US 20050006258 A1
A disc holder formed from a base layer of material and a top layer of material that has a surface area less than the base layer, the layers being adhered and arranged to provide that the trim edge is free of the top layer upon trimming thereby preventing contamination of a manufacturer's recycling process.
1. A disc holder suitable for binding, comprising top and base layers of material each having a generally flat surface and being adhered together wherein said top layer has a surface area less than said base layer and the trim edges of said top layer of said holder are within the trim edges of said base layer of said holder.
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12. A method for forming a disc holder suitable for binding having top and base layers of material each having a generally flat surface wherein said top layer has a surface area less than said base layer and the trim edge of said top layer of said holder is within the trim edge of said bottom layer of said holder, comprising the steps of:
a) providing top and base layers of material;
b) adhering said layers of materials.
13. The method of
c) inserting a data disc into said pocket.
14. A method of binding, into a publication, a disc holder suitable for binding having top and base layers of material each having a generally flat surface wherein said top layer has a surface area less than said base layer and the trim edge of said top layer of said holder is within the trim edge of said bottom layer of said holder, comprising the steps of:
a) providing the top and base layers of material;
b) adhering said layers of material;
c) inserting a data disc into said pocket;
d) providing at least one other signature;
e) gathering said holder with said at least one other signature;
f) binding said holder and said at least one other signature to form said publication.
15. The method of
(g) trimming said publication to remove the trim edge portion of said publication and said holder.
16. The method of
This invention relates generally to disc holders, more specifically, to a data disc holder suitable for binding into printed publications.
Publishers of books and other printed publications often desire to include additional materials with their publications, such as tear-out inserts, software, music or data. One common carrier of this additional content is a data disc, such as a compact disc or DVD, which can be bound into the publication, typically against the front or back cover of the publication. Publications are typically assembled by binding together a number of sections, commonly referred to as signatures. Accordingly, to include a data disc in a publication, the data disc is placed in the holder and the holder is then treated as a signature and bound into the publication.
A number of data disc holders have been fabricated for the purpose of including a data disc in a publication. Some common data disc holders include paper holders with windows, plastic holders and vinyl holders. However, paper holders are expensive to manufacture. The plastic holders are problematic because as the holders are treated as signatures, the holder is jogged to the top or bottom of the publication as the publication and data disc holder run through the jogging, gluing and trimming processes. During the trimming process, the holders with plastic are trimmed and the resulting waste material pollutes the paper recycling systems of the manufacturer. Vinyl holders, whether transparent, opaque or translucent, suffer from the same problems as both the plastic and paper holders.
Other combinations of materials have also been used, including data disc holders with a combination of a top transparent layer such as plastic and a bottom non-woven fabric. However, the combination holders cost substantially more to manufacture and either have signature trimming recycling problems or require costly preassembly and/or attachment operations.
Accordingly, as mentioned, the existing data disc holders intended for binding into publications include significant limitations. As a result, significant improvement can still be made relative to creating a less expensive and recycling compatible data disc holder.
The present invention is intended to provide an improved data disc holder that is less expensive, recycling compatible, easy to include in the binding process and securely holds the data disc during the binding process, and transparent thereby permitting viewing of the enclosed data disc.
The data disc holder is generally comprised of a transparent top layer and an opaque or translucent base layer. The two layers are glued together to form a pocket that can receive a data disc that is viewable from the outside. The top layer is glued substantially to the base layer on three of the four sides of the layers and on the fourth side a sufficient space is left to slide the data disc into the pocket; accordingly, the fourth side is only partially glued.
The glue on the fourth side terminates at a distance sufficient to permit the data disc to be inserted into the pocket between the layers at the unglued portion of the fourth side. Also, the glue is preferably of a strength that permits the edge of the data disc to penetrate the bond between the plastic and paper layers enough to allow the data disc to become wedged into the edges, but not so much as to permit the data disc to entirely break the bond and exit the holder. The top is also die-cut to form a zipper tab to permit easy removal of a portion of the top layer to enable access to the data disc pocket.
In a preferred embodiment, the base layer is paper and the top layer is plastic and sized to be less than the area of the base layer, thereby avoiding trimming of the top layer plastic during the trim portion of the binding process. In one embodiment this is achieved by having a top layer waste matrix that is removed from the holder's base layer. In another embodiment this is achieved by simply using a plastic layer that is smaller than the base layer.
In one process for manufacturing the holder, the paper and plastic materials are initially contained on two separate rolls. The rolls are aligned so the paper roll dispensed from the paper roll is located beneath the plastic dispensed from the plastic roll. As the paper is unrolled, it is stamped with an ultraviolet glue stamp that imparts the desired glue pattern onto the paper. The paper and plastic materials are then married together and an ultraviolet light cures the adhesive. The paper and plastic can be any thickness or composition, however, the marrying of the materials has been found to work well using a 2 mil polyethylene plastic layer to provide enough weight to enable marriage of the materials without using excess plastic.
One advantage of the present invention is that the data disc holder is less expensive to manufacture. Another advantage of the invention is that the data disc holder does not create plastic waste product during the trim portion of the binding process and is therefore compatible with existing paper recycling systems. The invention also has the advantage of permitting viewing of the data disc through the top layer of the holder. Another advantage is that the holder retains the disc more securely during the binding process. Another advantage is that the data disc can easily be removed from the publication by pulling the die-cut zipper tab.
The preceding description of the invention has shown and described certain embodiments thereof, however, it is intended by way of illustration and example only and not by way of limitation. Those skilled in the art should understand that various changes, omissions and additions may be made to the invention without departing from the spirit and scope of the invention.