Pop-up package assembly for a flat product and method of packaging

Abstract

Method and apparatus for packaging flat products such as a computer disk into a package assembly of sheet material wherein the sheet material folds closed into a two dimensional configuration having a thin lateral profile or folds open into a three dimensional self supporting display stand. The method of packaging comprises the steps of providing a single continuous web of sheet material having two horizontally oriented columns defining first and second major panels separated by a vertical slit line; forming sub-panels in the first major panel with the sub-panels separated by at least one centrally located vertically extending score or perforation line; forming sub-panels in the second major panel with a plurality of parallel spaced vertically extending score or perforation lines for separating each of the sub-panels in the second major panel; applying adhesive to each of the major panels to form linear parallel lines of adhesive on the first of major panel extending vertically down the first major panel and to form an array of adhesive lines on the second major panel at a location adjacent to the vertical slit line separating the first major panel from the second major panel; separating the first major panel from the second major panel along said vertical slit line; folding the second major panel over the first major panel such that at least the two outer sub-panel in the second major panel furthest from the slit line overlies said centrally located score or perforation line in said first major panel without causing any adherence between said outer sub-panels and the first major panel; folding over said two outer sub-panels over score or perforation lines to form a pocket or flap between an outer sub-panel and one of the other previously folded sub-panels for the placement of a flat product; folding the sub-panels of the first and second major panel into a folded over assembly forming a three dimensional configuration when folded open and forms a substantially two dimensional configuration when folded closed; and cutting the web transversely to form a plurality of package assemblies one for each flat product.

Description

BACKGROUND OF THE INVENTION

This invention relates to a pop-up-package assembly of sheet material and method of packaging a flat product such as a compact disc (“CD”) digital video disc (“DVD”) a credit card or the like into a closed package assembly having a thin lateral profile which opens to form a three dimensional stand for the product.

The pop-up-package of the present invention is designed such that the flat product can be incorporated into the package during assembly to form a closed package assembly possessing a thin lateral profile for placement of the closed package assembly in a printed publication such as a magazine which when opened forms a three dimensional pop-up-stand for display and removal of the flat product. The flat product is only partially embedded in the package assembly such that when the package assembly is opened the product is readily removable from the pop-up-stand.

Other advantages of the invention will become apparent from the following description when read in conjunction with the drawings of which:

DESCRIPTION OF THE DRAWINGS

FIG. 1 and FIG. 1(a) represent, in combination, a schematic perspective view of a preferred method for forming the pop-up-package assembly of the present invention with FIG. 1(a) representing a continuation of FIG. 1 with each of the Figures to be connected to one another as indicated by the arrows;

FIGS. 2a,2b and 2c are perspective views illustrating the folding sequence for forming of the pop-up-package of the present invention;

FIGS. 3a, 3b, 3c and 3d are perspective views illustrating the assembled pop-up-package of the present invention in the opened position with the flat product illustrated using dotted lines; and

FIG. 4 is a perspective view showing the pop-up-package of the present invention for a CD or DVD in a partially closed position.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to FIG. 1 and FIG. 1a which schematically illustrates a preferred method for assembling the pop-up-package assembly 10 of the present invention as shown in FIG. 4. A single continuous web of preferably paper 11 or any other conventional sheet material including cardboard or even plastic having two major linear panels (horizontally oriented columns), hereafter defined as major panel 1 and major panel 2, is shown in FIG. 1 for processing into a pop-up-package assembly 10 as is shown in FIG. 4. Major Panel 1 and major Panel 2 each contain sub-panels, which are hereafter defined as sub-panels 1a, 1 b, for major Panel 1 and sub-panels 2a, 2b, 2c, 2d and 2e for major Panel 2. The sub-panels 1a and 1b are separated by a score or perforation line 12 and the sub-panels 2a, 2b, 2c, 2d and 2e are separated from one another by score or perforation lines 13a, 13b 13c and 13d. The single continuous paper web 11 is fed from a paper web supply roll (not shown) by a conventional feed mechanism (not shown) past a conventional fixed slitting device (not shown) so as to separate the major Panels 1 and 2 along a press or slit line 14. Prior to slitting, an adhesive, preferably of the spline glue type, is applied to Major Panel 1 to form three linear parallel lines of adhesive 15, 16 and 17 which respectively extend vertically down the panel. In the same manner similar adhesive is applied on sub-panel 2a of Major Panel 2 using e.g., a flexographic or equivalent technique to form an array of glue lines 18 which define a geometrical space in which the flat product, such as a CD, DVD, credit card or other such substantially flat product may be placed to at least partially surround, or contain the flat product. It should be understood that the web of paper 11 may be printed upon in a conventional manner before or during the assembly procedure. The printing operations do not form a part of the present invention and will not hereafter be discussed.

Panel 2 is overlaid upon Panel 1 using e.g. a conventional ribbon-diverting tool such as a displacement bar assembly (not shown) such that Panel 2 is caused to overlay Panel 1. The overlaying of Panel 2 onto Panel 1 is illustrated in FIG. 1 at the bottom portion thereof. It is important that Panel 2 overlay Panel 1 to achieve correct overlaying of the perforations in a suitable manner such that the middle perforation line 13b on Panel 2 directly overlays the line of perforations 12 in Panel 1. Alternatively, the overlaying of perforation lines may be accomplished by employing a single deep perforation through the overlaid pair of major panels 1 and 2 thereby causing coincidence along the appropriate center line on Panel 2 with the line of perforations 12 on Panel 1. Once Panel 2 is folded over Panel 1, the adhesive lines 15, 16 and 17 previously applied to Panel 1 attach to the underside of Panel 2 wherein a first line of adhesive is attached to the underside of sub-panel 2b, and both the second and third lines of adhesive are attached to the underside of sub-panel 2c. Following this procedure, sub-panels 2d and 2e are not directly adhered to Panel 1 and may thereupon be caused to fold on their lines of perforations (or score lines) by means of such conventional apparatus as a “plow folder.”

Subsequent to folding panel 2e, the flat product such as a compact disc (CD) or other flat object is placed on panel 2a, as is shown in FIG. 1a with the CD positioned to avoid contact both with the previously applied adhesive and the interior edge of panel 2a. It may be desirable to have a fugitive adhesive spot applied prior to placing the flat product in order to prevent its movement during the following folding actions and web travel. Such fugitive adhesive does not affect the required properties of CD's or credit cards. Alternatively or additionally, a static charge is applied to the panel 2a surface to prevent object movement.

Thereafter sub-panels 1b and 2c are folded over in combination utilizing their superimposed perforations (or scores). The end result as shown in FIGS. 3a-3d and FIG. 4 is a closed package containing the flat product tucked in a pocket or flap 20 formed between sub-panel 2b and 2d as shown in FIG. 3a-3d. It is noted that sub-panel 2b remains non-adhered while sub-panel 2a becomes adhered to what had been the underside of the previously folded sub-panel 2d.

It should further be noted that, if desired, a third major panel (not shown) may be used and placed adjacent to Panel 1, to constitute a wider starting web than as described above to provide a secondary cover and additional print area. In addition, a wider Panel 1 can serve to provide a “tag” extension suitable for binding into a magazine, instruction manual and similar bound publications. A line of perforations in such a “tag” parallel to the binding will permit removal of the pop-up package from the binding.

Claims

1. A method of packaging flat products such as a computer disk into a package assembly of sheet material which when closed possesses a thin lateral profile and when opened forms a three dimensional display stand comprising the steps of:

providing a single continuous web of material having two horizontally oriented columns defining first and second major panels having a vertical slit line separating the first major panel from the second major panel;

forming sub-panels in the first major panel with at least one vertically extending score or perforation line centrally located for separating the sub-panels;

forming sub-panels in the second major panel with a plurality of parallel spaced vertically extending score or perforation lines for separating each of the sub-panels in the second major panel;

applying an adhesive to each of the major panels to form linear parallel lines of adhesive on the first of major panel extending vertically down the first major panel and to form an array of adhesive lines on the second major panel at a location adjacent to the vertical slit line separating the first major panel from the second major panel;

separating the first major panel from the second major panel along said vertical slit line;

folding the second major panel over the first major panel such that at least the two outer sub-panel in the second major panel furthest from the slit line overlies said centrally located score or perforation line in said first major panel without causing any adherence between said of outer sub-panels and the first major panel;

folding over said two outer sub-panels over score or perforation lines to form a pocket or flap between an outer sub-panel and one of the other previously folded sub-panels for the placement of a flat product;

folding the sub-panels of the first and second major panel into a folded over assembly which remains in a three dimensional configuration when the assembly is folded open and forms a substantially two dimensional configuration when the assembly is folded closed; and

cutting the web transversely to form a plurality of package assemblies one for each flat product.

2. A method as defined in claim 1 wherein the second major panel is folded over the first major panel such that the center of said second major panel overlies said centrally located score or perforation line in said first major panel.

3. A method as defined in claim 1 wherein the second major panel is folded over the first major panel so as to cause substantial alignment of either the center of the second major panel with the centrally located score or perforation line in said first major panel or between one of said plurality of vertically spaced score or perforation lines in said second major panel and the centrally located score or perforation line in said first major panel.

4. A method as defined in claim 2 wherein said array of adhesive lines on the second major panel lie in a horizontal direction and/or at acute angles thereto.

5. A method as defined in claim 2 further comprising forming at least one fugitive adhesive spot in said pocket or flap in which the product is placed for preventing movement of the product.

6. A method as defined in claim 2 further comprising adding a third major panel to the continuous web of material forming the first and second major panels to constitute a wider starting web and to provide a tag extension suitable for binding the package into a bound publication such as a magazine.

7. A method as defined in claim 6 further comprising adding a line of perforations in such tag extension parallel to the binding to permit removal of the packaged assembly from the bound publication.

8. A pop-up-package assembly of sheet material for a flat product such as a computer disk for storing the flat product in the package assembly comprising a plurality of major panels each including sub-panels and an array of lines of adhesive dispersed to permit the panels when folded over to adhere for forming a substantially two dimensional closed configuration having a thin lateral profile and to open into a self supporting configuration defining a three dimensional display stand for the stored product.

9. A pop-up-package assembly of sheet material as defined in claim 8 wherein the package assembly of sheet material comprises:

a first and second major panel each having sub-panels with lines of perforations or score lines permitting each to be folded over one another such that a pocket or flap is formed between a first outer sub-panel of said second major panel and a sub-panel of said first major panel for the placement of a flat product and wherein the second major panel has at least another outer sub-panel which overlies the first outer sub-panel; and

wherein the sub-panels of the first and second major panels are folded over so that the sheet material forms a self supporting three dimensional configuration when folded open and when folded closed substantially form a two dimensional configuration possessing a thin lateral profile.