Packaging module

Abstract

A packaging module is provided that is comprised of a porous deformable membrane, such as a net bag, and a mass of loose fill elements. The mesh openings in the bag are smaller than a loose fill element to retain the elements in place. The bag is deformable in three dimensions to allow the bag to be manipulated to accommodate the shape of an item to be packaged. A single module may be used to envelope an item to be packaged, for example, in a shipping container. A pair of modules may be used to sandwich an item therebetween for packaging in a shipping container. A shipping unit may also be formed by a pair of modules that are self adherent to each other. Also, the module may be fabricated into a pre-form with a pocket.

What is claimed is:  
     
         1 . A packaging module comprising 
 a porous deformable membrane defining an enclosed space; and    a mass of loose fill elements disposed within said membrane and occupying an amount of said space sufficient to permit said membrane to be shaped about an item of here dimensional shape to be packaged and to permit said elements to move within said membrane to accommodate the three-dimensional shape of the item.    
     
     
         2 . A packaging module as set forth in  claim 1  wherein said membrane is a net bag.  
     
     
         3 . A packaging module as set forth in  claim 2  wherein bag is made of plastic.  
     
     
         4 . A packaging module as set forth in  claim 1  wherein said elements are made of starch.  
     
     
         5 . A packaging module as set forth in  claim 1  wherein said elements are made of a foamed plastic selected from the group consisting of expanded polystyrene, expanded polyethylene, expanded polystyrene and expanded polypropylene.  
     
     
         6 . A packaging module as set forth in  claim 1  wherein said membrane is of elongated cylindrical shape with closed ends.  
     
     
         7 . A packaging module as set forth in  claim 1  wherein said membrane is of cubic shape.  
     
     
         8 . In combination, 
 at least one item of three dimensional shape;    at least one packaging module receiving said item, said module including a porous deformable membrane defining an enclosed space and a mass of loose fill elements disposed within said membrane and occupying an amount of said space sufficient to permit said membrane to be shaped about said item and to permit said elements to move within said membrane to accommodate the shape of said item; and    a packaging medium receiving said module and said item.    
     
     
         9 . The combination as set forth in  claim 8  wherein said membrane is a net bag.  
     
     
         10 . The combination as set forth in  claim 8  wherein bag is made of plastic.  
     
     
         11 . The combination as set forth in  claim 8  wherein said elements are made of expanded polystyrene.  
     
     
         12 . The combination as set forth in  claim 8  wherein said item is of spherical shape and said membrane defines a pocket receiving said item.  
     
     
         13 . The combination as set forth in  claim 8  comprising a pair of said membranes receiving said item therebetween in sandwiched relation, each said membrane being of elongated shape.  
     
     
         14 . The combination of the as set forth in  claim 13  wherein each membrane is a co-adherent material having a surface for adhering to the other of said membranes to retain said item therebetween.  
     
     
         15 . The combination as set forth in  claim 13  wherein said packaging medium is shrunk-fit about said modules to maintain said item therebetween.  
     
     
         16 . The combination as set forth in  claim 13  wherein said packaging medium is stretch-wrapped about said modules to maintain said item therebetween.  
     
     
         17 . The combination as set forth in  claim 8  wherein said packaging medium is a shipping tube receiving said module.  
     
     
         18  The combination as set forth in  claim 8  wherein said packaging medium is a box receiving said module.  
     
     
         19 . In combination, 
 a plurality of items;    at least a pair of packaging modules receiving said items therebetween, each said module including a porous deformable membrane defining an enclosed space and a mass of loose fill elements disposed within said membrane, each said module adapting to the shape of said items received therein; and    a packaging medium receiving said modules and said items therein.    
     
     
         20 . The combination as set forth in  claim 19  wherein said packaging medium is a carton.  
     
     
         21 . In combination 
 a carton;    a plurality of layers of packaging modules in said carton, each said packaging module including a porous deformable membrane defining an enclosed space and a mass of loose fill elements disposed within said membrane; and    a plurality of layers of items disposed in said carton in alternating relation with said layers of packaging modules, at least one of said layers of items including items of different three-dimensional shape, and wherein said packaging modules of adjacent layers of packaging modules adapt to the three-dimensional shape of said items therebetween.    
     
     
         22 . A packaging module comprising 
 a deformable net bag defining an enclosed space; and    a mass of loose fill elements disposed within said bag and occupying an amount of said space sufficient to permit said bag to be shaped about an item to be packaged and to permit said elements to move within said bag to accommodate the deformed shape of said bag.    
     
     
         23 . A packaging module as set forth in  claim 22  wherein said elements occupy up to 90% of said space within said bag.  
     
     
         24 . A packaging module as set forth in  claim 22  wherein said bag has a plurality of openings therein, each said opening being of a size smaller than any one of said elements to retain said elements therein.  
     
     
         25 . A packaging module as set forth in  claim 22  wherein said net bag is made of a material having self-adherent characteristics.  
     
     
         26 . In combination, 
 an item;    a pair of packaging modules receiving said item therebetween, each said module including a porous deformable membrane defining an enclosed space and a mass of loose fill elements disposed within said membrane and occupying an amount of said space sufficient to permit said membrane to be shaped about said item and to permit said elements to move within said membrane to accommodate the shape of said item; and    means securing said modules together.    
     
     
         27 . The combination as set forth in  claim 26  further comprising a shipping label secured to an exterior surface of at least one of said modules.  
     
     
         28 . A packaging module comprising 
 a mass of loose fill elements bonded together to form an agglomerated one-piece pre-form of stable shape with a pocket; and    a net bag containing and shaped to the contour of said perform.    
     
     
         29 . A packaging module as set forth in  claim 28  wherein said elements are made of starch.  
     
     
         30 . A method of making a packaging pre-form comprising the steps of 
 placing a packaging module formed of a net bag containing a free-flowing mass of loose fill elements made of starch about a three dimensional forming blank; and    applying moisture to the elements within the net bag to effect bonding of the elements together to form an agglomerated one-piece pre-form of stable shape with a pocket corresponding to the shape of the blank.    
     
     
         31 . A method as set forth in  claim 30  wherein moisture is applied in the form of a 
 spray of steam.  
 
     
     
         32 . A method of making a packaging pre-form comprising the steps of 
 placing a packaging module formed of a net bag containing a free-flowing mass of loose fill elements made of foamed plastic with an adhesive coating on the elements about a three dimensional forming blank; and    activating the adhesive on the elements within the net bag to effect bonding of the elements together to form an agglomerated one-piece pre-form of stable shape with a pocket corresponding to the shape of the blank.    
     
     
         33 . A method as set forth in  claim 32  wherein the adhesive is activated by a spray of solvent.  
     
     
         34 . A method as set forth in  claim 32  wherein the adhesive is activated by heat.