Patent Application
20140224699
This invention relates, generally, to methods of packaging and shipping items. More particularly, it relates to a method of cushioning an item to be shipped.
The use of different types of packaging for shipping articles is well known. Shipped articles can come in all sizes and shapes. These articles can be fragile or hardy (i.e., the article is considered non-fragile). There are several types and forms of packaging, including peanuts, paper, bubble plastic, foam, etc. However, all of the packaging materials mentioned can cause waste disposal and recycling issues.
Different attempts at providing an effective inflatable packaging material and/or system have been made, such as U.S. Pat. Nos. 4,905,835 and 4,969,312 to Pivert, which are limited to a rectangular box with inflatable structures that are inserts into the box, thereby requiring multiple steps for use, from insertion of the inflatable structures to closure of the box. In addition, U.S. Pat. No. 5,588,533 to Farison provides an inflatable cushion through a single inflation valve, which must be inserted into the box with the article. U.S. Pat. No. 6,076,677 to Pozzo is a shipping container and inflatable packaging cushion that must be partially filled, then the article is inserted, and following steps are required.
Hollingsworth, et al. (U.S. Pat. No. 6,334,534) discloses a package having foam cushions coated in a cover with an air flow controlling vent, permitting air to escape from the cushion upon impact. Sperry (U.S. Pat. No. 6, 253,919) discloses a single air bladder design. Kim (U.S. Pat. No. 5,624,035) discloses a carrying case having inflation sections and air interconnect conduits. Pharo (U.S. Pat. No. 4,793,123) discloses an inflation bladder that can be wrapped around an item and inflated.
While the prior art provides protection to the articles within a box, the conventional art suffers from a number of drawbacks. The inflation, insertion, and closure of the prior art devices all require multiple steps and are not simple, efficient methods of shipping articles or products using an inflatable cushion. The prior art requires tedious methods for inflation. For instance, the prior art requires that certain cushions be inflated before others in a specific sequence, that cushions be inflated before insertion into the box, and complex sequences of events for closure of box flaps and/or self-locking flaps. They require optimal inflation to work properly and finally require multiple cushions to provide adequate protection to the article shipped. The present invention is designed to address these shortcomings by providing a package as described below.
The present invention is designed to advance the art of packaging past the drawbacks of the prior art and provide packaging that is simple to use, requires minimal instruction, has the minimum number of parts, and is cost-effective. Another object of the present invention is to provide a method that allows for an easily automated process.
Certain embodiments of the present invention include a packaging device comprising a box or tube container having at least one fluid bladder disposed on the interior of the package. The at least one fluid bladder is optionally fixed by adhesive, tape, welding, or other means to the interior face of the box or tube container walls. For example, for the box the at least one fluid bladder is disposed on the interior face of the bottom wall, first side wall, second side wall, third side wall, fourth side wall, and at least one top wall panel of the box. For the tube container, the at least one fluid bladder is disposed on the interior face of the bottom wall, the side tubular wall, and the top wall. As an alternative, the at least one fluid bladder may include more than one fluid bladder. For example, the packaging may include a first fluid bladder having a plurality of edges and at least one fluid channel disposed on at least one of the plurality of edges and a second fluid bladder having a plurality of edges and at least one fluid channel disposed on at least one of the plurality of edges, wherein the at least one fluid channel on the second fluid bladder is in fluid communication with the at least one fluid channel on the first fluid bladder. The fluid bladder may be formed of rubber, plastic, graphene, or Mylar™. The fluid bladder may be connected to the interior wall of the container using glue, tape, staples, heat, welding or other connection found acceptable by one of skill in the art. An option bleed valve is disposed on the fluid bladder and in fluid communication with the interior of the fluid bladder.
A fluid inflation valve is disposed on the fluid bladder, on the interior face of a side wall or top wall panel, on the exterior face of a side wall or top wall panel, or in the side wall or top wall, for example attached to the corrugation material. Regardless of how the fluid inflation valve is attached, the valve is in fluid communication with an interior lumen of the fluid inflation bladder. Optional fluid inflation valves include, without limiting the invention, a rubber gasket valve, plastic duckbill valve, a pressure valve, a gas-piston pressure regulated flow valve, a stem valve, a tire valve, a snap-in tire valve, a free flow inflation valve, a non-return inflation valve, a fixed plug inflation valve, a pressure inflation valve, a free flow inflation valve without plug, a non-return no plug inflation valve, a Leafield valve, a Halkey-Roberts valve, a Riken-Achilles military valve, a military valve, a summit valve, a float bag valve, and a balloon valve, as seen in
The packaging is any shape used to ship product, such as dolls or circuit boards, such as round, rectangular or other shape. Optionally the package is a tube container having a bottom wall having an interior face, an exterior face, and a circular edge, with a side tubular wall having an interior face, an exterior face, a bottom edge, and a top edge attached to the bottom wall. A top wall having an interior face, an exterior face, and a circular edge is attached at a least one point to the side tubular wall. The box comprises a bottom wall having an interior face, an exterior face, at least a first edge, a second edge, a third edge, and a fourth edge. A first side wall having an interior face, an exterior face, a bottom edge, a top edge, a first side edge and a second side edge, wherein the bottom edge is in physical communication with the first edge of the bottom wall when assembled. A second side wall having an interior face, an exterior face, a bottom edge, a top edge, a third side edge and a fourth side edge, wherein the bottom edge is in physical communication with the second edge of the bottom wall and the third side edge is in physical communication with the first side edge of the first side wall when assembled. A third side wall having an interior face, an exterior face, a bottom edge, a top edge, a fifth side edge and a sixth side edge, wherein the bottom edge is in physical communication with the third edge of the bottom wall and the fifth side edge is in physical communication with the fourth side edge of the second side wall when assembled. A fourth side wall having an interior face, an exterior face, a bottom edge, a top edge, a seventh side edge and a eighth side edge, wherein the bottom edge is in physical communication with the fourth edge of the bottom wall, the seventh side edge is in physical communication with the sixth edge of the third side wall and the eighth side edge is in physical communication with the second side edge of the first side wall when assembled. At least one top wall panel having an interior face and an exterior face is in physical communication with the top edge of at least one of the first side wall, second side wall, third side wall, or fourth side wall. The packaging is optionally made of cardboard, paper, plastic, wood, corrugated paper, graphene or other suitable materials. Optionally, the packaging includes at least one overlapping top wall panel disposed on the top edge of at least one side wall. In some variations, a fluid bladder is disposed on the interior face of the least one overlapping top wall panel.
A method is also provides for cushioning a package for an item being shipped using the box or tubular container described above. The box is uniquely designed to allow for a simple one-step process using a box with an integrated inflating tube and bottom liner to expand internally by inflation. An item is introduced into the box or tube container and the box or tube container closed. The fluid inflation valve is then attached to a source of fluid under pressure, such as a gaseous fluid like air, and the fluid flowed into the at least one fluid bladder, such that the fluid inflates the at least one fluid bladder around the item. Optionally, the source of fluid under pressure is then removed from the inflation valve. The inflating tube and bottom liner cushion the article to be shipped three-dimensionally. This completely protects the article and removes the need for peanuts, paper or other fillers in boxes used for shipping goods once the box is closed, thus increasing the safety of using the inflatable devices. This would also lighten the weight of the package considerably. The package may then be shipped, stored or otherwise handled. When the packed item is to be retrieved, the at least one fluid bladder may be deflated the prior to removal of the item from the box or tube container.
Because the packaging is inflated after the item is inserted into the packaging, the invention increases safety by eliminating the hazard of the inflatable bladder (i.e., air cushion) exploding in the face of the user if over-inflated. Where a bleed valve is provided in the packaging, the packaging further avoids this by releasing air when pressure reaches a certain level. This would allow for automated and manual air filling without worry of over-inflating.
Other aspects and advantages of the present invention appear more clearly from reading the following detailed description of the preferred embodiment of the invention, given by way of example and made with reference to the accompanying drawings, such as the determination of which end of the box is the bottom or top. This is determined by which end of the box is closest to the inflatable bottom part of the cushion.
Certain aspects of the present art can be found in the prior art, but the prior art has failed to overcome its deficiencies and has failed to advance the state of the art in the inflatable packaging industry. Specifically, the current invention provides the user with the unexpected benefits of simplicity, efficiency and safety by placing an article(s) for shipment into a box, closing the box, filling it with air, and shipping it. The prior art appears to teach away from the present invention in that it teaches the use of multiple cushions, multiple steps to closure, inflation of cushions (bladders) before closure of the box, etc. Thus, the current invention advances the state of the art through its novel, useful, and nonobvious apparatus and methodology.
Other objects, features and advantages of the invention will become obvious from the following detailed description of the invention when taken in conjunction with the accompanying drawings, in which:
The present invention will be described more fully with reference to the accompanying drawings, in which the preferred embodiments of the present invention are shown. It is understood from the embodiments that a person skilled in the art may make variations and modifications without departing from the spirit and scope of the invention. Such variations and modifications may include changing the size or shape of a box, the optional addition of a bleed valve, or the addition of a small hand pump integrated into the sidewall of the box.
As used herein “substantially along” means that at least a majority of the distance is connected. For example, at least 75%, 80%, or 90% of the distance is connected.
As used herein “plastic” means any of various organic compounds produced by polymerization, capable of being molded, extruded, cast into various shapes and films, or drawn into filaments. A plastic can either be a thermosetting polymer or a thermoplastic polymer, such as acetals, acrylics, acrylonitrile-butadiene-styrene, alkyds, cellulosics, coumarone-indene, diallyl phthalate, epoxy, fluoropolymer, melamine-formaldehyde, nitrile resins, nylon, petroleum resins, phenolics, polyamide-imide, polyarylates, polybutylene, polycarbonate, polyethylene, polyimides, polyphenylene oxide, polyphenylene sulfide, polypropylene, polystyrene, polyurethanes, polyvinyl acetate, polyvinyl chloride, styrene acrylonitrile, styrene butadiene latexes, sulfone polymers, thermoplastic polyester, unsaturated polyester, urea-formaldehyde, hexachloroethane, or any combination thereof. Useful plastics include acrylonitrile butadiene styrene (ABS), high impact polystyrene (HIPS), acrylic (PMMA), cellulose acetate, cyclic olefin copolymer (COC), ethylene-vinyl acetate (EVA), ethylene vinyl alcohol (EVOH), polyvinylfluoride (PVF), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), fluorinated ethylene-propylene (FEP), perfluoroalkoxy polymer (PFA), polyethylenechlorotrifluoroethylene (ECTFE), polyethylenetetrafluoroethylene (ETFE), perfluoropolyether (PCPE), acrylic/PVC polymer, aromatic polyester polymers (liquid crystal polymer), polyoxymethylene (acetal), polyamide (PA, nylon), polyamide-imide (PAI), polyaryletherketone (PAEK), polybutadiene (PBD), polybutylene (PB), polybutylene terephthalate (PBT), polycaprolactone (PCL), polychlorotrifluoroethylene (PCTFE), polyethylene terephthalate (PET), polycyclohexylene dimethylene terephthalate (PCT), polycarbonate (PC), polyhydroxyalkanoate (PHA), polyketone (PK), polyester, polyethylene (PE), polyetheretherketone (PEEK), polyetherimide (PEI), polyethersulfone (PES), chlorinated polyethylene (CPE), polyimide (PI), polylactic acid (PLA), polymethylpentene (PMP), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polyphthalamide (PPA), polypropylene (PP), polystyrene (PS), polysulfone (PSU), polytrimethylene terephthalate (PTT), polyurethane (PU), polyvinyl acetate (PVA), polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), styrene-acrylonitrile (SAN).
Inflatable box 1, seen in
The plurality of air bladders are interconnected by bladder channels, as seen in
Valve 7 comprises first inflation valve half 12 and second inflation valve half 13 heat sealed on longitudinal edges 14, as seen in
Valve 7 is in communication with the exterior of inflatable box 1 using tube 30, seen in
Valve 7 is connected directly to the exterior face of a panel of inflatable box 1 for inflation of the box. An opening is formed in a panel of inflatable box 1 and collapsible inflation tube 15 is inserted into the opening. First mounting tab 10 and second mounting tab 11 were fixed to the exterior panel face using glue, tape, staples, heat sealing, welding, or other means known in the art.
Inflatable box 40 is shown is as a flat, unassembled unit in
Inflatable box 1 is assembled by folding first wall 3a, second wall 3b, third wall 3c, and fourth wall 3d, vertically, i.e. at a 90 degree angle from fifth wall 3e. The edges of first wall 3a are attached to second wall 3b using method or materials known in the art. Second wall 3b is then attached to third wall 3c, and so forth, forming an open box, as seen in
Inflatable box 1 is shown with top flaps 4a and 4b and top overlap panels 5a and 5b opened. Inflatable box 1 is assembled and ready for preparing the box for shipping or storage. Item 45 is placed into the interior lumen of inflatable box 1 and top flaps 4a and 4b bent over to close over item 45. Top overlap panels 5a and 5b are subsequently folded over top flaps 4a and 4b, securing the top of inflatable box 1. Air inflation needle 40 is then inserted into valve 7 and fluid flow F1 applied through air inflation needle 40, as seen in
The air bladders inflate to provide protection on the bottom, top and sides of item 45 within the interior of inflatable box 1. After inflation, air inflation needle 40 is withdrawn from valve 7. Optional bleed valve 8 allows fluid to escape from the air bladders in the instance where inflatable box 1 is overfilled or over-inflated with the fluid.
The inflatable packing may be shipped. As such, packing of inflatable box 1 and inflation of bladders 6a through 6f or bladder 46 can be automated. For example, an assembly line may have boxes traversing a conveyor belt with the bottom of the boxes closed, leaving the top open. Then an article can simply be placed inside of the box through automated means (via a machine) or manual means (via an operator). Then the box would continue traversing the conveyor belt to an air filling station where an automated or manual means could be utilized to inflate the box to the desired pressure. The current invention provides an apparatus and methodology that significantly improves cost efficiency within the packaging industry, for example in shipping time, weight, and labor.
In the preceding specification, all documents, acts, or information disclosed do not constitute an admission that the document, act, or information of any combination thereof was publicly available, known to the public, part of the general knowledge in the art, or was known to be relevant to solve any problem at the time of priority.
The disclosures of all publications cited above are expressly incorporated herein by reference, each in its entirety, to the same extent as if each were incorporated by reference individually.
While there has been described and illustrated specific embodiments of methods for the detection of grouper meat, it will be apparent to those skilled in the art that variations, modifications, and substitution of equivalent means can be effected and still remain within the spirit and scope of the invention and without deviating from the broad spirit and principle of the present invention. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
This application is a continuation in part of U.S. patent application Ser. No. 13/605,262, Sep. 6, 2012, entitled “Inflatable Box and Method of Use Thereof”, which is a divisional of U.S. patent application Ser. No. 09/898,958, filed Jul. 3, 2001, entitled “Inflatable Box”, the contents of which are hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 09898958 | Jul 2001 | US |
| Child | 13605262 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13605262 | Sep 2012 | US |
| Child | 13891811 | US |
