Patent Application
20250229969
The present invention relates generally to the field of packaging. More particularly, the present invention relates generally to the field of packaging pillows.
With the advent of the internet and online shopping, packaging has become omnipresent in shipping packages. Such packaging is used to secure and protect articles which are shipped in boxes and containers to prevent them shifting and/or becoming damaged during shipment. The types of packaging can vary from polystyrene (e.g., Styrofoam®) peanuts, to molded Styrofoam inserts, and more recently the use of air pillows.
Air pillows are advantageous in that they have an extremely low weight, especially when the inflation medium is air, which dramatically reduces shipping charges. However, while these air pillows are extremely helpful in safeguarding articles during shipment, unless they are reused in another shipment, they do need to be discarded after receipt of the shipment. Since depending on the package, there can be anywhere from one to a plurality of air pillows in the shipment, this can amount to a large volume of air pillows which require disposal.
Another issue is that all too often, air pillows are discarded in the general trash, and as such, are not recycled properly. Many air pillow manufacturers state on the product that it must be completely deflated prior to recycling, which presents an additional step many consumers are not willing to undertake. Further, not all air pillows in a series are necessarily inflated in the same volume, e.g., while some are inflated to 100%, due to inconsistencies in production, others can be inflated to as little as 30%, and some may not be inflated at all, which makes it difficult to get all the air pillows completely and uniformly deflated for recycling of the plastic(s) used therein. In terms of environmental friendliness, this make such air pillows less desirable for many manufacturers and shippers since it increases the disposal and/or recycling costs for the consumer.
In addition, prior to disposal and/or recycling, it is sometimes necessary to deflate the air pillows prior to being able to remove the shipped item from the packaging box. Even if the product can be removed from the shipping box without deflating the air pillows, such air pillows tend to take up a large amount of space. If even one package is received by a consumer, the air pillows therein can easily fill up a waste basket or recycling container. Thus, it is usually necessary to reduce the volume of these air pillows prior to discarding them so as to avoid taking up too much room in a refuse container or recycling container. As such, many consumers will puncture the air pillows individually with a sharp implement in order to deflate the air pillows and conserve space in refuse containers.
However, the individual deflation of these air pillows makes for a time-consuming and tedious task. This is greatly exacerbated if a consumer or business receives a large volume of shipments containing air pillows on a regular basis. Further, even if a sharp implement such as a knife or scissor is used to puncture the air pillows, the air pillows may still retain a sufficient amount of air therein such that when they are discarded in bulk, the overlying air pillows may block the puncture holes of the underlying air pillows. This prevents the ability to easily pile up the punctured air pillows and squeeze them down to a flat level since intervening air pillows may not be able to deflate all of their air in such a bulk squeezing step.
Accordingly, there remains a need for a solution to at least one of the aforementioned problems. For instance, there is an established need for a means to deflate air pillows quickly and completely such that they can be discarded and/or recycled more easily.
The present invention can be directed to a packaging pillow, such as the kind commonly inflated with air and used to cushion articles present in shipping packages. The packaging pillow contains a rip cord which is attached and/or incorporated to the surface of the packaging pillow and can be quickly removed with little effort in order to creature and/or expose an aperture in the pillow, and thus, enable the pillow to be rapidly deflated. The packaging pillow can be one of a series of packaging pillows, i.e., a system, which is produced in a continuous length of packaging pillows. A set amount of packaging pillows can be separated from the continuous length, and then used as cushion packaging. Such a system of packaging pillows can be deflated using the rip cord by pulling on the rip cord across the length of the plurality of pillows in order to quickly deflate a series of pillows without undue effort. Upon their deflation the apertured pillows can be discarded and easily recycled such that they do not occupy an undesirable amount of refuse or recycling container space. The easy deflation of the packaging pillows greatly increases the likelihood that more of these pillows may end up being ‘properly’ recycled and thus, make them more environmentally friendly.
The term “about” as used herein can entail a variance of 10% greater or lower than the value recited.
The term “comprising” as used herein also encompasses the terms “consisting essentially of” and “consisting of”.
The values of any endpoint(s) of any range(s) recited herein can be used to create different ranges or different endpoints of ranges to those described herein. The endpoints in any of the ranges described herein can also include any integer value in the recited range even if not expressly described. Thus, for example, a range of from 1.0 to 10 can include as alternate range endpoints any integer between 1 and 10, such as, the non-limiting integer examples of 2, 3, 4, 5, 6, 7, 8 and 9.
In a first implementation of the invention there can be provided a packaging pillow comprising:
In one aspect of the invention, there are at least two film layers, preferably two film layers, which film layers comprise a film material selected from the group consisting of polyethylene, low-density polyethylene, high-density, polyethylene, polypropylene, polyvinylidene chloride, polyethylene terephthalate, polystyrene, and acrylic. The thickness of the film is several hundred nanometers or more and several millimeters or less, preferably several micrometers or more and several hundred micrometers or less. For example, from about 20 to about 500 micrometers, preferably from about 25 to about 250 micrometers and most preferably from about 30 to about 100 micrometers.
In another aspect of the invention, the sealed film edges are heat sealed and/or sealed with adhesive. Heat sealing can include thermos-welding, hot-bar welding, impulse welding, and the like using heat sealers such as continuous motion heat sealers. An adhesive that can be employed for sealing can be polyacrylate, polyurethane, silicone, and reactive melt adhesives such as isocyanates and reactive hydrogen compounds, such as amino silanes, and the like. In one embodiment the edges of the films are aligned one over the other and then sealed, and thereafter, at a suitable time for use in shipping are inflated and used to cushion items during shipment.
In yet another aspect of the invention packaging pillow can be in the shape of a square or rectangle, of any suitable size, but preferably from about 3 inches to about 12 inches in length, and about 4 inches by 8 inches in width, preferably from about 4 inches to about 8 inches in length and about 4 inches to about 6 inches in width.
In yet even another aspect of the invention, the sealed film edges can be from about 0.25 inches to about 2 inches in width around the sides of the sealed film pocket.
In yet one other aspect of the invention, the sealed film pocket can contain a gas selected from the group consisting of air, argon, helium, oxygen, nitrogen, carbon dioxide and combinations thereof. The pocket can have the dimensions of the pillow described above minus the dimensions of the sealed film edges described above.
In yet even one other aspect of the invention the expression “air-tight” is understood to mean that the air pocket retains at least 90% of its gas content for a period of at least 30 days at a temperature of 25 degrees Celsius and at 1 atmospheric pressure.
In one aspect of the invention, the longitudinal rip cord can have a length of from about 1 inch up to the length or width of the air pillow, or series of continuous air pillows, e.g., from about 1 inch up to about 12 inches, preferably from about 2 inches to about 6 inches, and most preferably from about 3 inches up to about 5 inches for a single air pillow, and an additional length of any of the aforementioned lengths for each additional air pillow in a series of air pillows if such a series of air pillows is used. More preferably the longitudinal rip cord can be attached and/or incorporated into a rolled up series of air pillows, e.g., from 50 air pillows in series up to about 500 air pillows in series and can extend across a width of the air pillows when the air pillows are rectangular in shape. In such an embodiment, the longitudinal rip cord can be adhered to only the surface of one film layer over the area making up the sealed film pocket(s) and set parallel to one width edge, preferably from about 1 inch up to about 4 inches from the width edge in a straight continuous line along the length of the series of air pillows. In an alternative embodiment the longitudinal rip cord can be centered in a line across the width of the air pillows, only attached and/or incorporated at the sealed film pocket areas, in a straight line along the series of air pillows such that the longitudinal rip cord is equidistance from a top edge and a bottom edge of the width of the air pillows. The longitudinal rip cord described herein can lay across at least 30%, preferably at least 50%, more preferably at least 60%, even more preferably at least 70% and most preferably at least 80% of the width of the air-tight sealed pocket, and up to 100% of the width of the sealed pocket of the air pillow or the series of air pillows.
In another aspect of the invention, the longitudinal rip cord can have perforations along its width, i.e., in the direction perpendicular to its longitudinal length, which can facilitate an easier separation of the packaging pillows from each other along the weakened area as described herein without having to use a separate implement such as a scissor or knife to cut the rip cord between packaging pillows when separating packaging pillows along the weakened area. In addition to, or alternative to, perforations, the width of the rip cord can have preexisting incisions on either side of the rip cord in the same direction as the perforations of the weakened area to also facilitate an easier separation of the packaging pillows from each along the weakened area as described herein without having to use a separate implement such as a scissor or knife to cut the rip cord between packaging pillows when separating packaging pillows along the weakened area.
In yet still one other aspect of the invention, the longitudinal rip cord can be in the form of a tape, such as an adhesive tape, which can be removed from the packaging pillow(s) by pulling on a tab at the end of the rip cord while holding the packaging pillow along an edge thereof. Preferably the tape can be from 1/32 of an inch up to about ½ of an inch in width, preferably from about 1/16 of an inch up to about ⅓ of an inch in width. In one embodiment, each packaging pillow, alone or in a series of packaging pillows, can have its own tab on the rip cord, or alternatively there may be one tab on the end of the rip cord for each series of packaging pillows.
In yet still even another aspect of the invention, the longitudinal rip cord can be adhered using the same adhesive as described herein for the attachment of the sealed film edges. Preferably the longitudinal rip cord is made of a stronger material than that of the packaging pillow, and the adhesive has a stronger peel strength than the material of the packaging pillow such that the attempted removal of the rip cord from the sealed pocket creates an aperture in the pocket by the adhered film layer stretching and eventually breaking away the area of the film surrounding the adhered film layer as the rip cord is pulled off. One peel test that can be used to determine such peel strength can be the T-peel test and ASTM standards and tests which are known to those of ordinary skill in the art.
In another aspect of the invention, the aperture can have the same length and width as that of the rip cord employed, and in some embodiments can have an aperture of from 5% to about 50% greater than the dimensions of the rip cord due to the stretching and/or tearing of the underlying film layer upon removal of the rip cord. The aperture can be uniform along its edges or can be jagged. In another embodiment, the aperture is permanent and cannot be resealed or returned to its previous state.
In a second implementation of the invention there can be provided herein a method of rapidly deflating a packaging pillow comprising:
In a third implementation of the invention there can be provided herein a packaging pillow system comprising:
In one aspect of the invention, the plurality of connected packaging pillows can comprise a linear series of packaging pillows of rectangular shape which are each aligned, i.e., bonded to each other, along their length.
In another aspect of the invention, the plurality of connected packaging pillows bonded by their contiguous area of the sealed film edges, are bonded by their lengths such that they have a flush and even top and bottom width edge. The contiguous area can comprise the sum of two length-wise sealed edges which are formed by the welding techniques described herein when forming the sealed pockets of the two films.
In yet another aspect of the invention, the weakened area can comprise a seam or perforations. For example, such seams may be present on one side of packaging pillow. In yet another example, such a seam or weakened area may be present adjacent to one of the four edges of the packaging pillow.
The location or side of the packaging pillow with the seam or weakened area or perforations in the film can be chosen based upon the dimensions of the packaging pillow and/or type of seam used to create the sealed air pocket in an onsite manufacturing process. For example, if the cushion is rectangular, it may be preferential to use the long side of the cushion as the side with the seam or weakened area that can permit easy separation of the desired number and length of packaging pillow(s).
In one embodiment of the present invention, during manufacturing of the film used to form the packaging pillow(s), the perforations or weakened area are along a seam that allows for separation from the adjacent packaging pillow(s).
In one embodiment of the present invention, when manufacturing the film for the packaging pillow(s), a weakened area or perforations can be placed on the film in order to facilitate separation of the packaging pillows. The packaging pillow(s) can have one or more weakened areas or perforations in order to facilitate separation of the packaging pillow(s).
The weakened area of the packaging pillow(s) can utilize the methods known in the art to achieve a seam that is strong enough to resist the pressure of the payload in a shipped package but at the same time, be weak enough to be separated by pulling on it by hand without any tools or unusual physical strength.
The weakened area(s) can be aided by printed markings on the film.
There are a number of possible ways to create a seam and partially weaken the film or plastic for use in connection with the present invention. In each of the following ways, the film or plastic is not punctured, can withstand the pressures applied by the air or gas used to inflate the sealed pocket and the pressures associated with shipping. At the same time, the film may be easily torn along the perforation or weakened area so that the packaging pillow may be easily separated and then deflated with the rip cord and be ready for easy disposal.
In one embodiment a weakened seam may be created by way of a laser. A laser can be used to melt or deform the plastic or film. It is possible to focus a laser, such as a monochromatic laser, to a very small point at a precise depth. For example, if the plastic sheet or film from which the packaging pillow(s) is/are made about 50 uM thick, a laser beam could be focused on plastic strip with a depth of field of, e.g., 15 uM, which would have enough energy to melt, pit, or even ablate enough plastic to make separation along the line of laser pits sufficiently separable without destroying the air impermeability of the sealed pocket. The depth of field can be adjusted by one of skill in the art using known techniques based on the material and thickness used in connection with the packaging pillow(s). Laser pulse power and rate may also be adjusted and varied based on known techniques, considering the material of the plastic, film, or air cell, by one of skill in the art, in order to optimize the weakened area of the packaging pillow(s).
In another embodiment a weakened seam may be created by mechanical weakening. As the film used in connection with the packaging pillow(s) is produced, it may be passed through a series of rollers or a processing machine. Such rollers or machines may include an additional roller or other type of mechanism designed with small protrusions spaced around the periphery that can be used to indent the film or plastic and weaken it sufficiently, without puncturing. Such roller or machine may also be present during the time of inflation of the packaging pillow's sealed pocket and may indent the plastic or film at that time to sufficiently weaken it for purposes of this invention. The indentation in the film or plastic may be performed to a predetermined depth and adjusted by one of skill in the art using known techniques based on the material and thickness in order to optimize the weakened seam.
In yet another embodiment, directional polymerization may be used to create a weakened seam. During the production of the plastic used in connection with the packaging pillow to make the film or plastic tear easier in one direction than in the opposite direction. Air pressure may produce a force perpendicular to the surface of the film, while attempted tearing of the film will produce a strain along the surface, such a process might eliminate the need for any mechanical weakening.
Multiple layers of film may also be utilized to create a weakened seam suitable for use in connection with the present invention. Such multiple layers can be utilized on their own or in combination with any of the above manners to create a weakened seam. Any of the above manners of creating a weakened seam may also be combined in order to facilitate a weakened seam that can be utilized in connection with the present invention.
The methods for creating a weakened seam may be utilized at a factory during manufacturing of the film or plastic used for forming the packaging pillow. In another embodiment, the methods for creating a weakened seam may be utilized onsite while the packaging pillow is being formed, immediately or just prior to packaging an item that is being shipped.
In operation, the present invention may be utilized in the following manner: upon receipt of a shipment, the user removes the packaging pillows from the package. Next, the user removes the rip cord from the packaging pillow(s) to cause a longitudinal aperture in the packaging pillows, and thus, cause the packaging pillow(s) to deflate. If desired, the user may tear the film or plastic of the packaging pillows along the weakened area or seam to separate one or more of the packaging pillows and then remove the rip cord on each individual packaging pillow or set of packaging pillows.
In a fourth implementation of the invention, there can be provided a method of rapidly deflating a packaging pillow system comprising:
These and other objects, features, and advantages of the present invention will become more readily apparent from the attached drawings and the detailed description of the preferred embodiments, which follow.
The preferred embodiments of the invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, where like designations denote like elements, and in which:
Like reference numerals refer to like parts throughout the several views of the drawings.
The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
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In an alternative embodiment, the packing pillow(s) described herein either as a single pillow (see
Each of the plurality of packaging pillows in series 118 when unrolled has a contiguous area 126 of the sum of two adjoining sealed film edges 104 of adjacent packaging pillows 100. Each contiguous area 126 can have a weakened line/area 128 therein, which can be a perforation or seam and the like as described herein.
In one aspect of the invention, the plurality of connected packaging pillows 100 can comprise a linear series 118 of packaging pillows 100 of rectangular shape which are each aligned, i.e., bonded to each other, along their length 130.
Referring to
In alternative embodiments herein, the packaging pillow(s) 100 described herein are single use devices in that once they are deflated, they cannot be reinflated. The pillows 100 have no inflation means therein. The removal of the rip cord from the air pillow(s) described herein destroys the air pillows. The rip cord herein can be adhered to just one of the film layers, or alternatively to both of the film layers of the air pillow(s). In an alternative embodiment the air pillow(s) can contain a pre-existing aperture in the surface(s) of the air-tight sealed pocket(s), which is covered by a tape which is sealed to the surface of the sealed pockets surrounding the aperture and as such the pillow are deflated by removal of the tape/rip cord over the aperture. The rip cord or tape can be adhered by any of the adhesives described herein. The adhesive can be sufficiently adhesive to retain the air-tight sealed pocket from deflating in the amount and period as described herein, but also weak enough to separate from the surface of the sealed pocket without tearing the film layer. The air pillow(s) described herein can be in the absence of corrugated materials, such as corrugated fiberboard lattice.
Since many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Furthermore, it is understood that any of the features presented in the embodiments may be integrated into any of the other embodiments unless explicitly stated otherwise. The scope of the invention should be determined by the appended claims and their legal equivalents.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/620,917, filed on Jan. 15, 2024, which is incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63620917 | Jan 2024 | US |
