laminate throughtout a pair of parallel hinges thereby prolonging their life.

Abstract: A two-ply, book-style album (10) comprises an inside tray sheet (12) and an outside cover sheet (14). Sheets (12 and 14) are preferably formed of high-density polyethylene, and are thermally heat-sealed together by means of a peripheral seal (34) and spine rules (36). The spine rules (36) include longitudinal grooves (38) formed to a substantial depth into the front surface of the inside tray sheet (12) in order to define living hinges which provide a roundish, less square spine of more pleasing appearance.