Product Packaging that Remains with the Product and Functions as Acoustical and/or Thermal Insulation

Abstract

A shipping capsule for an electrical appliance comprises a blanket of insulating material and a layer of stretch wrap. Together these materials function as a durable shipping container eliminating the need for a corrugated cardboard outer carton currently in use. The invention further includes a method of reducing shipping costs and shipping waste associated with shipping an electrical appliance. The method includes the steps of covering at least a portion of the electrical appliance with insulation material that will remain with the electrical appliance after installation and providing a layer of stretch wrap over the insulation material whereby the combination of insulation material and stretch wrap form a shipping capsule.

1 . A shipping capsule for an electrical appliance, comprising:
 a blanket of insulating material including a first portion covering a front face of said electrical appliance; and   a layer of polymer film extending around at least a portion of said blanket of insulating material and holding said first portion in place on said front face of said electrical appliance.   
     
     
         2 . The shipping capsule of  claim 1 , wherein said blanket of insulating material includes a densified outer skin. 
     
     
         3 . The shipping capsule of  claim 2 , wherein said blanket of insulating material is a non-laminate. 
     
     
         4 . The shipping capsule of  claim 1 , wherein said blanket of insulating material includes a protector. 
     
     
         5 . The shipping capsule of  claim 4 , wherein said protector is held in a pocket so as to cover and protect said appliance. 
     
     
         6 . The shipping capsule of  claim 5 , wherein said protector is a corner protector made from a material selected from a group consisting of cardboard, fiber board, plastic, rubber, elostomer, neoprene, polyethylene terephthalate, composite material and combinations thereof. 
     
     
         7 . The shipping capsule of  claim 5 , wherein said blanket of insulating material remains with said electrical appliance following installation and said corner protector is removed from said pocket prior to installation of said electrical appliance. 
     
     
         8 . The shipping capsule of  claim 7 , wherein said first portion of said blanket of insulating material is displaceable from a shipping position wherein said first portion covers said front face of said appliance and an installation position wherein said first portion covers a rear face of said appliance. 
     
     
         9 . The shipping capsule of  claim 8 , wherein said first portion is a flap of insulating material connected by a hinge line to a main body of said blanket of insulating material covering said electrical appliance. 
     
     
         10 . The shipping capsule of  claim 1 , wherein said shipping capsule does not include an outer carton and said stretch wrap is exposed. 
     
     
         11 . The shipping capsule of  claim 1 , wherein said blanket of insulating material is made from a material selected from a group consisting of polyester, polyolefin, polyethylene, polypropylene, rayon, nylon, acrylic, hemp, kenaf, cotton, polyethylene terephthalate, polybutylene terephthalate and combinations thereof. 
     
     
         12 . The shipping capsule of  claim 11 , wherein said insulating material further includes reinforcing fibers selected from a group consisting of glass fibers, polypropylene fibers and combinations thereof. 
     
     
         13 . A shipping capsule for an electrical appliance, comprising:
 a hood of insulating material, said hood of insulating material provided in a shipping position covering a top wall, two opposing sidewalls and a front face of said electrical appliance; and   a layer of polymer film extending around said hood of insulating material and holding said hood of insulating material on said electrical appliance in said shipping position.   
     
     
         14 . The shipping capsule of  claim 13 , wherein said hood of insulating material is four sided and includes a densified outer skin. 
     
     
         15 . The shipping capsule of  claim 14 , wherein said hood of insulating material is a nonlaminate. 
     
     
         16 . The shipping capsule of  claim 13 , wherein said hood of insulating material includes at least one protector overlying said electrical appliance when said hood of insulating material is in said shipping position. 
     
     
         17 . The shipping capsule of  claim 16 , wherein said protector is held in a pocket so as to cover and protect said electrical appliance. 
     
     
         18 . The shipping capsule of  claim 17 , wherein said protector is a corner protector made from a material selected from a group consisting of cardboard, fiber board, plastic, rubber, elastomer, neoprene, polyethylene terephthalate, composite material and combinations thereof. 
     
     
         19 . The shipping capsule of  claim 17 , wherein said hood remains with said electrical appliance following installation and said corner protector is removed from said pocket prior to installation of said electrical appliance. 
     
     
         20 . The shipping capsule of  claim 19 , wherein, prior to installation, said hood is displaced from said shipping position into an installation position wherein said hood covers said top wall, said two opposing sidewalls and a rear wall of said electrical appliance. 
     
     
         21 . The shipping capsule of  claim 13 , wherein said shipping capsule does not include an outer carton and said stretch wrap is exposed. 
     
     
         22 . The shipping capsule of  claim 13 , wherein said hood of insulating material is made from a group consisting of polyester, polyolefin, polyethylene, polypropylene, rayon, nylon, acrylic, hemp, kenaf, cotton, polyethylene terephthalate, polybutylene terephthalate and combinations thereof. 
     
     
         23 . The shipping capsule of  claim 22 , wherein said insulating material further includes reinforcing fibers selected from a group consisting of glass fibers, polypropylene fibers and combinations thereof. 
     
     
         24 . The shipping capsule of  claim 19 , wherein said hood includes a removable panel covering said front face of said electrical appliance in said shipping position. 
     
     
         25 . The shipping capsule of  claim 24 , wherein said removable panel is attached to a rear wall of said electrical appliance prior to installing said electrical appliance. 
     
     
         26 . A shipping capsule for an electrical appliance, comprising:
 a five sided hood of insulating material, said hood provided in a shipping position covering a top wall, two opposing sidewalls, a front face and a rear wall of said electrical appliance; and   a layer of polymer fiber extending around said hood and holding said hood on said electrical appliance in said shipping position.   
     
     
         27 . The shipping capsule of  claim 26 , wherein said hood of insulating material includes a densified outer skin. 
     
     
         28 . The shipping capsule of  claim 27 , wherein said hood of insulating material is a nonlaminate. 
     
     
         29 . The shipping capsule of  claim 26 , wherein said hood of insulating material includes at least one protector overlying said electrical appliance when said hood of insulating material is in said shipping position. 
     
     
         30 . The shipping capsule of  claim 29 , wherein said protector is held in a pocket so as to cover and protect said electrical appliance. 
     
     
         31 . The shipping capsule of  claim 30 , wherein said protector is a corner protector made from a material selected from a group consisting of cardboard, fiber board, plastic, rubber, elastomer, neoprene, polyethylene terephthalate, composite material and combinations thereof. 
     
     
         32 . The shipping capsule of  claim 30 , wherein said hood remains with said electrical appliance following installation and said corner protector is removed from said pocket prior to installation of said electrical appliance. 
     
     
         33 . The shipping capsule of  claim 32 , wherein said hood includes a removable panel covering said front face of said electrical appliance in said shipping position. 
     
     
         34 . The shipping capsule of  claim 32 , wherein said hood includes a substantially T-shaped perforation extending along one corner and down a section of said hood, where tearing along said perforation allows said section of said hood to be folded back to expose said front face of said electrical appliance. 
     
     
         35 . A shipping capsule for an electrical appliance, comprising:
 a blanket of insulating material having a bottom wall, a top wall, a front wall, a rear wall, a right side wall and a left side wall;   a base pocket provided in said bottom wall;   a support base received in said base pocket;   a first perforation line extending along a top rear corner and rear side corner of said blanket;   a second perforation line extending along a top front corner and front side corner of said blanket;   corner protectors provided along at least two corners of said electrical appliance; and   a layer of polymer film provided overlying at least a portion of said blanket.   
     
     
         36 . A method of reducing shipping costs and shipping waste associated with shipping of an electrical appliance, comprising:
 covering at least a portion of said electrical appliance, including a front face of said electrical appliance, with insulation material that will remain with said electrical appliance after installation; and   providing a layer of polymer film over said insulation material whereby said combination of insulation material and stretch wrap for a shipping capsule.   
     
     
         37 . The method of  claim 36 , including providing a pocket in said insulation material and inserting a removable corner protector in said pocket adapted to protect a corner of said electrical appliance during shipping. 
     
     
         38 . The method of  claim 37 , including eliminating an outer carton around said electrical appliance.