Patent Publication Number: US-2005139509-A1

Title: Packaging module

Description:
This application is a Continuation of pending application Ser. No. 10/133,776, filed Apr. 26, 2002. 
    
    
      This invention relates to a packaging module. More particularly, this invention relates to a packaging module using loose fill packaging elements,  
      As is known, various types of materials have been used for shipping fragile items in containers of various types. In some cases, loose fill elements of foamed plastic are poured into a container to form a cushioning layer and then the item to be transported is placed on top of the loose fill elements. This is followed by pouring additional loose fill elements into the container to completely surround the item being packaged. Upon arrival at the ultimate destination, a user opens the container in order to remove the item. In doing so, the loose fill elements are usually first separated so that the item can be exposed and then the item is removed from the container. This generally creates at least two problems.  
      First, upon opening of the container and separation of the loose fill elements to access the packaged item, the loose fill elements generally spill over and out of the container. These loose fill elements must then be collected, generally, manually and placed back into the container for disposal purposes. This can be bothersome and time consuming.  
      Second, the loose fill elements usually have static electricity that causes the elements to stick to the hands and clothing of the user as well as to other surfaces outside the container. Thus, these elements also have to be manually removed and placed back into the container.  
      In other cases, foamed-in-place materials have been used. In these cases, an item is placed in a shipping carton and then a foamable material is directed into the container about the item so that upon foaming, the material molds to the shape of the item. However, this type of packaging technique is cumbersome and relatively expensive.  
      Accordingly, it is an object of the invention to provide a relatively simple technique for packaging an item with loose fill elements without the inconvenience of having the elements scatter upon opening of a container to remove the item.  
      It is another object of the invention to provide loose fill elements in prepackaged modules.  
      It is another object of the invention to provide loose fill elements in prepackaged modules sized to fit containers for the packaging of items in the containers.  
      It is another object of the invention to provide a module of free flowing loose fill elements that can be made into a packaging pre-form with a pocket to receive an item in mating relation,  
      Briefly, the invention provides a packaging module comprised of a porous deformable membrane defining an enclosed space and a mass of loose fill elements disposed within the membrane and occupying an amount of space sufficient to permit the membrane to be shaped about an item of three dimensional shape to be packaged and to permit the elements to move within the membrane to accommodate the three dimensional shape of the item.  
      In one embodiment, the membrane is in the form of a net bag, for example made of plastic. In this respect, the membrane is characterized in being deformable in three dimensions. That is to say, the bag may be deformed from a cylindrical shape into a spherical shape, a three-dimensional shape having a pocket, or a shape to envelop an item, such as a sphere, cube, or other regular or random shape.  
      A single module may be used for packaging an item. In this respect, the item to be packaged is placed on the module and the module shaped about the item. The enveloped item may then be placed in a box or carton in a snug fit manner. After closing, the box or carton may then be transported.  
      Multiple modules may also be used for packaging an item. For example, an item may be placed between two modules in sandwich-like manner. This unit may then be placed in a shipping container for shipping purposes. Alternatively, the unit may be wrapped with a shrink wrap material so that the unit is completely sealed. A shipping label may then be placed on the outside of the wrapped package for shipping purposes. Also, the unit may be held together by strips or bands of adhesive tape and shipped in that condition.  
      In another embodiment, a module may be placed on the bottom of a container with the item to be packaged simply placed in the center of the module in an upstanding manner. A second module may then be placed over the top of the item and the container closed over the upper module so as to slightly compress the modules within the container. In this embodiment, the two ends of the item are held by the two modules while the middle of the item is spaced from the side walls of the container. In such embodiment, there is no need for any loose fill elements to surround the middle of the item. This results in a savings of loose fill elements for packaging purposes.  
      In another embodiment, the packaging module is formed into a pre-form with a pocket to receive an item of three-dimensional shape. In this embodiment, the membrane is a net bag and the loose fill elements are made of starch. In order to make the pre-form, a three dimensional forming blank sized and shaped to the item to be packaged is placed on a support surface. Next, the module is placed over the blank and pressed down and around the sides of the blank. While in this state, moisture in the form of a spray of steam is introduced into the module to cause the loose fill elements of starch to bond together and form an agglomerated one-piece pre-form of stable shape with a pocket. The pre-form is then removed from the blank and additional pre-forms made in the same fashion. The resulting pre-form may then be placed, for example, in the bottom of a carton to receive a suitably sized and shaped three dimensional item in the pocket in mating relation. A second pre-form or a second unprocessed packaging module may then be placed over the item and the carton closed.  
      When processing a packaging module into a pre-form as above, the space about the forming blank may be limited by a box-like construction so that the pre-form takes on a rectangular shape suitable for fitting into a carton of rectangular shape.  
      Alternatively, instead of using loose fill elements of starch, the elements may be made of a foamed plastic, such as expanded polystyrene, and may be coated with a suitable heat sensitive adhesive, latex or similar material so that upon heating or spraying on of a solvent, the elements become bonded to each other to form an agglomerated one-piece pre-form of stable shape with a pocket. 
    
    
      These and other objects and advantages of the invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings wherein:  
       FIG. 1  illustrates and exploded view of the module constructed in accordance with the invention and an item to be packaged in the module;  
       FIG. 1A  illustrates a cross-sectional view of the module of  FIG. 1 ;  
       FIG. 2  illustrates the module and item of  FIG. 1  being deposited into a shipping container;  
       FIG. 3  illustrates a view of the module of  FIG. 1  being used as a shipping container;  
      Pie.  4  illustrates an exploded view of a modified embodiment employing a pair of modules constructed in accordance with the invention;  
       FIG. 5  illustrates the unit of  FIG. 4  being placed in a shipping container;  
       FIG. 6  illustrates a cross sectional view of the unit of  FIG. 4  with a shrink wrap film thereabout to form a shipping container;  
       FIG. 7  illustrates a cross-sectional view of a pair of modules being used to package an item in a shipping container; and  
       FIG. 8  illustrates a cross-sectional view of a plurality of layers of items packaged between layers of packaging modules in a carton in accordance with the invention. 
    
    
      Referring to  FIG. 1A , the packaging module  10  is formed of a porous deformable membrane  11  and a mass of loose fill elements  12 .  
      The membrane  11  is made of a net bag, for example of plastic, that is characterized in being deformable in three dimensions. That is to say, the bag may be deformed from a cylindrical shape into a spherical shape, a three-dimensional shape having a pocket, or a shape to envelop an item, such as a sphere, cube, or other regular or random shape. The net bag is formed with mesh openings that are sized to be smaller than the individual loose fill elements  12  in order to retain the elements  12  in place while allowing the bag to be deformed in a three-dimensional manner. Typically, the net bag is formed with criss-crossing fibers that define a rectangular mesh opening. However, the bag may be formed with mesh openings of diamond shape or any other suitable shape. Likewise, the net bag may be made of any other suitable material than plastic.  
      The membrane  11  is typically formed as a hollow tube in any conventional manner. One end of the tube is then closed, for example by a staple  13 , or by heat seal crimping and the tube  12  from the opposite end. The remaining end of the tube is then closed in a similar manner, for example by a second staple  14 .  
      By way of example, a machine constructed in a manner as described in U.S. Pat. No. 6,035,606 but to a smaller scale may be used for forming a plurality of modules  10 .  
      Typically, the loose fill elements  12  do not completely fill the membrane II. For example, the loose fill elements  12  need only occupy approximately 80 to 90 percent of the volume of the membrane  11 . However, in some cases, the entire membrane  11  may be filled with the elements  12 .  
      The loose fill elements  12  are made of starch or a foamed plastic, for example of expanded polystyrene, polyethylene, polyurethane or polypropylene. However, other suitable loose fill materials may be used such as, chopped blocks of rubber, scrap polymer materials, wood chips, shredded paper, popcorn and the like.  
      Referring to  FIG. 1 , in order to package an item such as a ball  15 , a module  10  is deformed from a generally tubular shape in which the module  10  is usually fabricated into a cubic shape that envelopes the ball  15 . To this end, the module  10  is initially flattened and then a pocket  16  is formed in the center of the module  10 , for example by manually manipulating the module  10 . At this time, the elements  12  freely shift within the membrane  11  to accommodate the reshaping of the module  10 .  
      Once a pocket  16  is formed, the ball  15  is placed in the pocket  16  and the module  10  further manipulated about the ball  15  into a condition, for example as shown in  FIG. 2  with the bail  15  completely surrounded by the module  10 .  
      Referring to  FIG. 2 , the module  10  and the enveloped ball  15  are then deposited into a shipping container  17  of conventional structure so that the module  10  is snugly fit within the container  17 . A plurality of flaps  18  on the container  17  may then be closed so as to push down on the module  10  and maintain the ball  15  in a non-movable condition within the container  17 .  
      The closed container may then be shipped to an ultimate user in any suitable manner. Upon arrival, the ultimate user would simply open the container  17  and remove the module  10  and enveloped ball  15 . The module  10  would then be unwrapped from the ball  15  and the ball retrieved. The module  10  of loose fill elements  12  and then be replaced in the container  17  for disposal purposes. Also, the module  10  of loose fill elements  12  may be reused for packaging purposes by the user.  
      Since the loose fill elements  12  are contained within the net bag  11 , there is little or no risk of the elements  12  spilling out of the container  17  when the container is opened or clinging to the hands and clothing of the user.  
      Referring to  FIG. 3 , a shipping label  19  may be applied the module  10  with the ball  15  enveloped therein in such a manner to seal the module  10  about the ball  15 . Alternatively, one or more strips of adhesive may be applied to the module  10  to seal the ball  15  in place. The resulting structure may then be shipped as such to the ultimate user.  
      Referring to  FIG. 4 , wherein like reference characters indicate like parts as above, a pair of packaging modules  10  may be used for shipping an elongated item  20 , such as a cylindrical tube. In this respect, the elongated item  20  is placed between a pair of modules  10  in sandwich-like manner. To this end, each module  10  is shaped into an elongated shape to accommodate the shape of the item  20 .  
      Referring to  FIG. 5 , after the item  20  has been enveloped, the resulting unit is placed in a shipping container  21 , for example, a shipping tube. At this time, the modules  10  are received in a snug fit manner in the container  21  to maintain the item  20  in a non-movable manner. A shipping label  22  may then be applied to the outside of the container  21  and the container  21  shipped to an ultimate user.  
      Referring to  FIG. 6 , after an item  20  has been enveloped between a pair of modules  10 , a shrink wrap film or a stretch wrap film  23  may be wrapped about the resulting unit in order to form a self-contained package. Any suitable device may be used to shrink a shrink wrap film  23  in place. Alternatively, the unit may be slid into a tube of shrink wrap material which can then be shrunk about the modules  10  to form a self-contained package. A shipping label (not shown) may then be applied to the outside of the package.  
      In another embodiment, each module  10  may have a self-adherent surface for adhering to the other module  10  in order to retain the item  20  therebetween. In this case, there is no need for any additional wrapping bands or films to form a package.  
      Referring to  FIG. 7 , wherein like reference characters indicate like parts as above, a module  10  may be placed in the bottom of the container  17  and then an item  24 , for example, of elongated shape is placed centrally of the module  10  in an upstanding manner. Next, a second module  10  is placed over the top of the item  24 . The flaps  18  of the container  17  are then closed to place the modules  10  under a slight pressure in order to maintain the item  24  in a non-movable manner. As illustrated, a free space is provided between the central portion of the item  24  and the side waits of the container  17 . That is to say, there is no need to fill this space with loose fill elements  12 .  
      After the container  17  is opened, the uppermost module  10  is removed to expose the item  24 . This item  24  may then be removed and the module  10  returned to the container  17 .  
      Referring to  FIG. 8 , wherein like reference characters indicate like parts as above, a plurality of packaging modules  10  may be employed for packaging a plurality of items, particularly hems of different three-dimensional shapes. In each case, a packaging module  10  would adapt to the different shapes and sizes of the hems contacted by the packaging module  10 . As illustrated, a carton  25  is provided with a first layer of packaging modules  10  on the bottom. Next, one or more items  26  are placed on the module layer. A second layer of packaging modules  10  is then placed over the items  26 . Next, a second layer of items  27  is placed in a carton on the second module layer. Finally, a third layer of packaging modules  10  is placed in a carton  25  over the second layer of items  27  and the flaps  28  of the carton  25  are closed in the usual manner. As the flaps  28  of the carton  25  are closed down on the top layer of modules  10 , the modules  10  within the carton  25  are somewhat compressed to firmly hold the package to items  26 , 27  in place.  
      Once the carton  25  arrives at a final destination, the recipient simply opens the carton  25  and removes the top layer of modules  10  to expose the uppermost layer of items  27  for removal. In like manner, the middle layer of modules  10  is removed to expose the lowermost layer of items  26  for removal. Thereafter, of the packaging modules  10  may be reused by the recipient for similar or other purposes. Since the loose fill materials  12  are contained within the membrane  11 , there is little or no risk of the loose fill materials  12  clinging to the recipient or spilling out of the carton  25  uncontrollably.  
      The packaging module  10  may also be made into a pre-form for packaging purposes. To this end, the packaging module  10  formed of the net bag  11  and containing a free-flowing mass of loose fill elements  12  made of starch is placed about a three dimensional forming blank (not shown) of a shape and size corresponding to the item to be packaged. For example, for packaging a bottle, the forming blank is of the size and shape of a longitudinal half of the bottle.  
      Typically, the forming blank is placed on a flat support within a surrounding box-like structure corresponding to the carton into which the bottle is to be placed.  
      Thereafter, moisture is applied to the elements  12  within the net bag  11  to effect bonding of the elements  12  together to form an agglomerated one-piece pre-form (not shown) of stable shape with a pocket corresponding to the shape of the blank. The moisture may be applied in the form of a spray of steam to ensure uniformity of application or in the form of a water spray.  
      Alternatively, where the packaging module  10  contains a free-flowing mass of loose fill elements made of foamed plastic, the elements are coated with an adhesive coating and the adhesive is activated by a spray of solvent or heated depending on the type of adhesive used. For example, the adhesive may be solvent-activated, or heat sensitive, or other.  
      In either embodiment, the otherwise free flowing mass of loose fill elements  12  are bonded together while disposed about the forming blank (not shown) to form an agglomerated one-piece pre-form of stable shape with a pocket. The net bag  11  remains to contain the agglomerated mass and is also shaped to the contour of the agglomerated mass.  
      Several pre-forms may be made in the same manner on the forming blank.  
      In use, a pre-form would be placed in the bottom of a carton with the pocket exposed to receive the item to be packaged in mating relation within the pocket. Next, a second like pre-form would be placed over the remainder of the item and the carton closed for shipping or storage purposes. Alternatively, a pre-form may be used to receive an item while a module  10  with free flowing elements  12  is placed over the item and pressed against the item upon closing of the carton.  
      The invention thus provides a packaging module that which adapts to all sizes of items to be packaged. The module may be used to package an individual item or a plurality of modules may be used to package one or more items of the same or different sizes and three-dimensional shapes.  
      The invention also provides a deformable membrane which is able to deform in three dimensions in order to the three-dimensional shape of a packaged item while allowing the loose fill elements to shift about within the membrane.  
      The invention thus provides a packaging module that contains a plurality of loose fill elements in a captured state so that the loose fill elements do not spill out of the container upon opening of the container and do not cling to the body of the user or other surfaces.  
      The invention also provides a packaging module of loose fill elements that can be fabricated in various sizes to accommodate the items to be packaged.  
      The invention also provides a packaging module that stops sliding and migration of the packaged item or items.  
      The invention further provides a packaging module that is easily removable from a shipping container, that is reuseable, and that provides excellent cushioning.