Packaging system and method

Abstract

 A packaging system includes an outer bag (21) having an inner bag (23) suspended therein to define an inflatable chamber (22) substantially surrounding the inner bag (23). When the chamber is charged with a filler medium, such as pressurized air, the outer bag (21) will inflate to suspend the inner bag (23) at a fixed position therein. The inner bag (23) defines a pocket (24) adapted to receive and retain an article A, pre-packaged therein. In one embodiment of this invention (Figures 1-10), the overlying panels (25-28) forming the bags are completely sealed together about their peripheral edges after the article is inserted into the pocket (24). In another embodiment (Figures 11-14), the frontal side of the packaging system remains open to permit insertion of the article into the pocket (24) whereafter the inflatable chamber (22) of the packaging system is pressurized to compress superimposed panels (27, 28) of the inner bag (23) against the article A to retain it within the pocket (24).

Description

Technical Field

[0001] This invention relates generally to a packaging system and method and more particularly to a package comprising an outer bag having an article-carrying inner bag suspended therein.

Background Art

[0002] U.S. Patent No. 4,597,244, issued on July 1, 1986 to Daniel A. Pharo for "Method For Forming An Inflated Wrapping," discloses a packaging system and method wherein an article is packaged within an inflated, sealed bag. The present invention provides certain improvements and variations over the packaging system and method taught in the above patent.

DISCLOSURE OF INVENTION

[0003] The improved packaging system of this invention comprises an outer bag defining a sealed, inflatable chamber and an inner bag disposed within the chamber. Peripheral edges of the bags are secured together to suspend the inner bag within the outer bag. Means are provided for at least substantially filling the chamber with a filler medium to substantially surround the inner bag within the outer bag. The inner bag defines an article-receiving pocket therein whereby the article is supported and maintained in out-of-contact relationship relative to surrounding walls of the outer bag.

[0004] In one embodiment of this invention (Figures 1-­10), the article is placed in the pocket and then peripheral edges of the bags are fully sealed together. In another embodiment (Figures 11-14), one side of the packaging system remains open to expose the pocket.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Other objects and advantages of this invention will become apparent from the following description of exemplary embodi­ments shown in the accompanying drawings, wherein:

Figure 1 is an isometric view illustrating a packaging system embodying this invention;

Figure 2 is a side elevational view of the packaging system with a sidewall portion of an outer bag thereof being removed to illustrate an article-retaining inner bag disposed in suspended and supported relationship within the outer bag;

Figure 3 is an exploded isometric view illustrating cut panels utilized to form a package from the inner and outer bags;

Figure 4 is an isometric view illustrating insertion of an article into an open end of the inner bag;

Figure 5 is an isometric view illustrating means for inflating the outer bag with a pressurized fluid, such as air;

Figure 6 is an enlarged sectional view, taken in the direction of arrows VI-VI in Figure 5, illustrating the ingress of the pressurized fluid into the outer bag;

Figure 7 is an enlarged top plan view of a filling stem after it has been sealed, subsequent to inflation of the outer bag;

Figure 8 is an isometric view, partially illustrating a modified packaging system;

Figure 9 is a cross-sectional view illustrating inflation of an outer bag of the modified packaging system of Figure 8;

Figures 10 illustrates an alternative end closure for the packaging system;

Figure 11 is an isometric view illustrating a frontal side of a modified packaging system embodying this invention;

Figure 12 is a longitudinal sectional view through the modified packaging system, taken in the direction of arrows XII-XII in Figure 11;

Figure 13 is a top plan view of a pre­fabricated package adapted to be formed into the packaging system; and

Figure 14 is a side elevational view of the package.

BEST MODE OF CARRYING OUT THE INVENTION

[0006] Figures 1 and 2 illustrate a packaging system 20 comprising an outer bag 21 defining an inflatable, sealed chamber 22 therein. An inner bag 23, defining a pocket 24 for retaining an article A therein, is disposed within split chamber 22 and has peripheral edges thereof secured to the outer bag, in a manner hereinafter fully described, to support and suspend the inner bag within the chamber. As illustrated in Figure 3, outer bag 21 comprises a pair of superimposed and identical panels 25 and 26 whereas inner bag 23 comprises a pair of superimposed panels 27 and 28 connected together at a fold 29.

[0007] Each panel 25-28 is preferably composed of a gas-impervious composite laminate, such as the type described in U.S. Patent No. 4,597,244. For example, each flexible panel may comprise an intermediate layer of aluminum and outer and inner layers of a plastic heat-­sealable coating, such as polyethylene, adapted to reactivate (melt) in the range of 300^∼F. These types of composite laminates (which may be constructed to be highly flexible and inextensible or extensible) are well known in the art and, therefore, further description thereof is unnecessary for a full understanding of this invention. In the embodiment illustrated, the panels of Figure 3 are heat-sealed together at selected overlying peripheral edges thereof to preform a package for the packaging system with a closeable end closure 30, illustrated in its open condition in Figure 4.

[0008] Figure 3 illustrates overlying common sealing areas peripheral edge portions of the panels by dot-dash lines 31 for explanation and clarification purposes. The panels may be suitably cut and sealed together by conventional apparatus and methods, such as those described in U.S. Patent No. 4,545,844. It should be noted in Figures 1-4 that stem portions 32 and 33, formed integrally with and extending outwardly from edges of panels 25 and 26, respectively, are heat-sealed together about their edges. These stem portions are further heat-­sealed to underlying parallel side edges of panel portions 34 and 35 of panels 27 and 28, respectively, which are joined together at fold 29.

[0009] Fold 29 and the remaining portions of panel portions 34 and 35, extending transversely between the superimposed and sealed edges of panel portions 31-34, remain unsealed relative to stem portions 32 and 33. As shown in Figure 6, fold 29 extends a limited distance into a filling stem 36, defined by overlying and sealed stem portions 31 and 32. As described more fully hereinafter, a pair of inlets are thus formed at fold 29 to communicate a pressurized fluid, such as air, to split chamber 22 on either side of inner bag 23.

[0010] A method for packaging article A to form packaging system 20 and to suspend the article at a fixed position within chamber 22 of outer bag 21, as shown in Figure 2, will now be described with particular reference to Figures 4-7. After the package has been prefabricated to assume its open-ended envelope-like configuration illustrated in Figure 4, article A is inserted through the open end of inner bag 23 and into pocket 24. It should be understood that the article could be placed at any desired position within the inner bag and will be firmly held in such position when the packaging system is inflated or otherwise charged or filled with the preselected filler medium, as described hereinafter.

[0011] After the article has been placed within pocket 24 of inner bag 23, overlying edge portions of formerly open end 30 are heat-sealed together at a seam 37, as illustrated in Figure 5, to form an end closure. The sealing apparatus used for this purpose may be of the type described in U.S. Patent No. 4,597,244, such as the impulse table top bag sealer Model 210-8 manufactured by A. I. N. Plastics, Inc. of Mount Vernon, New York. Sealing of the open end of the package will thus fully seal pocket 24 of inner bag 23 and will also substantially seal chamber 22.

[0012] Inflating means for charging and at least substantially filling chamber 22 with a pressurized fluid is shown in the form of an opening uncovered by a tab 38 defined by a cut line formed only through stem portion 32. An inlet passage 39 to the chamber is defined within filling stem 36 (Figure 6). Alternatively, the inflating means for charging chamber 22 could comprise an inflation valve, such as the one disclosed in U.S. Patent No. 4,586,910 and illustrated at 40 in Figure 8.

[0013] After the open end of the package has been sealed at seam 37, a standard inflation apparatus, including a fill tube 41 (Figure 5), can be utilized to charge and pressurize split chamber 22 to an inflation pressure exceeding ambient pressure, e.g., exceeding 14.7 psi at sea level. Alternatively, human lung power could be utilized to inflate chamber 22 with air. Other types of gases, such as helium, could be utilized as the filler medium, as well as a suitable liquid, such as water. Alternatively or in addition to the pressurized fluid, the chamber could be filled with a plastic (e.g., urethane, polystyrene, etc.) material in solid (injected in liquid form and solidified) or pieces (e.g., balls or pellets) form.

[0014] After the package has been inflated to suspend inner bag 23 and article A at its preselected fixed position within chamber 22, fill tube 24 is removed. Tab 38 is simultaneously compressed into stem 36 to prevent the pressurized fluid from escaping. As shown in Figure 7, stem 36 is then quickly heat-sealed at a seam 42 (sealing only stem portions 32 and 33 together) and/or at a seam 42′ (sealing stem portions 32 and 33 and panel portions 34 and 35 together).

[0015] Referring to Figure 2, article A is thus substantially encapsulated by the filler medium and supported and held at a fixed position within chamber 22. Compressive forces occasioned by the pressurized fluid will be directed inwardly and uniformly against the exposed upper and lower surfaces of inner bag 23 to compress and conform the flexible wall panels of the inner bag to the contours of the article. Retention of the article in a fixed position within split chamber 22 is further aided by the horizontal components of forces acting on inner surface portions of transversely disposed side seams 43 and 43′ of outer bag 21.

[0016] The latter holding force desiderata is more clearly illustrated and pronounced in modified packaging system 20′ (Figures 8 and 9) wherein horizontal force components F will tend to place panels 27 and 28 of the inner bag in tension. In order to increase the horizontal force components F in this manner, outer bag panels 25 and 26 are prefabricated to have widths greater than the widths of panels 27 and 28 (Figure 8).

[0017] Figure 10 illustrates an alternative end closure for packaging system 22 that can be used in lieu of heat sealed seam 37 (Figure 1). In Figure 10, panels 25-28 are cut to different lengths to define relatively longitudinally staggered panel edges 25′-28′. A standard tape 44 is heat-sealed or mechanically secured over the ends of the panels to close and seal chamber 22 and pocket 24. Other types of end closures can be used such as a standard tape that is folded over the end of the package and then heat-sealed or mechanically sealed in a conventional manner thereover. The opposite ends of the tape are then folded inwardly towards each other and secured in place. Also, a standard tape can be secured to the outer side of panel 25 and a protective strip removed from the tape after article A (Figure 4) has been inserted into inner bag 23. The panels of the bags can then be folded on a preformed crease or fold line to secure the panels together. If so desired, the end edges of the panels can be staggered longitudinally in the manner described above in reference to Figure 10. The end closure can also be formed by press-fitting and clamping an elongated cylindrical rod within a separate and generally C-shaped retainer. The rod should be sufficiently elastic to be compressed into the cavity of the semi-rigid retainer and permitted to expand to firmly compress the panels of the end closure therebetween to seal and isolate chamber 22 and pocket 24 (Figure 2). Alternatively, the rod could be composed of a semi-­rigid plastic material with the retainer also being composed of a plastic material, but exhibiting sufficient flexure to spread and permit the rod to snap-fit or press-fit within the retainer in a well known manner.

[0018] Various opening devices and constructions can be utilized and formed into the end closure to open packaging system 20. For example, a cord or thread can be implanted in the heat-sealed end closure to adapt it for removal by a consumer. As an alternative or in addition to the cord, a second cord can be likewise implanted adjacent to heat-sealed side seam 43 or 43′ (Figure 1) to permit its removal and opening of the packaging system. The cords may be suitably secured within the underside of one of the panels forming inner pouch 23 whereby article A (Figure 2) will be exposed when the cord is removed.

[0019] Various other modifications can be made to the preformed package and completed packaging system of this invention without departing from the spirit and scope thereof. For example, panels 27 and 28 of inner bag 23 could comprise an open mesh or fishnet material to expose article A (Figure 2) to the filler medium contained in chamber 22. The package could also include additional bags, secured to bags 23 and 25 in the manner described above. Instead of using distal end 30 of packaging system 20 as the open side thereof, this end of the system could be heat-sealed during prefabrication of the package and one of the lateral sides left open and utilized for packaging purposes in the manner described above. Stem 36 could be eliminated and inflating means 38 or 40 relocated on the package (e.g., valve 40′ could be secured on panel 25 as shown in Figure 8).

[0020] The heat-sealed seams of the system could be formed in the manner described above, or the panels folded onto each other and then heat-sealed together to form a seam having eight plies, for example. Gusseted seams could also be employed with the corners of end closure being folded inwardly towards each other and heat-sealed in place. In addition to the above described end closures, the end portions of the panels comprising the end closure could have encapsulated beads of glue formed thereon which would function to adhere and seal the panels together when pressure and/or heat is applied to the panels to rupture the beads of glue. These portions of the panels could also be multi-folded over each other and then heat-sealed or reverse folded onto each other and then heat-sealed.

[0021] Figures 11 and 12 illustrate a modified packaging system 10′′of this invention comprising an outer bag 21′ and an inner bag 23′ (corresponding to bags 21 and 23 of Figure 2) forming an upper or first bag portion 11′′ overlying a lower or second bag portion 12′′ to define a pocket 13′′ therebetween. Bag portions 11′′ and 12′′ define expandable and inflatable chambers 14′′ and 15′′ therein, respectively, whereby an article A is compressed between the bag portions to retain it in a fixed position within the packaging system. An intermediate or third bag portion 16′′ is pivoted on either side thereof to the first and second bag portions at heat-sealed seams 18′′ to thus provide hinge means pivotally connecting the bag portions together at a rearward side of the packaging system.

[0022] The opposite lateral sides of the packaging system are closed by overlying side edge portions 19′′ and 20′′(Figure 13) of the bag portions that are sealed together to form side seams 21′′ and 22˝, respectively. End edge portions 23′′ and 24′′ remain unattached to each other at the frontal side of the packaging system to expose pocket 13′′ which is adapted to receive article A therein when the packaging system is at least partially deflated. Inflating means, shown in the form of a valve 25′′ such as that disclosed in U.S. Patent No. 4,586,910, is shown secured on bag portion 11′′ to selectively communicate a filler medium to intercommunicating chambers 14′′ and 15′′, as described more fully hereinafter.

[0023] Figures 13 and 14 illustrate a pre-fabricated package adapted to form packaging system 10′′. The package comprises a pair of superimposed, generally rectangular and co-extensive panels 26′′ and 27′′ heat-­sealed together at longitudinally spaced and parallel seams 18′′, formed transversely across the panels and between longitudinally spaced ends thereof. The seams, as shown in Figure 3, each terminate short of side edge portions 19′′ and 20′′ of the package. This arrangement thus provides passages between overlying portions of panel 26′′, intercommunicating chambers 14′′, 15′′ and 17′′ when the package is formed by side seams 21′′ and 22′′ into packaging system 10′′ (Figures 11 and 12).

[0024] It should be understood that additional seams of this type could be utilized or a single seam, formed intermediate the ends of the package as illustrated by dot-dash line 28′′ in Figure 13, could be utilized to provide various hinge connections at the rearward side of the packaging system.

[0025] Panels 26′′ and 27′′ can be preformed as separate sheets that are heat-sealed together, entirely about the peripheries of the panels, to form side edge portions or seams 19′′ and 20′′ and end edge portions or seams 23′′ and 24′′. Alternatively, a single sheet of material can be folded laterally over itself and a single seam 19˝ or 20˝ used, along with the end seams. Also, the package can be formed from a seamless tube of material (eliminating both seams 19′′ and 20′′) heat-sealed at end seams 23′′ and 24′′.

[0026] The sheet material composing the package may comprise a gas-impervious composite laminate, such as the type described in U.S. Patent No. 4,597,244. For example, each flexible panel comprising the package may be composed of an intermediate layer of aluminum and outer and inner layers of a plastic heat-sealable coating, such as polyethylene, adapted to reactivate (melt) in the range of 300 F. These types of composite laminates (which may be constructed to be highly flexible and inextensible or extensible) are well known in the art, and, therefore, further description thereof is un­necessary for a full understanding of this invention. Further, the panels may be suitably cut and sealed together by conventional apparatus and methods, such as those described in U.S. Patent No. 4,545,844.

[0027] Once the package illustrated in Figures 13 and 14 has been prefabricated, the package is folded to superimpose bag portion 11′′ over bag portion 12′′, as illustrated in Figure 12. Overlying side edge portions 19′′ are then heat-sealed (or mechanically secured together by a standard adhesive, stitching, etc.) and opposite side edge portions 20′′ are also secured together in this manner to form side seams 21′′ and 22′′, respectively. The deflated package is thus adapted to have article A (Figure 12) inserted through the open frontal side of the packaging system and into pocket 13′′.

[0028] After the article has been inserted, a standard inflation apparatus, including a fill tube 29′′ (Figure 11), can be utilized to charge and pressurize intercommunicating chambers 14′′, 15′′ and 17′′ to an inflation pressure exceeding ambient pressure, e.g., exceeding 14.7 psi at sea level. Alternatively, human lung power could be utilized to inflate the chambers with air.

[0029] As described above in reference to packaging system 20 (Figures 1-10), other types of gases, such as helium, could be utilized as a filler medium, as well as a suitable liquid, such as water. Alternatively or in addition to pressurized fluid, the chamber could be filled with a plastic material (e.g., urethane, poly­styrene, etc.) material in solid (injected in liquid form and solidified) or pieces (e.g., balls or pellets) form.

[0030] Should it prove desirable to fill the chambers with a solid filler medium of the type described above, it may prove desirable to pre-pack such filler medium into the chambers prior to forming one or more of edge portions or seams 19′′, 20′′, 23′′ and 24′′ or to provide a separate inflating means or valve for communicating the filler medium to each chamber individually. In such an application, each seam 18′′ could be extended the full width of the package (Figure 13) to place the chambers out of communication in respect to each other. Other modifications can be made to the package and completed packaging system of this invention without departing from the spirit and scope thereof, as will be apparent to those skilled in the arts relating hereto.

Claims

1. A packaging system comprising an outer bag defining a sealed and inflatable chamber therein, an inner bag, defining a pocket adapted to retain an article therein, disposed within said chamber and secured to said outer bag to suspend said inner bag within said chamber, and means for at least substantially filling said chamber with a filler medium to substantially surround said inner bag and said article therewith.

2. The packaging system of claim 1 wherein said outer bag comprises a pair of overlying first panels having outer peripheral edges thereof sealed together to define said chamber and said inner bag comprises a pair of overlying second panels sealed to the outer peripheral edges of said first panels.

3. The packaging system of claim 2 wherein each of said first panels is composed of a gas impervious material and each of said second panels is composed of an open mesh material exposing said article to said filler medium.

4. The packaging sytem of claim 2 or 3 further comprising a filling stem for filling said chamber with a pressurised fluid.

5. The packaging system of claim 2,3 or 4 further comprising end closure means for securing adjacent edge portions of said first and second panels together and to seal said chamber and said pocket after an article has been placed in said pocket.

6. The packaging system of claim 1 wherein said packaging system has opposite frontal and rearward sides and opposite lateral sides, the outer and inner bags being formed from a pair of overlying panels which are sealed around their periphery to form a single bag which is folded transversely to form overlying first and second bag portions, and seam means securing overlying side edges of the first and second bag portions, the first and second bag portions remaining unattached to each other at the frontal side of said packaging system to form the entrance to said pocket.

7. The packaging system of claim 6 further comprising inflating means that allow the passage of filler medium between first and second bag portions to at least partially fill the first and second chamber portions of said chamber with said filler medium.

8. The packaging system of claim 6 or 7 wherein said first and second bag portions are each formed by a pair of overlying first and second panels and wherein said first panels oppose each other to define said inner bag and said pocket therebetween and wherein said seam means are formed at overlying side edge portions of said first and second panels.

9. A method for forming a package for an article comprising the steps of securing peripheral edges of an inner bag to an outer bag to suspend said inner bag within an inflatable chamber defined on opposite sides of said inner bag, placing an article within a pocket defined within said inner bag portion, and at least substantially filling said chamber with a filler medium to substantially surround said inner bag and said article and to maintain said article at a preselected fixed position within said outer bag.

10. The method of claim 9 wherein said outer bag comprises a pair of first panels, said inner bag comprises a pair of overlying second panels and said securing step comprises securing overlying peripheral edge of panels of said inner and outer bags together.

11. The method of claim 9 or 10 further comprising forming a filling stem on said outer bag and wherein said filling step comprises at least partially filling said chamber with a pressurized fluid through an inlet passage defined in said filling stem.

12. The method of claim 9,10 or 11 further comprising the step of fully sealing peripheral edges of said first and second panels and said inner and outer bags together.

13. The method of claim 9,10 or 11 wherein said securing step comprises securing overlying side edge portions of said first and second bags together at opposite lateral sides thereof to define said article retaining pocket therebetween and to expose said pocket on only one side of said package.

14. The method of claim 9,10,11,12 or 13 wherein said securing step comprises forming said inner and outer bags from inner and outer pairs of superimposed panels, respectively, with each of said inner panels forming a chamber portion of said chamber with a respective and overlying one of said outer panels.

Drawing