Packaging System With Inflatable Cushion
An air cushion is provided for protecting products during shipment, and is fabricated of two sheets of heat sealable thermoplastic material secured together at seams to define an inflatable tube and two product support panels extending across the inside of the tube. The inflatable tube may be rectangular or U-shaped. The product support panels provide a product placement area, including having an opening for receiving and holding a product between the product support panels. The product support panels may be seamed to provide multiple product placement areas or shaped placement product areas. The inflation tube may be provided with stacking height extension legs that fold to overlie or underlie the inflatable tube. The thermoplastic material may include a metallic layer for shielding products from electromagnetic radiation. The air cushion is used with a carton, which closely receives the inflatable tube with the product suspended and supported in the carton.
This application claims priority to U.S. Provisional Application Ser. No. 60/541,596 filed Feb. 4, 2004.
FIELD OF INVENTIONThe invention herein relates to a packaging system including an inflatable cushion that protects and stabilizes a product within a carton.
BACKGROUND OF INVENTIONProducts are generally packaged in boxes for shipment, in order that the product may be protected and kept clean. In many instances, the product is not inherently fragile, but must be stabilized and cushioned within the carton, because movement within the carton could damage the product or permit the product to damage the integrity of the carton. In other instances, the product is fragile and must be protected from impact, deformation or other damaging forces.
In some instances, the product is stabilized and secured within a box by one or more preformed foam inserts. The foam insert(s) fill the space between the product and the inside walls of the carton, being shaped to conform to the product and maintain space between the product and the walls of the carton. There are many drawbacks to foam insert packaging systems. First, the foam inserts themselves are relatively expensive to fabricate. Second, the use of foam inserts has many additional costs that are primarily due to the bulk of the inserts. These include the space and consequent high shipping costs of delivering the foam inserts to the user, the amount of storage space required by the foam inserts at the user's facility, and the bulk of the foam inserts when disposed of. In fact, the foam inserts are sufficiently bulky that many users can only keep a few days' supply of foam inserts on their premises, wherein there is a risk of running out of inserts upon any disruption in the delivery process. Also, the foam inserts are not ecologically friendly, in that they are generally not made of recycled materials and are themselves difficult to collect for recycling.
An alternative system for surrounding and stabilizing products within shipping cartons is the use of cardboard spacers. The spacers are generally custom-designed for the product and carton, and often require folding and carefully positioning in order to accept the product and place the product within the shipping carton. The cardboard spacing systems are also relatively expensive and bulky, in addition to being somewhat difficult and labor-intensive to use.
Air cushioning systems have also been provided. These systems generally utilize a pillow of one or a plurality of inflated air compartments positioned above, below and beside a fragile product, i.e. air cushioning is provided on all sides of the product. When the product is not fragile, air filled bags have been used to fill voids in a box containing the product, so that the product is stabilized in the box.
All of these systems have certain drawbacks, and improvements on them would be welcome to those who package and ship products.
SUMMARY OF THE INVENTIONIt is a principal object of the invention herein to provide improved packaging of products for shipment.
It is an additional object of the invention herein to provide an efficient alternative to foam inserts and/or cardboard spacers for protecting and stabilizing products in cartons.
It is also an object of the invention herein to reduce the shipping space, storage space and disposal space of protection systems utilized in shipping products in cartons.
It is a further object of the invention to provide improved air cushion packaging devices.
It is also an object of the invention to provide improved air cushion packaging devices that are adaptable to a wide range of products.
In carrying out the aspects of the invention herein, an air cushion for protecting products during shipment has a product placement area formed of two facing product support panels, which are portions of two substantially air impervious heat sealable thermoplastic sheets. An inflatable tube substantially surrounds the product placement area and is formed by tube walls that are respectively integral with the product support panels, namely, additional portions of the thermoplastic sheets that form the product support panels. An inside seam of the inflatable tube joins the thermoplastic sheets and the product support panels extend from the inside seam. An outside seam joins the two thermoplastic sheets opposed from the inside seam, thereby forming the inflatable tube. The outside seam may only have two segments if the two thermoplastic sheets are in the form of tube stock. An inflation valve is secured between the two thermoplastic sheets for admitting air to the inflatable tube and sealing air therein.
In other aspects of the invention, one of the product support panels has a slit creating an opening, whereby a product may be inserted in a product placement area between the two product support panels. Multiple slits may also be provided to accommodate a particular product.
The produce placement area may be rectangular and may be surrounded by the inflatable tube. The inflatable tube may be U-shaped, to expose an open end of the product support panels, and the distal ends of the U-shaped inflatable tube may fold across the open end of the product support panels to substantially surround the product placement area.
According to further aspects of the invention, the product support panels may be joined by a seam or seams to define a product placement area for a product of a particular shape. Also, the product support panels may be joined by seams to provide multiple product placement areas in the product support panels. Each such product placement area is provided with at least one opening in one of the product support panels.
In further aspects of the invention, two and preferably four additional stacking-height extension legs are provided adjacent to and extending from the inflation tube, the stacking-height extension legs being formed of further portions of the two thermoplastic sheets. The stacking-height extension legs are separated from the inflation tube by heat-fused seams, which are discontinuous to provide air communication for inflating the stacking-height extension legs with the inflation tube. The stacking-height extension legs are foldable for deployment generally perpendicular to the product support panels, and are thereby adapted for positioning adjacent the walls of the carton in which the air cushion and a product supported thereby is inserted. Stacking-height extension legs having an inflated height greater than the diameter of the inflatable tube may be tufted by heat-fused spots, to maintain a width not substantially greater than the inflatable tube and thereby coordinate with the inflatable tube in fitting into a carton. The stacking-height extension legs are preferably provided in two diametrically opposed pairs, and one pair may be folded upwardly and one pair may be folded downwardly for nesting multiple air cushions with stacking-height extension legs in a carton.
According to a further aspect of the invention, an air cushion may be formed of thermoplastic sheets including a metallic layer for electro-magnetically shielding products supported therein. The product support panels are configured to fully surround and shield the product.
In also carrying out additional aspects of the invention herein, a shipping system is provided for a product having a general shape consisting of a top, bottom, peripheral side wall. The shipping system includes a rectangular carton sized and shaped to receive the product with clearance between the peripheral wall of the product and the walls of the carton. The shipping system also includes an air cushion including an inflatable tube substantially surrounding the peripheral wall of the product placed in a product placement area on product support panels substantially surrounded by the inflatable tube and sized and shaped for receiving one of the top and bottom of the product, and an inflation valve for admitting inflation air for inflating the tube to substantially surround the peripheral wall of the product with the product suspended and substantially surrounded by the inflatable tube. The tube is dimensioned so that upon inflation thereof, it surrounds the peripheral wall of the product and stabilizes the position of the product within the shipping carton.
The product may have a flange extending from the peripheral wall as an extension of the top of the product, and the air cushion is dimensioned to receive the flange on the inflatable tube.
Also according to aspects of the invention, the air cushion is fabricated of two sheets of polymer heat sealable air impervious material. The surface of the polymer sheet material contacting the product may have a higher co-efficient of friction than the surface of the sheet contacting walls of the shipping carton. This permits the air cushion and product to be easily inserted into the shipping carton and enhances the ability of the air cushion to stabilize the air product within the shipping carton.
The foregoing and other objects and features of the invention herein will, in part, be apparent to those skilled in the art and will in part appear in the description of the preferred embodiments and the claims, taken together with the drawings.
BRIEF DESCRIPTION OF DRAWINGS
The same reference numerals refer to the same elements throughout the various figures.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS With reference to
The packaging system 10 includes a carton 12 and an air cushion 14. The carton 12 is fabricated of corrugated carton stock and has a bottom 16, peripheral side walls 18 and end walls 20, and cover flaps 22 and 24, which fold flat and are taped or glued to assemble the carton 12 in a rectangular closed configuration. As shown in
Prior to the invention herein, the product 1 was held in position by a foam carton insert consisting of a foam periphery, and a foam bottom panel. The tray 2 fitted in the foam insert with the flange supported on the peripheral foam wall which held the top of the tray against the underside of the cover flaps 22 and 24, when they were folded shut.
The air cushion 14 is shown in
With reference to FIGS. generally rectangular, with rounded corners, sized so that lly surrounds the peripheral side wall 3 of the product 1. With particular reference to
The packaging system 10 passes all drop and shock tests that are required of the foam packaging insert it replaces. It saves substantial amounts of shipping and storage room by the user. For instance, one pallet of air cushions 14 will provide for shipping the same number of products as seventy-five pallets of foam inserts. The recipient of the packages also benefits, in that the air cushion may be punctured or otherwise deflated to return it to its compact form for disposal. Disposal may include recycling.
With reference to
The air cushion 50 is characterized by a slit 52 in the support panel 38. The slit 52 creates an opening 54, which provides for inserting a product 56 into a product placement area 58 between the product support panels 38 and 39.
The air cushion 50 is used in conjunction with a carton 60, the side walls 61, 62 and end walls 63, 64 of which are seen in
In air cushion 70, the product support panels 38, 39 are heat fused together along seams 72 and 74, to divide the product support panels into four product placement areas 76-79. Each of the product placement areas 76-79 is respectively provided with a slit 80-83 in the product support panel 38, wherein products may be inserted into each of the product placement areas 76-79. The air cushion 70 is inserted in a carton 60 for shipping, as described above with respect to air cushion 50. This configuration is useful for packaging a plurality of small, fragile products.
In
With reference to
The air cushion 100 has a generally rectangular inflation tube 102 with opposed side portions 104, 105 and opposed end portions 106, 107. As with the other air cushions disclosed above, the comers between the side portions and end portions are rounded for smooth transmission and the avoidance of stress points on the seams.
The inflation tube 102 is defined by inside seam 110, and product support panels 112 and 113 extend from the inside seam 110. A slit 114 provides an opening for inserting a product 116 into a product placement area 118 between the product support panels 112 and 113.
Adjacent side 104 of the inflation tube 102, a first stacking height extension leg 120 is formed, by seam 122 and by the portion 124 of outer seam 125 defining the inflatable tube 102. The seam portion 124 has discontinuities to form openings 126, permitting air communication between the stacking height extension leg 120 and the inflatable tube 102. Thus, the inflation valve 128 for the air cushion 100 may be placed in seam 122, for inflating the stacking height extension leg 120, the inflatable tube 102, and additional stacking height extension legs, as further described below.
A second stacking height extension leg 130 is formed extending from side 105 of inflatable tube 102, opposite the stacking height extension leg 120, stacking height extension leg 130 is defined by seam 132 and by portion 134 of the outside seam 125. The seam 134 is discontinuous to provide openings 136 for inflating the stacking height extension leg 130.
Stacking height extension legs 140 and 142 are similarly respectively formed adjacent end portions 105 and 106 of the inflation tube 102. In the air cushion 100 illustrated, flaps of the two thermoplastic sheets forming the air cushion remain at the comers, such as flap 144. If desired, these may be cut away, but they do not interfere with the operation of the air cushion 100.
With reference to
To promote a vertical stacked relationship of the inflation tube 102 and the stacking height extension legs, it is preferred that the diameter D
As shown in
In some instances, it is desirable that the stacking height extension legs have a greater dimension than provided in air cushion 100, where the dimension is approximately equal to the diameter of the inflatable tube 102. However, it is also preferable to provide the stacking height extension leg having a thickness of approximately the same dimension as the diameter of the inflatable tube 102. An air cushion 160 shown in
The air cushion 160 is also fabricated of two thermoplastic sheets heat sealed together along seams that provide the structure and configuration required. The air cushion 160 has an inflatable tube 162, with side portions 164, 165 and end portions 166, 167. A first stacking height extension leg 170 is formed by seam 172 adjacent side 164, and seam 174 between the stacking height extension leg 170 and inflatable tube 162 is discontinuous for air communication. An inflation valve 163 is provided.
The stacking height extension leg 170 has a height H approximately twice as great as the diameter Dt of the inflatable tube 162. In order that the stacking height extension leg 170 does not assume a greater diameter, heat-fused spot seams 176 are provided joining the two thermoplastic sheets approximately midway across the stacking height extension leg 170. This causes the stacking height extension leg 170 to assume a tufted configuration when inflated, as best seen in
As best seen in
With initial reference to
With further reference to
A slit 212 is formed through both product support panels 205 and 206, and the slit is U-shaped having end legs 214 and 215 aligned with the product support seam 210. This provides end flap 216 of the product support panel 204 and end flap 218 of the product support panel 206 and the end flaps 216 and 218 are overfolded as shown in
Two product support panels extend from the side legs 234, 236 and the end leg 238, and define an entry opening at 250 for inserting a product. If desired, the product support panels can be provided with product support seams positioned to closely accommodate the dimensions of the product, such as a picture frame. One advantage of the air cushion 230 is that the entry to the product placement area between the two product support sheets is the full width between the legs 234 and 236, wherein a relatively wide product may be easily inserted.
With reference to PIG. 19, once the product has been inserted, the air cushion 230 and the product therein may be inserted into a carton 260 through an open end thereof. The end portions of the legs 234, 236 are then be folded inwardly to be contained within the carton when its end flaps are closed, and the two end portions provide the cushioning protection for the product at the open end of the product support panels, as illustrated in
The air cushions described above are preferably made of heat-fusible polymers, such as mono-layer of polyethylene, or polyethylene laminated with other and more highly air impervious layers if long air retention time is desired, all as is well known in the art. In addition, the surface of the air cushion which is received against a product may be provided with a different coefficient of friction, such as by selection of the film or embossing or matte finishing the film, to assist in holding the product in place on the air cushion. Further, the surface of the air cushion presented to the interior of the carton may be provided with a lower coefficient of friction, so that the air cushion and product slide easily into the carton. All air cushions described above share the benefits of being shipped compactly to the user and stored in a small space by the user. They are also easily reduced in bulk for disposal, and may be recycled. The inflatable tubes of the air cushions typically have a width and length of about 15″-20″ and a diameter of about 1″-3″ when inflated, but both larger and smaller dimensions are within the scope of the invention.
It will be appreciated that the inflatable tubes may continuously or substantially surround the product, and that the inflatable take may be provided in segments or connected chambers, as desired. Also, the configuration of slits, openings and seams utilized to receive a product on the product on the product support panels may be varied to accommodate a variety of products.
The foregoing packaging systems admirably achieve the objects of the invention herein. However, it will be understood that they are illustrative of the invention, and that various changes may be made without departing from the spirit and scope of the invention, which is limited only by the following claims.
Claims
1. An air cushion for protecting products during shipment, the air cushion fabricated of two sheets of heat sealable thermoplastic material secured together by heat sealed seams, and comprising:
- a. an inflatable tube having a closed or substantially closed configuration, the inflatable tube in part defined by an inside seam;
- b. two facing product support panels extending from the inside seam of the inflatable tube; and
- c. the product support panels providing a product placement area for receiving and holding a product suspended on the product support panels and substantially surrounded by the inflatable tube.
2. An air cushion for protecting products during shipment as defined in claim 1, wherein the inflatable tube has a continuous, closed configuration.
3. An air cushion for protecting products during shipment as defined in claim 2, wherein the inflatable tube has a generally rectangular configuration.
4. An air cushion for protecting products during shipment as defined in claim 1, the air cushion having a U-shaped configuration wherein the distal ends of the legs of the U-shaped inflatable tube are foldable to substantially surround a product in the product placement area.
5. An air cushion for protecting products during shipment as defined in claim 1, wherein one of the product support panels is slit to define an opening, and the product placement area is defined between the product support panels and accessible for inserting and removing a product through the opening.
6. An air cushion for protecting products during shipment as defined in claim 5, wherein the product support panels are joined by the seams to provide multiple product placement areas, and at least one of the product support panels in some of the product placement areas being provided with a slit defining an opening for inserting and removing a product.
7. An air cushion for protecting products during shipment as defined in claim 6, wherein the product support panels are joined by one or more seams to define one or more product placement areas closely accommodating the shapes of one or more particular products.
8. An air cushion for protecting products during shipment as defined in claim 1, and further comprising the plurality of stacking height extension legs extending from the inflatable tube at an outside seam thereof and foldable to overlie or underlie the inflatable tube.
9. An air cushion for protecting products during shipment as defined in claim 8, wherein the stacking height extension legs are sized to provide a thickness of approximately the same dimension as the diameter of the inflatable tube.
10. An air cushion for protecting products during shipment as defined in claim 9, wherein the stacking height extension legs have a stacking height greater than the diameter of the inflatable tube, and are provided with medial discontinuous seams limiting the thickness of the stacking height extension legs to approximately the same dimension as the diameter of the inflation tube.
11. An air cushion for protecting products during shipment as defined in claim 1, wherein the sheets of heat sealable thermoplastic material incorporate a conductive layer, whereby a product received in a product placement area between the product support panels is shielded from electromagnetic fields.
12. An air cushion for protecting products during shipment as defined in claim 1 and further comprising a carton for receiving the air cushion and product, the air cushion and carton sized and dimensioned such that the air cushion is supported against the sides, top and bottom of the carton and the product is suspended and substantially surrounded by the inflatable tube within the carton.
13. A packaging system as defined in claim 11 wherein the inflatable cushion is made of two sheets of substantially air impervious material, the surface of one sheet having a higher co-efficient of friction than the surface of the other sheet so that the surface with the higher co-efficient of friction grips the product to hold the air cushion in position and the sheet with the lower co-efficient of friction facilitates sliding the product and air cushion into the carton.
14. A packaging system for a product having a peripheral wall, a top and a bottom, the packaging system comprising:
- a. a generally rectangular carton dimensioned to receive the product with clearance around the peripheral wall of the product;
- b. an air cushion having inflatable tube sized for contacting and engaging the walls of the carton when inflated and placed therein, a valve for inflating the inflatable tube; and
- c. the air cushion having a product placement area defined by two facing product support panels integral with and extending from the inflatable tube,
- wherein the product support panels are adapted to support a product in the product placement area and provide air cushioned separation between the product and at least some walls of the carton, thereby stabilizing and cushioning the product therein.
15. A packaging system as defined in claim 14 wherein the inflatable tube fully surrounds a peripheral sidewall of the product.
16. A packaging system as defined in claim 15 wherein at least one of the product support panels defines an opening for inserting a product into the product placement area which is between the product support panels.
17. A packaging system as defined in claim 14 wherein the inflatable cushion is made of two sheets of substantially air impervious material, the surface of one sheet having a higher co-efficient of friction than the surface of the other sheet so that the surface with the higher co-efficient of friction grips the product to hold the air cushion in position and the sheet with the lower co-efficient of friction facilitates sliding the product and air cushion into the carton.
Type: Application
Filed: Feb 4, 2005
Publication Date: Dec 6, 2007
Inventor: Michell Tschantz (Newtown, CT)
Application Number: 10/588,055
International Classification: B65D 85/30 (20060101);