Abstract: A packaging assembly is disclosed in which an article is supported in a suspended position in an outer container during shipping. The article is sandwiched between a pair of cushions, each cushion including a noninflated central web and a pair of inflated sidewalls and end walls. The sidewalls and end walls of the bottom cushion project away from the central web downwardly and outwardly toward the bottom edges of the outer container. The sidewalls and end walls of the upper cushion project away from the central web upwardly and outwardly toward the top edges of the outer container. The sidewalls and end walls of the two cushions together define flexible arches which project in all of the orthogonal directions of the outer container, protecting the article against an impact force in any direction.

Abstract: A packaging device is disclosed for forming packaging cushions of the type that include a plastic bag filled with a solid foam, and wherein the cushions are initially formed of a plastic bag filled with a foamable material that reacts and then hardens to form solid foam. The device comprises means for advancing a sheet of plastic film material that has been center-folded to form a doubled web with one closed edge defined by the center fold and one open edge defined by the adjacent edges of the sheet. Means are included for injecting a foamable composition into the center-folded web between the two folded portions of the sheet, as are means for forming a substantially linear seal along the open edge and substantially parallel to the open edge to thereby longitudinally seal the open edge of the web.

Abstract: There is provided an inflatable packaging cushion for protecting an article and adapted to the shape and dimensions of an enclosed container. The inflatable packaging cushion has a plurality of inflatable chambers such that the sides and corners of the article are cushioned by the inflatable chambers. The inflatable chambers are interconnected through tie straps whereby at least one tie strap connects each chamber to an adjacent chamber. Each inflatable chamber includes a filling means for at least partially inflating each chamber with a filler medium. The inflatable chambers may assume various forms, depending on the shape of the article to be cushioned and the enclosed container. Additionally, there is provided a shipping container which includes a box and an inflatable packaging cushion for protecting an article adapted to the shape and dimensions of the box.