A PRODUCT IN THE CONTAINER

This invention relates to a container and, more especially, this invention relates to a container with inflatable compartments for protecting a product in the container.

Products are typically sold in single use packaging. There is a growing tendency for products to be ordered on line, and for retailers then to deliver the products to customers. Such e-commerce is rapidly growing. The retailers are required to ensure that the delivered products are safely packed. The retailers are also required to ensure that they operate with minimal adverse environmental impact. In particular, the retailers are coming under sustained pressure to tackle the problem of plastics waste damaging the environment.

It is known to use plastics material packaging comprising inflatable compartments in order to protect products to be delivered. The packaging is wrapped around the products. The wrapped products then have to be placed inside a container. In order to minimise on the use of plastics material and its adverse environmental impact, it is known for the packaging to be such that the inflatable compartments can be deflated and returned to a retailer for further use. This minimises on the use of the plastics packaging. However, the known inflatable packaging and the products being protected are still required to be placed inside the container. The container, which is typically made of cardboard, thus constitutes external packaging which needs to be disposed of.

It is an aim of the present invention to reduce the above mentioned problems.

Accordingly, in one non-limiting embodiment of the present invention there is provided a container for at least one product, which container comprises:

(i) a body portion for receiving the product;

(ii) a plurality of inflatable compartments which extend around the body portion and which are for protecting the product when it is in the body portion;

(iii) valve means for inserting air into the inflatable compartments; and

(iv) at least one flap for extending over the body portion such that the container is a wrappable container which is wrapped by the flap.

The container of the present invention is advantageous in that the product is able to be protected by the body portion with its plurality of inflatable compartments. There is no separate inflatable packaging requiring to be wrapped around the product to be protected, and then inserted into a separate container which forms external packaging. The container of the present invention is able to be a single item for receiving and protecting the product, and such as not to require the use of external packaging that needs to be disposed of.

The container may comprise fastener means for fastening the flap around the body portion. The fastener means may be separate from the remainder of the container. Alternatively, the fastener means may be integrally formed with the remainder of the container. The fastener means may be reusable fastener means constructed for more than one use. Alternatively, the fastener means may be a single use fastener means.

Any suitable fastener means may be employed in the container. Thus, for example, the fastener means may be adhesive fasteners. Alternatively, the fastener means may be press studs. Alternatively, the fastener means may be matrices of interlocking plastics members that push together to fasten and that pull apart to open. One example of such matrices is the product known as

Velcro (Registered Trade Mark). Alternatively, the fastener means may be one or more straps. The fastener means may be made of a plastics material or a metal, in dependence upon the type of fastener means being used.

The container may be one in which the valve means is for inserting air into the inflatable compartments and for releasing air from the inflatable compartments, whereby the container is a reusable container which is rendered reusable by release of air from the inflatable compartments via the valve means. The container may be flat in the re-use condition. This facilitates return of the container to a manufacturer or retailer for re-use. The return of the container may enable a customer returning the container to collect a deposit made against the return of the container. The container may comprise:

(i) at least one first flap for extending over the body portion in a first direction; and

(ii) at least one second flap for extending over the body portion in a second direction, with the second direction being different to the first direction.

The container may be one in which the first flap is for closing an opening in the body portion, and in which the second flap is for extending over the body portion and causing the container to be the wrappable container. The container may be one in which the first flap extends longitudinally of the body portion, and in which the second flap extends transversely of the body portion. The reverse arrangement may be employed. Alternatively, the first and second flaps may extend at other angles with respect to each other and with respect to the body portion.

In a first embodiment of the invention, the container may be one in which the body portion is configured as a preformed body portion for receiving the product. In this case, the body portion may have a closed end opposite the opening. The first flap may be for closing the opening in the body portion, and the second flap may be for extending over the body portion such that the container is the wrappable container.

In a second embodiment of the invention, the container may be one in which the body portion is configured as a wrappable body portion for being wrapped around the product. In this case, the container may be one in which the body portion comprises a first body part and a second body part, and in which the first and second body parts are movable together to encompass the product. The first and second body parts may be connected together as integral parts of the body portion.

The container may be one in which the first body part comprises a first container area and a pair of spaced apart side walls, and in which the second body part comprises a second container area and a pair of spaced apart second side walls. The first side walls and the second side walls may all have flanges, whereby the flanges of the first side walls engage the flanges of the second side walls when the first and second body parts are moved together to encompass the product.

The container may be one in which the first container area of the first body part and the second container area of the second body part are spaced apart by a third container area, in which the body portion comprises a fourth container area, and in which the first, second, third and fourth container areas are integrally formed together.

The container may be one in which the first flap extends longitudinally of the body portion, in which there are at least two of the second flaps, and in which the second flaps extend transversely of the body portion.

In a third embodiment of the invention, the container may be one in which the body portion is configured as a preformed body portion for receiving the product, in which the body portion has an opening, and in which there is only one flap. Preferably the flap extends longitudinally of the body portion. The flap may extend transversely of the body portion or in other directions with respect to the body portion if desired.

In all embodiments of the invention the air compartments may be longitudinally extending air compartments which are defined by longitudinally extending seams. The air compartments may be of any desired shape, and they may extend in any desired direction. Thus, for example, the air compartments may be air bubbles arranged in lines or arranged randomly.

Embodiments of the invention will now be described solely by way of example and with reference to the accompanying drawings in which:

Figures 1 - 8 are different views showing process steps for making a first container of the present invention, with Figure 6 showing the container and with Figures 7 and 8 showing how the container is used;

Figures 9 - 13 show process steps for making a second container of the present invention, with Figure 1 1 showing the container and with Figures 12 and 13 showing how the container is used; and

Figures 14 - 19 are different views showing process steps for making a third container of the present invention, with Figure 17 showing the container and with Figures 18 and 19 showing how the container is used.

Referring to Figures 1 - 8 there is shown in Figure 6 a first container 2 for at least one product. The container 2 comprises a body portion 4 for receiving the product. The container 2 also comprises a plurality of inflatable compartments 6 which extend around the body portion and which are for protecting the product when it is in the body portion 4. The container 2 also comprises valve means 8 for inserting air into the inflatable compartments 6 and releasing air from the inflatable compartments 6.

The container 2 has at least one first flap 10 for extending over the body portion 4 in a first direction. The container 2 also has at least one second flap

12 for extending over the body portion 4 in a second direction. The second direction is different from the first direction as can be appreciated from Figure

6.

As shown in Figures 7 and 8, the container 2 further comprises fastener means 14 for fastening the first and second flaps 10, 12 around the body portion

4.

As can be appreciated from Figures 1 - 8, the body portion 4 is a preformed body portion 4 which is configured for the insertion and removal of the product. The body portion 4 includes an opening 16 for the insertion and removal of the product through the opening 16. The body portion 4 has a closed end 18 opposite the opening 16.

As can be appreciated from Figures 7 and 8, the fastener means are such that the container 2 is a wrappable container 2 which is closable and wrappable by the first and second flaps 10, 12. More specifically, the first flap

10 extends longitudinally of the body portion 4 and closes the opening 16. The second flap 12 extends transversely of the body portion 4 and wraps around the body portion 4 such that the container 2 is a wrappable container 2 which is wrapped by the second flap 10.

The fastener means 14 provide good sized areas for receiving information as appropriate, for example printing. The fastener means 14 are re usable fastener means 14 constructed for more than one use. The container 2 is a re-usable container 2 which is rendered re-usable by opening of the fastener means 14 to allow removal of the product, and by release of air from the air compartments via the valve means 8.

The container 2 is such that it is flat in the re-use condition. This is advantageous for enabling the container 2 to be returned in the post and/or for storage. For example, the flat condition facilitates posting of the used container

2 back to a factory for re-inflation and re-use, and for a customer to claim back a previously paid deposit.

Figure 1 illustrates the start of a process for producing the container 2.

More specifically, Figure 1 shows two cut plastics film sheets 18, 20 and the valve means 8. The sheets 18, 20 are preferably composed of a flexible gas impervious and heat sealable material such for example as polyethylene.

Furthermore, the sheets 18, 20 are preferably made such that they melt at approximately 300ºF. This melting enables the sheets 18, 20 to be heat sealed.

Other sealing techniques may be employed to join the sheets 18, 20 at selected areas as may be desired. Figure 1 shows how the sheets 18, 20 are able to be heat sealed together at selected overlying peripheral edges along heat sealing areas 22 shown by dashed lines.

Figure 2 shows the sheets 18, 20 heat sealed together to form a panel 24. Further welding at regions 26 and 28 divides the panel 24 such as to define a panel portion 30 having the valve means 8 which forms an inflation/deflation valve means. The valve means 8 may be any type of known valve able to withstand repeated inflation and deflation. The valve means 8 may be configured such that it is able to be operated by machinery and/or also with just human lung power.

Figure 3 shows the panel portion 30 welded at a plurality of regions 32 to form tubular structures that enhances the protective capacity of the container 2. The tubular structures are in communication with one another so that the entire panel portion 30 is able to be inflated through the single valve means 8. Other welding locations of the panel portion 30 may be employed that are able to conform the container to a desired container shape when inflated.

Thus, for example, other welding locations may define a quilted shape or any other suitable pattern.

Figure 4 is a section through the container 2 in an inflated state. Under pressure of the air, the sheets 18, 20 create a pattern based on the welding points 22. This shape is a tubular shape as shown in Figure 4.

Figure 5 shows the panel 24 folded in half and ready to be heat welded along peripheral edges 34, 36. When this peripheral welding is accomplished, then the body portion 4 is formed with the opening 16. The body portion 4 is thus able to receive a product or products through the opening 16. This is more especially able to be appreciated from Figure 6. In Figure 6, it will be noted that the first flap 10 and the second flap 12 remain flat when the container 2 is in its inflated condition.

Figure 7 illustrates how the first flap 10 is folded longitudinally with respect to the container 2 in order to close the opening 16. Figure 7 also shows how the first flap 10 is provided with the fastener means 14. The fastener means 14 is shown in Figure 7 as sticky tape. In the position shown in Figure 7, it will be seen that the first flap 10 not only closes the opening 16 but it also covers the valve means 8.

Figure 8 shows the container 2 in its final form as ready for despatch and containing the product or products. In this final form, the second flap 12 has been wrapped transversely around the body portion 4. This wrapping partially covers the first flap 10 as can be appreciated from a comparison of Figures 7 and 8. The container 2 is thus securely closed. The second flap 12 is held in position by the fastener means 14. The container 2 is thus ready for shipment and without the need for the container 2 to have to be placed in external packaging such for example as a second cardboard container.

Because the first and second flaps 10, 12 are flat, they provide the extra facility of receiving shipping labels and/or printing and/or other desired information. The shipping labels may be glued in position or otherwise secured in position. The printing may be marketing information. The first and second flaps 10, 12 are advantageous in their ability to receive such information, as compared with known packaging which might just comprise the inflatable compartments 6 and which are not easily provided with labels and/or printing and/or similar material due to their undulating surfaces.

The dimensions of the container 2 are such that it is chosen to adequately protect its contents in the form of the inserted product or products.

The container 2 may be of any required size and shape.

Referring now to Figures 9 - 13, there is shown in Figure 11 a second container 38 of the present invention. Figures 12 and 13 show how the container 38 is used to enclose one or more products (not shown). As can best be appreciated from Figure 11 , the container 38 is such that it comprises a body portion 40 which is configured as a wrappable body portion

40 for being wrapped around the product or products.

As can best be appreciated from Figure 10, the body portion 40 comprises a first body part 42 and a second body part 44. The first and second body parts 42, 44 are movable together to encompass the product as can best be appreciated from a comparison of Figures 10 and 1 1.

Also as shown in Figure 10, the first and second body parts 42, 44 are connected together as integral parts of the body portion 40. The first body part

42 comprises a first container area 46 and a pair of spaced apart first side walls

48. The second body part 44 comprises a second container area 50 and a pair of spaced apart second side walls 52. The first side walls 48 have flanges 54.

The second side walls 52 have flanges 56. The flanges 54 of the first side walls 48 engage the flanges 56 of the second side walls 52 when the first and second body parts 42, 44 are moved together to encompass the product as can be appreciated from a comparison of Figures 10 and 11.

As shown in Figure 10, the first container area 46 of the first body part

42 and the second container area 50 of the second body part 44 are spaced apart by a third container area 58. The body portion 40 comprises a fourth container area 60 which is opposite a first flap 62. The first, second, third and fourth container areas 46, 50, 58, 60 are integrally formed together as shown.

The first flap 62 extends longitudinally of the body portion 40. Since the container 38 is square, the first flap 62 may be regarded as extending longitudinally because it is follows the longitudinal inflatable compartments 64 defined by heat welded seams 66.

The container 38 has two second flaps 68 which extend transversely of the body portion 40.

Figure 9 illustrates how two film sheets may be heat sealed together to form a panel having the illustrated panel portions and the valve means 8.

Figure 10 shows a first stage of assembly of the container 38.

Figure 11 shows the container 38 with its inflatable compartments 64 inflated, and in a second stage of assembly as mentioned above in which the flanges 54, 56 have been placed in contact with each other and then heat welded together to form seams. The container 38 is thus formed with its body portion 40 and an opening 70 for receiving a product or products.

Figure 12 shows how the two second flaps 68 are first wrapped around the body portion 4. The second flaps 68 are then held in position with fastener means 80 in the form of two adhesive panels.

Figure 13 shows the finished container 38 which has been formed by folding the first flap 62 over the body portion 4 as can be appreciated from a comparison of Figures 12 and 13. The first flap 62 then extends over the ends of the second flaps 68 and their fastener means 80. The first flap 62 is held in position by fastener means 82 which is again in the form of an adhesive panel.

Referring now to Figures 14 - 19, there is shown a third container 84 of the present invention. The container 84 comprises a body portion 86, inflatable compartments 88, and valve means 90. As best appreciated from Figure 17, the body portion 86 is configured as a preformed body portion 86 for receiving the product. The body portion 86 has valve means 90 for inflating the inflatable compartments 88. The body portion 86 has an opening 92 through which the products are inserted into the body portion 4.

The container 84 has a single flap 94. The flap 94 extends longitudinally of the body portion 86 and the inflatable compartments 88. Figure 17 shows the container 84 prior to use. Figure 18 shows the flap 94 being folded over the body portion 86. Figure 19 shows the flap 94 being further folded to form the container 84 as a wrappable container 84. As shown in Figure 19, the container

84 is maintained in its wrapped condition by fastener means 96.

The container 84 may be inexpensive to produce, and sufficiently inexpensive that it may be a one-use container 84 which is discarded after its first use. In this case, the valve means 90 will simply be an inlet valve means

90 for enabling the inflatable compartments 88 to be inflated with air. If the container 84 is desired to be produced as a re-usable container 84, then the valve means 90 will also be such that it enables the air in the inflated compartments 88 to be removed. The deflated container 84 will then be in the condition shown in Figure 15, i.e. the same condition as prior to its first use. The deflated container 84 may then be sent back to a manufacturer for re-use. Alternatively the container 84 may be retained by a user for subsequent reinflation and re-use by the user. In this latter case, the user may chose not to deflate the inflatable compartments 88, and the user may simply leave the inflatable compartments 88 inflated until such time as the user requires the container 84 for another use. If the container 84 is to be re-usable, then the fastener means 96 may be re-usable fastener means 96. Alternatively, the fastener means 96 may be removable fastener means 96 which can then be replaced by new fastener means 96 for each subsequent use. The fastener means 96 is shown in the form of an adhesive strip but other types of fastener means may be employed.

Figure 19 shows how the container 94 has top and bottom flat surfaces for receiving any desired information such for example as advertising information and/or manufacturing information and/or an address. Figure 14 shows how the container 84 is initially made from two elongate strips of plastics material 96, 98 which are sealed along their edges as shown by broken lines

98. If desired, the edge sealing may be such as to form a pocket, with the pocket then being available for receiving an insert such for example as an address insert or a marketing insert.

The containers 2, 38, 84 are such that the flap or flaps that they employ are not inflatable flaps. Typically, the container of the present invention will be one in which the or each flap is a non-inflatable flap.

It is to be appreciated that the embodiments of the invention described above with reference to the accompanying drawings have been given by way of example only and that modifications may be effected. Thus, for example, containers of shapes and constructions other than the containers 2, 38, 84 may be employed. Fastener means other than the illustrated fastener means 14, 80 may be employed. Individual components shown in the drawings are not limited to use in their drawings and they may be used in other drawings and in all aspects of the invention. The invention also extends to the individual components mentioned and/or shown above, taken singly or in any combination.