U.S. patent application number 11/018680 was filed with the patent office on 2006-06-22 for redundant reusable high volume cushion.
Invention is credited to Scott Kramer.
Application Number | 20060131202 11/018680 |
Document ID | / |
Family ID | 36594341 |
Filed Date | 2006-06-22 |
United States Patent
Application |
20060131202 |
Kind Code |
A1 |
Kramer; Scott |
June 22, 2006 |
Redundant reusable high volume cushion
Abstract
A redundant reusable high volume cushion with refillable tandem
tubes comprised of redundant cushion areas having two or four
discrete areas comprised of redundant geometrically shaped chambers
creating a high volume cushion. The redundant cushion areas
facilitates absorption of impact upon the cushion by permitting
redistribution of an inflation gas, e.g., air, from an area of
impact to a non-impacted area within the same cushion. Entry/exit
tandem tubes control the flow of inflation gas into and/or out of
the cushion.
Inventors: |
Kramer; Scott; (Winter Park,
FL) |
Correspondence
Address: |
SCOTT KRAMER
511 EAST LAKE SUE AVENUE
WINTER PARK
FL
32789
US
|
Family ID: |
36594341 |
Appl. No.: |
11/018680 |
Filed: |
December 22, 2004 |
Current U.S.
Class: |
206/522 |
Current CPC
Class: |
B65D 81/051 20130101;
Y02W 30/80 20150501; Y02W 30/807 20150501 |
Class at
Publication: |
206/522 |
International
Class: |
B65D 81/02 20060101
B65D081/02 |
Claims
1. A redundant reusable high volume cushion with refillable tandem
tubes for cushioning articles during shipping and handling, said
redundant reusable high volume cushion made of a first and second
outer film layers, said first and second film layers being secured
together along an outer perimeter to define the refillable tandem
tubes permitting cushion reusability.
2. A redundant reusable high volume cushion with refillable tandem
tubes comprised of a plurality of inflatable conical shaped
chambers configured to redistribute an inflation gas contained
therein from one or more conical shaped chambers compressed by and
external impact to at least one contiguous conical shaped chamber
which is not impacted.
3. The system of claim 2, wherein said conical shaped chambers
maximize cushion height for impact protection, said cushion height
respective of available chamber height, determined by base width of
conical chambers provided.
4. A Redundant Reusable High Volume Cushion with refillable tandem
tubes supporting four cushion areas, to cushion articles during
shipping and handling, redundant reusable high volume cushion use
the inner volume to form four separate cushion areas conical shaped
areas providing a high volume profile.
Description
FIELD OF THE INVENTION
[0001] The invention is directed to impact-resistant redundant
reusable high volume cushions for protecting articles during
shipping from shock and damage and, more particularly, to a
reusable, inflatable multi-area redundant reusable high volume
material that provides a higher fill volume profile, provided with
an air entry portal adapted for permitting independent
inflation/deflation of redundant areas.
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
redundant reusable high volume 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 redundant reusable high volume 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 Styrofoam.RTM. "chips," and
other particulate redundant reusable high volume materials provide
a loose fill and the packaged article may settle during transport,
reducing the cushioning effect. Moreover all of the
above--described redundant reusable high volume materials are
themselves voluminous to both ship and store. In addition, they
could create waste disposal 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. Pat. Nos. 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.
[0005] For example, some of the inflatable cushions include only a
single inflatable area, 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 areas, 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 cushion, i.e., from one chamber to
another, upon impact to the outer surface of one or more such
chambers. Additionally, many such prior art inflatable redundant
reusable high volume systems are further subject to other problems,
as described below, caused due to the use of valve systems that may
channel air under impact pressure directly toward the valve cap
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 redundant reusable high volume 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 cushion 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 cushion, with redundant areas and a higher volume
profile, 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 protective inflatable cushion 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 object 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 a
redundant, reusable high volume cushion formed with at least two
separately inflatable and deflatable redundant areas, adapted to
facilitate absorption of impact to the cushion and to redistribute
air from redundant area compressed by the impact to alternate
redundant areas.
[0008] It is another object of the invention to provide chambers
with a conical shape or configuration such that, maximum inflated
cushion height can be achieved in a redundant area format, by
balancing these conical chambers it is possible to provide security
in the event one air chamber is punctured in that adjacent
unaffected (i.e., unpunctured) redundant area will assist in
maintaining the inflated height of the cushion upon such an event
due to crossing-over of said redundant areas provided by cushion
redundant area layout.
[0009] It is another object of the invention to provide an
inflatable, redundant reusable high volume cushion wherein the flow
of air into the cushion is controlled by refillable tandem tubes
creating at least one area entry/exit portal which, due to its
design and construction, allows this portal to withstand a
significant air pressure caused due to impact, i.e., causing
compression, upon one of the inflated redundant areas of the
cushion, without forcing the portal open.
[0010] These and other objects of the invention are achieved
through the use of an inflatable, redundant reusable high volume
cushion with refillable tandem tubes as described and illustrated
herein.
[0011] In a first embodiment the invention is directed to a two
area redundant reusable high volume cushion which, areas can be
aligned side by side comprising a two area entry/exit portal tube.
Areas can also be aligned top and bottom, and right and left sides
wherein each said area directs impacted air pressure through the
central core of the cushion layout, also utilizing a two area
entry/exit portal tube. In a further embodiment, the redundant
reusable high volume cushion of the invention comprises a four area
redundant reusable high volume cushion utilizing a four area
refillable tandem tubes entry/exit portal tube wherein each said
area controls the flow of air into and out of a separate said area.
The four area cushion offers additional protection from accidental
deflation throughout the handling process.
[0012] The system of invention was designed with redundant areas,
each formed with redundant air chambers, in a single redundant
reusable high volume cushion to allow each cushion the ability to
absorb impact by distributing air to chambers not compressed by
impact. That is, the cushion comprises at least two inflation
areas, and each said area may be further broken down into a
plurality of inflatable chambers. The redundant reusable high
volume cushion of the invention can be manufactured in a variety of
shapes and sizes, that utilize a tapered redundant cushion area to
deliver the high volume developed through the conical taper, or
conical like taper and from a variety of materials as well. FIG. 1,
FIG. 15 and FIG. 12, FIG. 25, illustrating, respectively, a two
area and a four area cushion, FIG. 1 and FIG. 15, display an
exemplary geometric design for the cushion chambers wherein said
chambers are conical shaped and use the maximum film surface,
providing a high volume profile with added redundant area format
security. 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
cushion of the invention are not limited to a conical shape and
may, instead, be configured in a variety of alternate shapes that
provide a conical like taper. In the illustrated embodiment, the
cushion fill height can be increased by making the conical chambers
larger. Cushions 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 area security.
[0013] The ability to be inflated or deflated (see, e.g., FIG. 1
and FIG. 11, FIG. 15 and FIG. 24) as the task requires, provides a
reusable redundant reusable high volume cushion for all users in
the shipping cycle. The redundant reusable high volume cushion of
the invention can be stored deflated when not in use, thus reducing
storage space requirements.
[0014] The system of the invention, comprising a redundant reusable
high volume cushion with refillable tandem tubes at least one, area
entry/exit portal, is inflated and deflated through the use of the
area entry/exit portal tube and requires no special equipment to
operate. The cushions can be filled by mouth or with compressed
air, allowing the end user to store, reuse and recycle this
redundant reusable high volume fill. The system of the invention,
comprising a redundant reusable high volume cushion with refillable
tandem tubes can be stored as raw film material, assembled and
inflated by the manufacturer, then deflated by the end user by
cutting the refillable tandem tubes air portals and reused by the
end user, by putting air back into the refillable tandem tubes air
portal, providing once again the redundant reusable high volume
cushion. Security against unintended deflation is thus provided
through area design and the entry/exit portal tube tuck-away as
further described herein.
[0015] The redundant reusable high volume cushion with refillable
tandem tubes may be printed with a company logo or other graphics
inside and out, thus allowing redundant reusable high volume
cushion with refillable tandem tubes to be a marketing image
piece.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] 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:
[0017] FIG. 1 is a top plan view of the side by side two area
redundant reusable high volume cushion with refillable tandem
tubes
[0018] FIG. 2 is a perspective view of a side by side two area
redundant reusable high volume cushion with refillable tandem
tubes
[0019] FIG. 3 is a component view of the side by side two-area
redundant reusable high volume cushion with refillable tandem
tubes, illustrating relationship between the A and B film
entry/exit portal tube and area conical air chamber layout.
[0020] FIG. 4 is a perspective view of an inflated side by side two
area redundant reusable high volume cushion with refillable tandem
tubes, illustrating the inflated entry/exit portal tube and the
interior area layout.
[0021] FIG. 5 is a perspective view of an inflated side by side two
area redundant reusable high volume cushion with refillable tandem
tubes,
[0022] FIG. 6 is a perspective close-up view of an inflated side by
side two area redundant reusable high volume cushion, illustrating
the inflated entry/exit portal tube
[0023] FIG. 7 is a close-up front view of an inflated side by side
two area redundant reusable high volume cushion with refillable
tandem tubes, illustrating the inflated entry/exit portal tube
[0024] FIG. 8 is a close-up front view of the side by side two-area
redundant reusable high volume cushion with refillable tandem
tubes, illustrating the inflated entry/exit portal tube with the
first closing fold.
[0025] FIG. 9 is a close-up front view of the side by side two-area
redundant reusable high volume cushion with refillable tandem
tubes, illustrating the inflated entry/exit portal tube with the
second closing fold.
[0026] FIG. 10 is a close-up front view of side by side two-area
redundant reusable high volume cushion with refillable tandem
tubes, illustrating the inflated entry/exit portal tube in the
tuck-away position.
[0027] FIG. 11 is a perspective view of an inflated side by side
two area redundant reusable high volume cushion with refillable
tandem tubes, illustrating the closed tuck-away position of the
entry/exit portal tube.
[0028] FIG. 12 is a component view of the side by side four-area
redundant reusable high volume cushion with refillable tandem
tubes, illustrating relationship between the A and B film
entry/exit portal tube and area conical air chamber layout and the
center C film that creates the four areas.
[0029] FIG. 13 is a top plan view of the side by side two-area or
four-area redundant reusable high volume cushion with refillable
tandem tubes, illustrating layout orientation of two separate
cushions in a production layout
[0030] FIG. 14 is a top plan view of the side by side two-area or
four-area redundant reusable high volume cushion with refillable
tandem tubes, illustrating layout orientation of two separate
cushions and additional similar arranged cushions in a production
layout to accommodate rolled or sheet film raw material.
[0031] FIG. 15 is a top plan view of the top to bottom and side to
side two area redundant reusable high volume cushion with
refillable tandem tubes
[0032] FIG. 16 is a perspective view of a top to bottom and side to
side two area redundant reusable high volume cushion with
refillable tandem tubes.
[0033] FIG. 17 is a component view of the top to bottom and side to
side two-area redundant reusable high volume cushion with
refillable tandem tubes, illustrating relationship between the A
and B film entry/exit portal tube, central core film and area
conical air chamber layout.
[0034] FIG. 18 is a top perspective view of the top to bottom and
side to side two area redundant reusable high volume cushion
central core film, illustrating the heat-weld seams in the A film
that create air passage to the area two air chambers.
[0035] FIG. 19 is a through perspective view of the top to bottom
and side to side two area redundant reusable high volume cushion
with refillable tandem tubes central core film, illustrating the
heat-weld seams in the B film that create air passage to the area
one air chambers and their relationship to area two air
passageway.
[0036] FIG. 20 is a through perspective view of the top to bottom
and side to side two area redundant reusable high volume cushion
with A and B films connected only at the central core film,
illustrating the refillable tandem tubes created by the B film air
passage for area one air chambers and the A film air passageway for
area two air chambers
[0037] FIG. 21 is a completed sealed perspective view of FIG. 20,
illustrating the relationship of area one and two air chambers and
the central core film.
[0038] FIG. 22 is a perspective view of an inflated top to bottom
and side to side two area redundant reusable high volume cushion
with refillable tandem tubes, illustrating an open entry/exit
portal tube.
[0039] FIG. 23 is a close-up view of an inflated top to bottom and
side to side two area redundant reusable high volume cushion,
illustrating an open entry/exit portal tube.
[0040] FIG. 24 is a perspective view of an inflated top to bottom
and side to side two area redundant reusable high volume cushion,
illustrating the closed position of the entry/exit portal tube in
the tuck-away pocket.
[0041] FIG. 25 is a component view of the top to bottom and side to
side four-area redundant reusable high volume cushion, illustrating
relationship between the A and B film entry/exit portal tube, first
and second central core film and area conical air chamber layout
and the center C film that creates the four areas.
DETAILED DESCRIPTION OF THE INVENTION
[0042] The invention is therefore directed to a redundant reusable
high volume cushion with refillable tandem tubes wherein inflation
and deflation of each area is independently controlled by and
entry/exit portal comprised of a entry/exit portal tube and portal
tube tuck-away, and further wherein each said area 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 cushion from a compressed chamber to
a non-compressed chamber, for improving the reliability of the
cushion.
[0043] 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,
[0044] FIG. 1 illustrates top plan view of a side by side two area
cushion first conical air chamber of area one (1), area one
passageway (2), connecting air chamber one (1) and conical air
chamber two (3) In area one. First conical air chamber of area two
(7), area two passageway (6), connecting air chamber one (7) and
conical air chamber two (5) In area two. Entry/exit Portal Tube
(12), controlling airflow into and out of the cushion. Area one
entry/exit passageway (14), allowing air movement through area one
portal (9). Area two entry/exit passageway (13), allowing air
movement through area two portal (10). Tuck-away (8), creating a
pocket to secure the closed entry/exit Portal Tube (12). Extra wide
heat welded outer seam (4), seam reduction at entry/exit portal
tube (11).
[0045] FIG. 2 illustrates perspective view of a side by side two
area cushion first conical air chamber of area one (1), area one
passageway FIG. 1 (2), connecting air chamber one (1) and conical
air chamber two (3) In area one. Entry/exit refillable tandem
Portal Tube (12), controlling air flow into and out of the cushion.
Area one entry/exit passageway (14), allowing air movement through
area one portal FIG. 1(9). Area two entry/exit passageway (13),
allowing air movement through area two portal FIG. 1(10).
[0046] FIG. 3 illustrates component view of a side by side two area
cushion, with A and B film layouts first conical air chamber of
area one layout on film A (1a), area one passageway FIG. 1 (2),
connecting air chamber one layout in film A (1a) and conical air
chamber two layout on film A (3a) In area one. First conical air
chamber layout on film A of area two (7a), area two passageway
layout on film A (6a), connecting air chamber one layout on film A
(7a) and conical air chamber two layout on film A (5a) In area two.
Entry/exit refillable tandem Portal Tube layout on film A (12a),
controlling air flow into and out of the cushion. Area one
entry/exit passageway layout on film A (14a), allowing air movement
through area one portal FIG. 1 (9). Area two entry/exit passageway
layout on film A (13a), allowing air movement through area two
portal FIG. 1 (10). Tuck-away (8), creating a pocket to secure the
closed entry/exit refillable tandem Portal Tube FIG. 1 (12) first
conical air chamber of area one layout on film B (1b), area one
passageway FIG. 1 (2), connecting air chamber one layout in film B
(1b) and conical air chamber two layout on film B (3b) In area one.
First conical air chamber layout on film B of area two (7b), area
two passageway layout on film B (6b), connecting air chamber one
layout on film B (7b) and conical air chamber two layout on film B
(5b) In area two.
[0047] FIG. 4 illustrates perspective view of inflated side by side
two area cushion first conical air chamber of area one (1), area
one passageway (2), connecting air chamber one (1) and conical air
chamber two (3) In area one. First conical air chamber of area two
(7), area two passageway (6), connecting air chamber one (7) and
conical air chamber two (5) In area two. Entry/exit Portal Tube
FIG. 1(12), controlling airflow into and out of the cushion. Area
one entry/exit passageway (14), allowing air movement through area
one portal FIG. 1(9). Area two entry/exit passageway (13), allowing
air movement through area two portal FIG. 1 (10). Tuck-away (8),
creating a pocket to secure the closed entry/exit Portal Tube
(12).
[0048] FIG. 5 illustrates perspective view of inflated side by side
two area cushion with the refillable tandem entry/exit portal tube
in the open position
[0049] FIG. 6 is a perspective close-up view of an inflated side by
side two area redundant reusable high volume cushion, illustrating
the inflated entry/exit portal tube, first conical air chamber of
area one (1), First conical air chamber of area two (7), Tuck-away
(8), Entry/exit Portal Tube (12), controlling airflow into and out
of the cushion. Area one entry/exit passageway (14), allowing air
movement through area one portal FIG. 1(9). Area two entry/exit
passageway (13), allowing air movement through area two portal FIG.
1 (10).
[0050] FIG. 7 is a close-up front view of an inflated side by side
two area redundant reusable high volume cushion, illustrating the
inflated entry/exit portal tube (12), first conical air chamber of
area one (1), First conical air chamber of area two (7), Tuck-away
(8)
[0051] FIG. 8 is a close-up front view of the side by side two-area
redundant reusable high volume cushion, illustrating the inflated
entry/exit portal tube (12), with the first closing fold first
conical air chamber of area one (1), First conical air chamber of
area two (7), Tuck-away (8)
[0052] FIG. 9 is a close-up front view of the side by side two-area
redundant reusable high volume cushion, illustrating the inflated
entry/exit portal tube (12), with the second closing fold first
conical air chamber of area one (1), First conical air chamber of
area two (7), Tuck-away (8)
[0053] FIG. 10 is a close-up front view of side by side two-area
redundant reusable high volume cushion, illustrating the inflated
entry/exit portal tube (12), in the tuck-away position first
conical air chamber of area one (1), First conical air chamber of
area two (7), Tuck-away (8)
[0054] FIG. 11 is a perspective view of an inflated side by side
two area redundant reusable high volume cushion, illustrating the
closed tuck-away position of the entry/exit portal tube (12), first
conical air chamber of area one (1), area one passageway FIG. 1
(2), connecting air chamber one (1) and conical air chamber two (3)
In area one. First conical air chamber of area two (7), area two
passageway FIG. 1(6), connecting air chamber one (7) and conical
air chamber two (5) In area two. Entry/exit Portal Tube (12),
controlling airflow into and out of the cushion. Area one
entry/exit passageway FIG. 1 (14), allowing air movement through
area one portal FIG. 1(9). Area two entry/exit passageway FIG.
1(13), allowing air movement through area two portal FIG. 1 (10).
Tuck-away (8), creating a pocket to secure the closed entry/exit
Portal Tube (12).
[0055] FIG. 12 illustrates component view of a side by side four
area cushion, with A and B film layouts and the third film C (15),
that divides the cushion in half creating the four areas, the first
area is divided into areas one and three, and the second area is
divided into areas two and four. First conical air chamber of area
one layout on film A (1a), area one passageway FIG. 1 (2),
connecting air chamber one layout in film A (1a) and conical air
chamber two layout on film A (3a) In area one, film C (15) divide
this area in half allowing film A and film B to create areas one
and three. First conical air chamber layout on film A of area two
(7a), area two passageway layout on film A (6a), connecting air
chamber one layout on film A (7a) and conical air chamber two
layout on film A (5a) In area two, film C (15) divide this area in
half allowing film A and film B to create areas two and four.
Entry/exit Portal Tube layout on film A (12a), controlling air flow
into and out of the cushion. Area one entry/exit passageway layout
on film A (14a), allowing air movement through area one portal FIG.
1 (9). Area two entry/exit passageway layout on film A (13a),
allowing air movement through area two portal FIG. 1 (10), film C
(15) divides the portal tube into four entry/exit tubes supporting
four areas. Tuck-away (8), creating a pocket to secure the closed
entry/exit Portal Tube FIG. 1 (12) first conical air chamber of
area one layout on film B (1b), area one passageway FIG. 1 (2),
connecting air chamber one layout in film B (1b) and conical air
chamber two layout on film B (3b) In area one, film C (15) divide
this area in half allowing film A and film B to create areas one
and three. First conical air chamber layout on film B of area two
(7b), area two passageway layout on film B (6b), connecting air
chamber one layout on film B (7b) and conical air chamber two
layout on film B (5b) In area two, film C (15) divide this area in
half allowing film A and film B to create areas two and four.
[0056] FIG. 13 is a top plan view of the side by side two-area or
four-area redundant reusable high volume cushion, illustrating
layout orientation of two separate cushions in a production layout
Cushions are arranged to create a production pair improving raw
material film usage.
[0057] FIG. 14 is a top plan view of the side by side two-area or
four-area redundant reusable high volume cushion, illustrating
layout orientation of two separate cushions and additional similar
arranged cushions in a production layout to accommodate rolled or
sheet film raw material. Production pairs can be rolled or stamped
out of film rolls or film sheets for efficient production.
[0058] FIG. 15 illustrates top plan view of a top to bottom and
side to side two area cushion first conical air chamber of area one
(1), area one passageway (2), connecting air chamber one (1) and
conical air chamber two (3) In area one. First conical air chamber
of area two (7), area two passageway (6), connecting air chamber
one (7) and conical air chamber two (5) In area two. Entry/exit
Portal Tube (12), controlling airflow into and out of the cushion.
Area one entry/exit passageway (14), allowing air movement through
area one portal (9) . Area two entry/exit passageway (13), allowing
air movement through area two portal (10). Tuck-away (8), creating
a pocket to secure the closed entry/exit Portal Tube (12). Extra
wide heat welded outer seam (4), seam reduction at entry/exit
portal tube (11). Central core film (16), that creates the
passageway (2), for area one air chambers and passageway (6), for
area two air chambers.
[0059] FIG. 16 illustrates perspective view of a top to bottom and
side to side two area cushion first conical air chamber of area one
(1), area one passageway FIG. 15 (2), connecting air chamber one
(1) and conical air chamber two (3) In area one. Entry/exit Portal
Tube (12), controlling air flow into and out of the cushion. Area
one entry/exit passageway FIG. 15 (14), allowing air movement
through area one portal FIG. 15 (9). Area two entry/exit passageway
FIG. 15 (13), allowing air movement through area two portal FIG. 15
(10). Tuck-away (8), creating a pocket to secure the closed
entry/exit Portal Tube (12).
[0060] FIG. 17 is a component view of the top to bottom and side to
side two-area redundant reusable high volume cushion, illustrating
relationship between the A film, B film and central core film (16),
first conical air chamber of area one layout on film A (1a), area
one passageway FIG. 15 (2), connecting air chamber one layout in
film A (1a) and conical air chamber two layout on film A (3a) In
area one. First conical air chamber layout on film A of area two
(7a), area two passageway layout on film A (6a), connecting air
chamber one layout on film A (7a) and conical air chamber two
layout on film A (5a) In area two. Entry/exit Portal Tube layout on
film A (12a), controlling air flow into and out of the cushion.
Area one entry/exit passageway layout on film A (14a), allowing air
movement through area one portal FIG. 15 (9). Area two entry/exit
passageway layout on film A (13a), allowing air movement through
area two portal FIG. 1 (10). Tuck-away (8), creating a pocket to
secure the closed entry/exit Portal Tube FIG. 15 (12), first
conical air chamber of area one layout on film B (1b), area one
passageway FIG. 15 (2), connecting air chamber one layout in film B
(1b) and conical air chamber two layout on film B (3b) In area one.
First conical air chamber layout on film B of area two (7b), area
two passageway layout on film B (6b), connecting air chamber one
layout on film B (7b) and conical air chamber two layout on film B
(5b) In area two. Central core film (16), that creates the
passageway FIG. 15 (2), for area one air chambers and passageway
FIG. 15 (6), for area two air chambers.
[0061] FIG. 18 is a top perspective view of the top to bottom and
side to side two area redundant reusable high volume cushion
central core film FIG. 15 (16), illustrating the heat-weld seams
(17),in the A film that create air passageway (6) for the area two
air chambers FIG. 15 (7) (5). Reference FIG. 17 (1a) and (5A) for
film positions.
[0062] FIG. 19 is a through perspective view of the top to bottom
and side to side two area redundant reusable high volume cushion
central core film FIG. 15 (16), illustrating the heat-weld seams
(19), in the B film that create air passageway (2), for the area
one air chambers FIG. 15 (1) (3), and their relationship to area
two air passageway (6). Reference FIG. 17 (1a),(5a),(1b),(5b) for
film positions.
[0063] FIG. 20 is a through perspective view of the top to bottom
and side to side two area redundant reusable high volume cushion
with A and B films connected only at the central core film FIG. 17
(16), illustrating the B film air passageway (2), created by heat
welds FIG. 19 (19), for area one air chambers FIG. 15 (1) (3), and
the A film air passageway (6), created by heat weld FIG. 18 (17),
for area two air chambers FIG. 15 (7) (5). Reference FIG. 17
(1a),(5a),(1b),(5b) for film positions.
[0064] FIG. 21 is a completed sealed perspective view of FIG. 20,
illustrating the relationship of area one and two air chambers and
the central core film (16), first conical air chamber of area one
(1), area one passageway (2), connecting air chamber one (1) and
conical air chamber two (3) In area one. First conical air chamber
of area two (7), area two passageway (6), connecting air chamber
one (7) and conical air chamber two (5) In area two. Entry/exit
Portal Tube FIG. 15 (12), controlling airflow into and out of the
cushion. Central core film (16) that creates the passageway (2),
for area one air chambers and passageway (6), for area two air
chambers.
[0065] FIG. 22 is a perspective view of an inflated top to bottom
and side to side two area redundant reusable high volume cushion,
illustrating an open entry/exit portal tube (12), first conical air
chamber of area one (1), area one passageway FIG. 15 (2),
connecting air chamber one (1) and conical air chamber two (3) In
area one. First conical air chamber of area two (7), area two
passageway FIG. 15 (6), connecting air chamber one (7) and conical
air chamber two (5) In area two. Entry/exit Portal Tube (12),
controlling airflow into and out of the cushion. Area one
entry/exit passageway FIG. 15(14), allowing air movement through
area one portal FIG. 15 (9). Area two entry/exit passageway (13),
allowing air movement through area two portal FIG. 15 (10).
Tuck-away (8), creating a pocket to secure the closed entry/exit
Portal Tube (12).
[0066] FIG. 23 is a close-up view of an inflated top to bottom and
side to side two area redundant reusable high volume cushion FIG.
22, illustrating an open entry/exit portal tube (12).
[0067] FIG. 24 is a perspective view of an inflated top to bottom
and side to side two area redundant reusable high volume cushion,
illustrating the closed position of the entry/exit portal tube
(12), in the tuck-away pocket (8), first conical air chamber of
area one (1), area one passageway FIG. 15 (2), connecting air
chamber one (1) and conical air chamber two (3) In area one. First
conical air chamber of area two (7), area two passageway FIG. 15
(6), connecting air chamber one (7) and conical air chamber two (5)
In area two. Entry/exit Portal Tube (12), controlling airflow into
and out of the cushion in the closed tuck-away position.
[0068] FIG. 25 is a component view of the top to bottom and side to
side four-area redundant reusable high volume cushion, illustrating
relationship between the A and B film entry/exit portal tube (12),
first and second central core film (16), (21), and the center C
film (22) that creates the four areas, separating area one into
areas one and three, and separating area two into area two and
four. First conical air chamber of area one layout on film A (1a),
area one passageway FIG. 15 (2), connecting air chamber one layout
in film A (1a) and conical air chamber two layout on film A (3a) In
area one, film C divide this area in half allowing film A and film
B to create areas one and three. First conical air chamber layout
on film A of area two (7a), area two passageway layout on film A
(6a), connecting air chamber one layout on film A (7a) and conical
air chamber two layout on film A (5a) In area two, film C divide
this area in half allowing film A and film B to create areas two
and four. Entry/exit Portal Tube layout on film A (12a),
controlling air flow into and out of the cushion. Area one
entry/exit passageway layout on film A (14a), allowing air movement
through area one portal FIG. 15 (9). Area two entry/exit passageway
layout on film A (13a), allowing air movement through area two
portal FIG. 1 (10). Tuck-away (8), creating a pocket to secure the
closed entry/exit Portal Tube FIG. 15 (12), first conical air
chamber of area one layout on film B (1b), area one passageway FIG.
15 (2), connecting air chamber one layout in film B (1b) and
conical air chamber two layout on film B (3b) In area one, film C
divide this area in half allowing film A and film B to create areas
one and three. First conical air chamber layout on film B of area
two (7b), area two passageway layout on film B (6b), connecting air
chamber one layout on film B (7b) and conical air chamber two
layout on film B (5b) In area two, film C divide this area in half
allowing film A and film B to create areas two and four. Central
core film (16), that creates the passageway FIG. 15 (2), for area
one air chambers and passageway FIG. 15 (6), for area two air
chambers.
[0069] As shown in the accompanying drawing figures, the present
system includes everything needed to provide a redundant reusable
high volume system that can be inflated, deflated, and reused. The
redundant reusable high volume cushion of this invention is thus
designed to hold an item or inner package secure in a exterior
shipping carton. The redundant reusable high volume cushion may be
configured, in a first embodiment in a two area format (Side by
Side areas FIG. 1, and Top to Bottom Side to Side FIG. 15) wherein
the two areas are created by bonding two film sheets together (Side
by Side FIG. 3 and Top to Bottom Side to Side FIG. 17) to provide
air chambers for each area, and, in a second embodiment, with a
four area design (Side by Side areas FIG. 12 and Top to Bottom Side
to Side areas FIG. 25) created by heat welding three full film
sheets, ((FIG. 12, FIG. 25) with the central core film (16)(21)
FIG. 25, for the top to bottom side to side design (FIG. 15))
together, with the central film sheet (see (15) in FIG. 12, and,
(22) in FIG. 25) creating the air chambers for each area.
[0070] Additional security is provided by the use of a geometric,
heat welded design providing controlled areas to receive impact
compressed air (see FIG. 1 (1) (3) (7) (5), and FIG. 15 (1)(3) (7)
(5) within the cushion. Extra wide exterior seam (FIG. 1 (4)) and
narrower interior field seams add cushion integrity by allowing
severe impact to open an interior seam moving air into adjacent
areas, instead of an exterior seam rupture, allowing air to escape
the cushion enclosure.
[0071] Additional cushion volume is provided by the layout of each
geometric format, shape are placed side by side, maximizing the
inflated cushion surface, and providing greater depth in cushion
height.
[0072] Cushion areas each comprise redundant interconnected air
chambers to provide each cushion with the maximum ability to absorb
impact by distributing air to chambers not compressed by impact.
The cushions 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
cushion strength and security, and can be dictated as the product
to be shipped or budget require. Virtually any film that can hold
air can be securely welded together can be used to create a area
redundant reusable high volume cushion in accordance with the
invention.
[0073] The air in each area of a cushion is retained by a
entry/exit portal tube (see FIG. 1 (12), FIG. 15 (12)), and
tuck-away film, (see FIG. 1 (8), FIG. 15 (8)), once the cushion is
filled with air the (see FIG. 5 and FIG. 22) the entry/exit portal
tube is folded twice over itself, (see FIG. 7, FIG. 8, FIG. 9), and
then tucked under the tuck-away film (see FIG. 11 and FIG. 24) The
tuck-away film is heat sealed to the front and left exterior seam,
(see FIG. 1 (8), and FIG. 15 (8)). Creating a pocket to receive the
folded entry/exit portal tube (see FIG. 10). As noted the folds in
the entry/exit portal tube (see FIG. 8, FIG. 9 and FIG. 10),
provide a series of locking point, adding to cushion security.
Deflate each cushion by moving the entry/exit portal tube from the
tuck-away pocket and opening the folds, deflated cushions can be
reused by blowing air into the entry/exit portal tube, (FIG. 1
(12), FIG. 15 (12)),and securing the folded tube in the tuck-away
pocket, (FIG. 10), as described above. Interior air pressure forced
against the portal area (FIG. 1 (9), (10) and FIG.>15 (9),(10)),
will press the tube tighter into the tuck-away pocket (FIG. 11(8)
and FIG. 24(8)), adding and additional level of security.
[0074] Type of two area cushions, are distinguished by the
placement of an areas air chambers. In the side by side format, one
area controls the front and left side of the cushion while the
opposite area controls the left side and back of the cushion. In
the top to bottom and side to side, one area controls the front and
back of the cushion while the other area controls the left and
right side. The side by side is built by welding and A film and B
film together with a tuck-away film welded to the left and front
exterior seam. The top to bottom side to side is built welding the
A film and B film to a central core film, (to create the
passageways for each area), then to each other, with a tuck-away
film welded to the left and front exterior seam.
[0075] The four-area redundant reusable high volume cushion (FIG.
12, FIG. 25) of the invention has all the features of the two-area
system, (including an additional, i.e., second central core film,
(FIG. 25(21) for the top to bottom side to side cushion), with the
same features of air entry, locking and release in the same manner
described above for the two area cushion. Additional security is
offered by the four-area cushion in that there is a central film
layer (see(15) FIG. 12 and (22) FIG. 25), in each four-area cushion
that divides the inflated sections into four complete areas. The
interior film provides an additional area for absorbing impact.
That is, when one of the exterior film areas (see FIG. 12 and FIG.
25), is subjected to impact, the resulting force can be absorbed by
this soft flexible middle film layer (shown as (15) in FIG. 12 and
(22) in FIG, 25).
[0076] This multi-area feature adds a level of puncture resistance
to the cushion surface. That is, the use of four areas allows the
cushion to maintain a greater level of integrity if a area is
punctured.
[0077] 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 the
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.
* * * * *