# US 2018/0002095 A1 · Heat sealed packaging assemblies and methods of producing and using the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2018/0002095 A1 - Document ID: US20180002095A1 - Status: Published application - Kind: A1 - Application number: 15/706,594 - Filed: 2017-09-15 - Published: 2018-01-04 - Earliest claimed: 2014-03-21 - Inventors: John McDonald; Frank Comerford; Myles Comerford - Web page: https://patentgrep.com/patent/US20180002095A1 ## CPC - B65D 81/075: {the contents being located between two membranes stretched between opposed sides of the package} - B65D 5/5028: {Elements formed separately from the container body} - B65D: CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES ## Abstract A packaging device can include a resilient member formed of one or more layers of different materials and a frame member. The resilient member can be heat sealed to the frame member or to a coating on the surface of the frame member. The layers can he made from different materials or the same materials having different thicknesses, modules of elasticity, melting index, or other different characteristics. ## Claims ### Claim at position 1 1-22. (canceled) ### Claim 23 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. ### Claim 24 (depends on 23) The method of claim 23, further comprising reciprocating the cutting head to cut the thin, single layered, polyethylene film from the roll. ### Claim 25 (depends on 23) The method of claim 23, further comprising using the heat sealing head to cut the thin, single layered, polyethylene film from the roll. ### Claim 26 (depends on 23) The method of claim 23, further comprising folding the middle segment of the thin, single layered, polyethylene film between the first and second heat seals to create some degree of slack for allowing the article to be packaged within the heat-sealed packaging assembly. ### Claim 27 A method of manufacturing a heat-sealed packaging assembly, the method comprising: feeding a fibrous corrugated material towards a heat sealing device; feeding a thin, single layered, single polymer resilient sheet towards the heat sealing device such that the thin, single layered, single polymer resilient sheet is between the corrugated material and the heat sealing device; simultaneously applying heat and pressure to said resilient sheet and the corrugated material using the heat sealing device to form a heat-seal directly between the resilient sheet and a fibrous outer layer of the corrugated material, such that portions of the resilient sheet extend into and around a plurality of fibers of the fibrous outer layer and are entangled and mechanically engaged with the plurality of the fibers within the fibrous outer layer and thereby secured to the corrugated material. ### Claim 28 (depends on 27) The method of claim 27, further comprising forming openings on the corrugated. ### Claim 29 (depends on 28) The method of claim 28, wherein the step of forming openings is performed using the heat sealing device. ### Claim 30 (depends on 27) The method of claim 27, wherein the resilient sheet is made of one of the following polymers: polyethylene, polyurethane, polypropylene, and polystyrene. ### Claim 31 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature between about 850° F. to about 245° F., for between about 0.5 seconds to about 15 seconds, and at a pressure between about 10 lb. f/in2 to about 0.06 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polyethylene. ### Claim 32 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature between about 850° F. to about 350° F., for between about 0.5 seconds to about 5 seconds, and at a pressure between about 10 lb. f/in2 to about 1.5 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polyethylene. ### Claim 33 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature between about 850° F. to about 650° F., for between about 0.5 seconds to about 1 seconds, and at a pressure between about 10 lb. f/in2 to about 5 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polyethylene. ### Claim 34 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature of about 850° F. for about 0.5 seconds, and at a pressure of about 10 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polyethylene. ### Claim 35 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature between about 800° F. to about 225° F., for between about 0.5 seconds to about 15 seconds, and at a pressure between about 10 lb. f/in2 to about 0.5 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polyurethane. ### Claim 36 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature between about 800° F. to about 300° F., for between about 0.5 seconds to about 7 seconds, and at a pressure between about 10 lb. f/in2 to about 1.5 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polyurethane. ### Claim 37 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature between about 800° F. to about 550° F., for between about 0.5 seconds to about 1 seconds, and at a pressure between about 10 lb. f/in2 to about 5 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polyurethane. ### Claim 38 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature of about 800° F. for about 0.5 seconds, and at a pressure of about 10 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polyurethane. ### Claim 39 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature between about 900° F. to about 290° F., for between about 0.5 seconds to about 15 seconds, and at a pressure between about 10 lb. f/in2 to about 0.065 lb. f/in2 to form the heat-seal; wherein the resilient sheet is made of polypropylene. ### Claim 40 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature between about 900° F. to about 400° F., for between about 0.5 seconds to about 5 seconds, and at a pressure between about 10 lb. f/in2 to about 1.5 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polypropylene. ### Claim 41 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature between about 900° F. to about 750° F., for between about 0.5 seconds to about 1 seconds, and at a pressure between about 10 lb. f/in2 to about 5 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polypropylene. ### Claim 42 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature of about 900° F. for about 0.5 seconds, and at a pressure of about 10 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polypropylene. ### Claim 43 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature between about 900° F. to about 300° F., for between about 0.5 seconds to about 15 seconds, and at a pressure between about 10 lb. f/in2 to about 0.065 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polystyrene. ### Claim 44 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature between about 900° F. to about 425° F., for between about 0.5 seconds to about 5 seconds, and at a pressure between about 10 lb. f/in2 to about 1.5 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polystyrene. ### Claim 45 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature between about 900° F. to about 800° F., for between about 0.5 seconds to about 1 seconds, and at a pressure between about 10 lb. f/in2 to about 5 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polystyrene. ### Claim 46 (depends on 27) The method of claim 27, further comprising: pressing the heat sealing device against to the resilient sheet and the corrugated material at a temperature of about 900° F. for about 0.5 seconds, and at a pressure of about 10 lb. f/in2 to form the heat-seal; and wherein the resilient sheet is made of polystyrene.