Abstract:
An insulated packaging insert, and apparatus and a method of producing the insert are disclosed, wherein a sealing and a cutting process for producing the insert from a blank of material optimizes a fit of the insert to a shipping container; minimizes a contamination of the insert; and minimizes a cost of the insert.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/848,737 filed on Oct. 2, 2006, hereby incorporated herein by reference in its entirety. 
     
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to a package insert, and more specifically to an insulated package insert; and an apparatus and a method of producing the insert. 
       BACKGROUND OF THE INVENTION 
       [0003]    Insulated package inserts are used to provide thermal insulation and moisture proof linings to standard shipping containers. U.S. Pat. No. 5,820,268 is exemplary of an insulating container insert of the prior art. The insert is typically produced from a flat sheet of moisture resistant insulating material. The insulating material is formed into a desired shape such as a box adapted to fit into a cardboard shipping container, for example. A series of folds are made and selected edges are joined with adhesive strips or by heat sealing. The finished insert is placed inside the shipping container to form a liner that provides thermal insulation and a moisture barrier for the shipping container. 
         [0004]    Folding the flat sheet of insulating material into the desired shape results in formation of gusseted pouches of superfluous insulating material. The pouches can interfere with the fit of the insert to the associated container. Typically, the pouches must be secured to an outer surface of the insert with an adhesive strip to prevent the pouches from interfering with the fitting of the insert into the associated container. The process of securing the pouches increases the cost of manufacturing. Additionally, the adhesive strip may be damaged or lost during use, thereby allowing the pouches to become separated from secure attachment. 
         [0005]    The pouches are typically located at the closed end of the insert, where the contents of the insert can become trapped. Liquids and dry goods that are placed in the container having such an insert may travel into the pouches and become trapped. The trapped contents create a contamination issue when handling recycled inserts, and reduce the ability to reuse the inserts. 
         [0006]    Known processes for forming the insert typically include the creation of a series of folds to form a closeable top. The manufacturing cost of the insert is increased due to the additional time and labor associated with the folding process employed to form the closeable top. 
         [0007]    It would be desirable to produce an insulated package insert free of pouches to optimize a fit of the insert to a shipping container; to minimize a contamination of the insert; and to minimize the cost of the insert. 
       SUMMARY OF THE INVENTION 
       [0008]    Compatible and attuned with the present invention, an insulated package insert free of pouches to optimize a fit of the insert to a shipping container; to minimize a contamination of the insert; and to minimize the cost of the insert, has surprisingly been discovered. 
         [0009]    In one embodiment, an insert for a container comprises a bottom, a pair of opposing ends and a pair of opposing sides extending upwardly from the bottom forming an open upper end, wherein the insert is formed from a substantially planar sheet of material, the bottom and ends and sides having a single layer of the material. 
         [0010]    In another embodiment, an apparatus for manufacturing an insert for a container from a preformed pouch comprises a frame disposed on a base and having an upper plate and a spaced apart lower plate, the frame adapted to receive an open end of the pouch; and a sealing member disposed on the base adjacent to the frame providing a source of heat energy adjacent the upper plate of the frame, wherein the heat energy is employed to join selected surfaces of the pouch to facilitate forming the insert. 
         [0011]    The invention also provides a method of producing an insert for a package that comprises the steps of providing a pouch formed from a substantially rectangular planar sheet of material, the pouch having one sealed edge and a spaced apart opposing sealed edge, an open end and a spaced apart closed end between the edges; providing a generally box shaped frame to receive the open end of the pouch, the frame effective to shape the pouch into a generally box shaped insert having a bottom, a pair of opposing ends and a pair of opposing sides extending upwardly from the bottom forming an open upper end; folding the material adjacent the bottom of the insert to shape the bottom of the insert and form a pair of spaced apart gusseted pouches extending from the bottom of the insert; forming a seal at the bottom of the insert along an edge of each of the gusseted pouches; and separating the gusseted pouches from the insert. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The above, as well as other advantages of the invention, will become readily apparent to those skilled in the art from the following detailed description of an embodiment of the invention when considered in the light of the accompanying drawings, in which: 
           [0013]      FIG. 1  is a plan view of a blank of material from which the package insert shown in  FIG. 7  is formed; 
           [0014]      FIG. 2  is a perspective view of a preform formed from the blank shown in  FIG. 1  during an intermediate step in producing the insert shown in  FIG. 7 ; 
           [0015]      FIG. 3  is a perspective view of apparatus for producing the package insert illustrated in  FIG. 7  showing a sealing member and a cutting member of the apparatus in an open position; 
           [0016]      FIG. 4  is a perspective view of the preform shown in  FIG. 2  inverted and disposed on the frame shown in  FIG. 3 ; 
           [0017]      FIG. 5  is a perspective view of the preform and frame shown in  FIG. 4  showing the sealing member and the cutting member of the apparatus in a closed position; 
           [0018]      FIG. 6  is a perspective view of the preform and frame shown in  FIG. 6 , the preform partially moved upwardly on the frame showing the cutting member in the closed position to form slits in the preform to provide closure flaps in the completed insert; and 
           [0019]      FIG. 7  is a perspective view in partial section of the completed package insert incorporating the features of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0020]    The following detailed description and appended drawings describe and illustrate an exemplary embodiment of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. In respect of the methods disclosed, the steps presented are exemplary in nature, and the order of the steps is not regarded as necessary or critical. 
         [0021]    Referring now to the drawings and in particular to  FIG. 1 , a substantially planar rectangular blank of material  10  is shown. The blank  10  is employed to form an insert  100 , shown in  FIG. 7 . The insert  100  is designed to be removably received in a container, such as corrugated box, to provide a substantially fluid tight insulated lining to the container. The blank of material  10  is a deformable laminate having a layer  12  of a bubble pack material or air bubble cushioning material and a superposed layer  14  of metallic foil or film. The material is a thermoplastic material to facilitate the formation of welded or heat sealed seams between abutting edges and surfaces of the material. It should be understood that other materials can be used including a non-laminate material such as a polyethylene foam or a bubble pack material; or other laminates such as a layer of metalized polyethylene, metalized polyester, or metalized polypropylene, for example. 
         [0022]    The blank  10  has opposing spaced apart end edges  16 ,  18  and opposing spaced apart side edges  20 ,  22 . The sheet  10  is folded in half along fold line  24 . Once the blank  10  is folded, the abutting portions of the respective side edges  20  and  22  are joined together forming the generally bag shaped preform  26  having the metallic foil layer  14  at the outer surface as shown in  FIG. 2 . The end edges  16 ,  18  are not joined and form an open end of the preform  26 . The sides  20 ,  22  may be joined by heat sealing or by employing an adhesive strip, for example. 
         [0023]      FIG. 3  illustrates an apparatus incorporating the features of the invention. The apparatus is adapted to form the completed insert from the preform  26 . As is clearly seen in  FIG. 3 , the apparatus includes pairs of like members. For clarity, only one of the like members is described in detail. 
         [0024]    The apparatus includes a base  52  having a frame  54  disposed thereon. The frame  54  has an upper plate  56  and a spaced apart lower plate  58 . Vertical members  60  are disposed between plates  56 ,  58  to maintain the upper plate  56  in spaced apart relation to the lower plate  58 . A pair of elongate members  62  is disposed on opposing edges of the upper plate  56 . The frame  54  is adapted to be received by the open end of the preform  26 , as shown in  FIG. 4 . 
         [0025]    The apparatus includes a pair of cutting arms  64  hingedly attached to opposing sides of the lower plate  58 . The arms  64  can be pivoted between an open position as shown in  FIGS. 3 and 4  and a closed position as shown in  FIGS. 5 and 6 . The arms  64  are substantially coextensive in length to the side of the frame  54  to which the arms  64  are attached. 
         [0026]    An actuator mechanism is employed to simultaneously move the arms  64  between the open and the closed position. In the illustrated embodiment, a cable  68  is attached to each of the arms  64 . The cables  68  are simultaneously slackened or tightened to cause the arms  64  to move to the open position or the closed position, respectively. The slackening and tightening of the cables  68  can be accomplished manually or through an automated means such as a remote electric motor and spool assembly (not shown) to wind and unwind the cables  68  thereon, for example. 
         [0027]    A cutting blade  70  is disposed on each of the vertical edges of the cutting arms  64 . The blades  70  are adapted to contact the outer surface of the preform  26  adjacent the open end when the arms  64  are in the closed position, as shown in  FIGS. 5 and 6 . A guard  72  is disposed on the arms  64  adjacent each blade  74 . The guard  72  shields the blade  74  from inadvertently contacting the user of the apparatus or other materials that may be in the vicinity of the apparatus. 
         [0028]    A sealing member  74  is disposed on and supported by the base  52  in a spaced relation to the frame  54 . The sealing member  74  includes an upstanding support frame  76  having a rotatable cross member  78  suitably supported in journal bearings  79  disposed thereon. A pair of elongate spaced apart bars  80  is attached to the rotatable cross member  78 . The rotatable cross member  82  is adapted to allow the bars  80  to be pivoted between an open position as shown in  FIGS. 3 ,  4 , and  6  and a closed position as shown in  FIG. 5 . The bars  80  are adapted to juxtapose over the elongate members  62  when the bars  80  are moved to the closed position. 
         [0029]    An electrically powered heating element  82  is disposed on each of the bars  80 . The heating elements  82  are in electrical communication with a source of electrical energy (not shown). The heating elements  82  transform the electrical energy into heat energy, which is employed to join surfaces of the blank  10  to facilitate the manufacture of the insert  100 . A control device can be provided to control the heat energy provided by the heating elements  82 . A handle  84  is attached to the bars  80  to facilitate an operator of the apparatus moving the bars  80  between the open position and the closed position, and applying a downward force on the bars  80  against the elongate members  62  while in the closed position. It should be understood that the apparatus may include an automated means of moving the bars  80  to the open position and the closed position. 
         [0030]    Although only a source of heat energy is associated with the sealing member  74 , it should be understood that cutting means (not shown) can be provided in addition to the source of heat energy. The cutting means employed to separate any superfluous material from the insert  100 . 
         [0031]    The steps for forming of the completed insert  100  from the preform  26  employing are illustrated in  FIGS. 4 ,  5 , and  6 . The bars  80  and the arms  64  of the apparatus are disposed in the open position as shown in  FIG. 4 . The preform  26  is opened by spreading the mid-sections of the edges  16  and  18  and thereby causing the joined edges  20  and  22  to move toward each other forming the open end in the preform  26  between the ends  16 ,  18 . The preform  26  is inverted from the position illustrated in  FIG. 2  and the open end of the preform  26  is received by the frame  54 . The preform  26  is oriented on the frame  54  to substantially center the joined edges  20  and  22  in respect to the respective sides of the frame  54  having the elongate members  62  and the cutting arms  64 . 
         [0032]    The operator caused the preform  26  to be moved downwardly on the frame  54  until the closed end of the preform  26  contacts the upper plate  56 . When the preform  26  is fully received on the frame  54 , the preform  26  conforms to the general rectangular shape of the frame  54  forming the substantially rectangular sidewalls  104  of the completed insert  100 . The bottom  102  of the insert  100  is defined by folding the preform  26  along lines  90 ,  90 ′ and  92 ,  92 ′ shown in  FIG. 4 . The folds shape the closed end  102  of the insert  100  to conform to the generally rectangular shape of the upper plate  56  of the frame  54 . Additionally, the shaping of the preform  26  to the frame  54  and the folds  92 ,  92 ′ form a pair of spaced apart upstanding triangular pouches  94 ,  94 ′ adjacent the folds  92 ,  92 ′, respectively. The pouches  94 ,  94 ′ are formed of superfluous material that is removed from the preform  26  to form the insert  100 . 
         [0033]    To remove the pouches  94 ,  94 ′, the pouches  94 ,  94 ′ are folded inwardly along the fold lines  92 ,  92 ′, as shown in  FIG. 5 . The bars  80  are then pivoted downwardly to the closed position. In the closed position, the heating elements  82  are in contact with a side of the pouches  94 ,  94 ′ along the fold lines  92 ,  92 ′, respectively. The heat energy from the heating elements  82  cause the material of the insert  100  to become plastic and thereby after sufficient cooling forms a sealed seam  96 . the sealed seam  96  is more clearly illustrated in  FIG. 7 , along each fold line  92 ,  92 ′. 
         [0034]    After the bars  80  are moved to the open position, the pouches  94 ,  94 ′ are cut from the preform  26 . The cuts to remove the pouches  94 ,  94 ′ are made outboard of the sealed seam  98  to maintain the substantially fluid tight nature of the insert  100 . The process of cutting can be accomplished by manual means or an automated cutting means (not shown). The elongate members  62  provide a guide for a knife or other cutting tool to facilitate a straight cut to remove the triangular pouches  94 ,  94 ′. 
         [0035]    Next, the cutting arms  64  are moved to the closed position, as shown in  FIGS. 5 and 6 . When in the closed position, the cutting blades  70  are caused to contact and penetrate the material forming the sides of the preform  26 . The preform  26  is then moved upwardly on the frame  54  as shown in  FIG. 6 . As the preform  26  is moved upwardly, the cutting blades  70  form slits  98  in the preform  26  adjacent the vertical corners formed therein. The slits  98 , shown partially formed in the preform  26  in  FIG. 6 , originate at a selected point along the corners and extend vertically to the open end of the preform  26  creating the foldable top flaps  106  in the completed insert  100 . Each flap may be folded inwardly along a respective fold line  99  forming a closed top to the insert  100 . 
         [0036]    The flaps  106  formed by the cutting the slits  98  eliminate the costly labor associated with making a series of folds to create the closed top. Further, the flaps  106  are formed as part of the process of shaping the preform  26  into the completed insert  100 . By completing these two manufacturing steps in the same process, the manufacturing cycle time is shortened, which reduces a manufacturing cost of the insert  100 . 
         [0037]    The apparatus can also produce an insert without the flaps  106 . To produce the insert  100  without the flaps  106 , the arms  64  can be maintained in the closed position when the preform  26  is received on the frame  54 . This arrangement positions the preform  26  over the arms  64  and the frame  54 , rather than between the arms  64  and the frame  54 , which prevents the cutting blades  70  from contacting the preform  26  and cutting the slits  98  to form the flaps  106 . Alternatively, the arms  64  can be maintained in the open position for the entire manufacturing process, which also prevents the cutting blades  70  from contacting the preform  26  and cutting the slits  98  to form the flaps  106 . 
         [0038]    The completed insert  100  formed from the preform  26  employing the apparatus is shown in  FIG. 7 . The insert  100  has the bottom  102  with the sidewalls  104  extending upwardly from the respective edges  90 ,  90 ′,  92 ,  92 ′ of the bottom  102 . The sidewalls  104  include the flaps  106  extending therefrom which can be folded inwardly along the line  99  to form a closed top to the insert  100 . 
         [0039]    An adhesive strip  108 , such as a double sided pressure sensitive adhesive strip, can be disposed on at least one of the flaps  106 . The fastener  108  is adapted to secure the flaps  106  in the closed position. Additionally, an adhesive strip  110 , similar to the strip  108 , can be disposed on a outer surface of at least one of the sidewalls  104 . The adhesive strip  110  is adapted to secure the insert  100  within the container, such as the cardboard box, for example. The process of disposing the adhesive strips  108 ,  110  on the insert  100  can be accomplished by manual means or automated means (not shown). 
         [0040]    A single layer of material is present in the bottom  102  and sidewalls  104  of the insert to optimize the fit of the insert  100  to a shipping container. Additionally, the removal of the pouches  94 ,  94 ′ from the insert  100  eliminates the pouches  94 ,  94 ′ as a location for liquids and dry goods that are placed in the insert to be trapped which increase the ability to reuse the insert  100 . 
         [0041]    The completed insert  100  is manufactured at a minimized cost compared to the inserts of the prior art. Rather than making a multitude of precision folds as is required to make the inserts disclosed in the prior art, only the fold  24  and the pair of folds  92 ,  92 ′ are required to form the insert  100 . The reduced number of folds in the insert  100  reduces the labor cost to manufacture the insert  100  in respect to the inserts disclosed in the prior art. 
         [0042]    Additionally, manufacturing the insert  100  from the substantially rectangular planar blank of material  10  eliminates the necessity to pre-cut the sheet to a selected shape to facilitate the forming of the insert. The blank  10  can be obtained from a roll of the material by making a simple straight line cut across the width of the roll of material. The simple straight line cut can be completed quickly and economically as compared to die cutting a sheet to a selected shape or cutting a sheet to conform a selected pattern. 
         [0043]    From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.