1. Field of the Invention
The present invention relates to a space filler structure comprising a cushioning member to encircle a shock-brittle object such as a personal computer, an electronics part of complicated shape or a glass article for preventing the object from any shock action when it is contained in a container.
2. Related Art
As is well known, space fillers are made of foam polystyrene to fit the shape of goods to be contained in boxes. Specifically when a shock-brittle object is contained in a container, such a foam polystyrene cushion is used to fill the remaining space of the container in which the shock-brittle object is put. Such space filler is often larger than the object to be protected against a shock.
Accordingly the container such as a cardboard box is necessitated to be large enough to contain such a large cushion. Advantageously the foam polystyrene cushion can restore to its original shape and size even upon being shocked repeatedly, thus enabling the object to be kept in a safe condition.
Although the foam polystyrene cushion is satisfactory in protecting a shock-brittle object against a recurrent shock action, it needs to be shaped and sized to fit the object, and the so shaped and sized cushion is apt to become large in volume. Bulky cushions are difficult to be thrown away.
Recently the disposal of foam polystyrene poses a problem from the point of view of the public nuisance. Therefore, there has been an ever-increasing demand for shock-absorbing cushions as a substitute for foam polystyrene cushions.
In the hope of meeting such demand, there has been proposed an inflatable cushion or a pulp-molding cushion.
Japan Patents 10-114366(A) and 2001-199476(A) show inflatable cushions. Specifically Japan Patent 10-114366(A) shows a “container equipped with inflatable cushion”, which container is equipped with an inflatable cushion with an air-valve. The inflatable cushion is fastened to the inside of the container, and the inflatable cushion can hold an object firmly. The object is so firmly held by the cushion when inflated with air that the object cannot be taken out of the container without difficulty. Also, disadvantageously the inflatable cushion cannot be separated from the container without difficulty when the cushion is removed and thrown away.
Japan Patent 2001-199476(A) shows a “packing member and method of using the same”. The packing member comprises a tube-like bag, which can be used repeatedly. It can contain a small-sized cylindrical article such as a toner cartridge for a printer. When the tube-like bag is inflated with air for expansion, it cannot be yieldingly bent to be put in a square box. Another tube-like packing member comprises a lamination of inflatable tube-like sections each equipped with an air inlet for inflation. In use, the inflatable tube-like sections need to be inflated one by one. The tube-like bag has a lid to cover its opening when a toner cartridge is contained.
Different from a foam polystyrene cushion, a pulp-molding cushion cannot restore to its original shape when it is shocked, so that it may be partly deformed. Therefore, it cannot be used repeatedly. Also, disadvantageously the pulp-molding cushion needs to be shaped in conformity with an object to which the pulp-molding cushion is to be applied.
When an inflatable cushion is used, it is put at the center of a container to be inflated with air. The inflated cushion is sensitive to the surrounding temperature. Specifically its volume is liable to change with the surrounding temperature, increasing with the rise of the surrounding temperature, and decreasing with the descent of the surrounding temperature. The inflatable cushion, therefore, needs to be inflated with a controlled amount of air in consideration of the presumable change of the surrounding temperature.
Assuming that the package is being transported in tropical zones, the inflatable cushion is apt to be expanded, and the so expanded cushion when shocked, can be easily broken to be collapsed, losing its shock-absorbing capability.
One object of the present invention is to provide an inflatable space filler structure which permits an object to be taken out of the container with ease; permits the object to be wrapped no matter what size and shape the object may have; and prevents the breaking and collapsing of the expanded bag when being handled roughly even excessively inflated.
To attain this object an inflatable space filler structure comprising a cushioning member to encircle a shock-brittle object contained in a container for preventing the object from any shock action, is improved according to the present invention in that the cushioning member comprises: two rectangular pieces of resin film or sheet, which are laid on each other and thermowelded in air-tight condition along their sides and in their confronting major planes in the form of parallel partition lines reaching short of the opposite lateral sides of the rectangular pieces of resin film or sheet, thus defining divisional air-tight sections; and an air inlet equipped with a check valve for inflating the divisional air-tight sections with air, thereby applying the expanded divisional air-tight sections to the front, rear, upper and lower surfaces of the object. The word, “film” is used in describing a relatively thin sheet of resin material whereas the word, “sheet” is used in describing a relatively thick sheet of resin material.
With this arrangement the cushioning member need not be shaped to fit the object, assuring that a shock-absorbing effect be caused no matter what size and shape the object may have. The inflatable space filler can be put in condition for use simply by blowing air from the single air inlet into the cushioning member. The cushioning member thus inflated with air is adequate to prevent the whole of the object against a shock action.
Preferably extra buffers may be integrally connected to the opposite lateral edges of the rectangular pieces of resin film or sheet to protect the corresponding opposite sides of the object from any shock action.
The rectangular pieces of resin film or sheet may have stripes formed alternately with the partition lines on their major planes, which alternate stripes are formed by weakly thermowelding selected stripes in air-tight condition in the confronting major planes, so that such stripes may be broken prior to any of the partition lines in response to incidental application of excessive pressure to the inflatable space filler.
An inflatable space filler structure comprising a cushioning member to encircle a shock-brittle object contained in a container for preventing the object from any shock action, is improved according to the present invention in that the cushioning member comprises: outside and inside closed bags of resin film or sheet of different depths, the inside bag being fitted in the outside bag, their bottoms and opposite lateral and longitudinal sides being thermowelded and connected together to stagger their upper closed edges while the outside and inside bags communicate at their bottoms, making the inside bag form a pocket fastened onto the outside bag, the confronting planes of the outside and inside bags being thermowelded in the form of partition lines, which are predetermined distances apart from the longitudinal opposite sides of the outside-and-inside bag combination, and an air inlet equipped with a check valve for inflating the outside and inside bags, thereby applying the expanded outside and inside bags to the shock-brittle object in the pocket.
With this arrangement, a small-sized cylindrical object such as a fragile glass article can be enclosed easily by the cushioning member to be protected against any shock action in the container.
The outside-and-inside bag combination has sacrificial seals formed between each partition line and one or the other longitudinal side of the outside-and-inside bag combination.
An inflatable space filler structure as described above may further comprise an air-release hole made for uncorking, the air-hole has a seal piece to cover the air-hole in air-tight fashion, the seal piece being capable of being peeled off and attached repeatedly for use.
The container may be a cardboard box with a packing assistant, which facilitates the configuring and fitting of the cushion to the object when put in the container.
The inflatable space filler structure as described above provides the advantages of:
facilitating the taking-out of an object from the container;
facilitating removal of the cushion from the container for disposal because the cushion is not fixed to the container;
permitting the wrapping of any object no matter what size and shape it may have;
permitting the cushion to be put in condition for use simply by blowing air into the bag-like cushion from the single air inlet;
facilitating transportation or storage of cushions by removing air to collapse; and
permitting reuse of the cushion.
Other objects and advantages of the present invention will be understood from the following description of preferred embodiments of the present invention, which are shown in accompanying drawings.
FIGS. 1 to 9 show a space filler according to a first embodiment of the present invention. Referring to
For the purpose of facilitating the thermowelding of the confronting two rectangular pieces of resin film or sheet, one extra piece of “thermowelding easy” resin film or sheet (such as polyethylene) of the same size and shape as the confronting pieces of resin film or sheet may be sandwiched therebetween, and then, the composite lamination of resin film or sheet is heated along its four sides and at selected areas to be sealed together. Otherwise, extra pieces of “thermowelding easy” resin film or sheet may be arranged at the four sides and some selected areas to be thermowelded when the composite lamination of resin film or sheet is heated.
The major planes of the confronting resin film or sheet are thermo welded in the form of partition lines 3, which are arranged in parallel and so as to reach short of the opposite lateral edges of the rectangular shape, thus defining divisional air-tight sections 4 between adjacent partition lines 3. These divisional air-tight sections 4 communicate with each other by the opposite lateral margins, and are named upper, front, rear and lower pneumatic cells 4a, 4e, 4b, 4d and 4c for which part of an object the divisional air-tight sections 4 are applied to.
Extra buffers 6 are formed along the opposite lateral edges of the rectangular pieces of resin film or sheet to protect the corresponding opposite sides of the object from any shock action. Each extra buffer 6 is composed of two semi-buffers 6a and 6b connected in the form of an inverted “V”-shape, communicating with the divisional airtight sections 4 via marginal channels 5a and 5b (see
An air inlet 7 is provided at one sealed side 2 of the cushioning member 1, which is communicated with the marginal channels 5a and 5b. The air inlet 7 is equipped with a check valve 8. The divisional air-tight sections 4 and the extra buffers 6 can be inflated with air by blowing air from the air inlet 7 into the air bag 1, preventing the air from leaking to the surrounding atmosphere by the check valve 8. When the air bag is inflated with air to enwrap an object, the expanded divisional air-tight sections 4 and the extra buffers 6 are applied to the front, rear, upper, lower sides and the opposite sides of the object to protect the object against any shock action in all directions.
The cushioning member 1 has a semicircular uncorking hole (air-release hole) 10 made therein, and a sticky seal 9 closes the uncorking hole 10 in air-tight fashion, as seen from
When removing the air from the air bag 1, it is collapsed to be flat, and then, it can be folded to reduce its size for the sake of convenience of transportation and storage.
As the sticky seal 9 is made with a seal member which has the ability of peeling off and re-sticking, the air bag 1 can be used repeatedly by: inflating the air bag 1 with air; closing the uncorking hole 10 with the sticky seal 9; peeling the sticky seal 9 partly off to remove the air from the air bag 1; and repeating the sequence as many times as required.
Preferably the lower portion of the sticky seal 9 is fastened firmly to the air bag 1 to allow the upper part of the sticky seal 9 to be removably attached to the air bag 1, thereby permitting the upper part to close the semicircular uncorking hole 10. This assures that the sticky seal 9 is not lost when it is peeled off for uncorking; otherwise, if the sticky seal 9 were peeled off completely, there would be a fear of losing the same.
The semicircular shape of the uncorking hole 10 is convenient to the peeling-off of the sticky seal 9 to a half-way point of the complete removal. The uncorking hole should not be understood to be limited to the semicircular shape, but it may be circular, elliptical or polygonal in shape.
Referring to
Simultaneous thermowelding of the composite resin lamination may be followed by cutting into rectangular shapes for making space fillers. The process of making space fillers is advantageous to improvement of the manufacturing efficiency.
Referring to
Specifically when the space filler 1 is inflated with air, the bottom, front, rear and upper divisional sections 4c, 4b, 4d and 4a, 4e of the space filler 1 are changed to the bottom, front, rear and upper pneumatic cells to be applied to the bottom, front, rear and upper sides of the object 12. If the space filler 1 had no partition lines formed in its major plane, it could not bend accurately to fit the object 12.
Referring to
Referring to
The bottom pneumatic cell 4c is collapsed, bearing the weight of the object 12d, as shown in
The extra buffer 6 may have any shape other than the inverted “V”-shape (
When taking out the object 12 from the container 13a, the packaging assistant 13b is caught by the elongated holes 14 to pull up the packaging assistant-and-object from the container 13a. Removal of the packaging assistant 13b from the container 13a is easy because the packaging assistant 13b is not fixed to the container 13a.
As may be understood from the above, a single shock absorbing space filler 1 can be used to enwrap an object 12 completely by inflating the space filler with air. The space filler can be inflated simply by blowing air from the single air inlet 7 into the space filler. Use of the packaging assistant 13b facilitates the inputting of the object into the container 13a. The space filler 1 can be used repeatedly.
Referring to
The strength of each weak thermowelded lines 3a is fifty to sixty percent of the strength of the partition line, and accordingly each sacrificial line 3a allows the lying resin films or sheets to separate easily therealong compared with the partition line 3.
Assuming that a container falls inadvertently on the floor, a strong pressure is applied to the space filler instantly so that one or more selected sacrificial lines 3a may be broken, thereby making the volume of the bottom pneumatic cell 4c expand accordingly and absorb the pressure applied to the bottom pneumatic cell (see
Even if all sacrificial lines 3a of the inflated cushion 1 are broken, all of the front, bottom and rear pneumatic cells 4b, 4c and 4d are allowed to expand without being ruptured, and therefore, the object remains enwrapped by the space filler as it was.
Referring to FIGS. 12 to 14, a tubular space filler 21 according to the second embodiment is described below. The space filler 21 is composed of two rectangular pieces of resin film or sheet and a piece of “thermowelding easy” resin film or sheet sandwiched therebetween as is the case with the space filler according to the first embodiment.
The rectangular lamination is thermowelded along its four sides 22 as seen from the side and sectional views (
The space filler 21 has an air inlet 27 to open and communicate with the lateral, marginal channels 25a and 25b. The air inlet 27 is equipped with a check valve 28. In use the space filler 21 can be inflated like a balloon by blowing air from the air inlet 27 with an uncorking hole 30 closed with an associated sticky seal 29. When it is carried or stored, it can be flattened by unsealing the corking hole 30 and removing the air from the uncorking hole 30. Thus, the space filler 21 can be used repeatedly.
Referring to
An elongated object 32 other than the cylindrical one can be enwrapped, provided that the partition lines 23 are as long as the elongated object 32.
The space filler according to the second embodiment can have sacrificial lines alternating with the partition lines 23, thereby preventing rupture of the air bag 21 when an increased pressure is applied thereto, assuring that the article is kept in a safe condition.
Referring to
As seen from the drawings, the space filler 41 is rectangular in shape, the four sides of which rectangular shape are thermowelded. Four partition lines 43 are formed by thermowelding parallel-strip pattern in the major plane, thus defining five adjacent divisional sections 44 and opposite lateral, marginal channels 45a and 45b, which communicate with the divisional sections 44.
An air inlet 47 is formed to open and communicate with the lateral, marginal channels 45a and 45b. The air inlet 47 is equipped with a check valve 48. An uncorking hole 50 is made, and an associated sticky seal 49 is applied to close the uncorking hole 50. With this arrangement, the space filler 41 can be inflated to enwrap an article, thus protecting the article against any shock action. When the air is removed by peeling off the sticky seal 49 from the uncorking hole 50, the space filler 47 is flattened to facilitate its transportation or storage. The space filler 41 can be used repeatedly by inflating and uncorking the air bag.
The pneumatic cells 44 and 45a and 45b are applied closely to all sides of the article for protection. The partition lines 43 are as long as the length of the article to be enwrapped. The square rod-like air bag can be snugly put in a similar rectangular cardboard box.
The air inlet 47 can appear on the top side of the air bag 41 when put in the cardboard box, provided that the four partition lines 43 and the thermowelded margins 42 are formed as seen from
The air bag 41 may have sacrificial lines alternating with the partition lines as is the case with the first embodiment.
Referring to FIGS. 17 to 19, a space filler 51 according to the fourth embodiment of the present invention comprises a cushioning member in the form of a dual air bag. Specifically the cushioning member comprises outside and inside closed bags 52 and 53 of resin films or sheets of different depths. The inside bag 53 is inserted in the outside bag 52, and their bottoms and opposite lateral and longitudinal sides 56, 57 and 58 are thermowelded and connected together to stagger their upper closed edges while the outside and inside bags 52 and 53 communicate at their bottoms, as best seen from
The confronting planes of the outside and inside bags 52 and 53 are thermowelded so as to provide partition lines 59 and 60, which are predetermined distances apart from the longitudinal opposite sides of the outside-and-inside bag combination. Sacrificial lines 61 and 62 are formed so as to extend from the lower ends of the partition lines 59 and 60 to the opposite thermowelded longitudinal sides 56 and 57. It should be noted that the sacrificial lines 61 and 62 run parallel to the themowelded bottom 58, a short distance apart therefrom, and that the longitudinal partition lines 59 and 60 extend from the lateral sacrificial lines 61 and 62 toward the open side of the dual bag somewhat beyond the intermediate or center line of the dual bag. A shock-brittle object can be contained in the space defined by the longitudinal partition lines 59 and 60 and an imaginary line 53a extending from one to the other sacrificial line, thus holding the object in the lower half part of the dual bag.
The dual bag is provided with an air inlet 63 with a check valve, which are attached at the time of thermowelding the upper edge 54 of the dual bag. The outside and inside bags can be inflated with air by blowing air from the air inlet, so that the expanded outside and inside bags may be applied to the shock-brittle object in the pocket. An uncorking hole 10 has an associated sticky seal 9. The sticky seal 9 can be peeled off and applied to the corking hole 10 repeatedly.
Referring to
When the cardboard box falls on the floor inadvertently, the sacrificial lines 61, 62 are broken to prevent the rupture of the air bag, thereby assuring that the object be protected against any shock action.
A plan view of a fifth embodiment can be seen in
Number | Date | Country | Kind |
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2001-306419 | Oct 2001 | JP | national |
This application is a Continuation-In-Part application of application Ser. No. 10/260,295, filed Oct. 1, 2002.
Number | Date | Country | |
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Parent | 10260295 | Oct 2002 | US |
Child | 11447133 | Jun 2006 | US |