Patent Grant
11851260
The described embodiments relate generally to packaging materials. More particularly, the present embodiments relate to systems and devices for processing inflatable protective packaging units to be used as packaging materials.
Products and packages may be produced and/or shipped in a variety of containers and configurations for transportation and sale. In order to protect the packages from being crushed or damaged during transportation, producers may use various combinations of packaging materials to form a protective outer layer over the products and otherwise maintain the form factor of the product within the package. Many traditional systems for producing packaging material suffer from significant drawbacks that may affect the adaptability of the system to process inflatable packaging materials, such as processing inflatable packaging materials in rapid succession. As such, the need continues for improved approaches to facilitate inflatable packaging material production.
Embodiments of the present invention are directed to components and systems associated with an automatic protective packaging inflator.
In an embodiment, an inflatable protective packaging unit is disclosed. The packaging unit includes an inflatable component that includes overlaid flexible plies connected to each other to define a fluid chamber therebetween. The inflatable component can define an inflation region in fluid communication with the fluid chamber to allow fluid from the inflation region into the fluid chamber. The packaging unit can further include a receiver separably attached to the inflatable component at the inflation region and configured to direct fluid into the inflation region.
In another embodiment, the receiver can be disposed between the flexible plies. The receiver can be separably attached to the inflatable component by a frangible connection. The frangible connection can be defined by a spot weld between the receiver and one or more of the flexible plies.
In another embodiment, the receiver can be separably attached to the inflatable component by a loose connection. In some cases, air-permeable gaps can be defined between the receiver and the flexible plies.
In another embodiment, the receiver can be separably attached to the inflatable component by a friction fit.
In another embodiment, the inflatable component can include a valve configured to allow one-way fluid flow from the inflatable component into the fluid chamber. The valve can include opposing flaps defining therebetween a collapsible fluid passage that opens in response to increased pressure in the inflation region to allow fluid flow into the fluid chamber. The valve can collapse upon increased pressure in the fluid chamber to retain the fluid therein.
In another embodiment, flexible plies can define a group of fluid chambers in fluid communication with the inflation region, each of fluid chambers being fluidly isolated from one another.
In another embodiment, the inflatable protective packaging unit of claim 1, wherein the receiver has a rigidity that is greater than a rigidity of the inflatable component. The receiver can define an exterior facing entry opening to receive the fluid. The receiver can have sufficient rigidity to maintain open the entry opening. The receiver can be configured to receive an inflation component of an inflation device into the entry opening to thereby receive the fluid and direct the fluid into the inflation region.
In another embodiment, the receiver can include a body defining a channel therethrough that leads to the inflation region. The body can be sufficiently rigid to suspend the flexible plies. The receiver can be separable from the inflation component upon pulling the inflatable component axially with respect to the channel of the receiver.
In another embodiment, the packaging unit further includes a frangible connection between the receiver and the inflation component that is sufficiently strong enough to suspend the flexible plies from the body. The receiver can include a protrusion extending laterally with respect to the channel and configured to engage a track of an inflation device suitable to support the inflatable protective packaging unit therefrom. The protrusion can extend radially about the channel of the receiver and is configured to be received in a gap between opposite side of the track and supported by the opposite sides of the track.
In another embodiment, an inflation system. The system includes an inflatable protective packaging unit, such as any of the inflatable protective packaging units described herein. The system further includes an inflatable protective packaging unit support magazine configured to receive the inflatable protective packaging unit and another inflatable protective packaging unit.
In another embodiment, the system can further include an inflator that is guided into the receiver at a filling station and configured to deliver fluid into the receiver for filling the fluid chamber. In some cases, the system can further include an advancement mechanism configured to advance the inflatable protective packaging unit from a first position in the magazine to the filling station. Additionally or alternatively, the system can further include a separator disposed and configured to separate the receiver from the inflatable component after the inflatable component has been inflated with the fluid.
In another embodiment, the separator can be disposed at a separation station. This regard, the system can further include an inflator drive that drives the inflator from the filling station to the separation station such that the inflator thereby moves the receiver to the separator to cause the separation of the receiver from the inflatable component. In some cases, the separator can move the inflation component axially away from the receiver as the receiver is moved along a diverging element.
In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following description.
The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings in which:
The use of cross-hatching or shading in the accompanying figures is generally provided to clarify the boundaries between adjacent elements and to facilitate legibility of the figures. Accordingly, neither the presence nor the absence of cross-hatching or shading conveys or indicates any preference or requirement for particular materials, material properties, element proportions, element dimensions, commonalities of similarly illustrated elements, or any other characteristic, attribute, or property for any element illustrated in the accompanying figures.
Additionally, it should be understood that the proportions and dimensions (either relative or absolute) of the various features and elements (and collections and groupings thereof) and the boundaries, separations, and positional relationships presented therebetween, are provided in the accompanying figures merely to facilitate an understanding of the various embodiments described herein and, accordingly, may not necessarily be presented or illustrated to scale, and are not intended to indicate any preference or requirement for an illustrated embodiment to the exclusion of embodiments described with reference thereto.
The description that follows includes sample systems, methods, and apparatuses that embody various elements of the present disclosure. However, it should be understood that the described disclosure may be practiced in a variety of forms in addition to those described herein.
The following disclosure describes systems, devices, and techniques related to packaging systems that are used to produce inflatable packaging materials. The packaging system may include an inflation device that is configured to receive inflatable packaging materials, such as a group of inflatable protective packaging units, in an uninflated configuration. In the uninflated configuration, the inflatable packaging material may be stored and advanced toward a filling position, where the inflation device may operate to discretely provide fluid to the inflatable packaging materials. Once inflated, the inflation device may discretely eject the inflatable packaging material, such as into a bin or other components or systems where a producer may access the inflated packaging material. The inflation system may facilitate rapid, sequential inflation of inflatable packaging material, thereby allowing producers to access a continuous or substantially continuous supply of inflated packaging materials for packaging products or other appropriate uses.
As used here, “inflatable packaging materials” may generally refer to packaging materials having an inflatable fluid chamber. The inflatable fluid chamber may be defined by flexible walls that increase in volume or expand when the chamber is filled with a fluid, including air, nitrogen, and/or other appropriate fluids. When filled, the chamber may retain at least some of the fluid and be used to form a protective barrier around a product or other item. The inflatable packaging materials may therefore be constructed in a variety of sizes, shapes, weights, and other characteristics that are adapted to provide the desired protective characteristics.
As described in greater detail below, inflatable packaging materials, such as an inflatable protective packaging unit, may include, or be defined by, various suitable inflatable structures such as cushions, bags, or the like. The inflatable protective packaging unit may include multiple plies that define one or more fluid chambers. The plies may be flexible so that the fluid chambers are inflated when fluid is introduced via an inflation region. In the case of multiple fluid chambers, the plies may also define the inflation region that is configured to direct fluid from an opening in the inflatable protective packaging unit to each of the fluid chambers. In some embodiments, this may be an open channel. In other embodiments, this may be a closed channel. Multiple channels can come together to form an inflation region. The fluid chambers may be fluidly isolated from one another and configured to prevent fluid escape into the inflation region. This may allow each of the fluid chambers to define distinct inflatable segments of the inflatable protective packaging unit that are moveable with respect to one another, thereby allowing for adaptive positioning around a target product or other item for protecting.
In accordance with various embodiments, the inflatable protective packaging unit includes an inflation component receiver. The inflation component receiver may generally define a fluid path between an inflation component and one or more internal volumes of the inflatable protective packaging unit, such as one or more fluid chambers, manifolds, and so on. For example, the inflation component receiver may be positioned at least partially within an opening defined by the flexible plies of the inflatable protective packaging unit and direct fluid from a fluid source into the internal volume(s) of the inflatable protective packaging unit.
The inflation component receiver may also be used to facilitate coupling the inflatable protective packaging unit with the inflation device. For example, the flexible plies of the inflatable protective packaging unit may be suspended from the inflation component receiver, and the inflation component receiver may be received by the inflation device. To facilitate the foregoing, the inflation component receiver may include a protrusion or other engagement feature that is received by the inflation device in a manner suitable to support the inflatable protective packaging unit within the device. In some cases, the inflation component receiver may be separably attached to the flexible plies. For example, flexible plies may be suspended from the inflation component receiver in part by a friction fit, frangible connection, and/or other feature that allows the inflation component receiver to be separated from the flexible plies without substantially damaging the flexible plies.
In certain embodiments, the inflation device may detach the flexible plies from the inflation component receiver, for example, after inflation of the fluid chamber(s) of the inflatable protective packaging unit. In this regard, the inflation component receiver may be discarded or recycled rather than used as protective packing. This may be beneficial, for example, when the inflation component receiver is formed from a different, more rigid material than the flexible plies.
The inflatable protective packaging units can be inflated using the inflation device as further discussed herein. A group of inflatable protective packaging units may be provided to the inflation device in an uninflated configuration. An inflatable protective packaging unit support mechanism may define a magazine that receives the group of inflatable protective packaging units and stores the cushions for subsequent inflation by the inflation device. For example, the inflatable protective packaging unit support mechanism may define a track that is configured to receive the inflation component receiver (or other feature of the inflatable protective packaging unit) in a manner that allows the inflatable protective packaging unit to be suspended or otherwise supported by the inflatable protective packaging unit support mechanism.
The track, which may be a through portion of the inflatable protective packaging unit support mechanism defined by opposing wall portions, may define a path along which one or more of the inflatable protective packaging units may be discretely moved. The group of inflatable protective packaging units may be discretely moved toward, for example, a filling position (for inflation), a separator (for detachment of inflation component receiver and respective plies), a device exit, and/or other operation of the inflation device. The inflatable protective packaging unit support mechanism therefore may allow inflatable protective packaging units to be sequentially processed, which may facilitate rapid cushion inflation and deployment in packaging-related activities, as described herein.
Sequential processing, or other movement of the inflatable components, may be accomplished by an advancement mechanism of the inflation device. The advancement mechanism may be arranged relative to the track that is defined by the inflatable protective packaging unit support mechanism and engage one or more inflatable protective packaging units supported thereon. To facilitate the foregoing, in one embodiment, the advancement mechanism may include a pusher that at least partially extends into the track. The pusher may couple with an inflatable protective packaging unit supported in the track and bias the inflatable protective packaging unit along the path formed by the track. Where multiple inflatable protective packaging units are supported by the track, the pusher may couple with any given one of the inflatable protective packaging units, and cause the group of inflatable protective packaging units to be biased along the path. As such, the advancement mechanism may be used by the inflation device to move the inflatable protective packaging units as a group; however, in alternative arrangements, the advancement mechanism may move individual ones of a group of inflatable protective packaging units supported by the track, as described herein.
In some embodiments, the advancement mechanism causes one or more of the inflatable protective packaging units to be moved to a filling position where the plurality of inflatable protective packaging units may be discretely inflated with a fluid. A detent or suitable feature that locates the inflatable protective packaging units advance along the track in the filling position. For example, the advancement mechanism can, in certain embodiments, advance the inflatable protective packaging units as a group (or individually) toward the detent. The detent may prevent advancement of the inflatable protective packaging units so that one of the inflatable protective packaging units is arranged at the filling position.
The inflation device may include a filling station that is configured to provide fluid and inflate the group of inflatable protective packaging units. In a particular embodiment, the filling station may include an inflation component that is coupled with a fluid source. The inflation component may be a nozzle that is configured to be received by the inflation component receiver of the inflatable protective packaging unit. The filling station may include one or more actuators that move the inflatable protective packaging unit past the detent and toward an exit of the inflation device. For example, the nozzle may be coupled with the one or more actuators and move the inflatable protective packaging unit; however, this is not required. In other cases, inflation component may disengage from the inflation component receiver upon inflation, and the inflatable protective packaging unit may be advanced toward the exit of the inflation device by another component, including a component coupled with the advancement mechanism and/or mechanism of other devices. It will be appreciated, that as described herein, “actuator” may refer to substantially any component that is suitable to induce a force or movement on another object or system. For example, the “actuator” may encompass electrically-activated components, hydraulic systems, pneumatic systems, and so on. In various embodiments, passive components such as a springs, weights, or other biasing components can suitably substitute the actuator.
The inflation device may be configured to separate portions of the inflatable protective packaging unit as the cushion is advanced toward the exit of the device and subsequently ejected. This may help prepare the inflatable protective packaging units for use in a particular packaging application and/or remove portions of the inflatable protective packaging unit that may be undesirable for use as packaging material, such as the inflation component receiver. As an example, the inflation component receiver suspends or aids in suspending the inflatable chambers of the inflatable protective packaging unit as the fluid chambers are inflated by the inflation device. The inflation component receiver may be a different, possibly more rigid material than the flexible plies. The inflation device may operate to separate the inflation component receiver from the flexible plies. As described in greater detail below, the inflatable protective packaging unit advances along a dispensing path, for example, after being inflated by the filling station. A separator may be positioned along the dispensing path and configured to detach the inflation component receiver from flexible plies that define the fluid chamber.
In some cases, the separator may be a ramp that is positioned on an underside of a support element that supports the inflatable protective packaging units. As the inflatable protective packaging unit is advanced along the dispensing path, the ramp contacts the flexible plies and causes the flexible plies to move in a direction different from that of the direction of the dispensing path. The inflation component receiver may continue along the dispending path, for example, due to the operation of one or more actuators described herein, and thus the flexible plies may be separated as the flexible plies and the inflation component receiver travel in directions different from one another. In some cases, the flexible plies (and associated inflated chamber(s)) may be ejected from the inflation device and into a first bin, and the inflation component receiver may be ejected into a second bin.
It will be appreciated that to facilitate the foregoing, various mechanical and electromechanical components and systems may be used to perform one or more operations of the inflation device. Sample components and systems, such as those of the inflatable protective packaging unit support mechanism, the advancement mechanism, the filling station, the separator, and/or other assemblies or subassemblies of the inflation device, are presented and described herein for purposes of illustration. As described herein, the assemblies and subassemblies of the inflation device may be interconnected, and as such, rather than discrete systems, may be coupled to one another and use common components. In this regard, it will be appreciated that different components may be used to facilitate the various functionalities of the inflation device described herein, and that the following assemblies are presented for explanatory purposes and should not be construed as limiting.
Reference will now be made to the accompanying drawings, which assist in illustrating various features of the present disclosure. The following description is presented for purposes of illustration and description. Furthermore, the description is not intended to limit the inventive aspects to the forms disclosed herein. Consequently, variations and modifications commensurate with the following teachings, skill, and knowledge of the relevant art are within the scope of the present inventive aspects.
Broadly, the inflation system 100 may include an inflation device 104 and inflatable protective packaging units 150. The inflation device 104 may receive the inflatable protective packaging units 150 in an uninflated configuration. For example, the inflation device 104 may include an inflatable protective packaging unit support mechanism 110 that is configured to receive the inflatable protective packaging unit 150 and store the inflatable protective packaging unit 150 for subsequent discrete advancement toward a filling position or other portion of the device 104. Accordingly, the inflatable protective packaging unit support mechanism 110 may define a magazine that is used to support and store the inflatable protective packaging units, and is some cases, drive the units forward within the device. To facilitate the foregoing, the inflatable protective packaging unit support mechanism 110 may include a first wall portion 109a and a second wall portion 109b. The first wall portion 109a and the second wall portion 109b may cooperate to define a track 112. The track 112 may receive the inflatable protective packaging units 150 and define a path for movement of the inflatable protective packaging units 150.
The inflatable protective packaging units 150 may be moved along the track 112 by various actuators and associated assemblies, described herein. For purposes of illustration,
The inflatable protective packaging units 150 may be advanced along the track 112 and toward a filling station 122. The filling station 122 may be used to provide fluid to the inflatable protective packaging unit positioned at the filling position and/or other appropriate position. In various examples, the filling station 122 includes a fluid source port 125. The fluid source port 125 may be coupled with a hose, tube, or other conduit 122a that is used to deliver fluid to the inflation component 126 (e.g. nozzle). For purposes of illustration,
The filling station 122 may also include one or more actuators that operate to move the inflatable protective packaging unit from the filling position and toward an exit region of the inflation device 104, such as exit region 105. In the embodiment of
In operation, the first inflation component actuator 130a may move the inflation component 126 at least partially into the track, which may cause the inflation component 126 to engage the inflation cushion. In the engaged configuration, the filling station 122 may provide fluid to the inflatable protective packaging unit, thereby allowing the unit to inflate. The second inflation component actuator 130b may operate to use the inflation component 126 to move the cushion toward the exit region 105. For example, the inflation component 126 may be engaged with the inflatable protective packaging unit and the second inflation component actuator may cause the inflation component (and engaged cushion) to move toward the exit region 105. At the exit region 105, the inflation device 104 may cause the inflatable protective packaging unit to be ejected from the device. In some cases, as describe herein, the inflation device may also operate to separate inflated portions of the inflatable protective packaging units from, for example, a receiver used to suspend the inflated portions along the track of the inflation system 100.
The inflation device 104 may operate in manufacturing or commercial environments. The inflation device 104 may be used in conjunction with various structures, equipment, controls, and so forth, that facilitate use of the inflation device 104 in such environments. In the embodiment of
In accordance with various embodiments, as illustrated in
The inflation device 104 may also be connected with a control panel, such as the control panel 192 shown in
In the embodiment of
As described in greater detail below with respect to
The inflatable protective packaging unit 150a is also shown with a group of valve areas 162. As shown, the inflatable protective packaging unit 150a may have a valve area 162 at each of the fluid chambers 160. The valve area may include one or more structures, seals, adhesive, and the like described herein, that are configured to prevent fluid escape upon inflation of the inflatable packaging unit 150a. In various examples, the valve area 162 may include a check-valve, a heat seal, and other features.
The inflatable protective packaging unit 150a (or any of the inflatable protective packaging units 150) may be advanced along the track 112 using the inflation component receiver 154. For example, the inflation component receiver 154 may be received substantially between the first wall portion 109a and the second wall portion 109b that defines the track 112. The pusher 134 or other mechanism of the inflation device 104 may engage one of the group of inflatable protective packaging units 150 and cause the group of inflatable protective packaging units to move toward a filling position. The group of inflatable protective packaging units 150 may be arranged in a row along the track 112. As such, the pusher 134 may exert a force on one of the inflatable protective packaging units 150, such inflatable protective packaging unit 150b positioned furthest from the exit region 105 of the inflation device, which, in turn, causes the whole row of inflatable protective packaging units 150 to advance along the track 112. By advancing the whole row, inflatable protective packaging units 150 may cause a select inflatable protective packaging unit positioned nearest to the exit region 105, such as the inflatable protective packaging unit 150a, to advance into a filling position for subsequent inflation.
As described herein, one or more actuators may be used to manipulate the inflation component 126. In the example of
For purposes of illustration, the filling position of the inflation device 104 may be defined by a position of the inflation component 126 shown in
The inflatable protective packaging unit 150a (or any inflatable protective packaging unit) may have a separable inflation component receiver (e.g., inflation component receiver 154) and flexible plies (e.g., flexible plies 158). As such, once filled and adequately inflated, the inflation device 104 may operate to separate the inflation component receiver from the inflated packaging unit. Broadly, this separation may be accomplished by moving the inflation component receiver 154 along the track 112, while the inflated packaging unit is moved in another direction, e.g. down and away from the inflation component receiver 154. To facilitate the foregoing, the inflation system 100 may include a separator 132. In various embodiments, as illustrated in
The separator 132 may cause the flexible plies 158 to move in a direction other than a direction of the track 112. For example, the first ramp portion 133a and/or the second ramp portion 133b may contact the flexible plies 158 as the inflatable protective packaging unit 150a is moved toward the exit region 105 by the inflation component receiver 154. The first ramp portion 133a and/or the second ramp portion 133b may prevent movement of the flexible plies along the track 112 and therefore cause the flexible plies 158 to separate from the inflation component receiver 154 as the inflation component receiver 154 continues to advance toward the exit region 105 of the inflation device 104. The flexible plies 158 may separate from the inflation component receiver 154 without substantially damaging the inflated chambers of the inflatable protective packaging unit. The inflation component receiver 154 may continue to advance toward the exit region 105, where it may be ejected from the inflation device 104 separately from the ejection of the corresponding inflatable protective packaging unit.
The track 112 may also be arranged to eject the inflation component receiver 154 from the inflation system 100. As described herein, the inflation component 126 may be used to advance the inflation component receiver 154 along the track 112 and to an exit region 105 of the inflation system. The track 112 may have multiple different widths along a length of the track to facilitate the movement of the inflation component receiver 154, and subsequent ejection at the exit region 105. In the example shown in
As shown in
In some cases, the packaging inflation system 100 may operate to separate each individual protective packaging unit. As one possibility, inflation and subsequent advancement of a protective packaging unit may cause the protective packaging unit to tear or separate from the other protective packaging units. In other cases, the packaging inflation system 100 may employ various other structures to facilitate the separation of the protective packaging units 350 from one other, including various cutting mechanisms, mechanical separators, and so forth. Additionally or alternatively, the protective packaging units 350 may be torn or otherwise manually separated by a user of the packaging inflation system, for example, which may be prior, or subsequent to, inflation of the protective packaging units.
With respect to
The inflatable protective packaging unit 400 may be a fluid-filled cushion (e.g., air cushion) at least partially made by sealing plies of plastic to form one or more flexible plastic inflation chambers that may be connected and adjoined parallel to or in series with one another. Where multiple chambers are present, an inflation region may operate to direct air to the chambers. This may be accomplished continuously or discretely. In some examples, all of the separate inflatable chambers may be connected together, while in other examples, the inflatable chambers may be separated from one another (e.g., such as using one-way check-valves, an inflation region, heat seal, and so on), thereby allowing each chamber to inflate and maintain an inflated state without substantially causing fluid to leak into the inflation region or other portion of the inflatable protective packaging unit. Once inflated, one or more air cushions are configured to surround and cushion a target item. An example of such an air cushion is the AIRSPEED® CHAMBERPAK™ by Pregis Corporation. Descriptions of other examples of inflatable air cushions can be found in, for example, U.S. Pat. No. 5,261,466, and U.S. Application Publication Nos. 2003/0108699, 2004/0163991, and 2005/0109656.
In the embodiment of
The inflatable protective packaging unit 400 may also include a valve area 424. Broadly, the valve area 424 is configured to allow flow (such as flow F1 shown in
Further, the valve area 424 may be a portion of the inflatable protective packaging unit 400 that is configured to prevent fluid escape from respective ones of the inflatable chambers 420 back into the inflation region 416. Valve area 424 may, in some embodiments, define or otherwise include one-way check valves 428 (as described in greater detail below with respect to
In some embodiments, the inflatable protective packaging unit 400 further includes seal segments 430. The seal segments 430 divide the inflatable chambers 420 into transverse chamber portions. The seal segments 430 may be aligned longitudinally and separated by seals that separate the inflatable chambers from one another. The seal segments 430 create bendable lines that allow the inflatable protective packaging unit 400 to bend or fold. Such flexibility may allow the inflatable protective packaging unit 400 to wrap around target protected items of various shapes and sizes.
It will be appreciated that the inflatable protective packaging unit 400 may be constructed from various flexible materials, described herein.
The inflatable protective packaging unit may also include other flexible layers that may define a check valve, for example, at the valve area 424. As shown in
In an uninflated state, the inflatable protective packaging unit 400 may be substantially flat, for example, due to atmospheric pressure.
The check-valves may be formed in accordance with methods known to one of ordinary skill in the art in light of the disclosure herein. In one embodiment, the check-valves may include opposing the first flap 452a and the second flap 452b, which may be sandwiched between the first ply 450a and the second ply 450b. The internal surface of opposing first flap 452a and second flap 452b may include some ink. When heat is applied to the stack of opposing first flap 452a and second flap 452b sandwiched between the first ply 450a and the second ply 450b, all of the layers may fuse together except at a region having the ink on the internal surfaces. This inked region allows for fluid to pass through the collapsible channel substantially between the first flap 452a and the second flap 452b. And as such, the portion of opposing first flap 452a and second flap 452b internal to the inflatable chamber 420 defined between first ply 450a and second ply 450b may be kept closed by the internal chamber pressure, thereby allowing air into the chamber but not out of the chamber.
With further reference to
The receiver 404 may include a protrusion 408. The protrusion 408 may be an exploded flange, lip, or other feature that extends outward from the body 405. The protrusion 408 may allow the inflatable protective packaging unit 400 to be received and supported with an inflation device. For example, the protrusion 408 may be received by a track or other feature of an inflation device, and as such, the inflatable protective packaging unit 400 may be supported or suspended from the inflation device via the engagement of the protrusion 408. In some embodiments, the protrusion 408 may be used to slide the inflatable protective packaging unit along the track.
The receiver 404 is shown in
As described herein, the receiver 404 may be separably attached to the flexible plies 450a, 450b. This may allow the inflation component receiver to be discarded or recycled after inflation of the respective inflatable chambers. The receiver 404 may be separably attached to the flexibles plies 450a, 450b by a number of suitable methods, including by forming a frangible connection, a tight connection, or other separable connection. For example the tight connection can be formed by a friction fit or interference fit between the receiver 404 and the flexible plies 450a, 450b. In various examples, the frangible connection can be a semi-permanent connection between the inflation component receiver and the flexible plies. A semi-permanent connection may be one that is permanent but is easily separated, broken, severed, or the like, including spot welds, partial strong adhesives, complete weak adhesives, or any other combination or suitable adaptation of an attachment. For purposes of illustration,
In an embodiment, the receiver 404 may be separably attached to the flexibles plies 450a, 450b at the opening 418. The receiver 404 may form a loose connection with the flexible plies 450a, 450b. As such, as shown in
The receiver 404 may be constructed from a material distinct from that of the flexible plies 450a, 450b, and/or another component of the inflatable component 412 of the inflation component 404. For example, the component receiver 404 may be formed from a material that is more rigid than a material used to form the flexible plies 450a, 450b. The enhance rigidity of the receiver 404 may help the inflatable protective packaging unit 400 to be received, supported, and guided by the inflation device. For example, the receiver 404 may be constructed from a material that may not tear, deform, or damage due to a given force to the same extent as the material used to form the inflatable component 412. As such, the inflation device may exert forces on the inflation component receiver (e.g., for advancement toward a filling position, ejection, and so on), that may otherwise be inappropriate for the material of the inflatable component 412. The distinct material of the receiver 404 may in some cases render the receiver 404 unsuitable for use as a packaging material. As such, as described herein, the inflation device may detach the inflation component receiver from the inflatable component 412 and eject each from the device separately.
In one embodiment, the receiver 404 defines an entry opening 407 that faces and is open to the exterior to receive the fluid and direct it into the inflation region 416 of the inflatable component 412. For example, the receiver 404 can define an entry, avenue, passage, duct, and so, for fluid to flow into and through the receiver 404 and enter the inflatable component 412 for inflating one or more chambers 420 of the component 412, such as via the inflation region 416. In some cases, as described herein, the receiver 404 can define an entry for fluid into an inflation region 416 of the inflatable component 412, where the inflatable region can guide the fluid within the inflatable component 412 into one or more respective chambers 420.
To facilitate the foregoing, in the embodiments of
The receiver 404 can also be configured to receive the fluid and direct it into the inflatable component 412, such as by directing it into the inflation region 416, by receiving the fluid directly, for example by blowing the fluid into the entry opening 407 of the receiver 404, or by inserting an inflation component, such as a nozzle or other inflator through which fluid is dispensed, to pass the fluid through the entry opening 407 and at least partially into the channel 406. The receiver 404 can include a ring, body, tube or other structure that generally guides the inflator toward the inflation region of the inflatable component 412.
It will be appreciated, however, the receiver 404 can, in certain embodiments, be flexible, deformable and/or otherwise have a similar rigidity to that of the inflation component 412. For example and as described in greater detail below with respect to
To facilitate the foregoing, the inflatable protective packaging unit 400, including the plies 450a, 450b, and the receiver 404, may be formed from any of a variety of materials known to those of ordinary skill in the art. Such materials can include, but are not limited to, ethylene vinyl acetates (EVAs), metallocenes, polyethylene resins such as low density polyethylene (LDPE), linear low density polyethylene (LLDPE), and high density polyethylene (HDPE), and blends thereof. Other suitable materials and constructions can be used. The inflatable protective packaging units 400 may include components that may be rolled on a hollow tube, a solid core, or folded in a fan-folded box or in another desired form for storage and shipment.
In some embodiments, the plies 450a, 450b are between 10 and 100 microns thick. In some embodiments, the plies 450a, 450b are at least 20 microns thick. For example, in an embodiment, the plies 450a, 450b may be between 50 and 75 microns thick.
In some embodiments, the plies 450a, 450b are made from a co-extruded material that contains nylon. For example, the plies 450a, 450b may be made from polyethylene and nylon. Materials containing nylon serve as an air barrier and retain the air over the shipping and storage cycle of shoes. Other suitable materials and constructions can be used.
A monolayer or multilayer polymeric film material may also be used. Each ply, for example, may be made from a monolayer or multilayer film. Monolayer films are typically made of polyethylene, although other suitable polymers may be used. The one or more layers of multilayer film embodiments may include polymers of differing compositions. In some embodiments, the disclosed layers may be selected from ethylene, amide, or vinyl polymers, copolymers, and combinations thereof. The disclosed polymers can be polar or non-polar. The disclosed ethylene polymers may be substantially non-polar forms of polyethylene. In many cases, the ethylene polymer may be a polyolefin made from copolymerization of ethylene and another olefin monomer, for example an alpha-olefin. The ethylene polymer may be selected from low, medium, or high-density polyethylene, or a combination thereof. In some cases, the density of various polyethylenes may vary, but in many cases the density of low-density polyethylene may be, for example, from about 0.905 or lower to about 0.930 g/cm3; the density of medium-density polyethylene may be, for example, from about 0.930 to about 0.940 g/cm3; and high-density polyethylene may be, for example, about 0.940 to about 0.965 g/cm3 or greater. Other suitable densities of various polyethylenes may be used. The ethylene polymer may be selected from linear low-density polyethylene (LLDPE), metallocene linear low-density polyethylene (mLLDPE), high-density polyethylene (HDPE), medium-density polyethylene (MDPE), and low-density polyethylene (LDPE).
In some embodiments, the polar polymer may be a non-polar polyethylene which may be modified to impart a polar characteristic. In other embodiments, the polar polymer may be an ionomer (e.g., copolymers of ethylene and meth acrylic acid (E/MAA)), a high vinyl acetate content EVA copolymer, or other polymer with polar characteristics. In one embodiment, the modified polyethylene may be anhydride modified polyethylene. In some embodiments, the maleic anhydride is grafted onto the olefin polymer or copolymer. Modified polyethylene polymers may react rapidly upon coextruding with polyamide and other ethylene containing polymers (e.g., EVOH). In some cases, a layer or sublayer comprising the modified polyethylene may form covalent bonds, hydrogen bonds, and/or dipole-dipole interactions with other layers or sublayers, for example, sublayers or layers comprising a barrier layer. In many embodiments, modification of a polyethylene polymer may increase the number of atoms on the polyethylene that are available for bonding. For example, modification of polyethylene with maleic anhydride adds acetyl groups to the polyethylene, which may then bond with polar groups of the barrier layer, for example, hydrogen atoms on a nylon backbone. Modified polyethylene may also form bonds with other groups on the nylon backbone as well as polar groups of other barrier layers, for example, alcohol groups on EVOH. In some embodiments, a modified polyethylene may form chain entanglements and/or van der Waals interactions with an unmodified polyethylene.
The layers of the plies 450a, 450b may be adhered or otherwise attached together, for example, by tie layers. In other embodiments, one or more of the plies 450a, 450b are a single layer of material, for example, a polyethylene layer.
Mixtures of ethylene and other molecules may also be used. For example, ethylene vinyl alcohol (EVOH) is a copolymer of ethylene and vinyl alcohol. EVOH has a polar character and can aid in creating a gas barrier. EVOH may be prepared by polymerization of ethylene and vinyl acetate to give the ethylene vinyl acetate (EVA) copolymer followed by hydrolysis. EVOH can be obtained by saponification of an ethylene-vinyl acetate copolymer. The ethylene-vinyl acetate copolymer can be produced by a known polymerization, such as solution polymerization, suspension polymerization, emulsion polymerization and the like, and saponification of ethylene-vinyl acetate copolymer can be also carried out by a known method. Typically, EVA resins are produced via high pressure autoclave and tubular processes.
Polyamide is a high molecular weight polymer having amide linkages along the molecular chain structure. Polyamide is a polar polymer. Nylon polyamides, which are synthetic polyamides, have favorable physical properties of high strength, stiffness, abrasion, and chemical resistance, and low permeability to gas, for example oxygen.
Notwithstanding the foregoing similarities, the inflatable protective packaging unit 500 depicts that opening 518 along a transverse edge. In this manner, as shown in
The inflatable protective packaging unit 400, 500, and/or any of the inflatable units described herein, may be used with any of the inflation devices described herein. Turning now to
Various components, such as covers, plates, structural support members, and so on may be connected to the first wall portion 614a and/or the second wall portion 614b, according to one or more embodiments. This may structurally couple the first wall portion 614a and the second wall portion 614b to one another. More broadly, this may also allow the inflatable protective packaging unit support mechanism to be connected to other components, assemblies, and subassemblies of the inflation device 604.
For purposes of illustration,
In the embodiment of
Positioned over the first track cover 618a and the second track cover 618b may be the engagement member 620 and the filling station member 624. In the embodiment of
The filling station member 624 may also be a plate that is used to structurally couple components that define the track 612 with other components and assemblies of the inflation device 604. The filling station member 624 may be positioned near the end region 606 of the inflation device 604, such as about a filling position or other position where an inflation component may be used to provide fluid to an inflatable protective packaging unit. As such, the filling station member 624 may define an elongated slot 626. The elongated slot 626 may be positioned along a direction of the track 612. The elongated slot 626 may allow an inflation component, such as a nozzle from the filling station 650, to extend through the filling station member 624 and into the track 612.
Positioned above the inflatable protective packaging unit support mechanism 610 may be the advancement mechanism 616. The advancement mechanism 616 may be configured to advance inflatable protective packaging units that are received by the inflatable protective packaging unit support mechanism 610 along a direction of the track 612. To facilitate the foregoing, the advancement mechanism 616 may include a pusher 616. The pusher 616 may be connected to an actuator 638. The pusher 616 may include at least a first portion that is coupled to the actuator and a second portion that extends into the track 612.
The pusher 616 is shown in
The inflation device 604 may also include the filling station 650 that is used to discretely inflate inflatable protective packaging units supported by the track 612. It will be appreciated that while the filling station 650 is shown including various inflation components, actuators, support members, and so on, the embodiment shown in
Broadly, the filling station may include the inflation component 658. The inflation component 658 may be a nozzle, coupling, or other structure that is configured to channel fluid to the inflatable protective packaging units supported by, for example, the track 612. In this regard, the inflation component 658 may be connected with a fluid source and be received by an inflatable protective packaging unit (e.g., at an inflation component receiver).
The inflation component 658 is shown in
At the exit region 606 of the inflation device 604, the inflatable protective packaging unit may be ejected. In some cases, the inflation device 604 may also operate to separate separable portions of the inflatable protective packaging unit at the exit region 606. For example, as described herein, the inflation device 604 may separate an inflation component receiver from flexible plies or other materials that define an inflatable portion of the inflatable protective packaging unit. To facilitate the foregoing, the inflation device 604 may include a separator 680 having a first ramp portion 682a and a second ramp portion 682b. The first and second ramp portions 682a, 682b may generally define a separation station along a portion of the track 612. For example, the first ramp portion 682a may be positioned along a first side of the track 612 (e.g., and coupled to the first wall portion 614a) and the second ramp portion 682b may be positioned along a second side of the track 612 (e.g., and coupled to the second wall portion 614b). The first and second ramps portions 682a, 682b can define diverging elements of the separator 680. As explained in greater detail below with respect to
For example, for purposes of illustration,
The inflation component receiver 675 may be configured to receive the inflation component 658. In this manner, the inflation component 658 may deliver fluid to the inflatable chambers defined by the flexible plies 672 using the inflation component receiver 675. Broadly, in accordance with various embodiments, the inflation component 658 may be any suitable nozzle, such as one used to deliver a fluid through the one-way check-valve. In one example, the nozzle may include a body that tapers toward the distal end. The tapered portion is located at the distal end of the nozzle body. In other embodiments, the nozzle body can be untapered, tapered along substantially its entire length, or have multiple tapered portions. The tapered portion of the nozzle body advantageously facilitates insertion of the inflation nozzle into an inflation port (e.g., opening 318 of
The inflation component 658, shown in
With reference to
In the embodiment of
With reference to
With reference to
To facilitate the foregoing, in the embodiment shown in
In the embodiment of
With reference to
In accordance with some embodiments, as illustrated in
With reference to
While no longer supported by the track 812, the inflation component receiver 875 may remain connected to the inflation component 858. For example, the inflation component 858 may include O-rings 862. The inflation component 875 and the O-rings 862 may establish a friction or interference fit that allows the inflation component 875 to be connected to inflation component 858, despite not being supported by the track 812 at the release portion 806.
In this manner, the inflation device 804 may use one or more actuators, such as the first inflation component actuator 852, to separate the inflation component receiver 875 and the inflation component 858. For example, as shown in
As described above, the inflation component receiver 875 may be advanced along the track 812, past the transition 807, and to the release region 806 of the track 812. At the release region 806, the track 812 has an enlarged width, and thus the inflation component receiver 875 is no longer supported within the inflation device 804 at the release region 806. And as described above, the inflation component receiver 875 is loosely connected to the inflation component 858 and/or otherwise connected in a manner such that the inflation component 858 may not necessarily support the weight of the inflation component receiver 875. As such, the inflation component receiver 875 may fall from the track 816 upon progression past the transition 807 and into the release region 806.
Like reference numerals designate like structural elements, however, the presence of different reference numerals is not necessarily indicative of different structural elements. In particular, like reference numerals in the last two digits of a reference number may be indicative of like elements. For example, the separator shown in
Other examples and implementations are within the scope and spirit of the disclosure and appended claims. For example, features implementing functions may also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations. Also, as used herein, including in the claims, “or” as used in a list of items prefaced by “at least one of” indicates a disjunctive list such that, for example, a list of “at least one of A, B, or C” means A or B or C or AB or AC or BC or ABC (i.e., A and B and C). Further, the term “exemplary” does not mean that the described example is preferred or better than other examples.
The foregoing description, for purposes of explanation, uses specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.
This patent application is a non-provisional patent application of, and claims priority to, U.S. Provisional Application No. 62/702,175 filed Jul. 23, 2018, and titled “PACKAGING INFLATION SYSTEM”, and to U.S. Provisional Application No. 62/775,216 filed Dec. 4, 2018, and titled “AUTOMATIC PROTECTIVE PACKAGING INFLATOR”, each of which is hereby incorporated by reference in its entirety.
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