DE3879820T2 - PACKING SYSTEM AND METHOD. - Google Patents

Description

This invention relates generally to a packaging system and more particularly to a package having an outer pocket in which an inner pocket containing an article is suspended.

U.S. Patent No. 4,597,244 (Daniel A. Pharo) dated July 1, 1986, "Method for forming an inflated wrapping" describes a packaging system and method in which an article is packaged in an inflated, sealed bag. The present invention includes certain improvements and modifications to the packaging system and method disclosed in that patent.

U.S. Patent No. 4,155,453 describes a packaging structure having a sleeve having a plurality of flexible, contiguous wall members, an outer pair of the wall members being sealed together to form a first open-ended enclosure, and an inner pair of the wall members being sealed together to form a second open-ended enclosure defining an article-receiving zone therein, the inner pair of wall members being sealed to and between the outer pair of wall members such that the second open-ended enclosure is disposed within the first open-ended enclosure, the only path of entry or exit from the article-receiving zone being through the open end of the second open-ended enclosure, and the seal connecting the inner pair of wall members being located and configured to form a sealed, inflatable chamber above the second open ended enclosure and a sealed inflatable chamber beneath the second open ended enclosure, both inflatable chambers being inflated by a supply valve device. The chambers are sealed independently of one another and this makes it difficult to provide uniform protection for an article in the article zone.

According to one aspect of the invention there is provided a packaging structure as defined in claim 1.

According to a further aspect of the invention there is provided a method of packaging an article according to claim 9, which packaging method is particularly adapted to the previously mentioned packaging structure.

Preferred embodiments of the invention are specified in the dependent claims.

Advantages of this invention will become apparent from the following description of an embodiment shown in the accompanying drawings, of which:

Figure 1 is an isometric view showing a packaging system embodying this invention,

Figure 2 is a side elevational view of the packaging system with a side wall portion of an outer bag removed to show an inner bag suspended and supported within the outer bag and containing an article.

Figure 3 is an exploded isometric view showing cut parts used to form a package from the inner and outer pockets,

Figure 4 is an isometric view showing the insertion of an object into an open end of the inner pocket,

Figure 5 is an isometric view showing a device for inflating the outer bag with a fluid under pressure, such as air,

Figure 6 is an enlarged cross-sectional view in the direction of arrows VI-VI in Figure 5 showing the introduction of the pressurized fluid into the outer pocket,

Figure 7 is an enlarged plan view of a filler neck after it has been closed following inflation of the outer bag,

Figure 8 is an isometric view showing in part a modified packaging system,

Figure 9 is a cross-sectional view showing the inflation of an outer bag of the modified packaging system of Figure 8, and

Figure 10 shows an alternative end closure for the packaging system.

Figures 1 and 2 illustrate a packaging system 20 having an outer bag 21 having inside a inflatable, sealed chamber 22. An inner bag defining a container 24 for receiving an article A therein is disposed within the partitioned chamber 22 and its peripheral edges are secured to the outer bag in a manner fully described hereinafter to support and suspend the inner bag within the chamber. As shown in Figure 3, the outer bag 21 comprises a pair of superimposed and identical parts 25 and 26, while the inner bag 23 comprises a pair of superimposed parts 27 and 28 joined together at a fold 29.

Each of the members 25-28 is preferably constructed of a gas impermeable composite laminate, such as the type described in U.S. Patent No. 4,597,244. For example, each flexible member may comprise a middle layer of aluminum and outer and inner layers of a heat sealable plastic coating - such as polyethylene - designed to reactivate (melt) in the range of 150°C (300°F). These types of composite laminates (which may be constructed to be highly flexible and inextensible or extensible) are well known in the art and therefore further description thereof is unnecessary for a complete understanding of this invention. In the embodiment shown, the parts of Figure 3 are heat sealed at selected, superimposed marginal edges to prefabricate a package for the packaging system with a sealable end closure 30, as shown in its opened state in Figure 4.

Figure 3 shows superimposed common sealing areas of the outer edge portions of the parts in dotted lines 31 for purposes of explanation and clarity. The parts can be suitably cut and sealed together by conventional equipment and methods such as those of U.S. Patent No. 4,545,844. In Figures 1 through 4, it should be noted that stub portions 32 and 33 formed continuous with and projecting from edges of parts 25 and 26 are heat sealed together along their edges, respectively. These stub portions are further heat sealed to underlying parallel side edges of portions 34 and 35 of parts 27 and 28, respectively, which are joined together at fold 29.

The fold 29 and the remaining portions of the sections 34 and 35 extending transversely between the superimposed and sealed edges of the sections 31 to 34 remain unsealed with respect to the neck sections 32 and 33. As shown in Figure 6, the fold 29 extends a certain distance into a fill neck 36 defined by the superimposed and sealed neck sections 31 and 32. As will be described more fully below, a pair of inlet openings are thus formed at the fold 29 for introducing a pressurized fluid - such as air - into the divided chamber 22 on each side of the inner pocket 23.

A method of packaging an article A to form a packaging system 20 and for suspending the Article in a fixed position within the chamber 22 of the outer bag 21 - as shown in Figure 2 - will now be described with particular reference to Figures 4 to 7. After the package has been prefabricated to assume its envelope-like configuration on one end as shown in Figure 4, an article A is inserted through the open end of the inner bag 23 and into the compartment 24. It will be appreciated that the article could be placed in any desired position within the inner bag and be reliably held in such position when the packaging system is inflated or otherwise loaded or filled with the predetermined filling medium as described below:

After the article has been placed within the receptacle 24 of the inner bag 23, the overlying edge portions of the previously open end 30 are heat sealed together at a seam 37 as shown in Figure 5 to form an end closure. The sealing device used for this purpose may be of the type described in U.S. Patent No. 4,597,244 and such as the Model 210-8 Impulse Tabletop Bag Sealer manufactured by A.I.N. Plastics, Inc. of Mount Vernon, New York. Sealing the open end of the package will thus completely seal the receptacle 24 of the inner bag 23 and substantially seal the chamber 22 as well.

An inflation device for loading and at least substantially filling the chamber 22 with a pressurized The fluid is shown in the form of an opening exposed by a tab 38 defined by a cut line formed only through the nozzle portion 32. An inlet channel 39 into the chamber is formed within the inlet nozzle 36 (Figure 6). Alternatively, the inflator for charging the chamber 22 could include an inflation valve such as that disclosed in U.S. Patent No. 4,586,910 and designated 40 in Figure 8.

After the open end of the package has been sealed at seam 37, a conventional inflation device including a fill tube 41 (Figure 5) can be used to charge the partitioned chamber 22 and place it under an inflation pressure exceeding ambient pressure, i.e., 14.7 psi at sea level. Alternatively, human lung power could be used to fill the chamber 22 with air. Other types of gases, such as helium, could be used as the filling medium, as could a suitable liquid, such as water. Alternatively, or in addition to the pressurized fluid, the chamber could be filled with a plastic material (e.g., urethane, polystyrene, etc.) in solid (injected and solidified in liquid form) or piece form (e.g., as beads or pellets).

After the package has been inflated to suspend the inner bag 23 and an article A in its preselected fixed position within the chamber 22, the filling tube 24 is removed. The tab 38 is simultaneously pressed into the nozzle 36 to prevent the Pressurized fluid escapes. As shown in Figure 7, the nozzle 36 is then quickly heat sealed at a seam 42 (by sealing only the nozzle sections 32 and 33 together) and/or at a seam 42' (by sealing the nozzle sections 32 and 33 and the surface sections 34 and 35 together).

As shown in Figure 2, an article A is thus substantially enclosed by the filling medium and supported and held in a fixed position within the chamber 22. Compressive forces to which the pressurized fluid is subjected are directed inwardly and uniformly onto the exposed upper and lower surfaces of the inner pocket 23, thereby forcing the flexible wall portions of the inner pocket against and conforming to the contours of the article. The holding of the article in a fixed position within the partitioned chamber 22 is further assisted by the horizontal components of the forces acting on the inner surface portions of the transversely disposed side seams 43 and 43' of the outer pocket 21.

The latter holding force is more clearly illustrated and emphasized, if desired, in a modified packaging system 20' (Figures 8 and 9) in which horizontal force components F tend to hold the inner bag portions 27 and 28 in tension. In order to thus increase the horizontal force components F, the outer bag portions 25 and 26 are prefabricated so that their widths are greater than the widths of the portions 27 and 28 (Figure 8).

Figure 10 illustrates an alternative end closure for the packaging system 22 that can be used instead of the heat sealed seam 37 (Figure 1). In Figure 10, pieces 25 through 28 are cut to different lengths to define longitudinally offset panel edges 25' through 28'. A standard tape 44 is heat sealed or mechanically secured over the ends of the pieces to close and seal the chamber 22 and the pocket 24. Other types of end closures can also be used, such as a standard tape folded over the end of the package and then heat or mechanically sealed over it in a conventional manner. The opposite ends of the tape are then folded inward toward each other and secured there. In addition, a standard tape may be attached to the outside of the part 25 and a protective strip removed from the tape after the article A (Figure 4) has been inserted into the inner pocket 23. The parts of the pockets may then be folded along a pre-formed fold or crease line to secure the parts together. If desired, the end edges of the parts may be offset longitudinally in the manner described above with reference to Figure 10. The end closure may also be formed by pressure-bonding and clamping an elongated cylindrical rod in a separate and generally C-shaped holder. The rod should be sufficiently resilient to be pushed into the cavity of the semi-rigid holder and allow it to expand to compress the parts of the end closure therebetween to seal and separate the chamber 22 and the pocket 24 (Figure 2).

Alternatively, the rod could be made of a semi-rigid plastic material, with the holder also being made of a plastic material but having sufficient flex to expand and allow the rod to compressively or snap-fit into the holder in a known manner.

Various opening devices and structures may be used and formed in the end closure to open the packaging system 20. For example, a cord and thread may be inserted into the heat-sealed end closure to prepare it for opening by a consumer. As an alternative or in addition to the thread, a second thread may be similarly inserted adjacent to the heat-sealed side seam 43 or 43' (Figure 1) to allow its removal and opening of the packaging system. The threads may be suitably secured within the bottom of one of the parts forming the inner pocket 23, thus exposing the article A (Figure 2) when the thread is removed.

Various other modifications may be made to the preformed package and finished packaging system of this invention without departing from the spirit and point of view thereof. The package could include additional pockets secured to pockets 23 and 25 in the manner described above. Instead of using the distal end 30 of the packaging system 20 as its open side, that end of the system could be heat sealed during prefabrication of the package. and one of the side edges can be left open and used for packaging purposes in the manner described above.

The heat sealed seams of the system could be formed in the manner described above, or the parts could be folded over one another and then heat sealed together to form, for example, an eight layer seam. Gusseted seams could also be used, with the corners of the end closure folded inward facing one another and heat sealed there. In addition to the end closures described above, the end portions of the end closure-containing parts could have encapsulated beads of adhesive formed thereon which would cause the parts to stick together and be sealed when pressure and/or heat is applied to the parts, breaking up the beads of adhesive. These portions of the parts could also be folded over one another multiple times and then heat sealed, or folded over one another in opposite directions and then heat sealed.

Claims (13)

1. A packaging assembly comprising a sleeve having a plurality of flexible, contiguous wall members (25-28), an outer pair of the wall members (25,26) sealed together to form a first open-ended enclosure (22) and an inner pair of the wall members (27,28) sealed together to form a perimeter, the inner pair of wall members defining a second open-ended enclosure (24) having an article receiving zone therein, the inner pair of wall members (27,28) sealed to and between the outer pair of wall members (25,26) such that the second open-ended enclosure is disposed within the first open-ended enclosure, the only means of entry or exit into or from the article receiving zone being through the open end of the second open-ended enclosure (24), and the seal (43) connecting the pairs of wall members being located and configured is that it defines a sealable inflatable chamber above the second open-ended enclosure and a sealable inflatable chamber below the second open-ended enclosure, both inflatable chambers being inflated via a device (36) defining a sealable passageway (39); the structure being characterized in that the boundary of the inner pair of wall portions (27,28) defines an opening which forms the only fluid flow connection between the inflatable chambers, and in that the sealable passageway (39) extends from the first open-ended enclosure end (22) and is formed by a stem portion extending from the edges of the outer wall parts, such that a filling medium can be introduced into the inflatable chambers, both inflatable chambers being loaded with filling medium in order to build up a pressure against and cushion an object (A) contained in the object receiving zone. 2. Packaging structure according to claim 1, wherein the outer pair of wall parts (25, 26) have outer peripheral edges (43, 43') sealed to one another and the inner pair of wall parts (27, 28) are sealed to the outer peripheral edges of the outer pair. 3. A packaging structure according to claims 1 or 2, wherein the outer pair of wall parts (25,26) and the inner pair of wall parts (27,28) are generally rectangular and extend at least substantially coextensive with one another. 4. Packaging structure according to one of the preceding claims, wherein at least the outer pair of wall parts (25, 26) is formed from a gas-impermeable, flexible material. 5. Packaging structure according to one of the preceding claims, further comprising an end closure device (44) for securing adjacent edge portions of the inner and outer wall parts to each other and for sealing the article receiving zone after an article has been placed therein. 6. Packaging structure according to one of the preceding claims, wherein the filling medium comprises a compressed gas or a plastic foam material in solid or piece form or a combination of these. 7. A packaging structure according to any preceding claim, wherein the packaging structure has opposing front and rear edges and opposing side edges, the inner walls (27,28) being sealed to the outer walls (25,26) at the front, rear and side edges and the inner walls being sealed to each other at the rear and side edges. 8. A packaging assembly according to any preceding claim, further comprising a pressurized source of the filling medium and means for introducing the filling medium through the valve for loading the inflatable chambers. 9. A method for packaging an article (A) comprising the steps: (1) securing edges of an open-ended inner pocket (23) and an open-ended outer pocket (21) together such that their open ends correspond to each other, thereby suspending the inner pocket within chamber sections (22) defined within the outer pocket, and (2) placing an article through the open end of the inner pocket in a receptacle (24) defined within the inner pocket; characterized by the further steps: (3) forming a sealable filling device for defining an inlet passage (39) through the outer pocket, the inlet passage communicating with the inner chamber portion, (4) Sealing the open ends of the inner and outer bags and (5) simultaneously filling the chamber sections at least substantially with a filling medium through the sealable filling device to substantially encapsulate and hold the inner bag and the article, and sealing the chamber sections. 10. The method of claim 9, wherein the inner bag (23) and the article (A) are substantially encapsulated and held in a preselected fixed position proximate the chamber portions (22). 11. A method according to claim 9 or 10, wherein the outer pocket (21) comprises a pair of superimposed and generally rectangular first wall portions (25,26) and the inner pocket comprises a pair of superimposed and generally rectangular second wall portions (27,28) and the step of securing the edges of the inner and outer pockets together such that their open ends correspond to each other comprises securing superimposed edges of the inner and outer pockets together except for their open ends and without sealing the inlet passage. 12. A method according to any one of claims 9 to 11, wherein the chamber sections (22) are filled with a pressurized fluid through the inlet passage (39) defined by the filling device. 13. The method of claim 11 or 12, further comprising forming the first wall parts (25,26) so that they have widths between their opposite edges that are greater than the corresponding widths of the second wall parts (27,28).