Heat sealed packaging assemblies and methods of producing and using the same

A method of packaging an article for shipment with a retention packaging assembly, the method comprising:

• forming a fibrous corrugated sheet having first and second outer layers formed from a wood-based fibrous material, the first and second outer layers formed around a fluted inner layer;
• crushing the fluted inner layer of a first portion of the fibrous corrugated sheet to form a first fold line, the first fold line defining a boundary of a first peripheral portion, the first peripheral portion being pivotable with respect to a central portion about the first fold line;
• crushing the fluted inner layer of a second portion of the fibrous corrugated sheet to form a second fold line, the second fold line defining a boundary of a second peripheral portion, the second peripheral portion being pivotable with respect to the central portion and coupled with the central portion opposite the first peripheral portion, the first and second fold lines being substantially parallel;
• placing the fibrous corrugated sheet on a conveyor and feeding the fibrous corrugated sheet towards a cutting head and a sealing head;
• mounting a roll of thin, single layered, polyethylene film in a manner that provides resistance against turning and feeding an end of the roll towards the heat sealing device, the thin, single layered, polyethylene film unrolling from the roll as the end is pulled by the conveyor;
• overlaying the fibrous corrugated sheet with the thin, single layered, polyethylene film;
• reciprocating the cutting head to cut the fibrous corrugated sheet, the fibrous corrugated sheet sized to engage and provide support for an article during storage or shipping;
• heating the sealing head to about 850° F.;
• actuating the heat sealing head downwards to apply a pressure of about 10 lb. f/in2 against the thin, single layered, polyethylene film in the direction of the first layer of the first peripheral portion of the fibrous corrugated sheet and compressing the thin, single layered, polyethylene film between the heat seal head and the first layer;
• melting portions of the thin, single layered, polyethylene film into and around fibers of the fibrous corrugated sheet with the heat sealing head to form a heat-seal transition area between a first end and a middle segment of the thin, single layered, polyethylene film, the melted portions entangling and mechanically engaging with a fibrous outer layer of the fibrous corrugated sheet and thereby securing the thin, single layered, polyethylene film to the fibrous corrugated sheet;
• lifting the heat sealing head after about 0.5 seconds of contact with the first layer to form a first heat seal;
• forming a second heat seal on the second peripheral portion of the fibrous corrugated sheet, the middle segment of the thin, single layered, polyethylene film extending between the first and second peripheral portions to form the heat-sealed packaging assembly;
• cooling the first and second heat seals of the heat-sealed packaging assembly with a forced convection device;
• discharging the heat-sealed packaging assembly from the conveyor;
• temporarily placing the heat-sealed packaging assembly in a container and stacking the heat-sealed packaging assembly with a plurality of heat-sealed packaging assemblies;
• folding the first and second peripheral portions of the fibrous corrugated sheet about the first and second fold lines, respectively, to release tension in the thin, single layered, polyethylene film;
• lifting the middle segment of the thin, single layered, polyethylene film away from the central portion of the fibrous corrugated sheet;
• placing the article against the central portion;
• and
• folding the first and second peripheral portions outwardly and downwardly to increase tension in the thin, single layered, polyethylene film and secure the article in place against the central portion.