U.S. patent application number 15/148781 was filed with the patent office on 2017-01-26 for inflatable packaging cushion with suspension hammock.
The applicant listed for this patent is Inflatable Packaging, Inc.. Invention is credited to Carmine V. Caparaso, JR., Michell C. Tschantz.
Application Number | 20170021990 15/148781 |
Document ID | / |
Family ID | 57836841 |
Filed Date | 2017-01-26 |
United States Patent
Application |
20170021990 |
Kind Code |
A1 |
Tschantz; Michell C. ; et
al. |
January 26, 2017 |
INFLATABLE PACKAGING CUSHION WITH SUSPENSION HAMMOCK
Abstract
The present invention is directed to an inflatable packaging
cushion that may include a plurality of inflation tubes to define a
structure of the inflatable packaging cushion, in which the
structure includes an interior region defined by the plurality of
inflation tubes. The inflatable packaging cushion may further
include a suspension hammock positioned within the interior region
defined by the plurality of inflation tubes, and connected to at
least one of the inflation tubes. The inflatable packaging further
also includes a package receiving portion that is configured and
dimensioned to receive a product and a suspension portion that is
configured to retain and cushion the product within the inflation
tubes and suspension hammock. The suspension hammock is configured
so that the product within the suspension portion does not extend
past an end of the inflatable packaging cushion thereby reducing
the likelihood of damage to the product.
Inventors: |
Tschantz; Michell C.;
(Newtown, CT) ; Caparaso, JR.; Carmine V.;
(Monroe, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Inflatable Packaging, Inc. |
Newtown |
CT |
US |
|
|
Family ID: |
57836841 |
Appl. No.: |
15/148781 |
Filed: |
May 6, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62157641 |
May 6, 2015 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 81/052 20130101;
B65D 81/07 20130101 |
International
Class: |
B65D 81/07 20060101
B65D081/07; B65D 81/127 20060101 B65D081/127 |
Claims
1. An inflatable packaging cushion, comprising: a product housing
formed by a plurality of connected inflation tubes defining an
interior region of the product housing; and a suspension hammock
secured to the product housing and positioned at least partially
within the interior region of the product housing; wherein the
product housing of the inflatable packaging cushion comprises a
first portion and a second portion; and wherein a length of the
suspension hammock between a junction between the first portion and
the second portion and a point on the suspension hammock furthest
away from the first portion is less than the length of the second
portion.
2. The inflatable packaging cushion according to claim 1, wherein
the product housing comprises a first pair of walls formed from the
plurality of connected inflation tubes and positioned parallel with
respect to each other, a second pair of walls formed from the
plurality of connected inflation tubes and positioned parallel with
respect to each other and at an angle with respect to the first
pair of walls, and an end wall formed from the plurality of
connected inflation tubes and positioned perpendicular to the first
pair of walls and the second pair of walls.
3. The inflatable packaging cushion according to claim 1, wherein
the product housing comprises a first end and a second end, wherein
the first end is positioned at an end of the first portion and the
second end is positioned at an end of the second portion, and
wherein the suspension hammock creates a barrier within the
interior region of the product housing between the first end and
the second end of the product housing.
4. The inflatable packaging cushion according to claim 1, wherein
the suspension hammock is comprised of a suspension sheet
material.
5. The inflatable packaging cushion according to claim 4, wherein
the suspension sheet material is comprised of a laminate material
having a first side and a second side, and wherein the first side
is configured so as to not be weldable to itself and the plurality
of connected inflation tubes.
6. The inflatable packaging cushion according to claim 4, wherein
the suspension sheet material is polytetrafluoroethylene.
7. The inflatable packaging cushion according to claim 1, wherein
the suspension hammock comprises one or more extension sleeves
extending from the suspension hammock to an area outside of the
interior region of the product housing.
8. The inflatable packaging cushion according to claim 1, wherein
each of the plurality of connected inflation tubes comprises a
longitudinal axis, and wherein the longitudinal axis of each of the
plurality of connected inflation tubes is positioned perpendicular
to the junction between the first portion and the second
portion.
9. The inflatable packaging cushion according to claim 1, wherein
each of the plurality of connected inflation tubes comprises a
longitudinal axis, and wherein the longitudinal axis of each of the
plurality of connected inflation tubes is positioned parallel to
the junction between the first portion and the second portion.
10. The inflatable packaging cushion according to claim 1, wherein
the suspension hammock is secured to the product housing at the
junction between the first portion and the second portion of the
product housing.
11. The inflatable packaging cushion according to claim 1, wherein
the junction between the first portion and the second portion is a
seam connecting the suspension hammock to the plurality of
connected inflation tubes.
12. The inflatable packaging cushion according to claim 1, wherein
the product housing is configured for receipt of a product by
suspending the product with the suspension hammock within the
interior region of the product housing.
13. The inflatable packaging cushion according to claim 12, wherein
the product housing is configured for insertion into a carton and
for cushioning the product from contacting at least one of wall of
the carton.
14. The inflatable packaging cushion according to claim 1, wherein
each of the plurality of connected inflation tubes is inflatable
through an individual inflation valve.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Appl.
No. 62/157,641 filed May 6, 2015, which is hereby incorporated by
reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to an inflatable
packaging cushion with a suspension hammock for receiving a
product, and more particularly the inflatable packaging cushion
with the suspension hammock and product may be received in a
carton, and the inflatable packaging cushion with the suspension
hammock is configured for suspending and cushioning the product
therein.
[0004] 2. Description of Related Art
[0005] Inflatable packaging cushions for cushioning products in
cartons are known in the art as a substitute for foam pellets, air
pillows, fitted and unfitted foam blocks and corrugated support
structures. All of these types of packaging products are designed
to provide cushioning to reduce and/or eliminate the energy that is
applied to and/or exerted upon objects contained within the
packaging products during shipping and/or transport of the objects
in order to reduce or avoid damage to such objects. Such energy may
be the result of forces applied to and/or exerted upon the objects
as a result of compression, torsion, flexing or impact of the
cartons containing the objects.
[0006] Foam pellets are placed in cartons surrounding a product to
fill voids and separate the product from the walls of the carton
and to cushion the product. Foam pellets have disadvantages in that
they take a substantial amount of shipping and storage space to
make them available at the point of use, and are labor intensive to
achieve proper placement and cushioning of the product within its
carton. They are also difficult to dispose of after use, and are
difficult to recycle. They require substantial amount of raw
materials and cost to fabricate and transport.
[0007] Individual, small air pillows are often used in place of
foam pellets to fill voids in cartons, but are also difficult to
place operatively for full protection, and are generally not used
for products that require a high level of protection and
reliability in their packaging.
[0008] Foam blocks that are shaped to accommodate a product and to
fit snuggly in cartons while supporting the product are also
popular. However, they suffer many of the same disadvantages as
foam pellets, in that they are expensive to fabricate, occupy
substantial amount of space in shipping to the point of use and in
inventory prior to use, and are relatively labor intensive to place
on a product. They are also bulky and difficult to dispose of, both
at the point of unpacking and in recycling.
[0009] Corrugated support structures have also been used to support
a product within a carton, but are relatively expensive, and are
also labor intensive to install on the product and fit into a
carton, and may not provide an appropriate level of cushioning or
vibration protection. When combined with thermoplastic suspension
panels, they are not easily recycled.
[0010] There have been many custom inflatable packaging cushions
designed and used with particular products. While custom inflatable
packaging cushions may provide good protection for the product,
they generally occupy a substantial volume which requires the use
of large cartons and results in higher shipping costs, and often
designed for a product or product box of a specific size, which
limits their general usefulness.
[0011] Accordingly, there is a need for improved packaging
cushions.
SUMMARY OF THE INVENTION
[0012] The present invention is designed to overcome the above
noted limitations that are attendant upon the use of conventional
packaging materials and, toward this end, it contemplates the
provision of a novel inflatable packaging cushion having a
suspension hammock integrated therein.
[0013] It is a principal object of the invention herein to provide
an inflatable packaging cushion for protecting products.
[0014] It is a further object of the invention herein to provide an
inflatable packaging cushion for protecting products that may be
contained within cartons.
[0015] It is still another object of the invention herein to
provide an inflatable packaging cushion for reducing and/or
eliminating compression, torsional, flexing or impact forces
exerted upon products contained within cartons during transport or
shipping of the products.
[0016] It is yet another object of the invention herein to provide
an inflatable packaging cushion for protecting products that may be
irregularly shaped and/or have extensions extending therefrom.
[0017] It is a further object of the invention herein to provide an
inflatable packaging cushion for protecting asymmetrical
products.
[0018] It is yet another object of the invention to provide an
inflatable packaging cushion that is adapted for cushioning and/or
protecting multiple types of products.
[0019] It is still another object of the invention herein to
provide an inflatable packaging cushion that can be used to
surround all sides of a product and to prevent flexing of the
product when surrounded by the inflatable packaging cushion or
cushions.
[0020] It is a further object of the invention herein to provide an
inflatable packaging cushion that can be readily manufactured.
[0021] It is still another object of the invention herein to
provide an inflatable packaging cushion is comprised of materials
that are suitable for recycling and/or reuse.
[0022] It is an additional object of the invention herein to
provide an inflatable packaging cushion for protecting products in
cartons that minimizes the required volume of the carton.
[0023] It is a further object of the invention herein to provide an
inflatable packaging cushion for protecting products in cartons
that is adaptable to a plurality of products.
[0024] It is also an object of the invention herein to provide an
inflatable packaging cushion for protecting products in cartons
wherein the inflatable packaging cushion is adapted for easy
loading and unloading of the product.
[0025] It is another object of the invention herein to provide a
combination of an inflatable packaging cushion for protecting
products in cartons and a carton for receiving the inflatable
packaging cushion and product.
[0026] It is yet another object of the invention herein to provide
an inflatable packaging cushion having a suspension hammock therein
that is adapted to protect the inflatable packaging cushion from
puncture or other damage from a product contained within the
inflatable packaging cushion during shipping or transport of the
product.
[0027] It is still another object of the invention herein to
provide an inflatable packaging cushion that is adjustably
inflatable, and can be adapted to have a varying range of density
according to the use or application for the inflatable packaging
cushion.
[0028] In carrying out the invention herein, an inflatable
packaging cushion is provided that may include a plurality of
inflation tubes to define a structure of the inflatable packaging
cushion, in which the structure includes an interior region defined
by the plurality of inflation tubes. The inflatable packaging
cushion may further include a suspension hammock positioned within
the interior region defined by the plurality of inflation tubes,
and connected to at least one of the inflation tubes. The
inflatable packaging further also includes a package receiving
portion that is configured and dimensioned to receive a product and
a suspension portion that is configured to retain and cushion the
product within the inflation tubes and suspension hammock. The
suspension hammock is configured so that the product within the
suspension portion does not extend past an end of the inflatable
packaging cushion thereby reducing the likelihood of damage to the
product.
[0029] In accordance with an exemplary embodiment of the present
invention, the inflatable packaging cushion may include a product
housing formed by a plurality of connected inflation tubes defining
an interior region of the product housing, and a suspension hammock
secured to the product housing and positioned at least partially
within the interior region of the product housing
[0030] In accordance with the exemplary embodiment of the present
invention, the product housing of the inflatable packaging cushion
may include a first portion and a second portion. The first portion
may be configured for receipt of a product, and the second portion
may be configured for extension of the suspension hammock to cradle
the product, but it is understood that the second portion may also
be configured for receipt of the product and the first portion may
be configured for extension of the suspension hammock to cradle the
product.
[0031] In accordance with the exemplary embodiment of the present
invention, a length of the suspension hammock between a junction
between the first portion and the second portion and a point on the
suspension hammock furthest away from the first portion is less
than the length of the second portion.
[0032] In accordance with the exemplary embodiment of the present
invention, the product housing may include a first pair of walls
formed from the plurality of connected inflation tubes and
positioned parallel with respect to each other, a second pair of
walls formed from the plurality of connected inflation tubes and
positioned parallel with respect to each other and at an angle with
respect to the first pair of walls, and an end wall formed from the
plurality of connected inflation tubes and positioned perpendicular
to the first pair of walls and the second pair of walls.
[0033] In accordance with the exemplary embodiment of the present
invention, the product housing may also include a first end and a
second end. The first end may be positioned at an end of the first
portion and the second end may be positioned at an end of the
second portion, and the suspension hammock may be configured to
create a barrier within the interior region of the product housing
between the first end and the second end of the product
housing.
[0034] In accordance with the exemplary embodiment of the present
invention, the suspension hammock may be made from a suspension
sheet material.
[0035] In accordance with the exemplary embodiment of the present
invention, the suspension sheet material may be made of a laminate
material having a first side and a second side, and he first side
is configured so as to not be weldable to itself and the plurality
of connected inflation tubes.
[0036] In accordance with the exemplary embodiment of the present
invention, the suspension sheet material may be
polytetrafluoroethylene.
[0037] In accordance with the exemplary embodiment of the present
invention, the suspension hammock may include one or more extension
sleeves extending from the suspension hammock to an area outside of
the interior region of the product housing.
[0038] In accordance with the exemplary embodiment of the present
invention, each of the plurality of connected inflation tubes may
include a longitudinal axis, and the longitudinal axis of each of
the plurality of connected inflation tubes may be positioned
perpendicular to the junction between the first portion and the
second portion.
[0039] In accordance with the exemplary embodiment of the present
invention, each of the plurality of connected inflation tubes may
include a longitudinal axis, and the longitudinal axis of each of
the plurality of connected inflation tubes may be positioned
parallel to the junction between the first portion and the second
portion.
[0040] In accordance with the exemplary embodiment of the present
invention, the suspension hammock may be secured to the product
housing at the junction between the first portion and the second
portion of the product housing.
[0041] In accordance with the exemplary embodiment of the present
invention, the junction between the first portion and the second
portion may be a seam connecting the suspension hammock to the
plurality of connected inflation tubes.
[0042] In accordance with the exemplary embodiment of the present
invention, the product housing may be configured for receipt of a
product by suspending the product with the suspension hammock
within the interior region of the product housing.
[0043] In accordance with the exemplary embodiment of the present
invention, the product housing may be configured for insertion into
a carton and for cushioning the product from contacting at least
one of wall of the carton.
[0044] In accordance with the exemplary embodiment of the present
invention, each of the plurality of connected inflation tubes is
inflatable through an individual inflation valve.
[0045] In accordance with the exemplary embodiment of the present
invention, each of the plurality of connected inflation tubes is
inflatable through an individual inflation valve.
[0046] In accordance with the exemplary embodiment of the present
invention, the plurality of connected inflation tubes are
inflatable through a plenum.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0047] For a fuller understanding of the nature and object of the
present invention, reference should be had to the following
detailed description taken in connection with the accompanying
drawings, in which:
[0048] FIG. 1 is an isometric view of an exemplary inflatable
multi-chamber cushion that may be used for the inflatable packaging
cushion according to the present invention, a cutaway is used to
show that inflatable multi-chamber cushion may contain two layers
of film;
[0049] FIG. 2 is an isometric view of an exemplary suspension sheet
that may be used for the inflatable packaging cushion according to
the present invention, a folded over portion of the suspension
sheet indicates that it may have different types of
surfaces/treatments/materials on each side of the suspension
sheet;
[0050] FIG. 3 is an isometric view showing the overlay of the
suspension sheet from FIG. 2 on the inflatable multi-chamber
cushion from FIG. 1;
[0051] FIG. 4 is an isometric view of the overlay from FIG. 3
folded over on itself;
[0052] FIG. 4A is a cross-sectional view taken along line 4A-4A
from FIG. 4;
[0053] FIG. 5 is an isometric view showing tack welding of the
suspension sheet onto the inflatable multi-chamber cushion;
[0054] FIG. 5A is a cross-sectional view taken along line 5A-5A
from FIG. 5;
[0055] FIG. 6A is a bottom isometric view of an exemplary
embodiment of an inflatable packaging cushion according to the
present invention;
[0056] FIG. 6B is a top isometric view of the exemplary embodiment
of the inflatable packaging cushion according to the present
invention;
[0057] FIG. 6C is a cross-sectional view of the exemplary
embodiment of the inflatable packaging cushion taken along line
6C-6C in FIG. 6A;
[0058] FIG. 7A is a side isometric view of the exemplary embodiment
of the inflatable packaging cushion according to the present
invention;
[0059] FIG. 7B is a side isometric view of the exemplary embodiment
of the inflatable packaging cushion according to the present
invention containing an exemplary product;
[0060] FIG. 8 is a top isometric view of two exemplary inflatable
packaging cushions according to the present invention containing
the exemplary product;
[0061] FIG. 9 is a side view of the two exemplary inflatable
packaging cushions according to the present invention containing
the exemplary product, in which the inflatable packaging cushions
are shown transparently in order to show the exemplary product
contained therein;
[0062] FIG. 10 is an isometric view of another exemplary inflatable
multi-chamber cushion that may be used for the inflatable packaging
cushion according to the present invention;
[0063] FIG. 11 is an isometric view of the other exemplary
inflatable multi-chamber cushion folded in half;
[0064] FIG. 12 is an isometric view of the other exemplary
embodiment of the inflatable packaging cushion with its suspension
hammock extending outwardly;
[0065] FIG. 13 is an isometric view of the other exemplary
embodiment of the inflatable packaging cushion with its suspension
hammock extending inwardly;
[0066] FIG. 14 is a side isometric view of the other exemplary
embodiment of the inflatable packaging cushion containing an
exemplary product;
[0067] FIG. 15 is a bottom isometric view of the other exemplary
embodiment of the inflatable packaging cushion containing the
exemplary product;
[0068] FIG. 16 is a bottom isometric view of another exemplary
inflatable multi-chamber cushion that may be used for the
inflatable packaging cushion according to the present
invention;
[0069] FIG. 17 is bottom isometric view of another exemplary
inflatable multi-chamber cushion that may be used for the
inflatable packaging cushion according to the present
invention;
[0070] FIG. 18 is a top isometric view of the other exemplary
inflatable multi-chamber cushion from FIG. 17;
[0071] FIG. 19 is bottom isometric view of another exemplary
inflatable multi-chamber cushion that may be used for the
inflatable packaging cushion according to the present
invention;
[0072] FIG. 20 is a top isometric view of the other exemplary
inflatable multi-chamber cushion from FIG. 19;
[0073] FIG. 21 is a front isometric view of the other exemplary
inflatable multi-chamber cushion from FIG. 19;
[0074] FIG. 22 is a front isometric view of the other exemplary
inflatable multi-chamber cushion from FIG. 19 along with an
exemplary product inserted into the inflatable multi-chamber
cushion; and
[0075] FIG. 23 is a front isometric view of the other exemplary
inflatable multi-chamber cushion from FIG. 19 in which the
exemplary product is held in place by a self-taping extended
sleeve.
DETAILED DESCRIPTION OF THE INVENTION
[0076] The present invention now will be described more fully
hereinafter with reference to the accompanying figures, in which
exemplary embodiments of the invention are shown. The invention
may, however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein. Like
reference numerals refer to like elements throughout.
[0077] Referring now to FIGS. 6A, 6B, 6C, 7A and 7B, therein
illustrated is an exemplary inflatable packaging cushion, generally
indicated by reference numeral 10, according to the present
invention. The inflatable packaging cushion 10 includes a plurality
of inflatable tubes 12, and may be made from an inflatable
multi-chamber cushion that has a plurality of aligned individual
inflatable tubes 12, with each inflatable tube 12 having a
self-sealing inflation check valve (not shown) at one end. A
manifold (not shown) extends across the ends of the inflatable
tubes 12 in communication with the inflation check valve, and the
manifold has an opening at one end thereof for receiving an
inflation device. Suitable inflatable multi-chamber cushions that
may be used for the inflatable packaging cushion 10 are described
in U.S. Pat. Nos. 7,695,786, 7,854,243 and 8,770,408, which are all
hereby incorporated by reference in their entireties. The
inflatable packaging cushion 10 also includes a suspension hammock
14 affixed to at least some of the inflation tubes 12 and
configured to extend towards, but not past, an end of the
inflatable packaging cushion 10. The inflatable packaging cushion
10 may be divided into a product receiving portion 16 and a
suspension portion 18 by a seam 20 that connects the suspension
hammock 14 to at least one of the inflation tubes 12. The
attachment of the suspension hammock 14 to the inflation tubes 12
will be discussed below with respect to the construction of the
inflatable packaging cushion 10.
[0078] Still referring to FIGS. 6A, 6B, 6C, 7A and 7B, the
inflatable packaging cushion 10 is dimensioned and configured to
receive a product 25 in the product receiving portion 16 such that
the product 25 may be extended into the suspension portion 18, but
the suspension hammock 14 cradles the product 25 so that the
product 25 does not extend past the end of the suspension portion
18. The suspension hammock 14 is adapted to support the product 25,
and may preferably be constructed of resilient material to provide
cushioning for the product 25 by acting as a suspension system
within the inflatable packaging cushion 10. The suspension hammock
14 may also preferably be adapted to reduce and/or eliminate
torsional forces that the product 25 may be subjected to during
transport or shipping of the product 25. Since the suspension
hammock 14 is adapted to function as a suspension system within the
inflatable packaging cushion 10, twisting and/or turning motion of
a carton containing the product 25 may not be transferred to the
product 25, since the suspension hammock 14 may act to insulate the
product 25 from movements of the carton. In this manner, the
suspension hammock 14 also acts as a protection barrier to puncture
and/or damage to the inflatable packaging cushion 10 by the product
25 received within the inflatable packaging cushion 10. It is
understood that the present invention is not limited to any
particular dimension and/or configuration, and a rectangular
configuration of the inflatable packaging cushion 10 is illustrated
merely for exemplary purposes. However, it is contemplated that the
inflatable packaging cushion 10 may have any dimension and/or
configuration as appropriate for receiving and cushioning any type
of product 25, regardless of the shape and/or configuration of the
product 25. For example, since a plurality of inflation tubes 12
are utilized and the inflatable packaging cushion 10 is bendable at
each longitudinal connection between the inflation tubes 12, the
inflatable packaging cushion 10 may have any shape and/or
configuration. Exemplary shapes and/or configurations include
square, rounded, octagonal, elliptical, diamond, hexagonal and/or
pentagonal. While a rectangular shaped product 25 is shown, the
present invention is not limited to the inflatable packaging
cushion 10 having the same shape or configuration as the product
25, in order to function to cushion the product 25 during transport
or shipping of the product 25. Instead, it is understood that the
exemplary rectangular configuration of the inflatable packaging
cushion 10 shown FIGS. 6A, 6B, 6C, 7A and 7B may also be used for
asymmetrically shaped products (not shown). In this manner, the
same inflatable packaging cushion 10 configuration is adapted for
multi-purpose use as a result of being adapted to receive and
cushion multiple different products and/or product
configurations.
[0079] Still referring to FIGS. 6A, 6B, 6C, 7A and 7B, the
connection of the suspension hammock 14 to the inflation tubes 12
creates the seam 20 that divides the inflatable packaging cushion
10 into the product receiving portion 16 and the suspension portion
18. It is preferable that the suspension hammock 14 is connected to
one or more inflation tubes 12 such that the product 25 can be
sufficiently cradled by the suspension hammock 14 so that it is not
possible that the product 25 can slip past the suspension hammock
14 and extend out of the suspension portion 18 of the inflatable
packaging cushion 10. For example, the suspension hammock 14 may be
connected to inflation tubes 12 on opposite sides of the particular
configuration of the inflatable packaging cushion 10. It is also
preferable that the suspension hammock 14 be dimensioned and
attached to the inflation tubes 12 such that the suspension hammock
14 does not extend past the end of the suspension portion 18 so
that no portion of the product extends outside of the inflatable
packaging cushion 10. It may be even more preferable that the
suspension hammock 14 is positioned a sufficient distance away from
the end of the suspension portion 18 so that normal compression of
the inflation tubes 12 does not result in the product 25 contained
within the suspension hammock 14 extending outside of the
inflatable packaging cushion 10, which thereby may result in damage
to the product 25.
[0080] Referring now to FIGS. 7B, 8 and 9, the use of the
inflatable packaging cushion 10 according to the present invention
to contain and cushion the product will now be discussed. As shown
in FIG. 7B, the product 25 may be inserted into product receiving
portion 16 and extended into the suspension portion 18. As
discussed above, the suspension hammock 14 cradles the product 25
and prevents the product 25 from extending past the end of the
suspension portion 18 and out of the inflatable packaging cushion
10. A second inflatable packaging cushion 10 may now be placed on
the other end of the product 25 such that the product is
substantially completely enclosed by the inflatable packaging
cushions 10 as shown for example in FIGS. 8 and 9. With the two
inflatable packaging cushions 10 installed on the product 25, the
product 25 is now cushioned from potential damage on all sides of
the product 25 as a result of the inflation tubes 12 acting as
cushioning on the top, bottom and sides of the product 25, and the
suspension hammocks 14 in combination with the ends of the
inflation tubes 12 extending past the suspension hammocks 14 in the
suspension portion 18 cradling and cushioning the ends of the
product 25. The product 25 is also substantially enclosed within
the inflatable packaging cushions 10 such that flexing of the
product 25 is unlikely to occur due to the uniformity of cushioning
containing the product 25. While the product 25 is shown having a
substantially regular shape, it is understood that the inflatable
packaging cushion 10 according to the present invention is suitable
for use of any shaped product, whether regular or irregular, for
example as a result of components of the product extending
irregularly from the product such that normal packaging systems
would not be suitable for cushioning the irregularly shaped
product. It is further understood that while the inflation tubes 12
of the exemplary inflatable packaging cushion 10 are shown running
vertically and perpendicular to the seam 20, it is contemplated
that the inflation tubes 12 may also run horizontally and parallel
with the seam 20.
[0081] Referring now to FIGS. 1-4, 4A, 5 and 5A, the construction
of an exemplary inflatable packaging cushion 10 according to the
present invention will be discussed. FIG. 1 shows standard
inflatable multi-chamber cushion in its deflated configuration, in
which a gas has not yet been introduced into the inflation tubes
12. The multi-chamber cushion maybe constructed from two layers of
suitable film and contains valves 30 configured for introduction of
air or other gases into the inflation tubes 12. FIG. 2 shows a
suspension sheet 32 that is configured for single side welding, and
may be used to construct the suspension hammock 14 of the
inflatable packaging cushion 10 according to the present invention.
The suspension sheet 32 may preferably be made from a resilient
material that is adapted to stretch, but still return to
substantially its original position. The suspension sheet 32
includes a first side 34 and a second side 36, and may be
constructed so that the second side 36 is configured for welding to
the inflation tubes 12, but the first side 34 is configured so that
it does not weld to itself. This can be accomplished by having a
coextruded and/or laminated material, in which a material of the
second side 36 is capable of being welded to itself and/or the
material of the inflation tubes, but a material used for the first
side 34 does not weld to itself. Furthermore, printing may be used
on the first side 34 so that the printing interferes and/or
prevents welding the first side 34 to itself. As another
alternative, a material such as polytetrafluoroethylene (PTFE) can
be used that can be welded to the material of the inflation tubes
12, but not to itself. As shown in FIG. 3, the suspension sheet 32
is laid over a portion of the inflation tubes 12, such that the
first side 34, or the side that does not weld to itself, is facing
away from the inflation tubes 12.
[0082] As shown by the arrow in FIG. 3, the combination of the
suspension sheet 32 and inflation tubes 12 are then folded over
upon themselves to produce the configuration shown in FIGS. 4 and
4A. In this configuration, the first side 34 of the suspension
sheet 32 is positioned between the second side 36 of the suspension
sheet 32, and the second side 36 of the suspension sheet 32 is in
contact with the inflation tubes 12. As shown in FIGS. 5 and 5A,
then suspension sheet 32 may then be welded to at least one of the
inflation tubes 12 by one or more welds 38, and preferably the
inflation tubes 12 are in two layers so welding at one inflation
tube 12 location also welds the suspension sheet 32 to the
corresponding inflation tube 12. The welding of the suspension
sheet 32 to the inflation tubes 12 creates the suspension hammock
14 of the inflatable packaging cushion 10, which is shown in a
collapsed deflated configuration in FIGS. 5 and 5A, and attached to
the inflated packaging cushion 10 at the welds 38. The inflatable
packaging cushion 10 may then be inflated by introducing suitable
gas and/or air into the inflation tubes 12, and then the ends of
the inflated packaging cushion 10 may be connected together by
welding and/or suitable adhesives to form the desired configuration
for the product on which the inflated packaging cushion 10 will be
used. For example, the inflated packaging cushion 10 shown in FIGS.
6A and 6B has a substantially rectangular configuration in order to
receive and cushion rectangular package 25. The inflation tubes 12
of the inflatable packaging cushion 10 are configured to be
adjustably inflatable, and preferably may be inflated to a variety
of internal pressures, for example 10 to 20 psi, depending upon the
application or use of the inflatable packaging cushion 10. The
adaptability of the inflation pressure of the inflation tubes 12
allows for the inflatable packaging cushion 10 to have varying
density due to the amount of gas and/or air introduced into the
inflation tubes 12. The density of the inflatable packaging cushion
10 can be used to adjust cushioning provided by the inflatable
packaging cushion 10. However, it understood that the present
invention is not limited to any inflation pressure of the inflation
tubes 12 or any particular density of the inflatable packaging
cushion 10. It is also understood that the density of the inflation
tubes 12 refers to the relative firmness or softness of the
inflation tubes 12 and is not necessarily limited to the mass per
unit volume of the inflation tubes 12.
[0083] In addition to adjusting the density of the inflation tubes
12 by inflating the inflation tubes 12 to a variety of internal
pressures, the density of the inflation tubes 12 may also be
adjusted by allowing for controlled displacement of the gas and/or
air present in the inflation tubes 12. The displacement of gas
and/or air within the inflation tubes 12 as the result of an
external force applied to the inflation tubes 12, for example
motion of a product within the inflatable packaging cushion 10, can
be adjusted by a number of factors. For example, the diameter of
the inflation tubes 12 used for the inflatable packaging cushion 10
can be increased or decreased in order to allow for greater or
lesser density of the inflation tubes 12 at the same inflation
pressure. In general, larger diameter inflation tubes 12 tend to
react slower to external forces, thereby giving such inflation
tubes 12 a greater relative density, while smaller diameter
inflation tubes 12 react faster to external forces.
[0084] The reaction of the inflation tubes 12 to external forces is
influenced by the amount of gas and/or air displaced within the
inflation tubes 12 as a result of the external force. Larger
diameter inflation tubes 12 tend to have greater relative densities
compared to smaller diameter inflation tubes 12, because if the
same external force is applied to both sizes of inflation tubes 12,
the relative displacement of gas and/or air in the smaller diameter
inflation tubes 12 will be greater, thereby providing softer
cushioning and lower relative density.
[0085] By the same token, the displacement of the gas and/or air
within the inflation tubes 12 may be controlled by changing the
length of the inflation tubes 12 through the use of hinges and/or
compartmentalization. For example, different sections of the
inflatable packing cushion 10 may have different densities of
inflation tubes 12 due to the length of the inflation tubes 12 in
the various sections. For example, a section of the inflatable
packaging cushion 10 with short inflation tubes 12 may have a
relatively low density, thereby providing a softer cushioning
effect, due to the lesser amount of gas and/or air within the short
inflation tubes 12. However, a section of the inflatable packing
cushion 10 with long inflation tube 12 lengths may have a
relatively high density, thereby providing a firmer cushioning
effect, due to the greater amount of gas and/or air within the long
inflation tubes 12. Therefore, it is understood that the while the
present invention is not limited to any particular relative density
of the inflation tubes 12 that may be used for embodiments of the
inflatable packaging cushion 10, the present invention does provide
means for controlling the density of the inflation tubes 12 through
mechanisms that affect the displacement activity occurring within
the inflation tubes 12 due to external forces exerted upon the
inflation tubes 12.
[0086] Referring now to FIGS. 12-15, therein illustrated is another
exemplary inflatable packaging cushion, generally indicated by
reference numeral 110, according to the present invention. The
inflatable packaging cushion 110 includes a plurality of inflatable
tubes 112, and may be made from an inflatable multi-chamber cushion
that has a plurality of aligned individual inflatable tubes 112,
with each inflatable tube 112 having a self-sealing inflation check
valve (not shown) at one end. A manifold (not shown) extends across
the ends of the inflatable tubes 112 in communication with the
inflation check valve, and the manifold has an opening at one end
thereof for receiving an inflation device. Suitable inflatable
multi-chamber cushions that may be used for the inflatable
packaging cushion 110 are described in U.S. Pat. Nos. 7,695,786,
7,854,243 and 8,770,408, which, to any extent not already done so,
are all hereby incorporated by reference in their entireties. The
inflatable packaging cushion 110 also includes a suspension hammock
114 affixed to at least some of the inflation tubes 112 and
configured to extend towards, but not past, an end of the
inflatable packaging cushion 110. The inflatable packaging cushion
110 may be divided into a product receiving portion 116 and a
suspension portion 118, and it is understood that the suspension
hammock 114 may be positioned to extend past the end of the product
receiving portion 116, as shown for example in FIG. 12, but does
not extent past the suspension portion 118, as show for example in
FIG. 15. The attachment of the suspension hammock 114 to the
inflation tubes 112 will be discussed below with respect to the
construction of the inflatable packaging cushion 110.
[0087] Still referring to 12-15, the inflatable packaging cushion
110 is dimensioned and configured to receive a product 125 in the
product receiving portion 116 such that the product 125 may be
extended into the suspension portion 118, but the suspension
hammock 114 cradles the product 125 so that the product does not
extend past the end of the suspension portion 118. It is understood
that the present invention is not limited to any particular
dimension and/or configuration, and a rectangular configuration of
the inflatable packaging cushion 110 is illustrated merely for
exemplary purposes. However, it is contemplated that the inflatable
packaging cushion 110 may have any dimension and/or configuration
as appropriate for receiving and cushioning any type of product
125, regardless of the shape and/or configuration of the product.
For example, since the inflatable packaging cushion 110 is bendable
at each seam 126 formed in the inflation tubes 112, the inflatable
packaging cushion 110 may have any shape and/or configuration.
Exemplary shapes and/or configurations include square, rounded,
octagonal, elliptical, diamond, hexagonal and/or pentagonal. The
suspension hammock 114 may be connected to the inflation tubes 112
at any suitable location, and preferably on a seam between two of
the inflation tubes 112. It is preferable that the suspension
hammock 114 is connected to the inflation tubes 112 such that the
product 125 can be sufficiently cradled by the suspension hammock
114 so that it is not possible that the product 125 can slip past
the suspension hammock 114 and extend out of the suspension portion
118 of the inflatable packaging cushion 110. It is also preferable
that the suspension hammock 114 be dimensioned and attached to the
inflation tubes 112 such that the suspension hammock 114 does not
extend past the end of the suspension portion 118 so that no
portion of the product extends outside of the inflatable packaging
cushion 110. It may be even more preferable that the suspension
hammock 114 is positioned a sufficient distance away from the end
of the suspension portion 118 so that normal compression of the
inflation tubes 112 does not result in the product 125 contained
within the suspension hammock 114 extending outside of the
inflatable packaging cushion 110, which thereby may result in
damage to the product 125.
[0088] Referring now to FIGS. 14 and 15, the use of the inflatable
packaging cushion 110 according to the present invention to contain
and cushion the product will now be discussed. As shown in FIGS. 14
and 15, the product 125 may be inserted into product receiving
portion 116 and extended towards the suspension portion 118. As
discussed above, the suspension hammock 114 cradles the product 125
and prevents the product 125 from extending past the end of the
suspension portion 118 and out of the inflatable packaging cushion
110. A second inflatable packaging cushion (not shown) may be
placed on the other end of the product 125 such that the product is
substantially completely enclosed by the inflatable packaging
cushions 110. With two inflatable packaging cushions 110 installed
on the product 125, the product 125 is now cushioned from potential
damage on all sides of the product 125 as a result of the inflation
tubes 112 acting as cushioning on the top, bottom and sides of the
product 125, and the suspension hammocks 114 in combination with
the inflation tubes 112 extending past the suspension hammocks 114
in the suspension portion 118 cradling and cushioning the ends of
the product 125. The product 125 is also substantially enclosed
within the inflatable packaging cushions 110 such that flexing of
the product 125 is unlikely to occur due to the uniformity of
cushioning containing the product 125. While the product 125 is
shown having a substantially regular shape, it is understood that
the inflatable packaging cushion 110 according to the present
invention is suitable for use of any shaped product, whether
regular or irregular, for example as a result of components of the
product extending irregularly from the product such that normal
packaging systems would not be suitable for cushioning the
irregularly shaped product.
[0089] Referring now to FIGS. 10-13, the construction of an
exemplary inflatable packaging cushion 110 according to the present
invention will be discussed. FIG. 10 shows a standard inflatable
multi-chamber cushion in which a gas has been introduced into some
of the inflation tubes 112, and the remainder of the inflation
tubes 112 are left in a deflated status in order to provide a sheet
of material that can be used for the suspension hammock 114, as
discussed further below. One or more seams 126 may be formed or
provided in each inflation tube 112 in order to allow for folding
and/or bending of the multi-chamber cushion, as shown for example
in FIG. 11. The multi-chamber cushion may then be welded or glued
with suitable adhesive along the top and left-side edge as shown in
FIG. 11 in order to permit the inflatable packaging cushion 110 to
be opened into the configuration shown in FIG. 12. Once in the
configuration shown in FIG. 12, the suspension hammock 114 is then
pushed in towards the interior region of the inflatable packaging
cushion 110 in order to position the suspension hammock 114 within
the inflatable packaging cushion 110, as shown in FIG. 13. In the
configuration shown in FIG. 13, the inflatable packaging cushion
110 is now configured to receive and support a package or other
object.
[0090] FIGS. 16-23 show alternative embodiments and/or
modifications of the inflatable packaging cushion according to the
present invention. For example, FIG. 16 shows an exemplary
embodiment of an inflatable packaging cushion 210 that is
substantially similar to the inflatable packaging cushion 10
discussed above, and like elements are identified by reference
numerals increased by 200. The inflatable packaging cushion 210
shown in FIG. 16 provides an exemplary of an alternative shape and
configuration for the inflatable packaging cushion 210, and that
the suspension hammock 214 may be welded to the one or more
inflation tubes 212 at an end of the inflatable packaging cushion
210 instead of in the interior of the inflatable packaging cushion
210. By welding the suspension hammock 214 to the one or more
inflation tubes 212 at the end of the inflatable packaging cushion
210 it may provide the benefit of facilitating manufacture of the
inflatable packaging cushion 210. The provisional of an alternative
embodiment of inflatable packaging cushion 210 does not in any way
preclude the previously discussed embodiments of the inflatable
packaging cushion according to the present invention from having
the features specifically shown in FIG. 16.
[0091] Referring now to FIGS. 17-18, therein illustrated is another
exemplary embodiment of an inflatable packaging cushion 310
according to the present invention. The inflatable packaging
cushion 310 is substantially similar to the inflatable packaging
cushion 10 discussed above, and like elements are identified by
reference numerals increased by 300. The inflatable packaging
cushion 310 provides an example as to how the inflation tubes 312
may be extended around an end of the inflatable packaging cushion
310 so as to provide additional cushioning for fragile products
that may be inserted into the inflatable packaging cushion 310. In
contrast to inflatable packaging cushion 10, which in no way is
precluded from having any or all of the features of inflatable
packaging cushion 310, in which the ends are open, inflatable
packaging cushion 310 has a closed top design in which the
inflation tubes 312 extend around an end of the suspension hammock
314.
[0092] Referring now to FIGS. 19-23, therein illustrated is another
exemplary embodiment of an inflatable packaging cushion 410
according to the present invention. The inflatable packaging
cushion 410 is substantially similar to the inflatable packaging
cushion 10 discussed above, and like elements are identified by
reference numerals increased by 400. The inflatable packaging
cushion 410 includes extended sleeves of the suspension hammock 414
that may include a self-taping adhesive in order to allow for
closure of the extended sleeves, as seen for example in FIG. 23. As
shown in FIGS. 21-23, the exemplary product 425 may include a
portion that is more fragile than the rest of the product 425, so
this portion may be inserted into the inflatable packaging cushion
410, while the remainder of the product 425 is held in place with
the extended sleeves of the suspension hammock 414. The suspension
hammock 414 is adapted to receive asymmetrical products, such as
the exemplary product 425, and it is understood that the inflatable
packaging cushion 410 is configured for use with multiple different
product configurations. In this manner, it is not necessary to have
multiple packaging means available when preparing multiple
different types of products for shipping or transport. Instead, the
inflatable packaging cushion 410 can be used for a variety of
different products of varying shapes and sizes, and thereby reduces
the need to keep inventory of multiple different types of packaging
means. It is understood that this advantageous aspect of the
present invention is not limited to inflatable packaging cushion
410, but applies equally well to the other exemplary embodiments of
the inflatable packaging cushions discussed above.
[0093] It will thus be seen that the objects set forth above, among
those made apparent from the preceding description, are efficiently
attained and, since certain changes may be made in the above
article without departing from the scope of this invention, it is
intended that all matter contained in this disclosure or shown in
the accompanying drawings, shall be interpreted, as illustrative
and not in a limiting sense. It is to be understood that all of the
present figures, and the accompanying narrative discussions of
corresponding embodiments, do not purport to be completely rigorous
treatments of the invention under consideration. It is to be
understood that the above-described arrangements are only
illustrative of the application of the principles of the present
invention. Numerous modifications and alternative arrangements may
be devised by those skilled in the art without departing from the
scope of the present invention.
* * * * *