Abstract:
An air bladder packing system having an inflatable center body and extensions therefrom. The center body is generally for placement on top of an item placed in an outside box while the fingers are designed for positioning in the spaces between the item and the walls of the box. After placement, the air bladder is inflated to span the space between the item and the box, thereby securely holding the item in the box and providing protection against shifting during transport and providing impact protection.

Description:
This application is a continuation-in-part of U.S. patent application Ser. No. 10/721,846, filed Nov. 25, 2003 now abandoned. 
   CROSS-REFERENCE TO RELATED APPLICATIONS 
   Reference is made to commonly-assigned copending U.S. patent application Ser. No. 10/980,351, filed Nov. 3, 2004, entitled “AIR BLADDER PACKING SYSTEM AND PROCESS FOR USING THE SAME”, by Joop Peterse et al., the disclosure of which is incorporated herein. 

   BACKGROUND AND SUMMARY 
   Most consumer equipment, especially electronics, and much commercial equipment comes carefully packaged in rigid foam or other sturdy and form-fitting packaging material designed to cushion and hold the equipment firmly within an outer box. Where the equipment is mass produced and automatically packaged, custom-formed packing inserts are the norm. Where economies of scale cannot justify the costs of design, tooling, and production of specialized inserts, other packing materials are desired. The desire for a flexible and inexpensive packing material is particularly relevant to the repair and reconditioning industry. In particular, substantially sized equipment such as printers, television sets, and similar bulky items. 
   In addition to custom-fitting inserts, so-called packing “peanuts” or “shells” are sometimes used. Such loose packing typically comprises foam or cellulose pellets that are poured around equipment once placed in the outer box. Drawbacks include the shifting of the pellets during handling of the box and the danger of small particles or fibers separating from the pellets and infiltrating the equipment. Even when the equipment is wrapped in plastic, the tiny fibers and particles from pellets are messy and can infiltrate the equipment during unpacking. 
   For small to medium size items, a series of airbags are offered as packing material by companies such as Polyair Inter Pack, Inc. Polyair&#39;s Airspace Pillow Packaging System™ is typical in comprising a series of rectangular airbags of thin plastic that are initially held together along perforated edges. When packing equipment or small items, the requisite number of airbags are torn off and packed around the shipped items. Among disadvantages are the inability to tightly pack bulky items both because the airbags are made of easily broken thin membranes and because it is difficult to tightly pack airbags that are already inflated. This disadvantage is particularly likely to occur near the lower portions of outer boxes since fingers and hands become blocked by the airbags themselves. A product brochure with pictorial and text explanations is found at www.polvair.com. 
   Another example of an airbag packing system is found in U.S. Pat. No. 3,398,501 issued Aug. 27, 1968 to Aninger. According to its Abstract, this patent teaches a method and equipment for the packing of complex, irregularly shaped fragile and delicate articles of merchandise selectively. The packing is accomplished by means of an inflatable pneumatic cushion configuration adapted to be placed around the article of merchandise and to be joined through fastening means which are integral with said pneumatic cushion. Unfortunately, however, the need to fasten the extensions, or fingers, of the balloon in Aninger limits the size of item that can be packaged with any particular balloon. Also, as noted in column  2 , lines  1 – 4  and in  FIG. 4  (where the balloon conforms to the detailed contours of the packaged item), the balloon material in Aninger is “expandable”, or elastic. As discussed below, such elasticity works well for the fragile and delicate items contemplated in Aninger but would be detrimental if used to package bulkier, more massive items. 
   It would be desirable to have inexpensive, versatile, non-contaminating and easily installed inner packaging material, especially one suitable for packaging bulky and fairly massive items such as office equipment. 
   One embodiment of the invention is an air bladder packaging system for packing an item having sides in an outer box having walls wherein a space exists between a side and a wall, such packaging system comprising: an inflatable center body for placement proximate to one surface of the item; a plurality of inflatable fingers attached to the center body and having a length, at least a portion of the length being designed for placement along a side of the item in the space between the side and a wall of the outer box; and a valve through which compressed gas may be inserted into the air bladder; wherein, once sufficient gas is inserted, a portion of the finger spans the space between the side of the item and the wall of the box. 
   Another embodiment of the invention is an air bladder packaging system for packing an item having sides, such packaging system comprising: an outer container having walls wherein a space exists between a side of the item and a wall; an inflatable center body for placement proximate to one surface of the item; a plurality of inflatable fingers attached to the center body and having a length, at least a portion of the length of a first inflatable finger being designed for placement along a first side of the item in the space between the side and a wall of the outer box wherein the fingers are comprised of essentially inelastic material and wherein a second finger has a length and at least a portion of the length of the second finger is designed for placement along a second side of the item; and a valve through which compressed gas may be inserted into the air bladder; wherein, once sufficient gas is inserted, a portion of the finger spans the space between the side of the item and the wall of the container. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an elevated perspective view of one embodiment of the invention used in packing an item in an outer box. 
       FIG. 2  is an elevated orthogonal view of another embodiment of the invention in an uninflated condition. 
       FIG. 3  is an elevated orthogonal view of another embodiment of the invention in an uninflated condition. 
   

   DETAILED DESCRIPTION 
   For a general understanding of the present invention, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate identical elements. 
   Referring first to  FIG. 1 , a bulky item  11  such as a printer or television set is shown packaged in an outer box  12 . Box  12  is shown placed on pallet  13 . Inner packing is formed by air bladder  10 . Air bladder  10 , in this embodiment, is composed of a round central body  15 , a series of fingers  16 , and a valve  17  through which air may be inserted and removed. Air bladder  10  is inserted into box  12  on top of item  11  while air bladder  10  is either uninflated or slightly inflated. Once wrapped over and around item  11 , air bladder  10  is inflated sufficiently such that fingers  16  snugly span the space between the sides of item  11  and outer box  12 . In the event that central body  15  does not inflate to fill the entire height of box  12 , then additional packing material  19  such as an additional air bladder or other simple packing material can be added to firmly span the height. As shown in  FIG. 1 , item  11  will generally be packed with bottom packing material  18  to cushion the bottom of item  11 . 
   Referring to  FIG. 2 , another embodiment of air bladder  10  is shown prior to insertion and inflation. In contrast to a round central body  15  as shown in  FIG. 1 , center body  25  is rectangular and is suitable to fill the cross-sectional area of a rectangular box. As will be understood, central body  25  can be round, square, rectangular, elliptical, triangular, star-shaped, or any other regular or irregular shape. The central body may also simply comprise the junction of tubular appendages like fingers  16  of  FIG. 1 . 
   Fingers may also take any number of shapes and sizes. In  FIG. 1 , fingers  16  are long tubes that can extend down the entire side of box  12 . In  FIG. 2 , fingers  26  are essentially semicircles or other arc shaped appendages attached to central body  25 . Such a configuration may be preferred for comparatively short and wide outer boxes. Also shown in  FIG. 2  is a fill tube  27  topped with a valve  17 . Such a fill tube allows easier inflation by permitting the user to pull and maneuver the valve to more positions of choice. The seams  28  between fingers  26  and center body  25  are ideal locations to fold or bend fingers from the plane of the center body to the angles necessary to slip between the packed item  11  and outer box  12 . These seams may be completely formed between the intersection of fingers and the center body or may be partially formed in order to permit gas to flow from one chamber to the next. 
     FIG. 3  shows a round central body  35  with eight fingers  36 . Any number of fingers are feasible, and the more fingers  36 , the more that air bladder  10  can accommodate irregular shapes by draping various fingers over recessed areas of item  11 . Fingers  36  may also be of varying length, as shown in  FIG. 3 . Such varying length may be preferred in order to diminish the amount of compressed air that must be inserted into air bladder  10  for proper inflation. Each finger may have its own air valve or, more commonly, one valve  17  will be located on the central body, on any of the fingers, or on a filling tube that can be manipulated for easy attachment of an air hose or other means of inserting gas. In the event that only one valve  17  is present, then the central body and each of the fingers will have a communicable passage allowing air in one chamber to pass into adjoining chambers until all have filled with gas. 
   It is expected that air bladder  10  can be made of either thin film plastic for throw-away bags or made of heavier and more durable plastic for airbladders intended to be reused. Polyethylene, polypropylene, and PVC are among the large number of plastic resins suitable for use as the film material comprising air bladder  10 . Virtually any flexible, essentially inelastic plastic film material that is airtight can be used, especially if it is thermoplastic in order to make heat-sealing of seams possible. If thick enough, even film material comprising elastomers becomes essentially inelastic. For environmental benefits, air bladder  10  may be made of bio-degradable plastics and accordingly offer environmental advantages over existing packing materials such as non-degradable rigid foam. In addition, air bladders of the present invention occupy less volume when uninflated and are accordingly easier to ship and store. 
   The air bladder packing system described above is ideal for use whenever packing material customized for a bulky or heavy item is not available. Such lack of customized packing material often occurs when equipment is being picked up remotely from its manufacturing facility for repairs or reconditioning. Uninflated air bladders are ideal for providing drivers of trucks or other vehicles an inexpensive system for safely packing items of unpredictable size and shape. Lack of customized packing materials also often occurs when preparing to ship used equipment, including reconditioned equipment, for resale or other use, and for repaired items being returned. When dealing with non-factory items, it is often too expensive to inventory customized packing for many different items, and the flexibility of an air bladder system should considerably reduce inventory cost and space. Unlike elastic balloon-type bladders, the flexible and essentially inelastic bladders of the present invention provide adequate protection and holding capability when used to package heavy and bulky items. If elastic, then a packaged item having significant mass can shift from side to side within the outer container by compressing first one finger and then another of an elastic bladder. The essentially inelastic bladder thus provides firmer, more versatile, and more dependable packaging, especially for large and bulky items. 
   Although air bladder  10  may be inflated prior to insertion into box  12 , it is anticipated that in most instances, a valve such as valve  17  will be provided in order that air bladder  10  be inserted while uninflated or only partially inflated. One possible process for packing an item  11  such as a printer into a box  12  comprises: Prior to placing item  11  into the box, an air bladder of the present invention or other suitable packing material is placed into box  12  at the location on which item  11  is to be placed. If an air bladder is used, it may be at least partially inflated before item  11  is lowered into the box or it may initially remain uninflated. Item  11  is then placed into box  12  by usual handling techniques. Such techniques may comprise, without limitation, placing item  11  onto unfolded box  12  and then forming box  12  around item  11  by folding the sides upward. Similarly, the base of box  12  may be separate from the sides and top of box  12 , and after item  11  is placed on the base, the sides and top of box  12  are dropped over item  11  and fastened to the base member. In the normal course, box  12  will be pre-assembled and opened on the top. Item  11  will be manually or otherwise gripped, raised over the open end of box  12 , and lowered into the box. Next, packers place an uninflated or partially inflated air bladder of the present invention on item  11  and generally center its central body over item  11 . The appendages, or fingers, of air bladder  10  will then be draped over the sides of item  11  and inside outer box  12 . If the fingers are sufficiently uninflated, then they may be simply lowered, or dropped in the space between item  11  and box  12 . If simple lowering is not sufficient, than a packer&#39;s hand or simple tool can push and manually brush the fingers until they fully extend toward the bottom of box  12 . Air bladder  10  is then inflated by coupling valve  17  to a pressurized air hose until each of the fingers have expanded sufficiently to press and hold item  11  snugly against the sides of box  12 . In the event that an air bladder of the present invention was placed underneath item  11  prior to its placement into box  12 , then the bottom air bladder will be pressurized. This may be done immediately after item  11  is placed in box  12  or after the “top” air bladder has been placed and filled. The valve for the bottom air bladder may be reachable either because it is near the tip of one of its fingers which were lifted above the bottom of the box or because the box is turned over, and access to the valve was obtained through the end of the box proximate to the “bottom” airbladder. In the event that there is extra space between the top of the air bladder center body and the top lid or enclosure member of box  12 , then additional packing material can be added, including another air bladder if desired. Once delivered, removal of the air bladder is simplified by simply opening the air valve. The air bladder can then deflate and be ready for reuse. 
   In review, the inflatable air bladder of the present invention includes a center body, fingers, and an air valve and is designed to be inflated around an item to be shipped, thereby providing inexpensive, flexible, and reliable packing protection. When compared to non-custom packing materials in the prior art, the present invention is less contaminating, easier to install, easier to reuse, less likely to shift during transit, and more robust than other air-filled packaging. 
   It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.