GB2130557A - Disc record package - Google Patents

Abstract

A record caddy outer sleeve comprises a substantially U-shaped enclosure (144) closed on the opposite sides by a pair of substantially T-sectioned rails (146, 148). The inside surfaces (194, 196) of each T-rail may be inclined away from the respective intermediate flange portion (174) to accommodate excess molten plastic during welding to produce clean and uniform welds. <IMAGE>

Description

SPECIFICATION Disc record package This invention relates to a disc record package.

In certain systems, picture and sound signals are stored on a disc record in the form of physical undulations in a continuous spiral track disposed on the record surface. The variations in electrical capacitance between an electrode disposed on a recordengaging stylus and a conductive property of a turntable-supported record are sensed as the physical undulations on the record surface pass beneath the stylus tip. The capacitive variations are converted into electrical signals suitable for application to a conventional television receiver.

It is beneficial to enclose a video record in a caddy which comprises a record retaining spine removable located within an outer sleeve. The record retaining spine has an opening in which a record is received to form a record/spine assembly. The record retaining spine is provided with a pair of spaced apart locking fingers disposed at the opposite edges thereof to releasably secure the spine to the sleeve. The caddy sleeve is covered with a wrap-around label containing program information and graphics. For record loading, a full caddy is inserted into an input slot provided in the player along a pair of caddy guide rails. A record extraction mechanism disposed in the player removes the record/spine assembly from the sleeve when the sleeve is withdrawn to leave the record/spine assembly inside the player resting on a set of record receiving pads.The retained record is then transferred by a record handling mechanism to a turntable for playback. For record retrieval, the record is transferred back to the receiving pads, and an empty jacket is reinserted into the player to recapture the record/spine assembly.

U.S. Patent No. 4,239,108, issued to C.Coleman et al, describes a video disc caddy construction. The caddy sleeve shown in the Coleman et al patent comprises a pair of injection molded caddy halves which are welded together. U.S. Patent No.

4,316,539 (Torrington) discloses an alternative construction for the caddy sleeve. In Torrington, the caddy sleeve consists of a pair of inexpensive panels securely mounted to a U-shaped injection-molded frame.

Pursuant to the subject invention, a disc record package comprises a pair of T-shaped rails attached to a U-shaped enclosure. The U-shaped enclosure consists of a pair of spaced panel portions interconnected by an end portion along one side of the panel portions. Each of the side rails has an edge wall portion and an intermediate flange portion extending substantially perpendicularly from the edge wall portion to define a pair of channels. The side rails are mounted to the U-shaped enclosure so that the side edges of said panels are received in the respective channels to form a record access opening in communication with a record enclosing cavity.

Example embodiments of various aspects of the structure include the following. The T-shaped rails are in the form of plastic extrusions. The U-shaped enclosure consists of an extruded plastic sheet formed into the required shape. The T-rails are secured, such as by ultrasonically welding, to the U-shaped enclosure. The T-rails and the U-shaped enclosure are made from any suitable material, such as polystyrene.

In accordance with particular example embodiments, each of the side rails is provided with a slightly raised step portion on each side of the intermediate flange portion. The perpendicular flange portions of the side rails are inserted and held between the respective side edges of the panel portions so that the edge wall portions of the side rails are substantially flush with the side edges of the panel portions. The flange portions of the side rails are fused to the side edges of the panel portions by the application of ultrasonic energy to complete the assembly.

It is possible that the molten plastic from the side rail channels mightgettrapped between the outer edges of the panel portions and the interior surfaces of the edge wall portions of the side rails to produce discontinuities along the edges. It is also possible that the molten plastic from the step portions might form flash along the side edges of the enclosure.

To overcome these and other problems, the inside surfaces of the edge walls of the side rails may be tapered away from the intermediate flange portions.

The beveled side rails eliminate flash and produce uniform joints.

In the drawings: Figure 1 is a video disc player suitable for use with a video disc caddy fabricated in accordance with the subject invention; Figure 2 illustrates the video disc caddy comprising a record retaining spine adapted for selective retention in an outer sleeve constructed according to this invention; Figures 3-9 depict the sequence of operations utilized in fabricating the Figure 2 caddy sleeve.

Figures 10 and 11 depict the cross-sectional views of the side rails of the caddy sleeve of Figure 1; Figure 12 shows the caddy welding machine used for ultrasonically welding the side rails to the U-shaped enclosure to form the Figure 1 caddy sleeve; and Figures 13 and 14 indicate the sequence of steps involved in the caddy welding operation.

Shown in Figure 1 is a video disc player 20 suitable for use with the video disc caddy of the present invention. To play a disc, the player is turned on by pressing the 'POWER' button 22 located on the front panel 24. The video disc caddy, illustrated in Figure 2, is inserted into the player through a caddy input slot 26, and the caddy sleeve is then extracted leaving the enclosed record/spine assembly inside the player. The record is automatically deposited on the turntable, and played back through a conventional television receiver. At any point during playback, the viewer can reject the remainder of the record by depressing the 'REJECT' button 28, or interrupt the program by activating the 'PAUSE' button 30. Buttons 32 and 34 permit a non-visual rapid scan of the record in either direction. Buttons 36 and 38 allow a rapid visual search of the record in both directions.

The player has a 'CHANNELA/B' button 40 to select any one of two audio channels in the event of a bilingual program disc. An LED indicator 42 shows the elapsed playing time. Various player functions such as, SIDE 1-2, CHANNEL A/B, STEREO - are indicated by a plurality of light indicators 44.

The video disc caddy 50, depicted in Figure 2, consists of a planar injection-molded record retaining spine 52 removably enclosed in a flat outer sleeve 54 made in accordance with this invention.

The retaining spine 52 has an opening 56 in which a centrally-apertured record 58 is received forming a record/spine assembly 60. Integrally molded with the spine 52 are spine locking fingers 64 and 66 for releasably securing the spine 52 in its sleeve 54. The spine locking fingers 64 and 66 are fitted with protruding elements 68 and 70 which are received in the respective recesses 72 and 74 provided in the sleeve 54to hold the spine 52 in place. The spine 52 has cutouts 76 and 78 in which the respective spine latching members of a record extraction mechanism are received to secure the spine to the player, so that the record/spine assembly 60 is retained inside the player when the caddy sleeve 54 is withdrawn. The caddy sleeve 54 has a record access opening 80 in communication with a record enclosing cavity 82.

The construction of the illustrative caddy sleeve 54 in accordance with the invention will now be explained in conjunction with Figures 3-9. A flat extruded polystyrene sheet 100 is trimmed to size.

Illustrative dimensions of the plastic sheet, in inches are 0.070 thick x 12.690 wide x 28.165 long (1 .75mm x 317.25mm x 704.12mm). Any suitable material, e.g.

polystyrene, is extruded into a flat sheet, which is either cut into individual pieces or stored in a roll form for the subsequent die cutting and trimming operations. The flat sheet 100 is die cut at both ends to form cutouts 102 and 104 for reception of the front wall of the spine 52 so that the front edge of the spine is flush with the front edge of the outer sleeve 54. The lead-in edges of the flat sheet 100 are beveled at both ends 106 and 108, as shown in Figure 4, to facilitate insertion of the record/spine assembly 60 into the caddy sleeve 54. The bevels 106 and 108 are cold formed. The die cutting and beveling operations are performed simultaneously at a single station.

The recessed and beveled plastic sheet 100 is then cleaned by passing it through a set of cleaning rollers 110 and 112 depicted in Figure 5. Any suitable cleaning cloth can be used - for example, wiping fabric made by 3M Company. The plastic sheet is passed through a set of antistatic bars 114 and 116 at both the feed end and the output end of the cleaning machine 118 to get rid of any accumulated electrostatic charges.

A pair of lip seal pads 120 and 122 and center pads 124 and 126 are then applied to the plastic sheet 100 in the manner shown in Figure 6. The lip pads 120 and 122 serve to prevent scuffing and debris generation during record insertion and extraction. They also serve to keep dust and debris from entering into the record enclosing cavity 82. The center pads 124 and 126 protect the record 58 by providing soft sliding surfaces at the disc/caddy interfaces. The pads can be made from any suitable material - such as Sontara (Registered Trademark) made by DuPont.

The pads are covered with pressure sensitive adhesive on one side, and are die cut and firmly seated in place.

The heat from a pair of line-focus heaters 130 is applied to a narrow folding section 132 disposed between the panel portions 134 and 136 of the plastic sheet 100 for a preset time (e.g., 3 to 4 seconds) in the manner schematically shown in Figure 7. The temperature of the plastic sheet 100 in the folding line region 132 is raised to about 325 F (163"C). A pair of water-cooled folding plates 138 and 140 fold the plastic sheet 100 at the heated folding line 132 to cause the panel portions 134 and 136 to wrap around a spacer plate 142 to define a U-shaped enclosure 144 illustrated in Figure 8.The temperature of the water circulated through the folding plates 138 and 140 is chilled to approximately 55 F(13 C). The folding plates 138 and 140 are held in the folded-up position for about 4 to 5 seconds, and then shifted back to the flat position. The thickness of the spacer plate 142 defines the caddy internal clearance (e.g., 0.110 t 0.040 inches). (2.75mm j 1 mum).

A pair of T-shaped side rails 146 and 148 are ultrasonically welded to the enclosure 144 as diagrammatically shown in Figure 8 to form the caddy sleeve 54. The side rails 146 and 148 are equipped with notches 147 and 149 at their respective ends to accommodate the narrow midportion 135 of the enclosure 144. The T-shaped rail 146 has an edge wall 150 and an intermediate flange portion 152 extending substantially perpendicularly therefrom to define a pair of channels 154 and 156. The edge wall, the flange portion and the channel portions of the otherT-shaped rail 148 are respectively identified by numerals 158, 160, 162 and 164.The side edges of the panel portions 134 and 136 are snugly received in the respective channels 154, 162 and 156, 164. The T-rails are provided with recesses 72 and 74, as shown in Figure 2, to releasably capture the record/ spine assembly 60. The caddy sleeve 54 is, for example, covered with a heat-seal, wrap-around label 166 having appropriate program information and graphics as indicated in Figure 9. The label 166 may be made from any suitable material (e.g., 6-point Tyvec--Registered Trademark--manufactured by DuPont).

Figures 10 and 11 show the cross-sectional views of an example embodiment of the side rails 146 and 148. The side rails 146 and 148 comprise edge wall portions 170 and 172 and perpendicularly-disposed, intermediate flange portions 174 and 176. The side edges of the panel portions 134 and 136 of the enclosure 144 are subject to reception in the respec tivechannels 178,180 and 182,184 of the side rails 146 and 148. The application of the high frequency vibrations (e.g., 20,000 to 40,000 cycles per second) to the side rails 146 and 148 during the ultrasonic welding operation produces, through surface and intermolecular friction, sharply high temperatures at the joint area causing the plastic to melt. When the vibrations stop, the material solidifies under pressure to provide the required connection between the parts.

To produce a good bond between the enclosure 144 and the side rails 146 and 148, the intermediate flange portions 174 and 176 are fitted with slightly raised step portions (known as energy directors in the art) 186, 188 and 190, 192. The step portions 186-192 ensure that there is sufficient molten plastic to adequately cover the joint area.

As previously noted, the excess molten plastic has a tendency to form beads around the side edges of the enclosure 144. To prevent flashing or beading around the edges, the T-rails 146 and 148 are provided with slanted surfaces 194, 196 and 198,200 in accordance with an example embodiment of the invention. The principles of the structure will be explained in conjunction with Figures 12-14.

Figure 12 shows an ultrasonic welding machine 202 for welding the side rails 146 and 148 to the enclosure 144. The U-shaped enclosure 144 is inserted between a pair of spaced platens 204 and 206.

A flat spacer plate (not shown) is placed between the panel portions 134 and 136 to hold proper internal clearance during the welding operation. The side rails 146 and 148 are positioned by inserting the perpendicularly-disposed flanges 174 and 176 between the side edges of the panel portions 134 and 136 in the manner indicated in Figure 13. The welding machine 202 is equipped with a pair of horns 208 and 210 for applying ultrasonic vibrations to the respective side rails 146 and 148 to cause them to fuse to the enclosure 144. As the energy is applied to the side rails 146 and 148, the horns 208 and 210 are driven in to gradually bring the step portions 186-192 of the side rails into contact with the side edges of the panel portions 134 and 136 of the enclosure 144 in the fashion shown in Figures 13 and 14 to provide uniform and clean welds.The horns 208 and 210 are energized by respective actuators 212 and 214, which are, in turn, driven by individual power supplies 216 and 218. In this particular embodiment, the power supplies, actuators and horns are all made by Branson Sonic Power Company. The power supplies are Branson 800 series, Model 187P-1500 watts. The actuators are Branson Model 871, series 800.

The inclined surfaces 194, 196 and 198,200 of the side rails 146 and 148 provide room for excess molten plastic from the respective channels 178, 180 and 182,184 during the welding operation in the manner shown in Figure 14. This produces clean welds without beading along the edges of the enclosure 144.

Although particular embodiments of the subject invention are illustratively disclosed, several alternative constructions thereof are possible. For example The U-shaped enclosure can be made from inexpensive paper stock, instead of polystyrene base.

The T-rails can be glued, rather than welded, to the panels.

The program label can be pressure sensitive instead of heat-seal.

The illustrative caddy sleeve 54, constructed in accordance with the invention, is both performance and cost effective. Thus an inexpensive record package, or caddy, is provided.

Claims (14)

1. A disc record package comprising: a substantially U-shaped enclosure comprising a pair of spaced panel portions interconnected by an end portion along one side of said panel portions; a pair of generally T-shaped side rails; each of said rails having an edge wall portion and an intermediate flange portion extending substantially perpendicularly from said edge wall portion to define a pair of channels; and said side rails being securely mounted to said U-shaped enclosure so that the side edges of said panels are received in the respective channels to form a record access opening in communication with a record enclosing cavity.

2. A package as set forth in Claim 1 wherein said T-rails are attached to the opposite sides of said U-shaped enclosure to form said record access opening on the side of said enclosure oppositely disposed from said end portion.

3. A package as set forth in Claim 1 or 2 wherein said record enclosing cavity is defined by the interior surfaces of said U-shaped enclosure and said flange portions of said side rails.

4. A package as set forth in Claim 1 wherein said record access opening is formed by the open end of said U-shaped enclosure and front portions of said side rails.

5. A package as set forth in Claim 1,2,3 or 4 further comprising a planar record retaining spine subject to slidable reception in said record enclosing cavity; said package having means for releasably capturing said spine within said record enclosing cavity.

6. A package as set forth in any preceeding claim wherein said U-shaped enclosure is made from plastic material.

7. A package as set forth in any of Claims 1 to 5 said U-shaped enclosure is made from paper material.

8. A package as set forth in any preceeding claim wherein said T-rails comprise plastic extrusions.

9. A package as set forth in any preceeding claim wherein said side rails are ultrasonically welded to said U-shaped enclosure to form said record enclosing cavity.

10. A package as defined in any one of Claim 1 to 8 wherein said side rails are glued to said U-shaped enclosure to define said record enclosing cavity.

11. A disc record package according to any preceeding claim, wherein each of said side rails has a raised step portion in each channel thereof, said edge wall portions of said side rails are substantially flush with said side edges of said panel portions and the inside surfaces of said edge wall portion of each of said side rails extend away from said perpendicularly-disposed intermediate flange portion.

12. A disc record package as set forth in Claim 11 wherein said step portions are disposed on said intermediate flange portions.

13. A disc record package substantially as hereinbefore described with reference to Figures 2 to 9.

14. A method of making a disc record package substantially as hereinbefore described with reference to Figures 3 to 9 or, alternatively, to Figures 3 to 12.