U.S. patent application number 10/400001 was filed with the patent office on 2003-10-02 for disaster pack and method for making same.
Invention is credited to DiLiberto, Samuel L. JR..
Application Number | 20030183550 10/400001 |
Document ID | / |
Family ID | 28675370 |
Filed Date | 2003-10-02 |
United States Patent
Application |
20030183550 |
Kind Code |
A1 |
DiLiberto, Samuel L. JR. |
October 2, 2003 |
Disaster pack and method for making same
Abstract
A disaster pack comprising a pillow, a blanket, and a mattress
pad compressed and disposed within a first sealed bag comprised of
a cavity, and a seal at one end of the cavity is disclosed. A
packaged product comprising a compressible dry good compressed and
disposed within a sealed bag comprised of a cavity, and a seal at
one end of the cavity, wherein the compressed volume of the
compressible dry good disposed within the sealed bag is less than
about twenty percent of the free state volume of the compressible
dry good is also disclosed. A method for making the packaged
product comprises the steps of placing the compressible dry good
within a bag; placing the compressible dry good disposed within the
bag on a platen; compressing the compressible dry good within the
bag; sealing the open end of the bag to form a sealed bag; and
removing the dry good within the sealed bag from the platen.
Inventors: |
DiLiberto, Samuel L. JR.;
(Caledonia, NY) |
Correspondence
Address: |
GREENWALD & BASCH, LLP
349 WEST COMMERCIAL STREET, SUITE 2490
EAST ROCHESTER
NY
14445
US
|
Family ID: |
28675370 |
Appl. No.: |
10/400001 |
Filed: |
March 26, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60367558 |
Mar 26, 2002 |
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Current U.S.
Class: |
206/524.8 ;
206/223; 206/803; 53/434; 53/436; 53/445 |
Current CPC
Class: |
B65D 75/38 20130101;
B65D 85/07 20180101; B65B 63/02 20130101; B65B 63/026 20130101 |
Class at
Publication: |
206/524.8 ;
53/434; 53/436; 53/445; 206/223; 206/803 |
International
Class: |
B65B 031/00; B65B
063/02 |
Claims
I claim:
1. A disaster pack comprising a pillow and a blanket compressed and
disposed within a first sealed bag comprised of a cavity, and a
seal at one end of said cavity.
2. The disaster pack as recited in claim 1, wherein the compressed
volume of said pillow and said blanket disposed within said first
sealed bag is less than about twenty percent of the sum of the free
state volumes of said pillow and said blanket.
3. The disaster pack as recited in claim 2, wherein the compressed
volume of said pillow and said blanket disposed within said first
sealed bag is less than about twelve percent of the sum of the free
state volumes of said pillow and said blanket.
4. The disaster pack as recited in claim 3, wherein the compressed
volume of said pillow and said blanket disposed within said first
sealed bag is less than about eight percent of the sum of the free
state volumes of said pillow and said blanket.
5. The disaster pack as recited in claim 1, wherein said seal is a
heat seal.
6. The disaster pack as recited in claim 5, wherein said first
sealed bag further comprises a notch adjacent to said heat
seal.
7. The disaster pack as recited in claim 1, wherein said seal is a
compression seal.
8. The disaster pack as recited in claim 1, wherein said first
sealed bag is comprised of nylon and low density polyethylene.
9. The disaster pack as recited in claim 1 further comprising a
mattress pad disposed within a second sealed bag, wherein said
first sealed bag and said second sealed bag are disposed within a
packaging bag.
10. The disaster pack as recited in claim 9, wherein the compressed
volume of said pillow, said blanket, and said mattress pad is less
than about twenty percent of the sum of the free state volumes of
said pillow, said blanket, and said mattress pad.
11. The disaster pack as recited in claim 1, further comprising a
label applied to an outer surface of said sealed bag.
12. A disaster pack comprising a pillow, a blanket, and a mattress
pad compressed and disposed within a first sealed bag comprised of
a first cavity, and a first seal at one end of said first cavity,
wherein: a) said pillow and said blanket are disposed within a
second sealed bag comprised of a second cavity, and a second seal
at one end of said second cavity; b) said mattress pad is disposed
within a third sealed bag comprised of a third cavity, and a third
seal at one end of said third cavity; and c) said second sealed bag
and said third sealed bag are disposed within said first sealed
bag.
13. The disaster pack as recited in claim 12, wherein the
compressed volume of said pillow, said blanket, and said mattress
pad disposed within said first sealed bag is less than about twenty
percent of the sum of the free state volumes of said pillow, said
blanket, and said mattress pad.
14. The disaster pack as recited in claim 13, wherein the
compressed volume of said pillow, said blanket, and said mattress
pad disposed within said first sealed bag is less than about twelve
percent of the sum of the free state volumes of said pillow, said
blanket, and said mattress pad.
15. The disaster pack as recited in claim 14, wherein the
compressed volume of said pillow, said blanket, and said mattress
pad disposed within said first sealed bag is less than about eight
percent of the sum of the free state volumes of said pillow, said
blanket, and said mattress pad.
16. The disaster pack as recited in claim 12, wherein at least one
of said first seal, said second seal, and said third seal are heat
seals.
17. The disaster pack as recited in claim 16, wherein said first
sealed bag further comprises a notch adjacent to said first heat
seal.
18. The disaster pack as recited in claim 12, wherein at least one
of said first seal, said second seal, and said third seal is a
compression seal.
19. The disaster pack as recited in claim 12, wherein said first
sealed bag, said second sealed bag, and said third sealed bag are
comprised of nylon and low density polyethylene.
20. The disaster pack as recited in claim 12, wherein said mattress
pad is comprised of at least about sixty weight percent polymer
foam.
21. The disaster pack as recited in claim 12, wherein said pillow
is comprised of at least about 50 weight percent polyester
fibers.
22. The disaster pack as recited in claim 12, wherein said blanket
comprises a fabric of fibers selected from the group consisting of
wool, silk, linen, polyester, nylon, acetate, poly(ethylene
terephthalate), polytetrafluoroethylene, and mixtures thereof.
23. The disaster pack as recited in claim 12, further comprising a
label applied to an outer surface of said sealed bag.
24. A packaged product comprising a first compressible dry good
compressed and disposed within a sealed bag comprised of a cavity,
and a seal at one end of said cavity, wherein the compressed volume
of said first compressible dry good disposed within said sealed bag
is less than about eighty percent of the free state volume of said
compressible dry good.
25. The package as recited in claim 24, wherein the compressed
volume of said first compressible dry good disposed within said
sealed bag is less than about forty percent of the free state
volume of said compressible dry good.
26. The package as recited in claim 25, wherein the compressed
volume of said first compressible dry good disposed within said
sealed bag is less than about twenty percent of the free state
volume of said compressible dry good.
27. The package as recited in claim 24, wherein said first
compressible dry good is a pillow.
28. The package as recited in claim 24, wherein said first
compressible dry good is a blanket.
29. The package as recited in claim 24, wherein said first
compressible dry good is a foam pad.
30. The package as recited in claim 24, wherein said first
compressible dry good is a chair.
31. The package as recited in claim 24 further comprising a second
compressible dry good disposed within said sealed bag, wherein said
first compressible dry good is a pillow, and said second
compressible dry good is a blanket.
32. The package as recited in claim 24, wherein said seal is a heat
seal.
33. The package as recited in claim 32, wherein said sealed bag
further comprises a notch adjacent to said heat seal.
34. The package as recited in claim 24, wherein said seal is a
compression seal.
35. The package as recited in claim 24, wherein said sealed bag is
comprised of nylon and low density polyethylene.
36. The package as recited in claim 24, further comprising a label
applied to an outer surface of said sealed bag.
37. A method of preparing a packaged product comprising a first
compressible dry good compressed and disposed within a sealable bag
comprising a cavity and an open end, comprising the steps of: a)
placing said first compressible dry good within said sealable bag;
b) placing said first compressible dry good disposed within said
sealable bag on a platen; c) compressing said first compressible
dry good within said sealable bag; d) sealing said open end of said
sealable bag to form a sealed bag; and e) removing said first
compressible dry good within said sealed bag from said platen.
38. The method of claim 37, further comprising the step of first
placing said first compressible dry good within a packaging bag and
evacuating air from said packaging bag and said object before said
placing said first compressible dry good within said sealable
bag.
39. The method of claim 37, wherein after said step of compressing
said compressible dry good within said bag, the compressed volume
of said dry good is less than about eighty percent of the free
volume of said dry good.
40. The method of claim 37, wherein after said step of compressing
said compressible dry good within said bag, the compressed volume
of said dry good is less than about forty percent of the free
volume of said dry good.
41. The method of claim 37, wherein said step of sealing said open
end of said sealable bag to form a sealed bag is performed by a hot
press.
42. The method of claim 37, further comprising the step of applying
a label to a surface of said sealed bag.
43. A method of preparing a disaster pack comprising a pillow, a
blanket, and a mattress pad compressed and disposed within a
package comprising the steps of: a) placing said pillow and said
blanket within a first sealable bag comprising a first cavity and a
first open end; b) placing said pillow and said blanket disposed
within said first sealable bag on a platen; c) compressing said
pillow and said blanket within said first sealable bag; d) sealing
said first open end of said first sealable bag to form a first
sealed bag; e) removing said pillow and said blanket within said
first sealed bag from said platen; f) placing said mattress pad
within a second sealable bag comprising a second cavity and a
second open end; g) placing said mattress pad disposed within said
second sealable bag on said platen; h) compressing said mattress
pad within said second sealable bag; i) sealing said second open
end of said second sealable bag to form a second sealed bag; j)
removing said mattress pad within said second sealed bag from said
platen; and k) placing said first sealed bag and said second sealed
bag within a first packaging bag comprising a third cavity and a
third open end.
44. The method of claim 43, further comprising the step of placing
said mattress pad within a second packaging bag and evacuating air
from said second packaging bag and said mattress pad before said
placing said mattress pad within said second packaging bag within
said second sealable bag.
45. The method of claim 43, wherein after said step of placing said
first sealed bag and said second sealed bag within a first
packaging bag, the compressed volume of said pillow, said blanket,
and said mattress pad disposed within said first packaging bag is
less than about twenty percent of the sum of the free state volumes
of said pillow, said blanket, and said mattress pad.
46. The method of claim 43, wherein said steps of sealing said
first open end of said first bag to form a first sealed bag, and
sealing said second open end of said second bag to form a second
sealed bag, are performed by at least one hot press.
47. The method of claim 43, further comprising the step of applying
a label to a surface of at least one of said first sealable bag,
said second sealable bag, and said first packaging bag.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application claims the benefit of the filing date of
U.S. provisional patent application Serial No. 60/367,558 filed
Mar. 26, 2002.
[0002] This invention relates in one embodiment to a package
containing bedding for use by a human, and more particularly to a
highly compact package containing a foam mattress, a pillow, and a
blanket, which have been highly compressed and enclosed in a
compact package. The package of the present invention may be stored
and transported in minimal space, distributed under emergency
circumstances, and subsequently opened so that the bedding from
such package may be used by a human.
FIELD OF THE INVENTION
[0003] Compact packaging for any compressible dry goods made of
foam, pliable fiber filling, piled fabric, and any other flexible
material having a large void volume of air contained therein.
BACKGROUND OF THE INVENTION
[0004] There are numerous circumstances in which there is a need
for a highly compact package containing dry goods that are made of
foam, pliable fiber filling, piled fabric, and any other flexible
material having a large void volume of air contained therein. One
such circumstance is on the occasion of a natural or man-made
disaster, in which a significant number of people are suddenly
displaced from their normal residences, and must be temporarily
sheltered or at least kept warm until the situation improves. In
such a circumstance, it is almost always necessary to provide
temporary bedding for such people.
[0005] Minimal bedding for an individual typically comprises a foam
mattress, a pillow, and a blanket. One property in common for each
of these objects is that in their free state (i.e. while in use),
each contains a large void volume of air therein, such a property
being necessary to provide the required bedding functions of
padding, support, and thermal insulation. Such a required property
of bedding is exactly the opposite of desirable properties for the
storage, transportation, and distribution of such goods in an
emergency or other circumstance. The large volume of air contained
in such objects renders them unsuitable for timely and cost
effective storage, transportation, and distribution in an emergency
or other circumstance.
[0006] There are many other heretofore unmet needs and additional
uses for the disaster pack, and the packaging methods of the
present invention. For example, there is a need for a small number
of such packages to be carried on board emergency vehicles such as
police, fire and ambulance vehicles for use by a few individuals in
rescue situations. The storage of approximately between one and
five foam mattress, pillow, and blanket sets in their free state
would clearly be an unacceptable practice, as such bedding packages
would require excessive space within any of such vehicles.
[0007] In addition, such packages of bedding being relatively low
in cost, is also an attractive feature, because such packages could
be treated as one-use disposable bedding. In present times, with
there being such broad concern and even statutory and regulatory
requirements for the avoidance of transmission of blood-borne
pathogens and other contaminants, the disaster pack and packaging
methods of the present invention are clearly advantageous.
[0008] Individual travelers or families in some circumstances may
also have need for a disaster pack of the present invention
comprising a pillow and a blanket. Such circumstances would be when
an individual or family is traveling in a remote area having a cold
climate. In the event of a breakdown of the travelers' vehicle, a
small number of such disaster packs carried onboard the vehicle
could save the lives of the travelers, keeping them warm until help
arrives. Such disaster packs, being highly compact, could easily be
carried within a storage area of the vehicle, and such disaster
packs could further comprise articles of clothing such as hats,
mittens, gloves, cloth booties, and the like.
[0009] In like manner, a pillow packaged according to the present
invention, in a highly compact package, could be used by a traveler
staying in a hotel. Such a package could easily be carried in a
suitcase, and opened at the hotel room to provide the traveler with
a sanitary pillow, free of pathogens, allergens, and other
contaminants. It is well known that hotel pillows that undergo
repeated use by hotel customers, become infested with dust mites,
dust mite feces, and numerous other known and unknown pathogens and
allergens.
[0010] There is also a use for the packaging methods of the present
invention in more cost effective storage, transportation, and
display of dry goods for retail sale, or the transportation of dry
goods to the end consumer. Bedding, foam furniture, and all manner
of dry goods that are made of foam, pliable fiber filling, piled
fabric, and any other flexible material having a large void volume
of air contained therein, and a significant shape memory, are
products for which the packaging process of the present invention
may be used advantageously. Such products can be packaged at the
manufacturer's factory after fabrication, and subsequently shipped
to a warehouse or directly to the retail store using only a
fraction of the space for such transportation and storage that
would otherwise be required if such goods were shipped in their
free state according to the present practice.
[0011] In addition, such goods packaged by the process of the
present invention may be offered for sale in point-of-purchase
displays in such compact packaging, with a single unpackaged
product in its state of use on display. Consumers could buy the
product in its compact packaging, transport it home, and then open
such package and use the product. Thus the use of the packaging
process of the present invention, by reducing the space required
for storage, transportation, and display of the product offers the
opportunity for major cost savings for the retail store and the
consumer. In like manner, for those manufacturers that sell
directly to the end customer via mail order, the packaging process
of the present invention offers the opportunity to ship products
that otherwise require high-volume and unwieldy shipping boxes in
very compact flexible packaging such as fiber-reinforced envelopes,
or in the packaging itself, with appropriate shipping labels.
[0012] Although it is known that a packaging process exists for the
storage of clothing in an evacuated bag (marketed and sold as the
"Space Bag"), such packaging entails the use of a more costly,
non-disposable, non-heat sealable bag, and such packaging requires
the use of a vacuum cleaner to reduce the volume of air within the
clothing and the bag. Thus such a process is not considered
sufficiently cost-effective and efficient for the mass production
of packaged dry goods in a reduced volume.
[0013] To the best of the applicant's knowledge, no such packaging
is currently available, that can contain bedding or other
compressible dry goods in the minimum possible volume, in a sterile
or at least fully sealed and non-allergenic inexpensive
disposable/recyclable package, and in a regular geometric shape
that is optimal for storage and transportation in a minimum of
space.
[0014] It is therefore an object of this invention to provide a
highly compact bedding package containing a foam mattress, a
pillow, and a blanket, which have been highly compressed and
enclosed therein, and which may subsequently stored and transported
in minimal space, and distributed under emergency circumstances to
large numbers of people.
[0015] It is an object of this invention to provide a highly
compact bedding package containing a foam mattress, a pillow, and a
blanket, which is sufficiently compact to be carried on board
emergency vehicles such as police, fire and ambulance vehicles for
use in rescue situations.
[0016] It is an object of this invention to provide a highly
compact, inexpensive bedding package containing a foam mattress, a
pillow, and a blanket, which is sanitary and disposable after a
single use.
[0017] It is an object of this invention to provide a highly
compact bedding package containing a foam mattress, a pillow, a
blanket and/or articles of clothing, which is sufficiently compact
to be carried in one's personal vehicle, to be opened and used in
an emergency.
[0018] It is an object of this invention to provide a pillow
enclosed in a highly compact package, which could easily be carried
in a suitcase by a traveler, and subsequently opened at the hotel
room to provide the traveler with a sanitary pillow, free of
allergens.
[0019] It is an object of this invention to provide a method for
making a highly compact bedding package containing a pillow and a
blanket.
[0020] It is an object of this invention to provide a method for
making a highly compact bedding package containing a foam mattress,
a pillow, and a blanket.
[0021] It is an object of this invention to provide a method for
making a highly compact dry goods package that enables the more
cost effective storage, transportation, and display of dry goods
for retail sale.
[0022] It is an object of this invention to provide a method for
making a highly compact dry goods package that enables the more
cost effective transportation of the dry goods directly to the end
consumer.
SUMMARY OF THE INVENTION
[0023] In accordance with the present invention, there is provided
a disaster pack comprising a pillow, and a blanket compressed and
disposed within a first sealed bag comprised of a cavity, and a
seal at one end of said cavity. In one preferred embodiment, the
compressed volume of said pillow and said blanket disposed within
said sealed bag is less than about twenty percent of the sum of the
free state volumes of said pillow, said blanket, and said mattress
pad.
[0024] In accordance with the present invention, there is further
provided a disaster pack comprising a pillow, a blanket, and a
mattress pad compressed and disposed within a first sealed bag
comprised of a first cavity, and a first seal at one end of said
first cavity, wherein said pillow and said blanket are disposed
within a second sealed bag comprised of a second cavity, and a
second seal at one end of said second cavity; said mattress pad is
disposed within a third sealed bag comprised of a third cavity, and
a third seal at one end of said third cavity; and said second
sealed bag and said third sealed bag are disposed within said first
sealed bag.
[0025] In accordance with the present invention, there is further
provided a packaged product comprising a first compressible dry
good compressed and disposed within a sealed bag comprised of a
cavity, and a seal at one end of said cavity, wherein the
compressed volume of said first compressible dry good disposed
within said sealed bag is less than about eighty percent of the
free state volume of said first compressible dry good.
[0026] In accordance with the present invention, there is further
provided a method of preparing a packaged product comprising a
first compressible dry good compressed and disposed within a
sealable bag comprising a cavity and an open end, comprising the
steps of placing said first compressible dry good within said
sealable bag; placing said first compressible dry good disposed
within said sealable bag on a platen; compressing said first
compressible dry good within said sealable bag; sealing said open
end of said sealable bag to form a sealed bag; and removing said
first compressible dry good within said sealed bag from said
platen.
[0027] One aspect of the invention deals with a basic problem in
the packaging, storage, and transportation of dry goods that are
made of foam, pliable fiber filling, piled fabric, and any other
flexible material having a large void volume of air contained
therein. A property of such a dry good product is that in its free
state (i.e. while in use), such product contains a large void
volume of air therein. This property is usually required in order
to provide the functional performance of the product when used for
its intended purpose. Such a required property is exactly the
opposite of desirable properties for the storage, transportation,
and distribution of such goods in an emergency or other
circumstance.
[0028] This aspect of the invention is further based on the
discovery of a technique that alleviates this problem. The
technique involves the placement of the dry good product in its
free state within a package, collapsing the product, further
compressing the product into a compacted state, and sealing the
compacted product within the package.
[0029] The technique can be implemented with a machine that
provides a vacuum source to evacuate the package and the product, a
mechanical press to assist in compaction of the product, and
sealing means to seal the product in its compacted state, thereby
retaining the product in its compacted state until such package is
opened.
[0030] The technique described above is advantageous because it is
simple and inexpensive compared to other packaging approaches, and
it enables the packaging of dry goods in an extremely compact
volume. As a result of the invention, such dry goods may be stored
in minimal space in a warehouse or retail store, and/or may be
transported in minimal volume until such goods arrive at a retail
store, or at the intended location of end use by the consumer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The invention will be described by reference to the
following drawings, in which like numerals refer to like elements,
and in which:
[0032] FIG. 1 is schematic representation of a process in which one
embodiment of the package of the present invention is opened;
[0033] FIG. 1A is a detailed view of a corner of the package of
FIG. 1 comprising a notch to facilitate opening of such
package;
[0034] FIG. 2 is a perspective view of unpacked and fully deployed
bedding contained in one embodiment of the package of the present
invention;
[0035] FIG. 3 is a cross-sectional schematic view of the beginning
of a process of the present invention in which a pillow is
packaged.
[0036] FIG. 4 is a cross-sectional schematic view during a process
of the present invention in which a pillow is packaged, at a point
after the pillow is compressed, but before the packaging bag is
sealed;
[0037] FIG. 5 is a cross-sectional schematic view during a process
of the present invention in which a pillow is packaged, at a point
when the packaging bag is sealed;
[0038] FIG. 6 is a cross-sectional schematic view at the conclusion
of a process of the present invention in which a pillow is
packaged;
[0039] FIG. 7 is a perspective view of an uncompressed pillow and a
compressed pillow packaged and sealed by the process of the present
invention;
[0040] FIG. 8 is a perspective view of an uncompressed foam
mattress pad and a compressed foam mattress pad packaged and sealed
by the process of the present invention;
[0041] FIG. 9 is a perspective view of an uncompressed blanket and
a compressed blanket packaged and sealed by the process of the
present invention;
[0042] FIG. 10 is a perspective view of one preferred embodiment of
a package of the present invention, with its contents depicted
therein in phantom;
[0043] FIG. 11 is a top view of the package of FIG. 10 to which a
label has been affixed;
[0044] FIG. 12 is a cross-sectional schematic view of the beginning
of a preferred process of the present invention in which a foam
mattress pad is packaged using vacuum assistance means;
[0045] FIG. 13 is a cross-sectional schematic view during a
preferred process of the present invention in which a foam mattress
pad is packaged, at a point after a first packaging bag and foam
mattress pad contained therein are evacuated, but before the first
packaging bag and foam mattress pad are placed within a second
packaging bag;
[0046] FIG. 14 is a cross-sectional schematic view during a
preferred process of the present invention in which a foam mattress
pad contained in a first and a second packaging bag is packaged, at
a point after a first packaging bag and foam mattress pad contained
therein have been placed in a second packaging bag, but before the
foam mattress pad contained in the first and the second packaging
bag is compressed;
[0047] FIG. 15 is a cross-sectional schematic view during a
preferred process of the present invention in which a foam mattress
pad is packaged, at a point after the foam mattress pad is
compressed, but before the second packaging bag is sealed;
[0048] FIG. 16 is a cross-sectional schematic view during a
preferred process of the present invention in which a foam mattress
pad is packaged, at a point when the second packaging bag is
sealed;
[0049] FIG. 17 is a cross-sectional schematic view at the
conclusion of a preferred process of the present invention in which
a foam mattress pad is packaged;
[0050] FIG. 18 is a flow chart depicting the steps of one preferred
process for preparing a package containing a single object in
accordance with the present invention;
[0051] FIG. 19 is a flow chart depicting the steps of one preferred
process for preparing a package containing multiple objects in
accordance with the present invention;
[0052] FIG. 20A is a side view of one packaging apparatus for the
making of the compressible dry goods packaged in accordance with
the present invention;
[0053] FIG. 20B is a top view of the packaging apparatus of FIG.
20A; and
[0054] FIG. 21 is a side view of an alternate packaging apparatus
for the making of the compressible dry goods packaged in accordance
with the present invention.
[0055] The present invention will be described in connection with a
preferred embodiment, however, it will be understood that there is
no intent to limit the invention to the embodiment described. On
the contrary, the intent is to cover all alternatives,
modifications, and equivalents as may be included within the spirit
and scope of the invention as defined by the appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0056] For a general understanding of the present invention,
reference is made to the drawings. In the drawings, like reference
numerals have been used throughout to designate identical elements.
In describing the present invention, a variety of terms are used in
the description. As used herein, free state is meant to indicate
the fully expanded state or shape of a dry good at atmospheric
pressure, wherein such dry good is not subjected to any external
forces that deform it or reduce its volume. Free state volume is
meant to indicate the volume of a dry good in its fully expanded
state at atmospheric pressure. Compressed volume or packaged volume
is meant to indicate the volume occupied by a dry good in a
compressed state and contained by a package of the present
invention. Shape memory is meant to indicate the extent to which an
object is restored, either elastically, or with assistance, to its
original free state volume after being unpackaged and released from
a compressed state.
[0057] FIG. 1 is schematic representation of a process in which one
embodiment of the package of the present invention is opened.
Reference to FIG. 1 is illustrative of aspects of how the package
of the present invention is constructed, and how the package and
the contents therein are used by the end consumer. It is to be
understood that for the sake of illustration, the dry goods content
of the package 102 of FIG. 1 is shown as a bedding kit, but that
many other dry goods or combinations of dry goods may be contained
in the package of the present invention.
[0058] Referring to FIG. 1 and in one embodiment, package 102
comprises a sealed plastic bag. In the preferred package 102 is an
unsealed bag made of fabric material such as, e.g., non-woven
fabric. Referring again to FIG. 1, and in the embodiment wherein
package 102 is a sealed bag, in step 101 of process 100, strip 105
is torn from the end of package 102, thereby opening package 102.
In such embodiment, package 102 comprises a notch 105 (see also
FIG. 1A) adjacent to bag seal 134, which acts as a stress
concentrator that facilitates the tearing of package 102. Thus
package 102 is opened without cutting tools that might damage the
goods contained therein. In an alternate embodiment (not shown)
package 102 comprises a score mark disposed across the end thereof
in lieu of or in addition to notch 105, which further provides
stress concentration that facilitates the tearing of package 102.
Such stress concentration means to assist in package opening are
well known.
[0059] Referring again to FIG. 1, in step 103 of the embodiment of
package 102 comprising a bedding kit 107, three sealed bags 110,
114, and 118 are preferably removed from the bag 102. These sealed
bags 110, 114, and 118 contain, respectively, pillow 108, blanket
112, and foam mattress 116.
[0060] In one embodiment of bedding kit 107, pillow 108 is
compressed and contained in sealed bag 110 at a volume of less than
about twenty percent of its volume in its free state, and
preferably at a volume of less than about five percent of its
volume in its free state, and more preferably at a volume of less
than about three percent of its volume in its free state. The
operative requirements for each of pillow 108, blanket 112, and
foam mattress 116 are that each is compressible to a significantly
lesser volume than its respective free state, and that each has a
high "shape memory", i.e. each item is sufficiently elastic, or can
be "fluffed", such that after unpackaging, each object is restored
to approximately the same free volume that it occupied before
packaging.
[0061] In one preferred embodiment of bedding kit 107, pillow 108
is a Fiberfill pillow comprised of at least about 50 weight percent
polyester fibers with a compressed length of 20 inches, a
compressed width of 14.5 inches, and compressed thickness of 0.25
inches; and an uncompressed length of 26 inches, and uncompressed
width of 20 inches, and an uncompressed thickness of 7 inches.
Pillow 108 is thus compressed from a free state volume of about
3640 cubic inches to a compressed volume of about 72.5 cubic
inches, and is thus contained in sealed bag 110 at a volume of
about two percent of its free state volume.
[0062] In one embodiment of bedding kit 107, blanket 112 is
compressed and contained in sealed bag 114 at a volume of less than
about forty percent of its volume in its free state, and preferably
at a volume of less than about twenty five percent of its volume in
its free state, and more preferably at a volume of less than about
fifteen percent of its volume in its free state.
[0063] Many known fabrics and sheet goods having low bulk thermal
conductivity are suitable for use as blanket 112. In one
embodiment, blanket 112 is a Microfleece blanket. In another
embodiment, blanket 112 is a fabric formed from woven fibers
selected from the group consisting of wool, silk, linen, polyester,
nylon, acetate, poly(ethylene terephthalate), and mixtures
thereof.
[0064] In one preferred embodiment of bedding kit 107, blanket 112
preferably is formed by a needle-punching process, and consists
essentially of poly(ethylene terephthalate), fibers, such blanket
having a compressed length of 17 inches, a compressed width of 13
inches and a compressed thickness of 0.5 inch; and an uncompressed
length of 72 inches, an uncompressed width of 48 inches, and an
uncompressed thickness of 0.25 inches. Blanket 112 is thus
compressed from a free state volume of about 864 cubic inches to a
compressed volume of about 110.5 cubic inches, and is thus
contained in sealed bag 114 at a volume of about thirteen percent
of its free state volume.
[0065] In a further embodiment, blanket 112 includes fabric
comprising a micro-porous membrane manufactured of fibers formed of
expanded PTFE (polytetrafluoroethylene) such as Gore-Tex.RTM.
fabric manufactured by W. L. Gore and Associates.
[0066] In a further preferred embodiment, pillow 108 and blanket
112 are packaged together in a single bag, provided an alternative
embodiment of the disaster pack of the present invention. In such
an embodiment, pillow 108 and blanket 112 are compressed and
contained in sealed bag at a volume of less than about twenty
percent of the sum of their respective volumes in the free state,
and preferably at a volume of less than about ten percent of the
sum of their respective volumes in the free state, and more
preferably at a volume of less than about five percent of the sum
of their respective volumes in the free state.
[0067] In one embodiment of bedding kit 107, foam pad/mattress 116
is compressed and contained in sealed bag 118 at a volume of less
than about twenty percent of its volume in its free state, and
preferably at a volume of less than about fifteen percent of its
volume in its free state, and more preferably at a volume of less
than about ten percent of its volume in its free state.
[0068] In one preferred embodiment of bedding kit 107, foam
pad/mattress 116 is preferably a polymer foam pad comprising at
least about 60 weight percent polyurethane ether foam with a
compressed length of 18.5 inches, a compressed width of 11 inches,
and a compressed thickness of 1 inch; and an uncompressed length of
72 inches, an uncompressed width of 24 inches, and an uncompressed
thickness of 1.5 inches. Foam pad/mattress 116 is thus compressed
from a free state volume of about 2592 cubic inches to a compressed
volume of about 203.5 cubic inches, and is thus contained in sealed
bag 118 at a volume of about eight percent of its free state
volume.
[0069] Each of the pillow 108, the blanket 112, and the foam pad
116 preferably weights about 1.1 pounds. The total weight of
disaster pack 102 containing bedding kit 107, including the
respective individual enclosures for pillow 108, blanket 112, and
foam pad 116, is about 3.5 pounds. In general, it is preferable
that the disaster pack 102 of the present invention weighs less
than about eight pounds, and more preferably less than about five
pounds.
[0070] In one embodiment of disaster pack 102, the pillow 108,
blanket 112, and foam pad/mattress 116 are compressed and contained
therein at a volume of less than about twenty percent of the sum of
their respective free state volumes, and preferably at a volume of
less than about twelve percent of the sum of their respective free
state volumes, and more preferably at a volume of less than about
eight percent of the sum of their respective free state volumes. In
one preferred embodiment of disaster pack 102 comprising a
Fiberfill pillow, a woven blanket, and a polyurethane ether foam
pad as previously described, such components are compressed from a
free state volume of about 7096 cubic inches to a compressed volume
of about 386.5 cubic inches, and thus disaster pack 102 is
contained at a volume of about 5.5 percent of its free state
volume.
[0071] In one preferred embodiment, each of the pillow 108, the
blanket 112, and the foam pad 116 are individually packaged in a
sealed plastic bag comprising a stress-concentrating notch or score
mark, similar to the package enclosure 102 containing the entire
bedding kit 107. Thus the process to open each of the enclosures
for pillow 108, the blanket 112, and the foam pad 116 is
substantially the same as shown in step 101 for the opening of
package 102.
[0072] It will be apparent that although the foregoing description
has generally pertained to dry goods that are highly compressible,
i.e. dry goods having a packaged volume of less than forty pecent
of their free state volumes, the packaged objects, method, and
apparatus of the present invention are limited to such a relative
volume reduction in order to be useful. For example, there are many
dry goods made of less compressible materials, e.g. closed cell
foam. Such a closed cell foam object is compressible to a smaller
packaged volume, on the order of up to 80 percent if its free state
volume, wherein the method of the present invention compresses the
air trapped in the closed cells into a smaller volume at a higher
pressure, rather than displacing such air. Also of significant
importance is the result that somewhat irregularly shaped objects,
such as e.g., foam chairs, foam pet beds, stuffed toys, and the
like, are rendered into a more regularly shaped rectilinear or
cubic object that is more easily handled, stacked, and transported.
Thus, such dry goods packaged in accordance with present invention
are thus rendered less expensive to handle, store, transport, and
offer for retail sale. Accordingly, such moderately compressed
packaged dry goods are to be considered within the scope of the
present invention.
[0073] FIG. 2 is a perspective view of the unpacked and fully
deployed bedding kit contained in the embodiment of package 102 of
FIG. 1, prepared by the package opening process 100 of FIG. 1. As
is illustrated in FIG. 2, the package 102 containing bedding kit
107 (see FIG. 1) produces a functional bedding assembly 109
comprised of the foam mattress 116, the blanket 112, and the pillow
108.
[0074] FIGS. 3-6 are cross-sectional schematic views of steps of a
process of the present invention in which pillows, blankets, foam
mattress pads, or other compressible dry goods are packaged.
[0075] FIG. 3 is a cross-sectional schematic view of the beginning
of a process of the present invention in which a pillow is
packaged. Referring to FIG. 3, the uncompressed pillow 108 is first
disposed within a heat-sealable plastic bag 130. The heat sealable
plastic bag 130 preferably is substantially impermeable to gas; bag
130 may be any heat-sealable bag adapted to storing items from
which air has been evacuated.
[0076] In one embodiment, bag 130 is a heat-sealable bag comprised
of nylon and low density polyethylene. In one embodiment, the
heat-sealable bag is sold as "NOWVAC-HB" by NOW Plastics of One
Monarch Place, Springfield, Mass. This bag is identified as being a
" . . . clear, high barrier flexible and formable coextruded
multiple layer vacuum bag comprised of Polyamide (Nylon), EVOH
(Ethylene-Vinyl Alcohol) and Low Density Polyethylene or EVA
(Ethylene-Vinyl Acetate)."
[0077] In another embodiment, bag 130 consists essentially of poly
(ethylene terephthalate), (PET), also known commercially as
Mylar.RTM.. Such PET bag may be either heat sealed, or such bag may
be compression sealed, wherein a pressure sensitive adhesive is
disposed on the inside surface of end 119 of bag 130 prior to the
application of pressure by press 121. In such application, press
121 may be a cold press.
[0078] In another embodiment, a hot melt adhesive is disposed on
the inside surface of end 119 of bag 130 prior to the application
of pressure by press 121. For example, such adhesive may be formed
as an adhesive tape, or an adhesive gauze-like web, and selected
from the group consisting of polyurethanes, polyolefins,
polyamides, and polyesters. Such adhesives are sold commercially by
the Industrial Adhesives Division of the Bostik Findley Corporation
of Middleton, Mass. 01949, and are marketed in sales brochure AI 27
8/99 5M, the disclosure of which is incorporated herein by
reference. Numerous other adhesives will be apparent to those
skilled in the art. For example, one may use other hot melt
adhesives, reactive hot melt adhesives, liquid adhesives, and the
like, with the appropriate use of a cold press if the sealing bond
is formed at ambient temperature, or a hot press if the bond is
formed at elevated temperature.
[0079] Referring again to FIG. 3, pillow 108 disposed within cavity
133 of heat-sealable bag 130 is disposed on platen 111 and
compressed by press 113. The press 113, in one embodiment, is a 20
ton press, manufactured by the USM Corporation, which moves in the
direction of arrow 115. As press 113 compresses pillow 108, the air
(not shown) within such pillow 108 is displaced in the direction of
arrow 117 out of the opening in the end 119 of bag 130, such that
cavity 133 of bag 130 is significantly reduced in volume. At least
about 80 volume percent of the air within pillow 108 is displaced
in the pressing operation. In one embodiment, at least about 95
volume percent of the air is displaced in the pressing operation,
and more preferably, at least about 97 volume percent of the air is
displaced in the pressing operation.
[0080] In operations for the packaging of less compressible goods,
such as goods made of closed cell foam, press 113 compresses the
air trapped therein, thereby reducing the volume of such objects.
Such a volume reduction is at least about 20 volume percent,
preferably at least about 30 volume percent, and more preferably at
least about 40 volume percent.
[0081] FIG. 4 is a cross-sectional schematic view during the
process of the present invention in which a pillow is packaged, at
a point after the pillow is compressed by a press, but before the
packaging bag is sealed. FIG. 4 illustrates the situation where
substantially all of the air has been pressed and displaced out of
pillow 108. When substantially all of such air has been pressed out
of pillow 108, the end 119 of bag 130 is heated sealed as indicated
in FIG. 5 by heated press 121, which preferably is at a temperature
of from about 425 to about 475 degrees Fahrenheit. In one
embodiment, the end 119 of bag 130 is pressed under these
conditions for about 20 seconds. Depending upon conditions such as
the temperature of press 113, the temperature of the platen beneath
press 113, and the melting temperature of bag 130, a proper seal
may be achieved in a little as about 5 seconds.
[0082] Thereafter, as is illustrated in FIG. 6, cold press 113 and
hot press 121 are retracted, with end 119 of bag 130 having been
fused into-seal 134. Compressed pillow 108' within sealed bag 130
then comprises compressed pillow assembly 110 (as in FIG. 1).
Compressed pillow assembly 110 is ready to be packaged in bag 102
(see FIG. 1). In one embodiment, bag 130 is supplied from the bag
manufacturer with a notch 105 (see FIG. 1A) that after sealing is
positioned adjacent to seal 134. In another embodiment (not shown)
hot press 121 is provided with a die that forms a notch at the edge
of seal 134.
[0083] FIGS. 12-17 are cross-sectional schematic views of steps of
a preferred process of the present invention in which a foam
mattress pad, or other similar compressible dry goods are packaged,
with the use of vacuum assistance means.
[0084] FIG. 12 is a cross-sectional schematic view of the beginning
of a preferred process of the present invention in which a foam
mattress pad is packaged using vacuum assistance means. Referring
to FIG. 12, the uncompressed foam mattress pad 116 is first rolled
up and/or folded over upon itself and disposed within a first
packaging bag 129. Foam mattress pad 116 disposed within first
packaging bag 129 is disposed on platen 111, and vacuum assistance
means 140 is connected to first packaging bag 130. It is not
required that first packaging bag is a heat sealable bag. In one
embodiment, first packaging bag is a polyethylene bag.
[0085] In one preferred embodiment, vacuum assistance means 140
comprises a vacuum hose 143 that is operatively connected to a
vacuum pump (not shown). In another embodiment, vacuum assistance
means comprises a vacuum hose 143 that is operatively connected to
a vacuum cleaner (not shown) comprising an electric motor, a
blower, a vacuum tank, and a filter. In one preferred embodiment,
vacuum hose 143 is made of lightweight plastic and comprises a
flexible corrugated section 142 joined to a tubular cuff 144. In a
further embodiment (not shown) cuff 144 extends further into bag
129, and is formed into an elongated flat section with perforations
disposed therethrough. Such a structure facilitates the rapid and
uniform evacuation of bag 129. Vacuum hose 143 is preferably
between about one half inch and about three inches in diameter, and
more preferably between about one inch and about two inches in
diameter.
[0086] It is also preferred that vacuum assistance means 140 have
sufficient capacity to draw at least about 20 inches water column
of vacuum, and more preferably at least about 50 inches water
column of vacuum. In one embodiment, vacuum assistance means 140
comprises a Shop Vac Model 2010 vacuum cleaner rated at 1.0 HP sold
by the Sears and Roebuck Corporation.
[0087] Referring again to FIG. 12, vacuum assistance means 140 is
connected to first packaging bag 129, preferably by inserting
vacuum hose 143 into end 127 of bag 129 as indicated by arrow 152.
End 127 of bag 130 is then gathered around hose 143 by the
operator's hands (not shown), by automated robotic hands (not
shown) or by other suitable means, thereby forming a temporary seal
between bag 129 and hose 143. Vacuum assistance means 140 is then
actuated by suitable means, e.g. a foot switch (not shown)
operatively coupled to an electric motor, a valve (not shown)
disposed in vacuum hose 143 proximate to the packaging operation,
or by a second operator (not shown). Upon actuation of vacuum
assistance means 140, air is evacuated from bag 129 and from foam
mattress pad 116, flowing as indicated by arrow 154 out through
hose 143.
[0088] FIG. 13 is a cross-sectional schematic view during a
preferred process of the present invention in which a foam mattress
pad is packaged, at a point after a first packaging bag and foam
mattress pad contained therein are evacuated, but before the first
packaging bag and foam mattress pad are placed within a second
packaging bag. Referring to FIG. 13, most of the air contained in
foam mattress pad 116 and first packaging bag 129 has been
evacuated through hose 143, as indicated by arrow 154. Bag 129 has
collapsed such that cavity 135 thereof is substantially contiguous
with evacuated foam mattress pad 116, and has collapsed to a narrow
neck 132 between foam mattress pad 116 and hose cuff 144.
[0089] At some point in time, vacuum assistance means 140 has
evacuated air from bag 129 and foam mattress pad 116 to the limit
of its capacity. The capacity of vacuum assistance means 140 is
selected such that vacuum assistance means 140 is capable of
evacuating the limit of its capacity of the air within bag 130 and
foam mattress pad 116 within about twenty seconds, and more
preferably within about ten seconds. In a more preferred
embodiment, vacuum assistance means 140 is capable of achieving the
desired evacuation of air within about five seconds.
[0090] At such time as when vacuum assistance means 140 has
evacuated bag 129 and foam mattress pad 116 to near the limit of
the capacity of vacuum assistance means 140, the next step of
placing evacuated bag 129 and foam mattress pad 116 in heat
sealable bag 130 proceeds. Referring again to FIG. 13, heat
sealable bag 130 is drawn over evacuated bag 129 and foam mattress
pad 116 as indicated by arrow 164, and vacuum hose 143 is withdrawn
from end 127 of bag 129 as indicated by arrow 160. FIG. 14 is a
cross-sectional schematic view depicting foam mattress pad 116
contained in first packaging bag 129 and heat-sealable packaging
bag 130, at a point after first packaging bag 129 and foam mattress
pad 116 contained therein have been placed in heat sealable bag
130, but before foam mattress pad 116 contained in bags 129 and 130
is compressed.
[0091] Compressing of foam mattress pad 116 then proceeds,
resulting in the state depicted in FIG. 15. FIG. 15 is a
cross-sectional schematic view in which a foam mattress pad 116 is
compressed, but before the heat sealable bag 130 is sealed.
Refering to FIG. 15, press 115 has been lowered upon foam mattress
pad 116, further displacing a portion of the remaining air
contained therein out through end 119. The pressing operation
depicted in FIG. 15 is substantially identical to that shown in
FIG. 4 and previously described in this specification.
[0092] FIGS. 15 and 16 are cross-sectional schematic views during
the preferred process of the present invention, at a point when the
packaging bag is sealed, and at the conclusion of such process,
respectively. The steps depicted in FIGS. 15 and 16 are
substantially identical to those shown in FIGS. 5 and 6 and
previously described in this specification.
[0093] It is to be understood that the use of vacuum assistance
means 140 is optional, and not required in all embodiments of the
present invention. One reason for the use of vacuum assistance
means and first packaging bag 129 is that the clearance between the
platen 111 and cold press 113 in the retracted position is
insufficient to enable the placement of foam mattress pad 116 in a
bag upon platen 1111 without first partially compressing pad 116.
In an alternate embodiment of the apparatus of the present
invention, cold press 113 is retracted further vertically to
provide sufficient clearance. In another embodiment, cold press 113
is swiveled horizontally to provide sufficient clearance.
[0094] Another reason for the use of vacuum assistance means and
first packaging bag 129 is that it is preferable to use a small
heat sealable bag such that less gathering and slack are present
after sealing of such bag. Thus the foam mattress pad 116 is first
partially compressed such that it can be fitted into such smaller
heat sealable bag. In an alternate embodiment, heat sealable bag
may be a heat shrinkable bag, such that excess gathering and slack
are reduced as part of the packaging process.
[0095] FIGS. 7, 8, and 9 are perspective views of an uncompressed
pillow and a compressed pillow, an uncompressed foam mattress pad
and a compressed foam mattress pad, and an uncompressed blanket and
a compressed blanket, respectively, packaged and sealed by the
process of the present invention. FIGS. 7, 8, and 9 illustrate the
uncompressed pillow 108, and the compressed pillow assembly 110,
the uncompressed foam pad 116, and the compressed foam pad assembly
118, the uncompressed blanket 112, and the compressed blanket
assembly 114. As will be apparent, each of the compressed articles
110, 118, and 114 may be produced by the processes depicted in
FIGS. 3, 4, 5, and 6; or by the processes depicted in FIGS. 12, 13,
14, 15, 16, and 17. However, it is preferable that compressed
articles 110 and 114 are produced by the process depicted in FIGS.
2-6 without vacuum assistance, and article 118 is produced by the
process depicted in FIGS. 12-17. It will be further apparent that
each of the compressed articles 110, 118, and 114 is compressed and
packaged into a significantly smaller volume than the corresponding
articles contained therein in their respective free states.
[0096] In one preferred embodiment, pillow 108 of FIG. 7 and
blanket 114 of FIG. 9 are disposed together in a single heat
sealable bag 130 (see FIG. 3), and the subsequent process steps
depicted in FIGS. 4-6 are then performed to produce a packaged
blanket and pillow packaged as a single unit. Such a smaller and
simpler disaster pack has utility, e.g. when carried in one's
personal automobile in cold climates.
[0097] FIG. 10 is a perspective view of one preferred embodiment of
a package of the present invention, with contents depicted therein
in phantom. In an embodiment wherein package 102 contains a bedding
kit 107 comprising compressed pillow assembly 110, compressed foam
pad 116, and compressed foam pad assembly 118 (see FIGS. 1, and
7-9), such bedding kit 107 is sealed within package 102. The
respective compact rectangular shapes of each of such packaged
components as shown in FIGS. 7-9 results in an overall compact
rectangular shape of package 102 having a semi-rigid structure.
[0098] Such compact shape and semi-rigid structure of the bedding
kit, and of other dry goods packaged according to the present
invention, are very advantageous to the operations that occur in
the movement of such goods from the factory floor, to warehousing,
to retail sales location, to a storage location of the end
customer. Such operations include, but are not limited to, labeling
of such goods for inventory tracking and/or retail sale, placement
of goods on shipping skids or wire mesh cargo containers on the
factory floor, trucking of such goods to warehouses or retail sales
locations, shipping of such goods by direct mail or commercial
courier in very simple lightweight packaging such as a mailing
envelope, placement of such goods on overhead storage racks at the
retail store, offering of such goods on retail store shelves while
showing only a single unit of such goods in free state in a
point-of-purchase display. All of these operations are economically
and functionally advantageous compared to the equivalent operations
on uncompressed dry goods.
[0099] In one further embodiment, best illustrated by reference to
FIG. 8, a dry good comprising a small foam chair is packaged. Foam
chair has a rectilinear shape similar to foam pad 116, but with a
lower aspect ratio, i.e. foam chair 116 is more closely
approximated by a cube having a cavity hewn therefrom for the
seating of a human therein. In further embodiments best illustrated
by reference to FIG. 8, dry good 116 is a foam pet bed, a stuffed
toy, or a foam play ball.
[0100] FIG. 11 is a top view of the package of FIG. 10 to which a
label has been affixed or printed. It will be apparent that the
compact shape and semi-rigid structure of package 102 is
advantageous for labeling such package. In one embodiment, label
123 is a preprinted label comprising an adhesive backing, such
label being removed from a release paper and applied to package
102. In another embodiment, label 123 is directly printed upon
package 102 by printing means such as, e.g., ink jet printing,
screen printing, a hot stamp, and the like. Such labels may
include, but are not limited to, inventory management/tracking
barcodes, UPC barcodes, lot numbers, dates, trademarks, patent
numbers, logos, sales collateral, manufacturer's contact
information, pricing, instructions for use, recycling instructions,
safety warnings, materials contents, material safety data sheets,
country of origin, illustrations, photographs, and other
manufacturing, tracking, marketing, sales and use, and/or disposal
information.
[0101] FIG. 18 is a flow chart depicting the steps of one preferred
process for preparing a package containing a single object in
accordance with the present invention. Referring to FIG. 18,
packaging process 200 comprises a first step 210, placing the
object in a heat sealable bag, and placing the bagged object upon a
platen. The details of step 210 are depicted in FIG. 3.
[0102] Subsequent to step 210, in step 220, the object and bag are
compressed and a portion of the remaining air contained therein is
displaced from the bag, as depicted in FIGS. 4 and described
elsewhere in this specification. Step 230, sealing of the object in
the compressed bag, follows, as depicted in FIG. 5 and described
elsewhere in this specification. The completely sealed package
assembly is then removed from the platen in step 240, and delivered
to labeling and/or shipping processes, or other packaging
processes.
[0103] Referring again to FIG. 18, in the case where a large foam
object such as a mattress pad is being packaged, packaging process
200 optionally further comprises step 405, placing such foam object
in a first bag, and evacuating the first bag and foam object, as
depicted in FIGS. 12 and 13 and described elsewhere in this
specification. Subsequently, such foam object is packaged in steps
210-240, as depicted in FIGS. 14-17 and described elsewhere in this
specification.
[0104] In one embodiment, the completely sealed package assembly is
combined and further packaged with other package assemblies, in
order to prepare a package containing multiple objects. FIG. 19 is
a flow chart depicting the steps of one preferred process for
preparing a package containing multiple objects in accordance with
the present invention. Referring to FIG. 19, overall packaging
process 500, in the most simple embodiment, comprises step 510,
placing the multiple objects, or multiple packages containing
objects in a packaging bag. In one preferred embodiment, the
packaging bag is a cloth bag, as previously described in this
specification.
[0105] In an alternate embodiment, wherein the bag of step 510 is a
sealable bag, process 500 further comprises placing such bag on a
platen, followed by an optional step 520, compressing or evacuating
such bag containing multiple objects, or multiple packages
containing objects, thereby displacing air contained in such
multiple objects and/or multiple packages; 530, sealing the bag
containing the multiple objects, or multiple packages containing
objects; and 540, removing the multiple-object containing package
from the platen. Such multiple-object containing package may then
be delivered to labeling and/or shipping processes, to a warehouse,
a retail sales location, and/or to the end user of the product(s)
contained therein.
[0106] In one preferred embodiment, packaging process 500 further
comprises the steps of preparing individual packaged objects as
previously described and shown in this specification and FIGS.
1-18. Referring again to FIG. 19, process 500 further comprises the
steps of sub-process 200, in which a first object is packaged in
accordance with FIG. 18 as previously described in this
specification; and the steps of sub-process 300, in which a second
object is packaged in accordance with FIG. 18 as previously
described in this specification. In a further embodiment, process
500 further comprises the steps of sub-process 400, in which a
third foam object is packaged in accordance with FIG. 18 as
previously described in this specification.
[0107] It will be apparent that process 500 may further comprise
additional sub-processes for the packaging of individual dry goods,
or process 500 may include the packaging of other substantially
flat-shaped or small incompressible objects in addition to the
individually packaged compressible dry goods, such as in the case
of a disaster pack, e.g. a candle, a lighter, a match book, a small
flashlight, preserved flat foodstuffs, and the like. It will be
further apparent that individual labels may be applied or printed
on such individual packages prior to their being packaged in a
single bag, as indicated by optional step 505 of FIG. 18.
[0108] In one embodiment, process 500 is used to produce the
disaster pack 102 (see FIG. 1) of the present invention. Referring
to FIG. 1 and FIG. 19, in sub-process 200, the packaged pillow 110
is produced; in sub-process 300, the packaged blanket 114 is
produced; and in sub-process 400, the packaged foam pad 118 is
produced. Such individual packages may then be labeled in
accordance with step 505. Subsequently, pillow 110, blanket 114,
and foam pad 118 are combined in a heat-sealable bag and packaged
as depicted in steps 510-550 as previously described in this
specification. In an alternate embodiment, pillow 108 and blanket
114 are combined in a single heat sealable bag and a pillow/blanket
packaged assembly (not shown) is produced in sub-process 200, while
in sub-process 400, the packaged foam pad 118 is produced.
Subsequently, pillow/blanket assembly and foam pad 118 are combined
in a heat-sealable bag and packaged as depicted in steps 510-550 as
previously described in this specification. Disaster pack 102 may
then be delivered to labeling and/or shipping processes, to a
warehouse, a retail sales location, and/or to the end user
thereof.
[0109] It will be apparent that in making disaster pack 102, the
packaged pillow 110, packaged blanket 114, (or a combined packaged
pillow/blanket assembly), packaged mattress pad 118, and the
combined package 102 may be made serially using a single apparatus
comprising a platen, vacuum assistance means, a cold press, and a
hot press. Alternatively, a plurality of packaging apparatus may be
provided, with each individual apparatus packaging one of the
pillow 108, the blanket 112, the mattress pad 116, or the combined
package 102 simultaneously, so that higher manufacturing throughput
is attained.
[0110] It will be further apparent that disaster pack 102 may
comprises multiple sets of pillow 110, and blanket 114, and may
further comprise foam pad 118, so that disaster pack 102 may be
made suitable for two people, or suitable for a family of three or
more people. It will be further apparent that although in the
preferred embodiment, the pillow 110, blanket 114, and foam pad 118
are first packaged and sealed in individual bags, and then packaged
and sealed in a single bag, Alternatively pillow 110, blanket 114,
and foam pad 118 may all be disposed in a single bag, further
compressed, and sealed therein in accordance with the process of
the present invention. Alternatively, pillow 110 and blanket 114
may be sealed as an assembly in a first sealable bag, and foam pad
118 may be sealed in a second sealable bag, and such first and
second sealed bags may be further sealed in a third sealable
bag.
[0111] Apparatus for performing the methods of the present
invention are provided for the making of the packaged compressible
dry goods of the present invention. FIG. 20A is a side elevation
view of one packaging apparatus for the making of the compressible
dry goods packaged in accordance with the present invention; and
FIG. 20B is a top view of the packaging apparatus of FIG. 20A.
Referring to FIGS. 20A and 20B, apparatus 600 comprises a first
conveyor 602, a second conveyor 604, platen 611, and combination
press 610. In operation, first conveyor 602 conveys a bagged dry
good, e.g. pillow 108 in bag 130 onto platen 611. Combination press
610 then deploys cold press portion 613 to compress pillow 108 in
bag 130, thereby displacing the air therein. Combination press 610
then deploys hot or cold sealing press portion 621 to seal
compressed pillow 108 in bag 130, thereby forming a sealed package
110 comprising seal 134. Sealed package 110 is then conveyed by
conveyor 604 to a downstream operation such as e.g. labeling, or to
shipping/storage container 620.
[0112] In a further embodiment, vacuum assistance means 140 of FIG.
12 is provided proximate to platen 611 and combination press 610.
Such vacuum assistance means is used as previously described in
this specification.
[0113] In a further embodiment, apparatus 600 further comprises an
articulating arm (not shown) that precisely locates bag 130 on
platen 611 prior to the sealing thereof, and/or displaces sealed
bag 110 onto conveyor 604, wherein sealed bag 110 is conveyed to a
downstream operation such as e.g. labeling, or to shipping/storage
container 620.
[0114] In an alternate embodiment, apparatus 600 comprises conveyor
602 (and not conveyor 604), with platen 611 disposed within
conveyor 602, between the upper and lower belts thereof. In
operation of such embodiment, conveyor 602 ceases conveyance of dry
good 108 in bag 130 briefly, while sealing press 621 is deployed to
form seal 134 (see FIG. 6) in package 110. Subsequently, conveyor
602 is restarted, conveying sealed package 110 to a downstream
operation such as e.g. labeling, or to shipping/storage container
620.
[0115] FIG. 21 is a side view of an alternate packaging apparatus
for the making of the compressible dry goods packaged in accordance
with the present invention. Referring to FIG. 21, apparatus 700
comprises compressing conveyor assembly 705, ejection conveyor
assembly 715, platen 711, and sealing press 721. In operation,
compressing conveyor 705, comprised of conveyor belts 704 and 706,
conveys and compresses a bagged dry good, e.g. mattress pad 116 in
bag 130, between cold or hot sealing press 721 and platen 711, such
that end 119 of bag 130 is disposed between sealing press 721 and
platen 711. Sealing press 721 is then deployed to form seal 134 in
sealed bag 118. Ejecting conveyor 715, comprised of conveyor belts
714 and 716, then conveys sealed package 118 to a downstream
operation such as e.g. labeling, or to shipping/storage container
720.
[0116] It will be apparent that in one embodiment, end 119 of bag
130 is disposed in the upstream direction as shown in FIG. 21, and
in another embodiment (not shown) end 119 of bag 130 is disposed in
the downstream direction. Either operation is suitable, with the
operative requirement being that conveyors 705 and 715 temporarily
stop the motion of bag 130 such that the end 119 of bag 130 is
disposed beneath sealing press 721 on platen 711, so that sealing
press 721 can be deployed to form seal 134 in package 118. In the
preferred embodiment, sealing press 721 is a hot press, and platen
711 is a hot platen. In a further embodiment, vacuum assistance
means 140 of FIG. 12 is provided proximate to the entrance of
compressing conveyor 705. Such vacuum assistance means is used to
first place a dry good in a packaging bag as previously described
in this specification.
[0117] Referring again to FIG. 21, in a further embodiment (not
shown), apparatus 700 comprises at least one supply roll of heat
sealable film at the entrance to conveyor assembly 705, wherein a
dry good is disposed within and partially wrapped by such film, and
further drawn into and compressed by conveyor assembly 705. In one
embodiment, a partial bag wrap around such dry good is formed,
similar to bag 130. Apparatus 700 further comprises a cutter to cut
the required length of such film from the supply roll, additional
heat presses (not shown) disposed on each side of conveyors 705
and/or 715, which seal the side edges of such film, thereby forming
a bag around dry good 108. Such bag is then sealed by press 721 as
previously described.
[0118] In a further embodiment, apparatus 700 comprises a second
heat sealble film supply roll at the entrance to conveyor assembly
705, such that dry good 108 is disposed between two sheets of
sealing film from the first and second supply rolls. In such
embodiment, sealing press 721 seals the leading edge of the film
pieces together, side heat presses (not shown) seal the side edges
as described previously, and sealing press 721 seals the trailing
edge of the film, thereby sealing compressed dry good 108 in a bag
formed in situ by apparatus 700. In a further embodiment (not
shown), die cutters are provided that cut the sheet film, and/or
that cut and square up the excess material from the heat sealed
edges thereof.
[0119] It will be apparent that a plurality of apparatus 600 and/or
apparatus 700 may be provided and controlled in serial operation,
or in parallel operation, or in combinations thereof to form
manufacturing cells for the making of packages of dry goods
comprising multiple articles such as the disaster pack of the
present invention. Such apparatuses may be physically arranged in
parallel directions, in directions perpendicular to each other, or
in a radial configuration depending upon the particular package
being prepared.
[0120] It is, therefore, apparent that there has been provided, in
accordance with the present invention, a disaster pack comprising a
pillow, a blanket, and a foam pad contained in a highly compressed
state within a sealed package, and a process for making such
disaster pack. While this invention has been described in
conjunction with preferred embodiments thereof, it is evident that
many alternatives, modifications, and variations will be apparent
to those skilled in the art. Accordingly, it is intended to embrace
all such alternatives, modifications and variations that fall
within the spirit and broad scope of the appended claims.
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