TECHNICAL FIELD

The present invention relates to a container or a container liner that can be used for transporting or storing articles.

BACKGROUND ART

Conventional transportation packaging for multiple items is normally composed of corrugated cardboard boxes that are purchased in different sizes and stored in the warehouses of the companies that purchase them prior to their use. It is common for companies to acquire different size boxes composed of corrugated boards. These boxes may consume significant storage space. Normally, shipping cases made of corrugated boards are heavy, particularly in the aggregate, and their transportation has a significant negative environmental impact considering the high amount of carbon dioxide emissions during their transportation and handling.

Thus, there is a need for lighter packaging that minimizes negative environmental impact.

The use of pre-sealed rolls with a specific pattern for the production of air cushions is available in the market with one single air chamber design or with multiple air compartments. However, none of these rolls was designed with the purpose of creating a large stand-alone container that can be used for the transportation of multiple items without requiring an additional container.

SUMMARY OF INVENTION

A stand-alone container is produced by a thermoplastic film material formed by two plies folded or sealed at one edge and opened at a second edge. In the middle area of the film material, different compartments are sealed with different sizes to be filled later with air or other forced gas. The material can be fed in gas blower equipment in the form of preformed rolls that can have different widths according to the container size that is desired. The material can also be cut or tom at the tearing strips to produce the desired length that allows the formation of the container with the final desired dimensions. The container can be used for the transportation of goods.

Although this product is primarily intended to exist as a stand-alone container, it can also be placed within another container and/or it can serve as a container liner. This product is light compared to corrugated cardboard boxes, and prior to being inflated more compact too. Another benefit of the present invention is that it is waterproof. This property may be particularly valuable during inclement weather conditions or if a bottle carrying a liquid opens up during transport.

Importantly, the container is not designed to be used as a protective cushion inside other transportation containers, but rather the container is a stand-alone, self-contained product. Of course, those of skill in the art will recognize that the scope of the claims of this application will be governed by the language of the claims and not be intent. The container can be unfolded, stored, and reused. The film used to form the container can be composed of at least one high gas barrier material and can also be composed of recycled material to minimize environmental impact. If the film is composed of more than ninety percent polyethylene, it may be fully recyclable. The container may also have an easy opening feature that includes a perforated area or an additional perforated strip at one or more of any of the edges of the container, and can be placed in any direction and size, with the purpose of facilitating the opening of the container.

One aspect of the present invention is directed to a roll that includes a single two ply thermoplastic film from which plural self-contained inflated containers are formed. The single two ply thermoplastic film in the roll includes a right side, a left side, and a middle portion. The right side, left side and middle portion include a plurality of bubbles. The right side and left side have the same dimensions. A tearing strip separates the portion of the film that is used for each of the self-contained inflated containers.

In one embodiment, the plurality of bubbles in the right and left sides are substantially spherical.

In another embodiment, the plurality of bubbles in the middle portion are substantially square or rectangular.

In another embodiment, the plurality of bubbles are filled with a gas selected from the group consisting of air, nitrogen, helium and argon.

In another embodiment, the single two ply thermoplastic film is comprised of one or more of polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyethylene terephthalate, neoprene/chlorosulphonated polyethylene, polyurethane, thermoplastic polyurethane, ethylene vinyl alcohol, and polyamide.

In another embodiment, the single two ply thermoplastic film is comprised of more than seventy-five percent polyethylene.

In another embodiment, the single two ply thermoplastic film is opaque.

In another embodiment, the roll further includes a plurality of channels between the bubbles. In another embodiment, the single two ply thermoplastic film is fully or partially recyclable.

In another embodiment, the single two ply thermoplastic film is configured for receiving a gas between the two plies.

Another aspect of the present invention is directed to a self-contained inflated container for transporting articles. The container is formed from a single two ply thermoplastic film. The container when assembled includes a top, a bottom, and four sides. Each of the top and bottom includes a plurality of bubbles. The top and bottom have the same dimensions. Each of the four sides includes one or more bubbles, and each of the opposing sides have the same dimensions.

In one embodiment, the plurality of bubbles in the top and bottom are substantially spherical.

In another embodiment, the one or more bubbles in each of the four sides is substantially square or rectangular.

In another embodiment, the bubbles are filled with a gas selected from the group consisting of air, nitrogen, helium and argon.

In another embodiment, the single two ply thermoplastic film is comprised of one or more of polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyethylene terephthalate, neoprene/chlorosulphonated polyethylene, polyurethane, thermoplastic polyurethane, ethylene vinyl alcohol, and polyamide.

In another embodiment, the single two ply thermoplastic film is comprised of more than seventy-five percent polyethylene.

In another embodiment, the single two ply thermoplastic film is opaque.

In another embodiment, the container further includes partial tearing zones between each of the four sides.

In another embodiment, the container further includes a plurality of channels between the bubbles.

In another embodiment, the single two ply thermoplastic film is fully or partially recyclable.

Other aspects and advantages of the invention will be apparent from the following description and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a representation of the unwinding of a roll of single two ply thermoplastic film and use of gas equipment to blow gas into film. Figure 2 is a representation of a finished gas cushion sheet that has not yet been assembled into a container.

Figure 3 is a representation of a finished gas cushion sheet that has not yet been assembled into a container. The partial tearing zones are cut or torn and the gas cushion sheet is ready to be folded to form the container.

Figure 4 is a representation of the partially assembled container in which the overlap of the tear strips is disclosed.

Figure 5 is a representation of the container in which the flaps of the bottom of the container have been closed.

DESCRIPTION OF EMBODIMENTS

The present invention uses a thermoplastic film (1) that is waterproof, lightweight, with very high puncture resistance and high gas barrier, with multiple bubbles (4) that can be filled with gas/air to form a gas cushion sheet. The high gas barrier helps prevent the gas permeation from the interior of the gas cushion sheet to the exterior. This feature helps the container keep its stability, shape and functionality during the entire storage and transportation process. Examples of inflatable polymers with a high puncture resistance and a high gas barrier include neoprene/chlorosulphonated polyethylene (CSM) (also called HYPALON ^® ), polyvinyl chloride (PVC), polyurethane (PU) and thermoplastic polyurethane (TPU).

This sheet can be used to produce a transportation container (7) in which the gas bubbles form a cushion to protect the items that packaged in this container. These gas cushion sheets and the containers that result from these sheets can be produced immediately before they are needed, eliminating the need to store them in their fully inflated form in warehouses, saving space and reducing storage costs. The container, having a much lighter weight (than more conventional containers), would be more sustainable as well.

The thermoplastic film is comprised of one or more of polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyethylene terephthalate, neoprene/chlorosulphonated polyethylene (CSM) (also called HYPALON ^® ), polyurethane, thermoplastic polyurethane (TPU), ethylene vinyl alcohol (EVOH), synthetic rubber, phenolic resin, melamine resin, and polyamide (PA) (a.k.a nylon). In embodiments of the present invention, the thermoplastic film is comprised of more than 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89 or 90 percent polyethylene.

In another embodiment, the thermoplastic film is opaque. And in other embodiments, the thermoplastic film is translucent, partially translucent, or partially opaque. In some embodiments the film may be a polyethylene produced, for example, from a resin having a density range between 0.905 - 0.967 g/cm3 and a melt index between 0.40 - 150 g/10 min. Such a polyethylene resin may be prepared, for example, from use of Ziegler- Natta catalysts in combination with an octene-1 comonomer.

The type of polymer or polymers chosen ultimately depends on what the container will be used for. For example, containers for shipping expensive/fragile items should be more robust than containers used for shelf storage.

Gases that can be used in the bubbles include but are not limited to air, nitrogen, helium and argon. Further embodiments may include combinations of these gases, with or without additional gases.

Different roll widths, with different gas cushion bubble sizes forming different gas cushion sheets can be formed to produce different container sizes, with different final dimensions. Some non-limiting examples of dimensions include 12x12x12 inches, 16x16x16 inches, 18x18x18 inches, 22x22x22 inches, 24x24x24 inches, 15x12x10 inches, 16x12x12 inches and 18x18x16 inches. These are typically read as height by length by width, though the location of such dimensions on a container may be relative.

The process of making the container starts with a roll (10) formed by two layers of film that are superposed on each other and can be sealed in specific patterns to form channels (13) with specific sizes and designs. One edge of the roll is folded or sealed to avoid gas leakage. A second edge of the roll is open at one or more specific points, or channels, formed by the sealing pattern created in the film roll previously to the material inflation process.

The seals may be heat seals between the inner surfaces of the two film plies. Alternatively, the two film plies may be adhesively bonded to each other. The two film plies may include a thermoplastic heat sealable polymer on their inner surface. A sealing roller may be used which applies heat and forms seals between the two film plies. The polymer or polymers used in the sealing may include olefin homopolymers and copolymers, such as ethylene/alpha-olefin copolymer.

Using equipment that is able to blow gas into the film between the two film plies through the channels, the gas can inflate the different bubbles formed by the sealing profile created in the film roll. The small gas bubbles situated at the edges (right side (16) and left side (19)) of the film roll form the top (22) and bottom (25) of the container, and the biggest gas bubbles situated at the middle portion (28) of the film roll, form the four sides (31) of the container (see e.g., Figures 1 and 4). In other embodiments, the middle portion of the roll has a gas bubble or bubbles that have same size as those found in the right and left sides of the roll.

In some embodiments, the bubbles are substantially spherical, square, rectangular, triangular, oval, rhomboid, cylindrical, conical, pentagonal, hexagonal, heptagonal, octagonal, heart shaped, irregularly shaped, or any combination thereof.

The gas injection is a continuous process in which the film roll is unwinding, and the gas blower (50) and/or other gas inflation equipment is injecting the gas through the formed channels and filling the gas bubbles formed between the two layers of film. Immediately after the gas is injected into the film through the gas channels, a sealing device (53) seals the channels to avoid gas leakage.

After all the bubbles have been filled with gas, the final gas cushion sheet is formed by four side flaps at the right side of the gas cushion sheet, wherein the nonadjacent side flaps must have the same dimensions. The same four side flaps are also formed at the left side of the gas cushion sheet and they are equivalent to the ones formed at the right side. All of these side flaps contain gas which is distributed through small channels that are connected. At the middle portion of the gas cushion sheet, big gas pockets are formed. They are separated from each other by sealing areas that give them the correct volumetric shape and size in order to allow the right compaction of these gas pockets. The side flaps form the lower and upper edges and the gas pockets form the side edges, being the side flaps responsible to form the bottom and top of the container and the gas pockets responsible to give the structure, strength and top load resistance of the bubble container.

The side flaps on both the right and left sides of the inflatable material are separated by partial tearing zones (33) that can be cut or torn to separate the different side flaps in order to form the edges of the container (see e.g., Figures 2 and 3). Alternatively, the partial tearing zones may be formed already completely cut. After every four side flaps, there is a tearing strip (36), that is placed horizontally across the entire gas cushion sheet, and can be cut or torn to separate each individual sheet that will form each bubble container (i.e., self- contained inflated container). In some embodiments, the container may have an integral top, and in other embodiments the container does not have a top. In still other embodiments, the top may be formed separately. In still further embodiments the top need not have a bubble function.

The container may be further covered with some type of wrap film. The container may be inserted into another container. After the partial tearing zones are cut or torn (Figure 3), the gas cushion sheet is ready to be folded to form a finished bubble container.

To form a finished bubble container, first, the tearing strips A and B (see Figures 3 and 4) of the cross sections should be connected forming an overlap by any bonding means, e.g., glues or adhesive tapes.

The smaller side flaps from one of the gas cushion sheet sides should be folded towards the interior area formed by the gas pockets that are at the middle of the gas cushion sheet, in a manner such that the smaller side flaps should be placed into the interior of the container and the bigger side flaps should be folded towards the smaller side flaps to form the outside bottom edge of the container. The bigger side flaps should be connected forming an overlap by any bonding means, e.g., glues or adhesive tapes. Possible glues that may be used include but are not limited to polyvinyl acetate, phenol formaldehyde, ethylene vinyl acetate, and cyanoacrylate.

After the bigger side flaps are connected forming the bottom of the container, the container is ready to be filled with items (see Figure 5). When the container is filled, the side flaps that correspond to the top of the container are connected. Then the container could optionally be wrapped and/or placed into another container.

The following two documents are each relied upon and incorporated herein in their entirety. If at any point an incorporated reference conflicts with this written specification, this written specification controls.

Kit L. Yam (Editor), “The Wiley Encyclopedia of Packaging Technology, 3rd Edition”, ISBN: 978-0-470-08704-6.

Soroka, W and CCP, "Fundamentals of Packaging Technology-Fourth Edition", ISBN-13: 978-1930268289, ISBN-10: 1930268289.

Although the present invention has been described in terms of specific exemplary embodiments and examples, it will be appreciated that the embodiments disclosed herein are for illustrative purposes only and various modifications and alterations might be made by those skilled in the art without departing from the spirit and scope of the invention as set forth in the following claims.

INDUSTRIAL APPLICABILITY

Provided is a container useful for transporting commercial goods. The container is formed from a single two ply thermoplastic film, and when assembled includes a top, a bottom and four sides. The container allows for light packaging and minimizes negative environmental impact.