Patent Publication Number: US-8973756-B2

Title: Corner sleeve with hammock-like cushioning structure

Description:
BACKGROUND OF THE INVENTION 
     1. Technical Field 
     The present invention relates to a corner sleeve with a hammock-like cushioning structure. More particularly, the present invention relates to an open-ended cushioning structure pre-formed at a bent end corner of an air-column corner sleeve, the present invention involving an enclosing film which is provided at the bent end corner of the corner sleeve and in which an object to be packed can be supported as in a hammock. 
     2. Description of Related Art 
     Liquid crystal display televisions (LCD TVs) and like objects which must be properly packed for shipment have increased so much in size that they cause inconveniences in handling and installation. Therefore, even if they are packed, such objects are subject to wear or damage, especially at the corners, should they be impacted during transportation. In view of this, sleeve-like air-column bags were developed which can be mounted around the end corners of an object to be packed, such as an LCD TV, so as for the inflated air columns to enclose the end corners for cushioning. 
     However, as the air columns have a bent configuration corresponding in position to the edges of an end corner of an object to be packed, the bent portions of the air columns can easily break. In addition, the air columns of the aforesaid air-column bags or sleeves, which are generally made of polyethylene (PE), are likely to be punctured by the sharp end corners of the objects to be packed, and once punctured, the air columns will leak and eventually lose their cushioning effect. 
     Moreover, after an object to be packed is placed in an air-column bag, the gap between the bottom of the object and the inner wall of the bottom of the air-column bag will be reduced, if not closed, due to the weight of the object. Hence, if the bottom of the air-column bag hits the ground, there will be insufficient cushioning space, if at all, between the bottom of the object and the inner wall of the bottom of the air-column bag. The impact force generated by the bottom of the air-column bag hitting the ground will be transmitted directly to the bottom of the packed object and cause damage to the object. 
     BRIEF SUMMARY OF THE INVENTION 
     The primary object of the present invention is to provide an open-ended cushioning structure pre-formed at a bent end corner of an air-column corner sleeve, with a view to overcoming the aforesaid drawbacks of the prior art air column designs, namely susceptibility to breakage at the bent portions, potential loss of the intended cushioning effect when punctured by a sharp end corner of the packed object, and possible failure to protect the packed object from an impact force generated by collision with the ground, for the impact force may act directly on the bottom of the packed object and thus damage the packed object. 
     To achieve the aforesaid object, the present invention provides a corner sleeve having a hammock-like cushioning structure, wherein the corner sleeve includes a first air-column side, a second air-column side, and a bottom air-column side connected between bottom portions of the first and the second air-column sides. The first air-column side, the second air-column side, and the bottom air-column side are each provided with a plurality of air columns. Moreover, the first air-column side, the second air-column side, and the bottom air-column side jointly form a receiving space therebetween. The corner sleeve is characterized by the following: 
     The inner surface of the first air-column side and the inner surface of the second air-column side are bonded together at a first lateral end via one or more fixedly connected portions, except in the vicinity of the bottom air-column side. Consequently, a deformable opening is formed at an end corner of the corner sleeve by an air column of the first air-column side at the first lateral end, an air column of the second air-column side at the first lateral end, and an air column of the bottom air-column side at the first lateral end, wherein the deformable opening corresponds in position to the unbonded parts of the inner surfaces of the first and the second air-column sides at the first lateral end. The air columns forming the deformable opening surround the deformable opening and define a cushioning side at the end corner of the corner sleeve. In addition, a hammock-like enclosing film is provided in the receiving space, extends between the first air-column side and the second air-column side, and stays clear of the bottom air-column side. 
     Thus, when the first air-column side, the second air-column side, and the bottom air-column side of the corner sleeve are mounted around an end corner of an object to be packed, the deformable opening and the cushioning side of the corner sleeve are located at the end corner of the object, with the cushioning side covering the end corner of the object to provide a cushioning effect. In the meantime, the end corner of the object is wrapped in the enclosing film, supported or held in the receiving space, and kept from contact with the bottom air-column side. As a result, a cushioning distance is formed between the end corner of the object and the bottom air-column side. The cushioning distance and the air columns provide double cushioning. 
     The present invention further has the following features: 
     In addition to the foregoing primary structural features, a lateral opening is formed between the first air-column side and the second air-column side at a second lateral end and is in communication with the receiving space and an accommodating space formed by the enclosing film. Also, an upper opening is formed between a top portion of the first air-column side and a top portion of the second air-column side and is in communication with the receiving space, the accommodating space of the enclosing film, and the lateral opening. An object to be packed can be put into the receiving space and the accommodating space of the enclosing film through the lateral opening and the upper opening so as to be wrapped between the first air-column side, the second air-column side, the bottom air-column side, and the cushioning side. Not only that, the object will be wrapped in the enclosing film and thus supported or held in the receiving space without contact with the bottom air-column side. 
     In addition to the foregoing primary structural features, the one or more fixedly connected portions do not extend to the bottom air-column side, and a predetermined non-heat seal distance is thus formed between the one or more fixedly connected portions and the bottom air-column side. Because of this predetermined distance, the end corner of the corner sleeve forms the deformable opening, which has a triangular shape. 
     In addition to the foregoing primary structural features, the air columns of the first air-column side may extend to the top portion and the bottom portion of the first air-column side, the air columns of the second air-column side may extend to the top portion and the bottom portion of the second air-column side, and the air columns of the bottom air-column side may extend to two opposite middle sides of the bottom air-column side. 
     In addition to the foregoing primary structural features, plural air columns of the first air-column side and plural air columns of the second air-column side are respectively in communication with two opposite ends of a single air column of the bottom air-column side. 
     In addition to the foregoing primary structural features, the one or more fixedly connected portions may be heat-sealed points or heat-sealed lines. 
     In addition to the foregoing primary structural features, the one or more fixedly connected portions are formed, by heat sealing, on an air column of the first air-column side and an air column of the second air-column side. 
     In addition to the foregoing primary structural features, the first air-column side has at least one air column which lies between the first lateral end and the one or more fixedly connected portions and which is free of any fixedly connected portion, and the second air-column side has at least one air column which lies between the first lateral end and the one or more fixedly connected portions and which is free of any fixedly connected portion. The air columns free of any fixedly connected portion have larger volumes than those formed with the one or more fixedly connected portions. The end corner of the corner sleeve features enhanced elasticity thanks to the air columns free of any fixedly connected portion and the air columns formed with the one or more fixedly connected portions. 
     In addition to the foregoing primary structural features, the enclosing film is in the form of a hammock because it has two ends respectively provided at the top portion of the first air-column side and the top portion of the second air-column side and extends to a position adjacent to the bottom air-column side. 
     In addition to the foregoing primary structural features, the top portion of the first air-column side and/or the top portion of the second air-column side is provided with at least one extension air-column side which can be wrapped around the corner sleeve. Each extension air-column side is provided with a plurality of air columns. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The structure as well as a preferred mode of use, further objects, and advantages of the present invention will be best understood by referring to the following detailed description of some illustrative embodiments in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a front view of a preferred embodiment of the present invention; 
         FIG. 2  is a side view of the embodiment shown in  FIG. 1 ; 
         FIG. 3  is a sectional view taken along line A-A of  FIG. 1 ; 
         FIG. 4  is a sectional view taken along line B-B of  FIG. 1 ; 
         FIG. 5  illustrates how the embodiment shown in  FIG. 1  is used; 
         FIG. 6  is a partial enlarged view of  FIG. 5 ; 
         FIG. 7  is a sectional view similar to  FIG. 3 , showing a state of use; 
         FIG. 8  is a sectional view similar to  FIG. 4 , showing a state of use; and 
         FIG. 9  is a sectional view similar to  FIG. 8  but showing an additional embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The mode of implementation of the present invention is now described with reference to  FIG. 1  to  FIG. 8 , wherein  FIG. 1  is a front view of a preferred embodiment of the present invention;  FIG. 2  is a side view of the embodiment shown in  FIG. 1 ;  FIG. 3  is a sectional view taken along line A-A of  FIG. 1 ;  FIG. 4  is a sectional view taken along line B-B of  FIG. 1 ;  FIG. 5  illustrates how the embodiment shown in  FIG. 1  is used;  FIG. 6  is a partial enlarged view of  FIG. 5 ;  FIG. 7  is a sectional view similar to  FIG. 3 , showing a state of use;  FIG. 8  is a sectional view similar to  FIG. 4 , showing a state of use; and  FIG. 9  is a sectional view similar to  FIG. 8  but showing an additional embodiment. 
     The present invention provides a corner sleeve having a hammock-like cushioning structure. As shown in the drawings, the corner sleeve  100  includes a first air-column side  10 , a second air-column side  20 , and a bottom air-column side  30  connected between a bottom portion of the first air-column side  10  and a bottom portion of the second air-column side  20 . 
     Each of the first air-column side  10 , the second air-column side  20 , and the bottom air-column side  30  is provided with a plurality of air columns  11 ,  21 ,  31 , and a receiving space  40  is formed between the first air-column side  10 , the second air-column side  20 , and the bottom air-column side  30 . 
     The inner surface of the first air-column side  10  and the inner surface of the second air-column side  20  are bonded together at a lateral end (hereinafter referred to as the first lateral end) by one or more fixedly connected portions  50 , except in the vicinity of the bottom air-column side  30 . Consequently, a triangular deformable opening  60  is formed at an end corner  101  of the corner sleeve  100  by an air column  11   a  of the first air-column side  10  at the first lateral end, an air column  21   a  of the second air-column side  20  at the first lateral end, and an air column  31   a  of the bottom air-column side  30  at the first lateral end. The deformable opening  60  corresponds in position to the unbonded parts of the inner surfaces of the first and the second air-column sides  10 ,  20  at the first lateral end. 
     The first-lateral-end air column  11   a  of the first air-column side  10 , the first-lateral-end air column  21   a  of the second air-column side  20 , and the first-lateral-end air column  31   a  of the bottom air-column side  30  surround the deformable opening  60  and define a triangular cushioning side  61  at the end corner  101  of the corner sleeve  100 . 
     A hammock-like enclosing film  70  is provided in the receiving space  40 , extends between the first air-column side  10  and the second air-column side  20 , and stays clear of the bottom air-column side  30 . The enclosing film  70  has a curved configuration that forms an accommodating space  71  on the inner side of the enclosing film  70 . 
     More specifically, the present invention has the following technical features: 
     A lateral opening  41  is formed between the first air-column side  10  and the second air-column side  20  at the opposite lateral end (hereinafter referred to as the second lateral end). The lateral opening  41  is in communication with the receiving space  40  and with the accommodating space  71  on the inner side of the enclosing film  70 . Moreover, an upper opening  42  is formed between a top portion of the first air-column side  10  and a top portion of the second air-column side  20  and is in communication with the receiving space  40 , the accommodating space  71  on the inner side of the enclosing film  70 , and the lateral opening  41 . 
     Through the lateral opening  41  and the upper opening  42 , an object to be packed  90  can be put into the receiving space  40  and the accommodating space  71  of the enclosing film  70  so that not only is the object  90  wrapped between the first air-column side  10 , the second air-column side  20 , the bottom air-column side  30 , and the cushioning side  61 , but also the object  90  is wrapped in the enclosing film  70  and thus supported or held in the receiving space  40  without contact with the bottom air-column side  30 . In this embodiment, the object  90  may be a fragile object such as an LCD TV. 
     The fixedly connected portion  50  does not extend to the bottom air-column side  30 , thus allowing a predetermined non-heat seal distance h1 to be formed between the bottom end of the fixedly connected portion  50  and the bottom air-column side  30 . And because of this predetermined distance h1, the end corner  101  of the corner sleeve  100  forms the triangular deformable opening  60 . 
     The air columns  11 ,  11   a  of the first air-column side  10  may extend to the top portion and the bottom portion of the first air-column side  10 . The air columns  21 ,  21   a  of the second air-column side  20  may extend to the top portion and the bottom portion of the second air-column side  20 . The air columns  31 ,  31   a  of the bottom air-column side  30  may extend to the two opposite middle sides of the bottom air-column side  30 . 
     The first-lateral-end air column  11   a  of the first air-column side  10  and the first-lateral-end air column  21   a  of the second air-column side  20  are respectively in communication with the two opposite ends of the first-lateral-end air column  31   a  of the bottom air-column side  30 . Meanwhile, plural air columns  11  of the first air-column side  10  and plural air columns of the second air-column side  20  are respectively in communication with the two opposite ends of a single air column of the bottom air-column side  30 . As a result, the first-lateral-end air column  30  and the air columns  31  of the bottom air-column side  30  are different in size, which lends enhanced deformability and an increased cushioning ability to the air columns  31 ,  31   a  as a whole. 
     The fixedly connected portion  50  may be heat-sealed points or heat-sealed lines. 
     The fixedly connected portion  50  is formed by heat seating to heat seal the air column  11   a  of the first air-column side  10  and the air column  21   a  of the second air-column side  20 , thus reducing the inflated volumes of the air columns  11   a ,  21   a . The air columns  11   a ,  21   a  being heat sealed by the fixedly connected portions  50  are defined as fixedly connected air columns. When viewed from the side, therefore, referring to  FIG. 2 , the cushioning side  61 , the first-lateral-end air columns  11   a ,  21   a ,  31   a , and the air columns  11 ,  21 ,  31  are in a stacked configuration and have different outer sizes, which also contributes to enhanced deformability and effective cushioning. 
     Between a first-lateral-end edge  101   a  of the first air-column side  10  and the fixedly connected portion  50  is at least one air column  11   b  free of the fixedly connected portion  50 . Similarly, at least one air column  21   b  free of the fixedly connected portion  50  is provided between the first-lateral-end edge  101   a  of the second air-column side  20  and the fixedly connected portion  50 . The first-lateral-end edge  101   a  terminates the first lateral end. The air columns  11   b  and  21   b  free of any said fixedly connected portion  50  are defined as non-fixedly connected air columns. The air columns  11   b ,  21   b  (the non-fixedly connected air columns) free of the fixedly connected portion  50  are greater in volume than the air columns  11   a ,  21   a  (the fixedly connected air columns) formed with the fixedly connected portion  50 . The air columns  11   b ,  21   b  without the fixedly connected portion  50  and the air columns  11   a ,  21   a  with the fixedly connected portion  50  add to the elasticity of the end corner  101  of the corner sleeve  100  and further increase the deformability and cushioning ability of the end corner  101 . 
     The enclosing film  70  has two ends respectively provided on the inner surface  12  of the top portion of the first air-column side  10  and the inner surface  22  of the top portion of the second air-column side  20 . Moreover, the enclosing film  70  extends to a position adjacent to the bottom air-column side  30 . Thus, the enclosing film  70  resembles a hammock in form. 
     The present invention can be implemented with the components described above. Once the first air-column side  10 , the second air-column side  20 , and the bottom air-column side  30  of each of four corner sleeves  100 ,  100   a ,  100   b ,  100   c  are mounted around one of the end corners  91  of the object to be packed  90 , the deformable opening  61  and the cushioning side  61  of each corner sleeve  100 ,  100   a ,  100   b ,  100   c  are located at the corresponding end corner  91  of the object  90 , so as for the cushioning sides  61  to cover, and provide cushioning for, the end corners  91  of the object  90  respectively. 
     It should be pointed out that each end corner  91  of the object  90  is wrapped in the accommodating space  71  of the corresponding enclosing film  70  and is thus suspended or otherwise held in the corresponding receiving space  40 , without any contact with the corresponding bottom air-column side  30 . Consequently, a cushioning distance h 2  is formed between each end corner  91  of the object  90  and the corresponding bottom air-column side  30 . The air columns  31 ,  31   a  and the cushioning distance h2 provide a double cushioning effect. 
     The deformable opening  60  at the end corner  101  of each corner sleeve  100 ,  100   a ,  100   b ,  100   c  is so designed that the bottom ends of the first-lateral-end air columns  11   a ,  21   a ,  31   a  of the first, the second, and the bottom air-column sides  10 ,  20 ,  30  need not be connected to one another. This allows the air columns  11   a ,  21   a ,  31   a  to curve rather than bend sharply at the end corner  101 , thereby preventing the air columns  11   a ,  21   a ,  31   a  from breaking. Also, the cushioning side  61  at the end corner  101  of each corner sleeve  100 ,  100   a ,  100   b ,  100   c  is so designed that, after the corner sleeves  100 ,  100   a ,  100   b ,  100   c  are respectively mounted around the end corners  91  of the object  90 , the deformable opening  60  and the cushioning side  61  of each corner sleeve are located outward of the corresponding end corner  91  of the object  90 , so as for the cushioning side  61  at the end corner  101  of each corner sleeve  100 ,  100   a ,  100   b ,  100   c  to provide anti-impact cushioning for the corresponding end corner  91  of the object  90 . 
     Further, with the hammock-like enclosing film  70  located in the receiving space  40  but not in contact with the bottom air-column side  30 , each end corner  91  of the object  90  is wrapped between the inner walls of the corresponding enclosing film  70 , supported or held in the corresponding receiving space  40 , kept from direct contact with the corresponding bottom air-column side  30 , and therefore protected from damage or scratch which may otherwise result from an external impact force transmitted directly from the corresponding bottom air-column side  30 . Thus, the aforementioned problems of the conventional air column designs are solved, which are susceptibility to breakage at the bent portions, potential loss of the intended cushioning effect when punctured by a sharp end corner of the packed object, and possible failure to protect the packed object from an impact force generated by collision with the ground, for the impact force may act directly on the bottom of the packed object and thus damage the packed object. 
       FIG. 9  is a sectional view of an additional embodiment similar to that depicted in  FIG. 8 . As shown in  FIG. 9 , the top portion of the first air-column side  10  and/or the top portion of the second air-column side  20  is provided with at least one extension air-column side  80 , wherein each extension air-column side  80  is provided with a plurality of air columns  81  and configured for wrapping around the corner sleeve  100 . The extension air-column sides  80 ,  80   a  may have one or multiple sections. 
     The extension air-column sides  80 ,  80   a  can be wrapped around the first air-column side  10 , the second air-column side  20 , and the bottom air-column side  30  of the corner sleeve  100  for enhanced anti-impact cushioning.