Polymer encapsulations for item shipping

Abstract

Described are systems, methods, and apparatus for replacing the corrugated containers and dunnage to facilitate packaging of items in foam containers, referred to as “polymer encapsulations,” that can be used to protect and contain the item during shipment. When one or more items are ordered for delivery to a destination, the item(s) is picked from inventory and a rapidly setting polymer foam is injected around the bagged item to encapsulate and protect the item. For example, at packing, rather than placing the item in a corrugated container, temporary walls may be positioned around the bagged item and a pre-polymer injected into the space between the walls that surround the item such that a polymer forms that encases the item. After the polymer sets, the walls are retracted and the item is protected by the formed polymer encapsulation and available for transport to the destination.

What is claimed is: 
     
         1 . A method for preparing an item for shipping, comprising:
 receiving an order for an item that is to be shipped to a destination;   placing the item in a protective bag such that the protective bag contains the item;   positioning an encapsulation cavity around the protective bag that contains the item;   injecting a pre-polymer into the encapsulation cavity to form a polymer that expands and substantially encases the protective bag that contains the item, thereby forming a polymer encapsulation around the protective bag that contains the item, wherein:
 the polymer that forms the polymer encapsulation has a mechanical strength sufficient to enable the polymer encapsulation to function as a protective physical barrier for the item and as a transportation container for the item; 
   determining that a defined period of time has elapsed following injection of the pre-polymer into the encapsulation cavity;   removing the encapsulation cavity; and   applying shipping information to the polymer encapsulation that indicates the destination.   
     
     
         2 . The method of  claim 1 , further comprising:
 placing the protective bag that contains the item on a preformed base; and   wherein positioning the encapsulation cavity around the protective bag includes positioning the encapsulation cavity around the protective bag and the preformed base such that the pre-polymer, when injected into the encapsulation cavity, will expand and bond with the preformed base.   
     
     
         3 . The method of  claim 2 , wherein the preformed base includes an access mechanism incorporated into at least a portion of the preformed base, such that the access mechanism, when activated, will cause at least a portion of the preformed base to separate from the polymer encapsulation. 
     
     
         4 . The method of  claim 1 , wherein the protective bag includes an access mechanism that extends outside of the polymer encapsulation, wherein the access mechanism, when activated, will form an opening in the polymer encapsulation such that the item can be removed. 
     
     
         5 . A polymer encapsulation forming apparatus, comprising:
 a base surface upon which an item to be encased in a polymer encapsulation may be positioned;   an encapsulation cavity that may be removably positioned around the item when the item is positioned on the base surface; and   an injection port configured to inject a pre-polymer into a cavity formed by the encapsulation cavity and the base surface when the encapsulation cavity is positioned on the base surface, the pre-polymer operable to expand within the cavity and substantially encompass the item forming a polymer encapsulation around the item, wherein:
 the polymer that forms the polymer encapsulation has a mechanical strength sufficient to enable the polymer encapsulation to function as a protective barrier for the item and as a transportation container for the item. 
   
     
     
         6 . The apparatus of  claim 5 , further comprising:
 a second injection port configured to inject a gas into the cavity as the pre-polymer is injected such that at least a portion of the gas is entrained within the polymer that forms the polymer encapsulation.   
     
     
         7 . The apparatus of  claim 6 , wherein the gas is at least one of air, hydrogen, helium, oxygen, nitrogen, or carbon dioxide. 
     
     
         8 . The apparatus of  claim 5 , further comprising:
 a second injection port configured to inject a colored dye into the cavity as the pre-polymer is injected such that the colored dye alters a color of the polymer that forms the polymer encapsulation.   
     
     
         9 . The apparatus of  claim 5 , the encapsulation cavity further including:
 a plurality of surfaces that may be positioned around the item to form the cavity, wherein a position of each of the plurality of vertical surfaces is determined based at least in part on a dimension of the item.   
     
     
         10 . The apparatus of  claim 5 , wherein a volume of the cavity formed by the encapsulation cavity is determined based at least in part on a size of the item, a dimension of the item, a fragility of the item, a planned position in a stacking configuration for the polymer encapsulation, or a customer preference. 
     
     
         11 . The apparatus of  claim 5 , wherein:
 a preformed base is positioned between the base surface and the item; and   the pre-polymer, when injected into the cavity, bonds with the preformed base.   
     
     
         12 . The apparatus of  claim 5 , further comprising:
 a release agent applicator configured to apply a release agent to an inner-side of the encapsulation cavity such that the polymer does not adhere to the encapsulation cavity.   
     
     
         13 . A computing system, comprising:
 one or more processors; and   a memory coupled to the one or more processors and storing program instructions that when executed by the one or more processors cause the one or more processor to at least:
 determine a dimension value for an item to be encased in a polymer encapsulation based at least in part on a measurement of the item,
 wherein the polymer encapsulation is formed of a polymer that has a mechanical strength sufficient to enable the polymer encapsulation to function as a protective barrier for the item and as a transportation container for the item; 
 
 determine polymer encapsulation dimensions for the polymer encapsulation such that the polymer encapsulation will encase the item and provide a protective barrier around the item; 
 cause an encapsulation cavity to be positioned around the item; 
 cause a pre-polymer to be injected into the cavity to form a polymer that expands and forms the polymer encapsulation around the item; and 
 cause shipping information to be applied to the polymer encapsulation. 
   
     
     
         14 . The computing system of  claim 13 , wherein the program instructions that when executed by the one or more processors to cause shipping information to be applied to the polymer encapsulation include instructions that further cause the one or more processors to at least:
 cause the shipping information to be imprinted into a side of the polymer encapsulation.   
     
     
         15 . The computing system of  claim 13 , wherein the program instructions that when executed by the one or more processors further cause the one or more processors to at least:
 determine that a distance between the item and a surface of the encapsulation cavity is less than a minimum distance; and   cause a size of the encapsulation cavity to be adjusted such that the distance between the item and the surface is equal to or greater than the minimum distance.   
     
     
         16 . The computing system of  claim 13 , wherein the program instructions that when executed by the one or more processors further cause the one or more processors to at least:
 determine that a defined time has elapsed since the polymer was injected into the cavity; and   cause the encapsulation cavity to be removed from around the item and the polymer encapsulation.   
     
     
         17 . The computing system of  claim 13 , wherein:
 the polymer encapsulation, when formed, includes an access mechanism, and   the access mechanism, when activated, will form an opening in the polymer encapsulation such that the item can be removed from the polymer encapsulation.   
     
     
         18 . The computing system of  claim 13 , wherein the program instructions that when executed by the one or more processors further cause the one or more processors to at least:
 determine that a defined time has elapsed since the polymer was injected into the cavity; and   release the polymer encapsulation to a shipping operation.   
     
     
         19 . The computing system of  claim 13 , wherein the program instructions that when executed by the one or more processors further cause the one or more processors to at least:
 cause the item to be placed in a protective bag such that the protective bag contains the item;   cause a gas to be injected into the protective bag such that the protective bag is expanded around the item; and   cause the protective bag to be sealed such that the gas and the item are entrained in the protective bag.   
     
     
         20 . The computing system of  claim 13 , wherein the program instructions that when executed by the one or more processors further cause the one or more processors to at least:
 cause the item to be placed in a protective bag such that the protective bag contains the item;   cause a gas to be removed from the protective bag such that the protective bag is compressed around the item; and   cause the protective bag to be sealed such that the protective bag remains compressed around the item.