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Second Disc/Tray Inserter for DVD Amaray Box

IP.com Disclosure Number: IPCOM000022195D
Publication Date: 2004-Mar-01
Document File: 25 page(s) / 1M

Publishing Venue

The IP.com Prior Art Database

Related People

Phillip K. Neely: INVENTOR [+2]

Abstract

Most DVD movies come packaged in a single piece clam-shell type plastic container trade named the Amaray box. Recently, several DVD releases have included two DVD discs. This invention is a method to automate the placement of the second disc/tray into the Amaray box.

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         Sony Corporation

         Sony Electronics Inc.

         IPD Case #50R4893

Title:

Second Disc/Tray Inserter for DVD Amaray Box

Abstract:

Most DVD movies come packaged in a single piece clam-shell type plastic container trade named the Amaray box. Recently, several DVD releases have included two DVD discs. This invention is a method to automate the placement of the second disc/tray into the Amaray box.

Inventors:

Phillip K. Neely

Tracy E. Wheeler

Invention Disclosure Data Sheet:

1.      The standard DVD package is a single DVD disc in an Amaray box. The Amaray box is a trade name for a oneĀ­piece plastic clamshell type of a package that has a single hub to house a single disc. Recently, some of the movie studios have been releasing two disc DVD sets. Typically one of the DVD discs will contain the movie while the second disc will contain all of the "extras" that have become standard ware on DVD's. The Amaray box was modified with the inclusion of two hinge points molded into the spine of the case. A tray with a disc hub and hinge pins designed to mate with the hinge points in the case is then added into the Amaray box to make these two disc sets. When we first started packaging into this new configuration, the second disc tray was inserted manually into the case which previously had the first disc and the booklet(s) inserted. A crew size of (10) assembly personnel was required to achieve a production rate of 60+ pieces per minute. The invention was conceived in response to a large, 2,500,000 piece, double DVD order. The shear size of this order dictated that we develop an automated solution for placing the second disc tray into the Amaray box. The relative timing on the project required that a quick semi-automated design be used to meet the needs of this large order. With our semi-automated solution the crew size is reduced to four people. To our knowledge, at the time of the invention no one else had automated the assembly of this package.

2.      This invention disclosure is for a semi-automated system that inserts the second disc tray into an Amaray box. The system includes two main components namely a conveyor system and a pick and place robot. The system is integrated into a Kyoto Amaray box assembly machine. This assembly machine places the booklet(s) and the first disc into the DVD Amaray box then closes the box and discharges it onto a conveyor where it can then travel through other processes including stickering, shrink wrapping, and cartoning. The invention exploits an open "station" within the Kyoto assembly machine where the Amaray box has the booklet(s) and first disc previously inserted but the case is still open. It is at this position within the Kyoto assembly machine that the second disc tray is placed into the Amaray box. After the insertion of the second disc tray, the Amaray box is closed as usual and discharged onto a conveyor to be taken to the downstream processes.

The first step in the process of adding the second disc tray into the Amaray box is...