WO2010082041A1

WO2010082041A1 - Reusable enclosure

Info

Publication number: WO2010082041A1
Application number: PCT/GB2010/050028
Authority: WO
Inventors: Tony Black
Original assignee: Storsack Dorton Ltd
Priority date: 2009-01-13
Filing date: 2010-01-12
Publication date: 2010-07-22
Also published as: US20110290865A1; EP2389318A1; GB0900485D0

Abstract

The present invention relates to a reusable blank for a transport enclosure that is formed of at least one piece of sheet material that is housed or enclosed in at least one web of fabric or fibre. The web of fabric or fibre is synthetic material such as plastics. The transport enclosure of the present invention offers significant environmental benefits in reducing waste handling. The sheet material provides additional protection against damage. A transport enclosure which is formed therefrom and can be used to carry and protect articles. The present invention thus relates to a blank for a transport enclosure, and to a transport enclosure which is formed therefrom, which is convenient to use and which has minimal environmental impact. The enclosure which is formed from the blank is intended for temporarily housing or enclosing at least one relatively bulky and/or heavy, often generally cuboidal, article which is susceptible to and at risk of damage in transit. It is intended that the product be as environmentally friendly as possible in the sense that it is intended to be reused so preventing disposable single trip waste packaging and avoiding UK packaging waste levies after its first trip.

Description

REUSABLE ENCLOSURE

The present invention relates to a reusable blank for a transport enclosure that is formed of at least one piece of sheet material that is housed or enclosed in at least one web of fabric or fibre. The web of fabric or fibre is synthetic material such as plastics. The transport enclosure of the present invention offers significant environmental benefits in reducing waste handling. The sheet material provides additional protection against damage. A transport enclosure which is formed therefrom and can be used to carry and protect articles. The present invention thus relates to a blank for a transport enclosure, and to a transport enclosure which is formed therefrom, which is convenient to use and which has minimal environmental impact. It is intended that the product be as environmentally friendly as possible in the sense that it is intended to be reused so preventing disposable single trip waste packaging and avoiding UK packaging waste levies after its first trip.

Throughout the description and claims of this specification,

"reusable blank" means a sheet structure adapted to be assembled, often by folding and attachment to itself into an enclosure, often in the form of a enclosure, such as a box, chest, pack or package, but not excluding other forms, which may then be disassembled to revert to the blank;

"sheet" means any laminar structure, which may be flexible, pliable, elastic, expandable, resilient, firm, inflexible rigid, stiff or unbending, but often stiff, such as a sheet of polypropylene which is corrugated, ribbed, ridged and/or grooved, or formed from a plurality of longitudinally fused tubes or pipes, which may be of cylindrical or, more often rectangular, for example square cross-section; and

"fabric" means a textile material, which may be a lattice, mesh, net or often a closely woven web, such as woven polypropylene fibre, although the term does not exclude other moieties, such as non-woven fabrics.

The enclosure which is formed from the blank is intended for temporarily housing or enclosing at least one relatively bulky and/or heavy, often generally cuboidal, article which is susceptible to and at risk of damage in transit.

In particular, the present invention relates to a reusable blank for a transport enclosure and the transport enclosure which is formed therefrom, which enclosure is for the transportation of such articles whose edges or surfaces require protection from damaging contact in transit.

More particularly, such articles which are susceptible to and at risk of damage in transit include white goods, such as kitchen and catering equipment, for example, cookers, microwave cookers, ovens, rotisseries, stoves, toasters, warm cabinets, low temperature storage equipment, such as coolers, cold cabinets, chilling cabinets, ice makers, refrigerators, freezers, dish washers; and laundry equipment, for example washing machines, driers; bathroom equipment, for example bath tubs, bidets, wash hand basins, toilets and cisterns; and heating and cooling units, such as heaters, stoves, convectors, radiators, electric, gas and oil fires, central heating boilers, air conditioners; electrical equipment, such as television sets, stereo systems, audio and video recorders, radio sets, computer workstations, processors, VDU's and printers; and hard furnishings, such as cupboards, lockers, wardrobes, sideboards and chests-of- drawers.

Such articles which comprise enamelled metalwork are particularly susceptible to and at risk of damage in transit, including, e.g. white goods.

The enclosure is often in the form of a cuboidal enclosure, such as a box, chest coffer or trunk, which may conform to the article which is susceptible to and at risk of damage in transit and protects the edges and/or surfaces require protection from damaging contact in transit. The enclosure may then be disassembled to revert to the blank, which may then be reused.

Hitherto, articles such as white good, for example kitchen and catering equipment and laundry equipment, are packaged for transit in plastics film, often shrink wrapped around the article and with attached or enclosed protective cardboard or plastics corner units, in optionally corrugated cardboard enclosures, such as boxes, cartons, packs or packages, or between pairs of opposed optionally corrugated cardboard sheet material which are held in place by strong strapping bands or tape.

One disadvantage of such conventional means of protection is that they do not provide adequate protection against damaging contact in transit, in particular sharp edge or point impact to edges and/or surfaces. Goods with enamelled metalwork are particularly susceptible to and at risk of such damage in transit, including, e.g. white goods.

Thus in the case of protection in the form of a plastics film, often shrink wrapped around the article, such as white goods, the plastics film offers no protection to the surfaces of the article against damaging contact in transit, such as impacts sustained during normal handling, transportation and storage.

Even with attached or enclosed protective cardboard or plastics corner units, the edges and/or surfaces of the article are exposed to impact damage such as chipping.

Plastics film, even of relatively heavy gauge, is easily punctured, cut or torn by sharp points or edges.

Optionally corrugated cardboard sheet materials, either as pairs of opposed optionally corrugated cardboard sheets, held in place by strong strapping bands or tape around the article, or as part of an enclosure, such as an enclosure, such as a box, carton, pack or package, offers only marginally better protection to the enclosed article.

Even corrugated cardboard is susceptible to being punctured, cut or torn by sharp points or edges, and is significantly weakened by contact with water or moisture, thus offering less protection against impact damage, but also no protection against water damage.

Opposed optionally corrugated cardboard sheets, held in place by strong strapping bands or tape around the article, also leave surfaces and/or edges of the enclosed article exposed to damage in transit.

Additionally, optionally corrugated cardboard and plastics film packaging is not designed to be reused, from which it will be understood that it constitutes an ecological burden, however it is disposed of.

Traditional packaging materials are thus single use materials which are simply used to transport the goods to the consumer. Once the consumer has opened the goods the packaging materials have to be disposed of alongside the redundant white goods that are being replaced.

It is an aim of the present invention to provide an improved protective covering for domestic white goods and the like which are susceptible to damage. It is also an aim of the present invention that the protective cover is strong and resistant to tearing. It is a further aim that the protective cover provides a barrier to the ingress of dirt and moisture. Another aim is to provide a protective cover that does not lose strength on contact with water. It is a further aim that the protective cover is ale to provide protection against impacts sustained during handling, transportation and storage. Yet another aim is to provide protective cover that is relatively cheap and easy to manufacture, and ideally can also be reused a number of times.

It is thus an object of the present invention to provide a protective enclosure which provides adequate protection against damaging contact in transit, in particular sharp edge or point impact, especially to white goods, and against water damage, especially to hard furnishings and parts thereof.

It is a further aim of the present invention to provide a transport enclosure which can be reused, and ultimately also can be recycled. Another aim is to provide a system which after delivery of the new white goods can also be used to transport away the old white goods for disposal.

It is another object of the present invention to provide a protective enclosure which may be easily disassembled to revert to the blank, which may then be reused.

The present invention provides a transport enclosure which satisfies some or all of the above aims. The transport enclosure of the present invention is intended for cuboidal articles such as domestic white goods. To date no effective packaging for such articles is available.

Accordingly, in a first aspect the present invention provides a blank for a transport enclosure for housing or enclosing at least one article, the blank comprising a web which is formed from at least a base layer of woven fibre, having at least the following regions: a first protective region comprising a first pair of opposable portions adapted in the enclosure in use to cover two opposing surfaces of the article, a second protective region comprising a second pair of opposable portions adapted in the enclosure in use to cover another two opposing surfaces of the article, a third protective region comprising a portion integral with or attached to and joining the first and second pairs of opposable portions of the first and second region, and adapted in the enclosure in use to cover a further surface of the article, and optionally a fourth protective region comprising a portion integral with or attached to the first or second region, and adapted in the enclosure in use to cover a surface of the article opposing the further surface, wherein at least one of the portions and/or regions of the web comprises a layer of a plastics material which is retained in contact with a surface of the base layer.

In an embodiment, the blank is designed so that in use it covers a regular-shaped i.e. rectangular article (or an article packaged in such a way) to an article having similar dimensions of height, width and length. The article may thus be cuboidal or cube shaped.

In a second aspect the present invention provides a transport enclosure for housing or enclosing at least one article, which enclosure comprises a web which comprises a base layer of woven fibre, having at least the following regions: a first protective region comprising a first pair of opposed portions adapted in the enclosure in use to cover two opposing surfaces of the article, a second protective region comprising a second pair of opposed portions adapted in the enclosure in use to cover another two opposing surfaces of the article, a third protective region comprising a portion integral with or attached to and joining the first and second pairs of opposed portions of the first and second region, and adapted in the enclosure in use to cover a further surface of the article, and optionally a fourth protective region comprising a portion integral with or attached to the first or second region, and adapted in the enclosure in use to cover a surface of the article opposing the further surface, wherein at least one of the portions and regions comprises a layer of a plastics material which is retained in contact with a surface of the base layer. In a third aspect, the present invention provides a method of using a protective enclosure of the first aspect to transport a housed or enclosed article and/or to protect it against damaging contact.

The base layer of woven fibre which forms the web is a synthetic material. The synthetic material is preferably a polymeric material. Typical polymers include polyolefins such as polyethylene and polypropylene. The material may be a mixture of these or other polyolefins.

In an embodiment, the joint between one or more of the regions of the blank or the enclosure may be a fold in a continuous piece of web. Alternatively, one or more of the regions may be formed from separate webs of material and the joint may be made mechanical means such as by stitching and/or gluing and/or riveting, etc.

One significant advantage of the transport enclosure of the present invention is that it can be used to repackage waste white goods which are intended for disposal. Such goods at the end of their lifetime may be damaged or corroded and may be leaking fluid such as water or oil. Ordinarily, this would mean that they would be difficult or dangerous to handle and may also cause a mess to the purchaser's property. The transport enclosure of the present invention overcomes these problems by providing a re-sealable enclosure which can be used to repackage the waste goods. The waste goods can then be taken away for disposal without damage to the purchaser's property and without risk of injury to the delivery personnel. Additionally, the purchaser does not have to dispose of any packaging and is simply left with white goods ready for use. Similarly, the delivery agents do not have to dispose of packaging materials. Thus the cost of providing new packaging each time is avoided as is the cost of disposing of old packaging. There is also a significant environmental benefit which should not be underestimated.

The present invention has a number of advantages over the prior art. Firstly, it is relatively easy to manufacture. Secondly, it is easy to use because the article can simply be laid on the unfolded fibre web (which is in the form of a sheet) and then enclosed or easily introduced into the enclosure because of its relative rigidity. Also it aids the handling and carrying by the warehouse personnel. Thirdly, the sleeve is durable and provides considerable protection against damage to the article, and certainly more than would be the case with cardboard. Fourthly, the sleeve can be reused a number of times which provides a further economic advantage.

The different pairs of opposable portions may be the same size or of different size from one another.

In preferred embodiments of all aspects of the present invention, the first, second, third and optional fourth protective regions and the portions comprised therein will be so configured that the enclosure in use is in the form of a cuboidal box, chest coffer or trunk.

In the configuration, the portion of the third region integral with or attached to and joining the first and second pairs of opposable portions of the first and second regions forms the base of the enclosure, the first and second pairs of opposed portions of the first and second regions form the upright faces of the enclosure; and the optional fourth region comprising a portion integral with or attached to the first or second region forms a lid to the enclosure. In use this serves to enclose the article completely. One or more edges of each of the first, second, third and/or fourth regions may optionally, and independent of one another, include releasable fastenings. Such fastenings include press-fit couplings such as Velcro™ fastenings or studs and corresponding eyelets or zippers to enable fastening with the corresponding edge of an adjacent region when in use. The Velcro may be provided on flaps which overhang the relevant edge and the edge of the corresponding region.

In another embodiment the first pair of opposable portions comprise a laminate of the woven base layer and a layer of plastics material is provided for one or both of the portions as a reinforcing or stiffening aid to prevent damage to the goods within the container. The or each piece of plastics material may be in the form of rigid sheet or it may be a flexible layer or web of material. The or each piece of material is held adjacent to or fastened to the base layer so as to provide reinforcing. The plastics material may be bonded directed to the base layer, for example using adhesive. Alternatively, it may be mechanically fastened using stitching together with or without the use of an overlapping portion of web to hold it in place. The overlapping web may simply cover part of the edges and/or corners to hold the plastics sheet in place. Equally, the plastics sheet may be held adjacent to the respective opposable regions by mechanical means such as staples or rivets.

In the same way, the second, third and fourth protective regions may independently include a layer of plastics material. Again, this may be in the form of a rigid sheet such as corrugated polypropylene or a flexible layer or web of material eg woven synthetic fibre.

The plastics material used in any two corresponding opposable regions may be the same piece of plastics material if it continues through the third protective region. Similarly, in another embodiment the same piece of plastics material may be used to cover all of the protective regions and thus may be substantially the same shape as to the underlying blank web of material.

In another embodiment, each of the protective regions may independently be in the form of a pocket containing a layer of plastics material. The pocket is formed from two layers of the base layer of woven fibre which serve to encompass the plastic layer. Each region may thus include its own pocket which contains a plastic layer.

It will be seen that the portions of the regions used to form the enclosure in this embodiment will be rectangular. The transport enclosure in use is substantially cuboid in shape. As discussed previously, typical goods that might be transported include: fridges, freezers, cookers, washing machines and tumble driers. Other similar appliances could also be transported. Thus large electrical goods such as televisions may also be transported using the enclosure of the invention.

It will also be seen that the corresponding blank which is used to form the enclosure will be cruciform with the first and second pair of opposable portions of the protective regions forming the arms of the cross, and the portion of the optional fourth region that is integral with or attached to the first or second region forming an extension of one arm.

In this embodiment, the enclosure is often readily assembled by folding up the arms of the cross (including the portion of the optional fourth region if present) and reversibly attaching them to each other, for example along their edges to form the upright faces of the cuboidal box, chest coffer or trunk assembly, and the optional lid. The enclosure may be just as readily disassembled, e.g. by detaching the edges to revert to the blank, which is intended to be reused.

In other embodiments of all aspects of the present invention, the first, second, third and optional fourth protective regions and the portions comprised therein will be so configured that the enclosure in use is in not in the form of a cuboidal box, chest coffer or trunk. It will be seen that at least one of the portions of the regions used to form the enclosure in this embodiment will generally not be rectangular.

It will also be seen that the corresponding blank which is used to form the enclosure will be not be plain cruciform, and that when the enclosure is assembled by folding up the blank, the first and second pair of opposable portions of the protective regions and/or that of the optional fourth region if present may not meet or overlap each other, for example along their edges, to enclose the article completely.

If it is desired that the enclosure in any of the preceding embodiments will more fully enclose the article, it will be seen that the corresponding blank which is used to form the enclosure can optionally be provided with at least one further protective region. Alternatively, or in addition the various regions may independently also be so configured to include one or more additional regions of material to act as sealing regions. This means that the enclosure in use has such further protective 'sealing' regions, such that on folding up the blank the resultant enclosure will have sealing regions that bridge the gaps between the first, second, third and/or optional fourth portions of the protective regions.

Accordingly, in one embodiment of each of the various aspects of the present invention described above the web comprises at least one sealing region with a portion integral or attached to one or more of a first, second, third and fourth protective region, and adapted in the enclosure in use to cover or overlap partially with at least one surface of the article.

In all embodiments described previously, often at least the portion of the third region that forms the base of the assembled enclosure comprises a layer of a plastics material which is retained in contact with a base layer surface. This serves to brace, reinforce, strengthen, stiffen and/or support what is often the main load-bearing integer of the enclosure.

The present invention therefore provides a transport enclosure and a blank from which the enclosure may be assembled which have a number of advantages over conventional means of protection against the risk of damage in transit to, e.g. white goods.

The protective regions of the web are strong and resistant to puncture, cuts or tearing by sharp points or edges, and thus offer good protection to the surfaces of the article against such damaging impacts, in addition to protection against blunt impacts sustained during normal handling, transportation and storage.

The enclosure is readily assembled from the blank around the article, e.g. by reversibly attaching the pairs of opposable portions of the first and second and third regions of the web, and may be readily disassembled in whole or in part to permit easy removal of the article from the protective enclosure. It may be completely disassembled to revert to the flat blank, which may be stowed in minimal space, and then reused.

In this regard the present invention provides a protective enclosure which is as ecologically and economically friendly as possible, by avoiding single trip waste packaging that is not designed to be reused, and the corresponding EU packaging waste levies.

Even when reuse ceases to be a practical option through long term wear and tear, its component materials are recyclable, so that it may be disposed of by recycling, unlike known structures and assemblies of cardboard and plastics film.

Further, if one of the first and second layers of the web wears out before the other, it can be replaced without needing to replace the whole web.

The article within the enclosure is well protected from impact damage, and although relatively bulky and/or heavy is easily transported. The present invention clearly improves on the disadvantageous known structures and assemblies, such as those comprising plastics films.

The blank and enclosure of the present invention is constructed of at least one web.

They may be formed from a single web which is suitably folded and fastened. They may be formed from more than one web which are fastened together. The web or webs may be reversibly, or (preferably) fastened, for example by ties, bands, tapes, buckles, eyelets with cooperating retaining means, such as ties, catches, clasps, clips or hook- and-loop (Velcro') fasteners, press studs or preferably by permanent closures, such as seams of one or more lines of stitching, or bonding, e.g. with adhesive or thermobonding. As described above, where more than one layer of web is present, it may form a pocket and the pocket may contain a layer or sheet of plastics material as a reinforcing aid.

The enclosure is often intended for temporary protection to the enclosed article, often for white goods, for example kitchen and catering equipment, laundry equipment and heating equipment, either unpackaged or in a conventional, generally cuboidal, box, carton, pack or package, e.g. of corrugated cardboard sheet materials.

It is thus often designed to be marginally larger than the article which is bare or enclosed in its packaging, to provide a snug fit, and the blank from which the enclosure is formed and the web are correspondingly dimensioned.

The web comprises a base layer of woven fibre, having at least the following regions: a first protective region comprising a first pair of opposable portions adapted in the enclosure in use to cover two opposing surfaces of the article, a second protective region comprising a second pair of opposable portions adapted in the enclosure in use to cover another two opposing surfaces of the article, a third protective region comprising a portion integral with or attached to and joining the first and second pairs of opposable portions of the first and second region, and adapted in the enclosure in use to cover a further surface of the article, and optionally a fourth protective region comprising a portion integral with or attached to the first or second region, and adapted in the enclosure in use to cover a surface of the article opposing the further surface, . At least one of the portions and regions comprises a layer of a plastics material which is retained in contact with a surface of the base layer,

In an embodiment, the plastics material is corrugated plastics material. Preferably, the plastics material is corrugated polypropylene. This is a fluted material which has a high impact resistance and is very light. The material can be extruded in sheet format and cut to length. Additionally it has the advantage of being made from recycled materials. Preferably, the plastics material has a weight of 300 to 1 100 gm^"2.

The layer of a plastics material may be retained in contact with a surface of the base layer by a single piece of base layer fibre web being suitably folded and fastened around at least one piece of sheet material to house or enclose the or each piece in the base layer web, by fastening together two or more pieces of base layer around at least one piece of sheet material to house or enclose the or each piece in the fibre webs, and/or by attachment to one or more pieces of base layer fibre web by permanent or reversible cooperating attachment means.

The or each piece of sheet material is preferably enclosed in at least one piece of base layer fibre web.

The base layer may be reversibly, or (preferably) permanently fastened to itself and/or the plastics material, for example by ties, bands, tapes, buckles, eyelets with cooperating retaining means, such as catches, clasps, clips or hook-and-loop ('Velcro') fasteners, press studs or preferably by permanent closures, such as seams of one or more lines of stitching, or bonding, e.g. with adhesive or thermobonding.

The or each fibre web may as appropriate be folded or placed to form an overlap with itself or another fibre web along at least some of the edges of a layer of plastics material, and the overlaps fastened to each other along or near the edges of the overlap, conveniently with stitching or bonding (including thermobonding) opposing surfaces of the overlaps together to form a covering for the plastics material. This may be a loose wrap or jacket, or preferably a snug sheath. An important function of the overlapping material is to retain the layer of plastics material in place, and the overlaps need only be wide enough to take a line of bonding. They may thus not necessarily extend along all the edges of the fibre web to form a completely enclosing envelope, and may thus extend along some sides and/or part of some sides to form a bag, pocket or pouch for the plastics material, or to only retain the corners or edges of a sheet of plastics material.

Preferably, each portion of each region comprised in the base layer of woven fibre comprises two coterminous superimposed layers of woven fibre, between the opposing surfaces of which lies a slightly less than coterminous sheet of plastics material.

This is retained in contact with a surface of the base layer, by stitched or bonded seams around the edges of the layers of woven fibre forming a completely enclosing envelope sheet around the sheet which is held in place by the seams.

Generally, in preferred embodiments of all aspects of the present invention, the fibre web covers two opposing surfaces of the sheet material which is enclosed completely over the protective region.

As described in further detail below, the web of fibre, especially if of relatively heavy gauge, is intended inter alia to provide adequate protection against damaging contact in transit, in particular to make the enclosure in use resistant to punctures, cuts or tears by sharp points or edges, such as impacts sustained during normal handling, transportation and storage.

White goods with enamelled metalwork are particularly susceptible to and at risk of such damage in transit.

The often at least partially enclosed plastics material (often as a sheet) is intended inter alia to brace, reinforce, strengthen, stiffen and/or support the protective regions of the web.

Thus if one surface of the plastics material is not fully enclosed by the web in a protective region, it will be seen that in the enclosure corresponding to the blank, it is preferred that it forms an inner surface. In the present invention, the blank for a transport enclosure comprises a third protective region and an optional fourth region, each comprising a portion integral with or attached to the first and/or second pairs of opposable portions of the first and second region.

The blank which is used to form the enclosure may thus comprise a single integer when it comprises a third protective region and an optional fourth region, each comprising a portion integral with or attached to the first and/or second pairs of opposable portions of the first and second regions.

In such case, the enclosure is assembled by folding up the blank along the lines between the third protective region and the first and second regions.

The blank which is used to form the enclosure may thus also be formed from several integers when it comprises a third protective region and an optional fourth region, each comprising a portion attached to the first and/or second pairs of opposable portions of the first and second region.

In such case, the blank may be assembled by attaching together separate first and second opposable portions of the protective regions and/or those of the optional fourth region if present; the enclosure may then be assembled by folding up the blank.

Alternatively, the portions may be attached to each other In a folded-up configuration, for example along their edges to form the faces of a cuboidal box, chest coffer or trunk assembly directly. This will be significant in those embodiments generally in which not only the enclosure but also the blank is intended to be readily disassembled, e.g. by detaching the edges of the portions in the blank, to be stowed in even less space. In such cases, the means of attachment will be reversible.

In the present invention generally, any portion integral with the first or second region, may be conveniently formed in a blank which is used to form the enclosure by two coterminous superimposed layers of woven fibre, between the opposing surfaces of which lies a sheet of plastics material in each portion.

The blank may, e.g. be cruciform with the first and second pair of opposable portions of the protective regions forming the arms of the cross, and the portion of the optional fourth region that is integral with or attached to the first or second region forming an extension of one arm, with a sheet in each arm.

Each sheet of plastics material will be slightly less than coterminous than its respective portion, and it is retained in contact with a surface of the base layer in its portion, e.g. by stitched or bonded seams around the edges of the layers of woven fibre forming a completely enclosing envelope sheet around the sheet which is held in place by the seams.

A seam along each common edge of two integral portions, e.g. the third and optional fourth and the first and/or second pairs of opposable portions of the first and second region forms part of an enclosure around the adjacent sheet.

Correspondingly, in the present invention generally, and in this embodiment in particular, any portion attached to the first or second region, may be conveniently formed by two coterminous superimposed layers of woven fibre, between the opposing surfaces of which lies a sheet of plastics material in the portion, which are joined together as above to enclose the sheet.

Although only at least one of the portions of the regions thus formed need contain a layer of plastics material, embodiments in which all portions do so will generally be preferred.

In the embodiments of the aspects of the present invention which provide blanks and enclosures with sealing regions that bridge the gaps between the first, second, third and/or optional fourth portions of the protective regions, the or each sealing region will generally comprise a portion integral with or attached to the first or second region. This will generally be of similar construction, and integral with or attached in a similar way, to other portions in the blank or enclosure as described above.

In the protective enclosure assembled from the blank around the article, the first second, third and optional fourth protective regions and the portions comprised therein may be held in place by any applicable (generally reversible) means.

Often the upright faces of the enclosure are held in place. In less preferred embodiments of the enclosure of the present invention, the first and second and/or the third and optional fourth protective regions will be bound in place by flexible bands, belts, loops or straps, e.g. of extruded sheet or tubular plastics material.

These will pass around the outside of the first and second regions and/or the third and optional fourth regions.

The relevant regions may be provided with retaining loops, sleeves or conduits through which the bands, belts, loops or straps pass to hold them in place.

Alternatively or additionally, opposing portions of the first and second regions may be provided with pairs of such loops, sleeves or conduits in register through which the bands, belts, loops or straps pass over the portions of the other region or the optional fourth region or the top of the enclosed article to hold them in place.

In preferred embodiments of the invention, the regions are held together by any of the reversible attachment means and materials described above that are not separate integers to the blank or enclosure. Preferred such attachment means include hook- and-loop ('Velcro') fasteners and press studs, more preferably hook-and-loop ('Velcro') fasteners.

One advantage of such means is that the structure is thereby adapted to be readily assembled, and disassembled in whole or in part to permit easy removal of the article from the enclosure, by relatively unskilled persons.

In a preferred embodiment of the invention, e.g. relevant portions of the first, second, third regions and optional fourth regions of the web, are provided with cooperating attachment means, such as hook-and-loop (Velcro') fasteners or press studs, or less preferably eyelets and ties, catches, clasps, clips or the like.

At least some of the edges of a portion of the fibre web may as appropriate be provided with an extending flap of material adapted in the enclosure in use as appropriate to be folded or placed to form a overlap with part of an adjacent protective portion and/or a similar flap thereon. The opposing surfaces of the overlap comprise cooperating components of reversible attachment means, such as Velcro hooks and Velcro loops, or aligned press studs and cooperating sockets, or less preferably aligned eyelets with ties, often disposed along the flap or edge of the portion.

In one embodiment with rectangular protective regions, producing a generally cuboidal enclosure when assembled, the flaps and reversible attachment means are conveniently along upright edges of the enclosure.

In the enclosure and corresponding blank which is used to form the enclosure of the present invention, the protective regions should be strong and resistant to puncture, cuts or tearing by sharp points or edges.

They thus offer good protection to the enclosed article against such damaging impacts, in addition to protection against blunt impacts sustained during normal handling, transportation and storage.

The base layer of woven fibre is made of a flexible material in the form of a lattice, mesh, net or more often a closely woven web, such as woven polymer fibre, although other materials are not excluded. Preferred materials include such polymers as polyolefins, e.g. polyethylene and polypropylene.

One advantage of polypropylene is that it is sufficiently strong to withstand the tensile forces that occur when bulky and/or heavy articles are loaded or lifted in the transport enclosure.

Another is that woven sheets of it are sufficiently flexible to be folded into required shapes, e.g. in an enclosure such as a box or carton, and are easily fabricated.

The weight of the base layer of a woven plastics material such as polypropylene is preferably in the range of 100 to 300 gm^"2, more preferably 160 to 240 gm^"2. The base layer may include a coating which, when present, may account for a further 20 to 35 gm^"2 of the weight of the web. The coating may aid cleaning after use or may provide some other function such as waterproofing or prevention of the ingress of dirt into the web.

Such a structure has a compromise in properties between durability, strength, flexibility and provides adequate protection against damaging contact in transit.

Some structures of the enclosure of the present invention are each adapted to be assembled by folding and attachment to itself by means of eyelets with cooperating retaining means, such as ties, catches, clasps, clips, etc, often disposed along the flap or edge of a portion as referred to above.

The eyelets may impact on the necessary strength of the fibre web, as there may be a tendency to tearing of the base layer of woven fibre from the edges of the apertures in the fibre web which receive the eyelets, which disrupt the web.

In addition to giving protection against blunt impacts sustained during normal handling, transportation and storage, the web in the protective regions should be strong and resistant to any such tearing.

We have found that woven sheets of a plastics material such as polypropylene, preferably in the weight range of 100 to 300 gm^"2, more preferably 160 to 240 gm^"2 are sufficiently strong to withstand the shear forces that occur in such cases.

Alternatively, the portions along the edges by which, e.g. the faces of a cuboidal box, chest coffer or trunk assembly may be attached to each other and which contain the eyelets may be reinforced by means of one or more extra lines of stitching, or one or more extra layers of woven fibre which are joined permanently to the base layer, e.g. by seams of one or more lines of stitching, or bonding, e.g. with adhesive or thermobonding.

Such reinforcement may also be desirable when the attaching means are, e.g. hook- and-loop (Velcro') fasteners or press studs, which do not penetrate the fibre web but more appropriately are often stitched to the web. Any extra layers may, e.g. be formed by folding the web back to form an overlap with itself which extends along the relevant edge of the fibre web. Alternatively or additionally the overlap from the fold-back or from two coterminous superimposed layers of woven fibre may form a completely enclosing envelope or a bag, pocket or pouch between the opposing surfaces of which lies a sheet of plastics material, which will extend over part or all of the relevant portions of the regions of the blank and the enclosure formed from it.

Such a laminate may thus be formed from two or more superimposed layers of woven fibre, which may as above at least partially enclose a sheet of plastics material.

More than two layers of woven fibre may be used. Preferably, each layer of woven fibre is of woven polypropylene fibre, although other materials, and different materials in different layers or the same layer of woven fibre, are not excluded. The polypropylene may be low density or (preferably) high density polypropylene. Each layer may be of woven polyethylene fibre, which may be low density or (preferably) high density polyethylene.

The layers of woven fibre may have the same or different weave patterns.

Preferably the fibre weaves or directions in adjacent layers are at an angle to one another, to make the strength of the laminate less anisotropic. For this reason, in preferred embodiments of all aspects of the present invention, two coterminous superimposed fibre webs extend completely over each protective region, and at last partially enclose a sheet of plastics material which is thus held between their opposing surfaces by permanent lines of stitching, or bonding, e.g. with adhesive or thermobonding. Unlike an overlap formed by folding and attachment to itself of a single layer, the layers of the laminate may be aligned at an angle to each other.

The transport enclosure of the present invention is often intended for temporary protection to an enclosed article, which is often white goods, for example kitchen and catering equipment, laundry equipment and heating equipment, either unpackaged or in a conventional, carton or pack, These are often relatively bulky and/or heavy.

The enclosure of the present invention may thus conveniently be provided with generally two or more lifting grips, handholds or handles, often one or more pairs on opposite sides of the enclosure, e.g. on the first and second regions on the external surface of a generally cuboidal, box or package, unless the particular use context requires otherwise.

Accordingly, the fabric web of the enclosure is provided with one or more handles or lifting loops on one or more pairs of opposed sides to facilitate lifting and handling of the enclosure when it contains an article. These are generally provided in pairs on opposite sides of the enclosure. The handles can be in the form of loops of material which are stitched to the fabric web. Preferably, pairs of handles are provided at either side of the top and/or bottom of the enclosure.

The handles or loops may be in the form of flexible bands, belts, loops or straps formed from extruded or woven sheet or tubular plastics material, commensurate with the weight of the article to be transported and the amount of manual lifting that is required.

Preferred materials include those of the layers of fibre web described above as preferred, e.g. woven polypropylene fibre, or less favourably extruded tubes or pipes, which may be of cylindrical cross-section; and optionally ridged and/or grooved to provide a better grip.

All these are often stitched to the enclosure, which, it will be understood, may need to be reinforced as described above at the point of attachment.

In another form, the grips or handles may be in the form of rigid rings or D-bars, again optionally ridged and/or grooved to provide a better grip. All these are often stitched to the enclosure with loops, and the enclosure may need to be reinforced as described above at the point of attachment. They may be in pairs on opposing surfaces of the enclosure.

In another embodiment, the enclosure includes one or more loops which in use are in the region of the base. These loops may be in the form of handles to allow carrying by the delivery operator. Alternatively, one or more pairs of loops may be formed in the web in the region of the base (defined when in use) so that the tines of a fork lift truck can be inserted. This means that heavy goods can be mechanically lifted and transported easily. At least one protective region comprises plastics material (often as a sheet), intended inter alia to brace and reinforce the base layer fibre web in the relevant portions of the blank or the enclosure in use.

As above, the base layer web is often suitably folded and fastened around at least one piece of sheet material to house or enclose the or each piece in the web in the relevant protective region between the opposing surfaces of which lies a sheet of plastics material in the portion, which are joined together as above to enclose the sheet.

In the embodiments of the aspects of the present invention which provide blanks and enclosures with sealing regions that bridge the gaps between the first, second, third and/or optional fourth portions of the protective regions, the or each sealing region will generally comprise a portion integral with or attached to the first or second region.

This will generally be of similar construction, and integral with or attached in a similar way, to other portions in the blank or enclosure as described above.

In all the relevant regions and portions, preferably, the plastics material is fully enclosed by the web in a protective region.

Preferably, the plastics material is a sheet of polypropylene which is corrugated, ribbed, ridged and/or grooved. The polypropylene may be low density or (preferably) high density polypropylene. Alternatively the sheet may be of polyethylene. The polyethylene may be low density or (preferably) high density polyethylene.

More preferably, the sheet is a polypropylene sheet formed from a plurality of longitudinally fused tubes or pipes. These may be of cylindrical or more often rectangular, for example square cross-section, formed by conventional means, often by co-extrusion. Packaging comprising such multitubular sheet material is firm and stiff, but not rigid, and resiliently pliable, which gives it high impact resistance. Its tubular structure means that, although strong, it has a low density, typically only weighing 300 to 1 100 gm^"2. It is thus ideally adapted for use in the present blank and enclosure.

In addition to the (often waterproofed) web, the plastics sheet material structure prevents ingress of dirt and water, and so provides protection against water damage to and/or soiling of the enclosed article. A suitable coating enhances this property.

It is preferred that in the protective enclosure of the present invention, the fibre web and plastics material are of the same material, to be ecologically as friendly as possible. When reuse ceases to be a practical option through long term wear and tear, its component materials may be disposed of by recycling through a single channel unlike known composite assemblies of cardboard and plastics film. The use of the same materials facilitates recycling.

The present invention will now be described with reference to the following drawings, in which:

Figure 1 is a plan view of a blank of the present invention; and

Figure 2 is an isometric view of an enclosure which is formed from the blank is intended for temporarily housing or enclosing an article in transit.

In Figure 1 , a cruciform blank has a first protective region (1 ) comprising a first pair of opposed portions (2, 2) adapted in the enclosure in use to cover two opposing surfaces (here two opposing upright faces) of the enclosed article; a second protective region (3) comprising a second pair of opposed portions (4, 4) adapted in the enclosure in use to cover another two opposing surfaces (here another two opposing upright faces) of the article, with the first and second pair of opposable portions (2, 2, 4, 4) of the protective regions forming rectangular arms of the cross, a third protective region (5) comprising a portion (6) integral with and joining the first and second pairs of opposed portions (2, 2, 4, 4) of the first and second regions (1 , 3), and adapted in the enclosure in use to cover a further surface (here the base) of the article, and a fourth protective region (7) comprising a portion (8) integral with the first region (1 ), and adapted in the enclosure in use to cover a surface of the article opposing the further surface (here the top) of the article.

Each of the first and second portions (2,2,4,4) of the first and second regions (1 , 3) has a laterally extending flap (9,9,10,10,) and the portion (8) of the fourth region (7) has a longitudinally extending flap (1 1 ), each adapted in the enclosure in use to be folded to form an overlap with an adjacent part of a protective portion. Thus, the flaps (9,9,10,10) are each adapted in the enclosure in use to be folded to form an overlap with respective parts (12,12,13,13) of the adjacent protective portions to form the upright edges of the generally cuboidal enclosure shown in Figure 2. The portion (7) is adapted to form a lid to the enclosure in use to enclose the article completely. The longitudinally extending flap (1 1 ) is adapted in the enclosure in use to overlap an adjacent part (14) of a protective portion.

The plan view of the blank of Figure 1 for the enclosure of Figure 2 is a view of the eventual inner surface of the enclosure.

The 'inner' surfaces of the flaps (9,9,10,10,11 ) comprise first components of reversible attachment means, here pads of Velcro hooks or Velcro loops (15,15,16,16,17). The flaps are adapted to overlap opposing outer surfaces of the enclosure in use on the parts (12,12,13,13,14).

These opposing surfaces of the overlap comprise second cooperating components of the reversible attachment means, such as pads of Velcro loops and Velcro hooks respectively (18,18,19,19,20) (not shown), aligned with the first components.

The flaps and reversible attachment means are thus along upright edges of the generally cuboidal enclosure of Figure 2 when assembled, or respectively provide a closure for its lid.

It will be appreciated that the flaps may be adapted to overlap the inner surface of the enclosure, in which case, the first components of reversible attachment means, here pads of Velcro hooks or Velcro loops (15,15,16,16,17), will be on the 'outer' surfaces of the flaps, and the second cooperating components of the reversible attachment means, such as pads of Velcro loops and Velcro hooks respectively (18,18,19,19,20) (not shown), aligned with the first components will be on the 'inner' opposing surfaces of the overlap.

The blank from which the enclosure is formed is made up from two cruciform coterminous superimposed base layers of woven fibre (20, 21 ) (21 not shown), with the first and second pair of opposable portions (2,2,4,4) of the protective regions (1 ,3).

These are linked by the portion (6) of the third region (5) forming the arms of the cross, and the portion (8) of the fourth region (7) that is integral with the first region (1 ) forms an extension of one arm.

Between the opposing surfaces of each arm of the cross, is a slightly less than coterminous sheet of plastics material (22,22,23,23,24,25) (shown in dotted line).

Each is retained in contact with a surface of the base layer, by stitched or bonded seams (26) around the edges of the base layers (20,21 ) of woven fibre forming a completely enclosing envelope around the sheet which is held in place by the seams (26).

The seams (29,29,29,29,30) effectively form integral crease-line hinges respectively between the first and/or second pairs of opposable portions (2,2,4,4) of the first and second protective regions (1 ,3) and the portion (6) of the third protective region (5), and the portion (8) of the fourth region (7).

In this embodiment of Figure 1 , the enclosure of Figure 2 is readily assembled by folding up the arms of the cross (including the portion (8) of the fourth region (7)) and reversibly attaching them to each other along their edges to form the upright faces (31 ,31 ,32,32) of the cuboidal enclosure assembly of Figure 2, with its lid (33).

Often the article to be enclosed (often for white goods, for example kitchen and catering equipment, laundry equipment and heating equipment, either unpackaged or in a conventional, generally cuboidal, box, carton, pack or package, e.g. of corrugated cardboard sheet materials) is initially placed on the portion (6) of the third protective region (5). Pairs of opposable portions (2,2,4,4) are then folded up around and reversibly attached to each other to easily fabricate the enclosure of Figure 2 around the article in situ.

The enclosure may be just as readily disassembled, e.g. by detaching the edges to revert to the blank, which is intended to be reused.

In Figure 2, a transport enclosure for enclosing at least one article, which blank comprises a first protective region (1 ) comprising a first pair of opposable portions (2,2) adapted in the enclosure in use to cover two opposing surfaces of the article, a second protective region (3) comprising a second pair of opposable portions (4,4) adapted in the enclosure in use to cover another two opposing surfaces of the article, a third protective region (5) comprising a portion (6) integral with and joining the first and second pairs of opposable portions (2,2,4,4) of the first and second regions (1 ,2), and adapted in the enclosure in use to cover a further surface of the article, and a fourth protective region (7) comprising a portion (8) integral with the first region, and adapted in the enclosure in use to cover a surface of the article opposing the further surface.

Each of the first and second portions (2,2,4,4) of the first and second regions (1 , 3) has a laterally extending flap (9,9,10,10,) and the portion (8) of the fourth region (7) has a longitudinally extending flap (1 1 ), each forming an overlap with an adjacent part of a protective portion. Thus, the flaps (9,9,10,10) are each folded to form an overlap with respective parts (12,12,13,13) of the adjacent protective portions to form the upright edges of the generally cuboidal enclosure shown in Figure 2. The portion (7) forms a lid to the enclosure in use to enclose the article completely. The longitudinally extending flap (1 1 ) overlaps an adjacent part (14) of an upright side.

The 'inner' surfaces of the flaps (9,9,10,10,1 1 ) comprise first components of reversible attachment means, here pads of Velcro hooks or Velcro loops (15,15,16,16,17). The flaps are adapted to overlap opposing outer surfaces of the enclosure in use on the parts (12,12,13,13,14). These opposing surfaces of the overlap comprise second cooperating components of the reversible attachment means, such as pads of Velcro loops and Velcro hooks respectively (18,18,19,19,20) (not shown), aligned with the first components.

It will be appreciated that the flaps may be adapted to overlap the inner surface of the enclosure.

In such case, the first components of reversible attachment means, here pads of Velcro hooks or Velcro loops (15,15,16,16,17), will be on the 'outer' surfaces of the flaps, and the second cooperating components of the reversible attachment means, such as pads of Velcro loops and Velcro hooks respectively (18,18,19,19,20) (not shown), aligned with the first components will be on the 'inner' opposing surfaces of the overlap.

The enclosure is made up from two cruciform coterminous superimposed base layers of woven fibre (20, 21 ) (21 not shown), with the first and second pair of opposable portions (2,2,4,4) of the protective regions (1 ,3).

The enclosure of Figure 2 is readily disassembled by detaching the lid (33) and the upright faces (31 ,31 ,32,32) of the cuboidal enclosure assembly of Figure 2 from each other along their edges, to regenerate the blank of Figure 2, which is intended to be reused.

Claims

1. A blank for a transport enclosure for housing or enclosing at least one article, the blank comprising a web which is formed from at least a base layer of woven fibre, having at least the following regions: a first protective region comprising a first pair of opposable portions adapted in the enclosure in use to cover two opposing surfaces of the article, a second protective region comprising a second pair of opposable portions adapted in the enclosure in use to cover another two opposing surfaces of the article, a third protective region comprising a portion integral with or attached to and joining the first and second pairs of opposable portions of the first and second region, and adapted in the enclosure in use to cover a further surface of the article, and optionally a fourth protective region comprising a portion integral with or attached to the first or second region, and adapted in the enclosure in use to cover a surface of the article opposing the further surface, wherein at least one of the portions and/or regions of the web comprises a layer of a plastics material which is retained in contact with a surface of the base layer.

2. A transport enclosure for housing or enclosing at least one article, which enclosure comprises a web which comprises a base layer of woven fibre, having at least the following regions: a first protective region comprising a first pair of opposed portions adapted in the enclosure in use to cover two opposing surfaces of the article, a second protective region comprising a second pair of opposed portions adapted in the enclosure in use to cover another two opposing surfaces of the article, a third protective region comprising a portion integral with or attached to and joining the first and second pairs of opposed portions of the first and second region, and adapted in the enclosure in use to cover a further surface of the article, and optionally a fourth protective region comprising a portion integral with or attached to the first or second region, and adapted in the enclosure in use to cover a surface of the article opposing the further surface, wherein at least one of the portions and regions comprises a layer of a plastics material which is retained in contact with a surface of the base layer.

3. A blank or transport enclosure as claimed in claim 1 or 2, wherein the blank is designed so that in use it covers a regular-shaped article having similar dimensions of height, width and length.

4. A blank or transport enclosure as claimed in claim 1 , 2 or 3, wherein the base layer of woven fibre which forms the web is a polymeric material.

5. A blank or transport enclosure as claimed in claim 4, wherein the polymeric material is polyethylene, polypropylene or a mixture of these.

6. A blank or transport enclosure as claimed in any of claims 1 to 5, wherein the joint between one or more of the regions of the blank or the enclosure may be a fold in a continuous piece of web.

7. A blank or transport enclosure as claimed in any preceding claim, wherein one or more edges of each of the first, second, third and/or fourth regions may optionally, and independent of one another, include releasable fastenings to enable fastening with the corresponding edge of an adjacent region when in use.

8. A blank or transport enclosure as claimed in any preceding claim, wherein the first pair of opposable portions comprise a laminate of the woven base layer and a layer of plastics material is provided for one or both of the portions as a reinforcing or stiffening aid.

9. A blank or transport enclosure as claimed in any preceding claim, wherein any of the second, third and fourth protective regions may independently include a layer of plastics material.

10. A blank or transport enclosure as claimed in claim 8 or 9, wherein the or each piece of plastics material may be in the form of rigid sheet or it may be a flexible layer or web of material.

1 1. A blank or transport enclosure as claimed in any of claims 8, 9 or 10, wherein the or each piece of material is held adjacent to or fastened to the base layer so as to provide reinforcing.

12. A blank or transport enclosure as claimed in any of claims 9 to 1 1 , wherein the plastics material is corrugated polypropylene, preferably having a weight of 300 to 1 100 gm^"2.

13. A blank or transport enclosure as claimed in any preceding claim, wherein the fabric web of the enclosure is provided with one or more handles or lifting loops on one or more pairs of opposed sides, preferably wherein the handles or loops are in the form of flexible bands, belts, loops or straps formed from extruded or woven sheet or tubular plastics material.

14. A method of using a protective enclosure of the first aspect to transport a housed or enclosed article and/or to protect it against damaging contact.