GB2563313A

GB2563313A - Packaging method and article therefore

Info

Publication number: GB2563313A
Application number: GB1804613.6A
Authority: GB
Inventors: Archbold Yannis
Original assignee: Ahvc Ltd
Current assignee: Ahvc Ltd
Priority date: 2017-03-23
Filing date: 2018-03-22
Publication date: 2018-12-12
Also published as: GB201804613D0; GB201704598D0

Abstract

A method of forming an insulated packaging article for subsequent use comprises compressing an insulating layer 5, sealing it in an air-tight outer layer 3, and transporting or storing the compressed article for subsequent use, whereby the outer layer can be punctured in order to cause the insulating layer 5 to provide insulating properties by expanding through ingress of air. The article may be mechanically compressed to compress the insulation layer and then sealed (fig. 2a-2m), or may be vacuum sealed (not shown). The article may comprises a pouch or pocket member having exterior and interior faces (fig. 1c), with an exterior face being punctured to allow ingress of air. Alternatively the article may comprise an insulated panel or liner for use in a container (fig. 3a-3c). The insulating layer is preferably removable from the outer layer for insertion into another, non-punctured outer layer for re-use. An insulated packaging article which is provided in compressed and sealed form within an outer layer which is subsequently punctured to cause expansion of the insulation layer through ingress of air is also claimed. The insulating layer is preferably wool. Compressing the articles is intended to make them easier to transport before use.

Description

Packaging method and article therefore

The invention to which this application relates is a packaging method and an article therefore. Although the following description refers exclusively to packaging articles for food and perishable items, the person skilled in the art will appreciate that the present invention could also be used for the packaging and/or insulating of a wide range of articles.

There is an increasing number of online food retailers who send temperature sensitive goods to their customers. Most of these retailers use ambient distribution networks, such as parcel carriers. They therefore need a cost-effective means of posting the goods and maintaining the temperature. Many of the parcels are left at the property, rather than left on the doorstep. The container therefore needs to be cost effective (as it is rarely retrieved by the posting company in most instances). The most commonly used means of packaging the temperature sensitive goods is to place them in an expanded polystyrene box, often with an ice pack or some other means of keeping the goods chilled or frozen for a required period of time. However, polystyrene boxes (and most other insulative materials) are bulky as all utilize a great deal of space and consequently, transport is highly costly.

It is also known to provide insulated packaging in the form of boxes having an interior lining comprising a wool layer contained within a plastic outer layer. In order to ensure the air within the container is kept dry and dehumidified, the plastics layer containing the wool is perforated throughout. Since wool is a hygroscopic material, this serves to absorb any moisture in the air in the container. However, this possesses a similar problem as discussed above in that such insulated packages are bulky to transport even prior to the storage of perishable goods therein. Furthermore, as the moisture in the air disperses through the perforations in the outer layer of the lining and is absorbed by the wool or fibres, this can potentially compromise the insulating material and is also known to result in undesirable odours being emitted therefrom, and this may occur even prior to meat and other perishable items being placed into packaging. Furthermore, once the perishable items are located within the insulative packaging and because the outer layer is provided with perforations throughout, it is common for small strands of the wool and fibres to filter through the outer layer. Consequently, this results in the stored items being exposed to the insulative fibrous material, and a thin layer of the same may spread over the stored items.

It is therefore an aim of the present invention to provide an improved method of forming an insulating packaging article that overcomes the aforementioned problems associated with the prior art.

It is a further aim of the present invention to provide an improved insulating packaging article that overcomes the aforementioned problems associated with the prior art.

According to a first aspect of the invention there is provided a method of forming an insulated packaging article for subsequent use, said method including the steps of: providing an outer layer formed from a substantially impermeable material; providing an insulating layer to be located within said outer layer; compressing the insulating layer and sealing the same in an air-tight atmosphere within the outer layer; transporting and/or storing said sealed article for subsequent use, and characterised in that upon said subsequent use, said outer layer is punctured so as to have at least one aperture therein, allowing the insulating layer to expand, thereby providing the article with insulating properties.

In one embodiment, the insulating layer is compressed and sealed using a mechanical press. Typically, said seal is a heat seal, creating said air-tight atmosphere in which the insulating layer is located.

In one embodiment, said insulating layer combination is compressed and sealed under vacuum conditions.

In one embodiment, said insulating layer is provided of a fibrous material. Typically, said insulating layer is provided as a substantially wool material. In another embodiment, the insulating material may be formed from cotton or a cotton-containing material.

In one embodiment, said outer layer is formed as a pouch or pocket member, having one open end into which said insulating layer may be placed.

In one embodiment, said insulating material is provided as a panel of insulating material. Typically, said panel is folded in half and subsequently placed within the pouch or pocket member.

In one embodiment, said folded panel has a length dimension of less than half the length of the pouch or pocket member. In one embodiment, said panel is folded in half such that opposing ends or edges meet, and the opposing ends of the panel, in folded form, are fed into the pouch or pocket member first.

That is to say, the opposing, folded end of the folded panel enters the pouch or pocket member last.

In one embodiment, the folded end of the folded panel member is retained substantially at the open end of the pouch or pocket member. Subsequently, the opposing, closed end and portion of the pouch or pocket member is folded back into itself, and located between the opposing, folded ends of the panel of insulating material.

Thus, the insulating material is now located within the outer layer, formed as a cushioned and insulated pouch or pocket. The bottom or closed end of the pouch, however — at the folded end of the insulating material — still has an unsealed outer layer.

In one embodiment, the pouch and insulating material combination is subsequently subjected to compression and a vacuum suction, thereby removing all air from within the insulating material and reducing the external dimensions of the same. Typically, the open end of the pouch or pocket member is subsequently sealed, forming an article in which the insulating material is fully contained.

In another embodiment, said insulating material is provided as a panel of insulating material and said outer layer is provided to envelope said panel. Typically, said panel is inserted without any folding, and has dimensions that substantially meet the interior dimensions of the pouch formed by the outer layer.

Thus, the insulating material is now located within the outer layer, formed as a cushioned and insulated panel or liner member.

In one embodiment, an open end of the outer layer, through which said insulating panel was inserted into the outer layer, is subsequently subjected to compression and a vacuum suction, thereby removing all air from within the insulating material and reducing the external dimensions of the same. Typically, the open end of the outer layer is subsequently sealed, forming an article in the form of an insulated panel or liner member which the insulating material is fully contained.

In one embodiment, a plurality of insulated panels or liner members may be provided. Typically, said panels or liner members may be joined at or along one or more edges thereof. In one embodiment, three panels or liner members may be joined to one another, side-by side.

Typically, said panels or liner members may be provided to act as interior liners for a container. In one embodiment, said panels or liner members may be located adjacent interior walls of a container.

In one embodiment, said article, compressed and under vacuum, may be stored or transported prior to subsequent use.

Typically, said compressed article may be stored and/or transported in a stacked form with a plurality of further compressed articles. Thus, by stacking such articles together, this aids in maintaining them in a compressed state and prevents any gradual ingress of air therein.

In another embodiment, said compressed articles may be stored and/or transported in a rolled-up form. Such a rolled-up form also helps to maintain the articles in a compressed state and prevents any gradual ingress of air therein.

In one embodiment, said outer layer is formed from a substantially impermeable and/or air-tight material. Typically, said outer layer is formed from a plastics material. Further typically, said outer layer is formed from medium density polyethylene (MDPE), high density polyethylene (HDPE) or barrier film.

In one embodiment, said compressed article is provided for subsequent use and, typically, for the temporary storage of one or more items that require retaining at a specific temperature or within a specific temperature range.

In one embodiment, prior to storage of one or more items, an exterior face or faces of the compressed article is punctured to provide one or more apertures therein. Subsequently, air ingress into the insulating layer is permitted and the same may expand substantially to pre-compressed dimensions, forming an insulated packaging article.

Thus, by providing the article in a sealed and compressed form while it is to be stored and or transported prior to its use as a packaging article, the ingress of air and moisture into the insulating layer and, in some embodiments, the fibrous material etc. is prevented, thereby maintaining the material in optimum condition. This also substantially reduces the volume of the article, making it far more cost effective to transport and/or store prior to use — the article is only punctured and allowed to expand to its full volume and dimensions immediately before it is required to be used as a packaging article for one or more items. Furthermore, by providing the puncture or punctures on just the exterior face or faces of the article, if wool or fibrous material does filter out from the outer layer, it will be to the outside of the article and, thus, will not contact and potentially compromise the items stored within the article. The present invention, therefore, provides a number of substantial improvements over the articles and techniques currently available in the prior art.

In one embodiment, at least part of said insulated packaging article is reusable after storage and/or delivery of the said one or more items therein.

In one embodiment, said insulating layer may be removed from the outer layer and provided for insertion into another, non-punctured outer layer for re-use.

In one embodiment, said outer layer is formed from a recyclable or biodegradable material.

According to another aspect of the present invention there is provided an insulated packaging article formed from the method as described above.

According to another aspect of the present invention there is provided an insulated packaging article for subsequent use, said article including: an outer layer formed from a substantially impermeable material; an insulating layer located within the said outer layer, and characterised in that said article is provided sealed and compressed, maintaining the insulating layer in an air-tight atmosphere, and arranged to be punctured in subsequent use allowing the insulating layer to expand, thereby providing the article with insulating properties.

Typically, said impermeable material is substantially impermeable to gaseous and liquid fluids.

In one embodiment, said article is provided sealed and compressed in vacuum conditions.

In one embodiment, said article forms a pouch or pocket member, in a compressed form. Typically, said pouch or pocket member includes one or more exterior faces and one or more interior faces.

In another embodiment, said article forms an insulated panel or liner member in which the insulating material is fully contained, in a compressed form.

In one embodiment, one or more exterior faces of the article are arranged to be punctured, thereby to allow the ingress of air into the insulating layer.

In one embodiment, said insulating layer is provided of a fibrous material. Typically, said insulating layer is provided as a substantially wool material. In another embodiment, the insulating material may be formed from cotton, a cotton-containing material or a composed foam material, such as polyethylene.

In one embodiment, said outer layer is formed from a recyclable material.

In one embddiment, at least part of said insulated packaging article is reusable after storage and/or delivery of the said one or more items therein.

Embodiments of the present invention will now be described with reference to the accompanying figures, wherein:

Figures la — c illustrate, separately, an outer layer and an insulating layer of an insulated packaging article, and a fully-formed article in accordance with an embodiment of the present invention;

Figures 2a - p illustrate a series of method steps for preparing an insulated packaging article, in accordance with an embodiment of the present invention; and

Figures 3a - c illustrate an article according to an embodiment of the present invention being inserted for use in a container.

Referring now to the Figures, the present invention provides a novel method and article for providing insulated packaging for the temporary storage of one or more item therein. Packaging article 1, shown in Figure lc is formed from two components: an outer layer or pocket 3, shown in Figure la and an insulating layer which, in this embodiment, is provided as a slab of wool 5, having a length H and a width W, shown in Figure lb. Other fibrous materials that can act as insulators, such as cotton, a cotton-containing material, or a composed foam material, such as polyelthylene and the like may also be used in addition to or instead of the wool presently shown. The pocket 3 is formed from an impermeable material so as to prevent the ingress of air and/or fluids therethrough. Generally, this will be a plastics material and in the present embodiment, the pocket 3 is formed from medium density polyethylene (MDPE). The pocket 3 has a width A and a length B, and is sealed around three sides, with the top end 7 left open in order that the wool slab 5 may be placed therein.

The steps of forming the compressed and vacuum-sealed article are shown in Figures 2a — n, and the process begins by taking the wool slab 5 and folding the same in half, along dotted line 9, such that the new dimensions are W and 16 H. The pocket 3 is then taken, and the folded wool slab 5 is inserted into the pocket at its open end 7. It should be noted that the folded ends 11 of the slab 5 are inserted as the leading edge into the pocket 3, such that the folded end 13 of the slab 5 is at the rear when inserted. The width W of the slab and the length H of the slab 5 are provided slightly less than the equivalent dimensions of the pocket 3 in order that the slab 5 may fit therein. Furthermore, when folded, the dimension 16 H of the slab is less than 16 B of the pocket 3, such that once the slab 5 is inserted into the pocket 3, about half of the pocket 3 does not contain the slab 5, and this half 15 may then be folded back into itself such that it is located in between the folded ends 11 of the wool slab 5 (shown in Figures 2g — i). The half 15 of the pocket 3 being inserted between the folded portions of the slab 5 should be pushed all the way to the folded end 13 to ensure all sides and faces of the wool are covered with the pocket 3. Thus, the insulating wool slab 5 is now located within the outer pocket 3, forming a cushioned and insulated pouch 1. The bottom or closed end of the pouch 1, however — at the folded end 13 of the slab 5 — still has an unsealed edge; the end 7 of the pocket 3. As the slab 5 is initially inserted into the pocket 3, it should be inserted such that there is a portion of the pocket 3 at end 7 that extends past the folded end 13 of the slab 5 (Figure 2j). This is to ensure that the end 7 may be heat-sealed without compromising the folded end 13 of the wool slab 5.

In another embodiment of the present invention and as illustrated in Figures 3a — c, the insulated article may be provided as an insulated panel or liner member 301. This differs from the pouch 1 as previously described as there is no pocket provided for goods to be stored within the article 301, as can be done with the pouch 1. The liner 301 may be formed in much the same way as described above, however, rather than folding an elongate wool slab 5 prior to insertion, a single layer of insulating material may be inserted directly into the outer layer, and having dimensions that substantially meet the interior dimensions of the outer layer that envelopes it. The insulating material may therefore be located within the outer layer, formed as a cushioned and insulated panel or liner member. In some examples, and as shown in the figures, a plurality of liner members 301 may be provided and can be joined to one another along one or more edges, forming an elongate liner wall 311. The liner wall 311 can then be used for insertion into, for example, a container such as a box 313, as shown in Figures 3b and 3c. Providing two liner walls 311 as shown in in the arrangement in the Figures enables a user to line all the interior walls of the container 313, and items may subsequently be stored therein.

Once the slab 5 is inserted into the pocket 3 as described above, the combined article 1 may then be compressed and end 7 sealed using a vacuum sealer. The same can be done for the panel or liner member 301 once the insulated layer has been inserted into the outer layer, and the open end subsequently sealed. Such compression may be done manually or, more preferably, can be achieved mechanically using a press. This will significantly reduce the thickness of the article and remove all air from within, creating a compressed and air-tight article (Figures 2k — m). The vacuum-sealed article 1’ has now been prepared and is ready for subsequent use — this may be storage until such a time that it is required, or it may be transported immediately and prepared for use in storing and insulating one or more goods or items that require transport and storage. If the articles 1’ are being stored until they are required for further use, they may be stored via stacking atop one another as the weight of the stack will ensure the articles 1’ remain in a compressed state and prevent any gradual and inadvertent ingress of air. The stacking may be further aided by providing rigid boards between which the compressed articles may be packed and stored. Alternatively, the compressed articles 1’ may be stored by rolling the same and storing within a tube. Thus, by providing the article 1’ in a sealed and compressed form while it is to be stored and or transported prior to its use as a packaging article, the ingress of air and moisture into the wool layer is prevented. This therefore maintains the insulating material in optimum condition for insulation. This also substantially reduces the volume of the article, making it far more cost effective to transport and/or store prior to use. This also provides clear environmental benefits.

When the compressed article 1’ is required to be used for the temporary storage of one or more items that require retaining at a specific temperature or within a specific temperature range, a user may take the article 1’, and puncture one or both of the exterior faces of the compressed article 1’ one or more times. This subsequently permits the ingress of air into the insulating wool layer and allows the same to expand back to its full, precompressed volume and, thus, forming the packaging article 1 as shown in Figure lc and which regains its insulating properties. Therefore, the packaging article 1 is only punctured and allowed to expand to its full volume and dimensions immediately before it is required to be used as a packaging article for one or more items. In addition, the puncture or punctures made by a user are done so on only the exterior face or faces of the article 1. Consequently, if wool or other fibrous material were filter out through the outer layer 3, it will be to the outside of the article 1 and, thus, will not contact and potentially compromise the items stored within the pouch 1. The present invention, therefore, provides a number of substantial improvements over the articles and techniques currently available in the prior art.

In some examples of the present invention, the plastics material used to form the outer layer/pocket 3 is a recyclable material, and the article 1 itself may be reusable after storage and/or delivery of the one or more items therein. After such use, the now punctured outer layer 3 may be removed and recycled, and the wool slab 5 may then be re-used and inserted into a new, unpunctured outer layer/pocket 3, for further use.

Claims

1. A method of forming an insulated packaging article for subsequent use, said method including the steps of: providing an outer layer formed from a substantially impermeable material; providing an insulating layer to be located within said outer layer; compressing the insulating layer and sealing the same in an air-tight atmosphere within the outer layer; transporting and/or storing said sealed article for subsequent use, and characterised in that upon said subsequent use, said outer layer is punctured so as to have at least one aperture therein, allowing the insulating layer to expand, thereby providing the article with insulating properties.

2. A method according to claim 1, wherein the insulating layer is compressed and sealed using a mechanical press.

3. A method according to claim 1, wherein said seal is a heat seal, creating said air-tight atmosphere in which the insulating layer is located.

4. A method according to claim 1, wherein said insulating layer combination is compressed and sealed under vacuum conditions.

5. A method according to claim 1, wherein said insulating layer is provided of a fibrous material.

6. A method according to claim 1, wherein said outer layer is formed as a pouch or pocket member, having one open end into which said insulating layer may be placed.

7. A method according to claim 6, wherein said insulating material is provided as a panel of insulating material, folded in half and subsequently placed within the pouch or pocket member.

8. A method according to claim 7, wherein said folded panel has a length dimension of less than half the length of the pouch or pocket member.

9. A method according to claim 7, wherein said panel is folded in half such that opposing ends or edges meet, and the opposing ends of the panel, in folded form, are fed into the pouch or pocket member first.

10. A method according to claim 9, wherein the folded end of the folded panel member is retained substantially at the open end of the pouch or pocket member.

11. A method according to claim 10, wherein the pouch and insulating material combination is subsequently subjected to compression and a vacuum suction, thereby removing all air from within the insulating material and reducing the external dimensions of the same.

12. A method according to claim 11, wherein the open end of the pouch or pocket member is subsequently sealed, forming an article in which the insulating material is fully contained.

13. A method according to claim 1, wherein said insulating material is provided as a panel of insulating material and said outer layer is provided to envelope said panel, said panel being inserted into said outer layer without any folding.

14. A method according to claim 13, wherein an open end of the outer layer, through which said insulating panel was inserted into the outer layer, is subjected to compression and a vacuum suction, thereby removing all air from within the insulating material and reducing the external dimensions of the same, the open end of the outer layer subsequently being sealed, forming an article in the form of an insulated panel or liner member in which the insulating material is fully contained.

15. A method according to claim 14, wherein a plurality of insulated panels or liner members are provided, and which are joined at or along one or more edges thereof.

16. A method according to claim 14, wherein one or more of said panels or liner members are provided to act as interior liners for a container.

17. A method according to claim 1, wherein said compressed article is stored and/or transported in a stacked, rolled-up or other form with a plurality of further compressed articles.

18. A method according to claim 1, wherein said outer layer is formed from a substantially impermeable and/or air-tight material.

19. A method according to claim 1, wherein prior to storage of one or more items therein, an exterior face or faces of the compressed article is punctured to provide one or more apertures therein.

20. A method according to claim 1, wherein at least part of said insulated packaging article is reusable after storage and/or delivery of one or more items therein.

21. A method according to claim 1, wherein said insulating layer is removable from the outer layer to be provided for insertion into another, non-punctured outer layer for re-use.

22. An insulated packaging article formed from the method according to claims 1-21.

23. An insulated packaging article for subsequent use, said article including: an outer layer formed from a substantially impermeable material; an insulating layer located within the said outer layer, and characterised in that said article is provided sealed and compressed, maintaining the insulating layer in an air-tight atmosphere, and arranged to be punctured in subsequent use allowing the insulating layer to expand, thereby providing the article with insulating properties.

24. An insulated packaging article according to claim 23, wherein said article is provided sealed and compressed in vacuum conditions.

25. An insulated packaging article according to claim 23, wherein said article forms a pouch or pocket member, in a compressed form.

26. An insulated packaging article according to claim 25, wherein said pouch or pocket member includes one or more exterior faces and one or more interior faces, said one or more exterior faces being arranged to be punctured, thereby allowing the ingress of air into the insulating layer.

27. An insulated packaging article according to claim 23, wherein said article forms an insulated panel or liner member in which the insulating material is fully contained, in a compressed form.

28. An insulated packaging article according to claim 27, wherein one or more panels or liner members are provided to act as interior liners for a container.

29. An insulated packaging article according to claim 23, wherein said insulating layer is removable from the outer layer and provided for insertion into another, non-punctured outer layer for re-use.