Patent Publication Number: US-6981356-B2

Title: Compact packaging for garments made from delicate materials

Description:
CROSS-REFERENCE TO RELATED MPLICATION 
   This application represents a divisional application of U.S. patent application Ser. No. 09/826,924 filed Apr. 6, 2001, now U.S. Pat. No. 6,802,418. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention pertains to the art of packaging and, more specifically, to a compact packaging arrangement for garments made from delicate materials, particularly hosiery items. 
   2. Discussion of the Prior Art 
   There is a wide range of delicate garments sold in the marketplace today. Such garments encompass various items which collectively can be classified as hosiery, including stockings, leggings, knee-highs, panties, pantyhose, many undergarments and the like. A common characteristic of these types of garments is the delicate nature of the materials from which they are made, e.g., nylon, LYCRA, spandex, silk and the like. Due to the delicate nature of the material, particular care must be taken in packaging these types of garments in order to minimize tears or runs. 
   In the past, these types of delicate garments have been either sold in rather bulky packages or simply without separate packaging in order to minimize the possibility of damaging the items. However, bulky packaging is not considered to be economically advantageous. For instance, higher amounts of packaging materials are needed to form bulky packages as compared to compact packages. In addition, transportation and storage costs are inherently higher in connection with larger packaging. Furthermore, valuable store space can be wasted in displaying a product in bulky packaging as compared to a compact packaging arrangement. Providing products without packaging has applicability to sales in certain merchandise stores, but is not suitable for many other applications. 
   A significant improvement in the art of packaging delicate garments is considered to be presented in U.S. Pat. No. 5,692,606. The invention covered by the &#39;606 patent recognized the desire to present hosiery in an extremely compact package that can be manufactured, stored, shipped and displayed, as well as carried by consumers in a pocket or handbag, in a convenient and economical manner. Particularly advantageous in connection with the hosiery package disclosed in this patent is not only the compact nature of the package, but also the ability of the hosiery to readily assume an uncompressed state as soon as the package is opened. In this manner, the product can be carried by the user, while also being easily and conveniently useable. 
   Although significant improvements in the compact packaging of delicate garments have been made in the recent past, there still exists a need in the art for improvements relating to providing both additional assurance against damaging the garments during packaging and enhanced packaging systems. In addition, although various specific packaging arrangements have been proposed in the art, there still exists a need for an improved package which represents an economical and reliable package which can provide for enhanced consumer appeal and provide additional safeguards against potential product damage. 
   SUMMARY OF THE INVENTION 
   The present invention is directed to a compact packaging arrangement for delicate garments, wherein the packaging is designed to safeguard against damaging the delicate materials of the garments during packaging thereof. In accordance with the invention, each garment package includes a container body within which a garment is received, and a cover insert arranged within an upper portion of the container body. Preferably, the cover insert includes a cover member provided with a plurality of openings designed to permit air to pass through the cover member as the cover member is placed within the container body. In addition, the cover member is also preferably provided with a pull tab element, preferably a pivotable ring element, for use in connection with removing the cover member to access the garment. In one preferred embodiment of the invention, a buffer material is positioned atop the garment within the container body, between the garment and the cover member, to safeguard the garment from potential damage by the insertion of the cover member. 
   The package also includes a cap adapted to extend over the container body so as to seal the container body. In accordance with a most preferred form of the invention, upper interior wall portions of the container body are formed with projections beneath which the cover member is placed, thereby retaining the cover member in a position which maintains the garment in place until the cover member is manually removed. Similar projections are also provided on inner wall portions of the cap which cooperate with a lip provided about an open end of the container body in order to secure the cap atop the container body. 
   A machine and corresponding method for packaging the delicate garments are also provided. In accordance with these aspects of the invention, a fluid source, such as a pneumatic source, is utilized to generate a pressure differential in a delivery or pre-load tube in order to initially draw and then direct the garment, preferably followed by the buffer material, to a pre-positioned container body. Thereafter, the fluid source is used to shift a piston which forces the garment and buffer material into the container body, while also placing the cover member in a position of garment retention. Subsequently, the cap can be suitably positioned to complete the main package. In accordance with one preferred embodiment of the invention, a sealing arrangement is employed to further retain the cap on the container body. The sealing arrangement can include an upper extension having an aperture for hanging the package from a store display rod. 
   The machine for performing the packaging includes the fluid source, as well as a multi-positioning system designed to systematically arrange the container body for receipt of the garment and buffer material and, subsequently, the cover member. In a semi-automatic form of the machine, provisions are made to assure the safe operation of the machine by either requiring specific placement of the hands of a user during specific phases of operation, or by preventing operation of the machine when the user&#39;s hands are sensed in the actual work zones. 
   Additional objects, features and advantages of the present invention will become more fully apparent from the following detailed description of the invention when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an upper perspective view of a compact package for a delicate garment constructed in accordance with the present invention; 
       FIG. 2  is a partial exploded view of the compact package of  FIG. 1 ; 
       FIG. 3  is a further exploded view of the compact package of  FIG. 1 ; 
       FIG. 4  is an upper right perspective view of a packaging machine, constructed in accordance with a preferred embodiment of the invention, shown in both initial and final packaging stages; 
       FIG. 5  is a front plan view of the packaging machine in the stages of  FIG. 4 ; 
       FIG. 6  is an upper right perspective view of the packaging machine of  FIG. 4  in a subsequent packaging stage; 
       FIG. 7  is a front plan view of the packaging machine of the stage of  FIG. 6 ; 
       FIG. 8  is an upper right perspective view of the packaging machine of  FIG. 5  in a still further packaging stage; and 
       FIG. 9  is a front plan view of the packaging machine in the stage of  FIG. 8 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   With initial reference to  FIGS. 1–3 , a compact package, designed for garments made from delicate materials, is generally indicated at  2 . Package  2  includes a container body  6 , which is preferably molded, such as through an injection molding or blow molding process, of plastic so as to include a plurality of upstanding walls, one of which is indicated at  9 , a closed bottom  14  and an open upper end  16 . With this construction, open upper end  16  leads to an interior storage chamber  19  defined within container body  6 . As clearly shown in  FIGS. 2 and 3 , the upper inside surface portion (not separately labeled) of storage chamber  19  is formed with a plurality of inwardly extending projections  30 – 33 . In the most preferred form of the invention, container body  6  is transparent. As also shown in these FIGS., container body  6  is preferably provided with an annular, outwardly projecting lip  37  at open upper end  16 . 
   Package  2  also includes a cover member  40  which is defined by a base  43  and an upstanding annular sidewall  45 . As shown, base  43  is provided with a plurality of openings  47 . In the most preferred embodiment, base  43  is curved so as to include a concave upper side and a convex lower side. Cover member  40  also includes a pull-tab  58  that preferably takes the form of a ring. Pull-tab  58  is preferably connected to a portion of annular sidewall  45  through a living hinge generally indicated  60 . Therefore, pull-tab  58  can pivot from the position shown in  FIGS. 2 and 3  to a position wherein pull-tab  58  is arranged below an upper edge (not separately labeled) of annular sidewall  45 . In the most preferred embodiment, cover member  40  is preferably injection molded of plastic. 
   Package  2  also includes a cap member  65  which is also preferably formed of plastic, however, most preferably of an opaque, colored plastic. Cap member  65  includes a smooth top  68  and a depending, annular sidewall  70 . As best shown in  FIG. 2 , extending inwardly at space locations along annular sidewall  70  are projections  72  and  73 . In the most preferred embodiment, additional projections are provided along annular sidewall  70  opposite each of projections  72  and  73  as well. Furthermore, cap member  65  is formed with a flange  78  projecting from annular sidewall  70 . 
   The exploded view of  FIG. 3  clearly depicts the presence of a garment  83  within storage chamber  19 . In accordance with the invention, garment  83  is formed of a delicate material, such as nylon, LYCRA, silk or the like, which can be easily torn or caused to run. In the most preferred form of the invention, garment  83  constitutes a pair of pantyhose. However, a wide range of products which can be generically classified as “hosiery”, including stockings, leggings, knee-highs, panties and various other undergarments, even including sheer bras, could be utilized. At this point, it is important to note that the package  2  of the present invention is specifically designed to compensate for the type of material utilized to form garment  83 . To this end, in accordance with one preferred form of the invention, package  2  is also provided with a buffer material  86  which is adapted to be arranged upon garment  83  in storage chamber  19  as will be discussed more fully below. The particular manner in which the entire package  2  is assembled will also be detailed fully below. 
   Package  2  can also include a seal and hanger assembly  90  (see  FIG. 1 ) including a plastic strip  92  which is preferably, adhesively secured to opposing upstanding walls  9  and along top  68  of cap member  65 . As shown, plastic strip  92  is integrally formed with an upstanding hanger member  94  having an aperture  96  for use in connection with hanging package  2  from a conventional display hook or rod in a merchandising store. Also shown on package  2  is a band  100  that extends around terminal end portions (not separately labeled) of plastic strip  92 . Band  100  can actually be constituted by a thin strap or can be defined by an elongated label extending down container body  6 . 
   As indicated above, package  2  is specifically designed to store a garment  83  in a compact manner. In general, storage chamber  19  preferably has a total volume of less than 10 in 3  (164 cm 3 ). In accordance with the most preferred embodiment of the invention wherein garment  83  constitutes a pair of pantyhose, container body  6  is generally square in cross-section, with each of upstanding walls  9  having a cross-sectional side dimension of approximately 1.25 inches (3.175 cm) and a height of approximately 4 inches (10.16 cm). Therefore, container body  6  has an associated volume of approximately 6.25 in 3  (102.4 cubic cm 3 ). In any event, storage chamber  19  is rather small and must maintain garment  83  therein in a compact manner. More specifically, in order to present garment  83  within container body  6 , it is necessary to compress garment  83  within storage chamber  19  to multiple times a loose, uncompressed form of garment  83 . To this end, the compact package  2  of the present invention is intended to represent an improvement in the particular packaging for storing hosiery in the manner disclosed in U.S. Pat. No. 5,692,606 which is incorporated herein by reference. 
   Therefore, the packaging in accordance with the present invention is accomplished by compressing garment  83  into storage chamber  19 , with garment  83  being compressed to multiple times the loose, uncompressed form thereof. Cover member  40  is adapted to be inserted into storage chamber  19  of container body  6  to retain garment  83  in place. However, due to the delicate nature of the material of garment  83 , the present invention preferably incorporates buffer material  86  which is formed separate from garment  83  and is arranged upon garment  83  within storage chamber  19 . In accordance with the invention, buffer material  86  is formed from either a light paper material or fabric, even the delicate fabric from which garment  83  is itself formed. In any event, since cover member  40  is inserted into storage chamber  19 , there would be the possibility of pinching or otherwise damaging garment  83 . However, with buffer material  86  arranged atop garment  83 , cover member  40  can be safely inserted within storage chamber  19 . During insertion, annular sidewall  45  of cover member  43  abuts projections  30 – 33  and base  43  will further bow or distort in order to enable cover member  40  to reach the position shown in  FIG. 2 . Thereafter, cap member  65  can be placed upon container body  6 . Of course, pull-tab  58  will be maintained in a lowered position below cap member  65 . Due to the interaction between at least projections  72  and  73  of cap member  65  and annular lip  37  of container body  6 , cap member  65  will be snap-fitted upon container body  6 . Thereafter, if package  2  is to be hung from a conventional display hook, seal and hanger assembly  90  can be attached as described above. 
   Reference will now be made to  FIGS. 4–9  in describing a semi-automated machine  102  utilized in assembling package  2 . As shown, machine  102  includes a housing  106  supported by various pedestal legs  109 ,  110  which terminate in respective support feet  112 ,  113 . As shown, housing  106  includes a frontal opening  116  defined by a front ledge  119  of a front wall  121  of housing  106 , respective sidewalls  126  and  127  and a top segment  130 . Adjacent top segment  130 , along sidewall  126 , is a vertically open section  134 . 
   Provided within housing  106  is a platform  140  which is supported upon a floor  141  for lateral shiftable movement along rails  142 . Platform  140  includes a base  143 , a pair of opposed, angled side plates  145  and  146 , and a rear plate  148 . Between angled side plates  145  and  146  is arranged a shiftable, intermediate support plate  150 . Upon base  143  is fixedly secured a container holder  152  which includes a cylindrical support  155  provided with a central bore  157 . Intermediate support plate  150  supports a pre-load tube  161  having an upper opening  163 , a venturi zone  166  and a terminal discharge nozzle  169 . 
   Mounted above top segment  130  is a plate  180  which supports a plunger device  183 . Plunger device  183  includes a plunger piston rod  186  having an exposed, terminal head  187 . Plunger piston rod  186  is adapted to extend from and retract within a cylinder  189  of plunger device  183  as will be discussed more fully below. Also shown in these Figures, machine  102  includes a main power controller  192  having various buttons (not separately labeled) for on, off and pause operational states of machine  102 . Finally, machine  102  is shown to include a pair of finger housings  198  and  199  which, as will be detailed below, are provided to initiate a packaging sequence for machine  102  while functioning to assure a safe positioning of the hands of an operator during use of machine  102 . 
   In preparing package  2  with semi-automatic machine  102 , container body  6  is initially placed in a non-rotatable position within central bore  157  of holder  152 . Furthermore, cover member  40  is positioned within a lower opening (not shown) formed in terminal head  187  of plunger piston rod  186 . In accordance with the most preferred form of the invention, machine  102  is preferably, pneumatically operated. For simplicity, the pressurized air source and the respective pneumatic lines have not been shown in the drawings, along with the requisite electrical connections. However, from the following detailed description, the overall operation will be readily apparent to one of ordinary skill in the art. As will be detailed below, pneumatic pressure is utilized in loading garment  83  and buffer material  86  within storage chamber  19 , laterally shifting platform  140  along rails  142 , and both extending and retracting plunger piston rod  186 . In accordance with a preferred embodiment, the pneumatic source supplies approximately 90–100 psi, while developing a force of approximately 200 psi for plunger device  183 . In any event, other power sources and force ranges could be readily employed, particularly dependent upon the percentage to which garment  83  is to be compressed within container body  6 . 
   In accordance with the present invention, once container body  6  and cover member  40  are positioned within support  155  and terminal head  187  as discussed above ( FIGS. 4 and 5 ), the operator must engage electrical buttons (not labeled) provided in housings  198  and  199  in order to initiate and maintain an operating cycle for machine  102 . Once the operation cycle is initiated, support plate  150  is lowered to the position shown in  FIGS. 6 and 7  wherein discharge nozzle extends about upper end  16  of container body  6 . Most preferably, the lowermost inner end of discharge nozzle  169  is internally grooved to a thickness corresponding to a thickness of each of sidewalls  9 . In this position, garment  83  is dropped into upper opening  163  of pre-load tube  161 . Utilizing a pneumatic supply at venturi zone  166 , a suction effect is developed between upper opening  163  and venturi zone  166 , while air is blown from venturi zone  166  toward discharge nozzle  169 . In this manner, garment  83  is readily drawn into pre-load tube  161  and forced down towards discharge nozzle  169 . Therefore, when garment  83  is dropped into upper opening  163 , garment  83  will be forced down to discharge nozzle  169  and even a portion of garment  83  can extend into container body  6 . Thereafter, buffer material  86  is optionally, but preferably, dropped into upper opening  163  such that buffer material  86  is arranged atop garment  83  within pre-load tube  161 . Although not specifically shown in the drawings, it should be understood that pre-load tube  161  is internally tapered such that garment  83  and buffer material  86  are pre-loaded into a portion of tube  161  which essentially has internal dimensions substantially equal to that of storage chamber  19 . 
   Once this initial sequence pre-load is accomplished, an operator must again insert one or more fingers in respective finger housings  198  and  199 . Again, though not individually shown, buttons or other switching devices are provided within finger housings  198  and  199  which have to be engaged by the user to initiate the automatic operating sequence for machine  102 . Once the fingers of the user are properly positioned within finger housings  198  and  199 , machine  102  will next proceed on shifting platform  140  laterally until pre-load tube  161  is arranged directly beneath plunger device  183  as clearly shown in  FIGS. 8 and 9 . Thereafter, plunger piston rod  186  will be automatically extended within pre-load tube  161  thereby causing garment  83  and buffer material  86  to be compressed into storage chamber  19 , while also inserting cover member  40  within container body  16 . 
   In this preferred embodiment, buffer material  86  protects garment  83  from any direct engagement with cover member  40 , thereby preventing damage to garment  83 . During this step, garment  83  and buffer material  86  are each compressed to multiple times their associated loose densities and are retained in this compressed state due to the positioning of cover member  40 . During this compression, openings  47  in cover member  40  advantageously permits the exhausting of air being displaced from storage chamber  19 . Once cover member  40  is properly positioned, plunger piston rod  186  is automatically retracted, platform  140  is again laterally shifted, and intermediate support plate  150 , with pre-load tube  161 , is raised back to the position shown in  FIGS. 4 and 5 . At this point, one complete cycle of machine  102  is complete. The operator&#39;s fingers can then be removed from housings  198  and  199  such that container body  6  can be removed from central bore  157  of support  155 . During a subsequent assembly phase, cap member  65  and, if desired, seal and hanger assembly  90 , are applied to complete package  2 . 
   With the above construction, package  2  can advantageously maintain a pair of pantyhose or another delicate garment in a compressed state within container body  6 , while enabling garment  83  to be easily removed upon flipping off cap member  65 , pivoting and lifting pull-tab  58  in order to remove cover member  40 , and then withdrawing buffer material  86 . Thereafter, garment  83  can be readily pulled from storage chamber  19  for immediate use. In any event, although described with respect to preferred embodiments of the invention, it should be readily understood that various changes and/or modifications can be made to the invention without department from the spirit thereof. For instance, it should be readily apparent that, although machine  102  is constructed for semi-automatic operation, a fully automated system could be employed. In addition, although housings  198  and  199 , along with their associated buttons or switches, are shown to be provided for operator controlling and safety purposes. Various other systems could be equally employed. For instance, a foot actuator pedal controller, in combination with a safety light curtain provided at frontal opening  116 , could be utilized. Regardless, the invention is only intended to be limited by the scope of the following claims.