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.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

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

1. Field of the Invention

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.

2. Description of Related Art

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.

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.

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.

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.

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.

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.

Accordingly, there is a need for improved packaging cushions.

SUMMARY OF THE INVENTION

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.

It is a principal object of the invention herein to provide an inflatable packaging cushion for protecting products.

It is a further object of the invention herein to provide an inflatable packaging cushion for protecting products that may be contained within cartons.

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.

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.

It is a further object of the invention herein to provide an inflatable packaging cushion for protecting asymmetrical products.

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.

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.

It is a further object of the invention herein to provide an inflatable packaging cushion that can be readily manufactured.

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.

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.

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.

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

In accordance with the exemplary embodiment of the present invention, the suspension hammock may be made from a suspension sheet material.

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.

In accordance with the exemplary embodiment of the present invention, the suspension sheet material may be polytetrafluoroethylene.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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

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:

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;

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;

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;

FIG. 4 is an isometric view of the overlay from FIG. 3 folded over on itself;

FIG. 4A is a cross-sectional view taken along line 4A-4A from FIG. 4;

FIG. 5 is an isometric view showing tack welding of the suspension sheet onto the inflatable multi-chamber cushion;

FIG. 5A is a cross-sectional view taken along line 5A-5A from FIG. 5;

FIG. 6A is a bottom isometric view of an exemplary embodiment of an inflatable packaging cushion according to the present invention;

FIG. 6B is a top isometric view of the exemplary embodiment of the inflatable packaging cushion according to the present invention;

FIG. 6C is a cross-sectional view of the exemplary embodiment of the inflatable packaging cushion taken along line 6C-6C in FIG. 6A;

FIG. 7A is a side isometric view of the exemplary embodiment of the inflatable packaging cushion according to the present invention;

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;

FIG. 8 is a top isometric view of two exemplary inflatable packaging cushions according to the present invention containing the exemplary product;

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;

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;

FIG. 11 is an isometric view of the other exemplary inflatable multi-chamber cushion folded in half;

FIG. 12 is an isometric view of the other exemplary embodiment of the inflatable packaging cushion with its suspension hammock extending outwardly;

FIG. 13 is an isometric view of the other exemplary embodiment of the inflatable packaging cushion with its suspension hammock extending inwardly;

FIG. 14 is a side isometric view of the other exemplary embodiment of the inflatable packaging cushion containing an exemplary product;

FIG. 15 is a bottom isometric view of the other exemplary embodiment of the inflatable packaging cushion containing the exemplary product;

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;

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;

FIG. 18 is a top isometric view of the other exemplary inflatable multi-chamber cushion from FIG. 17;

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;

FIG. 20 is a top isometric view of the other exemplary inflatable multi-chamber cushion from FIG. 19;

FIG. 21 is a front isometric view of the other exemplary inflatable multi-chamber cushion from FIG. 19;

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

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

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.