Packaging System for Video Cassettes

The present invention relates to video cassettes and more particularly to a system for packaging video cassettes for retail display and sale.

Video cassette cartridges are manufactured primarily in one of two formats--VHS and BETA. These two types of cassette cartridges have different external dimensions. Specifically, the BETA cartridge is smaller than the VHS cartridge both in length and width.

Packaging such cassettes for retail display and sale requires two different size packages for the two different size cassettes. In one packaging system, two printed sleeves are provided. The first printed sleeve is dimensioned to closely receive a VHS cartridge therein. The second printed sleeve is dimensioned to closely receive the smaller BETA cartridge therein. The two separate sleeves create several problems. First, both types of video cassettes are typically manufactured by a common manufacturer, who must inventory both sizes of sleeves to be able to package both VHS and BETA cassettes. This duplication of inventory requires excessive storage area and creates ordering problems. Occasionally, if inventory is not carefully controlled, the manufacturer will exhaust his supply of one type of sleeve and consequently have only the wrong size sleeve for the cartridges to be packaged. Second, separate cutting dies are required for the two different size sleeves. The printer must also change negatives frequently to print two different sleeves for a plurality of titles.

At least two prior artisans have developed retail packaging systems for accommodating different size cassettes within a standard package. Examples of such packages include U.S. Pat. No. 4,134,495, entitled SINGLE SIZE DISPLAY CARTON FOR PACKAGING EITHER A TAPE CASSETTE OR TAPE CARTRIDGE, issued Jan. 16, 1979, to Friedman; and U.S. Pat. No. 3,675,763, entitled BOX FOR HOLDING TAPE CARTRIDGES, issued July 11, 1972, to Sandel. However, these packages have relatively complicated constructions and accordingly require relatively complicated and/or expensive manufacturing equipment. Further, these boxes are typically wasteful of packaging material because they are relatively large in comparison to the size of the cartridges packaged.

In addition to retail packaging materials, at least one storage box has been developed for different size video cassettes. An example of such a box is provided in U.S. Pat. No. 4,303,159, entitled VIDEO PACKAGE, issued Dec. 1, 1981, to Stone et al. This storage box is plastic and internally dimensioned to receive a VHS cassette therein. An L-shaped insert is provided and snap-fits within the box to accommodate the smaller BETA cassette therein. The Stone package is not readily suited to retail display in view of its relatively expensive manufacture and relatively complicated and bulky construction. Further, the plastic box is not readily printable.

The aforementioned problems are solved by the present invention in which a packaging system for video cassettes is provided enabling both of the prevalent video cassette sizes to be easily, yet efficiently, packaged in a common printed paperboard sleeve.

The present system comprises two elements. The first element is a printed paperboard sleeve dimensioned to closely receive the larger VHS video cartridge therein. A VHS cartridge to be packaged for retail sale is simply inserted into a printed sleeve bearing the appropriate title.

The second element is a one-piece cardboard tray insert receivable within the printed sleeve to accommodate the smaller format BETA cartridge therein. The tray insert includes a floor extending substantially the full width of the printed sleeve and a pair of sidewalls extending upwardly therefrom. The tray further includes a spacer structure at one end thereof for spacing the BETA format cartridge from one end of the printed sleeve when the tray and BETA cartridge are received therein. A BETA cartridge to be packaged is first positioned in a tray insert and then inserted into the common printed sleeve. The tray sidewalls provide appropriate spacing between the BETA cartridge and the sleeve sides; the tray spacer structure provides appropriate spacing between one end of the sleeve and one end of the BETA cartridge such that the opposite ends of the sleeve and cartridge are generally flush.

The packaging system of the present invention eliminates the duplication of inventory previously required both by the manufacturer and the printer. Specifically, the manufacturer need inventory only one size printed sleeve regardless of whether VHS, BETA, or both types of cartridges are to be manufactured and packaged. The tray inserts are common to all printed sleeves regardless of the titles printed on the various sleeves. The packaging system eliminates the need for duplicate printing negatives and cutting dies. In summary, the present invention results in tremendous savings, both to the cassette packagers and to the printers of the packaging.

These and other objects, advantages, and features of the invention will be more readily understood and appreciated by reference to the detailed description of the preferred embodiment and the drawings.

FIG. 1 is a plan view of the printed sleeve of the present invention prior to folding;

FIG. 2 is a plan view of the tray insert of the present invention prior to folding;

FIG. 3 is a perspective exploded view illustrating the packaging of a VHS cartridge within the printed sleeve;

FIG. 4 is a perspective exploded view showing the packaging of a BETA cartridge within the printed sleeve using the tray insert;

FIG. 5 is a transverse sectional view through the packaged BETA cartridge taken along plate V--V in FIG. 4; and

FIG. 6 is a longitudinal sectional view through the packaged BETA cartridge taken along plane VI--VI of FIG. 4.

The packaging system of the present invention is illustrated in the drawings and generally includes printed cardboard sleeve 10 and tray insert 12 (FIG. 4). Sleeve 10 is generally box-shaped defining open end 14. Tray 12 includes floor 16 and a pair of opposed sidewalls 18 and 20 and end wall 22 extending upwardly therefrom. A pair of spacing tabs 24 and 26 extend inwardly from sidewalls 18 and 20, respectively, proximate end wall 22.

VHS cartridge 28 (FIG. 3) is packaged by simply sliding the cartridge into the printed sleeve 10 through open end 14. BETA cartridge 30 (FIG. 4) is packaged by first positioning the cartridge within tray 12 on floor 16, between sidewalls 18 and 20, and abutting tabs 24 and 26. The tray and cartridge assembly is then slid into cardboard sleeve 10 through open end 14. Tray insert 12 supports cartridge 30 within the larger printed sleeve 10.

Video cassette cartridges 28 and 30 are generally well-known in the art. Each of the cartridges is generally a rectangular parallelepiped containing a quantity of video tape or other recording medium and suitable for play on a video cassette recorder. Larger cartridge 28 is a VHS format cartridge having dimensions of approximately seven and one-quarter inches by four and one-eighth inches by seven-eighths inch. The smaller cartridge 30 is a BETA format cartridge and has external dimensions of approximately six and one-eighth inches by three and seven-eighths inches by seven-eighths inch. The present invention is adaptable to virtually any cassette cartridges wherein all of the external dimensions of one are equal to or less than the corresponding external dimensions of the other. The VHS and BETA format cartridges are disclosed and described in the present application because these cartridges are the most popular video cartridges currently available.

The blank or stock of which sleeve 10 is fabricated is a lightweight paperboard and is illustrated in FIG. 1. Fold lines are designated by dashed lines, while cuts are illustrated by solid lines. Sleeve 10 includes rectangular top 32 and rectangular bottom 34 which are generally parallel one another in the assembled article (see FIGS. 5 and 6). A title 33 indicative of the cassette to be packaged therein is printed on top 32. Rectangular sidewalls 36 and 38 extend between top 32 and bottom 34 in the assembled article and are generally parallel one another. Sidewall 36 is joined to top 32 at fold line 37, and sidewall 38 is joined both to top 32 and bottom 34 by fold lines 39a and 39b, respectively. Trapezoidal gluing flap 40 extends from bottom 34 along fold line 41 opposite side 38 to be adhesively secured to side 36 in assembled sleeve 10. End tabs 42 and 44 extend from sidewalls 36 and 38 along fold lines 43 and 45, respectively, and are folded generally perpendicularly thereto in the assembled article. Top end flap 46 and bottom end flap 48 extend from top 32 and bottom 34 along fold lines 47 and 49, respectively, and are folded generally perpendicularly thereto to overlie one another in assembled sleeve 10. Closed end 50 is created in sleeve 10 by the folded and glued flaps 46 and 48 (see FIG. 6). Open end flaps 52 and 54 extend from top 32 and bottom 34 along fold lines 53 and 55, respectively, opposite flaps 46 and 48 and are folded inwardly upon the top and bottom, respectively, and adhesively secured thereto to provide a dressed appearance and increased strength for open end 14. Additionally, bottom flap 54 locks tray 12 within sleeve 10 when the tray is used as will be described (see FIG. 6).

The blank or stock from which tray 12 is fabricated is also a lightweight paperboard and is illustrated in FIG. 2. Tray 12 includes floor or bottom 16 having a pair of opposite parallel side edges 56 and 58 and an end edge 60 extending generally perpendicularly therebetween. Opposite arcuate end edge 62 extends between side edges 56 and 58.

Sidewall 18 (FIG. 2) includes rectangular outer flap 18a and rectangular inner flap 18b separated by fold line 64. Inner flap 18b defines edge 65 generally parallel to both of fold lines 56 and 64. Locking tab 66 is integral with and extends away from outer flap 18a along fold line 68 in a direction generally perpendicular to fold line 64. Spacing means is provided by spacing tab 70 which is connected to inner flap 18b at fold line 72. Tab 70 extends further away from floor 16 than does inner flap 18b in the unfolded blank. Fold line 72 is closer to floor 16 than edge 65 of inner flap 18b.

Sidewall 20 (FIG. 2) includes outer flap 20a and inner flap 20b separated by fold line 74. Inner flap 20b defines edge 75 generally parallel to both of fold lines 58 and 74. Locking tab 76 is integral with and extends from outer flap 20a along fold line 78. Spacer tab 80 is integral with and extends from inner flap 20b along fold line 82. Fold line 82 is closer to floor 16 than edge 75, while tab 80 extends further away from floor 16 than does inner flap 20b in the unfolded stock.

End wall 22 includes outer flap 22a and inner flap 22b separated by fold line 84.

The stock of which printed sleeve 10 is fabricated is printed, and preferably offset printed, to provide top 32, bottom 34, sides 36 and 38, and end flap 46 with desired printing indicia such as title 33. In addition to the title of the cassette to be packaged within the sleeve, other desired printing may include graphics, plot summary, names of actors and actresses, producer, director, and manufacturer. In the preferred embodiment, the printed stock is coated with a UV clear coating. The printed stock is then die cut to form the blank illustrated in FIG. 1, including the various fold lines and cut lines. Top 32 and bottom 34 are folded generally perpendicularly to side 38 such that the top and bottom are parallel one another. Glue flap 40 and side 36 are folded generally perpendicularly to bottom 34 and top 32, respectively, such that the side overlies the glue flap. Suitable adhesive is applied to the glue flap, and the glue flap and side 36 are secured together. Adhesive is applied to the underside of flaps 52 and 54 and the flaps are folded inwardly into the box interior against top 32 and bottom 34, respectively, to provide a finished and strong edge to open end 14. End tabs 42 and 44 are folded toward one another perpendicular to sides 36 and 38, respectively; and end flaps 48 and 46 are folded generally perpendicular to bottom 34 and top 32, respectively, over the folded end tabs. Suitable adhesive is applied to end flap 48 such that when end flap 46 is folded thereagainst, the two end flaps are adhesively secured together. As thus folded, sleeve 10 appears as illustrated in FIGS. 3-6. Assembled sleeve 10 is dimensioned to closely receive a VHS cassette therein. Specifically, the internal dimensions of the sleeve are seven and one-quarter inches between closed end 50 and open end 14, four and one-eighth inches between sidewalls 36 and 38, and seven-eighths inch between top 32 and bottom 34.

The blank (FIG. 2) from which tray 12 is folded is also die cut from a sheet of paperboard. Sidewalls 18 and 20 are folded along lines 56 and 58, respectively, to be generally perpendicular to floor 16. Locking tabs 66 and 76 are folded inwardly toward one another until both are generally perpendicular to their respective sidewalls 18 and 20. End wall 22 is folded generally perpendicularly to floor 16 such that outer flap 22a abuts locking tabs 66 and 76. Suitable adhesive is then applied to inner flap 22b which is folded downwardly upon outer flap 22a to be adhesively secured thereto and to secure locking tabs 66 and 76 therebetween. Adhesive is applied to inner flaps 18b and 20b which are folded downwardly against outer flaps 18a and 20a, respectively, to be adhesively secured thereto. Because spacing tabs 70 and 80 extend outwardly beyond edges 65 and 75, respectively, the spacing tabs engage floor 16 as inner walls 18b and 20b are folded into position. Locking tabs 70 and 80 are therefore automatically folded along lines 72 and 82, respectively, to be deployed as illustrated in FIGS. 4-6 as the sidewalls are folded into place. When so folded, tray 12 appears as illustrated in FIGS. 4-6.

Assembled tray 12 is dimensioned to be closely received within sleeve 10. Specifically, the length of sidewalls 18 and 20 is seven and one-quarter inches, the width of floor 16 is four and one-eighth inches, and the height of sidewalls 18 and 20 and end wall 22 is seven-eighths inch. Consequently, when tray 12 is positioned in sleeve 10, floor 16 extends the full width of the sleeve; sidewalls 18 and 20 extend the full length of the sleeve; and sidewalls 18 and 20 and end wall 22 extend the full height of the sleeve.

When the larger VHS cassette 28 is to be packaged for retail sale (FIG. 3), it is simply slid into printed sleeve 10 through open end 14. Because the printed sleeve has substantially the same length as the VHS cassette, end 84 of the cassette will abut closed end 50 of the sleeve and opposite end 86 of the cassette will be generally flush with open end 14 of the sleeve. Designator "VHS" 87 is printed on sidewall 36 to indicate that a VHS format cassette is contained within sleeve 10.

When the smaller BETA cassette 30 is to be packaged (FIG. 4), the cartridge is first positioned within tray 12; and the tray/cartridge subassembly is slid into printed sleeve 10. When the tray and cartridge are fully slid into position within sleeve 10, arcuate edge 62 locks behind flap 54 (see FIG. 6); cartridge end 88 abuts spacing tabs 24 and 26; and opposite end 90 is generally flush with open sleeve end 14. Sidewalls 18 and 20, each of which is approximately one-eighth inch thick, provides spacing between the cartridge and sleeve sidewalls 36 and 38. Cartridge 30 is therefore securely maintained within sleeve 10. Designator "BETA" 91 is printed on sleeve sidewall 36 to indicate that a BETA format cassette is contained within sleeve 10.

As will be readily appreciated, the present invention eliminates the previously required duplication of printing negatives and cutting dies required to provide two separate printing sleeves for the two different size video cassettes. Additionally, the present invention reduces inventory problems of the tape manufacturer, who need inventory only one size printed sleeve for each title manufactured.

The above description is that of a preferred embodiment of the invention. Various changes and alterations can be made without departing from the spirit and broader aspects of the invention as set forth in the claims, which are to be interpreted in accordance with the principles of patent law, including the doctrine of equivalents.