Three-dimensional filament network packaging structure

Abstract

A unitary packaging device for packaging an article includes a resilient three-dimensional web of extruded polymer monofilaments, the polymer monofilaments being heat welded at junctions to form an open network of tangled monofilament, and the resilient three-dimensional web of extruded polymer monofilaments is configured to modify the contact area between the article and an exterior container.

1 . A unitary packaging device for packaging an article comprising:
 a resilient three-dimensional web of extruded polymer monofilaments, the polymer monofilaments being heat welded at junctions to form an open network of tangled monofilament,   wherein the resilient three-dimensional web of extruded polymer monofilaments is configured to modify the contact area between the article and an exterior container.   
     
     
         2 . The unitary packaging device of  claim 1 , wherein the extruded polymer monofilaments comprise a polyolefin, polyimide, polyester, polyvinylhalide, polystyrene, polyvinylester, or a mixture of two or more thereof. 
     
     
         3 . The unitary packaging device of  claim 1 , wherein the resilient three-dimensional web of extruded polymer monofilaments has a plurality of protrusions. 
     
     
         4 . The unitary packaging device of  claim 3 , wherein the plurality of protrusions have a shape selected from among cones, truncated cones, pyramids having polygonal bases, truncated pyramids having polygonal bases, cylinders, prisms, spherical elements, and combinations of two or more thereof. 
     
     
         5 . The unitary packaging device of  claim 4 , wherein the plurality of protrusions is aligned into an array of rows. 
     
     
         6 . The unitary packaging device of  claim 1 , wherein the resilient three-dimensional web of extruded polymer monofilaments is configured to form an article-receiving cavity surrounded by an article-contacting surface. 
     
     
         7 . The unitary packaging device of  claim 6 , wherein the article-receiving cavity is contoured to the shape of the article. 
     
     
         8 . The unitary packaging device of  claim 1 , further comprising a compressible layer overlaying at least a portion of the resilient three-dimensional web of extruded polymer monofilaments. 
     
     
         9 . The unitary packaging device of  claim 8 , wherein the compressible layer comprises a high-loft nonwoven fabric. 
     
     
         10 . The unitary packaging device of  claim 8 , wherein the compressible layer is positioned between the article and the resilient three-dimensional web of extruded polymer monofilaments. 
     
     
         11 . A packaging system comprising two or more of the unitary packaging devices of  claim 1 , wherein each unitary packaging device contacts the article. 
     
     
         12 . A unitary packaging device of  claim 1 , wherein the resilient three-dimensional web has at least one pair of interlocking formations, wherein the resilient three-dimensional web is configured to be foldable onto itself and secured in a folded position by engaging the least one pair of interlocking formations. 
     
     
         13 . The unitary packaging device of  claim 1 , wherein the resilient three dimensional web comprises top and bottom shell halves and a hinge integrally formed with and interconnecting the top and bottom shell halves, the top and bottom shell halves cooperatively defining a cavity for containing the article. 
     
     
         14 . The unitary packaging device of  claim 13 , further comprising at least one pair of interlocking formations positioned at marginal portions of the top and bottom shell halves.