U.S. patent application number 14/661999 was filed with the patent office on 2015-09-24 for heat sealed packaging assemblies and methods of producing and using the same.
The applicant listed for this patent is Frank Comerford, Myles Comerford, John McDonald. Invention is credited to Frank Comerford, Myles Comerford, John McDonald.
Application Number | 20150266639 14/661999 |
Document ID | / |
Family ID | 54141389 |
Filed Date | 2015-09-24 |
United States Patent
Application |
20150266639 |
Kind Code |
A1 |
McDonald; John ; et
al. |
September 24, 2015 |
HEAT SEALED PACKAGING ASSEMBLIES AND METHODS OF PRODUCING AND USING
THE SAME
Abstract
A packaging device can include a flexible member which can be
resilient, substantially non-resilient, or non-resilient, which can
be formed of one or more layers which can be different materials
and a frame member. The flexible member can be heat sealed to the
frame member or to a coating on the surface of the frame member.
The layers can be made from different materials or the same
materials having different thicknesses, modules of elasticity,
melting index, or other different characteristics.
Inventors: |
McDonald; John; (Fallbrook,
CA) ; Comerford; Frank; (Laguna Niguel, CA) ;
Comerford; Myles; (Rancho Santa Fe, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
McDonald; John
Comerford; Frank
Comerford; Myles |
Fallbrook
Laguna Niguel
Rancho Santa Fe |
CA
CA
CA |
US
US
US |
|
|
Family ID: |
54141389 |
Appl. No.: |
14/661999 |
Filed: |
March 18, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14222410 |
Mar 21, 2014 |
|
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14661999 |
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Current U.S.
Class: |
206/497 ;
493/392 |
Current CPC
Class: |
B65D 65/14 20130101;
B65D 81/07 20130101; B65D 5/5028 20130101; B65D 65/42 20130101 |
International
Class: |
B65D 71/08 20060101
B65D071/08; B65D 65/14 20060101 B65D065/14; B65D 65/42 20060101
B65D065/42 |
Claims
1. A packaging assembly comprising: at least a first frame member
having a central portion; and a first thin sheet member disposed
over the central portion of the first frame member; wherein the
first thin sheet member includes a central portion heat-sealed to
the central portion of the first frame member, the first thin sheet
member further including first and second peripheral sides that are
configured to be folded over the central portion of the first frame
member.
2. The packaging assembly according to claim 1, further comprising
a bond that secures the first thin sheet member to itself.
3. The packaging assembly according to claim 2, wherein the bond
comprises adhesive tape that secures the first and second
peripheral sides of the first thin sheet member to one another.
4. The packaging assembly according to claim 1, wherein the first
and second peripheral sides are further configured to overlap one
another.
5. The packaging assembly according to claim 4, further comprising
a bond that comprises the first thin sheet member sticking to
itself.
6. The packaging assembly according to claim 5, wherein the first
thin sheet member includes a coating or treatment that increases
the ability of the first thin sheet material to stick to
itself.
7. The packaging assembly according to claim 6, wherein the first
thin sheet member has been subjected to at least one of a Corona
treatment, a Plasma treatment, and acid treatment, or a heat
treatment.
8. The packaging assembling according to claim 4, further
comprising a bond that comprises an adhesive substance disposed
between the first and second peripheral sides of the first thin
sheet member.
9. The packaging assembly according to claim 8, wherein the
adhesive substance comprises at least one of the set consisting of:
glue, adhesive tape, pressure sensitive adhesive (PSA), and
ultra-violet (UV) activated adhesive.
10. The packaging assembly according to claim 1, wherein the first
thin sheet member is made of a resilient material.
11. The packaging assembly according to claim 1, wherein the first
thin sheet member is made of a non-resilient material.
12. The packaging assembly according to claim 1, wherein at least a
portion of the thin sheet member is configured to be placed over an
article to be packaged such that the sheet member retains the
article upon the frame member.
13. The packaging assembly according to claim 12, wherein the thin
sheet member is made of a deformable material that can be molded to
fit around the article and to retain the article upon the frame
member.
14. A method of manufacturing a heat-sealed packaging assembly, the
method comprising: feeding corrugated material towards a heat
sealing device; forming cavities in the corrugated material;
feeding a thin sheet towards the heat sealing device such that the
thin sheet is between the corrugated material and the heat sealing
device; and applying heat to the thin resilient sheet and the
corrugated material using the heat sealing device such that at
least some heated material of the thin sheet flows into the
cavities formed in the corrugated material.
15. The method of claim 14, wherein the step of forming cavities in
the corrugated material is performed using one or more piercing
devices.
16. The method of claim 15, wherein the step of forming cavities in
the corrugated material is performed using one or more retractable
piercing devices of the heat sealing device.
17. The packaging assembly according to claim 14, wherein forming
cavities in the corrugated material further comprises forming
cavities in a bottom layer of the corrugated material.
18. The packaging assembly according to claim 14, wherein applying
heat to the thin resilient sheet and the corrugated material
further comprises applying pressure to the thin resilient sheet and
the corrugated material using the heat sealing device.
19. The method of claim 14, further comprising applying vacuum
pressure to a side of the corrugated material that is opposite a
side of the corrugated material to which the heat sealing device
applies heat.
20. The method of claim 19, wherein the step of applying vacuum
pressure occurs simultaneously with the step of applying heat.
Description
BACKGROUND OF THE INVENTIONS
[0001] 1. Field of the Inventions
[0002] The present inventions are directed to a package assembly.
In particular, the present inventions are directed to a package
assembly that includes a flexible member which can be stretchable
and resilient, substantially non-resilient, or non-resilient,
connected to a frame member.
[0003] 2. Description of the Related Art
[0004] Protective packaging devices are often used to protect goods
from shocks and impacts during shipping or transportation. For
example, when transporting articles that are relatively fragile, it
is often desirable to cushion the article inside a box to protect
the article from a physical impact with the inner walls of the box
that might be caused by shocks imparted to the box during loading,
transit, and/or unloading.
[0005] In most cases, some additional structure is used to keep the
article from moving uncontrollably within the box. Such additional
structures include paper or plastic packing material, structured
plastic foams, foam-filled cushions, and the like. Ideally, the
article to be packaged is suspended within the box so as to be
spaced from at least some of the walls of the box, thus protecting
the article from other foreign objects which may impact or
compromise the outer walls of the box.
[0006] U.S. Pat. No. 6,675,973 discloses a number of inventions
directed to suspension packaging assemblies which incorporate frame
members and one or more retention members. For example, many of the
embodiments of the U.S. Pat. No. 6,675,973 patent include the use
of a retention member formed of a resilient material. Additionally,
some of the retention members include pockets at opposite ends
thereof.
[0007] In several of the embodiments disclosed in the U.S. Pat. No.
6,675,973 patent, free ends of the frame members are inserted into
the pockets of the retention member. The free ends of the frame
member are then bent, pivoted, or folded to generate the desired
tension in the retention member. Because the retention member is
made from a resilient material, the retention member can stretch
and thus provide a mechanism for suspending an article to be
packaged, for example, within a box.
SUMMARY OF THE INVENTIONS
[0008] An aspect of at least one of the embodiments disclosed
herein includes the realization that packaging devices that are
designed to retain items to be packaged using a thin stretchable or
non-stretchable flexible sheet or film can be further improved by
heat sealing the thin flexible film to a frame member of the
package device. As such, the resulting packaging devices with a
thin flexible member attached thereto can be manufactured using
high speed, automated manufacturing processes, thus increasing the
total number of packaging devices prepared within a certain period
of time. Moreover, use of heat sealing can further reduce the total
size of the thin flexible member used by 20% to 30% depending on
the method of attachment for the thin flexible member.
[0009] For example, in some embodiments, the flexible member can be
heat sealed to a frame member with the flexible member disposed
over a central portion of the frame member. The flexible member can
be a thin resilient sheet and the frame member can be formed from
corrugated material. The flexible member can be heat sealed to one
or more rotatable portions of the frame member and sized such that,
when the rotatable portions are rotated relative to the central
portion, the flexible member can be stretched and thus aid in
forming shock absorbing packaging for an article.
[0010] Heat sealing of the flexible member to the frame member can
be achieved with a variety of different heat sealing techniques,
for example, by heat sealing the flexible member directly to a
surface of the frame member, by heat sealing the flexible member to
a coating placed over a surface of the frame member, or a
combination of both.
[0011] In some embodiments, in order to allow the flexible member
to be stretched or tensioned, less than all of the flexible member
is heat sealed to the frame member. In some embodiments, only about
10% or less of the flexible member is heat sealed. As should be
understood, the frame member can have a variety of different
shapes, wall portions, and apertures depending on the nature of the
item to be packaged, the desired packaging method (e.g., suspension
or retention), the container in which the frame member is placed,
and a variety of other factors.
[0012] In some embodiments, the flexible member can be formed with
two layers of different material, heat sealed to one another, and
optionally, heat sealed to the frame member. In some cases, the two
different materials can be different kinds of material, different
thicknesses of the same material, different grades of translucency
(e.g., one layer being opaque and one layer being transparent),
different modules of elasticity or other different characteristics.
When using heat sealing to attach the layers to one another,
different materials having melt index values over a large range of
such values can be used. For example, with regard to some
materials, different layers made from different materials can be
heat sealed together using high speed manufacturing equipment. Such
high speed heat sealing is achieved more easily when the melt index
of these materials falls approximately within the range of 7.0 to
10.0. However, other materials and other attachment techniques can
also be used.
[0013] Thus, in accordance with an embodiment, a packaging assembly
can comprise at least a first frame member having a central
portion. Additionally, a first thin sheet member can be disposed
over the central portion of the first frame member and can comprise
first and second peripheral sides configured to be folded over the
central portion of the first frame member.
[0014] In some embodiments, the packaging assembly can additionally
comprise a bond that secures the first thin sheet member to itself.
In some embodiments the bond can comprise an adhesive tape that
secures the first and second peripheral sides of the first thin
sheet member to one another.
[0015] In some embodiments, the first and second peripheral sides
are further configured to overlap one another. In some embodiments,
the bond comprise the first thin sheet member sticking to itself.
In some embodiments, first thin sheet member includes a coating or
treatment that increases the ability of the first thin sheet
material to stick to itself. In some embodiments, the bond
comprises an adhesive substance disposed between the first and
second peripheral sides of the first thin sheet member. In some
embodiments, the adhesive substance comprises glue, adhesive tape,
pressure sensitive adhesive (PSA), and/or ultra-violet (UV)
activated adhesive.
[0016] In some embodiments, the first thin sheet member is made of
a resilient material, and in some embodiments, the first thin sheet
member is made of a non-resilient material.
[0017] In some embodiments of the packaging assembly, at least a
portion of the thin sheet member is configured to be placed over an
article to be packaged such that the sheet member retains the
article upon the frame member. In some embodiments, the thin sheet
member is made of a deformable material that can be molded to fit
around the article and to retain the article upon the frame
member.
[0018] In accordance with an embodiment, a method of manufacturing
a heat-sealed packaging assembly can comprise feeding corrugated
material towards a heat sealing device, forming cavities in the
corrugated material, feeding a thin sheet towards the heat sealing
device such that the thin sheet is between the corrugated material
and the heat sealing device, and applying heat to the thin
resilient sheet and the corrugated material using the heat sealing
device such that at least some heated material of the thin sheet
flows into the cavities formed in the corrugated material.
[0019] In some embodiments, the step of forming cavities in the
corrugated material is performed using one or more piercing
devices. In some embodiments, the step of forming cavities in the
corrugated material is performed using one or more retractable
piercing devices of the heat sealing device. In some embodiments,
forming cavities in the corrugated material further comprises
forming cavities in a bottom layer of the corrugated material. In
some embodiments, applying heat to the thin resilient sheet and the
corrugated material further comprises applying pressure to the thin
resilient sheet and the corrugated material using the heat sealing
device.
[0020] In some embodiments, the method can comprise applying vacuum
pressure to a side of the corrugated material that is opposite a
side of the corrugated material to which the heat sealing device
applies heat. In some embodiments, the step of applying vacuum
pressure occurs simultaneously with the step of applying heat.
[0021] Further, in accordance with an embodiment, a suspension
packaging assembly can comprise at least one frame member having a
central portion, a first end and a second end disposed opposite the
first end relative to the central portion, a first foldable portion
disposed at the first end and a second foldable portion disposed at
the second end. Additionally, a flexible member can comprise a
first layer having first and second longitudinal ends and first and
second lateral edges and a second layer having first and second
longitudinal ends and first and second lateral edges, the first
layer being heat sealed to the second layer along the corresponding
first and second lateral edges.
[0022] In accordance with another embodiment, a flexible member for
providing damage protection for packaged goods can comprise a first
layer having first and second longitudinal ends and first and
second lateral edges. A second layer can include first and second
longitudinal ends and first and second lateral edges, where the
first layer is heat sealed to the second layer along the
corresponding first and second lateral edges.
[0023] All of these embodiments are intended to be within the scope
of at least one of the inventions disclosed herein. These and other
embodiments of the inventions will become readily apparent to those
skilled in the art from the following detailed description of the
preferred embodiments having reference to the attached figures, the
inventions not being limited to any particular preferred embodiment
disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] These and other features of the inventions are described
below with reference to the drawings of several embodiments of the
present package assemblies and kits which are intended to
illustrate, but not to limit, the inventions. The drawings contain
the following figures:
[0025] FIG. 1A is a plan view of a frame member having a central
portion and two foldable portions disposed at opposite ends
relative to the central portion.
[0026] FIG. 1B is a cross-sectional view along line A-A of the
frame member of FIG. 1A.
[0027] FIG. 2 is a plan view of a flexible member.
[0028] FIG. 3A is a schematic side elevational view of an assembly
including the frame member of FIGS. 1A and 1B and the flexible
member of FIG. 2 connected together with an article packaged
therewith showing a first heat sealing location.
[0029] FIG. 3B is a schematic side elevational view of an assembly
including the frame member of FIGS. 1A and 1B and the flexible
member of FIG. 2 connected together with an article packaged
therewith showing a second heat sealing location.
[0030] FIG. 3C is a schematic side elevational view of an assembly
including the frame member of FIGS. 1A and 1B and the flexible
member of FIG. 2 connected together with an article packaged
therewith showing a third heat sealing location.
[0031] FIG. 4 is a schematic side elevational view of the assembly
of FIG. 3C disposed inside a container.
[0032] FIG. 5 is a schematic view of a manufacturing system that
can be used to manufacture the frame member and flexible member
assembly illustrated in FIGS. 3A-C.
[0033] FIG. 6 is a schematic illustration of a heat sealing and
cutting device of the system of FIG. 5 which heat seals and cuts
apart frame members and flexible members from the continuous strips
of FIG. 5.
[0034] FIG. 7 is a plan view of a flexible member formed of two
layers.
[0035] FIG. 8 is a perspective view of the flexible member
illustrated in FIG. 7.
[0036] FIG. 9 is a schematic side elevational view of an assembly
including the frame member of FIGS. 1A and 1B and the flexible
member of FIGS. 7 and 8 connected together with an article packaged
therewith showing a heat sealing location similar to that of FIG.
3B.
[0037] FIG. 10 is a schematic side elevational view of the assembly
of FIG. 9 disposed inside a container.
[0038] FIG. 11 is a schematic view of a manufacturing system that
can be used to manufacture the frame member and flexible member
assembly illustrated in FIG. 9.
[0039] FIG. 12 is a schematic illustration illustrating the
function of an opening device that can be used at an opening
station in the system of FIG. 11.
[0040] FIG. 13 is a schematic illustration of a heat sealing and
cutting device of the system of FIG. 11 which heat seals and cuts
apart frame members and flexible members from the continuous strips
of FIG. 11.
[0041] FIG. 14A is a cross-sectional view along line A-A of a frame
member similar to that of FIG. 1A showing a flexible member being
heat sealed to the frame member where the frame member does not
have a coating.
[0042] FIG. 14B is a cross-sectional view of the frame member of
FIG. 14A showing a heat seal.
[0043] FIG. 14C is a cross-sectional view illustrating a
modification of the heat seal of the frame member of FIG. 14A,
including the use of a sealing head and vacuum head.
[0044] FIG. 15A is a cross-sectional view along line A-A of a frame
member similar to that of FIG. 1A showing a flexible member being
heat sealed to the frame member where the frame member has a
coating.
[0045] FIG. 15B is a cross-sectional view of the frame member of
FIG. 15A showing a heat seal.
[0046] FIG. 16 is a top plan view of another embodiment of a frame
member in an unfolded state showing potential locations for heat
seals.
[0047] FIG. 17 is a perspective view of the assembly shown in FIG.
16, with the rotatable portions of the frame member rotated
downwardly so as to tighten the flexible member over the article to
be packaged and with side walls of the frame member folded
upwardly.
[0048] FIG. 18 is a perspective view of a modification of the
assembly shown in FIG. 17, with the rotatable portions of the frame
member folded to a more extreme angle so as to form additional
cushions of the assembly.
[0049] FIG. 19 is a schematic side elevational view of the assembly
of FIG. 17 disposed inside a container.
[0050] FIG. 20 is a top plan view of another embodiment of a frame
member in an unfolded state having rotatable portions.
[0051] FIG. 21 is a perspective view of the frame member shown in
FIG. 20 in a partially folded state with two flexible members
assembled with the frame member such that the rotatable portions of
the frame member shown in FIG. 20 are heat sealed to the flexible
members.
[0052] FIG. 22 is a perspective view of the assembly shown in FIG.
21 with the frame member folded to a more extreme state and with an
article to be packaged disposed between unsupported portions of the
flexible members.
[0053] FIG. 23 is a top plan view of another embodiment of a frame
member illustrated in an unassembled and unfolded state.
[0054] FIG. 24 is an elevational and partial sectional view of the
frame member of FIG. 23 connected to a retention member and
supporting an article to be packaged.
[0055] FIG. 25 is an elevational and partial sectional view of the
arrangement shown in FIG. 24 and showing a deflected state of the
arrangement.
[0056] FIG. 26 is a schematic side elevational view of an assembly
including the frame member of FIGS. 1A and 1B and a flexible member
connected together with an article packaged therewith showing a
fourth heat sealing location.
[0057] FIG. 27 is a schematic side elevational view of the assembly
shown in FIG. 26, with the flexible member wrapped around the
article packaged therewith.
[0058] FIG. 28 is a schematic side elevational view of a first
embodiment of the assembly of FIG. 27 disposed inside a
container.
[0059] FIG. 29 is a schematic side elevational view of a second
embodiment of the assembly of FIG. 27 disposed inside a
container.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0060] An improved packaging assembly is disclosed herein. The
packaging assembly includes an improved structure which provides
new alternatives to known suspension packaging systems.
[0061] In the following detailed description, terms of orientation
such as "top", "bottom," "upper," "lower," "longitudinal,"
"horizontal," "vertical," "lateral," "midpoint," and "end" are used
herein to simplify the description in the context of the
illustrated embodiments. Because other orientations are possible,
however, the present inventions should not be limited to the
illustrated orientations.
[0062] Additionally, the terms "suspension" and "suspend" as used
herein, are intended to refer to packaging configurations where an
associated article is held in a position spaced from another member
using a suspension technique, such as where an article is
surrounded by stretchable films so as to be spaced away from rigid
walls including walls of a container or box or walls of other rigid
associated packaging members, devices, or mechanisms.
[0063] Further, the term "retention", as used herein, is intended
to refer to packaging configurations wherein an associated article
is held in the position pressed against another member, such as a
frame member, a rigid member, or other packaging member, device, or
mechanism, using techniques such as those including a stretchable,
thin film pressing the article against the other member. Some of
the embodiments of Packaging assembly is disclosed herein include
aspects of both retention configurations and suspension
configurations. Such embodiments might include, for example,
stretchable, thin film material used to present article against a
component made from rigid material but configured to be flexible
and providing shock absorption. Such embodiments can be considered
as a retention device and as a suspension device. Further, such
embodiments can also be referred to as an "retention-suspension
hybrid packaging configuration". Those skilled in the art will
appreciate that other orientations of various components described
herein are possible.
[0064] The packaging assemblies disclosed herein can include a
frame member 100 (FIG. 1A) and a flexible member 200 (FIG. 2). The
packaging assemblies and components disclosed herein are described
in the context of retention packaging assemblies, such as packaging
assemblies 140, 780, 1040 (FIGS. 3A, 16, 23), and suspension
packaging assemblies, such as packaging assemblies 958, 1040 (FIGS.
20, 23), and retention-suspension hybrid packaging assemblies 1040
(FIG. 23) formed from a frame member and a flexible member, because
they have particular utility in this context.
[0065] The inventions and embodiments disclosed herein are
described in the context of suspension packaging assemblies,
retention packaging assemblies, and hybrid suspension-retention
packaging assemblies because they have particular utility in those
contexts. However, the inventions disclosed herein can be used in
other contexts as well.
[0066] With reference to FIG. 1A, the frame member 100 is
illustrated in an unfolded state and is constructed in accordance
with an embodiment. Generally, the frame member 100 includes a
central portion 110 and a pair of opposing foldable portions 112,
114. The central member 110 can be configured to engage or provide
support for one or more articles to be packaged.
[0067] In some embodiments, the foldable portions 112, 114 are
configured to increase a tension in the flexible member 200 for
holding one or more articles in a desired position relative to the
central portion 110; an exemplary position being shown in FIGS.
3A-C and 4.
[0068] With reference to FIG. 1B, a cross-sectional view of the
frame member 100 is shown which illustrates multiple layers of the
frame member 100. In some embodiments, the frame member 100 can
include outer layers, such as a top layer 120 and bottom layer 122,
and an inner layer 124 between the outer layers. In some
embodiments, the outer layers can have a smooth surface, a textured
surface, or a combination of both. In some embodiments, the inner
layer 124 can have a corrugated structure. As shown in the
illustrated embodiment, the inner layer 124 can include a structure
similar to those used for producing fluted cardboard such as, but
not limited to, "A-Flute," "B-Flute," "C-Flute," "D-Flute, and
"E-Flute" cardboard. Other types of corrugated structures used in
cardboard packaging and similar devices can also be used. Moreover,
combinations of cardboard layers can also be used. In some
embodiments (not shown), the frame member 100 can include multiple
inner layers. These multiple inner layers can be separated by an
intermediate layer between each inner layer. The intermediate layer
can have a similar structure as the outer layers, such as top layer
120 and bottom layer 122. In some embodiments, the intermediate
layer can be composed of two outer layers bonded together. For
example, one can take the structure shown in FIG. 1B and place it
atop or below a similar structure to form a frame member having
multiple inner layers.
[0069] The outer layers can be formed from fibrous materials such
as paper-based and wood-based materials. This can include, for
example, pulp, cardboard, cartonboard, paperboard, paper, chipboard
and other such paper-based and wood-based materials known to those
in the art. The outer layers can be formed from other materials
such as plastics including high density polyethylene (HDPE), low
density polyethylene (LDPE), polyvinyl chloride (PVC), nylon,
composites such as fiberglass, metals, and any other such materials
used by those in the art. The outer layers can be porous, including
the fibrous materials and plastic materials described above, with
the porosity chosen to enhance the heat seal between the frame
member 100 and the flexible member 200. Heat sealing and the effect
of porosity will be discussed in further detail below.
[0070] It should be appreciated that different materials can be
used for different portions of the outer layers. For example, the
top layer 120 and the bottom layer 122 can be formed from different
materials. In some embodiments, particular portions of the top
layer 120 and the bottom layer 122 can be formed from different
materials. For example, the materials used for the foldable
portions 112, 114 can be different from the materials used for the
central member 100. By using different materials, it is possible to
further enhance the performance of the frame member 100. For
example, materials which are more suitable for heat sealing can be
used along surfaces upon which a heat seal is to be formed whereas
other types of materials can be used for the remaining
surfaces.
[0071] The inner layer 124 can be formed from any of the materials
as herein described as well as those used by those in the art. For
example, the inner layer 124 can be formed from paper-based
materials such as cardboard, paperboard, or paper. The chosen
material for constructing the frame member 100 can be any
substantially rigid, but foldable material. It will be appreciated
that, although denominated as rigid or substantially rigid, the
chosen material would preferably have an amount of flexibility in
the cases of physical impact. The illustrated frame member 100 is a
generally thin, planar member; however, the frame member 100 can
have other configurations.
[0072] With continued reference to FIGS. 1A and 1B, in some
embodiments, the frame member 100 can include one or more coating
layers, such as coating layers 130, 132. These coating layers can
be provided on one or more surfaces of the frame member 100 and can
be placed at and/or proximate desired locations of the heat seals
between the frame member 100 and the flexible member 200. As shown
in the illustrated embodiment, coating layers 130, 132 can be
provided on two separate sections of the upper layer 120.
[0073] These coatings can provide additional benefits when applied
to the frame member 100. For example, coatings can include:
ultraviolet (UV) coatings which assist with inhibiting deleterious
effects of ultraviolet rays on the surface, aqueous coatings which
can assist with inhibiting moisture from being absorbed into frame
member 100, varnish coatings which can provide a sheen on the
surface thus enhancing the appearance of the frame member 100, soft
touch coatings which can provide a smooth or softer surface which
can reduce the likelihood of damaging an article contacting the
surface, and other types of coatings. Moreover, such coatings can
also be beneficial in providing a surface to which a heat seal can
be formed as will be described in further detail below. In this
way, the coating layers can also be considered to work as a bonding
layer. For example, such coatings can be formed from materials such
as polyolefin, ethylene acrylic, polyurethane, low density
polyethylene (LDPE), high density polyethylene (HDPE), and other
types of polymers which can bond with the flexible member, such as
flexible member 200. Other types of coatings include: polyamides,
polyethylene terephthalates (PET), glycol-modified polyethylene
terephthalate (PETG), polyvinylidene chlorides, polyvinyl
chlorides, etc., and highly crystalline non-polar materials such as
high-density polyethylene and polypropylene, ethylene-vinyl acetate
(EVA), ethyl methyl acrylate (EMA), ionomers, acrylic polymers,
acrylate copolymer, modifications of these compounds, and similar
compounds. Such coatings can also include those produced by
companies such as Endura Coatings, Michelman Inc., The Seydel
Companies, Inc., Lubrizol Corporation, and other such
companies.
[0074] As shown in FIGS. 1A and 1B, there are two coating layers
130, 132 along different portions of the top layer 120. Of course,
a fewer or greater number of coating layers can be used and can be
placed on the top layer 120, the bottom layer 122 or both layers.
Moreover, the same or different types of coatings can be used for
different coating layers and the coating layers can be stacked
together. For example, a first coating layer can be placed over the
top layer 120 and a second coating layer can be placed over the
first coating layer. In some embodiments, the coating layers 130,
132 can have a length of 11 inches and a width of a half inch.
However, as should be understood by one in the art after reading
the remainder of this disclosure, the length and width can be
adjusted depending on factors such as the materials used for the
flexible member, the desired strength of the heat seal "hinge," and
other such factors.
[0075] Such "localized application" of coating layers can be
particularly advantageous in reducing the total amount of coating
used for the frame member thus reducing material waste and reducing
costs. For example, the coating layers can be placed along portions
on which a heat seal will be formed. Such coating layers can also
be placed proximate to portions on which a heat seal will be formed
in order to account for slightly misplaced heat seals due to
mechanical tolerances of the machinery used. In some embodiments,
frame member 100 can be "flood coated" such that a coating layer is
placed over a substantial portion, or the entirety of, the top
layer 120, the bottom layer 122 or both. "Flood coating" can be
preferable due to ease of application of the coating and/or if
there is a benefit to adding the coating layer over the entire
surface, such as the UV-coatings, aqueous coatings, varnish
coatings, or soft-touch coatings as described above.
[0076] The central portion 110 can be sized and dimensioned so as
to engage or provide support for one or more articles. Although the
central portion 110 is described primarily as being disposed at the
center of the frame member 100, the central portion 110 can be at
other locations. Additionally, the central portion 110 can comprise
a plurality of members, each configured to engage an article. For
the sake of convenience, the central portion 110 is described as a
generally planar centrally disposed member.
[0077] The size of the central portion 110, which defines a loading
area, can be chosen arbitrarily or to accommodate, support, or
engage an article of a particular size. The loading area size can
be chosen based on the number and configuration of the articles on
or proximate to the central portion 110. In some non-limiting
exemplary embodiments, the central portion can be used to package
one or more communication devices (e.g., portable phones, cellular
phones, radios, headsets, microphones, etc.), electric devices and
components, accessories (e.g., cellular phone covers), storage
devices (e.g., disk drives), and the like. In certain embodiments,
the central portion 110 is configured to package one more portable
music players, such as IPODs.RTM. or MP3 players.
[0078] It is contemplated that the central portion 110 can be
designed to package any number and type of articles. In the
illustrated embodiment, the central portion 110 is somewhat square
shaped and has a surface area (i.e., the loading area) of about
40-60 inches square. In some non-limiting embodiments, the central
portion has a loading area more than about 40 inches square, 45
inches square, 50 inches square, 55 inches square, 60 inches
square, and ranges encompassing such areas. However, these are
merely exemplary embodiments, and the central portion 110 can have
other dimensions for use in communication devices, packaging
modems, hard drives, portable phones, or any other article that is
to be packaged.
[0079] The illustrated central portion 110 has a generally flat
upper surface that an article can rest against. Other non-limiting
central portions can have mounting structures, apertures, recesses,
partitions, separators, or other suitable structures for inhibiting
movement of an article engaging the central portion or for
providing additional shock protection. For example, the central
portion 110 can have at least one holder that is sized and
configured to receive an article.
[0080] Fold lines 116, 118 can be defined between the central
portion 110 and the foldable portions 112, 114, respectively. The
fold lines 116, 118 can be formed as perforations in the frame
member 100, i.e., broken cut lines passing partially or completely
through the material forming the frame member 100. In the
alternative, or in addition, the fold lines 116, 118 can be crushed
portions of the material forming the frame member 100. Of course,
depending on the material used to construct the frame member 100,
the fold lines 116, 118 can be formed as mechanical hinges, thinned
portions, adhesive tape, or any other appropriate mechanical
connection which would allow various portions of the foldable
member to be folded or rotated with respect to each other. These
concepts apply to all the fold lines 116, 118 described herein,
although this description will not be repeated with respect to the
other fold lines described below.
[0081] With such fold lines 116, 118, the foldable portions 112,
114 can be bent upwardly or downwardly relative to the central
portion 110 as desired. With this flexibility, the foldable
portions 112, 114 can be folded upwardly so as to create slack in
the flexible member 200 to load an article to be packaged and
folded downwardly to increase tension in the flexible member 200,
described in greater detail below.
[0082] The illustrated configuration of the frame member 100 is
merely one example of many different kinds and shapes of frame
members that can be used. U.S. Pat. Nos. 6,675,973, 7,882,956,
7,296,681, 7,753,209, 8,028,838, 8,235,216, 8,627,958 and U.S.
patent application Ser. Nos. 12/958,261 and 13/221,784, the
contents of each of which is hereby incorporated by reference, all
disclose various different kinds of frame members with various
different combinations of additional folding portions which can be
used as a substitute for the illustrated frame member 100. Certain
of these embodiments are described in further detail below in
connection with FIGS. 16-25; however, it should be understood that
any other devices as described in the incorporated documents can
also be modified in much the same manner.
Single Layer Flexible Member
[0083] With reference to FIG. 2, the flexible member 200 can be
formed from a flexible sheet or film which can be resilient or
non-resilient. In this context, the term "flexible" is intended to
encompass members that are easily, arbitrarily bendable in all
directions, such as, for example, but without limitation, thin
sheet materials, examples of which are disclosed herein. As shown
in the illustrated embodiment, the flexible member 200 can be
formed from a single layer. The flexible member 200 is configured
to engage and cooperate with the frame member 100. Optionally, the
flexible member 200 can be configured to engage the foldable
portions 112, 114 of the frame member 100 so as to, among other
options, generate tension in the flexible member 200 when the
foldable portions 112, 114 are folded relative to the central
portion 110.
[0084] The flexible member 200 can be formed from a flexible body
202. For purposes of convenience for the following description, the
body 202 is identified as having a midpoint M positioned in the
vicinity of the middle of the flexible body 202. Flexible body 202
can also include ends 204, 206 disposed at opposite longitudinal
and thereof.
[0085] The flexible member 200, in some embodiments, has a Length
L.sub.1 that is sized depending in the devices with which the
flexible member 200 is to cooperate, such as goods. Thus, the
Length L.sub.1 can be sized such that when the flexible member 200
is in its final state, e.g., engaged with the foldable portions
112, 114, it generates the desired tension for the corresponding
packaging application. Thus, the Length L.sub.1 will be smaller
where a higher tension is desired and will be larger where a lower
tension is desired. Additionally, the Length L.sub.1 might be
different for different sized articles that are to be packaged. One
of ordinary skill in the art can determine the Length L.sub.1 for
the corresponding application. Additionally, one of ordinary skill
in the art is fully aware of how to perform industry standard drop
tests to confirm the appropriate dimensioning of the frame member
100 and the flexible member 200.
[0086] The flexible member 200 can be formed of any flexible
material, optionally in a sheet configuration. In some embodiments,
the flexible member 200 can be formed of a layer of polyethylene
film, low density polyethylene (LDPE), polyurethane, TPU, or
virtually any polymer, or plastic film. In some embodiments, the
flexible member 200 can be formed of a metallic foil or other
metallic material, nylon or other fabric, paper, or a combination
of any of the materials described above. In some embodiments, the
flexible member 200 can be formed as a sheet. In some embodiments,
the flexible member 200 can be formed as straps or strips of
material that provide the suspension and/or retention described
herein for the article 300 being packaged. The density of the
layers of film can be varied to provide the desired retention
characteristics such as overall strength, resiliency, and
vibrational response. The density of the material used to form the
flexible member 200 can be determined such that the flexible member
200 is substantially resilient when used to package a desired
article. Optionally, the density of the material used to form the
flexible member 200 can be determined such that the flexible member
200 is substantially non-resilient or non-resilient when used to
package a desired article. In some embodiments including a
non-resilient or substantially non-resilient flexible member 200,
the associated frame member 100 can be sized and configured to
provide all or substantially all of the desired shock absorption.
The layer used to form flexible member 200 can be monolayer or
multilayer sheet depending on the application.
[0087] As illustrated in FIGS. 3A-3C, the frame member 100 can be
used in conjunction with the flexible member 200 with the flexible
member 200 being attached to the frame member 100 via heat seals
302a-c, 304a-c. The heat seals 302a, 304a can be formed on the
upper or lower surfaces of the foldable portions 112, 114 proximal
to or distal from the fold lines 116, 118. In some embodiments, as
illustrated in FIG. 3A, the heat seals 302a, 304a can be formed on
the upper surfaces of the foldable portions 112, 114 near the fold
lines 116, 118. This location for the heat seal can be used, for
example, when packaging articles which are comparatively smaller in
area and/or height when compared to the loading area. Placement of
the heat seals 302a, 304a at this location can result in use of a
smaller flexible member 200 as can be seen in FIG. 3A.
[0088] As illustrated in FIG. 3B, the heat seals 302b, 304b can be
formed on the upper surfaces of the foldable portions 112, 114
further from the fold lines 116, 118 and nearer the ends of the
frame member 100. This location for the heat seal can be used, for
example, when packaging articles which are mid-sized in comparison
to the loading area. Placement of the heat seals 302b, 304b at this
location can result in use of a slightly larger flexible member 200
as can be seen in FIG. 3B.
[0089] As illustrated in FIG. 3C, the heat seals 302b, 304b can be
formed on bottom surfaces of the foldable portions 112, 114 further
from the fold lines 116, 118 and nearer the ends of the frame
member 100. This location for the heat seal can be used, for
example, when packaging articles which are comparatively larger in
area and/or height to the loading area. Placement of the heat seals
302c, 304c at this location can result in use of a larger flexible
member 200 as can be seen in FIG. 3B. Accordingly, the length
between the outer edges (i.e., the length of the packaging of the
frame member 100) of the foldable portions 112, 114 can be slightly
smaller or greater than the length L.sub.1 of the flexible member
200 depending on multiple factors such as the size of the article
to be packaged, the desired tension, and placement of the heat
seals. The article to be packaged 300 can be inserted between the
flexible member 200 and the frame member 100.
[0090] With reference now to FIGS. 3A-C and 4, with the article 300
disposed in the space between the flexible member 200 and the upper
surface of the central portion 110, and with the foldable portions
112, 114, engaged with the ends 204, 206 via heat seals, the
foldable portions 112, 114 can be rotated downwardly in the
direction of arrows R.sub.1. In this initial movement from the
position illustrated in FIGS. 3A-C, the foldable portions 112, 114
move away from the midpoint M of the flexible member 200, thereby
creating tension in the flexible member 200.
[0091] As the foldable portions 112, 114 are further pivoted
downwardly about the fold lines 116, 118, until they are doubled
back adjacent to the lower surface of the central portion 110, the
foldable portions 112, 114, continue to add additional tension into
the flexible member 200. The frame member 100 and the flexible
member 200 can be configured to form a spring when disposed in a
box or container 310 in the arrangement shown in FIG. 4. For
example, the frame member 100 itself can have some shape memory
such that the fold lines 116, 118 provide some resistance to
movement. Additionally, as noted above, the Length L.sub.1 of the
flexible member 200 can provide tension, resisting the further
bending movement of the foldable portions 112, 114 about the fold
lines 116, 118, respectively.
[0092] Accordingly, when the frame member 100, flexible member 200,
and the article 300 are arranged in the configuration shown in FIG.
4 inside the container 310, reaction Forces F.sub.r resist downward
movement of the article 300, thereby providing additional
cushioning for the article 300.
[0093] Further, the container 310 can define a maximum inner
height, for example, when the lid portion of the container 310 is
closed. With the maximum inner height set to a dimension less than
the maximum overall height of the article 300 and frame member 100,
the foldable portions 112, 114 are maintained such that the angular
position .gamma. (FIG. 4) is maintained at an angle more acute than
90 degrees. Thus, the foldable portions are maintained in an
orientation in which the frame member 100 and flexible member 200
work together to act as a shock absorbing spring for the article
300.
[0094] FIGS. 5 and 6 illustrate an optional system 400 for
manufacturing the flexible member 200 and heat sealing the flexible
member 200 to a frame member 100. The manufacturing system
illustrated in FIG. 5 can be made from well-known plastic film
processing equipment, such as those components in systems available
from the Hudson-Sharp Machine Company. The various rollers,
folders, cutters, guides, perforators, and heat sealing devices are
all well-known and commercially available. Those of the ordinary
skill in the art understand how to arrange the various components
described below in order to achieve the function and results
described below.
[0095] With reference now to FIG. 5, the manufacturing system 400
can include a source portion 420, a heat sealing portion 520, a
cutting portion 550 and a frame material feed portion 600.
[0096] The source portion 420 of the system 400 can include one or
more source rolls of raw material for making the flexible member
200. In the illustrated embodiment, the source portion 420 can
comprise, in some embodiments, a roll 422 of raw material for
forming the flexible member 200. As is well known in the art, the
roll 422 is mounted so as to provide some resistance against
turning, so as to thereby maintain an acceptable minimum
tension.
[0097] As illustrated in FIG. 5, a strip of film 426, during
operation, will unroll from the roll 422 and be pulled into the
system 400 for processing, as described below. The material 426 is
used for forming the body 202 of the flexible member 200. In some
embodiments, the strip 426 can have a melt index below 9. Those of
ordinary skill in the art are familiar with the use of the term
"melt index." In particular, the "melt index" is a number that is
assigned to a poly film and helps to organize the various types of
poly into general groupings based upon the melting temp of the
resin they are made out of. The softer the material, then usually
the lower the melt index will be assigned to that material.
[0098] In the illustrated embodiment, the heat sealing portion 520
and the cutting portion 550 are integrated into single component
referred to herein as the heat sealing device 552. However, other
configurations can also be used. In the illustrated embodiment, the
heat sealing device 552 is configured to form one or more heat
seals between the strip 426 and the frame material 604, such as
corrugated, fed towards the heat sealing portion 520 and cutting
portion 550 via a feed device 602. It should be noted that any
materials from which the frame member 100 can be made can be fed
using the feed device 602. Moreover, it should be noted that the
frame material 604 can either be unfinished frame material which
has not yet been cut to size and/or include folds, partially
unfinished frame material which has not yet been completely cut to
size and/or include all folds, or finished frame material which has
already been fully cut with all folds fully formed. In addition,
the frame material 604 can have coating layers applied to surfaces
of the frame material 604 for embodiments of a frame member, such
as frame member 100, in which a coating layer can be used for heat
sealing.
[0099] The heat sealing device 552 can also be configured to cut
the strip 426. In embodiments where the frame material 604 is
unfinished or partially unfinished, the heat sealing device 552 can
be used to also cut the frame material 604 into a frame member,
such as frame member 100. Individual heat-sealed packaging
assemblies such as packaging assembly 140 can then be discharged
from the device 552. The heat-sealed assemblies can then be placed
in a container 650 where they can be temporarily stacked and
stored.
[0100] With reference to FIG. 6, the heat sealing device 552 can
include one or more heat sealing heads, such as heat sealing head
553, and cutting heads, such as cutting head 554, mounted so as to
reciprocate relative to the incoming strip 426 and frame material
604. The heat sealing head 553 and cutting head 554 can be timed
relative to the movement of the strip 426 and the frame material
604 so as to provide the final product with the desired shape. The
heat sealing head 553 and the cutting head 554 can reciprocate
orthogonally to the strip 426 and the frame material 604. The heat
sealing head 553 and the cutting head 554 can also reciprocate
laterally with respect to the heat sealing head 553 and the cutting
head 554.
[0101] The cutting head 554 can include a cutting portion 560. In
some embodiments, the cutting head can also include a first heat
sealing portion (not shown) and a second heat sealing portion (not
shown) proximate the cutting portion 560. As the strip 426 and
frame material 604 move under the heat sealing head 553 and cutting
head 554, the heads can move downwardly and press the cutting
portion 560 down into the strip 426 and, in some embodiments the
frame material 604, so as to simultaneously cut the strip 426 into
a flexible member 200 and, in some embodiments, the frame material
604 into a frame member 100, as well as heat seal the strip 426
onto the frame material 604 along heat seals 302, 304. In
embodiments with the cutting head 554 including a first heat
sealing portion and a second heat sealing portion, this can also be
used to potentially heat seal other portions of the strip 426 to
the frame material 604.
[0102] It should be understood that, in some embodiments, the heat
seals can be created along a lower surface of the frame material
604 such as is shown in FIG. 3C. Accordingly, in some embodiments,
a folding device (not shown) can be used to fold the ends of the
strip 426 over the ends of the frame material 604 such that a
portion of the strip 426 is located adjacent a lower surface of the
frame material 604 to which these portions can then be heat sealed.
Moreover, it should also be understood that some slack may be
desired during the heat sealing process. Accordingly, in some
embodiments, the strip 426 can folded or pinched along a portion
between the heat seals 302, 304 such that, upon heat sealing and
releasing of the folded portion or pinched portion, the resulting
flexible member 200 has some degree of slack for allowing an
article to be packaged therein. Of course, other methods of
introducing some slack can be performed. For example, the heat seal
can be formed when the frame material 604 is at least partially
folded toward a tensioned state as shown in FIG. 4. Accordingly,
the strip 426 can be heat sealed to the frame material 604 while
the strip 426 remains taut.
[0103] The heat sealing portion 552 can include a conveyor system
to carry the strip 426 and the frame material 604 into the area
beneath the heat sealing head 553 and cutting head 554 to be cut
and heat sealed. The conveyor system can then carry the assembled
frame member 100 and flexible member 200 away from the heat sealing
head 553 and the cutting head 554. In some embodiments, a cooling
device, such as a forced convection device, can be located
downstream of the heat sealing device 552 to expedite cooling of
the heat seal. Of course, a forced convection device is entirely
optional particularly in cases where the heat seal can be air
cooled effectively.
[0104] In some embodiments, the assembled frame member 100 and
flexible member 200 can then be stacked in a container 650 where
they can be allowed to further cool. Due to the assembled frame
member 100 and flexible member 200 being stacked such that the heat
sealed flexible member 200 is placed between two frame members 100,
the risk of two assemblies sticking together is reduced since a
recently heat-sealed flexible member 200, after cooling slightly,
will stick to a frame member 100 stacked on top of it. As should be
understood by those of skill in the art, this risk can be further
reduced by allowing the assemblies to cool before being stacked in
container 650. Accordingly, in some embodiments, the conveyor can
be extended further such that the assemblies are provided
additional time to cool or by including a cooling device downstream
of the heat sealing device 552. As such, the assemblies can be
stacked in an automated manner, using well known high speed/high
volume devices for aligning dropping items into a container. Thus,
some embodiments can help reduce man power required for production
and thus reduce production costs.
[0105] Optionally, the cutting portion 560 can be configured to
only perforate or score the strip 426 and/or frame material 604 so
that the flexible members 200 and/or frame members 100 are still
attached but easily separable from each other.
[0106] As noted above, the strip 426 can be made from materials
having different melt indexes. The melt index of a material refers
to the temperature at which the material will begin to flow and
thereby can form clean heat seals. Most materials have different
melt index values. The melt index values of many soft polys vary
from about 7.0 to 9.7. Thus, the strip 426 can be conveniently heat
sealed to frame material 604 if the melt index is in the range of
about 7.0 to about 10.0, they can be easily heat sealed together
using the above-described apparatus 400 and provide clean heat
seals.
[0107] Further, the strip 426 can have different moduli of
elasticity. A more flexible material can be used or a relatively
stiffer material can be used. For example, the strip 426 can be a
polyurethane or a low density polyethylene. In this example, a six
inch wide, 24 inch long strip of low density polyethylene will
stretch only about six inches before failure while a six inch wide
by 24 inch long strip of polyurethane will stretch 18 inches before
failure. In some embodiments, the strip 426 can be formed from two
types of materials with certain materials being used along portions
which are heat sealed and other materials being used for other
portions. In some embodiments, between about 0% to about 40%,
between about 5% to about 30%, between about 10% to about 20%,
about 15%, or any other value including those within these ranges
of the flexible member 200 can be formed from a different
material.
[0108] The thicknesses of the strip 426 can also be different along
different portions. For example, depending on the application,
strip 426 can be thicker along portions which are heat sealed as
well as areas proximate the portions to be heat sealed whereas the
strip 426 can be thinner along others portions. This can
potentially enhance the strength of the bond of the flexible member
200 when it is attached to the frame member 100. In some
embodiments, between about 0% to about 40%, between about 5% to
about 30%, between about 10% to about 20%, about 15%, or any other
value including those within these ranges of the flexible member
200 can have a greater thickness than the remaining portions. This
can help save cost of materials because thinner materials are less
expensive, less waste, etc.
Multi-Layer Flexible Member
[0109] With reference to FIG. 7, in some embodiments, the flexible
member 200b can be formed from one or more flexible materials,
which can be resilient or non-resilient, and can optionally include
an opening device 208. As the flexible member 200b of FIG. 7 is
similar to the flexible member 200 described in connection with
FIG. 2, similar reference numbers are used to reference similar
features. Moreover, reference should be made to the discussion of
the flexible member 200 for further details regarding flexible
member 200b. The flexible member 200b is configured to engage and
cooperate with the frame member 100. Optionally, the flexible
member 200b can be configured to engage the foldable portions 112,
114 of the frame member 100 so as to, among other options, generate
tension in the flexible member 200b when the foldable portions 112,
114 are folded relative to the central portion 110.
[0110] The flexible member 200b can be formed from a flexible body
202. For purposes of convenience for the following description, the
body 202 is identified as having a midpoint M position in the
vicinity of the middle of the flexible body 202. Flexible body 202
can also include end portions 204, 206 disposed at opposite
longitudinal and thereof. In the illustrated embodiment, the
flexible member 200b is formed from two pieces of resilient
material connected together, and sized to cooperate with the
foldable portions 112, 114 of the frame member 100. As illustrated
in FIG. 7, heat sealing lines 210, 212 extend along lateral edges
of the flexible body 202 and act to secure two layers of material
to each other
[0111] One of ordinary skill in the art will appreciate that there
are numerous methods for securing the two layers of material to
each other. However, it has been found that heat sealing is
particularly advantageous as it does not require expensive
adhesives and the time consuming steps required for using such
adhesives. However, such adhesives can be used if desired. Welding
processes (e.g. induction welding), fusing techniques, and the like
can also be used to form the heat sealing lines 210, 212 as well as
any other heat sealing described herein.
[0112] The flexible member 200b, in some embodiments, has a Length
L.sub.1 that is sized depending in the devices with which the
flexible member 200b is to cooperate, such as goods. Similar to the
flexible member 200 described in connection with FIG. 2, the Length
L.sub.1 can be sized such that when the flexible member 200b is in
its final state, e.g., engaged with the foldable portions 112, 114,
it generates the desired tension for the corresponding packaging
application.
[0113] The flexible member 200b can be formed of any resilient
material. In some embodiments, the flexible member 200b can be
formed of two layers of polyethylene films, low density
polyethylene (LDPE), polyurethane, TPU, or virtually any polymer,
or plastic film. The density of the layers of film can be varied to
provide the desired retention characteristics such as overall
strength, resiliency, and vibrational response. In some
embodiments, the density of the material used to form the flexible
member 200b is determined such that the flexible member 200b is
substantially resilient when used to package a desired article.
Each of the layers used to form flexible member 200b can be
monolayer or multilayer sheet depending on the application.
[0114] As illustrated in FIG. 8, the flexible member 200b can be
formed from an upper layer of resilient material 230 and a lower
layer of resilient material 232. The layers 230, 232 can be
attached to each other along the heat sealing lines 210, 212 so as
to form a void there between.
[0115] As illustrated in FIG. 9, which is similar to the embodiment
shown in FIG. 3B with the use of flexible member 200b in lieu of
flexible member 200, the frame member 100 can be used in
conjunction with the flexible member 200b with the flexible member
200b being attached to the frame member 100 via heat seals 302b,
304b. Similar to the embodiment described in connection with FIGS.
3A-C, heat seals can also be located at other positions depending
on design requirements.
[0116] Due to the dual layer design of retention member 200b, the
article to be packaged 300 can be inserted between the flexible
member 200b and the frame member 100 or between the upper and lower
layers 230, 232 of the flexible member 200b. For example, in some
embodiments, the flexible member 200b can include the opening
device 208 which can be configured to allow the article 300 to be
inserted into the space between the upper and lower layers 230,
232. In some embodiments, the opening device 208 can be in the form
of perforations in the upper layer 230 configured to allow the
upper layer 230 to be ruptured and opened thereby allowing the
insertion of the article 300 into the space between the upper and
lower layers 230, 232.
[0117] In other embodiments, the opening device 208 can be in the
form of a zipper, a tongue-and-groove zip-type closure member,
Velcro.RTM., low strength adhesives, flaps, magnets, or any other
type of closing device.
[0118] Optionally, the opening device 208 can be positioned on the
lower layer 232 (illustrated in phantom line in FIG. 9). This
configuration can provide further advantages. For example, with the
opening device 208 positioned on the lower layer, 232, the opening
device 208 is juxtaposed to and faces toward the central portion
110 of the frame member 100. As such, it is less likely that the
article 300 can inadvertently pass through the opening device 208
and exit the space between the layers 230, 232.
[0119] In some embodiments, opening devices 208 can be provided on
both of the upper and lower layers 230, 232. As such, the flexible
member 200b can be used in various ways, allowing the article to be
inserted into the space between the layers 230, 232 through either
of the opening devices 208 on either layer 230, 232.
[0120] With reference now to FIGS. 9 and 10, with the article 300
disposed in either the space between the upper and lower layers
230, 232 or between the lower layer 232 and the upper surface of
the central portion 110, and with the foldable portions 112, 114,
engaged with the end 204, 206 via heat seals, the foldable portions
112, 114 can be rotated downwardly in the direction of arrows
R.sub.1. In this initial movement from the position illustrated in
FIG. 9, the foldable portions 112, 114 move away from the midpoint
M of the flexible member 200b, thereby creating tension in the
flexible member 200b.
[0121] As the foldable portions 112, 114 are further pivoted
downwardly about the fold lines 116, 118, until they are doubled
back adjacent to the lower surface of the central portion 110, the
foldable portions 112, 114, continue to add additional tension into
the flexible member 200b, and more particularly, the upper and
lower layers 230, 232 of the flexible member 200b. The frame member
100 and the flexible member 200b can be configured to form a spring
when disposed in a box or container 310 in the arrangement shown in
FIG. 10. For example, the frame member 100 itself can have some
shape memory such that the fold lines 116, 118 provide some
resistance to movement. Additionally, as noted above, the Length
L.sub.1 of the flexible member 200b can provide tension, resisting
the further bending movement of the foldable portions 112, 114
about the fold lines 116, 118, respectively.
[0122] Accordingly, when the frame member 100, flexible member
200b, and the article 300 are arranged in the configuration shown
in FIG. 10 inside the container 310, reaction Forces F.sub.r resist
downward movement of the article 300, thereby providing additional
cushioning for the article 300.
[0123] Further, the container 310 can define a maximum inner
height, for example, when the lid portion of the container 310 is
closed. With the maximum inner height set to a dimension less than
the maximum overall height of the article 300 and frame member 100,
the foldable portions 112, 114 are maintained such that the angular
position .gamma. (FIG. 10) is maintained at an angle more acute
than 90 degrees. Thus, the foldable portions are maintained in an
orientation in which the frame member 100 and flexible member 200
work together to act as a shock absorbing spring for the article
300.
[0124] FIGS. 11 to 13 illustrate an optional system 400b for
manufacturing the flexible member 200b and heat sealing the
flexible member 200b to a frame member 100. As the system 400b of
FIG. 11 is similar to the system 400 described in connection with
FIG. 5, similar reference numbers are used to reference similar
features. Moreover, reference should be made to the discussion of
the system 400 for further details regarding system 400b. In
addition, it should be understood that the components of system
400b can be incorporated in the system 400. The various rollers,
folders, cutters, guides, perforators, and heat sealing devices are
all well-known and commercially available. Those of the ordinary
skill in the art understand how to arrange the various components
described below in order to achieve the function and results
described below.
[0125] With continued reference to FIG. 11, the manufacturing
system 400b can include a source portion 420, an opening device
portion 450, a drive portion 500, a heat sealing portion 520, a
cutting portion 550, and a frame material feed portion 600.
[0126] The source portion 420 of the system 400b can include one or
more source rolls of raw material for making the flexible member
200b. In the illustrated embodiment, the source portion 420 can
comprise, in some embodiments, one or more rolls of raw material
for forming the flexible member 200b. In the illustrated
embodiment, a first roll 422 serves as a source of the upper layer
of film for forming the upper layer 230 of the flexible member 200b
and the second roll 424 serves as a source for the material
performing the second lower layer 232 of the flexible member 200b.
In the illustrated embodiment, the rolls 422, 424 are approximately
the same width. However, it should be understood that rolls of
different width can also be used.
[0127] Additionally, as described above, the material on the rolls
422, 424 can be different kinds of materials, different thicknesses
and have different melting indexes. Additionally, as well known in
the art, the rolls 422, 424 are mounted so as to provide some
resistance against turning, so as to thereby maintain an acceptable
minimum tension.
[0128] As illustrated in FIG. 11, a strip of film 426, during
operation, will unroll from the roll 422 and be pulled into the
system 400b for processing, as described below. Similarly, a strip
of material 428, during operation, unrolls from the roll 424. The
material 426 is used for forming the upper layer 230 of the
flexible member 200b and the second strip 428 is used for forming
the lower layer 232 of the flexible member 200b. In some
embodiments, the strips 426, 428 can have a melt index below 9.
[0129] The source 420 can also include one or more tensioning
rollers 430 configured for maintaining tension in the strips 426,
428 as they are pulled through the system 400b. The tensioning of
such layers of material is well known to those of ordinary skill in
the art, and thus is not described in further detail.
[0130] Optionally, as noted above, the manufacturing apparatus 400
can include an opening portion 450 configured to provide the
opening device 208 to the flexible member 200b. In the illustrated
embodiment, the opening device portion 450 is configured to
perforate the strip of material 426 so as to form an opening device
208 in the flexible member 200b. In some embodiments, the opening
portion 450 can include a block member 452 and a cutting head 454.
In such an arrangement, the cutting head 454 can include a cutting
blade (not shown) configured to reciprocate in a direction
perpendicular to the material 426 in a timed fashion so as to
create perforations at desired locations.
[0131] For example, as shown in FIG. 12, the cutting device 454
reciprocates upward and downwardly to create a series of
perforations 456 at spaced locations along the material 426. The
block 452 can provide support for the material 426 as the cutting
device 454 perforates the material 426. In some embodiments, both
strips can be routed through the cutting device 454, so as to
provide opening device 208 in both layers 426, 428.
[0132] Optionally, the system 400b can include a set of diverter
rollers 455, configured to allow the lower strip 428 to bypass the
opening portion 450. Thus, the opening portion can selectively
provide opening devices 208 to only one or to both of the strips
426, 428.
[0133] In some embodiments, one of or both of the strip 426, 428
can include printed portions 429, such as advertising, trade names,
trademarks, logos, coupons, or other indicia. Thus, the resulting
flexible member 200b can include such printing on one or both of
the layers 426, 428. In some embodiments, one or both of the layers
426, 428 can be pre-printed with the desired printed portions 429.
For example, in some embodiments, the printed portions 429 can be
applied to the layer 428 and the layer 426 can be translucent or
transparent. Thus, during use, the printed portions 429 can be
viewed through the upper layer 426 (layer 230 in FIG. 9).
[0134] With continued reference to FIG. 11, the system 400b can
approximately include a registration device 460 configured to
provide a registration function for the timing of actuation of the
opening device 450, the heat sealing portion 520, cutting portion
550, a feed portion 600 or any other device that may be used to
selectively alter the strips 426, 428 at desired locations. For
example, one or more of the strips 426, 428 can be provided with
one or more detectable registration marks, such as visible lines
(e.g., black marker), which can be used as a registration mark by
the registration device 460. The registration device 460 can
include an optical sensor (not shown) configured to detect such a
registration mark, and to output a signal that can be used to
control the various parts of the system 400b to trigger actuation
at the desired timing so as to produce the desired effects to the
strips 426, 428 at the desired location. Such registration devices
460 are well known in the art and thus are not described in greater
detail below.
[0135] Using such as registration device 460, the system 400b can
be configured to create opening devices and heat seals in locations
that are at predetermined spacings from the printed portions 429.
For example, the opening devices 208 can be centered on the printed
portions 429 and the cuts created by the cutting portion 550 can be
disposed between the printed portions 429. Other spaced
relationships can also be used.
[0136] With continued reference to FIG. 11, the drive portion 500
of the manufacturing system 400b can include a plurality of
rollers, one or more of which can be driven with a motor so as to
provide a substantial portion of the force for pulling the strips
426, 428 through the various portions of the manufacturing system
400b. The configuration of such a set of drive rollers is well
known in the art and is not described in greater detail below.
However, generally, the control of the speed of the drive rollers
500 is synchronized and otherwise controlled to be in a timed
relationship with the operation of the tension portion 430, opening
portion 450, registration device 460, heat sealing portion 520,
cutting portion 550, and feed portion 600 with a programmable logic
controller, a dedicated processor, a general purpose computer, a
hardwired controller, or the like.
[0137] In the illustrated embodiment, the heat sealing portion 520
and the cutting portion 550 are integrated into single component
referred to herein as the heat sealing device 552. However, other
configurations can also be used. In the illustrated embodiment, the
heat sealing device 552 is configured to form one or more heat
seals between the layers of the strips 426, 428 and the frame
material 604, such as corrugated, fed towards the heat sealing
portion 520 and cutting portion 550 via a feed device 602.
[0138] The heat sealing device 552 can also cut the strips 426,
428, between the two parallel heat seals. In embodiments where the
frame material 604 has not been fully cut, the heat sealing device
552 can be used to also cut the frame material 604 into frame
member 100. Individual flexible member 200b and frame member 100
heat-sealed assemblies can then discharged from the device 552. The
heat-sealed assemblies can then be placed in a container 650 (FIG.
6) where they can be temporarily stacked and stored.
[0139] With reference to FIG. 13, the heat sealing device 552 can
include one or more heat sealing heads, such as heat sealing head
553, and cutting heads, such as cutting head 554, mounted so as to
reciprocate relative to the incoming strips 426, 428 and frame
material 604. As with the opening portion 450, the heat sealing and
cutting head 554 can be timed relative to the movement of the
strips 426, 428 so as to provide the final product with the desired
shape.
[0140] The heat sealing and cutting head 554 can include a cutting
portion 560. In some embodiments, the cutting head can also include
a first heat sealing portion 556 and a second heat sealing portion
558 adjacent proximate the cutting portion 560. As the strips 426,
428 and frame material 604 move under the heat sealing head 553 and
cutting head 554, the heads can move downwardly and press the
cutting portion 560 down into the strips 426, 428 and, in some
embodiments, the frame material 604 so as to simultaneously cut
those the strips 426, 428 into a flexible member 200b and, in some
embodiments, the frame material 604 into a frame member 100, as
well as heat seal the strips 426, 428 onto the frame material 604
along heat seals 302, 304 and together along heat seals 210, 212.
In embodiments with the cutting head 554 including a first heat
sealing portion 556 and a second heat sealing portion 558, these
portions 556, 558 can be used to form heat seals such as heat seals
210, 212, heat seals the strips 426, 428 directly to the frame
member 100, or a combination of both.
[0141] The heat sealing portion 552 can include a conveyor system
to carry the strip 426, 428 and the frame material 604 into the
area beneath the heat sealing head 553 and cutting head 554 to be
cut and heat sealed. The conveyor system can then carry the
assembled frame member 100 and flexible member 200b away from the
heat sealing head 553 and the cutting head 554. In some
embodiments, a cooling device, such as a forced convection device,
can be located downstream of the heat sealing device 552 to
expedite cooling of the heat seal. Of course, a forced convection
device is entirely optional particularly in cases where the heat
seal can be air cooled effectively. The assembled frame members 100
can then be stacked in a container 650.
[0142] Optionally, the cutting portion 560 can be configured to
only perforate or score the strips 426, 428 and/or frame material
604 so that the flexible members 200 and/or frame members 100 are
still attached but easily separable from each other.
[0143] As noted above, the strips 426, 428 can be made from
materials having different melt indexes. The melt index of a
material refers to the temperature at which the material will begin
to flow and thereby can form clean heat seals. Most materials have
different melt index values. The melt index values of many soft
polys vary from about 7.0 to 9.7. Thus, the layer strips 426, 428
can have different melt indexes and conveniently if those melt
indexes are in the range of about 7.0 to about 10.0, they can be
easily heat sealed together using the above-described system 400b
and provide clean heat seals.
[0144] Further, the strips 426, 428 can have different moduli of
elasticity. In some embodiments, for example, more flexible
material can be used as the top layer 426 while a relatively
stiffer layer can be used as the lower layer 428. For example, the
upper layer, and some embodiments is a polyurethane while a low
density polyethylene is used as the lower layer 428. Although these
materials behave very differently with regard to failure, they can
be easily heat sealed together using the system 400b described
above and provide the desired shock absorption for packaging
articles 300 described above. As described above, the one or more
of the strips, such as strips 426, 428, can be formed from two
types of materials with certain materials being used along portions
which are heat sealed and other materials being used for other
portions.
[0145] The thicknesses of the strips, such as strips 426, 428, can
also be different compared to each other. In addition, the
thickness of the strips can also be different along different
portions as described above. Moreover, the widths of the strips
426, 428 can be slightly different. For example, the width of the
strip 428 can be greater than the width of the strip 426. Thus,
when heat sealed together, the ends of the lower layer 232 can
extend beyond the ends of the upper layer 230. This can be
particularly advantageous, for example, heat sealing the lower
layer 232 to the frame material 604 is more effective. This can be
the case, for example, if the strip 428 is a material which more
suitable for heat sealing to the frame material 604 such as the raw
frame material or a coating on the frame material 604. The strip
426 can then be heat sealed along portions of its periphery, such
as described herein, to the strip 428 rather than the frame
material 604. Of course, it should be understood that strip 426 can
also be heat sealed to the frame material 604.
[0146] Further, because various different kinds of material can be
heat sealed together as described above, the colors of the
materials can also be different. For example, the strip 426 could
be translucent or transparent and the strip 428 could be
translucent or opaque. Thus, the strip 428 could include printed
portions 429 that can be seen through the layer formed by the strip
426. The printed portions could be any form of advertising,
including but without limitation, trademarks, trade names, service
marks, logos, coupons, etc.
Heat Sealing Procedures
[0147] With reference now to FIGS. 14A-B and 15A-B, heat sealing of
the flexible member 200, either directly to an outer layer of the
frame member 100 or to a coating layer, such as coating layer 130,
is described in further detail. It should be understood that these
same processes can be applied to heat sealing of any resilient
sheet member, such as flexible member 200b, to any frame members
described herein.
[0148] With reference first to FIGS. 14A and 14B, heat sealing of
the flexible member 200 is shown where the flexible member 200 is
heat sealed directly to an outer layer, more specifically the top
layer 120, of the frame member 100. As shown in FIG. 14A, heat can
be applied using a heating source, such as heat seal head 553, to
the flexible member 200. Moreover, the heating source can apply a
force P on the flexible member 200 in a direction towards the top
layer 120 such that the flexible member 200 is compressed between
the heat seal head 553 and the top layer 120.
[0149] Generally, the amount of heat and pressure applied to the
flexible member 200 can be chosen so as to be sufficient to cause
the flexible member 200 to soften and/or partially melt so as to
generate a connection to the top layer 120. The amount of heat
applied can be controlled by selecting an appropriate temperature
for the heat seal head 553 and controlling the amount of time this
temperature is applied to the flexible member 200. The temperature
can also be varied as a function of time and/or force applied. The
amount of pressure can be controlled by controlling the amount of
force applied to the heat seal head 553, such as via motors or
other mechanisms. The pressure can also be varied as a function of
time and/or the temperature applied.
[0150] In some embodiments, the temperature, pressure and times of
application of each can be chosen such that the flexible member 200
can form a bond, upon cooling and solidifying, with a material to
which it is placed adjacent during the heat sealing process. For
example, in the illustrated embodiment, the temperature, pressure
and times of application of each can be chosen such that the
flexible member 200 forms a bond with an outer layer, such as the
top layer 120. For example, in some embodiments, the upper layer
120 can be made from a fibrous material, such as those noted above
commonly used for forming outer layers of materials known as
"corrugated cardboard". In such embodiments, the temperature,
pressure and times of the heat sealing process can be chosen such
that at least some of the flexible member 200 flows into close
contact with the fibers forming the upper layer, thereby forming a
connection that is enhanced with a mechanical engagement of the
material of the flexible member 200 and the surfaces of the fibers
contained in the upper layer 120. The more the flexible member 200
flows into and around the fibers, the stronger the connection
between the fibers and the upper layer 120. FIG. 14B illustrates a
portion of the flexible member 200 having flowed into and become
entangled and/or mechanically engaged with the upper layer 120.
[0151] In some embodiments, the flexible member 200 can melt and
flow through pores or openings of the outer layer and into cavities
125 of the inner layer 124. Such cavities 125 can be formed during
the processes for manufacturing the upper layer 120 or at any time
after manufacturing. For example, although not illustrated, a
"pricking" device can be used to generate one or a plurality of
cavities 125 with the upward openings at the first surface of the
upper layer 120. Thus, when the flexible member 200 is heated
during the heat sealing process, some of the flexible member 200
can flow more readily into the cavities 125, thereby enhancing a
connection between the flexible member 200 and the upper layer 120.
Further, in some examples, a heat sealing head can be modified to
include a plurality of pins which simultaneously form cavities 125
and heat the flexible member 200 sufficiently to cause the material
forming the flexible member 200 to flow into the cavities 125.
Other techniques can also be used.
[0152] With continued reference to FIG. 14B, upon cooling and
solidifying, portions 303 of the flexible member can be located
within an interior 303 of the upper layer 120. In some embodiments,
it is possible for some of the flexible member 200 to pass
completely through the upper layer 120. Without being limited to a
particular theory of operation, by allowing the flexible member 200
to at least soften and come into close contact with the outer layer
120, the flexible member 200 can solidify in such a manner as to
connect with and optionally become integrated with the structure of
the outer layer 120. By increasing the temperature, one can
potentially expedite the speed at which the material forming the
flexible member 200 can flow into contact with outer layer 120 by
causing the flexible member 200 to become more free-flowing.
Moreover, by increasing the pressure, one can also potentially
expedite the speed at which this flow into contact with the outer
layer 120 occurs by application of additional force in the
direction of flow toward the outer layer 120. However, it should be
understood that application of too much heat and/or pressure can
weaken the structure of the flexible member 200 upon cooling. This
is particularly important to consider in light of the significant
stresses applied to the flexible member 200 when placed in tension.
For example, with continued reference to FIG. 14B, the flexible
member 200 can be considered as including a transition area 309
spanning the portion of the flexible member 200 which includes a
terminal end area of the part of the flexible member 200 that has
flowed into an interior 303 or cavities 125 of the upper layer 120
and a portion of the flexible member 200 which is free to move, or
at least pivot, relative to the upper layer 120. This transition
area 309 can be considered as forming a hinge between the portion
of the flexible member 200 that is directly connected to the upper
layer 120, and the portion of the flexible member 200 that can
pivot relative to the upper layer 120.
[0153] If too much temperature and/or pressure had been applied
during the associated heat sealing process, too much of the
flexible member 200 might flow into the upper layer 120, thereby
leaving a thickness 311 that is insufficient to maintain a reliable
connection between the free portion of the flexible member 200 and
the upper layer 120, for example, allowing the flexible member 200
to tear in the vicinity of the transition portion 309 when
subjected to a load during normal use. One of ordinary skill in the
art, in light of the description set forth herein, can determine
the appropriate amount of pressure and/or temperature to use in
order to provide a transition portion 309 with sufficient
strength.
[0154] Fibrous materials, such as cardboard, paperboard, paper, and
the like can include pores or openings. Additionally, as discussed
above, other types of porous materials can be used for the outer
layer. Moreover, in some embodiments, to enhance the ability for
the flexible member 200 to flow into cavities 125 of the inner
layer 124, a separate device can be incorporated in the
manufacturing system, such as systems 400, 400b, to create
additional pores or openings at least along portions of the frame
member 100 on which the flexible member is to be heat sealed. This
device can include one or more pins, needles or other puncturing
devices to create pores or openings. This device can also be part
of the heat sealing head 553 or cutting head 554. The size of the
pores or openings can be chosen to allow sufficient flow into the
inner layer 124. In some embodiments, rather than creating pores or
openings, a device can be used to create one or more slits at least
along portions of the frame member 100 on which the flexible member
is to be heat sealed. Creation of pores, openings, or slits can
help improve the strength of the heat seal of the flexible member
200 to the frame member 100 and reduce the temperature, pressure
and/or time of application of each to form the heat seal 302b.
[0155] With reference to FIG. 14C, heat sealing 302d is shown of a
flexible member 220 that can be of a resilient or non-resilient
material and that can be heat-sealed to any portion, rotatable or
non-rotatable, of frame member 100 or of any other frame member
disclosed herein. As shown in FIG. 14C, cavities 126 can be formed
in one or more layers 120, 124, 122 of the frame member 100 in
order to facilitate a flow of heated portions 323 of the flexible
member 220 to impregnate material of the frame member 100. The
cavities 126 can be formed to extend through one or more of the
upper layer 120, the inner layer 124, and/or the lower 120 of the
frame member 100 in order to facilitate flow into the material of
those layers. The cavities 126 can be formed prior to and/or
simultaneous with application of a heat source to the flexible
member. The cavities 126 can also be formed as part of a heat
sealing process.
[0156] With further reference to FIG. 14C, a partially schematic
and exploded view of a heat seal head 553a is shown which includes
one or more piercing devices 555 for creating cavities 126 in the
frame member 100. In some embodiments, as the heat seal head 553a
is applied with force P onto the flexible member 220, the piercing
devices 555, which extend out from the heat seal head 553a, pierce
the flexible member 220 and one or more layers 120, 124, 122 of the
frame member. The heat seal head 553a can be configured so that the
piercing devices 555 can be retracted into the heat seal head 553a
while the heat seal head 553a applies heat to the
resilient/non-resilient material 220. This allows the heated
material 323 of the flexible member 220 to flow into the cavities
126 vacated by the piercing devices 555. The cavities can be any
size and arranged in any spacing desired. In some embodiments, the
cavities 126 can be approximately 1 mm in diameter, formed by 1 mm
piercing devices 555, and spaced approximately 1 cm apart. However,
other arrangements can also be used.
[0157] In some embodiments, a vacuum head 570 can be used to
enhance flow of the heated material into the frame member 100. The
vacuum head 570 can be in the form of vacuum heads which are used
on well-known material handling systems such as those designed for
handling corrugated cardboard. Typically, such vacuum heads are
used for manipulating corrugated material during processing. For
example, such vacuum heads are abutted against the subject
material, then a vacuum is applied in the space between the vacuum
head and the material, thereby securing the material to the vacuum
head.
[0158] In some embodiments, the vacuum head 570 can be moved the
bottom layer 122 to exert a vacuum force V on the frame member 100
during the heat sealing process to further facilitate flow of the
heated material 323 of the flexible member 220 into the material of
one or more layers 120, 124, 122 of the frame members.
[0159] With reference now to FIGS. 15A and 15B, heat sealing of the
flexible member 200 is shown where the flexible member 200 is heat
sealed to a coating on an outer layer, more specifically coating
130 on the top layer 120, of the frame member 100. As shown in FIG.
15A, heat can be applied using a heating source, such as heat seal
head 553, to the flexible member 200. Moreover, the heating source
can apply a force P on the flexible member 200 in a direction
towards the top layer 120. The discussion above with respect to
heat sealing directly to the outer layer can apply; however, it
should be understood that the temperatures, pressures, and times of
application of each can be different from that discussed with
respect to healing directly to the outer layer. More specifically,
in the illustrated embodiment, the temperature, pressure and times
of application of each can be chosen such that the flexible member
200 forms a bond with the coating 130.
[0160] For example, in embodiments where the flexible member 200 is
formed from a polymer or plastic-based material and the coating 130
is also formed from a polymer or plastic-based material, the
flexible member 200 and/or coating 130 can melt such that the
flexible member 200 and coating 130 bond upon cooling and
solidifying. Moreover, it should also be appreciated that some
degree of flow of the flexible member 200 and/or coating 130
through the outer layer, such as top layer 120, can also occur.
Reference should be made above to discussion above in connection
with FIGS. 14A and 14B for details regarding such flow and methods
of enhancing such flow.
[0161] As shown in FIGS. 14B and 15B, upon forming a heat seal
302b, a transition area 308 is formed between the heat-sealed
portion of the flexible member 200 and the free (i.e., non
heat-sealed) portion of the flexible member 200. Since this
transition area serves as a "hinge" for the flexible member and can
be subject to significant stress upon tensioning the flexible
member 200, the temperatures, pressures and times of application of
each, as well as the materials and thickness of the flexible member
200, should be chosen such that the "hinge" or transition area does
not fail by breakage or other failure modes upon tensioning. Thus,
temperatures, pressures, and times of application cannot be too
high such that structural integrity along this area is
compromised.
[0162] The following temperatures, pressures and times of
applications can be used for heat sealing the flexible member 200
directly to the frame member 100:
TABLE-US-00001 Seal Temp. Time Pressure Material (.degree. F.)
(Sec.) (lb. f/in) Polyurethane 225 15 0.5 300 7 1.5 550 1 5 800 0.5
10 Polyethylene 245 15 0.06 350 5 1.5 650 1 5 850 0.5 10
Polypropylene 290 15 0.065 400 5 1.5 750 1 5 900 0.5 10 Polystyrene
300 15 0.065 425 5 1.5 800 1 5 900 0.5 10
[0163] The temperatures, pressures and times noted above provide
acceptable results. Additionally, ranges of variations from the
above, specifically listed temperatures, pressures and times also
provide acceptable results. Magnitudes of such ranges of variations
can be affected by various other parameters, such as environmental
temperature, starting temperature of the materials, environmental
humidity, variations in material compositions, impurities in the
materials, impurities in the air, etc. In light of the ranges of
variations that can provide acceptable results, as used herein for
characterizing values of temperatures, pressures and times, the
term "about" is intended to mean that a variation of about 10% of
the stated number is included. For example, the statement
"polyurethane heat sealed at a temperature of about 225.degree. F.,
for about 15 seconds, at a pressure of about 0.5 lb. f/in" is
intended to include at least "a temperature of 202.5-247.5.degree.
F., for 13.5-16.5 seconds, at a pressure of 0.49-0.51 lb. f/in".
Larger ranges of included values may also be included.
[0164] In some embodiments, the heat sealed areas of the flexible
member 200 can account for between about 1% to 40% of the total
area of the flexible member 200, between about 5% to about 30% of
the total area of the flexible member 200, between about 10% to
about 20% of the total area of the flexible member 200, about 10%
of the total area of the flexible member 200, or any other value
including those within these ranges. Moreover, in some embodiments,
the area of the flexible member 200 between the heat sealed
portions can account for between about 50% to about 99% of the
total area of the flexible member 200, between about 65% to about
95% of the total area of the flexible member 200, between about 80%
to about 90% of the total area of the flexible member 200, about
90% of the total area of the flexible member 200, or any other
value including those within these ranges. In some embodiments, the
heat sealed areas of the flexible member 200 can account for
between about 1% to 40% of the total area of the frame member 100,
between about 5% to about 30% of the total area of the frame member
100, between about 10% to about 20% of the total area of the frame
member 100, about 10% of the total area of the frame member 100, or
any other value including those within these ranges.
[0165] The manufacturing process as herein described can be
modified to produce other articles, such as differently shaped
frame members, to which a flexible member can be attached.
Side Wall Retention Packaging Frame Member
[0166] With reference to FIGS. 16-19, another embodiment of a
retention packaging assembly is shown therein. The retention
packaging assembly includes a frame member 780 and a flexible
member 200c, similar to flexible members 200, 200b, which cooperate
with each other to form the packaging assembly 784.
[0167] As shown in FIG. 16, the frame member 780 is formed of a
rigid body member 786. In the illustrated embodiment, the rigid
body 786 is generally rectangular. However, it will be apparent to
one of ordinary skill in the art that the rigid body 786 can be
formed in various other shapes according to the desired overall
characteristics of the packaging assembly 784. As shown in FIG. 16,
the rigid body 786 includes a central portion 788 having a first
rotatable portion 790 and a second rotatable portion 792, each
being connected to the central portion 788 at fold lines 794, 796,
respectively. The construction of the rigid body 786 and the fold
lines 794, 796, as well as other fold lines included on the rigid
body 796 discussed below, can be constructed in accordance with the
description in U.S. Pat. No. 6,675,973, which has been expressly
incorporated by reference in its entirety.
[0168] As shown in FIG. 16, the rigid body 786 includes side walls
798, 800 which are connected to the central portion 788 along fold
lines 802, 804, respectively. The side walls 798, 800 are each
divided into a main panel 806, 808 and side panels 810, 812, 814,
816. The side panels 810, 812 are connected to the main panel 806
at fold lines 818, 820, respectively. Similarly, the side panels
814, 816, are connected to the main panel 808 at fold lines 822,
824, respectively.
[0169] Preferably, clearances 826, 828, 830, 832 are formed between
the side panels 810, 812, 814, 816, and the rotatable portions 790,
792. The clearances 826, 828, 830, 832 provide gaps between the
rotatable portions 790, 792 and the side panels 814, 816 such that
when a user rotates the rotatable portions 790, 792 around the fold
lines 794, 796, respectively, the rotatable portions 790, 792
rotate freely and thus, are not impeded by the side panels 810,
812, 814, 816.
[0170] As shown in FIG. 16, there are different portions on which
the flexible member 200c can be heat sealed to the device. Along
the upper surface, several locations of heat seals, 791a, 791b,
793a, 794b are illustrated. Moreover, heat seals can also be
located along the lower surface of the frame member 780. Reference
is made to FIGS. 3A-C which illustrate a frame member 100 which
includes similar design aspects to that of frame member 780. As
shown in FIGS. 3A-C, the heat seals 302a-c, 304a-c, can be
positioned at various locations on the frame member 100 including
both the upper and lower surfaces. In a similar fashion, heat
seals, such as heat seals 302a-c, 304a-c can be positioned at
various locations on the frame member 780. Moreover, reference
should be made to the discussion in connection with FIGS. 3A-C for
determining placement of the heat seals on the frame member 780 as
well as operation of the frame member 780. For example, heat seals
791a and 793a can be used for packaging smaller and/or lighter
articles while heat seals 791b and 793b can be used for packaging
larger and/or heavier articles.
[0171] With reference to FIG. 17, as noted above, the frame member
780 can include side walls 798, 800. As shown in FIG. 17, the side
walls 798, 800 can be folded upwardly so as to provide further
protection for the article 852. In the illustrated embodiment, the
side walls 798, 800 have been folded upwardly along fold lines 802,
804, respectively. Additionally, the side panels 810, 812 have been
folded inwardly, as viewed in FIG. 17, along fold lines 818, 820,
respectively. Similarly, side panels 814, 816 have been folded
inwardly along fold lines 822, 824, respectively. In this position,
the assembly 784 defines a maximum overall height H.
[0172] With reference to FIG. 16, by providing clearances 826, 828,
830, 832 between the rotatable portions 790, 792 and the end panels
810, 812, 814, 816, the rotatable portions 790, 792 can be easily
rotated from the position such as is shown in FIGS. 3A-C to the
position shown in FIGS. 18 and 19 without contacting the end panels
810, 812, 814, 816, particularly when the flexible member 200c is
engaged with the rotatable portions 790, 792.
[0173] With reference to FIG. 18, the length L.sub.1 of the
retention member optionally can be configured such that the
rotatable portions 790, 792 and the flexible member 200c itself
forms a further cushioning device or a spring. For example, as
shown in FIG. 19, the rotatable portions 790, 792 have been rotated
in the direction of arrows R.sub.2 from the position illustrated in
FIG. 17, to an angle .gamma. which is substantially less than
90.degree.. With the rotatable portions 790, 792 rotated to such a
position, further tension can be generated in the flexible member
200c thus causing a reaction force to bias the rotatable portions
790, 792 in the direction of arrow F.sub.R. Where the frame member
780 is formed of cardboard, the reaction forces along the arrows
F.sub.R are further enhanced due to the tendency of cardboard to
return to an unfolded state, despite the formation of fold lines,
such as the fold lines 794, 796, i.e., the "fibrous memory" of
cardboard creates a cantilever-type spring effect. Accordingly,
when the assembly 784 is positioned within a shipping container
such as a box 854, the reaction force F.sub.R provides additional
cushioning to the article 852. Thus, the length L.sub.1 of the
flexible member 200c can be configured such that the rotatable
portions 790, 792 and the flexible member form a spring, thus
providing a reaction force and cushioning for the article 852.
Clamshell Suspension Packaging Frame Member
[0174] With reference to FIGS. 20-22, a frame member 956 and two
flexible members 200d, 200d', similar to flexible members 200,
200b, cooperate to form a packaging assembly 958, as illustrated in
FIG. 22. Further details regarding this embodiment can be found in
U.S. Pat. No. 6,675,973, which has been expressly incorporated by
reference in its entirety.
[0175] As shown in FIG. 20, the frame member 956 is formed of a
rigid body 960 having first and second panel members 962, 964
connected along a fold line 966. The first panel portion 962
includes first and second rotatable portions 968, 970 which are
connected to the first panel portion 962 along fold lines 972, 974,
respectively to central portion 957. Similarly, first and second
rotatable portions 976, 978 are connected to the second panel
portion 964 along fold lines 980, 982, respectively to central
portion 959. The construction of the rigid body 960 and the fold
lines 966, 972, 974, 980, 982 is preferably in accordance with the
description of the frame member 780 illustrated in FIGS. 16, 20 and
21.
[0176] In the illustrated embodiment, as shown in FIG. 20, the
first and second panel members 962, 964 include apertures 984, 986
in the central portions 957, 959. The apertures 984, 986 are in the
form of through holes formed in the first and second panel members
962, 964, respectively. Additionally, the frame member 956 is
provided with a notch 988 provided between the rotatable portions
968 and 976. The notch 988 provides clearance between the rotatable
portions 968, 976. Similarly, the frame member 956 includes a notch
990 formed between the rotatable portions 970, 978. The function of
the notches 988, 990 will be described below.
[0177] With reference to FIG. 21, as noted above, the assembly 958
includes two flexible members 200d, 200d' each engaged with one of
the panel members 962, 964. Thus, for clarity, the flexible member
labeled as 200d is illustrated as engaged with the first panel
member 962 and a second flexible member labeled as 200d' is
illustrated as engaged with the second panel member 964. As shown
in FIG. 21, the rotatable portions 968, 970 are attached to
flexible member 200d via a heat seal 996 on rotatable portion 970
and a heat seal (not shown) on rotatable portion 968. Flexible
member 200d' is attached to panel 964 via multiple heat seals
994a-e. As such, unsupported spans 991, 993 of the flexible members
200d, 200d', respectively are formed over the apertures 984, 986,
respectively. It should be noted that heat seal location 996 can
allow use of a larger flexible members such as flexible member
200d. In contrast, heat seal locations 994a-e can allow use of
smaller flexible members such as flexible member 200d'. While the
illustrated embodiment illustrates the use of two different sized
flexible members 200d, 200d', it should be understood that flexible
members of the same size can be used. Moreover, these heat seal
locations are just for illustrative purpose and need not be used.
For example, only certain of heat seals 994a-e can be used.
Moreover, the heat seals can also be placed along the opposite
surfaces from for example, heat seal 996, to allow use of even
larger flexible members.
[0178] Flexible members 200d, 200d' have lengths L.sub.1A',
L.sub.1B', respectively, which are configured such that the
rotatable portions 968, 970, and 976, 978 can be moved between
positions in which the flexible members 200d, 200d' are slackened
and positions in which the flexible members 200d, 200d' are
tightened. For example, although not illustrated, the rotatable
portions 976, 978 shown in FIG. 21, can be rotated upwardly towards
the mid-point M.sub.B' in the directions indicated by arrows
R.sub.3. With the rotatable portions 976, 978 rotated to such a
position, the flexible members 200d, 200d' can be slid over the
rotatable portions 976, 978. Afterwards, the rotatable portions
976, 978 can be rotated away from the M.sub.B' in the direction
indicated by arrows R.sub.4, to the position illustrated in FIG.
21. In this position, the flexible member 200d' is tightened across
the second panel member 964. Thus, it is advantageous to configure
the length L.sub.1B' of the flexible member 200d' to produce the
desired tension when the rotatable portions 976, 978 are rotated to
the position shown in FIG. 21.
[0179] It is apparent to one of ordinary skill in the art that the
length L.sub.1B' can be adjusted accordingly to generate the
desired tension and in light of the overall strength of the frame
member 956 and the strength of the flexible member 200d'.
[0180] As shown in FIG. 22, with the flexible member 200d engaged
with the first panel member 962 and the flexible member 200d'
engaged with the second panel member 964, an article to be packaged
992 can be placed between the flexible members 200d, 200d' and
generally aligned with the apertures 984, 986 formed in the first
and second panel members 962, 964, respectively. As such, when the
first and second panel members 962, 964 are rotated towards each
other, in the directions indicated by arrows R.sub.5, such that the
article 992 is disposed between the flexible members 200d, 200d'.
As such, the unsupported spans 991, 993 of the flexible members
200d, 200d' protrude through the apertures 984, 986, respectively
and thereby substantially envelope the article 992 within the
respective flexible members 200d, 200d'. Thus, the article 992 can
be solely suspended by the flexible members 200d, 200d' without
contacting the frame member 956. Accordingly, the cushioning effect
and vibration dampening provided by the assembly 958 are determined
largely by the mechanical characteristics of the material used to
form the flexible members 200d, 200d' and partially to the overall
mechanical characteristics of the frame member 956.
[0181] With reference to FIG. 22, when the rotatable portions 968,
970 and 976, 978 are oriented such that they form an angle .gamma.'
of approximately 90.degree. with the main panel portions 962, 964,
respectively, the assembly 958 defines a maximum overall height H'.
The rotatable portions 968, 970, 976, 978 can be further folded
along the fold lines 972, 974, 980, 982, respectively, away from
the mid-points M.sub.A', M.sub.B' such that the angles .gamma.' are
substantially greater than 90.degree., thereby forming springs. As
such, the assembly 958 can be inserted into a box with a maximum
inner height that is less than H', thus maintaining the rotatable
portions 968, 970, 976, 978 at angles .gamma.' that are
substantially greater than 90.degree..
Suspension Packaging Frame Member
[0182] With reference to FIGS. 23-25, a frame member 1040 is
illustrated therein and identified generally by the reference
numeral 1040. The frame member 1040 shown in FIGS. 23-25 is
constructed substantially identically to the tray members 40, 40',
and 40'' as described in U.S. Pat. No. 7,882,956 which has been
entirely incorporated by reference herein except as noted
below.
[0183] With reference to FIG. 23, the frame member 1040 can also
include additional score lines 1090. In the illustrated embodiment,
the additional score lines 90 extend generally parallel to the fold
lines 1056. Optionally, the score lines 1090 can be arranged
generally concentrically around the central area of the base member
1042. The score lines 1090 can be formed in any of the above-noted
methods for forming fold lines or score lines, or other methods. A
flexible member 1010 is attached to the frame member 1040 via heat
seals such as, 1020a-d, 1022a-b, 1024a-b. For example, for use of a
smaller flexible member 1010, such as for packaging a smaller
article, heat seals 1020a-d can be used which are more centrally
located. For slightly larger flexible members (not shown), heat
seals 1022a-b or heat seals 1024a-b can be used. Of course, as with
the other embodiments of frame members as described herein, other
locations for heat seals can also be used.
[0184] With reference to FIGS. 24 and 25, when a force I is applied
to the article 1070, the score lines 1090 further aid in absorbing
the energy created by the force I by allowing the base member 1042
to further bend. Thus, the arrangement, size, and number of cut
lines 1082 and score lines 1084, 1090 can be adjusted to provide
the desired energy absorption characteristic of the retention
member 200e and frame member 1040.
Suspension/Retention Packaging with a Flexible Wrap
[0185] With reference to FIGS. 26-29, a flexible member 220 is
shown disposed on the frame member 100 and heat-sealed 302e to the
frame member 100 in a generally central portion of the flexible
member 220. In some embodiments, the flexible member 220 can be
heat-sealed or otherwise adhered to the frame member 100 in a
central, non-rotatable portion of the frame member 100. In some
embodiments, the flexible member 220 can be heat-sealed or
otherwise adhered to the frame member 100 in a rotatable portion of
the frame member 100. The flexible member 220 can be a thin sheet
of a resilient material, such as has been described above.
Additionally or alternatively, the flexible member 220 can be a
thin sheet of a non-resilient material, such as a non-resilient
plastic, paper, nylon, fabric, or metallic material, or a
combination of the foregoing. In some embodiments, a coating (not
shown) can be applied to the flexible member 220 before the
flexible member 220 is heat-sealed 302e to the frame member 100 to
strengthen the fiber bonds between the flexible member 220 and the
frame member 100. Additionally or alternatively, in some
embodiments, the methods illustrated in FIGS. 14B and 14C can be
employed to create cavities in the frame member 100 into which
heated portions 323 of the flexible member 220 can flow, either
with or without the application of vacuum pressure to assist the
impregnation of the heated portions 323 of the flexible member 220
into the frame member 100.
[0186] The size and shape of the flexible member 220 can be
selected based on the size and shape of the item 30 to be packaged.
The size of the flexible member 220 can be sufficiently large such
that peripheral portions of the flexible member 220 that have not
been heat sealed 302e or otherwise adhered to the frame member 100
can be wrapped around or across the article 300 to be packaged to
secure the article 300 to the frame member 100. In some
embodiments, when the flexible member 220 is wrapped around the
article 300, a first peripheral edge or side 221 of the flexible
member 220 overlaps a second, opposing peripheral edge or side 222
of the flexible member 220. With reference to FIG. 27, a bond 1095
is illustrated that secures the first peripheral side 221 and the
opposing peripheral side 222 of the flexible member 220. The bond
1095 can be effected in a number of ways, including but not limited
to those described below.
[0187] The bond 1095 can be a heat seal that attaches the first
peripheral side 221 and the opposing peripheral side 222 of the
flexible member 220.
[0188] The bond 1095 can be a piece of adhesive tape applied across
the flexible member 220 to secure the peripheral sides 221, 222 to
one another after the peripheral sides 221, 222 are overlapped.
[0189] The bond 1095 can be any of a variety of glues, double-sided
sticky tape, or other adhesive that is applied between the
peripheral sides 221, 222 of the flexible member 220 and that holds
the flexible member 220 securely around the article 300.
[0190] The bond 1095 can be one or more pressure sensitive adhesive
(PSA) strips between the peripheral sides 221, 222 of the flexible
member 220 that are subjected to pressure and that hold the
flexible member 220 securely around the article 300.
[0191] The bond 1095 can be one or more ultra-violet (UV) activated
adhesive strips disposed between the peripheral sides 221, 222 of
the flexible member 220 that are subjected to UV rays and that hold
the flexible member 220 securely around the article 300.
[0192] For embodiments in which the bond 1095 includes an adhesive,
the bond 1095 can be applied to the flexible member 220 before,
during or after a cutting process while the flexible member 220 is
disposed in a relatively open, flat configuration. Additionally or
alternatively, the bond 1095 can be applied between the peripheral
sides 221, 222 of the flexible member 220 as part of a wrapping
process for securing the article 300 with the flexible member 220
onto the frame member.
[0193] The bond 1095 can be effected by forming the flexible member
220 of a material that sticks to itself, such as polyvinyl
chloride, low-density polyethylene, or polyvinylidene chloride
(PVdC), among others. Alternatively, the flexible member 220 can be
made of a material such as aluminum foil or other deformable
material that is attached to the frame member 100 with an adhesive
(not shown) in place of the heat seal 302e and which can be
deformed to mechanically hold the article 300 in place on the frame
member 100. In other embodiments, a clip, pin, stretchable band, or
moldable strip, such as a piece of wire, can be used to secure the
flexible member 220 to itself so that it retains the article 300 in
place on the frame member 100.
[0194] The bond 1095 can also be effected when the material of the
flexible member 220 is treated to increase its ability to attach to
itself. Examples of such treatments include, but are not limited
to: Corona, Plasma, acid, and heat treatments.
[0195] The bond 1095 can also be a coating that is applied to the
flexible member 220 and that makes the surface of the flexible
member 220 sticky or tacky so that the flexible member 220 sticks
to itself.
[0196] For embodiments in which the bond 1095 includes a coating or
material treatment, the bond 1095 can be applied to the flexible
member 220 before, during or after a cutting process while the
flexible member 220 is disposed in a relatively open, flat
configuration. Additionally or alternatively, the bond 1095 can be
applied to the flexible member 220 as part of a wrapping process
for securing the article 300 onto the frame member.
[0197] In some embodiments, the bond 1095 can be stronger than the
tensile strength of the flexible member 220. In some embodiments,
the bond 1095 can be weaker than the tensile strength of the
flexible member 220.
[0198] It should be noted that although the suspension/retention
packaging illustrated and described with reference to FIGS. 26 and
27 includes the configuration of the frame member 100 as described
with reference to FIGS. 1A and 3A-C, other configurations of the
frame member can also be used with the suspension/retention
packaging illustrated in FIGS. 26 and 27. For example, the
configuration of the frame member 780 illustrated and described
with reference to FIGS. 16-19 can also be used with the
suspension/retention packaging illustrated in FIGS. 26 and 27.
[0199] With reference to FIGS. 28 and 29, the assembly of FIGS. 26
and 27 is illustrated disposed in a box or container 310, with
foldable portions of the frame member 100, 780 folded downwardly to
form angles .gamma.. As described above with reference to FIGS. 4,
10, 18, and 19, the frame member 100, 780 can have some shape
memory, such that fold lines defining the folded portions provide
some resistance to movement. For example, when the frame member
100, 780 is made of cardboard or similar material, the "fibrous
memory" of cardboard creates a cantilever-type spring effect that
can act as a shock absorber for the article 300.
[0200] With further reference to FIG. 29, the wrapped article 300
assembly illustrated in FIGS. 26 and 27 is illustrated as
heat-sealed or otherwise adhered to the frame member 780 that was
described with reference to FIG. 17, in which side walls 798 can be
folded upwardly to limit upward movement of the frame member 780
with respect to the container 310 when a top of the container 310
is closed.
[0201] While at least one exemplary embodiment has been presented
in the foregoing detailed description, it should be appreciated
that a vast number of variations exist. It should also be
appreciated that the exemplary embodiment or embodiments described
herein are not intended to limit the scope, applicability, or
configuration of the claimed subject matter in any way. Rather, the
foregoing detailed description will provide those skilled in the
art with a convenient road map for implementing the described
embodiment or embodiments. It should be understood that various
changes can be made in the function and arrangement of elements
without departing from the scope defined by the claims, which
includes known equivalents and foreseeable equivalents at the time
of filing this patent application.
* * * * *