Method of forming a pre-packaged, flexible container of ice and air

Abstract

A method of forming a pre-packaged container of ice and air is disclosed. The method includes forming a first member and a second member from a plastic material. The first and second members are physically overlapped one upon the other to establish a coterminuous outer periphery. A seal is formed about a portion of the outer periphery to form a void area. The seal extends from between about 50% to about 80% around the outer periphery and the unsealed portion of the periphery forms an inlet to the void area. Air is introduced through the inlet to create a cavity having a preselected volume. Individual pieces of ice are inserted into the cavity through the inlet. The method further includes sealing the inlet to form a pre-packaged, flexible container of ice and air. The air occupies at least about 50% of the volume of the cavity.

1 . A method of forming an individualized pre-packaged, flexible container of ice and air, comprising:
 a) forming a first member and a second member, each of said first and second members being constructed from a plastic material having a thickness of from between about 0.5 millimeters to about 10 millimeters;   b) physically overlapping said first and second members to establish a coterminuous outer periphery;   c) forming a seal about a portion of said coterminuous outer periphery to form a void area, said seal extending from between about 50% to about 90% around said coterminuous outer periphery, and said unsealed portion of said coterminuous outer periphery forming an inlet to said void area;   d) introducing air through said inlet at atmospheric pressure to create a cavity having a volume of less than about 25 cubic inches, and said air is introduced at a temperature below 40° F.;   e) inserting individual pieces of ice into said cavity through said inlet, said individual pieces of ice having a weight of from between about 0.1 ounces to about 5 ounces, and each of said individual pieces of ice having a predetermined shape; and   f) sealing said inlet to form said individualized pre-packaged, flexible container of ice and air, said air occupying at least about 50% of said volume of said cavity, and said container, ice and air having a combined weight of less than about 5 ounces.   
   
   
       2 . The method of  claim 1  further including introducing pressurized air having a pressure ranging from between 0 to about 1 psi and at a temperature of below 32° F. through said inlet to create said cavity. 
   
   
       3 . The method of  claim 2  wherein said pressurized air is introduced at a pressure ranging from between about 0.1 psi to about 0.5 psi. 
   
   
       4 . The method of  claim 2  wherein said cavity has a volume ranging from between about 5 cubic inches to about 15 cubic inches. 
   
   
       5 . The method of  claim 1  further comprising manipulating said first and second members to distort said coterminuous outer periphery to allow said air to pass through said inlet. 
   
   
       6 . The method of  claim 5  wherein said coterminuous outer periphery has a first side and a second side and said first and second sides are moved towards one another to form a void area therebetween which said air can occupy. 
   
   
       7 . The method of  claim 1  further comprising introducing pressurized air through said inlet to create said cavity, and said pressurized air is at a temperature ranging from between about 10° F. to about 32° F. 
   
   
       8 . The method of  claim 1  wherein said plastic material is polyethylene having a thickness ranging from between about 2 millimeters to about 3 millimeters. 
   
   
       9 . The method of  claim 1  wherein said plastic material is polypropylene having a thickness ranging from between about 2 millimeters to about 3 millimeters. 
   
   
       10 . A method of forming an individualized pre-packaged, flexible container of ice and air, comprising:
 a) forming a first member and a second member, each of said first and second members being constructed from a vapor-impermeable material having a thickness of from between about 1 millimeter to about 5 millimeters;   b) physically overlapping said first and second members to establish a coterminuous outer periphery;   c) forming a seal about a portion of said coterminuous outer periphery to form a void area, said seal extending from between about 50% to about 80% around said coterminuous outer periphery, and said unsealed portion of said coterminuous outer periphery forming an inlet to said void area;   d) introducing air through said inlet at a pressure ranging from between 0.1 psi to about 1 psi to create a cavity having a volume of less than 20 cubic inches, and said air being introduced at a temperature below 32° F.;   e) inserting individual pieces of ice into said cavity through said inlet, said individual pieces of ice having a weight of from between about 2 ounces to about 5 ounces, and each of said individual pieces of ice having a predetermined shape; and   f) sealing said inlet to form said individualized pre-packaged, flexible container of ice and air, said air occupying at least about 50% of said volume of said cavity, and said container, ice and air having a combined weight of less than about 4 ounces.   
   
   
       11 . The method of  claim 10  further comprising forming a tear strip in said first member to facilitate easy opening of said container, said container having a first side, a second side aligned opposite to said first side, a third side, and a fourth side aligned opposite to said third side, said tear strip including a pair of spaced apart weakened lines, said tear strip extending completely across said first member from said first side to said second side, and said tear strip having a finger tab which is integrally formed therewith. 
   
   
       12 . The method of  claim 11  wherein said tear strip has a first end which extends to said coterminuous outer periphery, and said tear strip is formed from a material which is different from the material from which said first member is formed. 
   
   
       13 . The method of  claim 10  further comprising forming a V-shaped notch partially through said seal which facilitates opening said container in order to remove said ice. 
   
   
       14 . The method of  claim 10  wherein said first member is folded upon itself to form a U-shaped member with a pair of spaced apart upstanding legs, each leg having an outer periphery, and a seal extends about said outer periphery of said pair of upstanding legs to form a cavity therein, and a single individual piece of ice is positioned in said cavity. 
   
   
       15 . The method of  claim 14  wherein said pair of upstanding legs is sealed together using heat and pressure, said folded portion extends 25% around said outer periphery of said container, and said seal extends around said remaining portion of said outer periphery of said container. 
   
   
       16 . A method of forming an individualized pre-packaged, flexible container of ice and air, comprising:
 a) forming a first member and a second member, each of said first and second members being constructed from a liquid-impermeable material having a thickness of from between about 2 millimeters to about 3 millimeters;   b) physically overlapping said first and second members to establish a coterminuous outer periphery;   c) forming a seal about at least a portion of said coterminuous outer periphery to form a void area, said seal extending from between about 55% to about 75% around said coterminuous outer periphery, and said unsealed portion of said coterminuous outer periphery forming an inlet to said void area;   d) introducing air through said inlet at a pressure ranging from between about 0.1 psi to about 0.5 psi to create a cavity having a volume of from between about 5 cubic inches to about 20 cubic inches, said air being introduced at a temperature of between about 10° F. to about 32° F.;   e) inserting multiple pieces of ice into said cavity through said inlet, each of said multiple pieces of ice having a weight of from between about 0.2 ounces to about 1 ounce, and each of said multiple pieces of ice having a dimension of less than about 1.5 inches; and   f) sealing said inlet to form said individualized pre-packaged, flexible container of ice and air, said air occupying more than about 50% of said volume of said cavity, and said container, ice and air having a combined weight of less than about 3 ounces.   
   
   
       17 . The method of  claim 16  wherein said container is in the form of a triangle having a first side, a second side and a third side, said container having an outer periphery and a seal which extends completely around said outer periphery, and said multiple pieces of ice include less than six ice cubes, and each of said ice cubes having a maximum dimension of less than about 1.25 inches. 
   
   
       18 . The method of  claim 17  wherein each of said first, second and third sides has the same dimension, and said multiple pieces of ice include less than five ice cubes, with each of said ice cubes having a maximum dimension of less than about 1 inch. 
   
   
       19 . The method of  claim 16  wherein each of said first and second members is formed from a polyethylene material having a thickness ranging from between about 2 millimeters to about 3 millimeters, and said air occupies from between about 55% to about 70% of said volume of said cavity. 
   
   
       20 . The method of  claim 19  wherein said polyethylene material has at least two layers and one of said layer is an insulating layer.