Abstract:
A sealable mailing package and a process for mailing an article are disclosed. In one embodiment, the sealable mailing package includes an enclosure having an open end and a compartment for receiving an article. The enclosure includes an exterior surface and an interior surface. The sealable mailing package further includes at least one inflatable bladder positioned adjacent to the interior surface of the enclosure, and a manual pumping device integrated into the compartment of the enclosure. The manual pumping device is in fluid communication with the at least one inflatable bladder. The sealable mailing package further includes a one way valve located between the pumping device and the at least one inflatable bladder that only allows gas flow from the pumping device to the at least one inflatable bladder, and a sealing member for sealing the open end of the enclosure.

Description:
RELATED APPLICATIONS 
       [0001]    The present application claims priority to U.S. Provisional Patent Application No. 61/264,063, filed on Nov. 24, 2009. 
     
    
     BACKGROUND 
       [0002]    Many and various different breakable and/or perishable items are mailed in packages on a daily basis. Various efforts have been undertaken to protect the items during shipping. For instance, those skilled in the art have used corrugated boxes in combination with foam materials. For smaller items, the items are typically wrapped in a “bubble wrap” material and inserted into a box or envelope. The bubble wrap material is typically made from polymer films and is comprised of a network of small bubbles inflated with air. The inflated bubbles protect the items during shipping providing an air cushion around the item. 
         [0003]    Some envelopes or other packages are manufactured such that inflated bubbles or bubble wrap material is integrated into the package. For instance, various envelopes are commercially available that have an interior lining made from inflated bubbles. 
         [0004]    Although bubble wrap and the above describe packages have been found well suited to protecting items during shipping, the packages themselves are somewhat bulky which presents various problems to the manufacturer of the packages and/or to the supplier of the packages. For instance, since the packages are filled with air, shipping a plurality of empty packages together requires a significant amount of space. In addition, suppliers of the package typically need a significant amount of shelf space for storing the packages. 
         [0005]    In view of the above, a need exists for an improved package capable of protecting items during shipping. In particular, a need exists for a package containing air bladders that takes up a minimal amount of space prior to use. 
       SUMMARY 
       [0006]    In general, the present disclosure is directed to a mailing package that includes at least one inflatable bladder. Prior to use of the package, the bladder is in a deflated condition allowing for the package to be stored in a flat configuration. In accordance with the present disclosure, the package includes an integrated pumping device that then can be used to inflate the bladder after the package has been loaded with an item for protecting the item during shipping. 
         [0007]    For instance, in one embodiment, the present disclosure is directed to a sealable mailing package comprising an enclosure having an open end and a compartment for receiving an article. The enclosure includes an exterior surface and an interior surface. At least one inflatable bladder is positioned adjacent to the interior surface of the enclosure. In accordance with the present disclosure, a manual pumping device is integrated into the compartment of the enclosure and is in fluid communication with the inflatable bladder. A one way valve is located between the pumping device and the inflatable bladder that only allows a gas such as air to flow from the pumping device to the inflatable bladder. The package further includes a sealing member for sealing the open end. 
         [0008]    The design of the pumping device incorporated into the package can vary depending upon the particular application. In one embodiment, for instance, the pumping device may comprise a collapsible chamber that includes a vent for permitting airflow into the chamber after the chamber has been collapsed. By collapsing the chamber, such as by compressing the chamber, airflow is forced through the one way valve and into the inflatable bladder. 
         [0009]    Thus, a user can press on the pumping device to collapse the chamber and cause air to inflate the bladder. Once pressure is removed from the chamber, air rushes into the chamber from the external vent. In one embodiment, a resilient member can be located in the chamber that causes the chamber to expand and fill with air after the chamber has been compressed. The resilient member may comprise, for instance, a foam material, such as an open cell foam. In other embodiments, the resilient member may comprise a spring. 
         [0010]    In one embodiment, the package can be in the shape of an envelope and can include a first panel attached to a second panel. A plurality of interconnected bladders can be located along the interior surface of each of the panels. The pumping device can be in fluid communication with all of the inflatable bladders, or alternatively, the package may include multiple pumping devices. For instance, a first pumping device may be used to inflate the plurality of bladders located adjacent to the first panel and a second pumping device can be used to inflate a plurality of bladders located adjacent to the second panel. 
         [0011]    As described above, the pumping device can include a chamber that is vented to the exterior environment. The vent, for instance, may extend from the chamber to the outside of the package forming an opening on an exterior surface of the package. Prior to use of the package, the vent opening can be covered and sealed by a covering device. For instance, the chamber of the pumping device can first be collapsed and the vent opening can be sealed so that the pumping device takes up little or no additional space prior to use of the package. Once the package is ready for use, the covering device can then be removed from the package to expose the vent opening in order to operate the pumping device. In one embodiment, for instance, the covering device may comprise an adhesive label that can be removed by a user. In another embodiment, the covering device may comprise a weakened area of the enclosure that can be punctured by a user for accessing the vent opening. 
         [0012]    The inflatable package of the present disclosure can be shipped and sold to consumers in a deflated condition. When it is time to use the package, a consumer can then load an article in to the package while the package is still deflated. One or more vent openings can then be exposed for operating the pumping device for inflating the plurality of bladders contained within the package. Of particular advantage, the inflatable bladders, in one embodiment, will surround the article loaded in to the package during inflation. Once the package is inflated, the package can then be sealed and shipped. 
         [0013]    Other features and aspects of the present disclosure are discussed in greater detail below. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    A full and enabling disclosure of the present invention, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which: 
           [0015]      FIG. 1  is a perspective view of one embodiment of a package made in accordance with the present disclosure; 
           [0016]      FIG. 2  is a cross sectional view of the package illustrated in  FIG. 1 ; and 
           [0017]      FIGS. 3A through 3C  illustrate one embodiment of a pumping device that may be incorporated into a package made in accordance with the present disclosure. 
       
    
    
       [0018]    Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention. 
       DETAILED DESCRIPTION 
       [0019]    It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention. 
         [0020]    In general, the present disclosure is directed to a mailing package containing at least one inflatable bladder. In accordance with the present disclosure, the mailing package includes a pumping device that has been integrated into the package. The pumping device is in fluid communication with the at least one bladder for inflating the bladder during use of the package to ship one or more items. 
         [0021]    Prior to use of the package, however, the bladder can remain in the deflated position so that the package takes up a minimum amount of space. In one embodiment, even the pumping device can be stored in a collapsed condition prior to use for further minimizing the size of the package. In this manner, the package is not only capable of protecting items during shipping by providing an air mattress around items contained in the package, but can be stored in a completely collapsed state so that the package does not become burdensome to ship and store prior to use. 
         [0022]    Referring to  FIG. 1 , one embodiment of a package  10  made in accordance with the present disclosure is shown. In this embodiment, the package  10  includes a first panel  12  attached to or integral with a second panel  14 . For instance, the first panel  12  can be attached to the second panel  14  along the side edges and along a bottom edge. Alternatively, the first and second panels  12  and  14  can be constructed from a single piece of material that has been folded along the bottom edge or along one of the side edges. When made from a single piece of material, the remaining edges can be attached together using any suitable technique. 
         [0023]    In the embodiment illustrated, the package  10  is generally in the shape of a large envelope defining an interior space that is configured to receive one or more items or articles for shipping. It should be understood, however, that the package  10  can have any of a wide variety of shapes depending upon the particular application. For instance, in one embodiment, the package  10  may include side panels that increase the depth of the package. The side panels, for instance, may be straight or fluted. 
         [0024]    In order to close the package  10  for shipping, the package includes a sealing member  16  that, in this embodiment, comprises a flap that can be folded over onto the first panel  12 . The sealing member  16  can include any suitable adhesive element  18  for securely attaching the sealing member  16  to the first panel  12 . The adhesive element  18 , for instance, may comprise a pressure sensitive adhesive, double-sided tape, or an adhesive that becomes active when wetted. In the embodiment illustrated in  FIG. 1 , the adhesive element  18  is covered by a release liner  20  that protects the adhesive element prior to use. The release liner  20  is designed to be removed and discarded thereby exposing the adhesive element  18  for attachment to the first panel  12 . 
         [0025]    The first panel  12  and the second panel  14  can be made from any suitable material. For instance, the panels can be made from polymer films, a paper, other nonwoven materials, woven materials, knitted materials, foils, or the like. In one embodiment, the package  10  can be made from a nonwoven web formed from synthetic fibers, such as olefin fibers. For example, in one embodiment, the package  10  can be made from a TYVEK material. TYVEK materials are produced by DuPont and are made from flash spun high density polyethylene fibers. The materials comprise spunbond webs. In other embodiments, however, meltblown webs may also be used. 
         [0026]    In accordance with the present disclosure, the package  10  further includes at least one inflatable bladder in combination with a pumping device. In the embodiment illustrated in  FIG. 1 , for instance, the interior surface of the package  10  is lined with a plurality of interconnected inflatable bladders  22 . As shown, the bladders  22  are interconnected by a network of conduits. The interconnected bladders are positioned adjacent to the interior surface of the first panel  12  and adjacent to the interior surface of the second panel  14 . 
         [0027]    In accordance with the present disclosure, the package  10  is initially manufactured such that the bladders  22  are in a deflated condition. In order to inflate the bladders  22 , at least one pumping device can be incorporated into the package  10 . For example, in the embodiments illustrated in  FIGS. 1 and 2 , the package  10  includes a first pumping device  24  and a second pumping device  26 . Both pumping devices  24  and  26  can be in fluid communication with all of the bladders  22 . Alternatively, the pumping devices  24  and  26  can be configured to inflate different sections of the interconnected bladders. For example, in one embodiment, the first pumping device  24  may be configured to inflate the bladders positioned adjacent to the first panel  12 , while the second pumping device  26  can be configured to inflate the interconnected bladders adjacent the second panel  14 . 
         [0028]    Referring to  FIGS. 3A through 3C , the pumping device  24  is shown in greater detail. In accordance with the present disclosure, the pumping device  24  can be initially incorporated into the package  10  in a collapsed or deflated condition. When the package  10  is used to ship an article, the pumping device can be configured to assume an expanded condition for injecting a gas, such as air, into the inflatable bladders. 
         [0029]    For instance, as shown in  FIG. 3A , the pumping device  24 , in one embodiment, includes a resilient member  28  contained in a vented chamber  30 . As shown, the chamber  30  includes a vent opening  32  that is covered by a covering device  34 . The pumping device  24  is also in communication with a one-way valve  36 . 
         [0030]    In  FIGS. 3A through 3C , the pumping device  24  is illustrated in an isolated condition. The pumping device  24  can be incorporated into the package  10  using any suitable technique. In one embodiment, as shown in  FIG. 1 , the pumping device  24  may be placed in one of the corners of the package. When incorporated into a package as shown in  FIG. 1 , the first panel  12  is positioned in between the covering device  34  and the vent opening  32 . In addition, the first panel  12  will define an opening that corresponds with the vent opening so that air can enter the chamber  30  from the outside environment. As shown in  FIG. 1 , in this embodiment, the covering device  34  is positioned over the first panel  12 . 
         [0031]    In  FIG. 3A , as described above, the pumping device  24  is generally shown in a collapsed condition. In this regard, the chamber  30  is made from a flexible material that will allow the pumping device to expand and contract. The one-way valve  36  allows a fluid, such as air, to exit the pumping device but does not allow air to enter the pumping device. Thus, when the covering device  34  covers the vent opening  32 , a substantially fluid tight seal is formed with respect to the chamber  30 . During production, the pumping device  24  is compressed into a contracted condition and the covering device  34  is then placed over the vent opening  32 . In this manner, the pumping device  24  remains in a collapsed state. 
         [0032]    The one-way valve  36  can comprise any suitable device capable of only allowing air flow in one direction. In the embodiment illustrated, for instance, the one-way valve comprises a pair of overlapping flaps. The flaps can be made from any suitable flexible material, such as a rubber material or plastic material. In alternative embodiments, the one-way valve  36  may comprise a single flap that only opens in a single direction, may comprise a membrane containing a slit for allowing gas flow, or may comprise any other suitable configuration. 
         [0033]    The resilient member  28 , on the other hand, comprises any suitable device capable of expanding and contracting when compressed and then released. In one embodiment, for instance, the resilient member may comprise a foam material, such as an open cell foam. Alternatively, the resilient member may comprise one or more springs. 
         [0034]    As shown in  FIG. 3B , in order to inflate the inflatable bladders  22  as shown in  FIG. 1 , the covering device  34  is first removed in order to expose the vent opening  32 . Exposing the vent opening  32  allows air to enter the chamber  30  causing the resilient member  28  to expand. The covering device  34  can comprise any suitable device capable of removably covering the vent opening  32 . The covering device  34 , for instance, may comprise a peelable label. Alternatively, the covering device  34  may comprise a weakened portion on the package that can be punctured for allowing access to the vent opening. 
         [0035]    In the embodiments shown in  FIGS. 3A through 3C , the chamber  30  includes a single vent opening  32 . It should be understood, however, that the chamber may contain multiple vent openings as desired. 
         [0036]    Once the pumping device  24  assumes an expanded configuration as shown in  FIG. 3B , a user can then cover the vent opening  32  and compress the pumping device causing air to flow through the one-way valve  36  and into the plurality of bladders  32 . In one embodiment, for instance, a user can put his or her hand or fingers over the vent opening for compressing the pumping device and inflating the interconnected bladders. Once the pumping device  24  has been compressed, a user can then remove his or her hand or fingers from the vent opening thereby allowing the chamber of the pumping device to expand. The motion of compressing the pumping device can then be repeated as desired until all of the interconnected bladders have been inflated to a desired pressure. 
         [0037]    In the embodiments illustrated in  FIGS. 1 and 2 , the inflatable bladders  22  appear as rectangular squares. It should be understood, however, that the bladders can have any suitable shape and can have any suitable size. The size or pattern of the bladders, for instance, can be modified depending upon the type of article being shipped. 
         [0038]    In one embodiment, for instance, the package  10  can be constructed so as to contain only a few inflatable bladders that have much larger dimensions. In one embodiment, for instance, the package may only contain a single inflatable bladder positioned on opposite sides of the interior of the package. 
         [0039]    In another embodiment, the bladders  22  can have different sizes depending upon the particular application. For instance, in one embodiment, the package can have relatively larger sized bladders along the edges and smaller bladders within the center of the package. In still another embodiment, the bladders appearing adjacent to the first panel  12  can have a different size than the bladders positioned adjacent to the second panel  14 . In still another embodiment, the bladders can have a shape that corresponds to the shape of an article or item to be placed in the package. For instance, relatively small bladders can form a pattern inside the package that corresponds to the shape of an article to be shipped. Larger bladders can then surround the smaller bladders so that the article does not move during shipment. 
         [0040]    When using the package, in one embodiment, the article or item to be shipped is first placed within the interior space of the package. Once the article is loaded in the package, the covering device can be removed from the pumping device for inflating the inflatable bladders. Loading the article into the package prior to inflating the bladders can, in some embodiments, cause the bladders to surround the article when inflated. Once the bladders are inflated, the package can be sealed and shipped. 
         [0041]    In one embodiment, the bladders can have sizes and shapes that fix any articles contained in the package into position when the bladders are inflated. Many prior envelopes containing bubble wrap, for instance, allow the items or articles to move within the package freely during shipment. The package of the present disclosure, however, can be configured such that the bladders surround the article or item loaded into the package and prevent the article or item from moving during shipment. In this manner, the article or item is better protected. 
         [0042]    These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims.