A commonly known form of packaging comprises moulded polystyrene blocks which are shaped and dimensioned for compatability with the article to be packaged. In particular the blocks can have shaped surfaces so that a set of the blocks can fit around the article whereby, when the article and block set are installed in a container e.g. cardboard box, the article is firmly located in the container. Although this gives a certain degree of protection to the article it may not protect adequately against severe jarring or jolting which can occur when the container is dropped or subject to collisions.

Instead of solid blocks, hollow packaging members have also been proposed. Thus US-A-4407898 shows a corner pad for a cubic article such as a speaker box, said pad

comprising linked generally rectangular hollow elements which are foldable to set the elements at right-angles to each other whereby the member can be applied at the corner of a cubic article.

However, this hollow member does not provide a substantially improved cushioning action in comparison with the known polystyrene block packaging. It is the principal object of this present invention to provide packaging members giving improved cushioning for articles being packaged.

According to the present invention a packaging or article protecting member comprises a hollow element formed by blow moulding, the element including means giving increased cushioning performance. These cushioning means preferably comprise recesses, grooves or protrusions in the element. More especially the recess, groove etc. of the cushioning means can be arranged for design deformation or collapse on loading of the element. By this arrangement pressure regulation is achievable in the element together with controlled damping for the provision of an improved cushioning action. As an alternative, a specific and separate pressure regulating device could be carried by the hollow element. The hollow space of the element may be at atmospheric pressure but it would be possible to utilise a pressure above atmospheric. The element may include means to enable inflation and deflation of the element.

In a preferred embodiment the hollow element includes reinforcing means either as an integral part of the element or as fitted subsequently to the element. Reinforcing seams or profiling may be present, for

example in the form of corrugations or by providing additional strengthening members.

Preferably the packaging member includes locating means for the location of an article to be protected by the packaging, the arrangement being such that the locating means is independently movable relative to portions of the element adjacent said means whereby the article being packaged (or protected or cushioned) can move relative to the hollow element. Preferably the element includes edge relief, or where the element has portions defining an internal corner, relief can be provided at said corner.

This feature has the advantage of:

l. Allowing relative movement between the article being packaged and the element; 2. Allowing loading to be taken remote from the corner to avoid stress concentration at the corner; and 3. Providing corner/edge clearance for the article being packaged.

A further preferred feature relates to the provision of a special facility enabling controlled or simplified puncturing of the element. Packaging elements in accordance with the present invention when discarded and especially in the deflated state e.g. after puncturing can occupy a minimum of space vis-a-vis polystyrene block packaging, and this represents a substantial environmental benefit. Further, the present packaging member conveniently can be made from a material facilitating recycling - again an environmental advantage. The packaging of the present invention can be used to package and protect a wide

variety of different types of articles. These articles may comprise components of a standard shape, for example items produced in an extensive production run, or again the article may be a special customised component. The packaging members may be applied at only parts of the article, for example as corner or edge pads, in particular where the article/packaging combination is to be ^ibused in a container/box; or again the packaging may substantially encapsulate the article in which case an additional outer container/box may not be necessary. Suitable materials for the packaging member of the invention can include polypropylene (standard) or high density polypropylene, polyethylene, PET, or rubber; or it may be appropriate to provide an individual material of special composition. In particular, the material can comprise a co-injected material, that is a material comprising recycled materials. By using these co-injected materials the blow moulding can be made to provide a wall having a core of recycled material (or aerated base material) sandwiched between outer skin of higher quality material. The material may include internal reinforcement.

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings.

Figs. 1 - 15A show generally how the present invention can be applied in packaging, whereas Figs. 16 - 24 show packaging utilising the present invention and adapted for protecting specific articles. Figs. 25 and 26 respectively illustrate the use of varying wall thicknesses and of inter-engaging formations in embodiments of the invention.

Fig. 1 shows pictorially a portion of a packaging member 1 formed as a blow moulding, a cylindrical intrusion 2 defining a recess (blind) being provided to give improved cushioning performance, the cylinder 2 being at right angles to the top surface 1A of the member 1. Fig. 1 shows the static condition whereas in Fig. 1A a downward load L has been applied (as can happen when a jarring force is imparted on the article/package combination) . The load L increases the internal pressure in the member 1 but the intrusion 2 deforms (as shown dashed) and by arranging for this deformation to be in a controlled manner the effect σf the pressure variation can be regulated, and controlled damping also applied.

Figs. 2 - 2B show a similar arrangement but in this case the intrusion 2 is of cuboid (parallelopiped) form.

In Figs. 3 and 3A, instead of a recess (cylindrical or cuboid) a slot 3 is provided for pressure regulation but the principle is again the same via controlled deformation (buckling) of the slot (Fig. 3A) .

To provide the pressure regulation and controlled deformation, the packaging member 1 in Figs. 4 to 4C utilises an external feature, i.e. a cylindrical protrusion 4 which "barrels" (Fig. 4A) when the load L is applied. The member 1 of Figs. 5A is similar but in this case the protrusion is of cuboid or parallelopiped form.

In the embodiment of Figs. 6 to 6C a groove 5 is provided extending around at least some of the peripheral faces (Fl, F2, F3) of the member 1 which,

when the load L is applied, moves from the normal state (Fig. 6A) to the collapsed state (Figs. 6B/6C) for controlled deformation and pressure regulation. The packaging member 1 can be fitted with strapping 6 (Fig. 7) to strengthen the member, or alternatively additional strengthening could be formed integrally with the member, for example by the ribbing 7 shown in Fig. 8. A further option would be to strengthen by the provision of corrugations 8 as shown in Fig. 9 to provide a reinforced seam. Also, corrugations may be added as shown for example in Fig. 9B to prevent buckling of the component as a whole or of a part thereof, when a load L is applied as shown.

In the preferred embodiment shown in Figs. 10/10A (part sectional side view) means are provided to enable a located article A to move substantially independently of the member 1. Thus a recess 9 (for example cylindrical) serves to receive an end of the article A while an annular groove 10 surrounds the recess 9. Fig. 10 shows the static state whereas Fig. 10A shows the situation where the article A has been displaced downwardly: it can be seen that the major effect is that the recess 9 is displaced whereas the bulk of the remainder of the member 2 including the faces remain undefor ed. Where the member 1 comprises portions set at an angle to each other, e.g. 90° for an edge or corner pad it is preferred that a relief groove 11 is formed at the corner of the portions as shown in Figs 11 to 11B. Figs 11 and HA show the undisturbed situation, Fig. 11A illustrating an article A abutting against the internal faces Ij _. , I ₂ of the member 1. Where a load is applied (Fig. 11B) the edge relief 11 enables an appropriate one only, e.g. Face !___ , of the internal faces to displace, and also encourage pressure and

deformation regulation. The outer wall I ₀ of the member 1 may be corrugated per Fig. 9B to resist buckling when a vertical load L is applied. In Fig. 12, showing a corner pad, corner relief 12 is provided additionally.

Figs. 13 and 13A show an arrangement for controlled puncturing of the member 1 which is desirable when the member 1 is to be discarded as it is then beneficial that the member can be deflated to occupy minimal space. Thus the member 1 includes a designated puncturing zone P guarded by a wall formation 13. For convenience it is preferable that a suitable puncturing tool is at hand and to this end the tool 14 e.g. pin form can be moulded integrally with the member 1 and be movable into the wall formation 13 for puncturing at zone P. It is advantageous for the zone P to be of thinner material for ease of puncturing.

A further possibility is to have some form of closable air inlet or valve to enable the member to be inflated and deflated - this especially will convenience storage and transport of the member 1 when not in use.

Figs. 14/14A show a further arrangement for pressure control and regulation. In this case, the member 1 has an annular recess 15 extending inwardly from a large diameter mouth portion 16 on a side face F _s of the member, and an additional resilient device D is provided for deformation (and pressure) control. In this example this device D includes a spring 17 located between the central cylinder A of the recess 15 and a disc 18 secured in the mouth portion 16. As can be seen from Fig. 14A, a load L applied as shown will deform the recess 15 (as indicated by dashed lines) but additionally the spring 17 will be compressed due to

the barrelling of the cylinder 15A. Figs. 15/15A show a similar concept but in this case a specific and separate pressure control device 19 is fitted to the member 1 and is in communication with the interior of the member via port 20. The device 19 may comprise a spring-biased piston device. Whereas the foregoing examples each describes a single pressure control member, it will be understood that the packaging member 1 could include a plurality of pressure control members.

Figs. 15 to 24 show the use of the blow moulded packaging members adapted for use with specific forms of articles or components. In particular the packaging members 1 can be adapted for use with articles of standard shape especially where there is an extensive production run of such articles. The members 1 can be of standard design to accommodate commonly occurring features on such articles requiring cushioning and for protection: this can embrace packing on edges, corners, flat surfaces, cylindrical portions on items with cylindrical features (external or internal) etc. Thus the member 1 of Figs. 16 and 16A is applied at the end faces of a cylindrical article, each member 1 being of annular form and including a cylindrical recess 9 to receive an end of the article (A) and an annular groove 10 for controlled deformation and pressure regulation. Members IT and IL of Figs. 17A serve to protect bottles and the like and include recesses 21 and 22 to receive respectively standard size top and bottom parts of bottles.

The packaging of the present invention can also be used with rather individual or customised articles or components. More specifically for this application the

members 1 will be specially designed and formed to accommodate specific features on the article requiring packaging (or cushioning or protection). Thus, in this connection, Fig. 18 shows an edge member 1, four of which are used to protect a television set 23 or V.D.U. as shown. Each member 1 comprises a specially shaped part 24 compatible with the edges of the set and includes a locating element 24A. The member 1 also carries strengthening corrugations 25.

Fig. 19 shows special end members l for cushioning an electric motor 26.

It is possible to have members 1 which encapsulate partially or completely the article to be packaged. Thus in Fig. 20 top and bottom members 1ET and 1EB encapsulate a car headlamp 32. In this packaging, there may be no need for an outer container, e.g. cardboard box, which may be required where simply edge or end protection is present. However, a strengthening member e.g. strap 6 (Fig. 7) may be desired.

Some articles have parts such as movable parts which require protection members in the form of separators. Merely as an illustration, Fig. 21 shows a cylindrical member 1 having a bore 27 to receive and separate a bell ring part 28A from the body of a hand bell 28, while Fig. 22 shows a packaging member 1 in the form of a separator for a printed circuit board assembly 29, the member 1 including slots 30 to receive flat portions 29A of the assembly.

Figs. 23 and 24 show yet further examples of packaging members 1, Fig. 23 showing a protection member for a standard A.C. mains plug, while Fig. 24 shows a

protector for the screw thread A of an item 31.

In accordance with another feature of the invention, the thickness of the walls of individual packaging members can be varied selectively within the member in order to optimise the cushioning and packaging characterisitics of the member. An example is illustrated in Figs. 25 and 25A, which show an assembly of two packaging elements 34, 36 encapsulating an object 38. The outer wall portions 34A and 36A, constituting the exterior surface of the encapsulant assembly, are formed so as to be thicker than the inner wall portions 34B and 36B, constituting the interior surface of the assembly in contact with the packaged object 38. The wall thicknesses of the various members described and illustrated herein can also be varied locally as required; for example, in order to provide locally enhanced shock or cushioning characteristics so as to optimise the performance of the components.

Finally, co-operating packaging members in accordance with the invention may be provided with inter-engaging formations such that two or more members can be positively coupled together in use. This is particularly desirable in the case wher members are adapted to encapsulate the packaged object. Fig 26 shows an example in which first and second packaging members 40, 42 are provided with inter-engaging male and female formations 40A and 42A on their mating surfaces. The formations 40A and 42A may comprise co- operating ridges and slots, pegs and sockets, or the like, and may be shaped so as to provide an interference-type push-fit as indicated in Fig. 26A.

The blow moulding techniques to manufacture the above

packaging members of the present invention are known in the art and include injection blow moulding.

Improvements and modifications may be incorporated without departing from the scope of the invention.