U.S. patent application number 09/878698 was filed with the patent office on 2002-12-12 for reusable inflatable packing system with tab valve.
Invention is credited to Russo, Thomas L..
Application Number | 20020185403 09/878698 |
Document ID | / |
Family ID | 25372609 |
Filed Date | 2002-12-12 |
United States Patent
Application |
20020185403 |
Kind Code |
A1 |
Russo, Thomas L. |
December 12, 2002 |
Reusable inflatable packing system with tab valve
Abstract
A reusable, inflatable packing system comprised of a
multi-chambered shipping pad formed of first and second outer film
layers and a third, central layer located between at least a
portion of the outer layers, and having two or four discrete
inflatable zones, wherein each zone is further comprised of a
plurality of inflatable chambers, preferably conical in shape. The
multi-chamber design facilitates absorption of impact upon the pad
by permitting redistribution of an inflation gas, e.g., air, from
an area of impact to a non-impacted area removed a distance
therefrom within the same zone. The flow of inflation gas into
and/or out of the pad zones is controlled by at least one tab valve
assembly, each of which is comprised of a main and a working tab
valve frame, which main frame is mounted within an outer film layer
while the working frame is mounted in the central film layer.
Sealing the central film along its opposed longitudinal ends to
respectively, the first and second outer films forms air pockets
adapted for directing air entering through the valve frames into
respective zones of the pad. The tab valve assembly contains no
moving parts and is closed or opened by snapping together or
peeling apart the two valve frames comprising the assembly. When
snapped together, the security of the snap seal is ensured by the
use of a three point locking system molded into the valve
frames.
Inventors: |
Russo, Thomas L.; (Rutland,
VT) |
Correspondence
Address: |
Intellectual Property Group
Greenberg Traurig, LLP
885 Third Avenue
New York
NY
10022
US
|
Family ID: |
25372609 |
Appl. No.: |
09/878698 |
Filed: |
June 11, 2001 |
Current U.S.
Class: |
206/522 ;
206/586; 206/594 |
Current CPC
Class: |
B65D 81/052 20130101;
Y02W 30/807 20150501; Y02W 30/80 20150501 |
Class at
Publication: |
206/522 ;
206/586; 206/594 |
International
Class: |
B65D 081/02 |
Claims
What is claimed is:
1. An impact-resistant packing system for protecting articles
during shipping from shock and damage, said system including a
reusable, inflatable shipping pad, said pad comprising first and
second outer film layers and a third, central film layer interposed
between said first and said second film layers, said first and said
second film layers being secured together along an outer perimeter
thereof to define an inner volume within said pad and said third,
central film layer being secured at opposed ends to, respectively
said first and said second film layers within said inner volume in
a location selected to form at least two separate zones within said
inner pad volume, said pad further comprising at least one tab
valve assembly configured and adapted to permit repeated
independent inflation and deflation of each said zone.
2. The system of claim 1, wherein said pad comprises a single tab
valve assembly configured and adapted to form two separately
repeatedly inflatable and deflatable zones within said pad inner
volume.
3. The system of claim 1, wherein each said tab assembly comprises
a first and a second tab valve frame, wherein said first frame is
mounted in said first or said second outer film layer, and said
second frame is mounted in said third, central film layer adjacent
said first frame and positioned to permit a snap-locking engagement
therewith.
4. The system of claim 3, wherein each said tab valve frame
comprises a frame portion provided with a tab portion extending
therefrom, and wherein said frame portion further comprises a valve
seat snap lock, a valve seat opening, an air portal, a valve seat
locking ridge, and a valve seat body groove.
5. The system of claim 4, wherein said valve frame tab portions are
adapted to permit closing and opening of said valve assembly by
respectively snapping together and pulling apart said valve frames
by use of said tab portions.
6. The system of claim 4, wherein said valve seat body groove is
configured and adapted for capturing a valve seat locking ridge of
a corresponding valve frame of said tab valve assembly to assist in
securing said first and said second tab valve frames together.
7. The system of claim 4, wherein said valve seat snap lock is
configured and adapted to substantially completely seal an air
portal of a corresponding valve frame of said tab valve
assembly.
8. The system of claim 1, wherein each said zone is comprised of a
plurality of inflatable chambers configured and adapted to
redistribute an inflation gas contained therein from one or more
chambers compressed by an external impact to at least one
contiguous chamber which is not impacted.
9. The system of claim 8, wherein said chambers are each
substantially conical in shape.
10. The system of claim 9, wherein a height ratio of the conical
chambers is balanced by alternating between restricted entry cones
and open entry cones.
11. The system of claim 1, wherein said pad further comprises a
cut-out handle area adjacent one end of said pad, said handle area
adapted for separating the inflatable zones and for creating an
alternate relief area for inflation gas compressed due to an impact
upon a remaining main fill area of the pad.
12. The system of claim 1, wherein said first, said second and said
third film layers are each formed from a plastic film-forming
material.
13. The system of claim 1, wherein said film layers are secured
together by heat sealing, sonic welding or other electrical bonding
process, by an adhesive, or by a chemical bonding process.
14. An impact resistant packing system for protecting articles
during shipping from shock and damage, said system including a
reusable, inflatable two-zone shipping pad, said pad comprising
first and second outer film layers secured together along an outer
perimeter thereof to form an inner pad volume, and a third, central
film layer interposed between said first and said second film
layers within said pad volume and secured, at opposed ends,
respectively to said first and said second film layers in a
location selected to form two separate zones within said volume,
said first, second and third film layers being comprised of a
plastic film forming material, said pad further comprising a tab
valve assembly comprising a first main valve frame and a second
working valve frame, respectively, said valve frames configured and
adapted to be snapped together and pulled apart to permit repeated
independent inflation and deflation of each said zone.
15. The system of claim 1, wherein said pad comprises two separate
tab valve assemblies configured and adapted to form a total of four
separately repeatedly inflatable and deflatable zones within said
pad inner volume.
16. The system of claim 15, wherein each said tab assembly
comprises a first and a second tab valve frame, wherein said first
frame is mounted in said first or said second outer film layer, and
said second frame is mounted in said third, central film layer
adjacent said first frame and positioned to permit a snap-locking
engagement therewith.
17. The system of claim 16, wherein each said tab valve frame
comprises a frame portion provided with a tab portion extending
therefrom, and wherein said frame portion further comprises a valve
seat snap lock, a valve seat opening, an air portal, a valve seat
locking ridge, and a valve seat body groove.
18. The system of claim 17, wherein said valve frame tab portions
are adapted to permit closing and opening of said valve assembly by
respectively snapping together and pulling apart said valve frames
by use of said tab portions.
19. The system of claim 17, wherein said valve seat body groove is
configured and adapted for capturing a valve seat locking ridge of
a corresponding valve frame of said tab valve assembly to assist in
securing said first and said second tab valve frames together.
20. The system of claim 17, wherein said valve seat snap lock is
configured and adapted to substantially completely seal an air
portal of a corresponding valve frame of said tab valve
assembly.
21. The system of claim 15, wherein each said zone is comprised of
a plurality of inflatable chambers configured and adapted to
redistribute an inflation gas contained therein from one or more
chambers compressed by an external impact to at least one
contiguous chamber which is not impacted.
22. The system of claim 21, wherein said chambers are each
substantially conical in shape.
23. The system of claim 22, wherein a height ratio of the conical
chambers is balanced by alternating between restricted entry cones
and open entry cones.
24. The system of claim 15, wherein said pad further comprises a
cut-out handle area adjacent one end of said pad, said handle area
adapted for separating the inflatable zones and for creating an
alternate relief area for inflation gas compressed due to an impact
upon a remaining main fill area of the pad.
25. The system of claim 15, wherein said first, said second and
said third film layers are each formed from a plastic film-forming
material.
26. The system of claim 15, wherein said film layers are secured
together by heat sealing, sonic welding or other electrical bonding
process, by an adhesive, or by a chemical bonding process.
27. An impact resistant packing system for protecting articles
during shipping from shock and damage, said system including a
reusable, inflatable four-zone shipping pad, said pad comprising
first and second outer film layers secured together along an outer
perimeter thereof to form an inner pad volume, and a third, central
film layer interposed between said first and said second film
layers within said pad volume and secured, at opposed ends,
respectively to said first and said second film layers in a
location selected to form four separate inflatable zones within
said volume, said first, second and third film layers being
comprised of a plastic film-forming material, said pad further
comprising two tab valve assemblies, wherein a first said assembly
is associated with a first and a second inflatable zone of said pad
and a second said assembly is associated with a third and fourth
inflatable zone of said pad, each said tab valve assembly
comprising a first main valve frame and a second working valve
frame, respectively, said valve frames configured and adapted to be
snapped together and pulled apart to permit repeated independent
inflation and deflation of each said zone associated therewith.
Description
FIELD OF THE INVENTION
[0001] The invention is directed to an impact-resistant packing
system for protecting articles during shipping from shock and
damage and, more particularly, to a reusable, inflatable multi-zone
shipping pad wherein control of the inflation gas within the pad
zones is respectively provided by one or more tab valve assemblies
adapted for permitting independent inflation/deflation of each said
zone.
BACKGROUND OF THE INVENTION
[0002] When articles are packaged in a container for shipping, void
spaces are typically created between the article and the inner
surface of the container. Packaged articles come in a variety of
shapes, thus producing a plurality of irregularly shaped voids. A
packing material is thus commonly inserted within these voids to
cushion and protect the packaged article during shipping.
[0003] It is known, therefore, to at least partially surround
shipped articles with packing materials having a variety of shapes
and sizes such as Styrofoam.RTM. "chips," injected Styrofoam.RTM.
moldings, "bubble" mats and other energy absorptive materials.
"Bubble" mats are intended to wrap close to the shipped item,
providing an enclosure that protects the item, but the spaces
between the "bubble" mat protected item and the interior surfaces
of the container are largely filled with a volume of a loose fill
type material such as Styrofoam.RTM. "chips," or other particulate
packing materials that provide a loose fill. The packaged article
may settle during transport, reducing the cushioning effect.
Moreover all of the above-described packing materials are
themselves voluminous to both ship and store. In addition, they
could create waste disposed problems with attendant problems of
environmental degradation.
[0004] In an effort to overcome the problems noted above, various
forms of inflated cushions have been utilized. Such cushions are
well known and have been commonly used for some time in the
shipment of goods. Several useful examples of inflatable cushions
are illustrated in, for example, U.S. Pats. No. 5,427,830;
5,447,235 and 5,487,470 to David A. Pharo. The inflatable packaging
systems described therein, and throughout the prior art have been
faced with a number of design challenges, however. For example,
some of the inflatable cushions include only a single inflatable
zone, such that a failure at any location in the packaging material
will lead to a total deflation of the system, thus resulting in a
total loss of function. Other examples include cushions with a
plurality of interconnected inflatable zones, i.e., providing, a
"quilted" appearance to the cushion. This arrangement still remains
prone, however, to the deflation problem described above. Still
other embodiments comprise a plurality of discrete, i.e., separate,
chambers, which do not, as is desirable, permit redistribution of
air within the pad, i.e., from one chamber to another, upon impact
to the outer surface of one or more such chambers.
[0005] Additionally, many such prior art inflatable packing systems
are further subject to other problems caused due to the use of
valve systems that may channel air under impact pressure directly
toward the valve cap, thus forcing open the valve, or self-sealing
valves that are most effective when cushions maintain a consistent
pressure once inflated. This consistent pressure provides a back
pressure helping to make the valve self-sealing. Thus, the
dimensions of these inflatable cushions may find it difficult to
adjust to different sized voids within a packing container. Still
further, due to the very nature of the self-sealing valves, such
inflatable devices are typically not readily reusable since it is
difficult, if not impossible, to empty the air out of an inflated
cushion or pad without reducing the useful life of each cushion,
i.e., puncturing the cushion or disrupting the self-sealing
properties.
[0006] It is thus readily apparent that there exists a long-felt
need, which is satisfied by the present invention as described
herein, for a reliable, efficient, adjustably inflatable protective
packaging system, with a reusable multi-locking valve, for
protecting fragile and/or valuable items during shipping. The
present invention meets these requirements with a simple design
that is readily and conveniently manufactured from inexpensive
starting materials. It may be used, and reused, for an unlimited
variety of shapes and sizes of product being packaged. The system
includes a protective inflatable pad that is self-adapting to the
size and shape of the item being packaged, which will not settle
during shipment, and that will secure itself around the object to
be shipped while substantially filling all of the void spaces
between the object and the outer container. The system of the
invention is thus relatively simple to ship and store and it is
cost competitive with presently existing systems.
SUMMARY OF THE INVENTION
[0007] It is therefore an object of the invention to provide an
inflatable, reusable packing system comprised of a shipping pad
formed with at least two separately inflatable and deflatable
zones, and further wherein each said zone is comprised of a
plurality of interconnected air chambers adapted to facilitate
absorption of impact to the pad and to redistribute air from
chambers compressed by the impact to alternate air chambers located
within each corresponding zone.
[0008] It is another object of the invention to provide the
chambers with a conical shape or configuration such that, by
balancing the height ratio of the conical chambers it is possible
to provide security in the event one of the air chambers is
punctured in that adjacent unaffected (i.e., unpunctured) zones
will assist in maintaining the width of the pad upon such an event
due to the balancing effect provided by the alternating high (i.e.,
raised) and (relatively) low cone portions.
[0009] It is a further object of the invention to balance
restricted entry cones and open entry cones having, respectively,
relatively narrow and relatively wide air entry passages, e.g., by
alternating these cone types within a particular zone or even
throughout the entire pad, to provide additional security against
accidental deflation.
[0010] It is another object of the invention to provide an
inflatable, reusable shipping pad formed with a cut-out handle
portion that separates the various inflatable zones while creating
an alternate relief area for air compressed by an impact to the
main fill area.
[0011] It is still another object of the invention to provide an
inflatable, reusable shipping pad wherein the flow of air into the
pad is controlled by at least one "floating" tab valve assembly
which, due to its relatively planar construction, allows the valve
assembly to withstand a significantly greater air pressure caused
due to impact, i.e., causing compression, upon one of the inflated
zones of the pad, without forcing the valve open.
[0012] It is an additional object of the invention to provide an
inflatable, reusable packing system utilizing a valve assembly, as
described above, having a plurality of distinct locking mechanisms
configured and adapted to improve the valve integrity.
[0013] These and other objects of the invention are achieved
through the use of an inflatable, reusable packing system as
described and illustrated herein.
[0014] In a first embodiment the invention is directed to a two
zone shipping pad comprising a single tab valve assembly. In a
further embodiment, the packing system of the invention comprises a
four zone shipping pad utilizing two separate tab valve assemblies
wherein each said assembly controls the flow of air into and out of
two of said zones. The four zone pad offers additional protection
from accidental deflation throughout the shipping process.
[0015] The system of the invention was designed with multiple
zones, each formed with multiple air chambers, in a single shipping
pad to allow each pad the ability to absorb impact by distributing
air to chambers not compressed by the impact. That is, the pad
comprises at least two inflation zones, and each said zone may be
further broken down into a plurality of inflatable chambers. The
shipping pads of the invention can be manufactured in a variety of
shapes and sizes, and from a variety of materials as well. FIGS. 14
and 21, illustrating, respectively, a two zone and a four zone pad,
display an exemplary geometric design for the pad chambers wherein
said chambers are conically shaped. The invention is not limited,
however, to the particular arrangement portrayed in the subject
drawing figures. That is, whereas a conical configuration is
preferred, the chambers of the system of the invention are not
limited to a conical shape and may, instead, be configured in a
variety of alternate shapes. In the illustrated embodiment, the pad
thickness can be increased by making the conical chambers larger.
Pads can also be made longer and shorter by adding or subtracting
cones from a design layout. This flexibility of design thus
provides a custom system useful for a variety of applications,
while still offering the same degree of zone security.
[0016] The ability to be inflated or deflated (see, e.g., FIG. 17,
FIG. 11) as the task requires, provides a reusable system for all
users in a shipping cycle. The shipping pad of the invention can be
stored deflated when not in use, thus reducing storage space
requirements. The shipping pads may additionally, if desired, be
folded (see FIG. 27) prior to being placed in the shipping carton,
and then inflated to provide a profile wider than that of a single
pad without the necessity of adding additional pads.
[0017] The packing system of the invention makes use of a simple
yet novel tab valve assembly that has no mechanical interior parts.
Each said valve assembly comprises two tab valve frames, i.e., a
main frame and a work frame, located one above the other and an air
pocket for each zone created by a dividing film (No. (31) in FIG.
12 and No. (55) in FIG. 19) in which the work frame is installed.
The valve frames are e.g., heat welded (they may also be attached
to the film via an alternate method such as electrical or chemical
bonding) to the appropriate film level as shown, e.g., in FIG. 15
and FIG. 22, such that the main frame (see (21) in FIG. 15) is
positioned above the working frame (see (20) in FIG. 15). The
working frame is, however, rotated 180.degree. to the main frame in
the same plane as the main frame, thus allowing a single frame
design to provide two profiles, as shown in FIGS. 1 and 2. This
arrangement allows the frame bodies to snap together as shown,
e.g., in FIGS. 3 and 10, to form the tab valve assembly.
[0018] The system of the invention, comprising a shipping pad with
at least one tab valve assembly, is inflated and deflated through
the use of the tab-valve assembly and requires no special equipment
to operate. The pads can be filled by mouth or with compressed air,
allowing the end user to store, reuse and recycle this packing
fill. Security against unintended deflation is thus provided
through zone design and the snap locking of the valve frames
together as further described herein. The above-described valve
system allows air into each zone through a controlling tab valve
frame (see (20), (21) in FIG. 15), and can secure the air in the
shipping pad by snapping the two valve frames together as shown in
FIG. 16. Pressing down on the working frame tab ((2) in FIG. 2),
and lifting up on the main frame tab ((2) in FIG. 1), will snap
open the valve assembly and allow the pad to be deflated.
[0019] The four-zone embodiment of the shipping pad system of the
invention uses two such tab valve assemblies, wherein each said
assembly controls the flow into and out of two pad zones (see,
e.g., FIGS. 22 and 23).
[0020] The above-described tab valve can be used in a variety of
other applications where air containment for simple inflation is
required, e.g., for beach and/or pool toys.
[0021] The packing system of the invention may, moreover, be
printed with a company logo inside and out, thus advertising a
company's policy to conserve energy and recycle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The foregoing objects and other advantages of the present
invention will be more fully understood from the following detailed
description and reference to the appended drawings, wherein:
[0023] FIG. 1 is a top plan view of a first tab valve frame
(referred to herein as the "main" valve frame) which, when snapped
together with a second tab valve frame (referred to herein as the
"working" or "work" frame and illustrated in FIG. 2) located below
the main frame, and which is identical to the main frame but
rotated 180.degree. in the same plane as the main frame, forms a
tab valve assembly;
[0024] FIG. 2 is a top plan view of the tab valve working frame,
illustrating its orientation of this frame with regard to the first
(main) frame shown in FIG. 1;
[0025] FIG. 3 is a top plan view of a tab valve assembly formed by
snapping together the main and working valve frames illustrated in
FIGS. 1 and 2, respectively;
[0026] FIG. 4 is a perspective view of the tab valve assembly shown
in FIG. 3;
[0027] FIG. 5 is a perspective view of the tab valve main frame
shown in FIG. 1;
[0028] FIG. 6 is a perspective view of the tab valve working frame
shown in FIG. 2;
[0029] FIG. 7 is a bottom plan view of a tab valve main frame;
[0030] FIG. 8 is a bottom perspective view of a tab valve
frame;
[0031] FIG. 9 is a sectional view through the first and second
(i.e., the "main" and "working") valve frames, illustrating the
relative position of these frames when the tab valve assembly is in
the open position;
[0032] FIG. 10 is a sectional view through the first and second
valve frames shown in FIG. 9 illustrating the relative position of
these frames when the tab valve assembly is in the closed
position;
[0033] FIG. 11 is a perspective view of a two-zone shipping pad
formed in accordance with the invention;
[0034] FIG. 12 is a perspective view of the film layer arrangement
used in forming the two zone shipping pad of the invention;
[0035] FIG. 13 is a view similar to FIG. 12 but additionally
illustrating the positioning of the main and working valve frames
in their respective film layers;
[0036] FIG. 14 is a top plan view of a two-zone shipping pad formed
in accordance with the invention;
[0037] FIG. 15 is a sectional view through a tab valve assembly as
mounted within the corresponding film layers of a two-zone shipping
pad, showing the tab valve assembly in the open position;
[0038] FIG. 16 is a view similar to that in FIG. 15, but
illustrating the tab valve assembly in the closed position;
[0039] FIG. 17 is a perspective view of a two-zone shipping pad
produced according to the invention, in an inflated condition;
[0040] FIG. 18 is a perspective view of a four-zone shipping pad
formed using two tab valve assemblies in accordance with the
invention;
[0041] FIG. 19 is a perspective view of the film layer arrangement
used in forming a four-zone shipping pad according to the
invention;
[0042] FIG. 20 is a view similar to FIG. 19 but additionally
illustrating the positioning of two "sets" or pairs of valve
frames, used in forming two separate tab valve assemblies adapted
for creating four separate inflatable zones, in their respective
film layers;
[0043] FIG. 21 is a plan view of a four-zone shipping pad produced
in accordance with the invention;
[0044] FIG. 22 is a sectional view through two tab valve assemblies
mounted within the corresponding film layers of a four-zone
shipping pad showing both assemblies in the open position;
[0045] FIG. 23 is a view similar to that in FIG. 22 illustrating
the two tab valve assemblies in the closed position;
[0046] FIG. 24 is a perspective view of a four-zone shipping pad
produced in accordance with the invention, in an inflated
condition;
[0047] FIG. 25 is a perspective view illustrating an outer shipping
container (partially broken away) containing a package therein
cushioned by shipping pads produced in accordance with the
invention, located at the corners and along the sides of the inner
container and extending upwardly and downwardly a sufficient
distance to cover at least a portion of the top and the bottom of
the inner package;
[0048] FIG. 26 is a view similar to that of FIG. 25 but showing a
smaller inner container protected by shipping pads located only in
the corners of the outer container; and
[0049] FIG. 27 illustrates a two zone shipping pad folded to fill a
void thicker than a single pad.
DETAILED DESCRIPTION OF THE INVENTION
[0050] The invention is therefore directed to an inflatable and
reusable multi-zone shipping pad wherein inflation and deflation of
each said zone is independently controlled by a novel tab valve
assembly comprised of a first, "main" valve frame and a second,
"working" valve frame, and further wherein each said zone is
comprised of a plurality of, preferably cone-shaped, chambers
configured and adapted to help absorb an impact thereupon and, upon
such impact, to redistribute air within the pad from a compressed
zone or chamber to a non-compressed area, for improving the
performance and reliability of the pad.
[0051] Turning now to a description of the components illustrated
in the drawing figures, which is thereafter followed by a
discussion of how these various components work together in the
invention, FIG. 1 illustrates tab valve main frame (1), comprised
of a tab portion (2), frame portion (3), valve seat snap lock (4),
valve seat opening (5), air portal (6) and valve seat locking ridge
(7).
[0052] FIG. 2 illustrates tab valve working frame (8) including, as
in main frame (1) discussed above, tab portion (2), frame portion
(3), valve seat snap lock (4), valve seat opening (5), air portal
(6) and valve seat locking ridge (7).
[0053] FIG. 3 illustrates a tab valve assembly formed by snapping
together the tab valve main frame (1) and the working valve frame
(8) shown in FIGS. 1 and 2. The assembly is shown in the snapped
closed position. Illustrated is main frame portion (3), valve seat
snap lock (4), valve seat opening (5), air portal (6), and valve
seat locking ridge (7).
[0054] FIG. 4 provides a perspective view of the main and working
tab valve frames snapped together to form the tab valve assembly.
The main, i.e., top, valve frame (1) is in the upright position and
is snapped (and locked, in a manner described below) into the
second (working) valve frame (8) which is rotated 180.degree. in
the horizontal plane from the position of the main frame. Shown is
tab portion (2) of the main valve frame, tab valve frame portion
(3), valve seat snap lock (4), valve seat opening (5), air portal
(6), and valve seat locking ridge (7).
[0055] FIG. 5 shows, in perspective, a tab valve main frame (1),
with tab portion (2) tab valve frame portion (3), valve seat snap
lock (4), valve seat opening (5), air portal (6), and valve seat
locking ridge (7).
[0056] FIG. 6 illustrates the tab valve working frame (8) in
perspective, showing tab portion (2), tab valve frame portion (3),
valve seat snap lock (4), valve seat opening (5), air portal (6),
and valve seat locking ridge (7).
[0057] FIG. 7 is a rear plan view of a tab valve main frame (1)
illustrating the frame portion (3), air portal (6), valve seat stem
snap lock (9) and valve seat exterior body (10).
[0058] FIG. 8 is a rear perspective view of a tab valve main frame
(1), illustrating valve frame portion (3), air portal (6), valve
seat stem snap lock (9), valve seat exterior body (10), and valve
seat body groove (11) which is configured and adapted to permit an
interlocking, i.e., "snap" fit with locking ridge (7) on a
corresponding valve frame.
[0059] FIG. 9 is a sectional view through the two tab valve frames
of a tab valve assembly, showing the valve assembly in the open
position. Shown are main valve frame (1) and working valve frame
(8). Also illustrated are tab valve frame portion (3), valve seat
snap lock (4), valve seat opening (5), air portal (6), and valve
seat locking ridge (7). Also shown are valve seat stem snap lock
(9) for blocking portal (6) when the tab valve assembly is closed,
valve seat exterior body (10), and valve seat body groove (11).
[0060] FIG. 10 shows a sectional view through two tab valve frames,
with the valve assembly in the closed position. Shown are main
valve frame (1), and working valve frame (8), tab valve frame
portion (3), valve seat opening (5), valve seat locking ridge (7),
valve seat stem snap lock (9), valve seat exterior body (10), valve
seat body groove (11), air portal seal (13), which is snap locked,
air portal seat snap lock (14), and valve seat body (15) which is
also snap locked.
[0061] The valve frames are thus locked together by a three-point
locking system wherein: (a) valve seat stem snap lock (9) locks
into air portal (6) on working frame (8); (b) valve seat snap lock
(4) on working frame (8) locks into air portal (6) on main frame
(1); and (c) there is an interlocking fit between valve seat body
groove (11) and valve seat locking ridge (7).
[0062] FIG. 11 is a perspective view of a two zone shipping pad
layout, and its associated tab valve assembly, as formed in
accordance with the invention. Shipping pad zone one (28) retains
air delivered to one-half of the pad area, which air is supplied by
manipulating the tab portion of the main valve frame (21) (see
FIGS. 15, 16) to permit the air to flow into said first zone. Pad
zone two (27) retains air delivered to the other one-half pad area,
wherein the air is supplied by manipulating the tab valve on the
working frame (20) (see FIGS. 15, 16) to permit the air to flow
therein. A zone one air pocket (25) is created by pocket notch
(23). A zone two air pocket (22) is created by pocket notch (24).
The central handle film (described more fully below) separates the
air and directs it to the appropriate zone, depending upon the
orientation of the tab valve assembly. Tab valve work frame (20) is
installed into the shipping pad handle central film (see 31 in FIG.
12). Tab valve main frame (21) is installed in the shipping pad
handle top film (see 30 in FIG. 12). Handle cut out (26) separates
the two zones.
[0063] FIG. 12 provides a perspective view of a two-zone pad film
layout. Lower pad film (29) determines the lower pad dimension from
side to side and top to bottom. Upper pad film (30) determines the
upper pad dimension from side to side and top to bottom. The
central film (31) in the handle portion of the two zone shipping
pad (i.e., referred to as the central handle film) creates two air
chambers that separate and supply air to each of the two zones. The
material used to form the film layers of both the two-zone and the
four-zone shipping pads of the invention is the type of plastic
material well known in the art for forming inflatable packing
materials. Useful film forming materials include, but are not
limited to, vinyl, polyethylene, polypropylene, polyester,
metallized nylons or other similar material often referred to as
"Mylar," and numerous other air-impervious plastic film
compositions. The invention is not limited, however, to the
specific film-forming materials listed above as numerous
alternative materials would be readily apparent to one of ordinary
skill in this art. The particular "plastic" material chosen is not
critical to the invention and may be varied among a variety of
these known materials in accordance with the intended application
for the packing system of the invention
[0064] FIG. 13 is similar to FIG. 12 but shows the relative
position of the two valve frames in their respective films. Central
film (31) is located in the handle portion of the two zone shipping
pad, i.e., separated from the remainder of the pad by handle
cut-out (26). It creates two air chambers that each separate and
supply air to a respective one of the two zones. As shown, tab
valve work frame (20) is installed into shipping pad handle central
film (31). Tab valve main frame (21) is installed in the shipping
pad handle top film (30).
[0065] Installation of the valve frames is preferably, but not
necessarily, carried out by cutting a hole in the film of a
suitable size, inserting the valve frame therein, and then securing
the frame to the film with the use of, e.g., a heat seal, an
adhesive, a sonic weld, or other electric bonding process, or by a
chemical bonding process. If desired, the valve frames may be
pre-installed at designated locations upon rolls of the film
material used in forming the pad layers, whereupon the respective
layers are simply matched, cut to an appropriate length, and sealed
along their edges and within their interior as required to produce
the discrete zones and the respective chambers. In an alternate
procedure the film layers (without the valve frames) are matched
and cut to an appropriate length, i.e., from a supply roll of such
material. Thereafter, the film layers are subjected, at one or more
work stations, to a series of processing steps whereupon (not
necessarily in the order described): (1) holes are cut in the films
wherein the valve frames are installed and sealed to the
surrounding film, (2) a handle cut-out is formed, (3) the outer
films are sealed along at least their peripheral edges, i.e., by
the methods described above, and (4) the central film is sealed at
its respective longitudinal edges to, respectively, the top and
bottom outer films, to form the respective air chambers.
[0066] FIG. 14 is a top plan view of a two zone shipping pad layout
including its tab valve assembly. Shipping pad zone one (28)
retains air delivered to one-half the pad area by manipulating the
tab portion on main valve frame (21). Zone two (27) of the shipping
pad retains air delivered to the other one-half of the pad area by
manipulating the tab portion on the work valve frame (20). A zone
one air pocket (25) is created by pocket notch (23) wherein the
upper film layer (30) is secured to one edge of central film (31),
e.g., by heat sealing. Zone two air pocket (22) is created by
pocket notch (24) wherein lower film layer (29) is secured to the
other (opposed) edge of central film (31). The central film located
within the handle area (i.e., the central handle film) separates
the air and directs it to the first and second zones, depending on
the positioning of the components of the tab valve assembly. Tab
valve work frame (20) is installed into shipping pad handle central
film (see (31) in FIG. 12). Tab valve main frame (21) is installed
in the shipping pad handle top film (see (30) in FIG. 12). Handle
cut out (26) separates the zones.
[0067] FIG. 15 is a sectional view through a two zone shipping pad
handle portion showing the tab valve assembly in the open position.
Shipping pad zone one (see (28) in FIG. 14) retains air delivered
to one-half of the pad area, which air is supplied by manipulating
the tab portion on valve main frame (21). Zone two (27) of the
shipping pad, which comprises the remaining one-half of the pad
area, retains air which is supplied by manipulating the tab portion
on work frame (20). A zone one air pocket (25) is created by pocket
notch (23) formed, as noted above, by sealing together the upper
and the central film layers. Zone two air pocket (22) is created by
pocket notch (24) formed by sealing the lower and the central film
layers. The central handle film directs the air to the first and
second zones depending upon the positioning of the components of
the tab valve assembly. Tab valve work frame (20) is installed into
the shipping pad handle central film (see (31) in FIG. 12). Tab
valve main frame (21) is installed in the shipping pad handle top
film (see (30) in FIG. 12).
[0068] FIG. 16 is a sectional view through a two zone shipping pad
handle assembly including the tab valve assembly, showing the valve
assembly in the closed position. As described above, shipping pad
zone one (28) retains air delivered to one-half of the pad area,
which air is supplied by manipulating the tab portion on main valve
frame (21). Shipping pad zone two (27) retains air delivered to the
other half of the pad area, wherein the air is supplied by
manipulating the tab portion of work valve frame (20). Zone one air
pocket (25) is created by pocket notch (23). Zone two air pocket
(22) is created by pocket notch (24). The central handle film
directs air to the first and second zones, depending upon the
arrangement of the components of the tab valve assembly. Tab valve
work frame (30) is installed into shipping pad handle central film
(see (31) in FIG. 12). The tab valve main frame (21) is installed
in the shipping pad handle top film (see (30) in FIG. 12).
[0069] FIG. 17 provides a perspective view of an inflated two zone
(27, 28) shipping pad with its tab valve assembly. Shown are tab
valve work frame (20), tab valve main frame (21), zone one air
pocket (25) created by pocket notch (23), zone two air pocket (22),
created by pocket notch (24) and handle cut out (26) which
separates the two zones.
[0070] FIG. 18 provides a perspective view of an alternate
embodiment of the invention comprising a four zone shipping pad
layout formed with the use of two tab valve assemblies, with each
said assembly controlling the flow of air into and out of two of
the four pad zones. Shipping pad zone one (50) retains air
delivered to one-fourth of the pad area, which air is supplied by
manipulating the tab portion of the valve main frame (41) in the
first of the two tab valve assemblies. Shipping pad zone two (51)
retains air delivered to another one-fourth of the pad area. The
air is directed therein by manipulating the tab portion of valve
work frame (40) which, in conjunction with main frame (41), forms
the first tab valve assembly. A zone one and two air pocket (47) is
created by pocket notch (45). The central zone film separates the
air and directs air into zones one and two, respectively, depending
on the arrangement of the components of the first tab valve
assembly.
[0071] Continuing with the description of FIG. 18, shipping pad
zone three (48) retains air delivered to another one-fourth of the
pad area, wherein the air is supplied by manipulating the tab
portion of valve main frame (43) which forms a component of the
second tab valve assembly (which also includes tab valve main frame
(42) as described below). Shipping pad zone four (49) retains air
delivered to the remaining one-fourth of the pad area. The air is
supplied by manipulating the tab portion valve main frame (42). The
central zone film (see (55) in FIGS. 19, 20) separates the air and
directs it to zones three and four depending upon the arrangement
of the components of the second tab valve assembly. Tab valve work
frame (40) is installed into shipping pad handle central zone film
(see (55) in FIG. 20). Tab valve main frame (41) is installed in
the shipping pad handle top film (see (30) in FIG. 20). Together,
frames (40, 41) form the first of two tab valve assemblies used in
forming the four-zone pad according to the invention. Tab valve
work frame (42) is installed into the shipping pad handle central
zone film (see (55) in FIG. 20). Tab valve main frame (43) is
installed in the shipping pad handle top film (see (30) in FIG.
19). Frames (42, 43) form the second tab valve assembly. Handle cut
out (52) separates the zones.
[0072] In FIG. 19 lower pad film (29) determines the lower pad
dimension from side to side and top to bottom. Upper pad film (30)
determines the upper pad dimension from side to side and top to
bottom. The central zone film (55) determines the four zone layout.
Its film size matches the full pad dimension from side to side and
top to bottom in at least the handle portion of the four-zone pad.
As shown, it creates air chambers that separate and supply air to
each of the four zones.
[0073] FIG. 20 is a view similar to that of FIG. 19, but shows the
placement of the tab valve assemblies in the film layers. Lower pad
film (29) determines the lower pad dimension from side to side and
top to bottom. Upper pad film (30) determines the upper pad
dimension from side to side and top to bottom. The central zone
film creates the four zone layout. The film size matches the full
pad dimension from side to side and top to bottom in the handle
portion. Film (55) creates air chambers as shown that separate and
supply air to each of the four zones.
[0074] The tab valve work frame (40) of the first tab valve
assembly is installed into central zone film (55) in the area of
the pad handle. The corresponding tab valve main frame (41) of this
first assembly is installed in the top film (30) in the pad handle
area. Tab valve work frame (42) of the second tab valve assembly is
installed into central zone film (55) in the handle area. The
corresponding tab valve main frame (43) of the second assembly is
installed in the top film (30) in the pad handle area. Handle cut
out (52) (see, e.g., FIG. 18) separates the inflation zones.
[0075] FIG. 21 provides a top plan view of a four zone shipping pad
layout with its tab valve assembly. Shipping pad zone one (50)
retains air delivered to one-fourth of the pad area, wherein the
air is supplied by manipulating the tab portion of valve main frame
(41). Shipping pad zone two (51) retains air delivered to another
one-fourth of the pad area, wherein the air is supplied by
manipulating the tab portion of valve work frame (40). Together,
frame portions (40, 41) comprise the first tab valve assembly. The
zone one and two air pocket (47) is created by pocket notch (45).
The central zone film separates the air and directs it to zones one
and two within the pad.
[0076] Shipping pad zone three (48) retains air delivered to
another one-fourth of the pad area, wherein the air is supplied by
manipulating the tab portion of valve main frame (43). Shipping pad
zone four (49) retains air delivered to the remaining one-fourth of
the pad area. The air is supplied by manipulating the tab portion
of valve work frame (42). Frames (42, 43) together form the second
tab valve assembly. The zone three and four air pocket is created
by pocket notch (45). The central zone film separates the air and
directs it to the respective zones.
[0077] Tab valve work frame (40) is installed into shipping pad
handle central zone film (see (55) in FIG. 20). Tab valve main
frame (41) is installed in the shipping pad handle top film (see
(30) in FIG. 20). Tab valve work frame (42) is installed into the
shipping pad handle central zone film (see (55) in FIG. 20). Tab
valve main frame (43) is installed in the shipping pad handle top
film (see (30) in FIG. 20). Handle cut out (52) (see, e.g., FIGS.
18, 21) separates the inflation zones.
[0078] FIG. 22 is a sectional view through a four zone shipping pad
handle with its attendant tab valve assemblies, with both valve
assemblies shown in the open position. Shipping pad zone one (50)
retains air delivered to one-fourth of the pad area, which air is
supplied by manipulating the tab portion of valve main frame (41)
of the first tab valve assembly. Shipping pad zone two (57) retains
air delivered to another one-fourth of the pad area, wherein the
air is supplied by manipulating the tab portion of valve work frame
(40) of the first tab valve assembly. Frames (40, 41) together form
the first tab valve assembly. The zone one and two air pocket (47)
is created by pocket notch (45). The central zone film separates
the air and directs it to zones one and two.
[0079] Shipping pad zone three (48) retains air delivered to
another one-fourth of the pad area, which air is supplied by
manipulating the tab portion of valve main frame (43) of the second
tab valve assembly. Shipping pad zone four (49) retains air
delivered to the remaining one-fourth of the pad area, wherein the
air is supplied by manipulating tab valve work frame (42) of the
second tab valve assembly. Frames (42, 43) together form the second
tab valve assembly. The zone three and four air pocket (46) is
created by pocket notch (45). The central zone film separates the
air and directs it to zones three and four. Tab valve work frame
(40) is installed into the shipping pad handle central zone film
(see (55) in FIG. 20). Tab valve main frame (41) is installed in
the shipping pad handle top film (see (30) in FIG. 20). Tab valve
work frame (42) is installed into the shipping pad handle central
zone film (see (55) in FIG. 20). The tab valve main frame (43) is
installed in the shipping pad handle top film (see (30) in FIG.
20).
[0080] FIG. 23 is a sectional view through a four zone shipping pad
handle showing the two tab valve assemblies in the closed position.
As described above, shipping pad zone one (50) retains air
delivered to one-fourth of the pad area, wherein the air is
supplied by manipulating the tab portion of valve main frame (41).
Shipping pad zone two (51) retains air delivered to another
one-fourth of the pad area, which air is supplied by manipulating
the tab portion of valve work frame (40). The zone one and two air
pocket (47) is created by pocket notch (45). The central zone film
separates the air and directs it to zones one and two.
[0081] Continuing with the description of FIG. 23, shipping pad
zone three (48) retains air delivered to another one-fourth of the
pad area, wherein the air is supplied by manipulating the tab
portion of valve main frame (43). Shipping pad zone four (49)
retains air delivered to the remaining one-fourth of the pad area.
The air is supplied by manipulating the tab portion of valve work
frame (42). The zone three and four air pocket (46) is created by
pocket notch (45). The central zone film separates the air and
directs it to zones three and four. The tab valve work frame (40)
is installed into the shipping pad handle central zone film (see
(55) in FIG. 20). The tab valve main frame (41) is installed in the
shipping pad handle top film (see (30) in FIG. 20). The tab valve
work frame (42) is installed into the shipping pad handle central
zone film (see (55) in FIG. 20). The tab valve main frame (43) is
installed in the shipping pad handle top film (see (30) in FIG.
20).
[0082] FIG. 24 provides a perspective view of an inflated four zone
shipping pad with its respective two tab valve assemblies. The
features illustrated are common with those of FIGS. 18 and 21 and
are identified with the same identification numbers as used
therein.
[0083] As shown in FIG. 25, the shipping pads of the invention can
be located in a variety of positions within an outer shipping
container to completely support interior items (61) in a shipping
carton (60). The pads can be placed, for example, in each corner
(63) and optionally around the sides of the interior item (61).
Moreover, the pads can additionally be folded to protect the bottom
(62) and top (64) of the interior items.
[0084] FIG. 26 illustrates a smaller (than the one shown in FIG.
25) shipping carton (60) containing a smaller package (61), which
package (61) can be completely supported with just a corner (63)
configuration that wraps from the bottom to the top of the interior
item.
[0085] FIG. 27 illustrates that the shipping pads produced
according to the invention can be folded and then inflated within a
package to fill wider spaces (i.e., wider than the thickness of a
single pad) with the use of only one. Illustrated is a pad
comprising zone one (28) and zone two (27), tab valve working frame
(20) that controls entry of air into zone two, separated by a
central film and air pocket (22), and tab valve frame (21) that
controls entry of air into the first zone, separated by a central
film and air pocket (25).
[0086] As shown in the accompanying drawing figures, the present
system includes everything needed to provide a packing system that
can be inflated, deflated, and reused. The shipping pad of the
invention is thus designed to hold an item or inner package secure
in a exterior shipping carton (see FIGS. 25, 26). The system may be
configured, in a first embodiment in a two zone format (see, e.g.,
(14, 15) in FIG. 14) wherein the two zones are created by bonding
two film sheets together (see (29, 30) in FIG. 12) wherein a
central film ((31) in FIG. 12) is interposed between at least a
portion of films 29, 30 to provide an air chamber for each zone,
and, in a second embodiment, with a four zone design (see FIG. 21)
with four areas of inflation in FIG. 21) created by heat welding
three film sheets, ((29),(30),(55) in FIG. 19) together, with the
central film sheet (see (55) in FIG. 19) creating air chambers for
each zone.
[0087] Additional security is provided by the use of a geometric,
heat welded design that provides a balanced height ratio in each
zone. If a zone is punctured this geometric design will allow the
other zone or zones to continue to support the interior package.
The preferred geometric design involves the use of cone-shaped
inflatable chambers to form the pad zones. The wide backs of the
cone design and the sharp points of each cone are positioned to
provide a height balance in each zone (see FIGS. 14, 21).
[0088] Pad zones each comprise multiple interconnected air chambers
to provide each pad with the maximum ability to absorb impact by
distributing air to chambers not compressed by the impact. The pads
of the invention may be formed of any number and type of film
substrates that can be welded together by, e.g., applying heat, or
by an electrical or chemical bonding process. Materials useful in
the formation of the films used in forming the invention are well
known among those of ordinary skill in this field and the
particular choice of material is not critical to the invention.
Moreover, varying the film thickness provides for varying levels of
pad strength and security, and can be dictated as the product to be
shipped or the budget require. Virtually any film that can hold air
and can be securely welded together can be used to create a zoned
shipping pad in accordance with the invention.
[0089] The air in each zone of a pad is retained by a tab valve
assembly, (see FIGS. 15, 16 and 22, 23). The tab valve assembly
provides an air entrance (see (6) in FIG. 9), a three-point locking
system (see (13),(14),(15), FIG. 10) (see below) and a tab release
feature (see (2) in FIGS. 1, 2) for the air contained in the pad.
The valve design is a simple structure with no moving parts, which
is easy to manufacture and assemble and which provides an
acceptable substitute for the valve types used in current low cost
packing materials. The tab valve frame supplies air flow through an
air portal (see (6) in FIG. 1). When the position illustrated in
FIG. 15 and FIG. 22, the main tab valve frame allows air through
its portal (see (6) in FIG. 9), and into air chamber (see (25) in
FIG. 15). This allows air to move to zone one of a two zone pad,
and thereafter through working tab valve frame (see (20) in FIG.
15) to air pocket (see (27) in FIG. 9) to inflate zone two of a two
zone pad. Once the pad is inflated the main valve body frame (see
(21 in FIG. 15) and the working valve frame (see (20 in FIG. 15)
are snapped together (see (20, 21), in FIG. 16), thus locking the
valve assembly and closing the shipping pad to air flow.
[0090] As noted above, the tab valve frames contain three locking
points (see FIG. 9 (7), (4), (9)). The most prominent snap lock
feature is the valve body stem lock (see (9) in FIGS. 8 and 9).
When a main valve frame is positioned over a working valve frame
the main frame stem snap lock is directly above the air portal in
the working valve frame (see (8), (6) in FIG. 9). When the main and
working valve frames are snapped together the stem fills the portal
in the working valve frame (see (13) in FIG. 10). The fit is flush
to the bottom of the working valve seat body (see (10) in FIG. 1O),
to permit the air pressure against the bottom of the valve to be
distributed over the complete valve seat surface, thus enhancing
the integrity of this snap fit.
[0091] The second snap lock is located inside the valve seat body,
protecting it from any external pressure against the valve seat
body (see (4) in FIG. 9). This arrangement allows the working valve
body to snap into the air portal of the main valve frame (see (14)
in FIG. 10), thus sealing off any air pressure through the main
valve frame when the valve assembly is closed (see FIG. 16).
[0092] The third locking point is created by seating the valve seat
body (see (10) in FIGS. 8, 9) into the working valve frame. The
valve seat locking ridge (see (7) in FIG. 2), that wraps around the
inside of the working valve frame, snap locks into the valve seat
body groove (11 in FIG. 8) that completely wraps the outside of the
exterior valve seat of the main valve frame FIG. 8.
[0093] An additional seal is created by welding each valve frame to
its corresponding film layer (see FIG. 15) at a point on the bottom
of the frame body (see (3) in FIG. 8).
[0094] A valve assembly is opened by pressing down on the working
frame tab (see e.g., (2) in FIG. 2 and (8) in FIG. 4), and lifting
up on the main frame valve frame tab (see (2) in FIGS. 1, 4).
Pressing down on the working valve frame (see (8) in FIG. 4),
spreads the locking ridge (see (7) in FIG. 2) and body groove (see
(11) in FIG. 8) open a little, and lifting up on the main frame
valve tab (see (2) in FIG. 1) provides a peeling action, allowing
the locking ridge (see (7) in FIG. 2) to release the body groove
(see (11) in FIG. 8) while allowing the snap stem (see (9) in FIG.
8) to be removed from the air portal of the working valve frame
(see (6) in FIG. 9) and releasing the final snap seat (see (14) in
FIG. 10). When the valve assembly is thus opened air moves out of
the pad through the air portals of each valve frame and the pad is
deflated.
[0095] Valve frame body FIG. 1, FIG. 2, can be produced by casting
any plastic material that can maintain a relatively rigid frame
profile, yet remain sufficiently flexible when the frames are
snapped open and closed. The plastic material must additionally be
able to keep its shape and valve integrity throughout the useful
life of the tab valve and shipping pad.
[0096] The four-zone shipping pad (FIG. 21) of the invention has
all the features of the two-zone system, including an additional,
i.e., second tab valve assembly, with the same valve features of
air entry, locking and release in the same manner described above
for the two zone pad. Additional security is offered by the
four-zone pad in that there is a central film layer (see (55) in
FIG. 19), in each four-zone pad that divides the inflated section
into four complete zones (see (48), (49), (50), (51) in FIG. 21,
and (48), (49), (50), (51) in FIG. 22). The interior film provides
an additional area for absorbing impact. That is, when one of the
exterior film areas (see (29), (30) in FIG. 19 and (29), (30) in
FIG. 22), is subjected to an impact, the resulting force can be
absorbed by this soft flexible middle film layer (shown as (55) in
FIGS. 19, 22).
[0097] This multi-zone feature adds a level of puncture resistance
to the pad surface. That is, the use of four zones allows the pad
to maintain a greater level of integrity if a zone is punctured.
The four-zone system additionally adds a level of valve security,
with a first tab valve assembly (see (40), (41) in FIG. 21)
controlling zones one and two, and a second tab valve assembly (see
(42), (43) in FIG. 21) controlling zones three and four. Valve
assembly one (see (40), (41), in FIG. 21 22) includes a main valve
frame, (see (41 in FIG. 22). The air moves through air portal (see
(6) in FIG. 1), of the main valve frame (see (41) in FIG. 22), and
into zone one, then through another air portal (see (6) in FIG. 2)
of the working valve (see (40) in FIG. 22) and through to zone two.
The divider for these two zones is created by the handle cutout
(see (51) in FIG. 21) and the central film layer illustrated, e.g.,
as (55) in FIG. 19.
[0098] The second tab valve assembly (see (42),(43), in FIGS. 21,
22) also includes a main valve frame (see (43) in FIG. 22 ), The
air moves through air portal (see (6) in FIG. 1), of the main valve
(see (43) in FIG. 22), and into zone three, then through air portal
(6) in FIG. 2), of the working valve (see (42) in FIG. 22 ) and
through to zone four. The divider for these two zones is created by
the handle cutout (see (52) in FIG. 21), and the central film layer
(see (55) in FIG. 19). In the four-zone embodiment the two valve
assemblies are closed in the same manner as the two-zone system
described above. Each two zone section is controlled by a separate
tab valve assembly. Both valve assemblies will need to be open to
deflate the pad completely.
[0099] As noted above, shipping pads in accordance with the
invention can be placed on each corner (see, e.g., (63) in FIG. 25)
of the interior package and then inflated, thus preventing the
interior package from moving back and forth within the container.
Shipping pads produced according to the invention can also be
placed on the bottom of the exterior carton. The interior package
can be lowered onto two, or four deflated shipping pads which may
thereafter be inflated so as to surround each side of the inner
container. Alternately, deflated shipping pads may be inserted down
each side of the interior package and then inflated. (see (64) in
FIG. 25) The pads may be folded to further prevent the interior
package from moving up and down during shipping. For a smaller or
lighter interior package, pads surrounding each corner of the
package, (see (60) in FIG. 26) can provide support for both the up
and down movement and the side to side movement, with the use of
only four properly sized shipping pads.
[0100] It is to be understood that the present invention is not
limited in scope by the exemplified embodiments which are intended
as illustrations of single aspects of the invention, and
embodiments and methods which are functionally equivalent are
within the scope of the invention. Indeed, various modifications of
the invention in addition to those described herein will become
apparent to those skilled in the art from the foregoing
description.
* * * * *