U.S. patent application number 11/062725 was filed with the patent office on 2005-06-30 for packaging module.
Invention is credited to Bussey, Harry (Buddy) III, Bussey, Harry JR..
Application Number | 20050139509 11/062725 |
Document ID | / |
Family ID | 29249049 |
Filed Date | 2005-06-30 |
United States Patent
Application |
20050139509 |
Kind Code |
A1 |
Bussey, Harry JR. ; et
al. |
June 30, 2005 |
Packaging module
Abstract
A packaging module is provided that is comprised of a porous
deformable membrane, such as a net bag, and a mass of loose fill
elements. The mesh openings in the bag are smaller than a loose
fill element to retain the elements in place. The bag is deformable
in three dimensions to allow the bag to be manipulated to
accommodate the shape of an item to be packaged. A single module
may be used to envelop an item to be packaged, for example, in a
shipping container. A pair of modules may be used to sandwich an
item therebetween for packaging in a shipping container. A shipping
unit may also be formed by a pair of modules that are self-adherent
to each other. Also, the module may be fabricated into a pre-form
with a pocket.
Inventors: |
Bussey, Harry JR.; (Marco
Island, FL) ; Bussey, Harry (Buddy) III; (Atlantic
Highlands, NJ) |
Correspondence
Address: |
Francis C. Hand, Esq.
c/o Carella, Byrne, Bain, Gilfillan,
Cecchi, Stewart & Olstein
5 Becker Farm Road
Roseland
NJ
07068
US
|
Family ID: |
29249049 |
Appl. No.: |
11/062725 |
Filed: |
February 22, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11062725 |
Feb 22, 2005 |
|
|
|
10133776 |
Apr 26, 2002 |
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Current U.S.
Class: |
206/593 ;
206/521 |
Current CPC
Class: |
B65D 81/051
20130101 |
Class at
Publication: |
206/593 ;
206/521 |
International
Class: |
B65D 085/30 |
Claims
What is claimed is:
1. A packaging module for an item of three-dimensional shape
comprising a porous deformable membrane defining an enclosed space
and characterized in being deformable in three dimensions to
envelop the item of three-dimensional shape therein; and a mass of
loose fill elements disposed within said membrane and occupying an
amount of said space sufficient to permit said membrane to be
shaped about the item of three dimensional shape and to permit said
elements to move within said membrane to accommodate the
three-dimensional shape of the item and to envelop the item
therein.
2. A packaging module as set forth in claim 1 wherein said membrane
is a net bag.
3. A packaging module as set forth in claim 2 wherein bag is made
of plastic.
4. A packaging module as set forth in claim 1 wherein said elements
are made of starch.
5. A packaging module as set forth in claim 1 wherein said elements
are made of a foamed plastic selected from the group consisting of
expanded polystyrene, expanded polyethylene and expanded
polypropylene.
6. A packaging module as set forth in claim 1 wherein said membrane
is of elongated cylindrical shape with closed ends.
7. A packaging module as set forth in claim 1 wherein said membrane
is of cubic shape.
8. A packaging module for an item of three-dimensional shape
comprising a deformable net bag defining an enclosed space and
characterized in being deformable in three dimensions to envelop
the item of three-dimensional shape therein; and a mass of loose
fill elements disposed within said bag and occupying an amount of
said space sufficient to permit said bag to be shaped about the
item of three dimensional shape and to permit said elements to move
within said bag to accommodate the deformed shape of said bag and
to envelop the item therein.
9. A packaging module as set forth in claim 8 wherein said elements
occupy up to 90% of said space within said bag.
10. A packaging module as set forth in claim 8 wherein said bag has
a plurality of openings therein, each said opening being of a size
smaller than any one of said elements to retain said elements
therein.
11. A packaging module as set forth in claim 8 wherein said net bag
is made of a material having self-adherent characteristics.
Description
[0001] This application is a Continuation of pending application
Ser. No. 10/133,776, filed Apr. 26, 2002.
[0002] This invention relates to a packaging module. More
particularly, this invention relates to a packaging module using
loose fill packaging elements,
[0003] As is known, various types of materials have been used for
shipping fragile items in containers of various types. In some
cases, loose fill elements of foamed plastic are poured into a
container to form a cushioning layer and then the item to be
transported is placed on top of the loose fill elements. This is
followed by pouring additional loose fill elements into the
container to completely surround the item being packaged. Upon
arrival at the ultimate destination, a user opens the container in
order to remove the item. In doing so, the loose fill elements are
usually first separated so that the item can be exposed and then
the item is removed from the container. This generally creates at
least two problems.
[0004] First, upon opening of the container and separation of the
loose fill elements to access the packaged item, the loose fill
elements generally spill over and out of the container. These loose
fill elements must then be collected, generally, manually and
placed back into the container for disposal purposes. This can be
bothersome and time consuming.
[0005] Second, the loose fill elements usually have static
electricity that causes the elements to stick to the hands and
clothing of the user as well as to other surfaces outside the
container. Thus, these elements also have to be manually removed
and placed back into the container.
[0006] In other cases, foamed-in-place materials have been used. In
these cases, an item is placed in a shipping carton and then a
foamable material is directed into the container about the item so
that upon foaming, the material molds to the shape of the item.
However, this type of packaging technique is cumbersome and
relatively expensive.
[0007] Accordingly, it is an object of the invention to provide a
relatively simple technique for packaging an item with loose fill
elements without the inconvenience of having the elements scatter
upon opening of a container to remove the item.
[0008] It is another object of the invention to provide loose fill
elements in prepackaged modules.
[0009] It is another object of the invention to provide loose fill
elements in prepackaged modules sized to fit containers for the
packaging of items in the containers.
[0010] It is another object of the invention to provide a module of
free flowing loose fill elements that can be made into a packaging
pre-form with a pocket to receive an item in mating relation,
[0011] Briefly, the invention provides a packaging module comprised
of a porous deformable membrane defining an enclosed space and a
mass of loose fill elements disposed within the membrane and
occupying an amount of space sufficient to permit the membrane to
be shaped about an item of three dimensional shape to be packaged
and to permit the elements to move within the membrane to
accommodate the three dimensional shape of the item.
[0012] In one embodiment, the membrane is in the form of a net bag,
for example made of plastic. In this respect, the membrane is
characterized in being deformable in three dimensions. That is to
say, the bag may be deformed from a cylindrical shape into a
spherical shape, a three-dimensional shape having a pocket, or a
shape to envelop an item, such as a sphere, cube, or other regular
or random shape.
[0013] A single module may be used for packaging an item. In this
respect, the item to be packaged is placed on the module and the
module shaped about the item. The enveloped item may then be placed
in a box or carton in a snug fit manner. After closing, the box or
carton may then be transported.
[0014] Multiple modules may also be used for packaging an item. For
example, an item may be placed between two modules in sandwich-like
manner. This unit may then be placed in a shipping container for
shipping purposes. Alternatively, the unit may be wrapped with a
shrink wrap material so that the unit is completely sealed. A
shipping label may then be placed on the outside of the wrapped
package for shipping purposes. Also, the unit may be held together
by strips or bands of adhesive tape and shipped in that
condition.
[0015] In another embodiment, a module may be placed on the bottom
of a container with the item to be packaged simply placed in the
center of the module in an upstanding manner. A second module may
then be placed over the top of the item and the container closed
over the upper module so as to slightly compress the modules within
the container. In this embodiment, the two ends of the item are
held by the two modules while the middle of the item is spaced from
the side walls of the container. In such embodiment, there is no
need for any loose fill elements to surround the middle of the
item. This results in a savings of loose fill elements for
packaging purposes.
[0016] In another embodiment, the packaging module is formed into a
pre-form with a pocket to receive an item of three-dimensional
shape. In this embodiment, the membrane is a net bag and the loose
fill elements are made of starch. In order to make the pre-form, a
three dimensional forming blank sized and shaped to the item to be
packaged is placed on a support surface. Next, the module is placed
over the blank and pressed down and around the sides of the blank.
While in this state, moisture in the form of a spray of steam is
introduced into the module to cause the loose fill elements of
starch to bond together and form an agglomerated one-piece pre-form
of stable shape with a pocket. The pre-form is then removed from
the blank and additional pre-forms made in the same fashion. The
resulting pre-form may then be placed, for example, in the bottom
of a carton to receive a suitably sized and shaped three
dimensional item in the pocket in mating relation. A second
pre-form or a second unprocessed packaging module may then be
placed over the item and the carton closed.
[0017] When processing a packaging module into a pre-form as above,
the space about the forming blank may be limited by a box-like
construction so that the pre-form takes on a rectangular shape
suitable for fitting into a carton of rectangular shape.
[0018] Alternatively, instead of using loose fill elements of
starch, the elements may be made of a foamed plastic, such as
expanded polystyrene, and may be coated with a suitable heat
sensitive adhesive, latex or similar material so that upon heating
or spraying on of a solvent, the elements become bonded to each
other to form an agglomerated one-piece pre-form of stable shape
with a pocket.
[0019] These and other objects and advantages of the invention will
become more apparent from the following detailed description taken
in conjunction with the accompanying drawings wherein:
[0020] FIG. 1 illustrates and exploded view of the module
constructed in accordance with the invention and an item to be
packaged in the module;
[0021] FIG. 1A illustrates a cross-sectional view of the module of
FIG. 1;
[0022] FIG. 2 illustrates the module and item of FIG. 1 being
deposited into a shipping container;
[0023] FIG. 3 illustrates a view of the module of FIG. 1 being used
as a shipping container;
[0024] Pie. 4 illustrates an exploded view of a modified embodiment
employing a pair of modules constructed in accordance with the
invention;
[0025] FIG. 5 illustrates the unit of FIG. 4 being placed in a
shipping container;
[0026] FIG. 6 illustrates a cross sectional view of the unit of
FIG. 4 with a shrink wrap film thereabout to form a shipping
container;
[0027] FIG. 7 illustrates a cross-sectional view of a pair of
modules being used to package an item in a shipping container;
and
[0028] FIG. 8 illustrates a cross-sectional view of a plurality of
layers of items packaged between layers of packaging modules in a
carton in accordance with the invention.
[0029] Referring to FIG. 1A, the packaging module 10 is formed of a
porous deformable membrane 11 and a mass of loose fill elements
12.
[0030] The membrane 11 is made of a net bag, for example of
plastic, that is characterized in being deformable in three
dimensions. That is to say, the bag may be deformed from a
cylindrical shape into a spherical shape, a three-dimensional shape
having a pocket, or a shape to envelop an item, such as a sphere,
cube, or other regular or random shape. The net bag is formed with
mesh openings that are sized to be smaller than the individual
loose fill elements 12 in order to retain the elements 12 in place
while allowing the bag to be deformed in a three-dimensional
manner. Typically, the net bag is formed with criss-crossing fibers
that define a rectangular mesh opening. However, the bag may be
formed with mesh openings of diamond shape or any other suitable
shape. Likewise, the net bag may be made of any other suitable
material than plastic.
[0031] The membrane 11 is typically formed as a hollow tube in any
conventional manner. One end of the tube is then closed, for
example by a staple 13, or by heat seal crimping and the tube 12
from the opposite end. The remaining end of the tube is then closed
in a similar manner, for example by a second staple 14.
[0032] By way of example, a machine constructed in a manner as
described in U.S. Pat. No. 6,035,606 but to a smaller scale may be
used for forming a plurality of modules 10.
[0033] Typically, the loose fill elements 12 do not completely fill
the membrane II. For example, the loose fill elements 12 need only
occupy approximately 80 to 90 percent of the volume of the membrane
11. However, in some cases, the entire membrane 11 may be filled
with the elements 12.
[0034] The loose fill elements 12 are made of starch or a foamed
plastic, for example of expanded polystyrene, polyethylene,
polyurethane or polypropylene. However, other suitable loose fill
materials may be used such as, chopped blocks of rubber, scrap
polymer materials, wood chips, shredded paper, popcorn and the
like.
[0035] Referring to FIG. 1, in order to package an item such as a
ball 15, a module 10 is deformed from a generally tubular shape in
which the module 10 is usually fabricated into a cubic shape that
envelopes the ball 15. To this end, the module 10 is initially
flattened and then a pocket 16 is formed in the center of the
module 10, for example by manually manipulating the module 10. At
this time, the elements 12 freely shift within the membrane 11 to
accommodate the reshaping of the module 10.
[0036] Once a pocket 16 is formed, the ball 15 is placed in the
pocket 16 and the module 10 further manipulated about the ball 15
into a condition, for example as shown in FIG. 2 with the bail 15
completely surrounded by the module 10.
[0037] Referring to FIG. 2, the module 10 and the enveloped ball 15
are then deposited into a shipping container 17 of conventional
structure so that the module 10 is snugly fit within the container
17. A plurality of flaps 18 on the container 17 may then be closed
so as to push down on the module 10 and maintain the ball 15 in a
non-movable condition within the container 17.
[0038] The closed container may then be shipped to an ultimate user
in any suitable manner. Upon arrival, the ultimate user would
simply open the container 17 and remove the module 10 and enveloped
ball 15. The module 10 would then be unwrapped from the ball 15 and
the ball retrieved. The module 10 of loose fill elements 12 and
then be replaced in the container 17 for disposal purposes. Also,
the module 10 of loose fill elements 12 may be reused for packaging
purposes by the user.
[0039] Since the loose fill elements 12 are contained within the
net bag 11, there is little or no risk of the elements 12 spilling
out of the container 17 when the container is opened or clinging to
the hands and clothing of the user.
[0040] Referring to FIG. 3, a shipping label 19 may be applied the
module 10 with the ball 15 enveloped therein in such a manner to
seal the module 10 about the ball 15. Alternatively, one or more
strips of adhesive may be applied to the module 10 to seal the ball
15 in place. The resulting structure may then be shipped as such to
the ultimate user.
[0041] Referring to FIG. 4, wherein like reference characters
indicate like parts as above, a pair of packaging modules 10 may be
used for shipping an elongated item 20, such as a cylindrical tube.
In this respect, the elongated item 20 is placed between a pair of
modules 10 in sandwich-like manner. To this end, each module 10 is
shaped into an elongated shape to accommodate the shape of the item
20.
[0042] Referring to FIG. 5, after the item 20 has been enveloped,
the resulting unit is placed in a shipping container 21, for
example, a shipping tube. At this time, the modules 10 are received
in a snug fit manner in the container 21 to maintain the item 20 in
a non-movable manner. A shipping label 22 may then be applied to
the outside of the container 21 and the container 21 shipped to an
ultimate user.
[0043] Referring to FIG. 6, after an item 20 has been enveloped
between a pair of modules 10, a shrink wrap film or a stretch wrap
film 23 may be wrapped about the resulting unit in order to form a
self-contained package. Any suitable device may be used to shrink a
shrink wrap film 23 in place. Alternatively, the unit may be slid
into a tube of shrink wrap material which can then be shrunk about
the modules 10 to form a self-contained package. A shipping label
(not shown) may then be applied to the outside of the package.
[0044] In another embodiment, each module 10 may have a
self-adherent surface for adhering to the other module 10 in order
to retain the item 20 therebetween. In this case, there is no need
for any additional wrapping bands or films to form a package.
[0045] Referring to FIG. 7, wherein like reference characters
indicate like parts as above, a module 10 may be placed in the
bottom of the container 17 and then an item 24, for example, of
elongated shape is placed centrally of the module 10 in an
upstanding manner. Next, a second module 10 is placed over the top
of the item 24. The flaps 18 of the container 17 are then closed to
place the modules 10 under a slight pressure in order to maintain
the item 24 in a non-movable manner. As illustrated, a free space
is provided between the central portion of the item 24 and the side
waits of the container 17. That is to say, there is no need to fill
this space with loose fill elements 12.
[0046] After the container 17 is opened, the uppermost module 10 is
removed to expose the item 24. This item 24 may then be removed and
the module 10 returned to the container 17.
[0047] Referring to FIG. 8, wherein like reference characters
indicate like parts as above, a plurality of packaging modules 10
may be employed for packaging a plurality of items, particularly
hems of different three-dimensional shapes. In each case, a
packaging module 10 would adapt to the different shapes and sizes
of the hems contacted by the packaging module 10. As illustrated, a
carton 25 is provided with a first layer of packaging modules 10 on
the bottom. Next, one or more items 26 are placed on the module
layer. A second layer of packaging modules 10 is then placed over
the items 26. Next, a second layer of items 27 is placed in a
carton on the second module layer. Finally, a third layer of
packaging modules 10 is placed in a carton 25 over the second layer
of items 27 and the flaps 28 of the carton 25 are closed in the
usual manner. As the flaps 28 of the carton 25 are closed down on
the top layer of modules 10, the modules 10 within the carton 25
are somewhat compressed to firmly hold the package to items 26,27
in place.
[0048] Once the carton 25 arrives at a final destination, the
recipient simply opens the carton 25 and removes the top layer of
modules 10 to expose the uppermost layer of items 27 for removal.
In like manner, the middle layer of modules 10 is removed to expose
the lowermost layer of items 26 for removal. Thereafter, of the
packaging modules 10 may be reused by the recipient for similar or
other purposes. Since the loose fill materials 12 are contained
within the membrane 11, there is little or no risk of the loose
fill materials 12 clinging to the recipient or spilling out of the
carton 25 uncontrollably.
[0049] The packaging module 10 may also be made into a pre-form for
packaging purposes. To this end, the packaging module 10 formed of
the net bag 11 and containing a free-flowing mass of loose fill
elements 12 made of starch is placed about a three dimensional
forming blank (not shown) of a shape and size corresponding to the
item to be packaged. For example, for packaging a bottle, the
forming blank is of the size and shape of a longitudinal half of
the bottle.
[0050] Typically, the forming blank is placed on a flat support
within a surrounding box-like structure corresponding to the carton
into which the bottle is to be placed.
[0051] Thereafter, moisture is applied to the elements 12 within
the net bag 11 to effect bonding of the elements 12 together to
form an agglomerated one-piece pre-form (not shown) of stable shape
with a pocket corresponding to the shape of the blank. The moisture
may be applied in the form of a spray of steam to ensure uniformity
of application or in the form of a water spray.
[0052] Alternatively, where the packaging module 10 contains a
free-flowing mass of loose fill elements made of foamed plastic,
the elements are coated with an adhesive coating and the adhesive
is activated by a spray of solvent or heated depending on the type
of adhesive used. For example, the adhesive may be
solvent-activated, or heat sensitive, or other.
[0053] In either embodiment, the otherwise free flowing mass of
loose fill elements 12 are bonded together while disposed about the
forming blank (not shown) to form an agglomerated one-piece
pre-form of stable shape with a pocket. The net bag 11 remains to
contain the agglomerated mass and is also shaped to the contour of
the agglomerated mass.
[0054] Several pre-forms may be made in the same manner on the
forming blank.
[0055] In use, a pre-form would be placed in the bottom of a carton
with the pocket exposed to receive the item to be packaged in
mating relation within the pocket. Next, a second like pre-form
would be placed over the remainder of the item and the carton
closed for shipping or storage purposes. Alternatively, a pre-form
may be used to receive an item while a module 10 with free flowing
elements 12 is placed over the item and pressed against the item
upon closing of the carton.
[0056] The invention thus provides a packaging module that which
adapts to all sizes of items to be packaged. The module may be used
to package an individual item or a plurality of modules may be used
to package one or more items of the same or different sizes and
three-dimensional shapes.
[0057] The invention also provides a deformable membrane which is
able to deform in three dimensions in order to the
three-dimensional shape of a packaged item while allowing the loose
fill elements to shift about within the membrane.
[0058] The invention thus provides a packaging module that contains
a plurality of loose fill elements in a captured state so that the
loose fill elements do not spill out of the container upon opening
of the container and do not cling to the body of the user or other
surfaces.
[0059] The invention also provides a packaging module of loose fill
elements that can be fabricated in various sizes to accommodate the
items to be packaged.
[0060] The invention also provides a packaging module that stops
sliding and migration of the packaged item or items.
[0061] The invention further provides a packaging module that is
easily removable from a shipping container, that is reuseable, and
that provides excellent cushioning.
* * * * *