Packaging material and a method for its manufacture

• US 5,489,464 A
• Filed: 04/18/1994
• Issued: 02/06/1996
• Est. Priority Date: 04/19/1993
• Status: Expired due to Fees

• Current Assignee: Tetra Laval Holdings & Finance SA (Tetra Laval Holdings BV)
• Original Assignee: Tetra Laval Holdings & Finance SA (Tetra Laval Holdings BV)
• Inventors: Bjorck, Bengt
• Primary Examiner(s): Loney, Donald J.
• Application Number:
  US08/229,345
• Time in Patent Office: 659 Days
• Field of Search: 428/178, 428/188, 428/72, 428/167, 428/35.2, 428/35.7, 428/152, 428/172, 428/179, 428/192, 428/195, 428/198, 156/268, 156/290, 264/510, 264/512, 264/545, 264/551, 383/3, 206/522, 206/525, 206/585, 206/593
• US Class Current: 428/178
• CPC Class Codes: B29C 65/4815 Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/52 characterised by the way of applying the adhesive B29C65/50 takes precedence; apparatus for applying liquids in general B05C; processes for applying liquids in general B05D
• CPC Class Codes: B29C 66/004 Preventing sticking together, e.g. of some areas of the parts to be joined
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/4326 for making hollow articles or hollow-preforms, e.g. half-shells
• CPC Class Codes: B29C 66/438 Joining sheets for making hollow-walled, channelled structures or multi-tubular articles
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/72321 consisting of metals or their alloys
• CPC Class Codes: B29C 66/72326 Glass
• CPC Class Codes: B29C 66/72341 for gases
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29L 2031/601 Multi-tubular articles, i.e. composed of a plurality of tubes hollow-walled B29L2024/00
• CPC Class Codes: B29L 2031/7138 Shock absorbing
• CPC Class Codes: B29L 2031/714 for use in loose form
• CPC Class Codes: B31D 5/0073 including pillow forming
• CPC Class Codes: B65D 81/03 Wrappers or envelopes with shock-absorbing properties, e.g. bubble films for thermal insulating purposes B65D81/3888
• CPC Class Codes: B65D 81/052 filled with fluid, e.g. inflatable elements
• CPC Class Codes: Y10T 156/1082 Partial cutting bonded sandwich [e.g., grooving or incising]
• CPC Class Codes: Y10T 428/2457 Parallel ribs and/or grooves
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/24661 : Forming, or cooperating to form cells
• CPC Class Codes: Y10T 428/24744 : Longitudinal or transverse tubular cavity or cell

Abstract

Packaging material for self-supporting packaging container walls includes two material layers that are fixed at a given spacing from one another. The two material layers define an interjacent chamber which is filled with gas under pressure. The material is produced by the material layers being sealed to one another over a portion of their surface such that a chamber is formed which is filled with, for example, air under pressure.

Claims

1. A packaging material for a self-supporting packaging container wall comprising at least two flexible material layers each having a surface area, the two material layers being interconnected with one another in a pattern of sealings distributed over the surface area of the at least two material layers to define between the two material layers a plurality of connected cells, said cells being filled with gas under pressure and being arranged in adjacent groups, the adjacent groups of cells being offset with respect to one another to define fold lines between adjacent offset groups of cells.

2. The packaging material as claimed in claim 1, wherein the at least two material layers are fabricated of gas-tight heat-sealable material.

3. The packaging material as claimed in claim 2, including an additional material layer which is connected to each one of the at least two flexible material layers and which is disposed to maintain the at least two flexible material layers at a predetermined distance from one another.

4. The packaging material as claimed in claim 1, wherein said at least two layers and said additional layer are interconnected by linear sealings.

5. The packaging material as claimed in claim 1, wherein said at least two layers and said additional layer are punctiformly interconnected with one another.

6. The packaging material as claimed in claim 4, wherein the cells are channel-shaped.

7. The packaging material as claimed in claim 6, including means for connecting each cell with ambient atmosphere.

8. The packaging material as claimed in claim 1, including a plurality of fold lines for allowing regions of the packaging material to be folded to produce a packaging container having a plurality of walls.

9. The packaging material as claimed in claim 1, wherein the gas is at an excess pressure of 1 to 10 bar.

10. The packaging material as claimed in claim 1, wherein the gas is air.

11. The packaging material as claimed in claim 1, wherein the gas is nitrogen gas.

12. A method of producing a packaging material for a self-supporting packaging container wall comprising providing at least two flexible material layers each having a surface area, interconnecting the material layers to one another over at least a portion of their surface areas to form a plurality of adjacent groups of cells with adjacent groups of cells being offset with respect to one another so that fold lines are defined by transitions between adjacent offset groups of cells, and filling the cells with gas under pressure.

13. The method as claimed in claim 12, wherein mutually facing surfaces of the material layers are heat-sealed linearly to one another.

14. The method as claimed in claim 12, including applying an anti-sealant between the mutually facing surfaces of the material layers.

17. The method as claimed in claim 12, wherein the cells are in communication with an external pressure gas container.

15. The method as claimed in claim 15, wherein the anti-sealant is printed in a desired pattern on one of the material layers.

16. The method as claimed in claim 15, wherein the anti-sealant applied between the facing surfaces of the material layers is a heat-resistant printing ink.

18. The method as claimed in claim 15, including providing the cells, prior to sealing, with an internal gas source.

19. The method as claimed in claim 18 including activating the gas source during reforming of the material into packaging containers.

20. The method as claimed in claim 18, wherein the gas source is printed onto the material in the form of a coating of the desired pattern prior to sealing together of the layers.

21. A method of making a packaging container for holding consumable contents, comprising:

providing two flexible material layers which each have oppositely disposed surfaces;

interconnecting facing surfaces of the two material layers at a plurality of places to define a packing material laminate in which a plurality of cells are located between the two material layers, the cells being divided into adjacent groups with adjacent groups of cells being offset with respect to one another to define fold lines between adjacent offset groups of cells;

filling the cells with gas under pressure; and

folding the packaging material laminate along the fold lines to produce a packaging container having a plurality of side walls that together define an interior for holding consumable contents.

22. The method according to claim 21, wherein said step of interconnecting the facing surfaces of the two natural layers includes interconnecting the facing surfaces of the two material layers along a plurality of sealing lines to produce said cells.

23. The method according to claim 22, wherein said folding step includes folding the packaging material laminates so that each side wall includes one of said groups of cells.

24. A packaging container comprising an end wall and a plurality of self-supporting upstanding side walls, adjacent side walls being connected to one another at corners, the side walls and end wall together defining an interior for holding consumable food, each of said side walls including a group of cells which are each filled with gas under pressure, the group of cells in each side wall being offset with respect to the groups of cells in adjacent side walls.

25. A packaging container according to claim 25, wherein each of the side walls is comprised of at least first and second flexible material layers interconnected to one another in a pattern of sealings to define said group of cells filled with gas under pressure, the cells in each group being positioned vertically above one another.

26. A packaging container according to claim 26, including an additional layer interposed between said first and second material layers.