TECHNICAL FIELD

[0001] The present disclosure relates to a customizable packaging, based in a single structure, for the protection during the storage and transport of sensitive and fragile products and items, such as, for example, electronic systems, medical devices or perishable goods.

BACKGROUND

[0002] The storage and transport of products is always a challenge, especially when the product or item to stow and transport is sensitive and fragile. The transport of products or items may occur in various situations. For instance, the transport may occur at the facilities of a company, between workstations, during the several stages of product production. In another situation, transport may be referent to shipping to distant locations.

[0003] Within scientific and technological advancements, to best correspond to market increasing demands, products integrate more complex features and multifunctional characteristics that require special care at all times. For some fragile products and items, during storage and transport, it is crucial to avoid excessive mechanical efforts (e.g., bending, vibration, impact), while for other types of products and items, it is necessary to assure protection from outside influences, as for example, from light and radiation, temperature fluctuations, or even from electrostatic discharges.

[0004] Nowadays, a common packaging solution, for the storage and transportation of sensitive and fragile products and items, includes tote-boxes with cardboard or polystyrene foam dividers between items, to keep them from moving around. In addition, several stacking supports have been used to accommodate a large number of products and items within the same package, respectively. Examples of such stacking supports can be found in U.S. Pat. No. 3,520,769, which discloses a lightweight, thermal-insulating foamed packaging material based on low-density cellular polystyrene and in U.S. Pat. No. 5,816,409, which discloses a moulded pulp fibre structures to provide interior packaging cushioning. However, certain features of the polystyrene foam are drawbacks for the support of certain products and items, and in particular, for fragile ones. For instance, polystyrene foam is somewhat rigid, relatively brittle, and thus has a minimum of structural flexibility. Additionally, mechanical degradation occurs with wear, hampering its performance for daily use applications, as for example, within a factory plant. The use of carton dividers and packages presents the same problems of long-term durability by continuous daily use, and have little effectiveness in absorbing shocks caused by vibrations during transport. Additionally, polystyrene or other plastic foam stacking supports do not typically compactly nest together and thus storage of these supports usually takes up a considerable space.

[0005] Another commonly used solution for stowing and carrying fragile and sensitive products and items consists in trays. The materials used in the manufacture of trays include carton (U.S. Pat. No. 2, 893,621), metal (U.S. Pat. No. 2,456,481) and several plastic materials (U.S. Pat. No. 3,843,009; U.S. Pat. No. 3,409,199; U.S. Pat. No. 6,186,328).

[0006] Trays can take many forms and may be used to carry a single product or item (U.S. Pat. No. 5,127,526) or multiple products or items simultaneously (U.S. Pat. No. 4,932,532). In addition, trays are usually designed to carry a specific product or item, thus having a particular design which perfectly fits the product or items shape, providing this way, maximum cushioning. Examples of such specific trays have been used to carry elongated fragile fluorescent tubes (U.S. Pat. No. 4,932,532) and carry cylindrical fluid containers (U.S. Pat. No. 5,267,649).

[0007] For the transport of multiple products or items, packing trays usually have an array of cell pockets that are commonly used to package fragile objects to enable, not only transport, but also their safe storage and display. This solution is often used in fruit transport between long distances from where the fruit is harvested, to where it will be consumed. Example patents of such packing trays include U.S. Pat. No. 3,049,259 of a dispatch tray for fruit and U.S. Pat. No. 4,298,156 for cushioning eggs. These types of trays are developed and used specifically with a particular fragile item to be transported. Items with different size and shape would need a different tray design.

[0008] Another possible solution, disclosed in U.S. Pat. No. 2015/000231, for the transportation of fragile items, uses a tray made of plastic foam sheet having a plurality of recessed cell pockets, each cell pocket having a relatively thinner cell sidewall with expandable (accordion-like) flutes. Although this solution may accept multiple items with varying dimensions and weights, its disposable design nature makes its continuous use difficult. After repeated use, the cells would widen and lose effectiveness in the cushioning of fragile items.

[0009] Most of the trays used in the transport of fragile products or items require an additional box to store the trays. Commonly used boxes include cartons or plastic tote- boxes. The additional use of tote-box, while suitable for transporting at long distances, is not very suitable for the transport within a factory. Besides the box being an additional cost and needing storage space, the task of placing the items on trays and then placing the trays inside a box is more time consuming. A commonly used practical solution includes nestable and stackable trays that do not require an additional box. Examples of such trays are disclosed in U.S. Pat. No. 7,207,458 Bl and U.S. Pat. No. 6,186,328 Bl which describes low-depth nestable trays for containers.

[0010] The majority of nestable and stackable trays are made in order to serve many purposes and present no special features to cushion fragile items, hampering their use with this type of objects. Examples include trays disclosed in U.S. Pat. No. 4,093,070, U.S. Pat. No. 3,270,913, U.S. Pat. No. 3,638,827 and U.S. Pat. No. 7,922001B2. Other nestable and stackable containers present design features for cushioning specific items. However, in most of these solutions, when some of these trays are filled with items to be transported and are subsequently stacked, the tray rests on the items that should protect, preventing this way, its use with fragile items. Examples of such trays include a tray structure for storing tubes, disclosed in U.S. Pat. No 3,272,371 and a shipping tray for bottles, disclosed in U. S. Pat. No. 6,820,743 B2 and U.S. Pat. No. 2004/0031711 Al. [0011] Trays with complex designs and specific features to accommodate sensitive items makes them specific to only one item or few. If a company produces many different fragile and sensitive items and products, a considerable amount of different specific trays would be needed to transport the variety of different fragile items and components produced within a factory plant. This policy of item specific tray would lead to large areas allocated for storage and long waiting times for the design and manufacture of new trays, along with all the associated costs.

[0012] An alternative possibility to the nestable and stackable specific trays consists in the use of a soft material that assures energy absorption from shocks and vibrations simultaneous to providing cushioning and protection to the fragile items. Examples of such soft materials include flexible foams made of polyurethane or other polymeric based materials. These materials are already employed in packing applications. For example, in U.S. Pat. No. 4,851,286A is disclosed a cushioning element of a polymeric foam material for placement between an impacting surface and a surface of an object to be cushioned against damage caused by impact during transport or storage. U.S. Pat. No. 2003/0102244 Al discloses a shipping and storage container for laptop computers, which includes an inner protective base insert and an inner protective cover insert, both inserts being fabricated from a protective foam material.

[0013] In addition, flexible foams can be easily modified to present other important specific properties. As an example, foams can be made electrostatic dissipative by adequate formulation (U.S. Pat. No. 2004/0259966 Al and U.S. Pat. No. 2015/0274924 Al) and used in the transport of devices that are sensitive to electric discharges. Examples of applications for static dissipative flexible foams include U.S. Pat. No. 5,273,158A that discloses a package fabricated from flexible polyurethane foam for the storing and the transportation of small electronic components (e.g. capacitors, resistors, diodes, transistors).

[0014] The majority of the flexible foams presented can release foam particles, which could lead to the contamination of sensitive items. This matter could be avoided by resourcing to integral skin foams. The integral skin foam consists of a low-density foamed core surrounded by a high-density skin of the same material. Several methods for the production of flexible polyurethane foams with integral skin have been disclosed (U.S. Pat. No. 5,132,329, U.S. Pat. No. 5,236,960 and U.S. Pat. No. 5,449,698).

[0015] In summary, typical solutions for the storage and transport of products and items with various typologies are based in packaging containers, commonly known as tote-box, with several stacking supports, in order to accommodate a large number of items within. Stacking supports include, for instance, thermoformed trays, pulp fibre structures, inflatable films, rigid foams made to measure, flexible foams with and without convoluted shapes. These structures present a series of drawbacks, for example, most of these structures present some level of rigidity which is inappropriate for use in the support of fragile items, thus limiting its application. Made to measure solutions (e.g. thermoformed trays, custom foams) are developed to present design features for cushioning specific products being quite advantageous in the perfect fit of a product, allowing the preservation of its shape and components while avoiding hampering its functionality. However, this type of solution approach is too specific in regarding to one or few products and consequently, leads to large quantities of waste and increase cost.

[0016] Flexible foams alone are insufficient to sustain the product to stow and transport, therefore, it is commonly necessary additional components to add some level of rigidity to the flexible foam for the direct contact with the product. Pulp fibre solutions, often based on polystyrene, also present drawbacks as they tend to degrade mechanically with continuous use.

[0017] The available solutions, for the storage and transport, within factory facilities and shipping to distant locations, are hampered by the need of several components to provide a safe and efficient packaging for an individual product, which may not be suitable for another one. The logistics associated to the preparation of an efficacious packaging, which assures protection of its content, requires some planning generating, long lead times and, consequently, cost expenses. Additionally, the employment of a series of stacking and support structures, within tote boxes, creates the need for greater numbers of tote boxes to fit within these structures and the products. This means that, there is a long time spent in the task of placing items and structures within the tote box, and second, larger storage areas are allocated for the great number of tote boxes required.

[0018] The presented issues related to the existent solutions can be avoided by the employment of stackable trays with some rigidity and built also with a soft material, that would assure energy adsorption in order to avoid shocks and vibrations, while simultaneously providing adequate cushioning and protection for various types of products, with a multiplicity of typologies and configurations. The majority of flexible foams typically releases particles due to constant wear, which may be an issue to specific highly sensitive products (e.g. electronic printed circuits boards, integrated circuits) leading to contamination and possible damaging and even failure. In regarding to other products and items which are enclosed or less fragile and sensitive, this matter is no problem.

[0019] In view of the abovementioned, it would be desirable to provide a new packaging solution for the storage and transport of sensitive and fragile items and products, while overcoming the above stated drawbacks and limitations of prior art solutions.

[0020] These facts are disclosed in order to illustrate the technical problem addressed by the present disclosure.

GENERAL DESCRIPTION

[0021] The present disclosure relates to a customizable packaging solution, namely a tray, based in a stackable single structure, for the storage and transport of sensitive and fragile products and items (e.g. radio frequency identification systems, lenses, led, capacitors, among others). The single structure packaging is based on a rigid structure formed by first polymeric rigid structure and a second polymeric rigid structure; and a resilient material, where the single structure contacts with the products to stow and transport. The solution disclosed herein enables varying design features and combine materials as intended, to best correspond to the product and item to stow and transport and is based in a simpler and cost-efficient approach. [0022] In an embodiment, the single structure customizable packaging solution can be manufactured by means of injection moulding technology and/or variants (e.g. reaction injection moulding), with a single mould tool. The mould tool presents a custom main structure and moulding inserts that shape the polymeric rigid structures and the resilient material, for example a soft layer(s), preferably selected from a list consisting of polymeric foams based in polyurethane (PU), polyethylene (PE), or polystyrene (PS) or mixtures thereof that compose the single structure packaging. The moulding inserts are easily changed providing variable design possibilities and geometrical configurations, for both the rigid structures (i.e. first polymeric rigid structure and second polymeric rigid structure) and also the resilient material. This faster and simple approach to change the mould inserts provides versatility for the customization and adequacy of the present disclosure to various product and items configurations. Also, the moulding tool presents movements or movement ability. This means that, after a first injection step of the injection moulding process, that shapes the rigid structure, the mould changes the position of the moulding inserts by moving them within the mould structure, creating this way, space for a new injection step. The new injection step enables the shaping of the resilient material and the obtaining of the single structure packaging in a single production process and, with a single moulding tool.

[0023] In an embodiment, the injected polymeric packaging comprises a first polymeric rigid structure, for example a sidewall, preferably four sidewalls, designed to enable a comfortable handling and an easy stacking. Connecting the first polymeric rigid structure is a second polymeric rigid structure, for example a reinforcing structure layer, similar to a bottom, that may be positioned at different heights of the sidewalls, depending on the application purpose and requirements. Again, this changeability and flexibility of design, for the first and second polymeric rigid structures and also for the resilient material, is assured by different insert moulds that may be assembled and changed, as necessary, into the mould structure.

[0024] In an embodiment, the first polymeric rigid structure and the second polymeric rigid structure provide structural stability and adequacy for sustaining the weight of the products or items to stow and carry, while allowing stacking over another single structure packaging. In terms of materials, the polymeric rigid structures may be manufactured with thermoplastic materials by conventional injection moulding or, with integral skin rigid foams by reaction injection moulding, as intended.

[0025] In an embodiment, the foam material of the first polymeric rigid structure and the second polymeric rigid structure are preferably selected from a list consisting of polymeric foams based in polyurethane (PU), polyethylene (PE), or polystyrene (PS) or mixtures thereof.

[0026] In an embodiment, the resilient material, for example a soft layer, like a foam, this element of the single structure customizable packaging solution covers the first polymeric rigid structure and second polymeric rigid structure, at the area where there is contact with the items or products to be stowed namely, at the second polymeric rigid structure. During a simple stow activity, the resilient material may be defined and produced only for the top part of the second polymeric rigid structure. In another example of case scenario, during stacking and transport situations, resilient material may be defined and manufactured on both top and bottom of the second polymeric rigid structure to assure a secure and safe cushioning while avoiding unwanted movements of the products or items. Regarding building materials, the resilient material may be built with flexible integral skin foams. Integral skin flexible foams present a harder skin and softer core which enables the combination between a soft and flexible performance suitable for cushioning, while the harder skin avoids foam particles release and maintains product quality and resistance to wear and abrasion for longer periods. Other type of soft and flexible materials may also be used (e.g. elastomers), if intended. In a different approach, in which mechanical efforts are not relevant or cavity designs are aimed, integral skin rigid foams may be employed. The resilient material is also obtained by injection moulding. In the case of integral skin foams, reaction injection moulding is the manufacturing technique, as foams require a particular equipment for the combining of components (e.g. polyol, isocyanate, additives).

[0027] In an embodiment, the single structure packaging is manufactured based in the injection moulding technique and by using a single mould structure with movements. In terms of building materials, as indicated, thermoplastic materials may be combined, in a single product, with foamy materials, or, in another hypothesis, only foamy materials may be used. The versatility regarding the use of polymers is that various materials are available and with a wide range of properties (e.g. mechanical, thermal, electrical) that, with adequate selection, assure the suitable performance to best correspond to the application requirements. Also, polymeric materials allow the addition of, for example, additives and fillers during the manufacturing process, which allows to change the material properties as intended. This is most beneficial as, for instance, if a product or item is sensitive to electrostatic discharges, functionalization of the material to present electrostatic dissipative or conductive properties is feasible. Other examples of changeability of material properties may be for aesthetic aspects, as for example colour change or for mechanical improvements as, for example, change the hardness of the foam material. Besides the presented examples, plenty material compounding and functionalization approaches are possible.

[0028] The present disclosure presents a series of improvements in comparison to what is already known and available. The invention consists in a customizable packaging solution, based in a single structure, that provides both rigidity and softness, as intended, enabling structural adequacy and flexibility to safely stow and transport sensitive and fragile products or items, without requiring additional elements or components. Customized performance and personalized fitting, for variable typologies and configurations of fragile and sensitive products and items, is achieved by material combinations and design configurations that are assured by a versatile moulding process and changeable moulding inserts of a single moulding tool. The changeability of mould inserts and the movement ability of the mould enables and facilitates the generation of various single structure customized packaging solutions in a short-time frame. The simplicity of the single structure packaging solution improves handling by the user, while also reducing time to perform stow and transport activities. The solution is also lightweight due to the reduction of the number of components to a single one, and also, by the integration of foamy materials. The resource to integral skin foams also provides a solution with longer service life, while avoiding contamination and damaging by possible particles' release, in comparison to common foam-based packaging solutions. With the single structure customizable packaging solution, it becomes unnecessary to employ tote boxes, lids, trays and custom components to provide a safe stow. This invention also improves logistics by reducing the total number of packaging required which leads to a diminishing of the allocated storage areas. The single structure customizable packaging solution consists of a simple, single structure, lightweight, versatile, low-cost, and short-time to market solution suitable for stow and transport activities, for sensitive and fragile products and items.

[0029] An aspect of the present disclosure relates to an injected polymeric packaging for a sensitive or fragile product comprising at least two different polymeric materials, wherein at least one of the materials is resilient material selected from a list of: a foam, an elastomeric material, or combinations thereof, wherein the resilient material is configured to be in contact with the product; a first polymeric rigid structure for supporting the resilient material; wherein the first polymeric rigid structure covers the side of the resilient material; wherein the first polymeric rigid structure is bound to the resilient material by interlock or chemical bounding; a second polymeric rigid structure for support the resilient material, wherein said second polymeric rigid structure layer is connected to the first polymeric rigid structure, wherein said second polymeric rigid structure is placed in the bottom, in the top or in the interior of the first polymeric rigid structure (i.e. in the interior of the sidewall of the first polymeric rigid structure).

[0030] In an embodiment, the second polymeric rigid structure comprises the resilient material on an upper surface or on a lower surface of said second polymeric structure.

[0031] In an embodiment, the first polymeric rigid structure and the second polymeric rigid structure is in the same material.

[0032] In an embodiment, the resilient material is a foam, preferably a soft foam.

[0033] In an embodiment, the resilient material may be selected from a list consisting of polyurethane, polyethylene, or polystyrene or mixtures thereof. [0034] In an embodiment, the resilient material is an integral skin flexible foam.

[0035] In an embodiment, the first polymeric rigid structure and the second polymeric structure are thermoplastic.

[0036] In an embodiment, the first polymeric rigid structure and the second polymeric structure are a rigid foam.

[0037] In an embodiment, the rigid foam is an integral skin rigid foam.

[0038] In an embodiment, the first polymeric rigid structure extends upwardly from the second polymeric rigid structure.

[0039] In an embodiment, the first polymeric rigid structure is a sidewall being a single-wall or double-wall or multi-wall.

[0040] In an embodiment, the first polymeric rigid structure comprises an upper rim at the end.

[0041] In an embodiment, the upper rim comprises a smooth surface or a surface with protrusions.

[0042] In an embodiment, the second polymeric rigid structure comprise cavities, convoluted shapes or gridded structures.

[0043] In an embodiment, the resilient material comprises a smooth or a convoluted shape surface.

[0044] In an embodiment, the convoluted shapes are cylindrical, conical, pyramidal, oval, cubic or their combinations.

[0045] In an embodiment, the injected polymeric packaging further comprises a grip section on the sidewalls.

[0046] In an embodiment, the injected polymeric packaging further comprises at least two handles on the sidewalls.

[0047] Another aspect of the disclosure comprises a method to produce an injected polymeric packaging for a sensitive or fragile product comprising the steps of: a first injection of a material into a closed mould that comprises a plurality of exchangeable inserts for the production of a first and a second polymeric rigid structure; moving the moulding exchangeable inserts within the mould to create a cavity on the material first injected, by the movement of the exchangeable inserts; a further injection of a resilient material into the cavity in order to bound said resilient material to the first and second polymeric rigid structure; demoulding and curing.

[0048] In an embodiment, the first injection material is a thermoplastic material or a rigid foam.

[0049] In an embodiment, the resilient material injected to the cavity is an elastomer or a foam.

[0050] In an embodiment, the plurality of exchangeable inserts of the mould are manufactured by conventional subtractive manufacturing processes or additive manufacturing processes.

[0051] In an embodiment, the packaging solution may be based on a single structure that is customizable in terms of materials and design and may be composed by a readily stackable polymeric rigid structures and soft layer(s).

[0052] In an embodiment, the packaging solution may be manufactured with a single moulding tool that may comprise movements and changeable moulding inserts.

[0053] In an embodiment, the packaging solution may be manufactured by conventional injection moulding or variant(s), or other processing approaches, if intended.

[0054] In an embodiment, the packaging solution may be a single structure for the safe stow and transport of sensitive and fragile products and items, being also suitable for other typologies of products and systems.

[0055] In an embodiment, the first polymeric rigid structure and the second polymeric rigid structure may provide structural stability and adequacy for sustaining the weight of the products and items to stow and carry. [0056] In an embodiment, the first polymeric rigid structure and the second polymeric rigid structure may comprise, four sidewalls connected by an upper rim and round edges in each corner.

[0057] In an embodiment, the first polymeric rigid structure and the second polymeric rigid structure may be manufactured with thermoplastic materials or integral skin rigid foams, or other materials, if intended.

[0058] In an embodiment, the first polymeric rigid structure and the second polymeric rigid structure may be manufactured based in conventional injection moulding or reaction injection moulding or others, if intended.

[0059] In an embodiment, the resilient material may provide a safe cushioning by directly contacting with the products to stow and transport.

[0060] In an embodiment, the soft layer(s) may be manufactured above or below or, if intended, on both sides of the reinforcing structure that the rigid structure comprises.

[0061] In an embodiment, the packaging solution may be a single where the customizable characteristic regarding design may be achieved by resourcing to variable and versatile design configuration to best address particular needs of the item or product to stow and carry.

[0062] In an embodiment, the packaging solution may be based in a single structure where the variable and versatile design configuration, for the first and second polymeric rigid structures, includes solutions based in handling by gripped surfaces or by the inclusion of handles, single-wall to multi-walled sidewalls, smooth surfaces or with features (e.g. protrusions, cavities) to facilitate stacking or improve structural performance, amongst other design possibilities.

[0063] In another embodiment, the packaging solution may be based in a single structure wherein the variable and versatile design for the resilient material may be a smooth surface or convoluted shapes (e.g. cylindrical, conical, pyramid, oval, cubic) and may present variable features across the surface of a single soft layer, or variable configurations between bottom and top soft layer(s), amongst other possibilities.

[0064] In an embodiment, the packaging solution may be a single structure, wherein the variable and versatile design configuration may include dimensions' variations (e.g. height, width, radius, opening angles) of both polymeric rigid structures and resilient material (i.e. soft layers).

[0065] In an embodiment, the packaging solution may be a single wherein the customizable characteristic is achieved by altering the moulding inserts, as intended.

[0066] In an embodiment, the packaging solution may be a single structure wherein the customizable characteristic regarding material may be achieved by resourcing variable materials selected based in specific material properties and for the application purpose or by compounding and functionalization activities during the manufacturing activity to achieve a particular property value range (e.g. hardness, electrical conductivity).

[0067] In an embodiment, the packaging solution may be a single structure which may be lightweight by reducing the total number of components to a single one, and by using lightweight materials with low density, as for example, foamy materials.

[0068] In an embodiment, the packaging solution may be single structure with the possibility of embedding systems (e.g. piezoelectric sensors, radiofrequency identification systems) during the manufacturing process, in order to add functionality and thus produce a smart single structure customizable packaging solution. These systems may be located in the first polymeric rigid structure, in the second polymeric rigid structure or in the resistive material, or in their combinations.

BRIEF DESCRIPTION OF THE DRAWINGS

[0069] The following figures provide preferred embodiments for illustrating the disclosure and should not be seen as limiting the scope of the present disclosure.

[0070] Figure 1: Schematic representation of an embodiment of the package, which is a top perspective view of a possible design configuration for the single structure customizable packaging design.

[0071] Figure 2: Schematic representation of an embodiment of the package, which is a partial cross-sectional view, through the length sidewalls for a possible design configuration of the single structure customizable packaging. [0072] Figure 3: Schematic representation of an embodiment of the package consisting of a diagram representing the main steps of the manufacturing process possibilities for the production of a single structure customizable packaging.

DETAILED DESCRIPTION

[0073] The present disclosure relates to a packaging solution, based in a customizable single structure, for the safe storage and transportation of sensitive and fragile products and items such as printed circuit boards, integrated circuits, medical devices or perishable goods among other. The single structure packaging disclosed herein is customizable in terms of materials and design, assuring therefore, a versatile protection and cushioning for a multiplicity of delicate products and items. The single structure, manufactured by a single process, may be simply described as a readily stackable rigid structure and a layer of a resilient material or layers, where the sensitive and fragile products and items are to be placed.

[0074] The present disclosure, as previously mentioned, is a single structure customizable packaging solution that is lightweight, stackable, and provides a versatile cushioning assuring protection during storage and transport activities, for sensitive and fragile products and items. Three figures were defined to depict design possibilities for the single structure customizable packaging solution and also, to present processing approaches based in the building materials.

[0075] In an embodiment, Figure 1, in which is depicted a perspective top view of a possible design configuration for the single structure customizable packaging, it is possible to visualize the composing elements.

[0076] In an embodiment, Figure 2, is presented a partial cross-section view of a possible design configuration for the present disclosure.

[0077] In an embodiment, the single structure customizable packaging solution comprehends a rigid structure (1) that comprises a second polymeric rigid structure (2) and a first polymeric rigid structure (3), for example four walls, connected by an upper rim (4) and, with round edges (5) in each corner. Resilient material (6) may be present above or below the second polymeric structure (2). If intended, the resilient material (6) may be manufactured on both sides of the second polymeric structure (2).

[0078] In an embodiment, the single structure customizable packaging solution is manufactured by injection moulding technique and variant(s). In this type of manufacturing process, a mould structure is necessary to shape the part to inject. In this case, to shape the rigid structure (1) and the resilient material (6). A single moulding tool with movements is sufficient for such manufacturing process. The movements allow that, after a first injection process, a new cavity space is formed to enable a second injection step.

[0079] In an embodiment, the rigid structure (1), including the second polymeric rigid structure (2), four sidewalls as example of first polymeric rigid structure (3) , an upper rim (4) and the round edges (5), may be manufactured with a thermoplastic material by means of conventional injection moulding or, by integral skin rigid foam by means of reaction injection moulding. The manufacturing of the rigid structure (1) is correspondent to the first injection step, after which, the movement is activated and the moulding inserts are readjusted within the mould structure to create a new cavity. In this cavity, by a second injection step, it if formed the resilient material (6), entirely composed by an integral skin flexible foam. Note that the resilient material may also be formed with other building materials, if intended. Elastomeric materials as flexible building material alternatives are feasible. Also, integral skin rigid foams and even foams without integral skin may be employed. However, foams without integral skin will hamper the main purpose of this disclosure by releasing foam particles which may contaminate and damage the products or items, while rigid foams should only be employed in specific cases, if building cavities specific for a particular item, or in cases in which the item or product is not fragile to mechanical efforts.

[0080] In an embodiment, the design configuration of the first polymeric rigid structure and the second polymeric rigid structure that form the rigid structure (1) and the resilient material (6) is variable and versatile to best address particular needs of a sensitive and fragile item or product. This design flexibility is assured by the use of a mould with moulding inserts that are easily changed. Moulding inserts may be manufactured by, for example, conventional subtractive manufacturing processes or additive manufacturing processes. The variety of available manufacturing processes greatly improves the versatility and speed of manufacturing and changing mould inserts. Each sidewall (3) may be composed by double-walls interconnected by a plurality of structural vertical ribs that protrude from the upper rim (4). Variants from the presented design configurations are feasible. The easy handling may be achieved by grip sections defined across the surface of the sidewalls (3). Other approaches are possible by changing the moulding insert such as, for example, the inclusion of handles. The upper rim (4) corresponds to the available area that enables an easy stacking. The surface of the upper rim (4) may be smooth or present features (e.g. protrusions, cavities) to facilitate stacking. Other design configurations are possible. The second polymeric rigid structure (2) may be placed at variable heights in relation to the first polymeric rigid structure (3) in order to best suit particular requirements and facilitate the stacking and cushioning in specific situations, while making the best use of the available space, to provide an easy and adequate stow for a multitude of fragile and sensitive products and items. Cavities, convoluted shapes, gridded structures, amongst other design configurations may be defined for the second polymeric rigid structure (2), as intended.

[0081] In an embodiment, the surface design configuration for the resilient material (6) is also variable, as intended. From a smooth surface to convoluted shapes (e.g. cylindrical, conical, pyramid, oval or cubic), the design configuration may be varied between single structure customizable packaging solutions, while also may vary across a single layer(s) of resilient material (6) surface or between a top layer of resilient material (6.1) and bottom layer of resilient material (6.2). Configurations are free based in the purpose and by changing the moulding inserts.

[0082] The dimensions (e.g. height, width, radius, opening angles) of the described elements composing the single structure customizable packaging solution may vary in accordance to the need. Materials are also variable as needed based in specific material properties and the application purpose. Compounding and functionalization activities may occur, if needed, during the manufacturing activity in order to achieve a particular property value range (e.g. hardness, electrical conductivity). [0083] In Figure 2, the partial cross-section view depicts in more detail an embodiment and how the resilient material (6) may be situated on the top and bottom surface of the second polymeric rigid structure (2) that composes the rigid structure (1) (see top soft layer (6.1) and bottom soft layer (6.2)). As previously indicated, the second polymeric rigid structure (2) provides support and a connection area for an improved attachment with the resilient material (6). Also, the configuration for the positioning of the second polymeric rigid structure (2) is merely an example, as it may vary in position based in the available height of the sidewalls (3). In this particular design configuration, double-walled sidewalls (3) are presented, also as an example of the first polymeric rigid structure. Other particular aspects in Figure 1 and Figure 2 related to the design of the single structure customizable packaging design are free to be personalized as intended.

[0084] In an embodiment, Figure 3 depicts a diagram of an embodiment which represents the main steps of the manufacturing process for the production of the single structure customizable packaging solution. The flowchart is divided in two, in order to describe in parallel, the case where the rigid structure is built with a thermoplastic material (left schematic flowchart) and, when it is built with an integral skin rigid foam (right schematic flowchart). The first approach resources to conventional injection moulding and reaction injection moulding to obtain a product combining thermoplastic and integral skin flexible foam materials. The second manufacturing approach resorts to solely reaction injection moulding to fabricate a single structure customizable packaging solution entirely based in integral skin foamy materials with varied densities, rigid for the rigid structure, and flexible for the soft layer(s). For both approaches, a single mould with movements is sufficient. The mould inserts are easily changeable to generate variable features and configurations, for both the second polymeric rigid structure and resilient material. Also, the movements within the mould structure allow the generation of new space, enabling multiple injection steps. For both approaches, a single injection machine is sufficient. The only requirement is related to the need for at least two barrels (for material mixing, homogenization and injection), one per type of material to inject. [0085] Focusing on the flowchart of the left, now explaining with more detail, the production process begins when the mould tool closes and generates an empty space, named cavity. Then, the injection step occurs, in which, molten thermoplastic material such as polypropylene (PP), acrylonitrile butadiene styrene (ABS) or polycarbonate (PC) inside the barrel is forced, under pressure, into the moulding cavity. Inside the moulding cavity, the molten thermoplastic material cools under pressure to acquire the cavity shape. Once dimensional stability is achieved by cooling, the mould movement is activated, the moulding inserts change position, and a new cavity space is generated. Then, a new injection step occurs. In this step, the components that compose the integral skin flexible foam preferably a foam selected from polyurethane (PU); polyethylene (PE) or polystyrene (PS) or mixtures thereof, mixed previously to the injection step, are injected under pressure into the newly generated mould cavity. Inside the mould cavity occurs the typical reaction steps and phenomena associated to foam production (e.g. cream time, gel time, gas generation). Once fully completed the reaction, the manufactured single structure is safely demoulded. Because foams are being used, a cure time must be accounted, in a controlled environment. Typically, 24 hours are suitable however, this time may change depending on the foam material.

[0086] Regarding to the flowchart on the right, the process similarly begins with the mould closing. Once the mould is closed and the cavity is generated, the injection of the mixed components that will result in an integral skin rigid foam are injected under pressure. Inside the mould cavity occurs a reaction between the components and corresponding typical foaming phenomena. Once foamy consistency is achieved for the rigid structure, the mould movement is activated and a new cavity space is generated. A similar injection step occurs, this time with integral skin flexible foam components, previously mixed in the barrel of the reaction injection moulding machine. Once the injection step for the soft layer(s) is completed, a new sequence of foaming stages and phenomena occurs. Once achieved the consistency enough that assures an easy removal without damaging, the ejection of the foamy-based single structure customizable packaging solution occurs. A cure step after demoulding, in controlled room conditions, is necessary. [0087] Nowadays there is an increasing need for the transport (short distances) and shipping (long distances) of sensitive and fragile products and items. This type of products and items present various shapes and dimensions and require a safe means for the storage and transport, in order to maintain product integrity and avoid premature damaging. Therefore, the secure accommodation of sensitive and fragile products and items became highly important. As previously stated, the stow and transport of products and items is commonly performed by resorting to packaging solutions composed by a series of elements which may be, for example, tote boxes, lids, racks and trays. The use of so many components increases lead times and associated cost to obtain a packaging, packaging complexity, and also, time spent to accommodate the products or items inside the packaging.

[0088] The present disclosure provides a safe, simple and comfortable packaging solution based in a single structure that is customizable in terms of material type (e.g. thermoplastic and foamy materials), material properties (e.g. electrical properties, hardness, biodegradable), and design configuration (e.g. handles, dimensions, features) to best fit the requirements related to the application purpose. The single structure customizable packaging solution corresponds to a product which consists of a unique structure. The unique structure is composed by a rigid structure of a first polymeric rigid structure and a second polymeric rigid structure, and resilient material which are produced in a single mould with movements and changeable moulding inserts, by means of injection based moulding processes. When ejected from the mould, the product is complete and independent, meaning that it does not require additional components or steps (e.g. assembly operations) to perform its purpose.

[0089] The possible combination of manufacturing processes (conventional injection moulding and reaction injection moulding), materials (e.g. rigid and flexible) and design flexibility, greatly contributes to the development of a lightweight, comfortable and multipurpose single structure customizable packaging. The use of a single moulding structure which allows the changeability of the moulding inserts to fabricate variable products, with features that best correspond and suit a specific product, consists in a simpler, quick-to-market and at a reduced cost solution. [0090] This disclosure gathers the necessary criteria to provide comfortable handling, flexibility to suit assorted products, lightweight, adequate structural performance and the stacking ability, which allows its functioning as a packaging container without resorting to a series of various components fabricated by different technologies to provide the perfect cushioning of products. This disclosure is a simplified customized solution with added potential to present improved performance and the adequacy for the stow and transport, in safety, of diversified products.

[0091] The term "comprising" whenever used in this document is intended to indicate the presence of stated features, integers, steps, components, but not to preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

[0092] The disclosure should not be seen in any way restricted to the embodiments described and a person with ordinary skill in the art will foresee many possibilities to modifications thereof. The above described embodiments are combinable.

[0093] The following claims further set out particular embodiments of the disclosure.