Patent Publication Number: US-6213167-B1

Title: Inflatable package cushioning and method of using same

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional application of application Ser. No. 09/057,297, filed Apr. 8, 1998, now U.S. Pat. No. 6,015,047. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to inflatable products. More particularly, the present invention relates to an inflatable device for packaging that has been specially provisioned to provide for rapid and simplified deployment. 
     The need for protecting products from damage during distribution has lead to the development of various shock absorbing packaging materials. These materials are intended to “float” a product within a shipping container and provide controlled deceleration to a packaged item during impact. Because of their low density, the transportation and storage cost of ready to use cushioning materials is significant. By utilizing “foam in place” or inflatable cushioning, the user may greatly reduce such costs. 
     The use of foamed polymer cushioning materials has many disadvantages. In order to use these “foam in place” materials a user must undertake the storage and mixing reactive chemicals that are hazardous in nature. Further to these problems, foamed cushioning materials are not readily recyclable or efficiently disposable by the recipient. Inflatable cushioning systems may offer solutions to many of these problems. 
     Inflatable cushioning systems use inert polymer films and do not require the handling of hazardous materials by the user. The various polymer films used in inflatable cushioning systems do not take up as much landfill space since the material is easily compacted after use by deflating the inflatable chambers, such as by cutting open the chambers. Inflatable cushioning systems may even require less storage space than the various components required for the use of foamed cushioning materials. 
     Example of inflatable cushioning systems and methods can be found in U.S. Pat. Nos. 5,254,074 and 5,339,602. In these devices, thermoplastic films are formed into a bag into which air is inserted. This inserted and entrapped air increases the volume of the bag so that the bag can fill the void between any fragile items and the carton or package in which the fragile item is being shipped. Typically, the bag will not be filled to its maximum capacity with air. Accordingly, the bag may be compressed between the packaging carton and the fragile item so as to block and brace the item within the container and better protect the item from breakage. While effective in achieving this end, the bag may provide only limited protection from deceleration forces that can damage the packaged item. 
     A further example of an inflatable cushioning system is described in U.S. Pat. No. 4,918,904 to Pharco. While providing improved deceleration characteristics that protect the item from shock, the cushioning system must be properly sized to the item to be packaged. 
     Presently available inflatable cushioning systems utilize a single or limited number of air receiving chambers. The systems will fail to provide any protection should an air leak occur. Further, present inflatable cushioning systems fail to provide means for rapid multiple deployment through automated or semi-automated processes. 
     SUMMARY OF THE INVENTION 
     Thus, it is an object of the present invention to provide an improved inflatable cushioning system. 
     It is a further object of the present invention to provide an inflatable cushioning system that provides for the use of a plurality of fluid receiving chambers. 
     It is a further object of the present invention to provide an inflatable cushioning system that provides for an automated or semi-automated deployment process. 
     It is a further object of the present invention to provide an inflatable cushioning system that can provide improved deceleration characteristics. 
     It is a further object of the present invention to provide an inflatable cushioning system that is adaptable to various sizes of shipping containers. 
     It is a further object of the present invention to provide an inflatable cushioning system having reduced risk of catastrophic failure. 
     These and other objects of the invention are achieved by an inflatable cushioning system having a plurality of independently maintained inflatable cushioning chambers. The inflatable chambers each have an integral one way inflation valve and corresponding inflation port. The outer terminus of the individual inflation ports are arranged along the interior wall of a common guideway. The guideway directs a specially designed inflation tool to the individual inflation ports. The guideway also yokes or otherwise couples the inflation tool to the inflation ports while the tool delivers fluid to the ports. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The features of the present invention will become apparent to those skilled in the art to which the present invention relates from a reading of the following specification with reference to the accompanying drawings in which: 
     FIG. 1 is a top plan of the present invention positioned between a container wall and a packaged item; 
     FIG. 2 is a perspective view of a first embodiment of a cushioning system according to the present invention; 
     FIG. 3 is a perspective view of a second embodiment of a cushioning system according to the present invention; 
     FIG. 4 is a cross-section view along line  2 — 2  of FIG. 2; 
     FIG. 5 is a perspective view of a multi-purpose inflation tool for use with the cushioning system according to the present invention; 
     FIG. 6 is an alternate embodiment of the multi-purpose inflation tool for use with the cushioning system according to the present invention; 
     FIG. 7 is a top plan view of a step in the valve assembly manufacture; 
     FIG. 8 is a top plan view of another step in the valve assembly manufacture; 
     FIG. 9 is a perspective view of another step of the valve assembly manufacture; 
     FIG. 10 is a perspective view of a step in the manufacture of the inflatable cushioning system exemplified by FIG. 1; 
     FIG. 11 is a perspective view of the heat sealing step in the manufacture of the inflatable cushioning system exemplified by FIG. 1; and 
     FIG. 12 is a perspective view of a semi automated assembly for inflating the cushioning system. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Inflatable cushioning systems are in many ways superior to their foamed agent counterparts. Inflatable cushioning systems have gained only limited industry acceptance because several problems remain. One problem is the reliability of the inflatable cushioning system. Current inflatable cushioning systems use a singular or limited number of cushioning chambers. If a chamber fails during transit, the packaged article loses most of its protection. 
     Another problem is the adjustability of current inflatable cushioning systems to varied packaged article sizes. Presently, users are compelled to inventory many different sizes of an inflatable cushioning system in order to meet all potential product applications and shipping carton sizes. The initial inventory and cost of maintaining may be considerable. 
     Another problem is the manual labor required to inflate currently available cushioning systems. Individual air cushioning chambers must be inflated one at a time. Automation has not been satisfactorily implemented. 
     With reference to the drawings, an inflatable cushioning chamber system and method for implementing and manufacturing the same that achieves the objects of the invention set forth above is described. The novel inflatable cushioning system and method for implementing and manufacturing same improves upon the above-mentioned problems. Accordingly, the present invention should be highly acceptable and advantageous to shippers and packers of all sizes. The novelty method of deploying the inflatable chambers is also applicable to other inflatable products, such as, but not limited to, greeting balloons. 
     FIG. 1 demonstrates the present invention use. The benefits, advantages, and objects of the invention are primarily achieved by providing a means of effectively deploying an inflatable cushioning system  10  with a plurality of inflatable air cushioning chambers  50 . Air cushioning members  50  support packaged article P at apex  51 . Inflatable cushioning system  10  is inserted between walls L of container C and packaged article P. Chambers  50  can physically deform to absorb transportation shock loads in two ways. The chambers  50  will distort as increased force compresses the gas contained in the chambers. The chambers  50  may also distort and absorb energy by elastic elongation of the material in the chamber walls. The chamber  50  of the current invention provides controlled deceleration characteristics that reduce possible damage to packaged article P during transit. The inflatable cushioning system  10  also exhibits excellent vibration dampening characteristics due to the independent action of each of the chambers. 
     The use of more than one inflatable cushioning chamber  50  provides increased protection to packaged article P. If one inflatable cushioning chamber  50  fails, the remaining inflated cushioning chambers  50  can continue to support and cushion packaged article P. 
     Furthermore, the present invention allows selective adjustment of inflatable cushioning system  10  to accommodate packaged article P of varying sizes. Inflatable cushioning system  10  spaces individual inflatable air cushioning chambers  50  at a fixed, predetermined distance along a continuous web of material. In this configuration, it is possible to separate any number of individual inflatable air cushioning chambers  50  in order to form a larger overall inflatable air cushion of almost any size. 
     Finally, by the use of a special tool, it is possible to increase the rate at which individual inflatable air cushions may be inflated. FIGS. 3 and 4 demonstrate two embodiments of the tool. 
     Inflatable cushioning system  10  will now be described with reference to FIGS. 2-4. FIGS. 2 and 3 show two examples of air cushioning system  10  according to the present invention. FIG. 2 depicts cushioning system  10  stored as roll R of individual inflatable air cushioning chambers  50  wrapped around a conventional core K. FIG. 3 depicts cushioning system  10  stored as a stack S of continuous individual inflatable air cushioning chambers fan folded one on top of the other in a zig-zag like configuration. 
     FIGS. 2 and 4 show an unrolled portion  11  of cushioning system  10 . FIG. 4 could equally depict portion  11  of FIG. 3, except stack S would replace roll R. Portion  11  generally comprises first and second layers or walls  25 ,  27  of thermoplastic film sealed together, such as by heat, thermal impulse or ultrasonic sealing. Primary seals  20  run parallel to web direction W. Secondary seals  21  run perpendicular to web direction W and may have perforations X on center to allow for the separation of a selected number of individual inflatable cushioning chambers  50  from the rest of cushioning system  10 . The separation of a section of individual cushioning chambers from cushioning system  10  is most preferably made following the inflation of the chambers using multipurpose tool  100 . Applicant also contemplates various size cushioning chambers  50  for customized application of the deployment method below described. Secondary seals  21  are formed, for example by heat, thermal impulse or ultrasonic sealing. 
     One way valve passages  23  are formed between secondary seals  21 . One way valve passages  23  are formed during manufacture of valve assembly  240  discussed below. As shown in FIG. 2, secondary seals  21  run the entire length of the material from seal  20  to form a seal  22  and intersect with both. Seals  22  may be adhesive, thermal, or combination thereof. Seals  22  define one side of chambers  50 , as well as the interior dimension of common inflation tool guideway  60 . The combination of the seals  20 ,  21 , and  22 , and valves  23  form a plurality of individual separate inflatable cushioning chambers  50 . Chambers  50  remain uninflated and are either wound on roll R (FIG. 2) or folded up into stack S (FIG. 3) during storage. 
     A common collapsible inflation tool guideway  60  extends along cushioning system  10  in web direction W. Common inflation tool guideway  60  is in fluid communication with and perpendicular to each one way valve  23 . Common inflation tool guideway  60  comprises upper and lower films  61 ,  62  located close together prior to the use of system  10  so as to make system  10  as flat as possible. Accordingly, films  61 ,  62  will need to be separated prior to use of system  10 . Common inflation tool guideway may be perforated (not shown), fabricated of linear tear polyethylene or include peel seals (not shown) for use with multi-purpose tool  300  shown in FIG.  6 . 
     The multi-purpose tool used to inflate individual cushioning chambers  50  will now be described with reference to FIGS. 5 and 6. FIG. 5 shows one embodiment of the device. The main body of tool  100  has a tapered closed first end  110  for spreading apart upper and lower films  61 ,  62  of common inflation tool guideway  60 . Tapered end  110  leads to main hollow cylindrical portion  115  having bores  125  therein for the passage of pressurized air. Hollow portion  140  connects to a source of pressurized air (not shown). Pressurized air flows from the source; through the perpendicular hollow portion  140  and main hollow cylindrical portion  115 ; and finally exiting bores  125 . The rear portion of hollow cylindrical portion  115  has a shielded blade  130  upstanding therefrom. Blade  130  is for slitting one of the upper or lower films  61 ,  62  as will be described below. 
     FIG. 6 shows a second embodiment of the device used to inflate individual cushioning chambers  50 . Similar to the embodiment of FIG. 5, the main body of tool  300  has a tapered closed first end  310  for spreading apart upper and lower films  61 ,  62  of common inflation tool guideway  60 . Tapered end  310  leads to main hollow cylindrical portion  315  having bores  325  herein for passage of pressurized air (not shown). Pressurized air follows from the source (not shown), through the perpendicular hollow portion  340 , through main hollow cylindrical portion  315 , and out bores  325 . The rear portion of main hollow cylindrical portion  315  has a protrusion  330  extending therefrom. Protrusion  330  is for breaking open a wall of common inflation tool guideway  60 . Protrusion  330  can break open and separate a wall of inflation tool guideway  60  at a perforation (not shown) or the peel seal (not shown). Further, the common inflation tool guideway  60  could be fabricated from linear tear polyethylene that is designed to fracture in web direction W. 
     The preferred method of inflating the individual cushioning chambers  50  will now be described. Although described in terms of the multi-purpose tool  100 , multi-purpose tool  300  can also be utilized. Tapered closed first end  110  of tool  100  is placed into the inflation tool guideway  60  at its opening by first manually separating upper and lower films  61 ,  62 . The inside dimension of common inflation tool guideway  60  closely corresponds to the circumference of the hollow cylindrical portion  115  of tool  100  so as to restrict the unwanted escape of air. Main hollow cylindrical portion  115  is inserted to a point before which blade  130  contacts films  61 ,  62 . Preferably, the length of main hollow cylindrical portion  115  is approximately the span of three individual cushioning chambers  50 . Bores  125  are positioned on hollow cylindrical portion  115  adjacent and lined-up with one-way valves  23  at each individual cushioning chamber  50 . In an alternate embodiment of multi-purpose tool  100  (not shown) the hollow cylindrical portion  115  may be constructed in part of screen (not shown) or mesh material (not shown) thereby eliminating the need for bores  125  and achieving multidirectional flow characteristics. 
     Pressurized air is injected through the open end of perpendicular hollow portion  140 . The pressured air passes into main hollow cylindrical portion  115 , out of bores  125 , and towards the ports that connect to one way valves  23 . The tight fit between main hollow cylindrical portion  115  and common inflation tool guideway  60  assures that an excess amount of pressurized air is not lost. Pressurized air emitted from bores  125  opens one way valves  23  and enters the individual inflatable cushioning chambers  50 . 
     The flow of pressurized air into the chambers  50  stops when the internal pressure rises to a level proportionate to that of the source air supply pressure. When the supply of pressurized air from multi purpose tool  100  is removed or discontinued, one-way check valves  23  close to maintain the pressurized air within the individual inflatable cushioning chambers  50 . 
     Tool  100  is further advanced along common inflation tool guideway  60  so as to place its bores  125  in line with one way valves  23  corresponding to the next set of individual air chambers  50 . The continued sliding advancement of tool  100  along common inflation tool guideway  60  is possible due to the operation of blade  130 . Blade  130  slices either the upper or lower film  61 ,  62 . This allows the continued movement of tool  100  along the length of system  10  in web direction W without slicing the entire cushioning systems  10  in half. If blade  130  was not present, the perpendicular hollow portion  140  and connected air supply tube (not shown) of tool  100  would prohibit further advancement of tool  100  along common inflation tool guideway  60 . 
     The use of tool  300  is the same as the method described above with respect to tool  100 , except for the operation of blade  130 . Instead, further insertion of tool  300  is possible due to the operation of protrusion  330 . Protrusion  330  ruptures the common inflation tool guideway. Protrusion  330  can split one of the films of common inflation tool guideway at a perforation ( 225 ) or a peel seal (not shown). Also, upper or lower film  61 ,  62  of common inflation tool guideway  60  could be fabricated from linear tear polyethylene. Forward movement of protrusion  330  along the common inflation tool guideway  60  perpetuates the splitting of upper or lower film  61 ,  62 . 
     Multipurpose inflation tool  100 ,  300  can have a variety of shapes without departing from the scope of the invention. For example, the tool may lack the L-shape of tools  100 ,  300  (not shown) or may be constructed with alternative cross-sectional shapes such as an oval (not shown). 
     The inflation process using the multipurpose tools can be fully automated, or at least may provide mechanical assistance to the deployment process. FIG. 12 shows the inflation of air cushioning system  10  using automated means. In particular, tool  100  may be mounted to a worktable T and provided with a means  400  for automatically feeding air cushioning  10  towards tool  100 . As shown in FIG. 12, automatic feeding means  400  includes a central feed roller  401  and a transmission  403  for driving feed roller  401 . Feed roller  401  draws cushioning system  10  in web direction W toward tool  100 . Feed roller  401  may be intermittent or continuous in motion and set at such a rate that provides for complete filling of the individual inflatable cushioning chambers  50 . Automatic feeding means  400  may comprise any of the known devices for the controlled movement of a sheet product along a given path. 
     The preferred method of constructing inflatable cushioning system  10  will be described with reference to FIGS. 7-11. Briefly, inflatable cushioning system  10  is formed through the merger of two sets of superimposed film webs. The first set of film webs comprise lower valve web  200  and upper valve web  220 . Webs  200 ,  220  are preferably a heat sealable 3 to 5 layer co-extrusion with a thickness in the range of approximately 1.0 to 4.0 mils. The upper and lower valve webs are joined to form a continuous valve assembly  240 . The second set of films webs comprise webs  245 ,  246 . Webs  245 ,  246  are preferably a blown polyethylene coextruded film with a 5-30% nylon content, total thickness in the range of 0.015 to 0.006 inches, and at least one outer film surface of heat sealable polyethylene. Valve assembly  240  is sandwiched between the second set of webs  245 ,  246 . Webs  245 , 246  comprise walls  25 ,  27  of inflatable cushioning system  10 . Heat seals  20 ,  21  and  22  converge the plurality of webs into a unitary and continuous web structure. 
     FIGS. 7-9 show the steps of constructing valve assembly  240 . As shown in FIG. 7, a zone coating  210  is printed on the upper side of the lower valve web  200 . Zone coating  210  is preferably a non-migratory formula containing a surfactant agent, light grease or humectant. Alternately, the coating may be an ultraviolet curable heat resistant acrylate. The zone coating  210  is then dried or cured as required before subsequent processing. The zone coating  210  serves to ensure an air tight seal between the upper surface of lower valve web  200  and lower surface of valve web  220  following the inflation process. A secondary function of zone coating  210  is to prevent the sealing of valve passage  23  during the later phases of manufacture. 
     FIG. 8 shows another step in the manufacture of valve assembly  240 . A wet adhesive film is applied to the upper side of lower valve web  200  in zones  215 . Wet adhesive film  217  (not shown) is preferably an ultraviolet radiation cured 100% solids system. Applicant contemplates the use of other adhesives, such as rubber-based adhesives, acrylics and hot melts. 
     FIG. 9 shows another step in the manufacture of valve assembly  240 . Nip rollers  230  join the upper sides of valve web  200  with the lower side of valve web  220 . The joined webs are passed through an ultraviolet energy source  235  for curing and setting adhesive film  217  in zones  215 . Zones  215  produce a permanent adhesive seal between webs  200 ,  220 . An adhesive seal is not produced in the areas which lack adhesive film  217 . The adhesive juncture of valve web  200  and valve web  220  define the two dimensional areas of common inflation guideway  60 , and valve passages  23 . The areas which lack adhesive coating  217  include: (1) areas that have zone coating  210 ; and (2) all other areas that lack both zone coating  210  and adhesive film  217 . The completed valve assembly  240  is a planar, continuous two-ply web with a common inflation tool guideway  60  and valve passages  23  extending perpendicularly from both sides of common inflation tool guideway  60 . Although valve passages  23  are shown to be straight sided and parallel, applicant contemplates that the use of other one way valve designs known to those skilled in the art are possible without departing from the purpose and spirit of the invention. 
     Valve passages  23  operate as follows. Prior to inflation, valve passages  23  have a two-dimensional, planar form. A non-distorted planar form is ensured by the use of adhesive film  217  and nip rollers  230  during assembly of valve assembly  240 . Opposing webs  200 ,  220  in the area of valve passage  23 , with the aid of Zone Coating surfactant  210 , create an airtight seal. 
     During inflation, air pressure applied causes webs  200 ,  220  to separate and form a three-dimensional passage. The passage is formed by upper web  220 , lower web  200  and adhesive seals  215 . When the supply of pressurized air is shut off, valve passages  23  return to their normalized, planar state. 
     Applicant contemplates different embodiments of valve assembly  240  and the construction thereof. The valve assembly web could be constructed with the valve passages extending from only one side of the inflation air inlet (not shown). In this embodiment, the upper and lower valve webs may be formed from a single web, folded upon itself. The valve assembly could also be constructed by heat sealing the webs to define the valve passages  23 , rather than using adhesive and ultraviolet curing. The webs could also be made from materials that make the need for zone coating unnecessary. For example, the webs may be constructed of a lamination of corona treated polyester and polyethylene. The adhesive film is applied to the polyester surface of web  200  and joined with the opposing polyester surface of web  220 . The high energy polyester surfaces have auto adhesion properties that help to prevent the escape of air. 
     FIGS. 10 and 11 demonstrate the final steps of constructing inflatable cushioning system  10 . As shown in FIG. 10, completed valve assembly  240  is sandwiched between webs  245  and  246 . Webs  240 ,  245 ,  246  then pass through rollers  250  to remove any air lodged therebetween. 
     FIG. 11 shows the location of heat seals  20 ,  21 ,  22  on webs  240 ,  245 ,  246  after using a conventional sealer. Webs  240 ,  245 ,  246  are heat sealed after passing through rollers  250  shown in FIG.  10 . Heat seals  20 ,  21 ,  22  fix valve assembly  240  in position and form individual inflation chambers  50 . Primary heat seals  20  run parallel to web direction W and along the edges of webs  245 ,  246 . Secondary heat seals  21  run perpendicular to web direction W and between primary seals  20 . Heat seals  22  parallel primary heat seals  20  and intersect secondary heat seals  21 . Hermetic juncture of webs  200 ,  220 ,  245   246  along the parallel sides of common inflation guideway  60  is completed by heat seals  21 , except between webs  200 ,  220  in the area of zone  210 . Therefore, valves  23  remain open in valve assembly  240  to allow air to pass therethrough. 
     Parallel seals  22  may further define the dimensions of common inflation tool guideway  60 . Alternately, webs  245 ,  246  need not overlap web  240  in the area of common inflation guideway  60  (not shown). 
     Inflatable cushioning system  10  has been described herein as using air as the inflation medium. Applicant contemplates the use of any suitable fluid as the inflation medium to achieve similar results. 
     Applicant also recognizes other numerous variations from the embodiments described herein. These variations are apparent to one of ordinary skill in the art from reading of the disclosure of the invention. Such variations and modifications apparent to those skilled in the art are within the scope and spirit of the instant invention as defined by the following appended claims.