Protective packaging comprised of shape memory foam

Abstract

In one embodiment of the present invention, a protective packaging for protecting an at least one article is disclosed. The protective packaging is comprised of a shape memory foam (SMF) structure conforming to at least a portion of to at least one article for protecting the at least one article. The SMF has a glass transition temperature (T g ).

What is claimed:  
     
         1 . A protective packaging for protecting an at least one article, the protective packaging comprised of a shape memory foam (SMF) structure conforming to at least a portion of the at least one article for protecting the at least one article wherein the SMF has a glass transition temperature (T g ).  
     
     
         2 . The protective packaging of  claim 1 , wherein the SMF structure has a T g  of at or above about 21° C., the SMF structure being rigid below the T g  and elastic above the T g , the SMF structure having a shape memory characteristic such that when the SMF structure in an original shape is deformed or compressed above the T g  to produce a compressed shape and cooled in the compressed shape below the T g , the SMF structure retains the compressed shape without the need of external forces and when the temperature is raised above the T g , the SMF structure returns substantially to the original shape.  
     
     
         3 . The protective packaging of  claim 2 , wherein the SMF structure is comprised of a thermoset or thermoplastic SMF.  
     
     
         4 . The protective packaging of  claim 2 , wherein the SMF structure is comprised of a structure of polyurethane foam produced by reacting an isocycate and a polyol.  
     
     
         5 . The protective packaging of  claim 4 , wherein the polyurethane foam is prepared using a polyol selected from the group comprised of an aromatic polyester polyol, a polycarbonate polyol, a polyether polyol, and mixtures thereof.  
     
     
         6 . The protective packaging of  claim 5 , wherein the polyol has an average functionality between about 2 and about 4.  
     
     
         7 . The protective packaging of  claim 4 , wherein the isocyanate is an aromatic isocyanate having a functionality between about 2 and about 3.  
     
     
         8 . The protective packaging of  claim 4 , wherein the polyurethane foam is produced by reacting the isocyanate with the polyol and a chain extender.  
     
     
         9 . The protective packaging of  claim 2 , wherein the SMF has a substantially open cell structure.  
     
     
         10 . The protective packaging of  claim 2 , wherein the T g  is less than about 21° C.  
     
     
         11 . The protective packaging of  claim 2 , wherein the SMF is compressible to less than about 50% of the original volume.  
     
     
         12 . The protective packaging of  claim 2 , wherein the SMF further includes a natural or synthetic additive.  
     
     
         13 . The protective packaging of  claim 1 , wherein the SMF structure is at least partially wrapped, coated, laminated, or encased in a film.  
     
     
         14 . The protective packaging of  claim 2 , wherein the SMF is hydrophobic.  
     
     
         15 . The protective packaging of  claim 2 , wherein the SMF is resistant to moderate levels of ionizing or non-ionizing radiation.  
     
     
         16 . A method for producing a protective packaging for protecting an at least one article, the method comprising placing a shape memory foam (SMF) structure having a glass transition temperature (T g ) and an at least one article in a container, whereby the SMF conforms to at least a portion of the at least one article to protect the at least one article.  
     
     
         17 . The method of  claim 16  wherein the SMF is at a temperature of about below or about above the T g .  
     
     
         18 . The method of  claim 16  further comprising: 
 deforming or compressing the SMF structure in an original shape to produce a compressed shape;  
 cooling the compressed shape to below the T g  to retain the compressed shape; and  
 raising the temperature of the compressed shape to above about the T g  to substantially regain the original shape,  
 whereby the original shape or the compressed shape conforms to at least a portion of the at least one article to protect the at least one article.  
 
     
     
         19 . The method of  claim 18  wherein the raising of the temperature of the SMF is accomplished by a process selected from the group consisting of convection heating, conductive heating, microwave heating, or chemical reaction.  
     
     
         20 . The method of  claim 18  wherein the cooling of the SMF is accomplished by a process selected from the group consisting of free convection, forced convection, refrigeration, conductive cooling, cooling baths, and liquid gas or nitrogen.  
     
     
         21 . The method of  claim 18  further comprising providing a plurality of SMF structures and a plurality of articles.  
     
     
         22 . The method of  claim 21  whereby the plurality of SMF structures are stackable for protecting the plurality of articles.  
     
     
         23 . A method for producing a protective packaging, the method comprising: 
 providing a shape memory foam (SMF) structure having a glass transition temperature (T g );    providing a transportation or storage container;    deforming or compressing the SMF structure to produce a compressed shape; and    placing he compressed shape in the transportation or storage container.    
     
     
         24 . The method of  claim 23  wherein the compressed shape is substantially flat.  
     
     
         25 . The method of  claim 23  further comprising providing a plurality of SMF structures suitable for deforming or compressing into deformed shapes for storing in the transportation or storage container.