Heat sealed packaging assemblies and methods of producing and using the same

Abstract

A packaging device can include a flexible member which can be resilient, substantially non-resilient, or non-resilient, which can be formed of one or more layers which can be different materials and a frame member. The flexible member can be heat sealed to the frame member or to a coating on the surface of the frame member. The layers can be made from different materials or the same materials having different thicknesses, modules of elasticity, melting index, or other different characteristics.

What is claimed is: 
     
         1 . A packaging assembly comprising:
 at least a first frame member having a central portion; and   a first thin sheet member disposed over the central portion of the first frame member;   wherein the first thin sheet member includes a central portion heat-sealed to the central portion of the first frame member, the first thin sheet member further including first and second peripheral sides that are configured to be folded over the central portion of the first frame member.   
     
     
         2 . The packaging assembly according to  claim 1 , further comprising a bond that secures the first thin sheet member to itself. 
     
     
         3 . The packaging assembly according to  claim 2 , wherein the bond comprises adhesive tape that secures the first and second peripheral sides of the first thin sheet member to one another. 
     
     
         4 . The packaging assembly according to  claim 1 , wherein the first and second peripheral sides are further configured to overlap one another. 
     
     
         5 . The packaging assembly according to  claim 4 , further comprising a bond that comprises the first thin sheet member sticking to itself. 
     
     
         6 . The packaging assembly according to  claim 5 , wherein the first thin sheet member includes a coating or treatment that increases the ability of the first thin sheet material to stick to itself. 
     
     
         7 . The packaging assembly according to  claim 6 , wherein the first thin sheet member has been subjected to at least one of a Corona treatment, a Plasma treatment, and acid treatment, or a heat treatment. 
     
     
         8 . The packaging assembling according to  claim 4 , further comprising a bond that comprises an adhesive substance disposed between the first and second peripheral sides of the first thin sheet member. 
     
     
         9 . The packaging assembly according to  claim 8 , wherein the adhesive substance comprises at least one of the set consisting of: glue, adhesive tape, pressure sensitive adhesive (PSA), and ultra-violet (UV) activated adhesive. 
     
     
         10 . The packaging assembly according to  claim 1 , wherein the first thin sheet member is made of a resilient material. 
     
     
         11 . The packaging assembly according to  claim 1 , wherein the first thin sheet member is made of a non-resilient material. 
     
     
         12 . The packaging assembly according to  claim 1 , wherein at least a portion of the thin sheet member is configured to be placed over an article to be packaged such that the sheet member retains the article upon the frame member. 
     
     
         13 . The packaging assembly according to  claim 12 , wherein the thin sheet member is made of a deformable material that can be molded to fit around the article and to retain the article upon the frame member. 
     
     
         14 . A method of manufacturing a heat-sealed packaging assembly, the method comprising:
 feeding corrugated material towards a heat sealing device;   forming cavities in the corrugated material;   feeding a thin sheet towards the heat sealing device such that the thin sheet is between the corrugated material and the heat sealing device; and   applying heat to the thin resilient sheet and the corrugated material using the heat sealing device such that at least some heated material of the thin sheet flows into the cavities formed in the corrugated material.   
     
     
         15 . The method of  claim 14 , wherein the step of forming cavities in the corrugated material is performed using one or more piercing devices. 
     
     
         16 . The method of  claim 15 , wherein the step of forming cavities in the corrugated material is performed using one or more retractable piercing devices of the heat sealing device. 
     
     
         17 . The packaging assembly according to  claim 14 , wherein forming cavities in the corrugated material further comprises forming cavities in a bottom layer of the corrugated material. 
     
     
         18 . The packaging assembly according to  claim 14 , wherein applying heat to the thin resilient sheet and the corrugated material further comprises applying pressure to the thin resilient sheet and the corrugated material using the heat sealing device. 
     
     
         19 . The method of  claim 14 , further comprising applying vacuum pressure to a side of the corrugated material that is opposite a side of the corrugated material to which the heat sealing device applies heat. 
     
     
         20 . The method of  claim 19 , wherein the step of applying vacuum pressure occurs simultaneously with the step of applying heat.