WO1995001923A1

WO1995001923A1 - Inflatable package

Info

Publication number: WO1995001923A1
Application number: PCT/GB1994/001491
Authority: WO
Inventors: Alan Nigel Burns
Original assignee: Alan Nigel Burns
Priority date: 1993-07-08
Filing date: 1994-07-08
Publication date: 1995-01-19
Also published as: GB2285799A; AU7128994A; GB9314106D0; GB9404541D0; GB9504548D0

Abstract

Inflatable packaging (100) comprises a first rigid package member (52) and a second package member (53), which may be of a rigid or flexible material. The members (52, 53) are secured together to define an inflation chamber (70) between them. The chamber (70) is typically inflated with pressurised gas, usually air. The first member (52) is provided with formations (65) to accommodate an article (1) to be packaged. The second package member (53) may be provided with a valve (60) to allow selected inflation/deflation of chamber (70). The packaging (100) can provide reasonable shock absorbing protection for the article (2) even in the event of a puncture. Also, especially if the same materials are used for members (52, 53) it is readily recyclable.

Description

INFLATABLE PACKAGE

The present invention relates to an inflatable packaging system.

There is a need to protect manufactured products from damage during transit and storage. Products such as domestic appliances, brown goods, electronic equipment and telecommunication equipment, for example, are all susceptible to damage in transit/storage. Currently, protection is provided typically by packaging of cardboard, moulded expanded polystyrene, or perhaps a combination of the two materials. For such applications, the packaging is required to protect the manufactured item and to provide some shock absorption. It is also essential that the packaging is able to provide protection and to absorb shocks until the item is ready to be removed from the packaging. This may be after a considerable period of time, perhaps during which the packaging has been subjected to repeated shocks. A particular problem with existing packaging made of cardboard, for example, is that it has limited repeatability in its shock absorbing properties.

Environmental legislation regarding packaging requires that the packaging be both recyclable and returnable to the supplier. In the cases of cardboard and expanded polystyrene, returning the used packaging to the supplier is a problem, owing to the considerable bulk of the packaging product. Also, whilst disposal and recycling may be relatively straightforward with cardboard, expanded polystyrene cannot be crushed and is difficult to incinerate. It therefore has limitations with regard to recycling.

Some forms of inflatable plastic packaging are also available. However, they can be susceptible to puncturing and, under those circumstances, provide little protection for the item/article to be packaged.

The present invention recognises and seeks to alleviate at least some of the aforementioned problems. With this in mind, the present invention seeks to provide packaging which is capable of protecting an article and which has repeatable shock absorbing properties. The invention also aims to provide packaging which is recyclable and may be readily disposed of, after use.

Accordingly, in one aspect, the present invention provides inflatable packaging for supporting an article, the packaging comprising first and second package members which co-operate to define an inflation chamber between them, wherein the first member is of a rigid material formed to a shape to receive an article to be packaged.

Thus, packaging in accordance with the invention is inflatable to provide protection for an article, including shock absorbing protection. Use of a rigid formed material for at least the first package member is advantageous in that it can provide protection for the article even in the event of a puncture. Preferably the first package member has sufficient rigidity to be essentially form sustaining during inflation.

The present packaging may be inflated by a gas, typically air. Preferably, the chamber in the packaging will, in use, be inflated with a pressurised gas. In particularly preferred embodiments, the packaging is pressurised to between about 1 to 3 psi above ambient pressure, most preferably to between about 1.5 to about 2 psi above ambient. Pressurising the packaging in this way has been found to be advantageous in increasing the crush resistance of example packaging by a factor of about 3 or 4.

Suitably, the first package member, which is of rigid material, defines a well to accommodate at least part of an article. Preferably, the first and second members are secured together at their respective inner surfaces to define a chamber between them, and the outer surface of the first member has formations which define a well for the article. Preferred means for securing the first and second package members together comprise heat sealing and hot melt adhesives.

In some preferred embodiments, the first and second package members co-operate to define a plurality of communicating chambers. Preferably, at least the first package member comprises a plurality of interconnected compartments which, in combination with the second package member, define a plurality of interconnected chambers. Suitably, the compartments in the first package member are of various selected depths, so as to define formations on the outer surface of the first member to accommodate the article. Preferably, the compartments are interconnected by relatively narrow channels. Preferably the formations in the first package member are spaced apart, because the spacings can also enhance shock absorbing properties of the packaging.

The second package member may be of a flexible material or of a rigid material, perhaps compatible with or essentially the same as the first package member. In some embodiments it is preferable to utilise a rigid second package member, preferably of a similar material to the first packaging member. This may facilitate recycling by avoiding the need for separation of different materials for different recycling procedures. In some other preferred embodiments the second package member is of a flexible material, preferably also releasably securable to the first package member. Thus, the first and second materials may be sealingly secured together for inflation and subsequently separated for disposal after use. The separated packaging members may be more readily stacked or flattened for disposal.

In some preferred embodiments, the packaging has means for enabling the chamber defined between the first and second package members to be selectively inflated and deflated, perhaps when an article is in situ in the packaging. Thus, preferably the packaging incorporates a valve means. Suitably, the valve means are provided in a rigid package member. Preferably, any such rigid package member is recessed and accommodates a valve means in such a recess.

In other aspects the present invention provides methods of packing and methods of manufacturing packaging.

Embodiments of the present invention will now be described further, by way of example, with reference to the accompanying drawings in which:

Fig. 1 shows a schematic illustration of packaging according to a first embodiment;

Fig. 2 shows an underneath view of a first packaging member for the first embodiment;

Fig. 3 illustrates stages in the manufacture of the first embodiment; Figs. 4 to 6 illustrate stages in the inflation of the first embodiment;

Fig. 7 is a schematic illustration of packaging according to a second embodiment;

Fig.8 shows an underneath view of a first packaging member of the second embodiment;

Fig. 9 illustrates stages in the manufacture of the second embodiment;

Figs. 10 and 11 illustrate stages in the inflation of the second embodiment;

Fig. 12 illustrates a two part packaging system according to a third embodiment;

Fig. 13 illustrates a sectional view of the packaging for the third embodiment;

Fig. 14 illustrates stages in the manufacture of the packaging of the third embodiment;

Fig. 15 illustrates stages of inflation for the packaging of the third embodiment;

Fig. 16 illustrates a fourth embodiment; and

Fig. 17 illustrates a fifth embodiment.

Turning firstly to Fig. 1, this illustrates inflatable packaging part 10 comprising a first package member 2 and a second package member 3. The first package member 2 is perhaps vacuum formed or injection moulded, as appropriate from high impact polystyrene or PVC, for example. It typically has a thickness of between about 180 to 500 microns, especially about 250 microns. The second package member 3 comprises a flexible material, suitably laminated polythene having a thickness of about 180 microns. In use, the inner surface 33 of the second package member 3 is sealingly secured to the inner surface 32 of the first package member 2 to define an inflation chamber 22 between them.

The features of the first package member 2 are shown in more detail in Fig. 2. Here, the first package member 2 is formed to provide several spaced, generally rectangular, compartments. In the illustrated embodiment, there is a large central compartment 15, which communicates with four smaller compartments 15' by way of narrow channels 16. The compartments 15, 15' are of various selected depths and provide spaced formations 25, 25' respectively on the outer surface 12 of the first package member 2. The formations 25, 25' are arranged to define a well 18 to snugly accommodate an article 1 to be packaged. Typically, in use, the appropriate forms of the compartment(s) and well will be selected to match the outer dimensions of the article 1. It is desirable for the article 1 to be quite firmly retained within the packaging 10.

The first package member 2 has a peripheral flange 5 which has a reduced thickness portion 4 at one corner on its inner surface 32. The package member 2 is also provided with an inlet port 7 near its inner surface 32, which has an associated lip 17 which extends beyond flange 5. The inlet port 7 is to allow inflation means to be inserted into the packaging 10 for inflating chamber 22. The reduced thickness portion 4 is for assisting the separation of the two package members 2, 3, discussed in more detail below.

In use, the first and second package members 2, 3 are secured together at their inner surfaces 32, 33, suitably by heat sealing or by any appropriate hot melt adhesive acting between flange 5 of the first member 2 and the periphery of the second member 3. Typically, the second package member 3 will be selected to be of a larger size than the perimeter of flange 5 of the first package member 2, and subsequently cut to size after the two package members have been secured together. A suitable method of manufacture is illustrated schematically in Fig. 3B. Thus, the two package members 2,3 will be secured together around the full perimeter of member 2, apart from at inlet port 7.

Once the two package members 2, 3 have been secured together, pressurised air is fed into the chamber 22 defined between the two package members 2, 3. This is illustrated in more detail in Figs. 5 and 6. The gas, typically air, is injected at a predetermined pressure through a nozzle 9 into port 7. As the gas is being supplied, the nozzle 9 will be sealed to the package members 2, 3 by a gasket 11. Once the chamber 22 has been inflated to the desired extent, the pressurising port 7 is subsequently closed by clamps 26, 27 which interlock flange 4 and second member 3.

Thus, the completed packaging part 10 provides well 18 to accommodate an article 1 to be packaged. Suitably, two packaging parts 10 may be employed, arranged to face one another, and to accommodate an article between them to provide greater protection. Preferably, means are provided for securing the two parts together in this way. For example, interengagable formations may be provided in the respective parts. After use, the first and second package members 2, 3 may be separated, by the user gripping the two package members 2, 3 at the reduced thickness portion 4. The two members 2, 3 may then be torn apart to break the seal between them for separate recycling. It will be appreciated that, once separated in this way, the package members 2, 3 are much less bulky than the inflated packaging part 10. If desired, members 2, 3 may be crushed or stacked, after use.

Figs. 7 and 8 illustrate an alternative embodiment of first and second package members 42, 43 and in which the inlet port 37 for the pressurised gas is arranged generally centrally of the first package member 42. In the illustrated embodiment, the port 37 is provided in a central compartment 35 formed in the first package member 42. In use, the compartment 35 presents an upstanding formation 36 on the outer surface 48 of the first package. The formation 36 co-operates with other formations 39 in the first package member 42 to support the article to be packaged. A method of manufacture of such packaging is illustrated in Figs. 9 to 11.

In the method of manufacture of the second embodiment, gas is supplied at port 37 and, once the chamber between the members 42, 43 has been inflated to the desired degree, the members 42, 43 are sealed together around compartment 35 at 34. This is illustrated schematically in Figs. 10 and 11. This version of the packaging is expected to be preferred in terms of ease of manufacture.

Figs. 12 to 14 illustrate a third embodiment of the present invention showing packaging parts 100. In this embodiment, the second package member is also of a rigid material. The second package member 53 is formed to provide a recess 55 in its outer surface 63. The second package member 53 also has a flange 58 around its periphery. A valve 60 is accommodated in recess 55.

The first package member 52 is made of the same rigid material as the second package member 53. The first package member 52 is constructed to define a well or recess 65 in its outer surface 62. The first package member 52 also has a flange 68 at its periphery. The first and second package members 52, 53 are, in use, secured together at flanges 58, 68 to define a chamber 70 between them. Pressurised gas, typically air, is supplied to chamber 70 through the valve 60. A section of part 100, through line A-A is shown in Fig. 13.

As illustrated in Fig. 12, in use, two packaging parts 100 are typically provided, arranged with first package members 52 facing one another, to accommodate an article between them. If desired, the two parts 100 may, be secured together. For example, interengagable male and female formations may be provided on the respective parts. This embodiment is preferred in that the use of two rigid package members may provide particularly effective shock absorbency. Also, for recycling, it is desirable to utilise essentially the same materials for both package members an thus avoid the need for subjecting the members to different recycling processes. It will be appreciated that minor differences between the materials may be tolerated without the need for separate recycling.

A method of manufacture of a packaging part 100 is illustrated schematically in Fig. 14. Typically, a valve

60 is secured to second package member 53, and first package member 52 is secured to second member 53 by heat sealingly at their respective peripheries (Fig. 14A). An article 1 to be packaged is located in recess 65 provided in the first member 52. (Again, the form of recess 65 may be carefully selected so that the article is a reasonably tight fit in the packaging part 10). A second equivalent packaging part 100' is mounted on the article 1, so that the article 1 is snugly accommodated in a recess in the part 100'. This is illustrated in Fig. 14C.

Once the parts 100, 100' are located in position, pressurised air is supplied via valves 60, 60' to inflate chambers defined in each part 100, 100'. The degree of desired inflation will be dependent upon the nature of the materials which make up the packaging parts 100, 100' and also the nature of the article 1 to be packaged. Suitably, the chambers are inflated to a pressure of between about 1 to 3 psi above ambient pressure to provide a desired crush resistance.

The stages of inflation of a part 100 are illustrated schematically in Fig. 15. In this embodiment, the nozzle 70 has an associated probe 80 for depressing and opening valve 60. Once the packaging part 100 has been inflated to the desired degree, probe 80 is released to permit valve 60 to close.

Turning now to Figs. 16A and 16B, they illustrate modifications to the packaging parts of the third embodiment. In this example, the packaging parts 110,

110' are provided with interengagable formations to permit stacking.

In more detail, a packaging part 110 comprises a first package member 102 and a second package member 103.

Features of the first package member may be essentially as shown in Fig. 12. In this embodiment, the second package member 103 in part 110 is provided with a series of longitudinally extending rib formations 108, including protrusions 109. As regards part 110', the second package member 103' has longitudinally extending rib formations 108' including channels 109' adapted to receive protrusions 109. Thus, as illustrated in Fig. 16B, the second package member 103 of a part 110 may interlock with second package member 103' of part 110' to permit stacking. This is particularly preferred in terms of saving space.

The illustration also shows the packaging parts 110, 110' provided with interengagable formations (shown generally at 120' ) to permit items to be locked together with an article secured between them.

Figs. 17A and 17B illustrate additional modifications which may be made to packaging of the present invention. To assist sealing properties one of the package members 150 is provided with a deflectable flange 155 which, in use, may be deflected to overlie flange 165 of the other package member 160, once the two members 150, 160 have been secured together at their inner surfaces. The deflected flange 155 is substantially secured to outer surface of flange 160 by heat sealing or by an alternative. The resultant double seal is particularly effective when the packaging is pressurised. It is shown in Fig. 17B. Various modifications may be made to this process. For example, whilst Fig. 17A shows a flange deflected before the two package members are secured together, in the alternative the two members could be secured together and the flange subsequently deflected.

It will be appreciated that various modifications may be made to the illustrated embodiments and, of course, features of certain embodiments may be incorporated into products illustrated as other embodiments.

Claims

1. Inflatable packaging for an article, the packaging comprising first and second package members which co¬ operate to define an inflation chamber between them, wherein the first member is of a rigid material formed to accommodate at least part of the article to be packaged.

2. Inflatable packaging according to Claim 1 wherein the first and second package members are releasably secured together so as to be separable for disposal.

3. Inflatable packaging according to claims 1 or 2 wherein the first and second package members co-operate to define a plurality of communicating chambers.

4. Inflatable packaging according to any preceding claim wherein the second package member comprises the same material as the first package member.

5. Inflatable packaging according to any preceding claim wherein the second package member comprises a rigid material.

6. Inflatable packaging according to any one of claims 1 to 4 wherein the second package member comprises a flexible material.

7. Inflatable packaging according to any preceding claim having means for enabling a chamber defined between the first and second package members to be selectively inflated and deflated.

8. Inflatable packaging according to Claim 7 provided with valve means.

9. Inflation packaging according to any preceding claim accommodating pressurised gas.

10. Inflatable packaging according to Claim 9 pressurised to between 1 to 3 psi above ambient pressure.

11. Inflatable packaging according to any preceding claim having surface formations to permit interengagement of two items of packaging.

12. Inflatable packaging according to Claim 11 having surface formations to permit stacking.

13. Inflatable packaging substantially as hereinbefore described with reference to, and as illustrated in any one of the accompanying Figures 1 to 17.