WO2015150719A1

WO2015150719A1 - Packaging system and method

Info

Publication number: WO2015150719A1
Application number: PCT/GB2014/051039
Authority: WO
Inventors: Neville Howes; Derek Roger PAYNE
Original assignee: Dubble Bubble Limited
Priority date: 2014-04-03
Filing date: 2014-04-03
Publication date: 2015-10-08

Abstract

Machines and methods for making a package or assembly of packages for an article (1) comprising a pressurised outer bag (5) and an inner web (2) adapted to support the article (1) within the outer bag (5) by elastically gripping the article (1) within a preformed cavity (3) or a hole (89) cut through the web (2). The web (2) is maintained under sufficient tension by the pressure within the outer bag (5) to suspend the article (1) within the bag (5) and to maintain a space between the article (1) and the outer bag (5).

Description

PACKAGING SYSTEM AND ME THOD

Field

This concerns machines and methods of making a flexible package in which an inner web is held in suspension inside a protective inflated outer pack. The pack may contain solid products and may be manufactured on automated production machinery . Background and Summary

Packaging of products serves several functions, including protecting the contained item from contamination or deterioration, and minimising mechanical damage during handling or transport.

Packaged items are often sealed within a pouch, for example a vacuum pack or a blister pack. However, depending on the packaging material, such sealed pouches may not provide sufficient mechanical protection. Conventionally, this problem is addressed by increasing the thickness or rigidity of the sealed pouch. Additionally or

alternatively, the sealed pouch may be cushioned by

surrounding material, such as bubble wrap, corrugated card or expanded foam material, for example.

However, these and other methods of protection tend to increase the bulk or weight of the package or a consignment of packages, and thereby increase costs and waste along the supply chain.

EP 0306207 Al , filed 24 August 1988, describes a packaging system including an outer bag having an inner bag suspended therein to define an inflatable chamber

substantially surrounding the inner bag.

Our UK Patent GB 2475770 B, filed 16 November 2010, and equivalents elsewhere describe and claim a package for an article comprising a pressurised outer bag having gas-tight seals at opposite ends, and an inner pouch for supporting the article within the outer bag, wherein the pouch extends along the length of the inner bag and is secured to the outer bag only at the gas-tight seals, and wherein the pouch is maintained under sufficient tension by the pressure within the outer bag to suspend the article within the bag and to maintain a space between the article and the outer bag on all sides of the article: characterised in that back seals closing the inner pouch and the outer bag respectively are laterally offset from one another. GB2475770 B also describes and claims a corresponding method of packaging an article and a packaging machine for packing a continuous stream of articles.

We now provide a modification of the invention of GB 2475770 B directed towards replacing the inner pouch used to contain the article with a single web of material where the article is held securely within a formed cavity.

According to another aspect, we provide a package as described above wherein the single web has a punched hole which is used to secure the article within the outer bag.

The present configuration offers a way of protecting a large range of delicate and semi-delicate products, in that delicate items are held in a single web of material whilst the entire body of the product and inner web is then

encapsulated within a cushion of air or gas mixture totally supporting and surrounding the product. The system also comprises a method of packaging, together with packaging machinery capable of producing the pack in-line and in one procedure .

According to one aspect, we provide a method of packaging an article comprising the steps of:

(a) forming an outer bag having gas-tight seals at opposite ends together with an inner web extending along the length of the outer bag and, in use, supporting the article within the outer bag;

(b) pressurising the outer bag so as to tension the web to suspend the article within the bag and to maintain a space between the article and the outer bag; and

(c) sealing the outer bag;

characterised in that the article is inserted through an aperture in the web and is securely received by the

aperture . According to another aspect, we provide a packaging machine for packaging a continuous stream of articles comprising :

A first stage at which the articles are inserted at

intervals through apertures in a longitudinally extending web;

A second stage at which the web and the articles supported therein are enveloped in a tube;

A source of pressurised gas for inflating the tube; and A sealing station at which the inflated tube is sealed by gas-tight seals transverse to the length of the web and the tube on opposite sides of each article, so as to form a sealed outer bag within which the article is packaged, wherein the web extends along the length of the outer bag and the pressure within the tube serves to tension the web in order to suspend the article within the outer bag and maintain a space between the article and the outer bag;

characterised in that each article is securely received by its respective aperture.

According to a further aspect, we provide a package for an article comprising a pressurised outer bag having gas tight seals at opposite ends and an inner web supporting the article within the outer bag, wherein the web extends along the length of the outer bag and is maintained under

sufficient tension by the pressure within the outer bag to suspend the article within the bag and to maintain a space between the article and the outer bag;

characterised in that the article is supported by means of an aperture in the web securely receiving the article.

Conveniently, the web is secured to the outer bag only at the gas-tight seals.

The packaged article is held in suspension within a sealed inflated bag and in this way is protected against mechanical impact. In order to maximise cushioning, as far as possible the space between the article and the outer bag should extend on all sides of the article.

The article to be packaged may be secured to the web by means of any receptacle, cavity or cut hole. Conveniently, the elasticity of the web grips the article. In one configuration, there is provided a package comprising an inner web suspended within a pressurised outer pack. The inner web is drawn from a reel, with the material used being thermoformable (such as polyethylene, or

coextrusions or laminates of polyethylene/nylon/polyethylene for example) . The inner web then has a cavity formed by heat and pressure to a sufficient depth and shape to fit the article to be packed. The size of the opening of the formed cavity at the surface of the web is slightly smaller than the article, at the article's largest point. The elasticity of the material will then allow the web to expand slightly to permit the insertion of the article to just beyond its largest point, at which point the web reverts to its original thermoformed dimension, thus securing the article within the cavity. There is then sufficient tension in the material to hold the product securely in place within the cavity in the web. The outer bag may be pressurised with air or an inert gas or gaseous mixture.

Alternatively, the web may have an aperture, such as a slit, adapted to grip the article. The aperture may be a through hole substantially the shape of the article wherein the size of the hole is slightly smaller than the size of the article.

An outer bag formed from a flat sheet that is drawn from a reel and made into a tubular sleeve by means of a hermetic back seal will be generally pillow shaped with a rounded cross section, but to improve the stackability of the packages and offer additional protection, the outer bag may include longitudinally extended pinches to impart a cusped cross section to the outer bag.

Embodiments can thus be seen to provide an integrated pack that protects and cushions a product, while reducing extraneous packaging material. The pack can be produced on a range of automatic packaging machinery.

"Gas-tight" means providing a substantially effective barrier to passage of at least one gas or vapour, at least for the expected lifetime of the package.

Preferably, at least one linear portion of the inner web adheres to the outer pack. Ideally, at least two opposed edges of the inner web adhere to the outer pack. Conveniently, that portion of the web secured to the outer bag extends along at least a major proportion of the

respective edge of the web.

"Linear" means extending along a straight or curved line beyond a single point. By "adhere" and "adhesion" there is meant significant bonding between portions

contacting each other.

Especially when a number of packages are produced on automated or semi-automated machinery, those portions of the web adhering to the outer pack are sealed thereto in

substantially the same manner as the web is sealed.

Ideally, each sealed portion comprises substantially the whole of the relevant edge of the inner web. By "seal" is meant substantial integration of the material or materials contacting each other. Depending on the package

requirements, all seals should be substantially hermetic, at least for the expected lifetime of the package.

The outer pack may be pressurised with air or any inert gas or mixture of gases. Carbon dioxide and nitrogen are convenient and readily available.

The inner web and the outer pack may be made of the same or different materials, provided that they can be sealed or otherwise adhere to each other. The outer pack must be substantially gas tight, taking account of the applicable pressure differentials. Materials to produce both the inner web and outer pack can each be tailored to the varied requirements of the products contained. A wide range of flexible packaging materials may be utilised.

Examples of suitable materials are:

1. Recyclable materials such as Mono or co-extruded

Polyethylene and Mono Polypropylene-based flexible

materials .

2. Co-extrusions of (for example)

Polyethylene/Nylon/EVOH/Nylon/ Polyethylene, where oxygen barriers may be incorporated in the co-extrusion.

3. Two layer laminates of Oriented Polypropylene/modified Polyethylene (sealing compatible to the OPP) . 4. Three or more layer laminates of (for example)

Polyethylene/ Polyester/Polyethylene .

Embodiments may allow the potential replacement of several current packaging systems offering product

protection methods that use heavyweight materials and are more energy hungry in their construction and manufacture. The package uses air as the protective medium rather than conventional rigid or semi-rigid constructions such as:

blister pack materials (amorphous polyethylene

terephthalate, polyvinyl chloride etc) ; polystyrene; carton and corrugated board; or cellulose acetate propionate food packs (amorphous) polyethylene terephthalate /polyethylene) . The invention may thus be environmentally friendly.

The invention allows lower weight flexible packaging materials to be tailored to the exact oxygen and barrier requirements of the product. It may be possible to enable significant reductions in the total weight of packaging material required and in the carbon footprint resource.

The invention also offers the potential to use recycled materials in its construction and to use recyclable

materials to pack many non oxygen-sensitive products.

Some embodiments may enable continuous assembly of packages by modifying existing machines.

The description below relates to a particular

embodiment in which the package is produced by thermoforming a web of material into sufficient depth and shape to fit the article to be packed. The size of the opening of the formed cavity at the surface of the web is slightly smaller than the article, at the article's largest point. The elasticity of the material will then allow the web to expand slightly to permit the insertion of the article to just beyond its largest point, at which point the web reverts to its

original thermoformed dimension, thus securing the article within the cavity. There is then sufficient tension in the material to hold the product securely in place within the cavity in the web.

At this point the side trims are removed but the web not cut, and the material now holding the article continues to a second stage on the machine or to another machine, where it enters a horizontal form fill and seal section forming a larger outer bag that encases the inner web. A back seal is made to the outer material before an

overpressure of either air or mixed gases is blown into the package to inflate the outer pack, before end seals are applied. A mixture of gasses may be applied when a

controlled atmosphere is desirable.

Alternatively, the web now holding the article

continues to a second stage on the machine, or to another machine, where it enters a vertical form fill and seal section forming a larger outer bag that encases the inner web. A back seal is made to the outer material before an overpressure of either air or mixed gases is blown into the package to inflate the outer pack, before end seals are applied. A mixture of gasses may be applied when a

controlled atmosphere is desirable.

Only at this stage is the outer pack sealed to the inner web and only through the end seals of the outer bag. The inner web is therefore held in suspension within the outer pack, protecting it within a cushion of air or mixed gases. The invention allows for a mixture of gases to be used to inflate the outer pack when a controlled atmosphere is desirable.

In another aspect, the description below relates to an embodiment in which the package is produced by punching or cutting a hole in a web of material of a shape to

approximate the shape of the article to be packed. The hole should be made with a heated knife to seal the edge of the web to avoid later tearing of the material. The size of the hole is slightly smaller than a designated and designed point on the article. The material used for the inner web is pliable (such as polyethylene or co-extrusions of different plastics such as polyethylene/nylon/polyethylene for example) . The elasticity of the material will also allow the web to expand slightly to allow the insertion of the article to the designated and designed point on the article, at which point the reduced size of the article will permit the web to return to its original cut dimension, holding the article in place. There is then sufficient tension in the material to hold the article securely in place in the web.

It will be apparent that this embodiment is less suitable for articles without a cusp or depression which could have been engaged and elastically gripped by the hole in the web. For example, a spherical article would be difficult to retain in the hole.

At this point the side trims are removed but the web is not cut, and the material now holding the article continues to a second stage on the machine, or to another machine, where it enters a horizontal or vertical form fill and seal section forming a larger outer bag that encases the inner web, as described previously.

Alternatively, the package may be produced from a web wound onto a separate reel where the holes have been pre^¬ punched into the web to a shape to approximate the fit the article to be packed.

Brief description of the drawings

The invention will now be described further, by way of example, with reference to the accompanying drawings, in which :

Fig. 1 is a drawing of the finished package profile for both horizontal and vertical methods where a formed cavity is employed to secure the article;

Fig. 2 shows the side profile of the formed cavity prior to the insertion of the article to be packed;

Fig. 3 is a drawing of the end profile for the formed web showing the side profile of an Easter Egg (as an example of an article to be packed), for both horizontal (see Fig. 8) and vertical (see Fig. 9) production methods;

Fig. 3A is a drawing of the uncut web after the first stage of production in the vacuum forming / Horizontal and vacuum forming / Vertical versions (see Figs 8 and 9);

Fig. 4 is a drawing of the finished package profile for both horizontal and vertical methods where a punched, and pre-punched web is employed to secure the article (see figs. 10 to 13) ; Fig. 5 is a drawing of a pre-punched web for both horizontal (see Fig. 12) and vertical (see Fig. 13) methods;

Fig. 6 shows the side profile of an article (showing a light bulb as an example) positioned above a pre-punched web prior to insertion;

Fig. 7 shows the article again in side profile, now lowered into and held by the web;

Fig. 7A is a drawing of the uncut web after the first stage of production in the punched and pre-punched /

Horizontal and / Vertical versions (see Figs 10 to 13);

Fig. 8 shows as a schematic a machine adaption wherein a modified vacuum forming machine operates in tandem with a horizontal form fill and seal machine to produce the package shown in Fig. 1;

Fig. 9 shows as a schematic a machine adaption wherein a modified vacuum forming machine operates in tandem with a vertical form fill and seal machine to produce the package shown in Fig. 1;

Fig. 10 shows as a schematic a machine adaption wherein a hole-punching machine operates in tandem with a horizontal form fill and seal machine to produce the package shown in Fig. 4;

Fig. 11 shows as a schematic a machine adaption wherein a hole-punching machine operates in tandem with a vertical form fill and seal machine to produce the package shown in Fig. 4;

Fig. 12 shows as a schematic a machine adaption wherein an adaption of a vacuum forming machine is used to take pre^¬ punched reels and operates in tandem with a horizontal formfill and seal machine to produce the package shown in Fig. 4; and

Fig. 13 shows as a schematic a machine adaption wherein an adaption of a vacuum forming machine is used to take pre^¬ punched reels and operates in tandem with a vertical form fill and seal machine to produce the package shown in Fig. 4.

Description of embodiments In Fig. 1, 1 is the article to be packaged. 2 shows the inner web after it has been formed and with the article contained, with a formed cavity shown as 3. The outer material having been wrapped around the inner web 2 is shown as 5, with four welded pinches which define four corner cusps 80. The back seal of the outer bag is incorporated into one of the cusps, shown as 80/6. An over pressure is trapped inside the pack by virtue of the back seal 80/6 and end seals 7, hermetically sealing the material together. The final pack end seals 7, on opposite sides of the article

1, seal the inner web material 2 to the outer material 5, thus allowing the article 1 to be held in suspension within a cushion of air or mixed gases.

In Fig. 2, 2 shows a side profile of the thermoformed inner web with 3 being the formed cavity. 4 shows the narrowing at the neck of the cavity, which being a pliable material as described, will expand momentarily to allow the article to be inserted.

In Fig. 3, 1 shows the article and 2 shows the inner web restraining the product by means of a formed cavity 3 and showing the narrowing of the neck of the thermoform 4, forming a pressure point around the article, thus holding it securely .

In Fig. 3A, the drawing shows the completed but uncut inner web 2, after leaving the vacuum forming stage with the article 1 inserted in the cavity 3. 41 shows the knives that remove the reel edge trim 42 from both sides of the material. The drawing shows the completed but uncut inner web before entering the second stage where the outer bag is applied, inflated and sealed.

An alternative embodiment of the invention is shown in Fig. 4, which differs from Fig 1 only in that the inner web

2, has a punched hole, rather than a formed cavity. 1 is the article with 2 showing the inner web after it has been punched and with the article 1 restrained at 92, allowing the article to be securely held by the inner web. 5 then shows the outer material having been wrapped around the inner web 2 with four welded pinches which define four corner cusps 80. The back seal of the outer bag is incorporated into one of the cusps, shown as 80/6. An over pressure is trapped inside the pack by virtue of the back seal 80/6 and end seals 7, hermetically sealing the material together. The final pack end seals 7, on opposite sides of the article 1, seal the inner web material 2 to the outer material 5, thus allowing the article 1 to be held in suspension within a cushion of air or mixed gases.

In Fig. 5, 2A shows a reel to produce inner web 2 with pre-punched holes 89, for feeding to horizontal or vertical form, fill and seal machines (shown in Fig. 12 and Fig. 13), the size and shape of the pre-punched holes being determined by the article to be packed.

Fig. 6 shows the article 1 and inner web 2 in side profile. The article 1 is shown (using a light bulb as an example of an article) before being inserted in the web 2, with the width of the article shown as 90. The size of the hole cut in the inner web 2, to fit the article 1, is shown as 91, being marginally smaller than 90, the size of the article 1. The article to be packed has a notch or recessed area 92, that will enable the web 2 to hold the product securely .

In Fig. 7, the article 1 is seen after insertion into the hole 89 of the web 2. As the web has been constructed from a pliable material with an inherent polymer memory such as for example, a co-extrusion of polyethylene or other materials described elsewhere, the aperture 91, has

momentarily stretched to allow the article 1 to pass

through, before expanding at point 92 where the profile of the article has reduced. The article is therefore held secure within the web 2.

In Fig. 7A, the drawing shows the completed but uncut inner web 2, after leaving the hole cutting stage with the article 1 inserted and held securely at point 92. 41 shows the knives that remove the reel edge trim 42 from both sides of the material. The drawing shows the completed but uncut inner web before entering the second stage where the outer bag is applied, inflated and sealed.

In Fig. 8, 1 is the article on a supporting conveyor (not shown) entering the second stage tandem machine and 2A is the reel of material at stage one of a first machine. The web is held in conventional grippers 40, holding the web on both sides where forming station 74 thermoforms the web to produce a cavity 3, (as shown in Fig. 2) . The article 1 is inserted into the formed cavity 3 either manually, semi- automatically or automatically at 75 before the reel's edge trim 42 is removed by knives positioned at 41. The uncut web 2, containing the articles 1, then moves along a

supporting conveyor (not shown) to the forming box 55 where an outer reel of material 5A is formed around the inner web 2 and article 1. A back seal and cusps are then applied by either heated rollers or heated pads 56 to produce a back seal 6 which seals the outer material 5A only to itself. The outer material is not attached to the inner pack at this point. 2B shows the inner web still held in suspension within the outer wrap and 5B the outer pack inflated with either air or a mixture of gases, such as carbon dioxide or nitrogen. The outer pack is then sealed on opposite sides of the article 1, as shown at 57, with the inner web 2 and outer pack also being sealed together at 57 before being cut into individual packages. 58 indicates the finished

individual packages leaving the production machine (see also Fig. 1) .

In the schematic of Fig. 9, a horizontal forming machine works in tandem with a vertical form fill and seal machine. The article 1 is shown held within cavities formed in the web 2 as previously described. 2A is the reel of material at stage one of the first machine. The web is held in conventional grippers shown at position 40, holding the web on both sides where a base web forming station 74 forms a cavity 3 (as shown in Fig. 3) . The article is inserted into the formed cavity either manually, semi-automatically or automatically at 75 before the reel's edge trim 42 is removed by knives positioned at 41. The uncut web,

containing the articles 1, indicated at 72 then moves along a supporting conveyor (not shown) to a unit 60, that

repositions the web above the second stage of the tandem machine. The inner web 2 continues vertically into a forming collar and tube at 62, where material from reel 5A is formed around the collar 62 and pulled or driven down the outer tube, for example by means of a moving belt or reciprocating aws 63, with a fin or lap back seal being applied at 56. The back seal is applied only to the outer material, with the inner web 2 being in free suspension at this stage. The outer pack is then inflated with an overpressure of either air or a combination of gases, such as carbon dioxide or nitrogen, before the end seals are applied at 57 on opposite sides of the article 1. This sealing station also seals the inner web 2 to the outer pack before being cut at 57 and dropping onto a supporting conveyor (not shown) , with the finished packages being indicated at 58 (see also Fig. 1) .

A schematic of a tandem machine to produce an

alternative embodiment of the invention is shown in Figs. 10 and 11, which differs from Figs. 8 and 9 in that a hole is punched in the web to hold the article rather than a formed cavity .

Fig.10 shows the article 1 inserted and held in the inner web 2, on a supporting conveyor (not shown) . 2A is the reel of material at stage one of the first part of this tandem machine. The web is held in conventional grippers 40, holding the web on both sides where punching station 64 punches and removes a part of the web to produce a hole 89 (as shown in Fig. 5) . The article 1 is inserted into the cut hole either manually, semi-automatically or

automatically at 75 before the reel's edge trim 42, is removed by knives positioned at 41. The uncut web 2, securing the articles 1 then moves along a supporting conveyor (not shown) to the second part of this tandem machine, to a forming box 55 where an outer reel of material 5A is formed around the inner web 2 and article 1. A back seal and cusps are then applied by either heated rollers or heated pads 56 to produce a back seal 6 which seals the outer material 5A only to itself. The outer material 5A is not attached to the inner web 2 at this point. 2B shows the inner web still held in suspension within the outer wrap and 5B the outer pack inflated with either air or a mixture of gases, such as carbon dioxide or nitrogen. The outer pack is then sealed on opposite sides of the article 1, as shown at 57, with the inner web 2 and the outer pack also being sealed together at 57 before being cut into individual packages. 58 indicates the finished individual packages leaving the production machine (see also Fig. 4) .

Fig. 11 is a schematic where a dual machine is

constructed using a punching machine in tandem with a vertical form fill and seal machine. Article 1 is the product to be inserted and held in the inner web 2, on a supporting conveyor (not shown) . 2A is a reel of material at stage one of the machine. The web 2 is held in conventional grippers 40, holding the web on both sides where punching station 64 punches and removes a part of the web to produce a hole 89 (as shown in Fig. 5) . The article 1 is inserted into the cut hole either manually, semi-automatically or automatically at 75 before the reel's edge trim 42 is removed by knives positioned at 41. The uncut web 2, now securing the articles 1A then moves along a supporting conveyor (not shown) to the second part of the machine to a unit 60, that repositions the web above the second stage of the machine. The inner web 2, continues down through the centre of the forming collar and tube at 62, where material from reel 5A is formed around the collar 62 and pulled or driven down the outer tube, for example by means of a moving belt or reciprocating aws 63, with a fin or lap back seal being applied at 56. The back seal is applied only to the outer material 5A, with the inner web 2 being in free suspension at this stage. The outer pack is then inflated with an overpressure of either air or a combination of gases, such as carbon dioxide or nitrogen, before the end seals are applied at 57 on opposite sides of the article 1. This sealing station also seals the inner web to the outer pack before being cut at 57 and dropping the packs onto a supporting conveyor (not shown) , with the finished packages being indicated at 58 (see also Fig. 4) .

A schematic of a tandem machine to produce an variant of the invention is shown in Figures 12 and 13, which differs from figure 10 and 11 in that the machine is

designed to use reels of pre-cut web. In Fig. 12 article 1 is the product to be packaged, shown here prior to being inserted and held in the inner web 2, on a supporting conveyor (not shown) . 2A is a reel of material at stage one of the first part of this tandem machine, showing pre-cut punched holes 89 (as shown in

Fig.5). The web is held in conventional grippers 40, holding the web on both sides. The article 1 is inserted into the cut hole either manually, semi-automatically or automatically at 75, before the reel's edge trim 42 is removed by knives positioned at 41. The uncut web 2, securing the articles 1, then moves along a supporting conveyor (not shown) to the second part of this tandem machine, to a forming box 55 where an outer reel of material 5A is formed around the inner web 2 and article 1. A back seal and cusps are then applied by either heated rollers or heated pads 56 to produce a back seal 6 which seals the outer material 5A only to itself. The outer material is not attached to the inner pack at this point. 2B shows the inner web still held in suspension within the outer wrap and 5B the outer pack inflated with either air or a mixture of gases, such as carbon dioxide or nitrogen. The outer pack is then sealed on opposite sides of the article 1, as shown at 57, with the inner web 2 and outer pack also being sealed together at 57 before being cut into individual packages. 58 indicates the finished individual packages leaving the production machine (see also Fig. 4) .

In Fig. 13, Article 1 is the product to be packaged shown here prior to being inserted and held in the inner web 2, on a supporting conveyor (not shown) . 2A is a reel of material at stage one of the first part of this tandem machine, showing pre-cut punched holes 89 as shown on

Fig.5). The web is held in conventional grippers 40, holding the web on both sides. The article is inserted into the cut hole either manually, semi-automatically or

automatically at 75, before the reel's edge trim 42 is removed by knives positioned at 41. The uncut web 2, now securing the articles shown as 1A, then moves along a supporting conveyor (not shown) to the second part of this tandem machine to a unit 60, that repositions the web above the second stage of the machine. The inner web 2 continues down through the centre of the forming collar and tube at 62, where material from reel 5A is formed around the collar 62 and pulled or driven down the outer tube, for example by means of a moving belt or reciprocating aws 63, with a fin or lap back seal being applied at 56. The back seal is applied only to the outer material, with the inner web 2 being in free suspension at this stage. The outer pack is then inflated with an overpressure of either air or a combination of gases, such as carbon dioxide or nitrogen, before the end seals are applied at 57 on opposite sides of the article 1. This sealing station also seals the inner web to the outer pack before being cut at 57 and dropping the packs onto a supporting conveyor (not shown) , with the finished packages being indicated at 58 (see also Fig. 4) .

Claims

1. A method of packaging an article comprising the steps of:

(a) forming an outer bag (5) having gas-tight seals (7) at opposite ends together with an inner web (2) extending along the length of the outer bag (5) and, in use, supporting the article (1) within the outer bag (5);

(b) pressurising the outer bag (5) so as to tension the web (2) and suspend the article (1) within the bag (5) and to maintain a space between the article (1) and the outer bag

( 5 ) ; and

(c) sealing the outer bag (5);

characterised in that the article (1) is inserted through an aperture (89) in the web (2) and is securely received by the aperture (89) .

2. A method of packaging an article as claimed in Claim 1 wherein the web (2) is secured to the outer bag (5) only at the gas-tight seals (7) .

3. A method of packaging an article as claimed in Claims 1 or 2 wherein the aperture (89) is the opening of a cavity (3) receiving the article (1) and the opening (89) of the cavity (3) is slightly smaller than the article (1) .

4. A method of packaging as claimed in Claim 3 wherein the cavity (3) is thermoformed in the web (2) .

5. A method of packaging as claimed in Claims 3 or wherein the cavity (3) has a similar shape to the article (1) .

6. A method of packaging as claimed in Claims 1 or 2 wherein, in use, the aperture (89) grips the article (1) by means of the elasticity of the web (2) .

7. A method of packaging as claimed in Claim 6 wherein the aperture (89) is a slit.

8. A method of packaging as claimed in Claim 6 wherein the aperture (89) is a through hole substantially the shape of the article (1) and the size of the hole is slightly smaller than the size of the article (1) .

9. A method of packaging as claimed in any one of the preceding claims wherein the outer bag (5) is formed by wrapping a film (5A) around both the inner web (2) and the articles (1) secured thereto and then sealing a back seam (6) in the film (5A) to form a tube.

10. A method of packaging as claimed in any one of the preceding claims wherein that portion of the web (2) secured to the outer bag (5) extends along at least a major

proportion of the respective edge of the web (2) .

11. A method of packaging as claimed in any one of the preceding claims, further comprising the step of forming longitudinally extended pinches (80) in the outer bag (5) to impart a cusped cross section to the outer bag (5) .

12. A method of packaging a continuous stream of articles as claimed in any one of the preceding claims, further comprising the step of severing the inner web (2) and the outer bag (5) at the seals (7) located on opposite sides of each article (1) to create individually packaged articles .

13. A packaging machine for packaging a continuous stream of articles comprising:

A first stage (75) at which the articles (1) are inserted at intervals through apertures (89) in a longitudinally

extending web (2); A second stage (55) at which the web (2) and the articles

(1) supported therein are enveloped in a tube;

A source of pressurised gas for inflating the tube; and A sealing station (57) at which the inflated tube is sealed by gas-tight seals (7) transverse to the length of the web

(2) and the tube on opposite sides of each article (1), so as to form a sealed outer bag (5) within which the article (1) is packaged,

wherein the web (2) extends along the length of the outer bag (5) and the pressure within the tube serves to tension the web (2) in order to suspend the article (1) within the outer bag (5) and maintain a space between the article (1) and the outer bag (5);

characterised in that each article (1) is securely received by its respective aperture (89) .

14. A packaging machine as claimed in Claim 13 wherein the aperture (89) is the opening of a cavity (3) receiving the article (1) and the opening of the cavity (3) is slightly smaller than the article (1) .

15. A packaging machine as claimed in Claim 13 wherein the aperture (89) is a through hole substantially the shape of the article (1) and the size of the hole (89) is slightly smaller than the size of the article (1) .

16. A packaging machine as claimed in any one of Claims 13 to 15, including a further stage (56) forming longitudinally extended pinches (80) in the outer bag (5) impart a cusped cross section to the outer bag (5) .

17. A package for an article (1) comprising a

pressurised outer bag (5) having gas tight seals (7) at opposite ends and an inner web (2) supporting the article (1) within the outer bag (5), wherein the web (2) extends along the length of the outer bag (5) and is maintained under sufficient tension by the pressure within the outer bag (5) to suspend the article (1) within the bag (5) and to maintain a space between the article (1) and the outer bag (5) ;

characterised in that the article (1) is supported by means of an aperture (89) in the web (2) securely receiving the article ( 1 ) .

18. An assembly comprising a plurality of packages as claimed in Claim 17 connected end-to-end to one another.