REUSABLE INFLATABLE PACKAGING DEVICE

Abstract

A reusable packaging device that in a use state is a rhomboid outer structure with an internal inflatable and reusable vessel that surrounds and protects a payload, that can be converted into a storage state by deflating the vessel and folding the outer structure flat in order that it may be stacked.

Description

FIELD OF INVENTION

This invention relates to devices used to package or encase merchandise for shipment to customers.

BACKGROUND

The rise of the Internet has increased the practice of buying and selling goods remotely, where selection and purchase of goods may be done on-line. This commercial activity has been growing at an exponential rate. In order to ship merchandise purchased on-line, the shipper typically houses the merchandise in a corrugate box filled with some kind of shock absorbing filler. The popularity of ecommerce is a direct cause of skyrocketing use of corrugate boxes. This is an ecological problem.

One third of the average landfill dump is packaging material. 69 Million tons of paper and paperboard are used each year. Materials recycling is only of limited value. While it is true that cardboard and corrugate boxes are recyclable, the fibers are only usable 11 times before the fibers are too weak to use. In any case, recycling of boxes places a burden on consumers: they have to break down and store the boxes in order to place them out for pickup by local recycling services. The reaction is often not to recycle at all. The current packaging experience holds its fair share of frustrations. Once you receive a package, especially a large one or one carrying fragile items, there is a mountain of “stuff” that the user needs to get rid of Including but not limited to; styrofoam, packaging peanuts, packaging airbags, internal corrugate pieces and finally the entire corrugate box itself. The current packaging experience is both frustrating for the consumer, as well as environmentally damaging. Therefore, there is a need for a foldable, collapsible, stackable packaging system that the user could compress down to something flat and mail back to the sender for immediate reuse.

DESCRIPTION OF THE FIGURES

The headings provided herein are for convenience only and do not necessarily affect the scope or meaning of the claimed invention. In the drawings, the same reference numbers and any acronyms identify elements or acts with the same or similar structure or functionality for ease of understanding and convenience. To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the Figure number in which that element is first introduced (e.g., element 101 is first introduced and discussed with respect to FIG. 1).

FIG. 1 is a cutaway view of the interior of the packaging system

FIG. 2 depicts the claimed invention in its relaxed state, and in its inflated state as shown next to the air pump used to inflate

FIG. 3 is an exploded view of the packaging system

FIG. 4 depicts the claimed invention in a second embodiment

FIG. 5A-5E depicts the claimed invention in its relaxed, non-inflated state, where the user removes the package, deflates the package and replaces the shipping label with a return receipt

FIG. 6 shows how the claimed invention is deflated and folded for further use, and further depicts the crease at the bottom of the packaging system

FIG. 7A-7D depicts the steps of deflating, or collapsing, and folding the claimed invention

FIG. 8 is a drawing showing the claimed invention according to four different exploded or expanded perspectives

FIG. 9 is a model of the claimed invention depicting two heat sealed layers with ribbing and the outer layer.

FIG. 10A-10C is a model of the claimed invention depicting the outer layer and valve formed from the heat sealing of the two inner layers

FIG. 11A-11D is a model of the claimed invention depicting the layers that are heat sealed and sewn

FIG. 12 is a depiction of an 8″×8″ square piece of jute

FIG. 13 is a depiction of the “stiffness test” as further set forth in the specification

FIG. 14 shows is a further depiction of the “stiffness test” as further set forth in the specification

FIG. 15 is a depiction of the “corner test” as further set forth in the specification.

FIG. 16 is a depiction of the “corner test” as further set forth in the specification.

FIG. 17 is a depiction of the “corner test” as further set forth in the specification.

FIG. 18 is a depiction of a 12.25″×21″ rectangular piece of jute

FIG. 19 is a depiction of a punch with a tetrahedron shape at one end

FIG. 20 is a depiction of one embodiment where the mylar inner wall is being punctured as further set forth in the specification

FIG. 21 is a depiction of one embodiment of the wall section of the invention

FIG. 22 is a depiction of one embodiment of the wall section of the invention

DETAILED DESCRIPTION

Various examples of the invention will now be described. The following description provides specific details for a thorough understanding and enabling description of these examples. One skilled in the relevant art will understand, however, that the invention may be practiced without many of these details. Likewise, one skilled in the relevant art will also understand that the invention can include many other features not described in detail herein. Additionally, some well-known structures or functions may not be shown or described in detail below, so as to avoid unnecessarily obscuring the relevant description. The terminology used below is to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific examples of the invention. Indeed, certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this Detailed Description section.

The inflatable packaging is comprised of three layers, an outer layer (102), and one or more inner layers (103) that form an inflatable vessel or bladder. See FIG. 1. The interior vessel can include a metal coated film, aluminum coated mylar and/or may be covered by a fourth, protective, textile layer. In the preferred embodiment, the inner two layers are comprised of Mylar. When inflated, the inflated vessel stiffens the walls of the outer layer and provide structural support. The outer layer (101) material is made of a sufficiently flexible material that becomes rigid in combination when the vessel is inflated. In one embodiment, outer layer is formed from a layer of material that forms a rhomboid, with a bottom, four sides and a top. (FIG. 8). The outer layer and vessel layers are formed from flat pieces that are substantially the same dimensions that fold in the same way to form a rhomboid shape. The vessel layers are an inflatable device that in one embodiment encircles the interior proximate to the four sides of the rhomboid. In other embodiments, the vessel can be formed to be further proximate to the bottom or top (102) (or both) of the rhomboid.

The package is configured to be usable in two states. In a first state, the vessel is deflated and the bottom and two sides of the rhomboid are each folded in on themselves with at least a bifold, in order that packaging device lay substantially flat, with the top laying over one of the sides. (FIG. 6). The folded configuration is flat, with the lid of the package folded over, and the bottom and two sides folded on itself at the center of each panel in order that the device to be substantially flat and stackable. In the second state, the vessel is inflated, and the bottom and two sides of the rhomboid unfolded. In this state, the packaging device is ready to receive a payload that is placed in its interior region. The vessel is further inflated until the vessel presses against the payload. The top may then be closed and fastened. The outer layer preferably has a transparent pouch attached to its exterior into which shipping labels may be inserted. (FIG. 5C-5E).

The outer layer top is attached along a first edge to a corresponding top edge of one side of the rhomboid, such that the top may be open and closed using that first edge as a hinge. (102) A fastener may be attached along the opposing edge from the first edge, for example a first side of a zipper seam may be attached along the opposing edge and the second side of the zipper seam may be sewn along the corresponding top edge of the opposite side of the rhomboid from the side that attaches the hinging first edge. In other embodiments, one side of a zipper seam may be sewn along three edges of the top of the rhomboid, with mating side sewn along the corresponding three edges at the top of three sides of the rhomboid. The rhomboid itself may be a cube.

The material comprising the outer layer is selected of a sufficiently stiff material that resists penetration by corners of other boxes, especially cardboard or corrugate box corners. In other embodiments, the outer layer material is selected to be resistant to needle penetration. In the preferred embodiment, the outer layer is a textile comprised of jute fibers. However, other embodiments include woven synthetic fibers. Both jute or synthetic fibers have high tenacity (breaking force), sound and heat insulation properties and low thermal conductivity. In the preferred embodiment, the outer layer is a jute textile, with synthetic fibers comprising a hem sewn along the edges of the jute textile piece that, when folded and sewn at the seams, forms the package. Materials that may be used as an outer layer include a stiff plastic, cardboard, corrugate, or a synthetic fiber textile. The material stiffness must be sufficient to protect from puncture. In one embodiment, the sufficient stiffness resists puncture by the corners of other boxes that may be sharing space in a truck or airplane. In other embodiments, the material is sufficiently stiff so as to resist puncture by needles. For example, an embodiment may have an outer layer that resists a needle puncture up to a piercing by a force between 2 and 10 Newtons by a 25 gauge needle penetrating perpendicular to the material.

In order to determine whether the material is sufficiently stiff so that it resists penetration by corners of other boxes, the following test, as depicted in FIGS. 12-14, may be performed. An exemplary embodiment is explained in further detail as follows:

• • 1) Placing an 8″×8″ square piece of jute on the edge of a rigid wooden board. See FIG. 12, where the piece is placed such that exactly half of it is off the edge of the board—4″ off the edge, and 4″ still on the surface of the board. See FIG. 13.
  • 2) The 4″ half that remains on the wooden surface is held in place by two pieces of tape—one on each corner—between the jute and the wooden board. See FIG. 13.
  • 3) The vertical distance between the edge of the jute furthest from the wooden board and the horizontal plane of the wooden board is measured, where in the preferred embodiment, the measurement is 1.75″; (See FIG. 14), resulting in a stiffness of about 44%, calculated by dividing the vertical distance of the edge that drops down because of gravity by the distance out from the edge of the test bench.
  • 4) In alternative embodiments, this value for stiffness may range from around 33% to around 73%.
  • 5) In yet another embodiment, for some applications this value of stiffness is greater than 73%.

The inner layers can be made of any thin, flexible material, including, but not limited to; mylar, polyethylene based plastics, pulp based fibers, aluminum foil, rubber, or latex, that may be sealed to form an airtight but flexible chamber. Some of these materials may be more puncture proof than the others. Regardless of material, the inner layers may also be coated in a polyurethane based compound to provide increased puncture resistance. In a preferred embodiment, the material will be mylar. A 200 gauge (0.002″) mylar layer specifically has a puncture resistance of around 12 lbf (pound force, 1 lbf≈4.448222 N)—however it can range from 10 lbf-22 lbf. Layers of between 100 and 300 gauge mylar may be sufficient for some applications. In other applications, the puncture resistance of the inner layer has to be more than 22 lbf.

In order to determine whether the material is sufficiently puncture resistant so as to resist puncture by corners, the following test, as depictured in FIGS. 15-19, may be performed. An exemplary embodiment is explained in further detail as follows:

• • 1) Placing a 12.25″×21″ rectangular piece of jute (reinforced on the edges with fabric) pulled taught and centered over two vertical wooden boards spaced 12″ apart (outside edge to outside edge). See FIG. 15.
  • 2) Where the jute is pulled such that the ends of the piece of jute around the edges and clamp to the sides of each board. See FIG. 15 where there is one clamp placed at each corner of the piece of jute.
  • 3) Thereafter, using a punch with a tetrahedron shape at one end, with the corners of the point meeting at 45 degree angles (to mimic the corner of a rectangular box). FIG. 19.
  • 4) Pressing the punch into the center of the taut piece of jute with its center axis directly vertical or perpendicular to the flat piece of jute. FIG. 16, 17.
  • 5) Measuring the force (in pounds) for the punch to puncture the jute, where, in one embodiment, puncture occurred between 18-22 pounds of pressure.
  • 6) In alternative embodiments, puncture occurs between 10 and 25 pounds of pressure.
  • 7) In yet another embodiment, puncture occurs at at least 10 lbf.

In yet another embodiment, the following test, as depicted in FIG. 20 is performed:

• • 1) A 12.25″×21″ rectangular piece of jute (reinforced on the edges with fabric) and a 12.25″×21″ rectangular piece of mylar are aligned directly on top of each other and pulled taught and centered over two vertical wooden boards spaced 12″ apart (outside edge to outside edge).
  • 2) The ends of the pieces of jute and mylar are pulled around the edges and clamped to the sides of each board, where one clamp is placed at each corner of the piece of jute and mylar.
  • 3) Using a punch with a tetrahedron shape at one end, with the corners of the point meeting at 45 degree angles, the punch is pressed into the center of the taut piece of jute and mylar (the punch hit the jute first then the mylar) with its center axis directly vertical or perpendicular to the flat piece of jute.
  • 4) Measure the force (in pounds) it takes for the punch to puncture the jute AND mylar.
  • 5) In said embodiment, the puncture occurred between 25-40 pounds of pressure.
  • 6) In alternative embodiments, the puncture occurs at at least 25 pounds of pressure.

The reason the puncture resistance is high is that there is airspace between the mylar and the jute, and the mylar has some give to it (see FIGS. 20-22). When the punch punctures the jute, it then pushes the mylar wall another inch or so before it punctured the mylar (see FIG. 20.).

The vessel is an air-tight compartment that is formed of a flexible material such that when deflated, it occupies little volume, but when fully inflated occupies substantially all of the interior region of the packaging device. See FIG. 2. This makes it possible to have a one-size fits all device, in that a payload that is smaller than the interior region of the packaging device is inserted into the interior and is protected by inflating the vessel until the payload is secure—whatever its size.

In the preferred embodiment, the vessel is comprised of ribs along the interior surface of the vessel (901) in order to prevent the walls of the outer layer from being appreciably deformed or rounded when the vessel is inflated. See FIG. 9.

The ribbed vessels may be comprised of textile enforced plastic, or mylar, however, the former permits a higher pressure load. In the preferred embodiment, the vessel is formed of two layers of mylar. The two inner layers that form the vessel are made of Mylar film—which is a high tensile strength plastic that forms a gas tight and odor barrier. Multiple sheets of Mylar may be melted and sealed together under high temperatures, referred to herein as heat sealing. A heat susceptible plastic layer may be used such that heat sealing or heat forming of ribs or creases may be accomplished. In addition, the vessel may be further comprised of a textile later that covers at least the interior layer of the plastic in order that the package payload not directly chafe or puncture the plastic layer forming the vessel itself. This textile layer may be of a sufficient strength to be resistant to corner punctures or needle punctures. See FIG. 20.

The vessel is made as one inflatable component, rectangular in overall shape, the width of which is the height of the rhomboid and the length of which is the perimeter of the top or bottom side of the rhomboid. The vessel is comprised of ribs that, when fitted into the box, are parallel to the plane of the lid and floor. The vessel is further formed with depressions running along the widths are points such that when fitted into the box, the depressions are situated at the corners of the box, occupying the region along the four vertical corners of the rhomboid.

The two layers of mylar that form the vessel are heat sealed around the edges. Within that heat seal, the vessel is then sewn into the outer textile layer forming the outer layer. See FIG. 11. The heat seal forming the vessel is along the perimeter of the top and bottom and sewn along those perimeters to the outer layer.

The ribs are formed by using the heat sealing device to sufficiently heat the mylar so as to distort it along the desired orientation of the rib line but not to actually seal the two layers of mylar on either side. The result is a defined crease in the interior layer, referred to as the rib. Creases in the vessel are also formed along the line that forms the vertical corners of the rhomboids. There are pre-defined lines that form three vertical corners where heat is applied on both the exterior side of the vessel and interior of the vessel in order that the corner be well defined, but the interior and exterior layers are preferably not sealed together.

In one embodiment of the invention, the vessel is formed from two rectangular sheets of mylar. The vessel thus formed is attached to be proximate to the four sides of the rhomboid. In other embodiments, the two sheets of mylar are “T” shaped. Additional corner creases are applied such that one arm of the “T” can be placed proximate to the bottom of the rhomboid and the other arm proximate to the top or lid of the rhomboid. The creases are formed where the edge of the bottom meets one of the sides of the rhomboid and where the edge of the top meets the side of the rhomboid. In this embodiment, the vessel can be inflated so as to push against the payload in 6 directions.

The vessel is further comprised of a valve that can selectably be used to inflate or deflate the vessel. In another embodiment, the valve for the inner vessel unit is incorporated into the invention by way of an inflatable valve technology using mylar components cut or shaped out of the mylar sheets or a separate valve system. The valve is comprised of a standard attachment into which a pressurizing device may be connected, for example an air pump. Further, the valve can be operated so as the pressure in the vessel is released in order that it be deflated. In one embodiment, the valve comprised of the mylar layers comprising the vessel itself. See FIG. 10a-c. For example, the mylar layers may be shaped so that upon heat sealing of the two layers, a valve stem is created. Further, the mylar may be folded internally to the stem region in order to form a valve, such that when pressure is created on the interior of the vessel, the pressure forces a flap of mylar within the valve stem to remain closed. Further, the flap is movable by means of a foreign object inserted into the valve stem in order to move its position and deflate the vessel. In this way, the valve itself is fully integrated with the vessel—the two layers with some added technology form the valve. By being integrated using the mylar layer, the valve stem and valve folds flat when not in use, whether the package is in the folded state or the inflated state with the lid or top closed. The valve itself is comprised of two halves, where each half comprises its respective half of the entire inner vessel. The interior walls of the vessel and interior half of the valve all comprise one sheet. The exterior walls of the vessel and exterior half of the valve will all comprise one sheet. See FIG. 3. In this latter embodiment, the two mylar layers forming the vessel will have a stem potion that when heat-sealed together comprise the valve.

In alternative embodiments, the valve may be comprised of bike valve stems, a Boston Valve, a Silicone Medical Resuscitator Intake Umbrella Valve, a silicon respirator valve, or a rubber ball inflation valve—any of which may be attached via heat sealing; welding or adhesives at the base or the brim of any of the aforementioned types of valves.

In an alternative embodiment, the vessel may be attached at vertical corners using an adhesive. Further, an adhesive may bond the vessel to the outer layer. The vessel is then configured so that as it inflates, each portion of the vessel corresponding to each side of the rhomboid expands primarily at the center, so as to form, in cross section, an arc, where the maximum point of expansion is at the center of the polygon formed by the corresponding side of the rhomboid. See FIG. 4.

In yet another alternative, instead of one contiguous vessel comprising the package, there may be more than one vessel within the package, each inflated individually. In another embodiment, each panel comprising the sides, top and bottom of the rhomboid may have a vessel attached to it that has its own valve, the vessels being configured such that when fully inflated together, the vessels together occupy substantially all of the interior of the rhomboid.

The foregoing description discloses only exemplary embodiments of the invention. Modifications of the above disclosed apparatus and methods which fall within the scope of the invention will be readily apparent to those of ordinary skill in the art. Accordingly, while the present invention has been disclosed in connection with exemplary embodiments thereof, it should be understood that other embodiments may fall within the spirit and scope of the invention as defined by the following claims.

Claims

1. An inflatable packaging device that is adapted in a first state to be folded in a substantially flat configuration and in a second state, to be expanded and inflated to enclose and protect an article, said packaging device comprising: An outer layer material that in the second state forms a rhomboid with four sides, a bottom and a top and an interior region;An inflatable vessel comprised of at least one inner layer material, said vessel inside the interior region placed in proximity to at least the interior four sides of the rhomboid, said vessel expandable so as to occupy substantially all of the interior region when the vessel is inflated without a payload, without appreciably deforming the outer layer rhomboid shape;A valve attached to the vessel, said valve operable to selectively admit air under pressure in order to expand the vessel or release air from the vessel in order to compact the vessel.

2. Claim 1 where the vessel is comprised of a region that is proximate to the bottom of the rhomboid.

3. Claim 2 where the vessel is further comprised of a region that is proximate to the top of the rhomboid.

4. Claim 1 where the vessel is comprised of a flexible plastic membrane layer,

5. Claim 4 where the plastic layer is further covered in a textile material layer.

6. Claim 1 where vessel is comprised of textile reinforced plastic material

7. Claim 1 where the vessel is comprised of mylar.

8. Claim 1 where the vessel is comprised of ribs that retard the local dimension of expansion in order that the vessel not appreciably distort the rhomboid shape.

9. Claim 1 where the vessel is comprised of corner lines that that retard the local dimension of expansion in order that the expansion of the vessel into the interior region is primarily at the center line of each side of the rhomboid.

10. Claim 1 where the exterior layer is jute.

11. Claim 1 further comprising an insulating layer between the outer layer and the vessel.

12. Claim 11 where the insulating layer is a metallic coated plastic.

13. Claim 12 where the plastic is mylar.

14. Claim 1 where the packaging device is configurable into a second state, where the vessel is deflated, the bottom of the rhomboid folded onto itself with at least a single bifold, at least two sides of the rhomboid are folded onto themselves with at least a single bifold and the top of the rhomboid is attached to the sides along a seam with one of the sides, and folded over the sides in order that the device is substantially flat.

15. Claim 1 where the vessel is comprised of mylar.

16. Claim 15 where the mylar is formed by two sheets of mylar that are heat sealed along the edges.

17. Claim 1 where the vessel is formed of a heat-susceptible plastic and further comprised at least one heat-formed rib crease placed on the interior surface of the vessel and placed in a plane parallel to the bottom of the rhomboid.

18. Claim 1 where the vessel is formed of a heat-susceptible plastic and further comprised of at least one heat-formed crease on at least one interior and corresponding exterior corner of the vessel.

19. Claim 1 where the valve is formed of the material comprising the vessel.

20. Claim 16 where the vessel is attached to the box by a seam sewn through the heat seal along the perimeter of the top or the bottom.

21. The packaging device of claim 1 where the outer layer material has a stiffness of between around 33% to around 73%.

22. The packaging device of claim 1 where the inner layer is comprised of between 100 and 300 gauge mylar.

23. The packaging device of claim 1 where the inner layer material has needle puncture resistance of between 2 and 10 Newtons using a 25 gauge needle penetrating perpendicular to the material.

24. The packaging device of claim 1 where the inner layer material has a corner puncture resistance of between 10 lbf-22 lbf.

25. The packaging device of claim 1 where the outer layer material has a corner puncture resistance of between 18 to 22 pounds.

26. The packaging device of claim 1 where the outer layer material has a corner puncture resistance of between 10 to 25 pounds.

27. The packaging device of claim 1 where the outer layer in combination with the inner layer has a corner puncture resistance of between 25 and 40 pounds.

28. The packaging device of claim 1 where the stiffness is equal to or greater than 73%.

29. The packaging device of claim 1 where the outer layer material has a corner puncture resistance equal to or greater than 10 lbf.

30. The packaging device of claim 1 where the outer layer in combination with the inner layer has a corner puncture resistance equal to or greater than 25 lbf.

31. The packaging device of claim 1 where the inner layer material has a corner puncture resistance equal to or greater than 22 lbf.

32. The packaging device of claim 1 where the inner vessel is covered in a textile fabric.

33. The packaging device of claim 1 where the inner layer of the inner vessel that is proximate to the outer wall is attached only along at least part of the perimeter of the corresponding side of the outer layer.