SYSTEMS, PROCESSES, AND ARTICLES FOR ENCAPSULATED SEALING OFCOLLECTIBLE ITEMS AND OTHER HIGH ASSET OBJECTS

Abstract

Automated and semi-automated systems, processes and articles are disclosed for providing encapsulated sealing and protection of collectible items and other potentially high asset objects. The encapsulating systems, processes and articles provide a range of options for protecting collectible objects which include providing identification and other information inside the encapsulated container. The resultant encapsulated articles themselves provide collectibles with a secure placement that prevents movement and/or rotation of the collectible within the container, while preventing the majority of the collectible from making contact with the interior surface of the container. The lack of contact provides additional protection for such collectible features such as original signatures while also assisting in the display of the collectibles by maintaining the desired orientation regardless of movement, shaking, etc., of the encapsulated container. Movement and rotation are prevented by the inclusion of inserts within the container that are adhered to or formed integral with the top and/or bottom surface of the container.

Claims

1. A method for fabricating an encapsulation case for collectibles, comprising: selecting a type of encapsulation case; inputting size dimensions for the encapsulation case; fabricating the encapsulation case and at least one interior structure according to the specified dimensions; and assembling the encapsulation case with the at least one interior structure.

2. The method of claim 1, further comprising: welding by utilizing a welding machine that comprises at least one of: handheld ultrasonic welders, bench-top ultrasonic welders, automated ultrasonic welding systems, multi-head ultrasonic welders, and ultrasonic spot welders; configuring welding parameters including frequency, amplitude, and pressure; and applying ultrasonic vibrations to permanently bond the encapsulation case to at least one interior structure.

3. An encapsulation case, comprising: a top casing and a bottom casing, wherein said top casing and said bottom casing are adhesively and permanently sealed to each other such that molecular bondage from said permanent seal exists internal to said encapsulation case and exterior surfaces of said top casing and said bottom casing are free from said molecular bondage of said seal.

4. The encapsulation case of claim 3, further comprising: a first insertable interior structure placed within said encapsulation case which is adhesively and permanently sealed to a first interior wall of said encapsulation case, and wherein molecular bondage from said permanent seal exists on at least one internal surface of said encapsulation case while exterior surfaces of said encapsulation case are free from said molecular bondage.

5. The encapsulation case of claim 4, further comprising: a second insertable interior structure placed within said encapsulation case which is adhesively and permanently sealed to a second interior wall of said encapsulation case, wherein molecular bondage from said permanent seal exists on at least a second internal surface of said encapsulation case while exterior surfaces of said encapsulation case are free from said molecular bondage.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The principles and advantages of the present invention can be more clearly understood from the following detailed description considered in conjunction with the following drawings, in which the same reference numerals denote the same structural elements throughout, and in which:

[0014] FIG. 1 is an illustration of flow charts constructed in accordance with the principles of the present invention;

[0015] FIG. 2 is an illustration of a collectible item architecture constructed in accordance with the principles of the present invention;

[0016] FIG. 3 is an illustration of a collectible item architecture constructed in accordance with the principles of the present invention;

[0017] FIG. 4 is an illustration of a collectible item architecture constructed in accordance with the principles of the present invention;

[0018] FIG. 5 is an illustration of a collectible item architecture constructed in accordance with the principles of the present invention; and

[0019] FIG. 6 is an illustration of flow charts constructed in accordance with the principles of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0020] FIG. 1 shows a process which demonstrates a possible fabrication method for the encapsulation cases and any required interior structure alongside a process for permanent adhesion of the encapsulation cases, indefinitely sealing the stored collectible inside. A user begins by selecting the type of encapsulation case needed for the project 101. This could involve entering specifications directly into the injection molder's control interface or, if the machine requires physical mold loading, manually installing the correct mold for the encapsulation case type. This step ensures the molder is set to produce the intended case type for housing the interior structures. Once the case type is specified, the user inputs the size dimensions of the encapsulation case 102. Similar to the previous step, this may be done through a digital interface or by manually loading a mold with the appropriate size. Accurate size selection can be critically important, as it may ensure the case can accommodate the interior structures that will be fabricated in the following steps. With the encapsulation case type and size defined, the system automatically identifies the necessary interior structures that need to fit inside 103. This autonomous determination can save time and reduce errors. However, if the user needs specific interior structures that differ from the standard, they can manually load alternative molds into the molder for custom fabrication.

[0021] The machine may calculate the exact dimensions for each interior structure to ensure a proper fit within the encapsulation case 104. Alternatively, if custom dimensions are preferred, the user may manually install molds with the desired dimensions. This flexibility allows for both automated precision and user-defined customization. The system then initiates fabrication, producing both the encapsulation case and the interior structures according to the input specifications 105. This step is typically automated, with the processor coordinating all machine actions to shape each part. By the end of this step, all parts required for assembly are ready. Following fabrication, the user assembles the individual parts 106. This involves arranging the interior structures within the encapsulation case in line with the specifications.

[0022] Proper alignment and assembly are essential to ensure a secure fit and maintain the integrity of the finished product. Once the encapsulation case and interior structures are assembled, the user prepares the unit for ultrasonic welding, selecting from available options, which include handheld ultrasonic welders, bench-top ultrasonic welders, automated ultrasonic welding systems, multi-head ultrasonic welders, or ultrasonic spot welders 107. For this step, the unit is positioned in the selected welding machine, with each component aligned according to the machine's specifications. If necessary, the user configures specific welding parameters, such as frequency, amplitude, and pressure, in line with the plastic materials and weld requirements. With the assembled unit placed in the ultrasonic welding machine, the device uses high-frequency ultrasonic vibrations to create a strong bond between the encapsulation case and interior structures 108. The machine's horn or sonotrode makes direct contact with the joint area, applying ultrasonic energy and pressure that generate heat through friction, causing the plastic to melt and fuse. This produces a secure, seamless connection without adhesives or additional fasteners. For specialized applications, a customized ultrasonic welder may be used to optimize welding parameters and ensure an accurate fit. Once the ultrasonic welding process is complete, the encapsulation case is fully integrated with the internal structures, resulting in a finished, permanently sealed collectible encapsulation.

[0023] FIG. 2 shows one possible variant for a sealable encapsulation case. The possible iteration shown has a 2-piece pre-seal configuration comprised of top casing 201 and a bottom casing 202. The casings may be transparent or non-transparent. The material used for the top casing 201 and bottom casing 202 may be fabricated from a hard material (e.g., a hard polycarbonate, polystyrene, and/or acrylic) and may be fabricated through a molding (e.g., injection molding process).

[0024] A security tag 203 may be placed in the encapsulation case so that identifies the item as well as additional characteristics (e.g., encapsulation entity, condition grading entity and condition grade, authentication entity and authentication grade, etc). Accordingly, the tag 203, which may or may not be permanently attached to a cavity in the encapsulated case, may identity the collectible and viewable from a consumer from outside the case in addition to the collectible being viewable. The tag 203 may be tamper-proof so that the tag 203 is destroyed and rendered unusable if the encapsulation case is broken in order to remove the collectible.

[0025] FIG. 3 shows a possible iteration of a three or more structure thermally formed encapsulated case which may be provided, for example, to have an interior structure 302 that functions to secure one or more items. The perimeter of the three (or more) layers may share some of the same dimensions. For example, an observed exterior layer 305 and a reverse exterior layer 306 may have the same length and width. An inner layer 307, for example, may have the same length and width in some areas but, for example, not in other areas. As such, for example an inner structure may form a stabilizing holder that allows a collegiate sports ball to rest in place.

[0026] All three layers can be thermally sealed within a proximity of a perimeter so all three layers are melted together in the same area. This insert is not limited to a rest for balls, but includes a vast array of interior structures, such as a mannequin insert which holds an item in place. For example, a jersey (e.g., a basketball jersey, a glove, a pair of pants, a screen worn costume). Accordingly, for example, an inner layer of material may be the shape of a worn item in the shape or pose desired to be displayed. For example, in a jersey, the shape may be the shape of a human torso. The arms neck and waist, however, may extend through the jersey to the perimeter of the exterior layers such that when all three layers are heat-sealed together, a single structure is provided with the appearance of a jersey on a plastic layered mannequin inside. All or some layers may be transparent (e.g., clear such as water clear) or non-transparent. For example, all three layers may be transparent such that the jersey (or other clothing item) appears to float in the slab.

[0027] A user shaking the slab vigorously would not see the jersey move as the jersey would be fixed on the inner mannequin layer. Such a heat-sealed slab may have layers that are flexible and/or non-flexible and may form an encapsulated case that is flexible or non-flexible. A thermally sealed encapsulated case may be formed by vacuum formed pieces. Accordingly, sheets of plastic (e.g., 12 thousandths of an inch thick or more, 0.2 millimeters (thick or more) 0.4 millimeters thick or more, 0.6 millimeters thick or more, 0.8 millimeters thick or more, 1 millimeter thick or more, and/or 1.2 millimeter thick or more) may be utilized. Different layers may have different thicknesses. Such layers may be thermoformed by, for example, applying heat to a layer of plastic to make it permeable and then vacuum pulling the sheet into a mold to thermoform a shape. One of the layers (e.g., an exterior layer) may be flat, one of the layers (e.g., the other exterior layer may have the cavities) and the middle layer may have a mannequin.

[0028] Persons skilled in the art will appreciate that two of the cavity layers may be utilized in a symmetrical cavity design on a layer for both exterior layers in order to, for example, increase the size of the cavity such that the thickness of the cavity may be modified by using one or both exterior layers as cavity layers. The possible iteration shown in FIG. 3 has a 3-piece pre-seal configuration comprised of a transparent top casing 301, a transparent or non-transparent interior structure 302, and a transparent bottom casing 303. The material used for the top casing 301, interior structure 302, and bottom casing 303 may be fabricated from a hard material (e.g., a hard polycarbonate, polystyrene, and/or acrylic) and may be fabricated through a molding (e.g., injection molding process).

[0029] A security tag 304 may be placed in the encapsulation case so that identifies the item as well as additional characteristics (e.g., encapsulation entity, condition grading entity and condition grade, authentication entity and authentication grade, etc). Accordingly, the tag 304, which may or may not be permanently attached to a cavity in the encapsulated case, may identity the collectible and viewable from a consumer from outside the case in addition to the collectible being viewable. The tag 304 may be tamper-proof so that the tag 304 is destroyed and rendered unusable if the encapsulation case is broken in order to remove the collectible.

[0030] A slab having three or more (e.g., four) pieces may be formed from multiple pieces that are non-flexible and, for example, manufactured through an injection molding process. An injection molded part can be, for example, a complex three-dimensional shape yet be a single part and, as a result, have a higher strength with no visible attachment lines as the parts are a singularly formed part. One or parts may be transparent (e.g., water clear) and/or non-transparent. An injection molded encapsulation case part 401 may be ultrasonically sealed to another injection molded case part 404 to form a sealed part with a cavity or cavities for permanently storing one or more collectibles.

[0031] An ultrasonically sealed case may need to be permanently broken and/or visually damaged to remove a part so that a part cannot be removed with case still being re-usable for another collectible. In doing so, the security of an ultrasonically sealed case may be relied upon by a user and its contents (e.g., an identification tag, RFID, and/or collectible) may be assumed by the user as having never been taken out of an ultrasonically case as doing so would destroy the case. Additional parts may be fabricated and ultrasonically welded to the internal surface of one or more parts that form the exterior case so that those parts can be utilized to hold and stabilize the orientation of collectibles. For example, two interior structure parts, 402 and 403 (which may be the same part or different parts) may be attached to the top 406 and bottom 407 of an interior case to hold a basketball of a certain size (e.g., a size 7 basketball) and two different interior structure parts 408 and 409 (which may be the same part of different parts) may be attached to the top 406 and bottom 407 of the same case to hold a different sized basketball (e.g., a size 6 basketball).

[0032] Attachment features may be present on the interior of the case to more easily ultrasonically weld collectible adapter pieces to the interior of a case. The exterior part of the case around those attachment features may remain smooth with no features. As the attachment pieces are welded interior to the case, no welds are made to the exterior of the case. Accordingly, no user can access the weld between the adapter (e.g., that holds the collectible) and the formed case from outside the formed case. Persons skilled in the art will appreciate that attachment features may be placed on the exterior surface of a case as well as additional adaptor units to be placed on the exterior of a case. For example, an external adaptor may include an adapter that holds a light fixture so that light may be shined into a case and a power source may be replaced from the outside of the case (or the light replaced if broken from the outside of the case). Additionally, an external feature may be an extension such that, for example, an extension may be welded to attachment features on the outside of the case to, for example, stand the case on top of the extension to give the case height for display purchases.

[0033] Any number of adapters to achieve any number of structures and functions may be provided on any surface of one or more parts of a case. An adapter may be welded across more than one parts so that parts are welded together and then an adapter part is welded across both of the newly welded pieces. The possible iteration shown in FIG. 4 has a 6-piece pre-seal configuration comprised of a transparent top casing 401, 4 transparent or non-transparent interior structures 402, 403, 408, and 409, and a transparent bottom casing 404. The material used for the top casing 401, interior structures 402, 403, 408, and 409, and bottom casing 404 may be fabricated from a hard material (e.g., a hard polycarbonate, polystyrene, and/or acrylic) and may be fabricated through a molding (e.g., injection molding process).

[0034] A security tag 405 may be placed in the encapsulation case so that identifies the item as well as additional characteristics (e.g., encapsulation entity, condition grading entity and condition grade, authentication entity and authentication grade, etc). Accordingly, the tag 405, which may or may not be permanently attached to a cavity in the encapsulated case, may identity the collectible and viewable from a consumer from outside the case in addition to the collectible being viewable. The tag 405 may be tamper-proof so that the tag 304 is destroyed and rendered unusable if the encapsulation case is broken in order to remove the collectible.

[0035] The possible iteration shown in FIG. 5 may utilize a 2-piece pre-sealed configuration comprised of a transparent or non-transparent top casing 501 and a transparent or non-transparent bottom casing 502. The material used for top casing 501 and bottom casing 502 may be fabricated from a hard material (e.g., a hard polycarbonate, polystyrene, and/or acrylic) and may be fabricated through a molding (e.g., an injection molding process). A security tag 503 may be placed within the encapsulation case to assist in the identification of the item as well as additional characteristics (e.g., encapsulation entity, condition grading entity and condition grade, authentication entity and authentication grade, etc.). Accordingly, tag 503, which may or may not be permanently attached to a cavity in the encapsulated case, may identity the collectible and viewable from a consumer from outside the case in addition to the collectible being viewable. Tag 503 may be tamper-proof so that tag 503 is destroyed and rendered unusable if the encapsulation case is broken in order to remove the collectible.

[0036] FIG. 6 illustrates a method and process in which scrap material is initially generated from two primary manufacturing processes: ultrasonic welding or thermal forming. These processes are used to create encapsulation cases, and scrap piecesoffcuts, excess material, or defectively formed casesare a byproduct 601. The next step involves grinding down this scrap material into fine granules 602. By converting the scrap into granules, it becomes manageable for recycling and repurposing, facilitating reuse in other manufacturing steps. Once ground, the granules are assessed for uniformity in color and quality 603. This step ensures that only granules meeting consistent standards will proceed further, as material differences in color or quality can impact the visual and structural properties of the final product. If the material fails this assessment and does not match the required color or quality standards, it is deemed unsuitable for recycling and discarded as unusable scrap 604. If the material passes the assessment, the material is then melted down and prepared for recycling 605.

[0037] The melting process prepares the granules for two potential pathways depending on the desired form of the recycled plastic. The recycled material can be used in one of two forms: either molded into polymer sheets or used directly as granules in injection molding. If the recycled material is formed into polymer sheets, it can be used in thermoforming processes 607. Thermoformed recycled plastic parts are generally used for components where transparency is not a primary requirement, as recycled plastic may have slight imperfections that impact clarity. These thermoformed parts are especially suitable for internal components or adapters that do not need a clear finish, such as holders or structural elements for collectibles 608. Alternatively, the granules can bypass the sheet-forming process and be used directly in injection molding 609. This application is suitable when recycled plastic needs to fill molds directly to form parts, making the process more efficient and minimizing additional reshaping steps. Injection-molded parts using recycled granules are ideal for applications where transparency or specific structural properties are required 610. However, the final decision on usage depends on whether the part's functional demands can accommodate the recycled material's qualities.

[0038] Persons skilled in the art will appreciate that the present invention is not limited to only the embodiments described, and that features described in one embodiment may be used in a different embodiment. The present invention more generally involves encapsulated cases for collectibles that are sealed. 1Persons skilled in the art will also appreciate that the systems, processes and articles of the present invention may be implemented in other ways than those described herein. All such modifications are within the scope of the present invention, which is limited only by the claims that follow.