Package For Holding Multiple Media Discs And Methods Of Making The Same

Abstract

A package for holding media discs is disclosed, having a hinged tray assembly that includes at least two transparent disc-holding trays each having a hinge edge and means for securing a media disc to the tray, the trays being constructed such that the disc securing means of each tray is positioned offset with respect to the disc securing means of adjacent trays such that when the tray assembly is in a closed configuration, the trays are arranged in a stack with hinge edges lined up and each disc securing means being offset from the disc securing means of adjacent trays in the stack, the trays being hinged to each other. The package can also include a jacket with a plurality of panels folding around the tray assembly to close the package.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 60/781,445 filed Mar. 10, 2006, the disclosure of which is incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to improvements to product packaging, and more particularly to advantageous aspects of packaging for holding multiple media discs and methods for making same.

2. Background of the Related Art

Numerous packages have been developed for holding media discs. The basic media disc package is the so-called “jewel case,” which typically includes a tray for holding a media disc, and a hinged cover that snaps into place over the tray. Jewel cases have been developed to hold two media discs. One such jewel case includes a two-sided central tray that receives a media disc on each side. Another jewel case provides for two media discs to be stacked, one on top of each other, in the same tray. However, neither of these designs is entirely satisfactory for a number of reasons, including ease of use, prevention of damage to the disc and aesthetic appearance. Further, it is becoming increasingly common for media discs to be packaged in sets having more than two discs.

There is thus a need for easy-to-use, esthetically appealing packaging for holding multiple media discs that can be manufactured at an acceptably low cost.

SUMMARY OF THE INVENTION

The subject invention is directed to a package for holding media discs and methods for making the same. The package includes a hinged tray assembly and a jacket. The jacket has a plurality of panels that fold around the tray assembly to close the package and it has an interior surface to which the tray assembly is mounted.

The hinged tray assembly includes at least two transparent disc-holding trays which each have a hinge edge and include means for securing a media disc to the tray. The trays are constructed such that the disc securing means (e.g., hub, rosette, etc.) of each tray is positioned offset with respect to the disc securing means of adjacent trays such that when the tray assembly is in a closed configuration, the trays are arranged in a stack with their hinge edges lined up and each disc securing means being offset from the disc securing means of adjacent trays in the stack.

These and other aspects of the device and method of the subject invention will become more readily apparent to those having ordinary skill in the art from the following detailed description of the invention taken in conjunction with the figures and appended material.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those having ordinary skill in the art to which the disclosed system appertains will more readily understand how to make and use the same, reference may be had to the drawings wherein:

FIG. 1 is a perspective view of a package for holding media discs in accordance with a first embodiment of the present invention, wherein the disc trays are assembled into a hinged stack;

FIG. 2 is an enlarged perspective view of the package of FIG. 1 wherein a first disc tray of the hinged disc tray assembly has been pivoted along the hinge edge so as to permit access to the second disc tray;

FIG. 3 is a perspective view of a package for holding media discs which has been constructed in accordance with a second embodiment of the present invention;

FIG. 4 is a perspective view taken from above of the media package of FIG. 3 wherein the first trays in the left and right hinged tray assemblies have been pivoted to a partially open position;

FIG. 5 is an enlarged perspective view of media package of FIG. 3 showing the right side disc tray assembly having its first tray pivoted to a partially open position;

FIG. 6 is an enlarged perspective view of the left side disc tray assembly illustrating the longitudinal offset of the disc securing means of the first disc tray with respect to the disc securing means of the second tray;

FIG. 7 is a perspective view of the media package of FIG. 3 showing the covers for the left and right disc tray assemblies in the partially open position; and

FIG. 8 is a perspective view of the media package of FIG. 3 showing the package in the substantially closed configuration.

FIG. 9 is a side view showing two additional embodiments of disc tray assemblies in accordance with the invention, one tray disc assembly being shown hinged in accordion fashion, and the other being shown hinged in a combination of common hinge edge fashion and accordion fashion.

These and other features of the subject invention will become more readily apparent to those having ordinary skill in the art from the following detailed description of preferred embodiments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As used herein, the term “media disc” refers to a compact disc (CD), digital video disc (DVD), or other disc or disc-shaped media item that is used to store analog or digital information.

Reference is now made to the accompanying figures for the purpose of describing, in detail, exemplary embodiments of the present disclosure. The figures and detailed description are provided to describe and illustrate examples in which the disclosed subject matter may be made and used, and are not intended to limit the scope thereof.

Referring now to the accompanying figures, there is illustrated in FIGS. 1 and 2 a media package 10 which has been constructed in accordance with a first embodiment of the present invention. The media package 10 includes first and second disc-holding trays 12 and 14 which are transparent and arranged in a hinged stack. The disc-holding trays each have a hinge edge and a hub or rosette 16 for securing a rnedia disc to the tray. As best shown in FIG. 1, the trays are constructed such that when the disc trays 12 and 14 are arranged in a stack, the rosette 16a of tray 12 is vertically/longitudinally offset a distance “d” with respect to the rosette 16b of tray 14. When the tray assembly is in a closed configuration, the trays are arranged in a stack with their hinge edges lined up and the rosette of one disc tray is offset from the rosette of adjacent trays in the stack.

The transparency of disc tray 12 allows disc tray 14 and any media disc attached thereto or graphics associated therewith to be seen without the need to move disc tray 12 (i.e., pivot tray 12 along hinge 22 to the open position). Those skilled in the art will readily appreciate that a tray stack can include more than two disc trays without departing from the inventive aspects of the present disclosure. Moreover, the offset distance “d” can dimensioned such that only the edge of a media disc affixed to the next tray in the stack can be seen or the offset “d” can be made large enough to allow graphics or text printed on or adhered to face of the media disc or disc tray to be viewed through the disc tray positioned above the tray in the stack.

As shown in FIG. 2, the trays are hinged to each other by a flexible hinge member 22 that is affixed to the left edge of the stack of trays. However, other hinge configurations can be employed as will be discussed herein below. In the presently disclosed embodiment, the stack of trays is mounted onto an interior panel of an outer jacket 20. Alternatively, the stack of trays may be inserted into an open-ended sleeve or other carrier.

The hinge member 22 can be fabricated from any suitable material, such as a styrene-based film or tape, polyethylene, polypropylene, or the like. The hinge member 22 may be fabricated, for example, from a strip of commercially available poly tape. The hinge member 22 must be flexible enough to allow the package 10 to be opened and closed freely, but must be strong enough to prevent failure of the hinge member or separation of the tray stack from the jacket 20. The hinge member may be affixed to the trays using an adhesive, or using a mechanical technique, including techniques using ultrasound or heat. In addition, the stack of trays 12 and 14 may be hinged in a number of different configurations without departing from the spirit of the invention. In the package 10 shown in FIG. 1, the hinge member 22 is positioned proximate to the spine 18 of the jacket 20, in a parallel relationship with the folds in the jacket 20. However, it would also be possible to position the hinge member 22 distal from the spine of the jacket 20, or in a transverse relationship with the folds in the jacket 20.

Each tray in the package 10 includes a cavity 24 (24a for disc tray 12 and 24b for disc tray 14) for receiving a media disc. Media discs commonly include a central spindle hole which engages with the rosette of the disc tray to releasably secure the media disc thereto.

The style, shape, and dimensions of each tray 12/14, including the number of indentations therein and the design and shape of the rosette 16a/16b, may be varied and are not limited in any way by this disclosure. The trays may suitably be fabricated from a plastic material that has been injection molded. Suitable materials for the tray include polystyrene, polypropylene, and environmentally friendly materials such as polylactic acid. As noted above, the trays are fabricated from a clear material, such as crystal styrene. The use of a clear material is desirable from an aesthetic point of view. Further, the use of a transparent material for the trays allows a user of the package to quickly determine whether any of the trays are empty.

As noted above, media package 10 includes a jacket 20 suitable for use in some embodiments of the media package 10. Prior to the addition of any text, graphics, and the like to the jacket 20, the exterior side of the jacket 20 is substantially identical in appearance to the interior side. According to one aspect of the invention, the jacket 20 is shaped such that it can be folded around the stack of trays mounted into the jacket 20 to form a boxlike package. The jacket may be fabricated from paper, paperboard, cardboard, plastic, or other suitable material. According to a further aspect of the invention, the jacket is fabricated from a material that is suitable for a high-speed printing process. As shown in FIG. 1, the jacket includes crease lines which are used to fold the jacket 20 cleanly around the stack of trays mounted into the jacket. The crease lines divide the jacket 20 into three sections: a front panel 56, a spine 18, a rear panel. As further discussed below, additional panels, creases and spines can be added to the jacket.

The creases may be introduced into the jacket using a number of different techniques. For example, if the jacket is fabricated from paperboard or cardboard, the creases can be introduced by pressing a scoring blade into the jacket. If the jacket is fabricated from plastic, the creases may be formed using an electron beam, RF creasing, microperforation or other suitable technique.

It should be noted that the shape of the jacket may be modified, as desired, without departing from the spirit of the invention. For example, it may be desirable to include cutout regions in the jacket. Further, it may be desirable for portions of the jacket to extend beyond the perimeter of the stack of trays.

As shown in FIG. 1, the hinge for the trays is located proximate the spine of the jacket. However, depending on how the package is used, the location of the hinge away from the spine of the jacket may result in less strain on the package as it is unfolded. For example, hinging the trays to an edge of the jacket opposite the spine allows the inside front panel of the jacket to remain visible as the trays are fanned open. Thus, if informational content is printed on the inside front panel, this informational content will continue to be visible as each tray is fanned out. Further, if the package is opened for display, the location of the hinge along an outside edge of the jacket allows more of the package interior to be displayed. In other embodiments (not shown), the hinge edge may be located along the top edge of the jacket, such that the stack of trays may be opened by folding upward and outward.

Referring now to FIGS. 3 through 8, there is illustrated a second preferred embodiment of the media disc package of the present invention which has been designated as reference numeral 100. Unlike media package 10, media package 100 includes a first (left) hinged disc tray assembly 130 and a second (right) hinged disc tray assembly 140, wherein each tray assembly includes first and second disc-holding trays 112 and 114 which are transparent and arranged in a hinged stack. The disc-holding trays each have a hinge edge 122 and a hub or rosette 116 for securing a media disc to the tray. As best shown in FIG. 6, the trays of each disc tray assembly 130/140 are constructed such that when the disc trays 112 and 114 are arranged in a stack, the rosette 116a of tray 112 is vertically/longitudinally offset a distance “d” with respect to the rosette 116b of tray 114. When the tray assembly 130/140 is in a closed configuration, the trays 112/114 are arranged in a stack with their hinge edges lined up and the rosette of disc tray 112 is offset from the rosette of adjacent tray 114.

As before, the transparency of disc tray(s) 112 allows disc tray(s) 114 and any media disc attached thereto or graphics associated therewith to be seen without the need to move disc tray 112 (i.e., pivot tray 112 along hinge 122 to the open position). Those skilled in the art will readily appreciate that a tray stack can include more than two disc trays without departing from the inventive aspects of the present disclosure. Moreover, the offset distance “d” can sized such that only the edge of a media disc affixed to the next tray in the stack can be seen or the offset “d” can be made large enough to allow graphics or text printed on or adhered to face of the media disc or disc tray to be viewed through the disc trays positioned above the tray in the stack.

As described hereinbefore, the trays in a stack are hinged to each other by a flexible hinge member 122 that is affixed to an edge (left edge for disc tray assembly 130 and right edge for disc tray assembly 140) of the stack of trays. However, other hinge configurations can be employed as will be discussed herein below. In the presently disclosed embodiment, the stack of trays is mounted onto an interior panel of an outer jacket 20. Alternatively, the stack of trays may be inserted into an open-ended sleeve or other carrier.

The media package 100 includes a jacket 150 suitable for use in some embodiments of the media package 100. Prior to the addition of any text, graphics, and the like to the jacket 150, the exterior side of the jacket 150 is substantially identical in appearance to the interior side. According to one aspect of the invention, the jacket 150 is shaped such that it can be folded around each stack of trays mounted into the jacket 150 to form a boxlike package. As shown in FIG. 3, the jacket includes six crease lines 152a, 152b, 153, 154, 155a and 155b, which are used to fold the jacket 150 cleanly around both stacks 130/140 of trays mounted into the jacket. The crease lines 152a, 152b, 153, 154, 155a and 155b divide the jacket 150 into seven sections: a front interior panel 156, a main spine 158, a rear panel 160, a first disc tray assembly cover 162, a second disc tray assembly cover 164 and interior spines 166 and 168.

As described above, the creases may be introduced into the jacket using a number of different techniques and the shape of the jacket may be modified, as desired, without departing from the spirit of the invention.

FIG. 4 shows a perspective view of media package 100 according to a further embodiment of the present invention in which the two tray stacks are hinged away from the main spine 158 of the jacket 150. Those skilled in the art will readily appreciate that the location of the hinge can be changed without departing from the scope of the present invention.

Media package 100 may be advantageously combined with a slip case that is shaped to closely receive the closed package 100.

Commonly owned U.S. patent application Ser. No. 11/060,576, published as US 2005/0189244, the disclosure of which is herein incorporated by reference in its entirety, illustrates techniques for fabricating a plurality of hinged assemblies simultaneously. (See FIGS. 17 through 21 and specification referring thereto). As shown in FIG. 17, according. to a first technique, a plurality of trays 160 is arranged side by side so that their hinge edges are in alignment. The number of trays is a multiple of the number of trays in each hinged assembly in the finished package.

A swath of hinge material 162 is then prepared, having dimensions corresponding to the size of the combined hinge edges. As shown in FIG. 18, the swath of hinge material 162 is then affixed onto the hinge edges of the trays 160 to form an integral unit 170. As shown in FIG. 19, the swath of hinge material is then cut between trays at regular intervals 171, 172, 173 and 174, each interval including the desired number of trays. As shown in FIG. 20, individual hinged assemblies 175, 176, 177, 178 and 179 are then separated. The hinged assemblies are then mounted into jackets, as described above. The swath of hinge material may be cut, for example, in a single stroke using a bar having cutting blades mounted thereon. Of course, the cuts may also be made one at a time.

In the previously described embodiments, the disc trays were hinged along a common longitudinal/vertical edge. However, it should be understood that the trays can be hinged along a transverse/horizontal edge. Moreover, it is not required that the all of the trays in a stack be hinged along a common edge. As shown in FIG. 9, the trays can also be hinged into a stack in an accordion fashion having hinges positioned on the top and bottom edges or on opposing side edges, as in tray assemblies 900 and 950.

It should be noted that the offset “d” described above does not have to be a vertical/longitudinal offset and can be a horizontal/transverse offset or simply a radial offset between the center of the rosette for adjacent disc trays.

While the foregoing description includes details which will enable those skilled in the art to practice the invention, it should be recognized that the description is illustrative in nature and that many modifications and variations thereof will be apparent to those skilled in the art having the benefit of these teachings. It is accordingly intended that the invention herein be defined solely by the claims appended hereto and that the claims be interpreted as broadly as permitted by the prior art.

Claims

1. A package for holding media discs, comprising:

a) a hinged tray assembly that includes at least two transparent disc-holding trays each having a hinge edge and means for securing a media disc to the tray, the trays being constructed such that the disc securing means of each tray is positioned offset with respect to the disc securing means of adjacent trays such that when the tray assembly is in a closed configuration, the trays are arranged in a stack with their hinge edges lined up and each disc securing means being offset from the disc securing means of adjacent trays in the stack, the trays being hinged to each other; and

b) a jacket, comprising a plurality of panels that fold around the tray assembly, the jacket including an interior surface to which the tray assembly is mounted, the plurality of panels folding around the tray assembly to close the package.

2. A package for holding media discs as recited in claim 1, wherein each disc securing means is offset from the disc securing means of adjacent trays by an offset distance large enough to reveal at least an edge of each disc to be visible when a disc is secured to each disc securing means and when the tray assembly is in the closed configuration.

3. A package for holding media discs as recited in claim 2, wherein the offset distance is large enough to reveal at least a portion of graphics and/or text on each disc when a disc is secured to each disc securing means and when the tray assembly is in the closed configuration.

4. A package for holding media discs as recited in claim 1, wherein the disc securing means are offset along a line parallel to the hinge edges of the trays.

5. A package for holding media discs as recited in claim 1, wherein the disc securing means are offset along a line perpendicular to the hinge edges of the trays.

6. A package for holding media discs as recited in claim 1, wherein the disc securing means are offset along a line oblique to the hinge edges of the trays.

7. A package for holding media discs as recited in claim 1, wherein the trays are hinged together with at least one hinge member affixed to each tray proximate the hinge edge.

8. A package for holding media discs as recited in claim 7, wherein the at least one hinge member is of a material selected from a list including: styrene-based film, styrene-based tape, polyethylene, and polypropylene.

9. A package for holding media discs as recited in claim 7, wherein the at least one hinge member is affixed to each tray with an adhesive.

10. A package for holding media discs as recited in claim 7, wherein the at least one hinge member is affixed to each tray with a mechanical technique selected from a list including ultrasound and heating.

11. A package for holding media discs as recited in claim 7, wherein the tray assembly is mounted to the jacket so that the hinge member is proximate to a spine in the jacket configured and adapted to fold around the hinge member to close the package.

12. A package for holding media discs as recited in claim 7, wherein the tray assembly is mounted to the jacket so that the hinge member is parallel to and distal from a folding spine in a middle portion of the jacket.

13. A package for holding media discs as recited in claim 7, wherein the tray assembly is mounted to the jacket so that the hinge member is transverse to a folding spine in a middle portion of the jacket.

14. A package for holding media discs as recited in claim 1, wherein the trays are of a material suitable for injection molding.

15. A package for holding media discs as recited in claim 14, wherein the trays are of a material selected from a list including polystyrene, polypropylene, polylactic acid crystal styrene.

16. A package for holding media discs as recited in claim 1, wherein the jacket is of a material selected from a list including paper, paperboard, cardboard, and plastic.

17. A package for holding media discs as recited in claim 16, wherein the jacket is of a material suitable for a high-speed printing process.

18. A package for holding media discs as recited in claim 16, wherein the panels in the jacket are separated from one another by folds in the jacket, the folds being scored into the jacket.

19. A package for holding media discs as recited in claim 1, wherein the jacket is of a plastic material.

20. A package for holding media discs as recited in claim 19, wherein the panels in the jacket are separated from one another by RF creases, electron beam creases, or microperforation.

21. A package for holding media discs as recited in claim 1, wherein the jacket defines cutout regions.

22. A package for holding media discs as recited in claim 1, wherein the jacket includes portions that extend beyond a perimeter defined by the tray assembly.

23. A package for holding media discs as recited in claim 1, further comprising a slip case configured and adapted to closely receive the closed jacket and tray assembly.

24. A package for holding media discs as recited in claim 1, wherein the tray assembly includes two disc trays.

25. A package for holding media discs as recited in claim 1, wherein the tray assembly includes three disc trays.

26. A package for holding media discs as recited in claim 1, wherein the at least two trays are hinged to one another in accordion fashion.

27. A package for holding media discs as recited in claim 1 wherein the hinged tray assembly includes more than three disc trays, and wherein at least three of the disc trays are hinged to one another in accordion fashion.

28. A package for holding media discs, comprising:

a) a hinged tray assembly that includes at least two transparent disc-holding trays each having a hinge edge and means for securing a media disc to the tray, the trays being constructed such that the disc securing means of each tray is positioned offset with respect to the disc securing means of adjacent trays such that when the tray assembly is in a closed configuration, the trays are arranged in a stack with their hinge edges lined up and each disc securing means being offset from the disc securing means of adjacent trays in the stack, the trays being hinged to each other; and

b) an open-ended sleeve, slideably connected to enclose the tray assembly.

29. A package for holding media discs, comprising:

a) a first hinged tray assembly that includes at least two transparent disc-holding trays each having a hinge edge and means for securing a media disc to the tray, the trays being constructed such that the disc securing means of each tray is positioned offset with respect to the disc securing means of adjacent trays such that when the tray assembly is in a closed configuration, the trays are arranged in a stack with their hinge edges lined up and each disc securing means being offset from the disc securing means of adjacent trays in the stack, the trays being hinged to each other;

b) a second hinged tray assembly that includes at least two transparent disc-holding trays each having a hinge edge and means for securing a media disc to the tray, the trays being constructed such that the disc securing means of each tray is positioned offset with respect to the disc securing means of adjacent trays such that when the tray assembly is in a closed configuration, the trays are arranged in a stack with their hinge edges lined up and each disc securing means being offset from the disc securing means of adjacent trays in the stack, the trays being hinged to each other; and

c) a jacket, comprising a plurality of panels that fold around the first and second tray assemblies, the jacket including an interior surface to which the tray assemblies are mounted, the plurality of panels folding around the tray assemblies to close the package wherein the first and second tray assemblies are mounted to the jacket with the hinge edges of the first tray parallel to and distal from a folding spine in the jacket and the hinge edges of the second tray assembly are parallel to and distal from the folding spine on a side of the jacket opposite the hinge edges of the first tray assembly.