U.S. patent application number 09/777992 was filed with the patent office on 2002-08-08 for article-embedded folding sleeve and method for producing same.
Invention is credited to Lux, Gerard Paul JR., McRae, Thompson G., Moore, Melanie A..
Application Number | 20020104767 09/777992 |
Document ID | / |
Family ID | 25111942 |
Filed Date | 2002-08-08 |
United States Patent
Application |
20020104767 |
Kind Code |
A1 |
Lux, Gerard Paul JR. ; et
al. |
August 8, 2002 |
ARTICLE-EMBEDDED FOLDING SLEEVE AND METHOD FOR PRODUCING SAME
Abstract
A packaging blank capable of forming a sleeve having at least
one internal cavity comprises in one embodiment a substantially
rectangular bottom panel, a substantially rectangular top panel
connected to the bottom panel along a fold line, and a perforated
retaining wall formed in the top panel, wherein the top panel
includes at least one display window. Upon construction the
packaging blank provides a sleeve having at least one internal
cavity that is viewable through at least one display window. A
method of packaging an article comprises in one embodiment the
steps of providing a blank, placing an article to be packaged on
the blank, folding the top panel over the bottom panel, and binding
the sleeve formed by the blank into a publication.
Inventors: |
Lux, Gerard Paul JR.;
(Charlotte, NC) ; Moore, Melanie A.; (Charlotte,
NC) ; McRae, Thompson G.; (Charlotte, NC) |
Correspondence
Address: |
SUMMA & ALLAN, P.A.
11610 NORTH COMMUNITY HOUSE ROAD
SUITE 200
CHARLOTTE
NC
28277
US
|
Family ID: |
25111942 |
Appl. No.: |
09/777992 |
Filed: |
February 6, 2001 |
Current U.S.
Class: |
206/308.1 ;
206/312; 206/38; 281/29; 281/38; 402/79; G9B/33.01 |
Current CPC
Class: |
G11B 33/0422
20130101 |
Class at
Publication: |
206/308.1 ;
206/312; 281/29; 206/38; 281/38; 402/79 |
International
Class: |
B65D 085/57 |
Claims
That which is claimed is:
1. A packaging blank that is capable of forming a sleeve for
securing articles, said blank comprising: a substantially
rectangular top panel having a display window; and a substantially
rectangular bottom panel that is connected to said top panel;
wherein said blank is capable of being folded to form an interior
cavity in which a substantially flat or near planar article is
positioned.
2. A packaging blank according to claim 1, wherein said packaging
blank consists essentially of a one-piece flexible blank.
3. A packaging blank according to claim 2, wherein said one-piece
flexible blank has an external planar side and an internal planar
side, said external planar side being finished.
4. A packaging blank according to claim 3, wherein said display
window is positioned on said top panel such that said internal
planar side is viewable through said display window when said
packaging blank is formed into a sleeve.
5. A packaging blank according to claim 1, wherein said top panel
further comprises a perforated retaining flap, said retaining flap
substantially surrounding said display window.
6. A packaging blank according to claim 5, wherein said perforated
retaining flap and said display window are substantially
circular.
7. A packaging blank according to claim 6, wherein the radius of
said display window is less than the radius of said perforated
retaining flap.
8. A packaging blank according to claim 6, wherein the diameter of
said perforated retaining flap is about equal to or greater than
the diameter of a compact disc or a digital video disc.
9. A packaging blank according to claim 5, wherein said perforated
retaining flap and said display window are substantially
concentric.
10. A packaging blank according to claim 5, wherein said top panel
includes at least one access slot formed adjacent said perforated
retaining flap for facilitating the removal of said retaining
flap.
11. A packaging blank according to claim 5, wherein said top panel
includes at least one access tab formed adjacent said perforated
retaining flap for facilitating the removal of said retaining
flap.
12. A packaging blank according to claim 5, wherein said top panel
includes at least one access slot and at least one access tab
adjacent said perforated retaining flap, wherein said access slot
and said access tab are correspondingly aligned with respect to one
another.
13. A packaging blank according to claim 1, wherein said top panel
includes a plurality of display windows and a plurality of
perforated retaining flaps corresponding to said plurality of
display windows.
14. A packaging blank according to claim 1, wherein said top panel
includes a binding flap opposite said bottom panel, said binding
flap having a width that is less than or about equal to the width
of said top and bottom panel.
15. A packaging blank that is capable of forming a sleeve for
securing articles, said blank consisting of: a substantially
rectangular top panel having at least one display window and at
least one perforated retaining flap, said retaining flap
substantially surrounding said display window; and a substantially
rectangular bottom panel that is connected to said top panel along
a fold line formed in said blank; wherein said blank is capable of
being folded to form an interior cavity in which a substantially
flat or near planar article is positioned.
16. A packaging blank according to claim 15, wherein said top panel
includes a binding flap opposite said bottom panel, said binding
flap having a width that is less than or about equal to the width
of said top and bottom panel.
17. A packaging blank according to claim 15, wherein said
perforated retaining flap and said display window are substantially
circular.
18. A packaging blank according to claim 17, wherein the radius of
said display window is less than the radius of said perforated
retaining flap.
19. A packaging blank according to claim 17, wherein the diameter
of said perforated retaining flap is about equal to or greater than
120 millimeters.
20. A packaging blank according to claim 15, wherein said
perforated retaining flap and said display window are substantially
concentric.
21. A packaging blank according to claim 15, wherein said top panel
includes at least one access slot formed adjacent said perforated
retaining flap for facilitating the removal of said retaining
flap.
22. A sleeve for securing articles having at least one internal
cavity, said container comprising: a substantially rectangular top
wall comprising a display window and a perforated retaining flap
corresponding to said display window; and a substantially
rectangular bottom wall that is connected to said top wall; wherein
said perforated retaining flap substantially surrounds said
corresponding display window.
23. A sleeve according to claim 22, wherein said top wall includes
a binding flap opposite said bottom wall, said binding flap having
a width that is less than or about equal to the width of said top
and bottom walls.
24. A sleeve according to claim 23, wherein said sleeve consists
essentially of a one-piece flexible blank.
25. A sleeve according to claim 24, wherein said one-piece flexible
sleeve has an external planar side and an internal planar side,
said external planar side being finished.
26. A sleeve according to claim 25, wherein said display window is
positioned on said top wall such that said internal planar side is
viewable through said display window upon construction of said
sleeve.
27. A sleeve according to claim 22, wherein said display window and
said perforated retaining flap are substantially circular.
28. A sleeve according to claim 27, wherein the radius of said
display window is less than the radius of said perforated retaining
flap.
29. A sleeve according to claim 27, wherein the diameter of said
perforated retaining flap is at least greater than 120
millimeters.
30. A sleeve according to claim 22, wherein said perforated
retaining flap and said display window are substantially
concentric.
31. A sleeve according to claim 22, wherein said top wall includes
at least one access slot formed adjacent said perforated retaining
flap for facilitating the removal of said retaining flap.
32. A sleeve according to claim 22, wherein said top wall includes
at least one access tab formed adjacent said perforated retaining
flap for facilitating the removal of said retaining flap.
33. A sleeve according to claim 22, wherein said top wall includes
at least one access slot and one access tab adjacent said
perforated retaining flap for facilitating the removal of said
retaining flap, wherein said access slot and said access tab are
correspondingly aligned with respect to one another.
34. A sleeve according to claim 22, wherein said top wall comprises
a plurality of display windows.
35. A sleeve according to claim 34, wherein said top wall comprises
a plurality of perforated retaining flaps corresponding to said
plurality of display windows.
36. A sleeve according to claim 22, packaging a compact disc.
37. A sleeve according to claim 22, packaging a digital video
disc.
38. A sleeve according to claim 22, packaging a consumable
good.
39. A sleeve according to claim 22, packaging a health care
product.
40. A sleeve according to claim 22, bound into a printed
publication.
41. A method of packaging articles, said method comprising:
providing a flexible blank having an internal planar side and an
external planar side, the blank having a substantially rectangular
top panel comprising a display window and perforated retaining flap
corresponding to the display window, and a substantially
rectangular bottom panel connected to the top panel along a fold
line; positioning the article to be packaged on an internal planar
side of the flexible blank; folding the top panel over the bottom
panel, thereby forming an internal cavity in which the article is
positioned; and binding a sleeve formed by the flexible blank in a
publication.
42. A packaging method according to claim 41, wherein the step of
positioning the article to be packaged further comprises securing,
with a static charge, the article to the internal planar side of
the flexible blank.
43. A packaging method according to claim 41, wherein the step of
positioning the article to be packaged further comprises securing,
with adhesive, the article to the internal planar side of the
flexible blank.
44. A packaging method according to claim 41, wherein the step of
folding the top panel comprises: folding the top panel to a
position substantially parallel to the bottom panel; and adhering
portions of the top and bottom panels together.
45. A packaging method according to claim 44, wherein the step of
folding the top panel further comprises folding the top panel over
the bottom panel such that at least one article is viewable through
a display window formed in the top panel.
46. A packaging method according to claim 41, wherein the step of
binding a sleeve comprises: positioning the sleeve in a binding
production line; advancing the sleeve into the production line such
that the sleeve is adjacent matter to be bound; and binding the
sleeve into a publication.
47. A packaging method according to claim 46, wherein the step of
binding a sleeve further comprises adhering the sleeve to the
matter to be bound such that the sleeve is secured to the bound
matter.
48. A packaging method according to claim 46, wherein the blank
provided includes a binding flap connected to the top panel,
opposite the bottom panel; and the step of binding further
comprises stitching the binding flap such that the sleeve is
secured to the bound matter.
Description
FIELD OF THE INVENTION
[0001] The invention relates to a packaging sleeve. In particular,
the invention relates to a packaging blank capable of forming a
sleeve having at least one internal cavity. The invention further
relates to a sleeve formed from the blank that includes at least
one internal cavity and at least one retaining panel. Still
further, the invention relates to a method of packaging an article
in the sleeve wherein the sleeve is formed around the article to be
packaged.
BACKGROUND OF THE INVENTION
[0002] Publications such as magazines have become a popular vehicle
for promoting the goods and services of a variety of
consumer-oriented providers. For example, the advances in media
technology coupled with the popularity of sound and video recording
have resulted in the packaging and binding of large numbers of
stored media items, such as compact discs (CD) and digital video
discs (DVD), into magazines. As applied to the media industry,
packaging is often used to ship complimentary CDs and DVDs
containing software for on-line service providers. Alternatively,
packaging is used to ship CDs or DVDs containing promotional
presentations of a merchant's goods or services to potential or
existing customers. Moreover, providers often distribute
substantially flat or near planar articles via magazines.
Consequently, the packaging industry is attempting to meet
increased demand by providing improved packaging tailored to CDs,
DVDS, and substantially flat articles, and developing more
efficient methods of packaging the same.
[0003] For ease of reference, the term "article" will refer to a CD
or DVD. Nevertheless it will be understood that the article may
include any number of substantially flat or near planar articles.
It will be further understood by those skilled in the art that as
used herein, the term CD refers to a stored media item made of
single-piece construction. Further, the term DVD refers to a stored
media item made of multi-piece construction, thereby allowing
increased storage capacity.
[0004] Conventional packaging includes a top wall, bottom wall, and
closure panels for containing various articles, such as stored
media items, or substantially flat articles. As known to those
skilled in the art, packaging is typically formed from packaging
blanks, or blanks for short. It will be understood that as used
herein the term "blank" may include paperboard, rigid paper,
flexible polyester film, or similar products made of paperboard or
polyester film. These blanks are capable of being formed into
sleeves for incorporation into printed publications (e.g.,
magazines, periodicals, etc.). Typical sleeves are formed from
flexible polyester film. Another form of sleeve for shipping CDs
and DVDs is comprised of a flat blank of paperboard divided into
equal first and second sections by a fold line. A scored line
typically defines the fold line.
[0005] The publishing industry favors substantially rectangular
one-piece flexible blanks because the blanks are readily
incorporated into automated processes for binding sleeves into
publications, such as magazines and books. Actual insertion of the
article into the sleeve is accomplished by either manual or
automated processes. Manual insertion of articles is slow and labor
intensive. Although typically more efficient than manual insertion,
current automated insertion systems may result in increased waste,
slower production speeds, and may also require additional labor on
the production line. By supplying an article-embedded sleeve, the
need for manual or in-line insertion of articles is eliminated,
thus creating significant efficiencies in the production
process.
[0006] Most current processes employed create packaging on one
apparatus and then insert articles on a separate apparatus after
the container is formed. The method of packaging articles described
above typically uses a belt-driven conveyor for advancing a blank
along a production line. In production, the blank is folded along
fold lines and portions of the blank are secured to one another
(e.g., by adhesive) to form a sleeve. Subsequently, the primary
article (e.g., CD) is either mechanically or manually inserted into
the sleeve.
[0007] The more efficient methods for packaging CDs or DVDs into
sleeves are automated. One method for packaging includes the
following steps: advancing blanks along a conveyor to a scoring
position, scoring the blank along a center line dividing the blank
into two equal portions, advancing the scored blank to an adhering
position, applying adhesive to edges of the sleeve positioned
perpendicular to the fold line, advancing the blank to a folding
position, folding the blank along its score line such that the
equal portions are folded against and adhered to one another to
thereby form a sleeve, advancing the sleeve to an article inserting
position, laterally inserting the CD or DVD into the sleeve, and
subsequently sealing the remaining open end.
[0008] Unfortunately, the lateral insertion of CDs or DVDs (i.e.,
coplanar movement) into the open end or slit in the sleeve is
inherently slow. Stated differently, the automated process of
laterally inserting CDs and DVDs leads to misalignment and
misplacement, thus resulting in breakage of the article or complete
failure to place the article into the sleeve. In the event that the
article is broken or misplaced, the production line must be halted.
Furthermore, the likely occurrence of misplaced articles, thus
resulting in empty sleeves, requires increased vigilance on the
part of quality control managers.
[0009] Several types of sleeves lack windows that permit a view of
the packaged article and any information (e.g., CD title) printed
on the media item. Without such a window, it is not obvious that
the package contains the media item it carries. This often results
in the recipient discarding a package without the knowledge that it
contains a valuable media item. Therefore, it is desirable to
provide a packaging blank capable of forming a sleeve that includes
at least one display window that permits viewing of an article
contained therein.
[0010] Moreover, most sleeves lack a retaining flap that
facilitates frontal access to an article positioned in the sleeve.
For example, most sleeves include a closure panel attached to an
open end of the sleeve and adhered to an exterior portion of the
sleeve. In order to access the article, a consumer must detach a
corner of the closure panel that is adhered to the sleeve and then
tear the closure panel from the sleeve. Typically, the consumer
tears the sleeve during the removal of the article. Accordingly,
there is a need for a packaging sleeve suitable for use with
conventional binding machinery that permits frontal access to an
article positioned therein.
[0011] The packaging industry has attempted to meet the demand for
providing, for example, promotional CDs through joint efforts with
the publishing industry. One method is to stack the sleeve on top
of a magazine and then wrap the sleeve-magazine combination in an
oftentimes transparent film to form a bag. This method is commonly
referred to as "polybagging." As known to those of ordinary skill
in the art, polybagging includes loosely wrapping polyester or
polyethylene based film around the magazine-sleeve combination and
thereafter heat sealing the ends of the bag.
[0012] Alternatively, a CD may be placed in a packaging sleeve and
then bound to a magazine with an adhesive. One method of adhering a
sleeve to a publication in this manner involves binding the sleeve
into the spine and is commonly referred to as the "perfect bound"
method. Another method utilizing adhesive requires the sleeve to be
attached to the face of one of the pages in the publication and is
commonly referred to as "tipping." Yet another method for binding a
sleeve and a magazine includes fastening a portion of the sleeve to
the pages of the magazine by stitching during the binding process.
The method of stitching is commonly refereed to as "saddle
stitching." In order to perform the stitching, however, the sleeve
must provide a binding flap for receiving the stitching that binds
the sleeve to the pages of the publication.
[0013] The prior art reveals sleeves that are approximately the
same size as a CD. In other words, prior art sleeves fail to
provide excess surface area extending beyond the perimeter of the
CD. As a result, the prior art sleeves containing a rigid CD lack
the flexibility for inclusion into conventional binding machinery.
Moreover, the relatively smaller size of the sleeves, as compared
to the pages of the publication to which they are bound, minimizes
the print space available for advertising or related information.
Current sleeves capable of being fed using standard feeders require
that those feeders operate at significantly slower speeds as
compared to their maximum rate of speed.
[0014] Typical conventional automated binding processes require
prior art sleeves to be fed into the pages of a publication with
specialty feeders. Unfortunately, the specialty feeders tend to
slow the binding process along the automated production line.
Consequently, the entire automated process is slowed. Stated
differently, the maximum production speed for providing sleeves
bound in publications is limited by the rate at which the feeders
are able to feed the sleeves into the production line. Thus, there
is a need for an article-embedded sleeve that does not require the
use of a specialty feeder during binding and does not slow the rate
of production for a standard feeder.
[0015] For example, U.S. Pat. No. 5,694,743 to Beighle describes a
sleeve containing a computer disc product that is incorporated into
a book and a method of providing the combined product. The sleeve
of Beighle is a five-section blank that includes a base ply, cover
ply, gluing flap, trim flap, and a closure and access flap. The
method of the '743 patent includes directing pressurized air into
an opening in the sleeve, laterally inserting the disc into the
enlarged opening in the sleeve, and then sealing the sleeve. Stated
differently, the disc is laterally inserted into a completed
sleeve. As disclosed, the '743 patent fails to disclose a sleeve
having a display window and frontal access that is capable of
incorporation into conventional binding processes without the need
for specialty feeders. Moreover, Beighle fails to disclose a method
of forming a sleeve around the article to be packaged. As
described, Beighle's method of laterally inserting, for example, a
CD slows the binding process for the reasons stated above (i.e.,
misplacement).
[0016] Thus, there is a need for a sleeve that can be bound into a
publication utilizing current common feeders that minimizes or
eliminates the hindrances associated with current sleeves.
Additionally, these sleeves should allow the advertiser to take
advantage of the full-page size of the publication to communicate
their advertising messages. Furthermore, the sleeve needs to be
flexible enough to allow it to bend sufficiently to wrap around the
wheels and drums associated with publication bindery equipment.
OBJECT AND SUMMARY OF THE INVENTION
[0017] It is therefore an object of the present invention to
provide for the packaging of a substantially planar article (e.g.,
CD or DVD) suitable for use in automated binding.
[0018] Another object of the invention is the provision of a sleeve
formed from a blank that increases the efficiency of automated
binding processes.
[0019] Yet another object of the invention is the provision of a
sleeve that promotes frontal access to an article without
destroying the sleeve.
[0020] A further object of the invention is to increase the
manufacturing efficiencies associated with placing articles in
sleeves.
[0021] Another object of the invention is to maximize the
advertising space on a sleeve.
[0022] Yet a further object of the invention is the provision of an
article-embedded sleeve that can be readily incorporated into
existing binding processes without the need for specialty feeders
in order to increase the rate of production for bound publications
including sleeve inserts.
[0023] The invention meets these objectives with a packaging blank
capable of forming a sleeve having at least one internal cavity. In
particular, the invention is a packaging sleeve having at least one
display window that provides a view of the internal cavity of the
container upon construction. In another aspect, the invention is a
method for packaging an article that incorporates the blank wherein
the sleeve is formed around the article.
[0024] The foregoing and other objects and advantages of the
invention and the manner in which the same are accomplished will
become clearer based on the following detailed description taken in
conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a perspective view of the invention as used in
connection with a bound publication.
[0026] FIG. 2 is a top plan view of the sleeve displaying a CD
placed on the bottom panel, the top panel including a perforated
retaining flap, a display window, and access slots.
[0027] FIG. 3 is a cross-sectional view of the sleeve illustrating
the CD positioned in the internal cavity between the top and bottom
walls.
[0028] FIG. 4 is a perspective view of the invention depicting a
consumer inserting a finger into an access slot formed in the top
wall and raising an edge of an access tab adjacent the slot to gain
access to the article contained within the internal cavity.
[0029] FIG. 5 is a perspective view of the invention depicting the
user detaching a selective portion of retaining flap.
[0030] FIG. 6 is a perspective view of the invention illustrating
the user removing the article from the internal cavity.
[0031] FIG. 7 is a top plan view of the packaging blank depicting
the top panel, bottom panel, access slots, display window, and
perforated retaining flap of the preferred embodiment.
[0032] FIG. 8 is a top plan view of an alternative embodiment of
the packaging blank displaying the top panel, bottom panel, access
slots, display window, perforated retaining flap, and a binding
flap.
DETAILED DESCRIPTION OF THE INVENTION
[0033] The present invention will now be described more fully
hereinafter with reference to the accompanying drawings, in which a
preferred embodiment of the invention is shown. This invention may,
however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein. Rather,
these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the
invention to those skilled in the art. Like numbers refer to like
elements throughout.
[0034] An overall view of the packaging blank 10 formed into a
sleeve 11 containing a CD 20 used in conjunction with a printed
publication 12 that incorporates features of the present invention
is set forth in FIG. 1. As used herein, the term "panel" is used in
conjunction with the packaging blank 10 of the present invention
and refers to sections of the blank. See FIGS. 7 and 8. Further,
the term "wall" is used in conjunction with the sleeve 11 of the
present invention and refers to structures forming the sleeve.
[0035] As depicted in FIG. 7, a preferred embodiment of the
packaging blank 10 includes a top panel 13, a bottom panel 14, and
a retaining flap 15. It will be understood by those of skill in the
art that the terms top panel and bottom panel, and top wall and
bottom wall, are also referred to as front panel and rear panel in
the packaging industry.
[0036] With reference to the orientation of the invention in FIG.
7, it will be understood that the term "width" refers to a distance
measured from the left edge of a panel or binding flap to the right
edge of a panel or binding flap. It will be further understood that
the term "height" refers to a distance measured from the lowermost
edge of a panel, binding flap, or sleeve to the uppermost edge of
the panel, binding flap, or sleeve.
[0037] It will be further appreciated by those of ordinary skill in
the art that, as used herein, the concept of a panel or wall being
"between" two other panels or walls does not necessarily imply that
the three panels or walls are contiguous (i.e., in intimate
contact). Rather, as used herein, the concept of one panel or wall
being between two other panels or walls is meant to describe the
relative positions of the panels or walls within the blank or
container structure, respectively. Similarly, as used herein, the
concept of a first panel being connected to a second panel by a
third panel, "opposite" the second panel, merely describes the
relative positions of the first and second panels within the blank
structure.
[0038] The top panel 13 of the preferred blank 10 as shown in FIG.
7 includes at least one display window 16. An alternative
embodiment of the preferred blank 10 may include a plurality of
windows (not shown). The bottom panel 14 is connected to the top
panel 13 along a fold line. Upon constructing the blank 10 into a
sleeve 11, the window facilitates viewing of a substantially flat
or near planar article 20 contained within the sleeve 11 as
discussed herein.
[0039] In an alternative embodiment as illustrated in FIG. 8, the
top panel 13 includes a substantially rectangular binding flap 21
positioned opposite the bottom panel 14. Thus, the top panel 13 is
positioned between the bottom panel 14 and binding flap 21 in the
alternative embodiment. The width and height of the binding flap 21
is preferably less than or about equal to the width of the top and
bottom panels 13, 14. It will be understood, however, that the
width and height of the binding flap 21 may be greater than the
width and height of the top and bottom panels 13, 14 for use on,
for example, modified binding machinery. The binding flap 21 of the
alternative embodiment facilitates the binding of the sleeve 11
formed from the blank 10 into a publication 12. Specifically, the
binding flap 21 provides a generally flat planar surface for
receiving conventional saddle stitching used to bind publications.
In other words, the binding flap 21 provides an ample stitching
surface into which stitches are placed in order to bind the sleeve
11 into a publication along with the primary pages of the
publication.
[0040] In the preferred embodiment, the top and bottom panel 13, 14
are substantially rectangular. Likewise, in the alternative
embodiment, the binding flap 21 is substantially rectangular, but
is not limited to a rectangular shape. Nevertheless, it will be
understood that the top and bottom panels 13, 14 are not limited to
a rectangular shape and may, for example, may be oval, polygonal,
or elliptical.
[0041] As illustrated in the preferred embodiment of FIG. 7, the
packaging blank 10 may be a one-piece flexible blank formed from a
flexible material capable of incorporation into conventional
binding machinery (e.g., flexible polyester film or paperboard)
without assistance from a specialty feeder. The flexible blank 10
includes an external planar side 22 and an internal planar side 23.
The external planar side 22 is preferably finished. As used herein,
it will be understood that the term "finished" means coated with a
material to produce a attractive glossy finish. The term "finished"
will also be understood to mean the inclusion of printed material
or other identifying indicia (e.g., a company's logo).
[0042] In order to facilitate the formation of a substantially
rectangular sleeve 11, the width and height of the top and bottom
panels 13, 14 of the preferred embodiment are about equal to one
another.
[0043] As shown in FIG. 7, the preferred embodiment of the present
invention provides a retaining flap 15 that is formed by
perforations in the top panel 13. An alternative embodiment may
include a plurality of retaining flaps 15. Further, the top panel
13 of the preferred embodiment includes at least one display window
16. Alternatively, the top panel 13 may include a plurality of
display windows 16, such that each retaining flap 15 includes a
corresponding display window 16. It will be appreciated that, as
used herein, the concept of a retaining flap corresponding to a
display window refers to an ordered relationship (e.g., wherein the
retaining flap is substantially surrounding the display
window).
[0044] The retaining flap 15 is positioned on the bottom panel 14
such that the flap substantially surrounds the display window 16.
Stated differently, the display window 16 is bordered by the
retaining flap 15. As configured, the retaining flap 15 of the
preferred embodiment defines the entire perimeter of the display
window 16.
[0045] In the preferred embodiment, the retaining flap 15 and
display window 16 are substantially circular. Nevertheless, it will
be understood that the retaining flap 15 and display window 16 are
not limited to a circular shape and may be, for example,
rectangular, oval, polygonal, semi-circular, or elliptical.
Further, the radius of the display window 16 is preferably less
than the radius of the perforated retaining flap 15. To accommodate
the packaging of a CD or DVD, the diameter of the perforated
retaining flap 15 is preferably greater than 120 millimeters. In
one embodiment, the retaining flap 15 and the display window 16 may
be substantially concentric.
[0046] In this configuration, the retaining flap 15 formed in the
top panel 13 provides a consumer with frontal access to a
substantially flat or near planar article, for example, a CD that
may be placed in an internal cavity 24 formed when the blank 10 is
constructed into a sleeve 11. In a preferred embodiment of the
blank 10, the top panel 13 includes at least one access slot 25
formed adjacent the perforated retaining flap 15. Further, the top
panel 13 of an alternative embodiment may include at least one
access tab 26 formed adjacent the perforated retaining flap 15. In
this configuration, the access slot 25 and access tab 26 facilitate
the removal of the retaining flap 15. It will be understood that
the access slot 25 and the access tab 26 may be formed on either
side of the perforations defining the retaining flap 15. In one
embodiment, the access slot 25 and the access tab 26 are aligned
with respect to one another such that the access tab 26 engages the
access slot 25 in a corresponding fashion. For ease of use in
conventional binding machinery, however, it will be understood that
a preferred embodiment will include at least one access slot 25 and
no access tab 26, as the tabs may catch adjacent printed matter
during binding procedures.
[0047] In use, the sleeve 11 formed from the blank 10 permits the
consumer to grasp the edge of the retaining flap 15 adjacent an
access slot 25, lift the retaining flap upwardly and away from the
sleeve 11 to tear the perforations in the top panel 13, thereby
separating at least a portion of the retaining flap from the bottom
panel 14 and providing access to the article 20 contained within
the internal cavity 24. See FIGS. 4, 5, and 6.
[0048] As configured, the display window 16 is positioned on the
top panel 13 such that the internal planar side 23 of the bottom
panel 14 is viewable through the display window 16 bottom upon
construction of the sleeve 11. Multiple display windows 16 thereby
provide a view of at least two different positions on the internal
planar side 23 of the bottom wall 31. Accordingly, two windows
would provide a view of two separate articles and any indicia
(e.g., tile or bar code) printed thereon.
[0049] Another aspect of the present invention, as illustrated in
FIGS. 1-3, includes a sleeve 11 formed from the packaging blank 10
that has at least one internal cavity 24. As described above, the
term "wall" is used in conjunction with the container of the
present invention--as opposed to the previously described blank.
Further, the term wall refers to structures forming the
container--opposed to the sections of the blank 10.
[0050] With reference to FIGS. 2 and 3, a preferred embodiment of
the sleeve 11 includes a top wall 30, a bottom wall 31, and a
retaining flap 15. In the preferred embodiment the top wall 30 and
bottom wall 31 are substantially rectangular in shape, but may be
oval, polygonal, or any similar shape supporting the construction
of a sleeve 11. The bottom wall 31 is connected to the top wall 30
along a fold line. A display window 16 is provided in the bottom
wall 31 for viewing an interior portion of the bottom wall. See
FIG. 3. It will be understood that an alternative embodiment of the
sleeve 11 may include multiple retaining flaps 15 and multiple
display windows 16 corresponding to each retaining flap.
[0051] The top wall 30 of an alternative embodiment of the sleeve
11 (not shown) includes a substantially rectangular binding flap 21
positioned opposite the bottom wall 31. In the alternative
embodiment, the binding flap 21 is substantially rectangular, but
is not limited to a rectangular shape. The width and height of the
binding flap 21 is preferably less than or about equal to the width
and height of the top and bottom walls 30, 31. The binding flap 21
facilitates the binding of the sleeve 11 into a publication.
Specifically, the binding flap 21 provides a flat surface for
receiving conventional saddle stitching used to bind
publications.
[0052] The top and bottom walls 30, 31 of the preferred embodiment
are substantially rectangular, however, it will be understood that
the top and bottom wall are not limited to a rectangular shape and
may be, for example, oval, polygonal, or elliptical. In order to
facilitate the formation of a substantially rectangular sleeve 11,
the height and width of the top and bottom walls 30, 31 of the
preferred embodiment are about equal to one another.
[0053] As shown in FIGS. 2 and 3, the preferred embodiment of the
present invention provides a retaining flap 15 that is formed by
perforations in the top wall 30. The top wall 30 of an alternative
embodiment may include a plurality of retaining flaps 15. The top
wall 30 includes a display window 16, but it will be understood
that the top wall may include a plurality of display windows
corresponding to a plurality of retaining flaps 15. The retaining
flap 15 is positioned on the top wall 31 such that the flap
substantially surrounds the display window 16.
[0054] In the preferred embodiment, the retaining flap 15 and
display window 16 are substantially circular. It will be
understood, however, that the retaining flap 15 and display window
16 are not limited to a circular shape and may be, for example
rectangular, oval, polygonal, semi-circular, or elliptical. The
radius of the display window 16, likewise, is preferably less than
the radius of the perforated retaining flap 15. The diameter of the
perforated retaining flap 15 is preferably greater than 120
millimeters to accommodate the packaging of a CD. The retaining
flap 15 and the display window 16 may also be concentric.
[0055] In this configuration, the retaining flap 15 formed in the
top wall 30 provides a consumer with easy access to a substantially
flat or near planar article 20 positioned in the internal cavity 24
of the sleeve 11 formed from the blank 10. See FIGS. 4, 5 and 6. In
a preferred embodiment of the blank 10, the top wall 30 includes at
least one access slot 25 formed adjacent the perforated retaining
flap 15. See FIG. 2. Further, the top wall 30 of an alternative
embodiment may include at least one access tab 26 formed adjacent
the perforated retaining flap 15. In this configuration, the access
slot 25 and access tab 26 facilitate the removal of the retaining
flap 15. It will be understood that the access slot 25 and the
access tab 26 may be formed on either side of the perforations
defining the retaining flap 15. In one embodiment, the access slot
25 and the access tab 26 are aligned with respect to one another
such that the access tab engages the access slot in a corresponding
fashion.
[0056] The sleeve 11 formed from the blank 10 thereby permits the
consumer to grasp the edge of the retaining flap 15 adjacent an
access slot 25 and lift the retaining flap away from the sleeve to
tear the perforations in the top wall 30. The lifting motion
separates a portion of the retaining flap 15 from the bottom wall
31 and provides access to the article 20 contained within the
internal cavity 24. See FIGS. 4, 5, and 6.
[0057] As configured from the blank 10 of the present invention,
the display window 16 is likewise positioned on the top wall 30
such that the internal planar side 23 of the bottom wall 31 is
viewable through the display window upon construction of the sleeve
11. Multiple display windows 16 thereby provide a view of at least
two different positions on the internal planar side 23 of the
bottom wall 31. Thus, two windows would provide a view of two
separate articles.
[0058] Another aspect of the invention includes the use of the
packaging blank 10 in conjunction with a method for packaging an
article. This method is preferably accomplished at a packaging
supplier's facility, thereby eliminating the requirement for a
publisher to package the article 20 in a sleeve 11 and then bind
the article-embedded sleeve in separate insertion steps. Stated
differently, the publisher is not required to independently stock
and track the primary article 20 and the sleeve.
[0059] In a preferred method, a flexible blank 10 is provided that
includes a substantially rectangular top panel 13 and a
substantially rectangular bottom panel 14 that are connected along
a fold line. The blank 10 includes a retaining flap 15 formed by
perforations in the top panel 13. It will be understood that the
blank 10 may include a plurality of retaining flaps 15 that each
include a window. In an alternative method, the blank provided may
include a binding flap 21 attached to the top panel 13 opposite the
bottom panel 14. Next, the article 20 to be packaged is placed on
the internal planar side 23 of the flexible blank 10. It will be
understood that the article 20 may be placed on the top panel 13 or
bottom panel 14 in this first preferred method. In a preferred
method, the article 20 is positioned and secured to the bottom
panel 14 by means of a static charger. The static charger secures,
for example, a CD to the bottom panel 14 at its original placement
for approximately fifteen seconds or a time sufficient for folding
the top panel 13 over the bottom panel 14 while the CD is
temporarily secured to the panel. Alternatively, the article 20 may
be secured to the blank 10 with adhesive.
[0060] The top panel 13 is then folded over the bottom panel 14 to
form an internal cavity 24 in which the article 20 is positioned.
Alternatively, the folding of the top panel 13 may likewise form a
plurality of internal cavities when the blank 10 provided includes
a plurality of retaining flaps 15 having a plurality of display
windows 16. In a preferred method, the top panel 13 is folded to a
position substantially adjacent to the bottom panel 14. Next,
portions of the top panel 13 and bottom panel 14 are adhered to one
another. It will be understood that the top and bottom panels 13,
14 may be adhered with a variety of adhesives to include glue
(e.g., fugitive glue).
[0061] The step of positioning an article 20 may incorporate a
conventional device that includes an arm having a suction means
which retrieves an article 20 and then positions the same on a
panel of the blank 10. For example, an item may be retrieved and
then selectively placed on the blank 10 such that a bar code on an
article 20 is viewable through the display window 16 upon
construction of the container. Accordingly, a bar code scanner
positioned along an automated production line may scan the bar code
on the article, thereby expediting publication compliance (i.e.,
matching articles with their respective publications). In other
words, the publisher can ensure that the appropriate
article-embedded sleeve 11 is matched with the appropriate matter
to be bound.
[0062] This placement method, commonly referred to as a "pick and
place" action, eliminates many of the jamming problems associated
with current insertion methods whereby articles are laterally
inserted into a sleeve 11. The lateral insertion typically results
in the edges of the CD catching the edges of the sleeve walls,
thereby preventing proper insertion.
[0063] Upon folding the top panel 13, the article-embedded sleeve
11 is positioned in a standard feeder--as opposed to a specialty or
modified feeder--common to conventional binding machinery along
with the matter (e.g., magazine pages) to be bound. Next, the
sleeve 11 and matter to be bound are simultaneously fed (i.e.,
stacked one atop the other) into the production line for binding.
The sleeve 11 can be bound in the publication in several manners.
First, the sleeve 11 can be adhered to the pages of the publication
by adhesive in a "perfect bound" method. Alternatively, the sleeve
11 is capable of being bound with stitching. Advantageously, the
sleeve 11 of the present invention is capable of being incorporated
into conventional binding machinery without requiring publishers to
retool or modify existing feeding mechanisms incorporated into the
automated binding production line. In other words, the sleeve 11
can be readily fed into existing binding machinery along with pages
to be bound without using a specialty feeder required when binding
prior art sleeves.
[0064] As known to those skilled in the art, the sleeve 11 may be
bound in a publication such that the top wall 30 or the bottom wall
31 is initially presented to the reader. Accordingly, it will be
understood that the binding flap 21 may be presented before the top
wall 30 or bottom wall 31, depending upon the orientation of the
sleeve 11 during the binding process.
[0065] Accordingly, the present method whereby an article 20 is
positioned on the blank 10, and the sleeve 11 is subsequently
formed around the article, promotes substantially higher assembly
speeds and lower waste than existing methods, whereby the sleeve 11
is formed and then the article 20 is inserted into the finished
sleeve. Stated differently, the present method positions an article
20 during the formation of the sleeve 11, as opposed to inserting
the article 20 after construction of the sleeve 11 (e.g., lateral
insertion of CD into sleeve with the assistance of a directed air
stream). Thus, the finished sleeve 11 includes an article 20 and is
ready for incorporation into conventional binding machinery.
Moreover, the present method is capable of incorporating a wide
variety of substantially flat or near planar articles into the
present sleeve 11. For example, cosmetics samplers, consumable
goods (e.g., instant coffee), small toys, and the like may be
packaged in accordance with the present invention. In addition,
multiple products can be placed in the same sleeve 11.
[0066] In the drawings and specification, there have been disclosed
typical embodiments on the invention and, although specific terms
have been employed, they have been used in a generic and
descriptive sense only and not for purposes of limitation, the
scope of the invention being set forth in the following claims.
* * * * *