Flame resistant packaging system and method of making same

Abstract

A flame resistant packaging system has an outer box and a flame and heat resistant liner inside the box. The liner is constructed of a layer of a ceramic fiber and a layer of metal foil. The edges of the liner are joined at a seam, forming a compartment for holding an article to be packaged. The foil layer of the liner faces the inside of the compartment. A patch, similarly constructed of foil and ceramic fiber, is attached over the seam to prevent hot gasses from entering the compartment at the seam. The compartment is substantially closed by folding the sides of the liner inward. End inserts, similarly constructed of foil and ceramic fiber, are inserted into the compartment to substantially cover the areas where the liner is folded to close the compartment.

1 . A flame resistant packaging system, comprising:
 a box;   a liner inside the box; the liner further comprising:
 a layer of ceramic fiber; 
 a layer of foil; 
 the liner having first and second edges;
 the first and second edges abutted at a seam, so that 
 the liner forms an compartment; 
 where the foil layer of the liner faces the compartment; 
 
 the liner having folds substantially closing the compartment; 
   a patch; the patch further comprising:
 a layer of ceramic fiber; 
 a layer of foil; 
 the patch disposed on the liner to cover the seam, so that the patch layer of foil faces the compartment; 
   an end insert; the end insert comprising;
 a layer of ceramic fiber; 
 a layer of foil; 
 the end insert disposed inside the compartment so as to substantially cover the folds in the liner substantially closing the compartment, and;
 so that the layer of foil of the end-insert faces the compartment. 
 
   
     
     
         2 . The system of  claim 1 , where the foil is aluminum foil. 
     
     
         3 . The system of  claim 1  where the foil is attached to the ceramic fiber with glue. 
     
     
         4 . The system of  claim 1  where the first and second edges of the liner are joined by staples. 
     
     
         5 . The system of  claim 4 , where the box has a wall; and, the staples pass through the wall of the box and the liner. 
     
     
         6 . The system of  claim 1 , where the patch is attached to the liner with glue. 
     
     
         7 . The system of  claim 1 , where the end insert further comprises a second layer of foil attached to the ceramic fiber layer of the end insert. 
     
     
         8 . A method of making a flame resistant packaging system, comprising:
 constructing a liner comprising a layer of foil and a layer of ceramic fiber;   the liner having first and second edges;   joining the first and second edges of the liner at a seam, so as to form a compartment for receiving an article;   attaching the liner to the inside of a box; and,   covering the seam with a patch comprising a layer of foil and a layer of ceramic fabric.   
     
     
         9 . The method of  claim 8 , further comprising attaching the layer of foil and the layer of ceramic fiber with glue. 
     
     
         10 . The method of  claim 8 , where the attaching of the liner to the inside of the box further comprises connecting the liner and the box with staples. 
     
     
         11 . The method of  claim 8 , where the patch is attached to the liner over the seam with glue. 
     
     
         12 . The method of  claim 8 , where the compartment has an open end; the method further comprising:
 folding the liner so as to substantially close the compartment at the open end;   placing an end insert inside the compartment over the location where the liner is folded to substantially close the compartment.   
     
     
         13 . The method of  claim 12 , where the end insert is constructed by:
 placing a layer of foil over a layer of ceramic fiber; and,   folding the foil over the layer of ceramic fiber.   
     
     
         14 . A method of assembling a flame resistant packaging system for transport of an article, where the packaging system comprises a box having first and second openings, a flame and heat resistant liner having sides; the liner attached to the inside of the box to form a compartment; the method comprising:
 folding the sides of the liner to substantially close the compartment at the first opening;   closing the first opening of the box corresponding to the first opening of the compartment over the liner;   sealing the closed first opening of the box;   placing a first end insert in the compartment over the location where the liner is folded to substantially close the compartment at the first opening;   placing an article into the compartment;   placing a second end insert in the compartment over the article;   folding the sides of the liner to substantially close the compartment at the second opening;   closing the second opening of the box corresponding the second opening of the compartment over the liner; and,   sealing the closed second opening of the box.