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

Abstract

A packaging device can include a resilient member formed of one or more layers of different materials and a frame member. The resilient 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 first panel comprising a central portion and a peripheral portion extending from the central portion, the peripheral portion including at least first and second sides disposed on opposite sides of the central portion;   a first thin resilient sheet member disposed over the central portion of the first frame member and over at least portions the first and second sides, respectively, of the peripheral portion;   wherein the thin resilient sheet member includes a first portion heat-sealed to the first side of the peripheral portion of the frame member and a second portion heat-sealed to the second side of the peripheral portion of the first frame member.   
     
     
         2 . The packaging assembly according to  claim 1 , additionally comprising an aperture disposed in the central portion of the frame member. 
     
     
         3 . The packaging assembly according to  claim 1 , wherein the first side of the peripheral portion of the first frame member is pivotable relative to the central portion, wherein the thin resilient sheet member is sized such that when the first side of the peripheral portion of the first frame member is folded toward a back side of the central portion, tension is increased in the thin resilient sheet member. 
     
     
         4 . The packaging assembly according to  claim 1 , wherein the first frame member comprises corrugated cardboard having at least a first outer smooth surface and at least a corrugated inner portion, the first smooth surface comprising a fibrous material. 
     
     
         5 . The packaging assembly according to  claim 4 , wherein the thin resilient sheet member is heat-sealed directly to the fibrous material. 
     
     
         6 . The packaging assembly according to  claim 1 , wherein at least the first side of the peripheral portion of the first frame member comprises a coating bonded to an upper surface of the first peripheral portion, the first portion of the thin resilient sheet member being heat-sealed to the coating. 
     
     
         7 . The packaging assembling according to  claim 6 , wherein the coating is applied only at and proximate locations in which the resilient member is to be heat-sealed. 
     
     
         8 . The packaging assembly according to  claim 1 , wherein no more than 10% of the thin resilient sheet member is heat-sealed to the first frame member. 
     
     
         9 . The packaging assembly according to  claim 1 , wherein the thin resilient sheet member is heat sealed on a same side on which an article to be packaged is placed. 
     
     
         10 . The packaging assembly according to  claim 1 , wherein the thin resilient sheet member is heat sealed on an opposite side on which an article to be packaged is placed. 
     
     
         11 . The packaging assembly according to  claim 1 , wherein the thin resilient sheet member comprises at least two layers, the two layers being heat sealed to form a void. 
     
     
         12 . The packaging assembly according to  claim 11 , wherein the thin resilient sheet further comprises an opening device. 
     
     
         13 . The packaging assembly according to  claim 1 , wherein the thin resilient sheet member is configured to be placed over an article to be packaged such that the resilient sheet member retains the article upon the frame member. 
     
     
         14 . The packaging assembly according to  claim 1 , wherein the thin resilient sheet member is configured to be placed between an article to be packaged and the frame member such that the resilient sheet member suspends the article above the frame member. 
     
     
         15 . The packaging assembly according to  claim 1 , wherein the frame member further comprises a second panel member, the second panel member comprising a central portion and a peripheral portion extending around the central portion, the peripheral portion including at least first and second sides disposed on opposite sides of the central portion. 
     
     
         16 . The packaging assembly according to  claim 15 , wherein the central portions of the first and second panel members comprise an aperture, the first thin resilient sheet member placed over the aperture on the first panel and a second thin resilient sheet member placed over the aperture on the second panel. 
     
     
         17 . A method of manufacturing a heat-sealed packaging assembly, the method comprising:
 feeding corrugated material towards a heat sealing device;   feeding a thin resilient sheet towards the heat sealing device such that the thin resilient sheet is between the corrugated material and the heat sealing device;   applying heat to the thin resilient sheet and the corrugated using the heat sealing device.   
     
     
         18 . The method of  claim 17 , wherein the method further comprises applying pressure to the thin resilient sheet proximate the area on which heat is applied. 
     
     
         19 . The method of  claim 18 , wherein the step of applying pressure is performed using the heat sealing device. 
     
     
         20 . The method of  claim 18 , wherein the step of applying pressure occurs simultaneously with the step of applying heat. 
     
     
         21 . The method of  claim 17 , further comprising forming openings on the corrugated. 
     
     
         22 . The method of  claim 21 , wherein the step of forming openings is performed using the heat sealing device.