Method of forming foam cushions for packaging purposes and cushions formed thereby

• US 5,139,151 A
• Filed: 04/05/1991
• Issued: 08/18/1992
• Est. Priority Date: 07/11/1989
• Status: Expired due to Term

• Current Assignee: Sealed Air Corporation (Sealed Air)
• Original Assignee: Sealed Air Corporation (Sealed Air)
• Inventors: Chelak, Yaroslaw S.
• Primary Examiner(s): Foster, Jimmy G.
• Application Number:
  US07/681,864
• Time in Patent Office: 501 Days
• Field of Search: 206/521, 206/523, 206/524, 206/594, 383/120, 383/902, 383/907, 428/68, 428/69, 428/71, 428/76, 428/34.3, 428/36.5
• US Class Current: 206/523
• CPC Class Codes: B29C 44/182 Filling flexible bags not having a particular shape
• CPC Class Codes: B31D 2205/0047 Feeding, guiding or shaping the material
• CPC Class Codes: B31D 5/0078 and filling with a material other than air or gas
• CPC Class Codes: B65B 55/20 Embedding contents in shock-absorbing media, e.g. plastic foam, granular material
• CPC Class Codes: B65D 81/051 using pillow-like elements filled with cushioning material, e.g. elastic foam, fabric
• CPC Class Codes: Y10T 428/233 Foamed or expanded material encased

Abstract

The invention is a method of forming large-volume foam cushions for packaging purposes wherein each cushion comprises a closed bag formed from respective first and second superposed sheets of plastic material and filled with foam. The method comprises folding at least one of the first and second sheets of plastic material along one side edge portion of the sheets inwardly to form a first longitudinally extending gusset therein; folding at least one of the first and second sheets of plastic material along the opposite side edge portion of the sheets inwardly to form a second longitudinally extending gusset therein; longitudinally sealing the outer side edges of the first and second sheets together to form a gusseted tube thereof; transversely sealing the first and second sheet together along a line generally perpendicular to the longitudinal side edge seals to thereby form a closed end of the gusseted tube; injecting a predetermined amount of a foamable composition into the closed end of the gusseted tube; and transversely sealing the gusseted tube along a line longitudinally spaced from the first transverse seal to thereby form a sealed bag containing the foamable composition, wherein as the foamable composition foams the gussets expand to produce a cushion of greater volume.

Claims

1. A large volume packaging cushion for custom packaging applications of the type in which a bag containing a foamable composition is added to a container holding an item to be cushioned, said cushion comprising:

first and second superimposed sheets of heat sealable thermoplastic material wherein at least one of said first and second sheets of plastic material has an inwardly extending fold along one side edge portion that forms a first longitudinally extending gusset therein and wherein at least one of said first and second sheets of plastic material has an inwardly extending fold along the opposite side edge portion that forms a second longitudinally extending gusset therein;

a pair of longitudinal seals in said first and second sheets and positioned along the respective outer side edges of said first and second sheets so that said longitudinal seals define a gusseted tube formed from said sealed sheets;

at least one longitudinal side edge portion that defines at least one side edge opening for said bag;

a pair of transverse seals along lines generally perpendicular to said longitudinal seals and wherein each transverse seal intersects each longitudinal seal so that said longitudinal seals and said transverse seals define a gusseted bag with said sealed outer edges for providing a bag with an increased potential filled volume as compared to a bag having similar size unfolded sheets; and

a predetermined amount of foamable composition inside said sealed gusseted bag.