Paperboard CD or DVD tray with paper hub
A CD or DVD tray made from paperboard is provided. The tray may be made from 100% recycled paperboard and can be 100% recyclable. The design of the tray or holder (used interchangeably throughout) uses the structural geometry of facets, central hole and radial slits to form a hub that achieves the function of securing the CD to the tray. Non-structural paper stock is formed into an effective fastening device whereby the fit of the hub is determined by the geometry of the folded paper. The paper tray of the present invention duplicates the functionality of plastic trays and is compatible with industry auto-loading, while providing the environmental benefits of paper.
This application claims the benefit of U.S. Provisional Patent Application No. 60/903,747, filed Feb. 27, 2007, the entirety of which is hereby incorporated by reference into this application.
BACKGROUND OF THE INVENTION1. Field of the Invention
The present invention relates to holders for CD's and DVD's or other digital media. More particularly, the invention relates to CD and DVD trays or holders made of paperboard.
2. Description of Related Art
While there are numerous holder designs being used in the mass production and distribution of CD's, the vast majority are made entirely or contain significant components molded from plastic. Although designs for CD and DVD holders made from paper are known, all have significant drawbacks that prevent their commercial viability. For example, most designs are in the form of a slip case that cannot be used in the auto-loading equipment that the digital music industry currently uses to load recorded CD's onto plastic trays.
U.S. Pat. No. 6,375,003 discloses a paper based holder. The mounting hub, however, is described as being “punched out of the same cardboard material as the case and being disposed on an inside face of the case, the fastening element further having a substantially round and flat structure with the outside diameter thereof being matched to the inside diameter of the centrally disposed hole of the compact disk.”
It would be desirable and environmentally beneficial to provide a CD tray made entirely of paper that duplicates the functionality of plastic and allows industry auto-loading while providing the environmental benefits of paper. It would also be desirable to provide a 100% recyclable paper tray for CDs and DVDs and other discs.
SUMMARY OF THE INVENTIONA CD or DVD tray or cover made from paperboard is provided. The tray may be made from 100% recycled paperboard and can be 100% recyclable. The design of the tray or holder (used interchangeably throughout) in one embodiment uses the structural geometry of folded facets or laminated facets to achieve its function. The paper tray of the present invention duplicates the functionality of plastic trays and is compatible with industry auto-loading, while providing the environmental benefits of paper.
Non-structural paper stock is formed into an effective fastening device whereby the fit of the post or hub (used interchangeably throughout) is determined by the geometry of the folded paper. Prior art plastic CD holders are strong, rigid, often clear, and typically inexpensive to manufacture. However, plastic CD cases are not durable. Even slight impacts can break the plastic tray. The paper tray of the present invention has improved durability over plastic trays and can have graphics printed directly on it. Additionally, paper trays are relatively inexpensive to manufacture.
In a preferred embodiment, a central hole in the formed hub causes the adjacent paper to form a protruding shallow cone which provides a tactile target for positioning the hole in the disc. The hub that is formed has a number of facets which are determined by the number of radial slits on the paper rosette. In the preferred embodiment, the engineering of the center post or hub is designed to enable high volume mass production using conventional paper fabricating equipment. Rather than relying on the “elastic” properties of a punched cardboard hub cited in U.S. Pat. No 6,375,003, this aspect of the invention uses the structural geometry of the facets, central hole and radial slits to achieve its function.
The invention will be more fully described by reference to the following drawings.
Reference will now be made in greater detail to a preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings and the description to refer to the same or like parts.
A preferred embodiment has two components: a tray 10 and a post 50 (or interchangeably referred to as a hub). The hub 50 protrudes from the surface of the tray 10 on the side of the tray 10 that will secure the disc (not shown) CD, DVD or other similar flat circular object with a circular aperture in the approximate center of the object (hereinafter reference to a CD or disc includes CDs, DVDs, digital CDs and any other flat circular object that is to be secured by the tray). The hub 50 can be integral with the tray 10, or alternatively, the hub 50 can be a separate component that is attached or adhered to the tray 10. The tray serves to protect the CD from being scratched or damaged during loading, shipping or handling.
The tray 10 is a flat, typically square or rectangular piece of biodegradable material, such as, for example paper or biodegradable plastic. The shape and dimensions of the tray 10 are not critically important and are preferably compatible with trays currently used in the industry for packaging CDs and DVDs. The dimensions however can be changed to accommodate discs of different sizes. The tray 10 is preferably a die cut piece of paperboard that is folded or laminated or formed into a tray with a circular well 12 that can accommodate a CD. The tray 10 does not have to be die cut or laminated but can be manipulated in any number of ways know in the art such as thermoformed or pressure formed. A circular well 12, however, is not required for the tray to function. In an alternate embodiment the tray is manufactured using paperboard and additional cutouts are laminated onto the paperboard to create the well 12. In another embodiment, the circular well is formed from protruding ridges on the surface of the tray to define a well 12. In yet another embodiment the tray has no circular well 12.
Optionally, the tray can be affixed inside a folded (preferably paperboard) jacket or cover to complete the product package. However, the tray can function to secure the CD or DVD without being incorporated into a jacket or cover.
The center hub or hub 50 is a three dimensional, preferably paper, structure protruding from the surface 11 of the tray 10. The center hub 50 functions to releasably secure the CD (not shown) to the tray 10.
The slits 44 in the side wall 46 and central hole 42 of the hub 50 create the ridges that allow for compression of the hub when a CD is pressed onto the hub 50. The ridges of the hub or “retaining ridges” generally define a circular shape that corresponds to that of the hole in the disc to be secured to the tray. The outer circumference of the retaining ridges in the relaxed (non-compressed) state will generally be slightly larger than that of the hole of the disc. The compression of the ridges created by pressing the CD onto the hub allows the CD to be slid past the ridges at the top of the post 50 and held onto the lower post, thereby securing the CD to the tray. Once inserted onto the post 50, the CD is held in place due to the slight outward pressure applied to the CD by the compressed hub 50. This geometry of the hub 50 allows the CD or DVD to be attached and removed from the tray as effectively as a plastic tray and hub.
In the example of
The top view of this series of folds to form the hub 50 from the paper rosette 40 is illustrated in
In addition to paper or paperboard, the hub 50 may be constructed as illustrated in
In operation, a hub pattern 49 (radial slits 44 and central hole 42) is punched into tray stock 30 using the hub pattern punch 55, as illustrated in
The mandrel 64 pushes the rosette 40 into the pass-thru hole 84 in the upper plate 86, as shown in
The process is then complete. The assembly clears the upper plate 86. The hub stock 30 and card stock advance both advance and the cycle is repeated, as illustrated in
The tray stock with the attached hub is then cut to form individual trays. The tray can then be folded if desired as discussed above in reference to
In an alternate embodiment, the post or hub is constructed of biodegradable plastic, such as for example PSM Bioplastic from telNnovations Inc.
In another embodiment, the tray and/or hub are made in part, or entirely, from recycled paper. Preferably, the entire tray, and cover if used is recyclable. In yet another embodiment, the tray is made from paper and the center hub is made from another biodegradable material, or both the tray and the center hub are made from non-paper, non-plastic biodegradable material.
The hub technology of the present invention is not limited to CD trays and can be used in any application where temporary fastening of a planar object—(via a punched or drilled hole) is required, and a secondary fastener or other material is currently being used. There are numerous packaging/display applications where the hub could be utilized allowing the product to be 100% recyclable.
It is to be understood that the above-described embodiments are illustrative of only a few of the many possible specific embodiments, which can represent applications of the principles of the invention. Numerous and varied other arrangements can be readily devised in accordance with these principles by those skilled in the art without departing from the spirit and scope of the invention.
Claims
1. A disc holder comprising:
- a tray comprised of paperboard; and
- a hub constructed of biodegradable material protruding from the surface of the tray, wherein the outer circumference of the hub is compressible.
2. The disc holder of claim 1 wherein the hub is a paper structure.
3. The disc holder of claim 2 wherein the hub is hollow.
4. The disc holder of claim 3 wherein the hub has walls that are compressible.
5. The disc holder of claim 4 wherein the hub is secured to the tray with adhesive.
6. The disc holder of claim 5 wherein the hub is comprised of a rosette containing a small central hole and a series of radial slits.
7. The disc holder of claim 6 wherein the rosette has a plurality of facets corresponding to the number of radial slits punched into the paper rosette and wherein the rosette is folded to form a side wall with ridges that occur between the facets.
8. The disc holder of claim 1 wherein the hub is constructed of biodegradable plastic.
9. The disc holder of claim 5 wherein the tray and hub are made from recycled material.
10. A hub for a CD or DVD holder comprising: a three dimensional structure comprised of biodegradable material, wherein the outer circumference of the hub is compressible.
11. The hub of claim 10 wherein the biodegradable material is paper.
12. The hub of claim 10 wherein the three dimensional structure is hollow.
13. The hub of claim 12 wherein the walls of the three dimensional structure are compressible.
14. The hub of claim 10 wherein the three dimensional structure is comprised of a rosette containing a small central hole and a series of radial slits.
15. The hub of claim 14 wherein the rosette has a plurality of facets corresponding to the number of radial slits punched into the paper rosette and wherein the rosette is folded to form a side wall with ridges that occur between the facets.
16. The hub of claim 10 wherein the three dimensional structure is constructed of biodegradable plastic.
Type: Application
Filed: Aug 24, 2007
Publication Date: Aug 28, 2008
Inventors: Mark Lacko (Garrison, NY), James O'Rourke (Garrison, NY)
Application Number: 11/895,480
International Classification: B65D 85/57 (20060101);