Water Balloon Packaging Unit and Methods

Abstract

A water balloon packaging unit and methods are provided. The water balloon packaging unit includes a packaging structure for receiving filled water balloons. The packaging structure is transitionable between a finished state and an unfinished state. In the finished state, the packaging structure and filled water balloons form the packaging unit. The water balloons are held by the packaging structure in a tight cluster by virtue of a vacuum seal implemented on the packaging structure.

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This patent application claims the benefit of U.S. Provisional Patent Application No. 61/530,445, filed Sep. 2, 2011, the entire teachings and disclosure of which are incorporated herein by reference thereto.

FIELD OF THE INVENTION

[0002] This invention generally relates to packaging and more specifically to packaging for water balloons.

BACKGROUND OF THE INVENTION

[0003] Water balloons are a mainstay in various recreational activities including social gatherings and games. Despite their popularity, however, introducing water balloons into any social event can be a daunting task given that the balloons must first be filled with water, and given that usually a large quantity of water balloons is required for an enjoyable experience. As an unfortunate result, water balloons are often omitted from an event when the task of filling them is taken into consideration.

[0004] As such, a niche has developed wherein water balloons are sold pre-filled to consumers. This niche has extended into mail order sales. However, current shipment methods do not provide a reliable solution for shipping water balloons without breakage of one or more the water balloons. Such breakage can cause water damage to the packaging of the water balloons as well as damage to adjacent packages. Therefore, there is a need in the art for a packaging unit and methods related thereto that will substantially reduce or entirely eliminate the risk of breakage of the water balloons during shipment.

[0005] The invention provides such a packaging structure and methods. These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein.

BRIEF SUMMARY OF THE INVENTION

[0006] In one aspect, the invention provides a filled water balloon packaging unit for containing filled water balloons in a tightly packed cluster. By holding the filled water balloons in said cluster, the risk of breakage of any one of the water balloons during shipment is substantially reduced or eliminated entirely. The packaging unit includes a packaging structure and filled water balloons. The packaging structure is transitionable between a finished and an unfinished state. In the finished state, the packaging structure includes an evacuated region and a non-evacuated region separated by a seal boundary. In certain embodiments, the seal boundary is a heat seal.

[0007] Other aspects, objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:

[0009] FIG. 1 is a perspective view of an embodiment of a packaging structure filled with water balloons according to the teachings of the present invention;

[0010] FIG. 2 is a front view of the packaging structure of FIG. 1 in an unfinished state;

[0011] FIG. 3 is a perspective view of the packaging structure of FIG. 2 loaded into a vacuum chamber of a vacuum sealing machine;

[0012] FIG. 4 is side view of the packaging structure of FIG. 2 sealingly contained within the vacuum chamber;

[0013] FIG. 5 is a top perspective view of the packaging structure of FIG. 2 sealingly contained within the vacuum chamber;

[0014] FIG. 6 is a top perspective view of the packaging structure in a finished state and within the vacuum chamber;

[0015] FIG. 7 is a front view of the packaging structure in the finished state; and

[0016] FIG. 8 is a front view of the packaging structure in the finished state and loaded into a shipping container.

[0017] While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

[0018] Turning now to the drawings, there is illustrated in FIG. 1 an exemplary embodiment of a packaging structure 20 containing filled water balloons 22. The packaging structure 20 and water balloons 22 together form a water balloon packaging unit 24. As will be described in greater detail below, the water balloons 22 are vacuum sealed within the packaging structure 20 such that they are forced into a tightly packed cluster.

[0019] As used herein, the term "cluster" is used to define a tightly packed grouping of filled water balloons wherein any one of the filled water balloons is not capable or substantially incapable or substantially prevented from relative motion between or separation from the remaining water balloons forming the cluster. Further, as used herein, the word "substantially" shall mean to a great extent, but not entirely.

[0020] The cluster configuration is advantageous to the extent that it substantially reduces or eliminates breakage of the filled water balloons 22 during shipment because the water balloons 22 are maintained in the cluster formation by the packaging structure 20 as explained below.

[0021] It will be recognized that the particular size and shape of the water balloons 22 is for exemplary purposes only and is not limiting on the invention. Indeed, the illustrated water balloons 22 are filled with approximately 10 to 30 ounces of water. However, in other embodiments, other volumes of water can be carried by the water balloons 22. A typical packaging structure 20 can carry a variety of amounts of water balloons 22. These amounts will vary depending upon the packaging structure 20 size and the size of the filled water balloons 22 carried thereby. It is contemplated that standardized amounts can be carried by a particular packaging structure 20 for ordering purposes. As an example, the filled water balloons 22 may be provided in 10 count, 20 count, 25 count, 30 count, 40 count, 50 count, 75 count, or 100 count quantities in any given packaging structure 20. However, it will be recognized that the lot sizes are for exemplary purposes only and other lot sizes are contemplated.

[0022] The water balloons 22 may be made from a latex material or alternatively a biodegradable latex material. However, latex-free materials are also contemplated.

[0023] The packaging structure 20 is illustrated in FIG. 1 in a finished state wherein it has been vacuum sealed to form the shipping unit 24. The shipping unit 24 tightly holds the cluster of filled water balloons 22 as illustrated. As one exemplary embodiment, the packaging structure 20 can be a two-ply vacuum sealing bag formed from nylon and polyethylene materials. The packaging structure 20 has a wall thickness about 1 MIL to about 5 MILs in the illustrated embodiment. The packaging structure can assume a variety of outer dimensions and thus any particular dimension is not limiting on the invention. However, as an example of typical sizes of packaging structures 20, the same can be supplied with an overall length dimension "L" of about 4 inches to about 24 inches and a width dimension "W" of about 4 inches to about 24 inches (see FIG. 2).

[0024] The packaging structure 20 is illustrated in the finished state at FIG. 1. As used herein, the phrase "finished state" means that all air has been evacuated by vacuum from an evacuated region 34 of the packaging structure. The evacuated region 34 is bounded by the outer edges of the packaging structure 20 and a seal boundary 32 formed therein. As will be described in greater detail below, the seal boundary 32 is a heat applied seal wherein the packaging structure 20 is fused to itself or fused to itself in addition with a chemical substance applied to the interior surfaces of the packaging structure 20 at the seal boundary 32 to enhance the heat sealing effect. Also illustrated at FIG. 1, on the other side of the seal boundary 32 is an end region 36. The end region 36 is non-evacuated and can function as a handle for the shipping unit 24 formed by the packaging structure 20 and the filled water balloons 22. Additionally, the end region 36 can include other structural features such as holes and/or grommets to hang the shipping unit 24 from a retail merchandise hook or the like.

[0025] With reference now to FIG. 2, the packaging structure 20 is shown in an unfinished state. As used herein, the phrase "unfinished state" means a state in which the packaging structure 20 has not undergone the vacuum sealing process. As shown at FIG. 2, the packaging structure 20 best resembles a bag in the unfinished state. The packaging structure 20 includes an opening 40 at an end thereof for loading the packaging structure 20 with the filled water balloons 22 prior to the vacuum sealing process.

[0026] Turning now to FIG. 3, the packaging structure 20 is illustrated within a vacuum chamber 52 of a vacuum sealing apparatus 50. It will be recognized that various styles of vacuum sealing apparatuses could be employed and thus the illustrated vacuum sealing apparatus 50 is not limiting on the invention. Once positioned within the vacuum chamber 52, the end of the packaging structure 20 is pulled into proximity with a sealing arrangement 54 used for forming the seal boundary 32 illustrated at FIG. 1.

[0027] Turning now to FIG. 4, a lid 56 of the vacuum sealing apparatus 50 is then closed to draw a vacuum on the packaging structure 20 and subsequently form the seal boundary 32 (see FIG. 1) therein. This vacuum may be on the order of -0.1 MPa to about -0.5 MPa. However, those skilled in the art will recognize that other vacuum ratings are possible depending upon packaging structure 20 size as well as the size and rating of the vacuum sealing apparatus 50. Generally, any vacuum rating is acceptable so long as it is not to an extent that it bursts the water balloons 22 within the vacuum chamber 52.

[0028] Turning now to FIG. 5, the lid 56 can incorporate a viewing window 60 to allow an operator of the vacuum sealing apparatus 50 to monitor the filled water balloons 22 during the vacuum sealing process to ensure that none have broken. Once a sufficient vacuum has been drawn upon the packaging structure containing the filled water balloons 22, the sealing arrangement 54 applies the aforementioned heat seal to form the seal boundary 32 (see FIG. 1).

[0029] Turning now to FIG. 6, once this heat seal is formed, the lid 60 (see FIG. 5) of the vacuum sealing apparatus 50 is open to access the packaging structure 20 in its finished state within the vacuum chamber 52. With reference to FIG. 7, the packaging structure 20 and filled water balloons 22 which now form the shipping unit 24 are removed from the vacuum sealing apparatus 50. At this stage, the aforementioned additional structures can be implemented into the end region 36 (e.g. holes, grommets, etc.).

[0030] Turning now to FIG. 8, once the aforementioned steps are completed, the finished shipping unit 24 is then placed in a shipping container 70. The shipping container 70 is generally a box structure that can take on a variety of dimensions depending upon the size of a particular shipping unit 24 and the number of shipping units 24 to be placed within the shipping container 70. The shipping container 70 is then sealed and shipped to a customer. From inspection of FIG. 8 it will be recognized that the shipping unit 24 generally assumes the clustered shape of the filled water balloons 22. As a result, relative movement of each water balloon 22 to the other water balloons 22 within a particular shipping unit 24 is substantially reduced or eliminated entirely. Advantageously, reduces the likelihood that the filled water balloons 22 will move about within the shipping container 70 and break during shipment to a customer. Additionally, and also due to the clustered shape of the filled water balloons 22, each shipping unit 24 presents a generally unitary fluid-like structure that permits the absorption of shock and other impact across all of the clustered water balloons 22 as opposed to any single one of said water balloons 22. This also reduces or eliminates the likelihood of breakage during shipment.

[0031] All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

[0032] The use of the terms "a" and "an" and "the" and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms "comprising," "having," "including," and "containing" are to be construed as open-ended terms (i.e., meaning "including, but not limited to,") unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., "such as") provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0033] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims

1. A method of packaging a plurality of water balloons into a water balloon packaging unit comprising the steps of: loading a plurality of water balloons into an opening of a packaging structure; vacuuming the air from the packaging structure; forming the packaging structure around the plurality of water balloons such that the plurality of water balloons becomes a cluster of water balloons held within the packaging structure; and sealing the opening of the packaging structure.

2. The method of claim 1, further comprising the step of forming a vacuum sealed packaging structure such that the cluster is a tightly packed cluster and the vacuum sealed packaging structure substantially prevents relative movement between each water balloon of the cluster of water balloons.

3. The method of claim 1, wherein the step of vacuuming further comprises vacuuming air from an evacuated region of the packaging structure, the evacuated region is bounded by outer edges of the packaging structure.

4. The method of claim 3, wherein the step of sealing forms a seal boundary, and the seal boundary further bounds the evacuated region of the packaging structure.

5. The method of claim 4, further comprising the step of forming an end region disposed oppositely from the evacuated region and across the seal boundary.

6. The method of claim 5, further comprising the step of forming a handle in the end region.

7. The method of claim 5, further comprising the step of cutting a hole into the end region.

8. The method of claim 1, further comprising the step of applying heat to material of the packaging structure such that the material of the packaging structure fuses together thereby creating an air tight seal boundary.

9. The method of claim 8, wherein the step of applying heat is enhanced by pretreating the material of the packaging structure with a chemical substance that enhances the heat at the seal boundary.

10. The method of claim 1, wherein each water balloon of the plurality of water balloons contain between 10 and 30 ounces of water.

11. The method of claim 1, wherein the plurality of water balloons comprises between 10 and 100 water balloons.

12. A water balloon packaging unit comprising: a packaging structure including an opening; a plurality of water balloons disposed within the packaging structure; and a seal, sealingly enclosing the opening of the packaging structure; wherein the packing structure is vacuumed sealed such that an evacuated region is formed inside the opening of the packaging structure and around the plurality of water balloons such that the plurality of water balloons forms a cluster of water balloons.

13. The water balloon packaging unit of claim 12, wherein the cluster of water balloons is a tightly packed cluster and the evacuated region prevents relative movement between each water balloon of the cluster of water balloons, the cluster of water balloons is a generally unitary fluid-like structure.

14. The water balloon packaging unit of claim 12, wherein each water balloon of the plurality of water balloons is made from a biodegradable latex material.

15. The water balloon packaging unit of claim 12, wherein the packaging structure is a two-ply vacuum sealing bag formed from nylon and polyethylene.

16. The water balloon packaging unit of claim 12, wherein a wall thickness of the packaging structure is between 0.75 to 5.25 MILs.

17. The water balloon packaging unit of claim 12, wherein the packaging structure is between 4 inches and 24 inches in length.

18. The water balloon packaging unit of claim 12, wherein the packaging structure is between 4 inches and 24 inches in width.

19. The water balloon packaging unit of claim 12, wherein the plurality of water balloons comprises between 10 and 100 water balloons.

20. A method of preventing breakage of water balloons packaged in a shipping container comprising the steps of: loading a plurality of water balloon packaging units into a shipping container, each water balloon packaging unit comprising: a packaging structure including an opening; a plurality of water balloons disposed within the packaging structure; and a seal, sealingly enclosing the opening of the packaging structure; wherein the packing structure is vacuumed sealed such that an evacuated region is formed inside the opening of the packaging structure and around the plurality of water balloons such that the plurality of water balloons forms a cluster of water balloons, the cluster of water balloons is a generally unitary fluid-like structure; and wherein the cluster of water balloons is a tightly packed cluster and the evacuated region prevents relative movement between each water balloon of the cluster of water balloons.

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