Method for making a light-tight cassette

Claim 1

A method of making a light-tight cassette for enclosing and dispensing a roll of web material, said method comprising the steps of: providing a fiberboard sheet of predetermined dimensions; folding siad sheet to form a housing having a plurality of housing wall portions with oppositely projecting lateral edges defining first and second open sides of said housing, said plurality including first and second substantially planar wall portions that extend substantially perpendicularly to each other to respective first and second ends thereof which are disposed in spaced alignment to define an opening therebetween; providing first and second extruded plastic light-locking members having means for respective attachment thereof to said first and second ends of said first and second wall portions, wherein said providing said light-locking members includes extruding each of said members so that its means for attachment comprises a resiliently flexible U-shaped portion with open and closed ends defining a channel configured to slidably receive and resiliently grip one of said wall portion ends, and wherein said providing said members further includes extruding said first member so that it has a substantially planar intermediate portion extending substantially perpendicularly from its U-shaped portion closed end to a cantilever portion thereof, and so that said cantilever portion is flexibly joined to said intermediate portion to project therefrom in a resiliently flexible manner; attaching said first and second light-locking members to said first and second wall portion ends, respectively, so that said first member intermediate portion extends across said opening toward said second member to define web exit passageway therebetween, and so that said first member cantilever portion projects inwardly from said intermediate portion and is resiliently biased toward an opposing portion of said second member, at least one of said cantilever and opposing portions having light-locking material thereon for light-locking said passageway; providing said roll of web material wound upon a hollow roll forming core having first and second opposite ends substantially flush with respective lateral edges of said web material wound thereon, said roll forming core ends defining an overall roll width therebetween; providing a roll bearing core configured to fit slidably within said hollow roll forming core, said roll bearing core having first and second oppositely projecting end portions that define a bearing core length greater than said overall roll width; providing first and second molded plastic side caps having means for respective attachment thereof to said first and second open housing sides and means for receiving, respectively, said first and second end portions of said roll bearing core; attaching said first side cap to said first open housing side so that said first housing side is thereby closed; inserting said roll bearing core through said second open housing side and fully into said housing so that said first bearing core end portion is received by said receiving means on said first side cap; inserting said roll of web material through said second open housing side, around said roll bearing core, and slidably along said bearing core into said housing so that both of said bearing core end portions extend beyond side roll forming core ends, respectively, and so that an end portion of said web material leading from said roll projects outwardly through said passageway; and attaching said second side cap to said second open housing side so that said second bearing core end portion is received by said receiving means on said second side cap, and so that said second housing side is thereby closed.

Claim 2

A method of making a light-tight cassette for enclosing and dispensing a roll of web material, said method comprising the steps of: providing a fiberboard sheet of predetermined dimensions; folding siad sheet to form a housing having a plurality of housing wall portions with oppositely projecting lateral edges defining first and second open sides of said housing, said plurality including first and second substantially planar wall portions that extend substantially perpendicularly to each other to respective first and second ends thereof which are disposed in spaced alignment to define an opening therebetween; providing first and second extruded plastic light-locking members having means for respective attachment thereof to said first and second ends of said first and second wall portions, wherein said providing said light-locking members includes extruding each of said members so that its means for attachment comprises a resiliently flexible U-shaped portion with open and closed ends defining a channel configured to slidably receive and resiliently grip one of said wall portion ends, and wherein said providing said members further includes extruding said first member so that it has a substantially planar intermediate portion extending substantially perpendicularly from its U-shaped portion closed end to a cantilever portion thereof, and so that said cantilever portion is flexibly joined to said intermediate portion to project therefrom in a resiliently flexible manner; attaching said first and second light-locking members to said first and second wall portion ends, respectively, so that said first member intermediate portion extends across said opening toward said second member to define web exit passageway therebetween, and so that said first member cantilever portion projects inwardly from said intermediate portion and is resiliently biased toward an opposing portion of said second member, at least one of said cantilever and opposing portions having light-locking material thereon for light-locking said passageway; providing said roll of web material wound upon a hollow roll forming core having first and second opposite ends substantially flush with respective lateral edges of said web material wound thereon, said roll forming core ends defining an overall roll width therebetween; providing a roll bearing core configured to fit slidably within said hollow roll forming core, said roll bearing core having first and second oppositely projecting end portions that define a bearing core length greater than said overall roll width; providing first and second molded plastic side caps having means for respective attachment thereof to said first and second open housing sides and means for receiving, respectively, said first and second end portions of said roll bearing core; attaching said first side cap to said first open housing side so that said first housing side is thereby closed; inserting said roll bearing core through said second open housing side and fully into said housing so that said first bearing core end portion is received by said receiving means on said first side cap; inserting said roll of web material through said second open housing side, around said roll bearing core, and slidably along said bearing core into said housing so that both of said bearing core end portions extend beyond side roll forming core ends, respectively, and so that an end portion of said web material leading from said roll projects outwardly through said passageway; and attaching said second side cap to said second open housing side so that said second bearing core end portion is received by said receiving means on said second side cap, and so that said second housing side is thereby closed.