COMPACT DISC PACKAGE
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to packaging systems and more
particularly to packages for holding and shipping CD and CD-ROMs and
similar disc and disk-like articles.
Art Background
The Compact Disc (CD) introduced into the United States in 1983 was
primarily a device, like a phonograph record, used for recording sound. Data
is recorded on the CD in digital form as a series of tiny pits that are covered
with a clear, protective coating. Instead of a needle vibrating in the grooves,
a laser in a CD player shines light onto the pits and picks up the reflections as
binary code. Thus the CD is also referred to an an optical disc. The Compact
Disc Read Only Memory ("CD-ROM") is a compact opdcal disc based upon
the Compact Audio ("CD") consumer product. The CD-ROM is used to hold
text, graphics and sound. The CD-ROM is 120 mm in diameter, single sided
and can hold in excess of 600 MegaBytes of data.
The CD has become the medium of choice in the music recording industry and the CD-ROM has similarly become ubiquitous in the electronics systems business. Computer hardware and software manufacturers now ship millions of CD-ROM units each month, containing various kinds of software, including computer programs, databases, documentation, etc. A CD or CD-ROM has no inherent protective covering like the earlier vintage thin mylar floppy disks with their enclosing protective cases. As a result, these CD and CD-ROM are typically packaged in the standard single or double disc plastic "jewel case" package for protection in shipping and storage. Hereinafter "CD" will refer to both CD and CD-ROM unless otherwise indicated. A single disc jewel case is depicted in Figure 1. Referring to Figure 1, a typical jewel case package 10 is shown comprising a bottom member 16 which is typically made of clear plastic, an opaque molded plastic holding member 18 which is seated in the bottom plastic member 16 and which has a recessed area 19 for receiving a CD and a central hub 17 for holding the CD in the holding member 18. The typical jewel case 10 also has a top member 12 which is also made of clear plastic, this top member 12 usually having small tabs 14
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on opposing sides which are used to receive on the underside of the top member 12 an identification label or explanatory booklet. There are various embodiments of the plastic jewel case for holding two CDs. They all typically have the same components. Referring to Figure 2 one embodiment of a two CD case 30 is shown comprising a bottom clear plastic member 33 having an opaque plastic insert 34 which is molded to receive and hold one of the CDs, and a top clear plastic member 32 also having an opaque plastic insert 34 which is molded to receive and hold one of the CDs. The top member 32 and the bottom member 33 are connected by means of hinging mechanisms to a central molded plastic member 36.
These prior art packages are characterized by the pervasive use of expensive and non-biodegradable plastics. In an attempt to reduce the expensive use of the clear plastic top and bottom members, some recent embodiments (see for example Figure 3) have incorporated a heavy paper material member (item 42 in Figure 3) with the molded plastic holding member (item 44 in Figure 3) for holding a single CD glued to one end of the paper member, whereby the other end of the paper member can be folded over the CD to form a protective cover. One type of such package is the DIGLPAKR By AGI, Inc., Melrore Park, Illinois.
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In spite of the reduced use of the non-biodegradable plastic in such embodiments of a CD package as exemplified by the unit shown in Figure 3, any use of non-biodegradable materials (such as the formed plastic holding member 44) is objectionable to many persons in the United States and to official authorities in other countries. In the European Communities Council Directive on Packaging and Packaging Waste (93 /C 129/08), Section 2, it points out that the directive's main objective (2.2.1) is "to minimize the total impact on the environment of packaging and packaging waste, . . .", and suggests the following to reduce such waste in order of priority (2.2.3):
"elimination/reduction of superfluous packaging; prevention/reduction of the volume of one way packaging . . .; re-use of packaging; recycling of packaging waste; only in the last resort, final disposal." Actions taken by some EC countries include:
Austrian Packaging Waste Law: requires manufacturers and importers to take back used packaging without a fee, or alternatively paying up to 1.136 ECU/ton for plastics disposal.
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German Green Dot Scheme (Waste Management): similar to Austrian scheme with the emphasis on manufacturers and importers to restrict packaging to the absolute minimum in volume and weight to the dimensions actually required to protect the contents and to market the product. Has a quota for industry to recycle 64% of all plastics used to take effect July 1, 1995.
UK; government has challenged industry and importers to reduce packaging waste by 50% to 75% by the year 2000.
The assignee of this invention, Sun Microsystems, Inc., like most international computer hardware or software companies, as well as most major music publishing companies, ship thousands of copies of CD-ROM and CD into the European countries each month. The expense of dealing with the non-biodegradable materials resulting from such laws relating to import and removal of such materials is therefore enormous.
Applicants invention is an elegant and simple paper package capable of securely and protectively holding up to four CDs, CD-ROM or other disk- like articles, using minimum materials in volume and weight and no non-biodegradable plastic materials. Most significantly however, this simple yet effective package reduces the average cost of manufacture of the package dramatically. For example, in relation to the
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type of package illustrated in Figure 3, the present invention, when used to contain a single CD, reduces the packaging cost from 35% to 50%; and when used to hold two CDs, reduces the cost from 60% to 75%, while providing adequate protection in shipping and storage for the fragile disks.
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SUMMARY QF THE INVENTION
A disc or similar disk-like article container is disclosed, which is made
from a single sheet of packaging materials configured in a form which is
foldable to produce the container, having a first section with overlapping
components of the materials to form pockets adaptable to receive and hold the
disk-like articles, and having a second section with overlapping components
of the materials and the second section being foldable over the first section to
provide a protective cover for the first section.
The first section of the container has overlapping components of the
materials sufficient to form pockets adaptable for receiving and holding up to
three of me disk-like articles, and die second section may have its overlapping
materials configured to form a pocket adaptable for receiving and holding one
of the disk-like articles or for holding a descriptive booklet or other type of
materials.
The container materials incorporates a minimum of 30% recycled
fiber.
Additionally the container is coated with an aquaous coating that
serves to protect the enclosed discs drom loose fibers generated by the
container's recycled paper materials.
Also disclosed is a method for configuring and making a disk or similar
disk-like article container from a single sheet of packaging materials, which
is adaptable to receive and hold up to four of the disk-like articles, using
minimum materials in volume and weight and using no non-biodegradable
plastic materials.
DESCRIPTION OF THE DRAWINGS
The objects, features and advantages of the Compact Disk package of
the present invention will be apparent from the following description in which:
Figure 1 illustrates a typical prior art molded plastic single CD jewel
case.
Figure 2 illustrates a typical prior art molded plastic double CD jewel
case.
Figure 3 illustrates a prior art embodiment of a single CD package made of paper and a molded plastic CD holding member.
Figure 4 illustrates the present invention in a plane view of a single
paper sheet showing all surfaces and connecting tabs.
Figure 5 illustrates the present invention in folded form showing the
sections for receiving two CDs and a descriptive booklet.
Figure 6 illustrates a perspective view of the present invention shown
holding two CDs.
Figure 7 illustrates a perspective view of an alternative embodiment
of the present invention shown holding four CDs.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is a paper based container for a compact disc
("CD"), a compact disk read only memory ("CD-ROM") or other similar
disk-like article, and a method for making such a container wherein the
container may hold up to four of the disk-like articles while using minimum
materials in volume and weight and yet providing adequate protection for the
articles, and using no non-biodegradable plastic materials. In the following
description, particular specifications are disclosed when describing the various
embodiments of the invention. These specifications are intended to provide
an illustration of a specific application of the invention but are not intended to
limit the application of the invention to any specific type of CD, CD-ROM or
similar disk-like article. It will be apparent to one skilled in the art that the
present invention may be practiced in a wide range of packaging systems of
various specifications and configurations. The following description also
contains references to material types and components which are well known
in the art, and these should be interpreted in the illustrative and not in the
limited sense.
The container of the present invention is used to facilitate the
packaging, shipment and storage of CD and CD-ROM and other disc and
disk-like units containing various types of data including music, video,
software, such as computer programs of various kinds, databases of
information, documentation, and combinations of these. The shipments of CD
and CD-ROMs in these containers will be made to almost all countries in the
world.
Referring now to Figure 4, a plan layout 50 of the preferred
embodiment is illustrated. In this preferred embodiment, the materials used
have the following characteristics:
Type: Printkote Eagle® by Westvaco
Thickness: 20 point
Grain Direction: Vertical
Color: White
Finish: Gloss
Recycle Content: 30% post-consumer recycled fiber
Additionally, the package is coated wim an environmentally friendly aqueous
coating that also serves to add protection to the enclosed disc or disk-like
articles from loose fibers generated by the container's recycled paper
materials. Moreover, in the preferred embodiment the container package is
printed on one side and folded so that the printed surface appears on all sides,
thereby reducing cost and ink surface. Referring now to Figure 4, a preferred
configuration of the invention is illustrated in plan view 50, showing six major
component parts 52, 55, 56, 57, 58 and 62. Components 56, 57, 58 and 62 are
folded together to form a first section of the container, and components 52 and
55 are folded together to form a second section of the container. The first
section of the container is formed as follows:
Component 56 is folded upwards along line 71 and folded over
component 57;
Tab 59 is folded upwards and over onto component 58 and glue
is applied to the side of tab 59 opposite component 58, and tab 60 is
folded upwards and over component 58 and glue is applied to the side
of tab 60 opposite component 58, and component 58 is folded upwards
along line 72 and over component 56 and secured to component 57 by
means of the glue on tab 60 which meets component 57 through the
cut-out portion 80 of component 56 and secured to component 57 by
means of the glue on tab 59 which meets component 57 through the
cut-out portion 81 of component 56 ;
finally, tab 64 is folded up and over component 62 along line
75 and glue is applied to the side of tab 64 opposite component 62 and
tab 65 is folded up and over component 62 along line 74 and glue is
applied to the side of tab 65 opposite component 62 and component 62
is folded up along line 73 and folded over component 58 and secured
to component 57 by means of the glue on tabs 64 and 65.
This first section of the container therefore contains an air pocket in the
space between components 57 and 56, as well as an air pocket between
components 56 and 58, and an air pocket between components 58 and 62. Each
of these air pockets may contain a CD or CD-ROM each of which would be
cushioned by each other and the intervening component layers of the
container. Alternatively, and in the preferred embodiment, a CD or CD-ROM
would be contained in the pockets between components 56 and 58, and
components 58 and 62 and would be cushioned by each other and by the air
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It is therefore clear that up to four discs may be securely placed in the
container described. It is anticipated that the normal configuration would
contain one or two discs with accompanying booklets of explanatory matter.
However an alternative embodiment holding four CDs is shown in Figure 7,
wherein the container is comprised of two first section parts, with one being
foldable over the other. Referring to Figure 5, a booklet in the air pockets
between components 56 and 57 and components 52 and 55 would provide
additional padding for the protection of one or two discs in the container, but
the air pockets themselves are deemed adequate protection for one or two discs
placed in the pockets between components 56 and 58 and components 58 and
62, when the second section (comprising components 52 and 55) is folded over
the first section along line 77 to form a closed package.
Referring to Figure 6, a perspective view of the invention is shown,
containing two CD-ROMs 90 and 92. The first CD-ROM 90 is shown seated
in the pocket formed by components 62 and 58. The second CD-ROM 92 is
shown seated in the pocket formed by components 58 and 56. In the shipping
configuration, the second section of the container formed by components 52
and 55 is folded along line 77 over the top of the CD-ROMs 90 and 92, thereby
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pocket between components 57 and 56. In another alternative, a descriptive
booklet or other information may be contained in the pocket between
components 57 and 56, thereby providing additional cushioning for the disks.
In an alternative embodiment, component 56 is secured to component 57 by
means of glue along the edge 83 of component 56.
The second section of the container is formed as follows:
tab 54 is folded up and over component 55 along line 79 and
glue is applied to the side of tab 54 opposite component 55;
tab 53 is folded up and over component 55 along line 88 and
glue is applied to the side of tab 53 opposite component 55;
component 52 is folded up along line 78 and over component
55, being secured to component 55 by means of the glue on tabs 53 and
54 thereby forming an air pocket between components 52 and 55. This
air pocket provides additional space for holding an additional disc or
disk-like article or a booklet or other information thereby providing
additional cushioning for disks located in the first section, when this
second section is folded over the first section along line 77.
providing a protective covering for the CD-ROMs cushioned either by the air pocket between components 52 and 55 or by a descriptive booklet which may be placed in that air pocket.
It is pointed out again that the container is made from 20 point stock paper, containing 30% post-consumer recycled fiber, and contains no plastic inserts or holding pieces to protect the disks, and yet the disks obtain adequate protection from the various air pockets and component layering of the invention.
Those skilled it the arts of manufacturing such packages for disks will recognize that there are alternative methods for folding and pasting together the components of such a device, and that changes of form of the various components and/or tabs or variations in the weight and/or composition of the paper will not change the invention. In the claims which follow, the word "disk" is used to mean also "disc", and the hyphenated word "disk-like" is used to mean CD, CD-ROM and other similar devices, including floppy disk type devices that are of equal or smaller size to a standard CD.
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