Packaging Assembly for Solar Cover for Swimming Pool

Abstract

A packaging assembly for a large item such as a solar pool cover in an exemplary embodiment utilizes a shrink-wrap packaging material. The packaging material may be formed of a polyolefin material, and may have a thickness of about 1.0-2.5 mils. The packaged item, such as a solar cover, may be formed at least partially of polyethylene. Additionally, the solar cover may be rolled into a roll having a cylindrical shape with a cylindrical diameter of at least about 30 inches and a cylindrical width of at least about 48 inches. Other items of similar size may be packaged using the packaging assembly.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Application No. 61/358,712, filed Jun. 25, 2010, which application is incorporated by reference herein in its entirety and made part hereof.

TECHNICAL FIELD

[0002] The present invention generally relates to a packaging system for a large item and more particularly to a packaging assembly for a solar cover utilizing a shrink-wrap material over the solar cover.

BACKGROUND

[0003] Items shipped in commerce commonly use some type of packaging such as cardboard boxes or plastic bags. The packaging serves to protect the items prior to being removed by the end-user. One type of item shipped in commerce is a swimming pool cover, such as a solar swimming pool cover. A solar swimming pool cover may also be referred to as a solar blanket or solar cover. The solar covers are typically formed from polymeric materials, such as a polyethylene-based material. The solar covers are large members dimensioned to be positioned over an entire swimming pool, which can be of significant size. Because of their large size and the material construction, solar covers are typically shipped in large, rigid cardboard boxes to sufficiently protect the solar cover during shipping. Such packaging containers, however, are bulky and expensive. Shrink wrap materials have not previously been used as a packaging option because of the size of the solar cover as well as the material construction of the solar cover.

[0004] Thus, while packaging assemblies for large items such as solar covers for swimming pools according to the prior art provide a number of advantageous features, they nevertheless have certain limitations. The present invention seeks to overcome certain of these limitations and other drawbacks of the prior art, and to provide new features not heretofore available.

BRIEF SUMMARY

[0005] The present invention provides a packaging assembly for a large item. In one exemplary embodiment, the large item is a solar blanket used to cover swimming pools and the packaging assembly includes a shrink-wrap material.

[0006] Aspects of the invention relate to a packaging assembly that includes a solar pool cover including a generally planar sheet that is rolled to form a roll, and a polymeric packaging material shrink-wrapped around the roll. According to one aspect, the roll is cylindrical in shape and may have a cylindrical diameter of at least about 30 inches and a cylindrical width of at least about 48 inches, or may have a cylindrical diameter of at least about 6 inches and a cylindrical width of at least about 36 inches.

[0007] According to another aspect, the cover is formed at least partially of a first polymer material, and the packaging material is formed of a second polymer material. The second polymer material of the packaging material contacts the first polymer material of the cover when the packaging material is shrink-wrapped around the roll. In one embodiment, the cover is formed at least partially of a polyolefin-based material, and the packaging material is formed of a polyolefin-based material, such that the polyolefin material of the packaging material contacts the polyolefin-based material of the cover. The polyolefin-based materials of the cover and/or the packaging material may be or include polyethylene and/or polypropylene.

[0008] According to a further aspect, the packaging material has a thickness of about 1.0-2.5 mils (i.e. 0.001'' to 0.0025'').

[0009] According to a still further aspect, the solar pool cover may include a generally planar sheet formed at least partially of a polyethylene-based material, the cover being rolled to form a roll having a cylindrical shape with a cylindrical diameter of at least about 30 inches and a cylindrical width of at least about 48 inches. The packaging material may be a polyolefin-based packaging material shrink-wrapped around the roll, with the packaging material having a thickness of between about 1.0-2.5 mils. The packaging material contacts the polyethylene-based material of the cover when the packaging material is shrink-wrapped around the cover.

[0010] According to additional aspects of the invention, the a packaging assembly may be used for a packaged item other than a solar cover. For example, the packaging assembly may be used with an item formed at least primarily of a polyolefin-based material and having an outer surface formed at least partially of the polyolefin-based material. A polyolefin-based packaging material can be shrink-wrapped around the item, wherein the packaging material contacts the polyolefin-based material of the outer surface of the item. The polyolefin-based materials of the cover and/or the packaging material may be or include polyethylene. The item may also have a relatively large size, such as an item having a first dimension measuring at least about 6 inches and second dimension measuring at least about 36 inches.

[0011] According to one aspect, the item has a generally cylindrical shape, where the first dimension is a cylindrical diameter of the cylindrical shape and the second dimension is a cylindrical width of the cylindrical shape.

[0012] Further aspects of the invention relate to a packaging material for use in packaging assemblies and processes. The packaging material may include a film of polymer material configured to be shrink-wrapped around a solar pool cover that includes a generally planar sheet rolled to form a cylindrical roll. The film of polymer material has a thickness of between about 1.0-2.5 mils (i.e. 0.001'' to 0.0025''). The film of polymer material may be formed of a polyolefin-based material, such as a polyethylene-based and/or polypropylene-based material.

[0013] According to one aspect, the packaging material is configured to be shrink-wrapped around the pool cover having a cylindrical shape with a cylindrical diameter of at least about 30 inches and a cylindrical width of at least about 48 inches.

[0014] According to another aspect, the film of polymer material is configured to be shrink-wrapped around the pool cover, where the pool cover is formed at least partially of a polyethylene material, and the film of polymer material is configured to contact the polyethylene-based material of the pool cover after being shrink-wrapped.

[0015] According to a further aspect, the film of polymer material is formed of a substantially transparent material.

[0016] Still further aspects of the invention relate to a method for packaging an item as described above, including shrink-wrapping the item with a packaging material. The shrink wrapping process may include preparing the item for shrink-wrapping, and then wrapping the item in the packaging material. The packaging material can then be sealed to form a cocoon around the item to form a sealed packaging assembly. The packaging material can then be shrink-wrapped, such as by passing the packaged item through a heat tunnel on a conveyor or similar device.

[0017] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. The Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:

[0019] FIG. 1 is a perspective view of a solar pool cover for use in one embodiment of a packaging assembly according to the present invention;

[0020] FIG. 2 is a perspective view of a packaging material being wrapped around the solar pool cover of FIG. 1;

[0021] FIG. 3 is a perspective view of the packaging material and the solar pool cover of FIG. 2 after a sealing process has been performed;

[0022] FIG. 4 is a cross-sectional view taken along lines 4-4 of FIG. 3;

[0023] FIG. 5 is a cross-sectional view taken along lines 5-5 of FIG. 3;

[0024] FIG. 6 is a perspective view of a packaging assembly including the packaging material and the solar pool cover of FIG. 3, after shrink-wrapping of the packaging material;

[0025] FIG. 7 is a side view of the packaging material and the solar pool cover of FIG. 6;

[0026] FIG. 7A is a magnified view showing area 7A in FIG. 7;

[0027] FIG. 8 is an end view of the packaging material and the solar pool cover of FIG. 6;

[0028] FIG. 8A is a magnified view showing area 8A in FIG. 8;

[0029] FIG. 9 is a cross-sectional view of one embodiment of a solar pool cover; and

[0030] FIG. 10 is a schematic view of a heat tunnel for shrink-wrapping a packaging material to form a packaging assembly according to the present invention.

DETAILED DESCRIPTION

[0031] While this invention is susceptible of embodiment in many different forms, there is shown in the drawings, and will herein be described in detail, preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

[0032] The present invention relates generally to a packaging assembly for large items or articles, as well as packaging materials and methods for use in such packaging assemblies. Referring now in detail to the Figures, FIGS. 1-8A illustrate a packaging assembly according to an embodiment of the present invention, generally referred to with the reference numeral 10. The packaging assembly shown generally includes an item 12 that is packaged in a packaging material 14, also referred to as an overwrap or wrapping material. In the exemplary embodiment illustrated in FIGS. 1-8A, the packaged item 12 is a rolled solar swimming pool cover 11, however in other embodiments, other types of items may be packaged, as described below. Such a solar cover 11 is a generally planar sheet that can be spread to cover a swimming pool or similar structure, such as shown in FIG. 5, and may be rolled into a cylindrical, elongated roll for packaging, as illustrated in FIGS. 1-8A.

[0033] One example of a solar cover 11 is shown in FIG. 9, and may include several layers of one or more polymer materials, such as a polyethylene-based material or another polyolefin-based material, as described above. As used herein, a material is "based" on a polymer (e.g., polyolefin-based, polyethylene-based, etc.) if the named polymer makes up more than 50% of the material or is otherwise the most prevalent component in the material. The solar cover 11 may additionally or alternately include a different type of material in another embodiment, such as polyvinyl chloride. In this general embodiment, the solar cover 11 has a transparent or translucent front layer 32 that is formed into a cellular or chambered structure that contains and/or encapsulates air, and a transparent or translucent back layer 36, which combines with the cellular structure of the front layer 32 to define a plurality of air bubbles or pockets 34. The transparent or translucent layers 32, 36 may be colorless or clear blue, or may have another visual appearance. The solar cover 11 may contain additional layers as well, such as an opaque layer that may be absorptive and/or reflective, and it is understood that different layers of the solar cover 11 may be formed of different materials.

[0034] In one embodiment, the packaged item 12 may be formed primarily or at least partially by a plastic or other polymer material, for example, a polyolefin-based material such as polyethylene or polypropylene. At least a portion of the outer surface 16 of the item 12 may be formed by such polymer material, and in one embodiment, the outer surface 16 of the item 12 may be primarily or entirely formed by such polymer material. Additionally, in one embodiment, the packaging material 14 may be at least partially formed of the same or a similar polymer material as the packaged item 12, and the packaging material 14 may be in contact with the portion(s) of the outer surface 16 of the item 12 formed of the polymer material. A solar cover, such as the solar cover 11 illustrated in FIGS. 1-8A, may be formed wholly or partially of a polyethylene-based material, and in this exemplary embodiment, the packaging material 14 is formed of one or more polyolefin-based materials. In further embodiments, items 12 and packaging materials 14 formed of different materials may be used, including other types of polymers, such as other polyolefins or polyvinyl chloride (PVC).

[0035] In another embodiment, the packaged item 12 may be large in size, relative to items that are typically packaged using shrink-wrap packaging or similar packaging materials. For example, in one embodiment, the packaged item 12 may have at least one dimension (length, width, or height) that is at least about 30 inches, and may have at least one other dimension that is at least about 48 inches. In another embodiment, the packaged item may have at least one dimension that is at least about 6 inches and another dimension that is at least about 36 inches. In a further embodiment, the packaged item may have at least one dimension that is from about 6-30 inches and another dimension that is from about 36-50 inches. As another example, the packaged item may have a volume of at least about 30,000 cubic inches in one embodiment, at least about 1,000 cubic inches in another embodiment, and from about 1,000 to about 35,000 cubic inches in a further embodiment.

[0036] In the embodiment illustrated in FIGS. 1-8A, the item 12 is a solar cover that is generally rolled into an elongated, cylindrically-shaped roll having a cylindrical diameter of at least about 30 inches and a cylindrical length of at least about 48 inches. In another embodiment, the rolled solar cover 11 may have a cylindrical diameter of at least about 6 inches and a cylindrical length of at least about 36 inches. In a further embodiment, the rolled solar cover 11 may have a cylindrical diameter of from about 6-30 inches and a cylindrical length of from about 36-50 inches. In further embodiments, items 12 of different sizes may be packaged as described herein, including other types of generally planar/sheet items rolled into cylindrical, elongated rolls. It is understood that the packaging assembly 10 may include a solar cover 11 in a non-rolled form, such as a flat or folded form, packaged using the packaging material 14.

[0037] The packaging material 14 is generally a polymer film material that is shrink-wrapped around the packaged item 12 to form the packaging assembly 10. As described above, the packaging material 14 may formed of one or more polyolefin-based materials, such as polyethylene and/or polypropylene, and may include a polyolefin material blended with another type of polymer material, such as various copolymers. Additionally, the film may be a single-layer film or a multi-layer film. In one embodiment, the film may be a multi-layer film formed of a number of different materials, including polyethylene as well as one or more copolymers such as ethylene vinyl acetate, ethylene butylene, ethylene propylene, etc. In other embodiments, the packaging material 14 may be formed of any polymer material(s) that may be shrink-wrapped, such as other polyolefin-based materials, PVC, etc. The packaging material 14 may be made from a transparent or substantially transparent material, in order to provide visibility to the item 12. Additionally, in one embodiment, the thickness of the packaging material 14 is about 1.0-2.5 mils (i.e. 0.001'' to 0.0025''). In another embodiment, the thickness of the packaging material 14 is about 150-200 gauge (1.5-2.0 mils or 0.0015'' to 0.002''). In a further embodiment, the thickness of the packaging material 14 may be about 4-6 mils (i.e. 0.004'' to 0.006''). As described below, the thickness of the packaging material 14 may be adjusted according to processing factors, to help prevent the shrink-wrap from melting together with the packaged item 12.

[0038] The item 12 can be packaged in the packaging material 14 by a shrink-wrapping process, an exemplary embodiment of which is shown in FIGS. 1-8A with respect to a solar cover 11 rolled to form the packaged item 12, as described above. The solar cover 11 is prepared for packaging, including rolling the generally planar solar cover 11 into the rolled form, as shown in FIG. 1. Additionally, a strap or tie may be placed around the cover 11 before wrapping, to stop the cover 11 from unrolling. After the item 12 is prepared for packaging, the packaging material 14 is wrapped around the item 12, as illustrated in FIG. 2. This may be performed by hand or by a machine. Other articles may be placed inside the packaging material in addition to the item 12, such as labeling, product information, etc. As shown in FIGS. 3-5, the packaging material 14 is wrapped to cover all sides and surfaces of the item 12. The packaging material 14 may then be sealed to form a sealed cocoon 18 to enclose the item 12, as also illustrated in FIGS. 3-5. The sealing may be accomplished by hot sealing, such as using a sealer tool, to form a sealed seam 20, which includes an end seam 22 and two side seams 24.

[0039] The packaging material 14 can then be shrink-wrapped around the item 12 to create the packaging assembly 10, as shown in FIGS. 6-8A. The shrink-wrapping process is described below in greater detail. It is understood that the sealing and shrink-wrapping may be performed together and/or in a single step in one embodiment. After shrink-wrapping, the packaging material 14 is more tightly wrapped around the item 12, and the packaging material 14 is in contact with at least a portion of the outer surface 16 of the item 12, as described above. Further, in one embodiment, where at least a portion of the outer surface 16 of the item 12 includes a polyethylene-based or other polyolefin-based material, the packaging material 14 contacts the polyolefin-based material of the item 12. As shown in FIGS. 6-8A, although at least a portion of the packaging material 14 may be in contact with the item 12, no portion of the item 12 is bonded or melted to the packaging material 14 or the seam 20 after sealing and heat-shrinking, and the entire packaging material 14 is separate and separable from the item 12.

[0040] The shrink-wrapping process generally includes the application of heat to the packaging material 14, such as through passing the product through a heated tunnel or chamber, or other techniques, such as by using a hand held heat gun. The parameters of the shrink-wrapping process and apparatus are described in greater detail below. In one embodiment, as illustrated in FIG. 10, the shrink-wrapping is performed by passing the sealed cocoon 18 containing the item 12 enclosed by packaging material 14 through an apparatus 38 that includes a sealing apparatus 40 and a heated tunnel 48, by use of one or more conveyors 42 or similar device(s). Although the conveyor 42 is shown schematically as a series of rollers, various other types of conveyors 42 may be used, including belts and various types of devices that are capable of carrying the item 12. The apparatus 38 may also include a device 43 for controlling airflow through the tunnel 48. As illustrated schematically in FIG. 10, the item 12 is wrapped in the packaging material 14 and moved into the sealing apparatus 40, which seals the edges and ends of the packaging material 14, forming the sealed cocoon 18. The cocoon 18 containing the item 12 wrapped in packaging material 14 is then moved into the entrance end 44 of the tunnel 48, and the packaging material 14 is heat-shrunk within the tunnel 48 to form the wrapped packaging assembly 10, which exits from the exit end 46 of the tunnel 48. The temperature applied to the packaging material 14, the velocity of the conveyor 42 within the heat tunnel 48, the timing of the heating and cooling within the tunnel 48, the airflow within the tunnel 48, and other parameters of the shrink-wrapping process can be controlled or adjusted based on the nature (materials, size, shape, etc.) of the item 12 and/or the thickness and material makeup of the packaging material 14. Additionally, the thickness of the packaging material 14 and/or the type or material makeup of the packaging material 14 can also be controlled or adjusted based on the nature of the item 12 and/or the parameters of the shrink-wrapping process.

[0041] For example, in one embodiment for shrink-wrapping a polyethylene-based solar cover 11 with a polyolefin-based packaging material 14, the temperature in the tunnel 48 may be from 260° F. to 330° F., with no spot in the tunnel 48 exceeding 330° F. In this embodiment, the conveyor 42 is moved at a velocity so that the cover 11 travels completely through the tunnel 48 in no more than 20 seconds. High air velocity within the tunnel may also be used to assure proper shrink-wrapping. In other embodiments, different parameters may be used, such as where different items and/or packaging materials, having different sizes and/or made of different materials, are used.

[0042] The packaging assembly, packaging materials, and packaging process of the present invention provide benefits over prior art packaging assemblies, materials, and processes. The present packaging assembly allows items such as a solar pool cover to be shipped in a shrink-wrapped over-packaging, which is smaller, lighter, and less expensive than the bulky, more expensive cardboard boxes and heavy gauge plastic bags in which solar covers are typically packaged. Additionally, the packaging material has sufficient strength to protect the solar cover during shipping, due to its material composition and thickness. The packaged solar cover can more easily be shipped by traditional package carriers, offering more cost-effective shipping. Further, the high-clarity shrink-wrapped packaging offers a better and cleaner looking, retail-like packaging appearance, with greater flexibility on custom labeling. Still further, the shrink-wrap packaging material has a suitable melt temperature so the solar cover is not melted during the shrink-wrapping process.

[0043] While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention and the scope of protection is only limited by the scope of the accompanying Claims.

Claims

1. A packaging assembly comprising: a solar pool cover comprising a generally planar sheet that is rolled to form a roll; and a polymeric packaging material shrink-wrapped around the roll.

2. The packaging assembly of claim 1, wherein the roll is cylindrical in shape and has a cylindrical diameter of about 30 inches and a cylindrical width of about 48 inches.

3. The packaging assembly of claim 1, wherein the roll is cylindrical in shape and has a cylindrical diameter of at least about 6 inches and a cylindrical width of at least about 36 inches.

4. The packaging assembly of claim 1, wherein the roll is cylindrical in shape and has a cylindrical diameter of about 6-30 inches and a cylindrical width of about 36-50 inches.

5. The packaging assembly of claim 1, wherein the cover is formed at least partially of a first polymer material, and the packaging material is formed of a second polymer material, wherein the second polymer material of the packaging material contacts the first polymer material of the cover.

6. The packaging assembly of claim 1, wherein the cover is formed at least partially of a polyolefin-based material, and the packaging material is formed of a polyolefin-based material, wherein the polyolefin-based material of the packaging material contacts the polyolefin-based material of the cover.

7. The packaging assembly of claim 6, wherein the polyolefin-based material of the cover is a polyethylene-based material.

8. The packaging assembly of claim 6, wherein the polyolefin-based material of the packaging material comprises at least one of polyethylene and polypropylene.

9. The packaging assembly of claim 1, wherein the packaging material has a thickness of about 1.0-2.5 mils.

10. A packaging material comprising: a film of polymer material configured to be shrink-wrapped around a solar pool cover, wherein the film of polymer material has a thickness of between about 1.0 mil and about 2.5 mils.

11. The packaging material of claim 10, wherein the packaging material is configured to be shrink-wrapped around the pool cover having a cylindrical shape with a cylindrical diameter of about 30 inches and a cylindrical width of about 48 inches.

12. The packaging material of claim 10, wherein the packaging material is configured to be shrink-wrapped around the pool cover having a cylindrical shape with a cylindrical diameter of at least about 6 inches and a cylindrical width of at least about 36 inches.

13. The packaging material of claim 10, wherein the packaging material is configured to be shrink-wrapped around the pool cover having a cylindrical shape with a cylindrical diameter of about 6-30 inches and a cylindrical width of about 36-50 inches.

14. The packaging material of claim 10, wherein the film of polymer material is formed of a polyolefin-based material.

15. The packaging material of claim 14, wherein the polyolefin-based material of the packaging material comprises at least one of polyethylene and polypropylene.

16. The packaging material of claim 10, wherein the film of polymer material is configured to be shrink-wrapped around the pool cover where the pool cover is formed at least partially of a polyethylene material, wherein the film of polymer material is configured to contact the polyethylene material of the pool cover after being shrink-wrapped.

17. The packaging material of claim 10, wherein the film of polymer material is formed of a substantially transparent material.

18. A packaging assembly comprising: a solar pool cover comprising a generally planar sheet formed at least partially of a polyethylene-based material, the cover being rolled to form a roll having a cylindrical shape with a cylindrical diameter of about 6-30 inches and a cylindrical width of about 36-50 inches; and a polyolefin-based packaging material shrink-wrapped around the roll, the packaging material having a thickness of between about 1.0-2.5 mils, wherein the packaging material contacts the polyethylene-based material of the cover.

19. The packaging assembly of claim 18, wherein the packaging material comprises at least one of polyethylene and polypropylene.

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