FIELD OF THE INVENTION
The present invention relates to a box shipper with an internal inflatable bag.
BACKGROUND OF THE INVENTION
Consumers frequently purchase goods from mail order or internet retailers. Many of these packages include small items such as pharmaceuticals, books, medical supplies, electronic parts, and the like. These items are normally packaged in small containers such as a box or envelope. To protect the items during shipment, they are typically packaged with some form of protective dunnage that may be wrapped around the item or stuffed into the container to prevent movement of the item and to protect against shock. One common packaging method uses corrugated boxes to hold the items to be shipped. The void spaces between the items and the inside walls of the box are filled with void-filling dunnage such as foam “peanuts,” air cellular cushioning materials, crumpled or shredded paper, and other air filled packaging materials. Typically, the corrugated boxes are supplied to the shipper in a collapsed condition so that the boxes occupy less space. Each box must then be erected and taped before use by the shipper which may result in additional labor costs for shipping. The shipper typically maintains a supply of collapsed boxes for subsequent use.
SUMMARY OF THE INVENTION
In a first aspect, a packaging system comprises an inflatable bag folded on itself to form a first inflatable panel and a second inflatable panel, the inflatable bag comprising a first side, a second side, a first end, a second end, a valve secured to the first end of the inflatable bag, and two heat seals each extending from the second side of the bag, the two heat seals spaced apart from each other, and spaced apart from the first side, the first end, and the second end of the bag, the two heat seals each bonding a portion of the first inflatable panel to a portion of the second inflatable panel; and a flat blank to which the inflatable bag is adhered; the system adapted upon inflation of the bag to hold an article disposed between the first and second panels of the bag.
In a second aspect, an inflatable bag, folded on itself to form a first inflatable panel and a second inflatable panel, comprises a first side, a second side, a first end, a second end, a valve secured to the first end of the inflatable bag, and two heat seals each extending from the second side of the bag, the two heat seals spaced apart from each other, and spaced apart from the first side, the first end, and the second end of the bag, the two heat seals each bonding a portion of the first inflatable panel to a portion of the second inflatable panel of the inflatable bag; the bag adapted, upon inflation of the bag, to hold an article disposed between the first and second panels of the bag.
In a third aspect, a method of preparing a package comprises providing a flat blank having a first wall; and adhering an inflatable bag to the first wall of the flat blank, the inflatable bag folded on itself to form a first inflatable panel and a second inflatable panel, the inflatable bag comprising a first side, a second side, a first end, a second end, a valve secured to the first end of the inflatable bag, and two heat seals each extending from the second side of the bag, the two heat seals spaced apart from each other, and spaced apart from the first side, the first end, and the second end of the bag, the two heat seals each bonding a portion of the first inflatable panel to a portion of the second inflatable panel of the inflatable bag.
In a fourth aspect, a packaging system comprises an inflatable bag folded on itself to form a first inflatable panel and a second inflatable panel, the inflatable bag comprising a first side, a second side, a first end, a second end, a valve secured to the first end of the inflatable bag, and a heat seal extending along the second side of the bag, the heat seal bonding an edge portion of the first inflatable panel to a corresponding edge portion of the second inflatable panel of the inflatable bag; and a flat blank to which the inflatable bag is adhered; the system adapted upon inflation of the bag to hold an article disposed between the first and second panels of the bag.
In a fifth aspect, an inflatable bag, folded on itself to form a first inflatable panel and a second inflatable panel, comprises a first side, a second side, a first end, a second end, a valve secured to the first end of the inflatable bag, and a heat seal extending along the second side of the bag, the heat seal bonding an edge portion of the first inflatable panel to a corresponding edge portion of the second inflatable panel of the inflatable bag; the bag adapted, upon inflation of the bag, to hold an article disposed between the first and second panels of the bag.
In a sixth aspect, a method of preparing a package comprises providing a flat blank having a first wall; and adhering an inflatable bag to the first wall of the flat blank, the inflatable bag folded on itself to form a first inflatable panel and a second inflatable panel, the inflatable bag comprising a first side, a second side, a first end, a second end, a valve secured to the first end of the inflatable bag, and a heat seal extending along the second side of the bag, the heat seal bonding an edge portion of the first inflatable panel to a corresponding edge portion of the second inflatable panel of the inflatable bag.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of embodiments of the invention follows, with reference to the attached drawings, wherein:
FIG. 1 is a schematic plan view of a flat blank of the prior art;
FIG. 2 is a perspective view of the flat blank of FIG. 1, after construction of the box;
FIG. 2
a is a perspective view of another embodiment of the flat blank of FIG. 1, after construction of the box;
FIG. 3 is a schematic plan view of an inflatable bag of the prior art;
FIG. 4 is a cross sectional view of a portion of the bag of FIG. 3, taken along line 44 of FIG. 3;
FIG. 5 is a cross sectional view of a portion of the bag of FIG. 3, taken along line 5-5 of FIG. 3;
FIG. 6 is a schematic plan view of a folded inflatable bag;
FIG. 7 is a cross sectional view of a portion of the bag of FIG. 6, taken along line 7-7 of FIG. 6;
FIG. 8 is a cross sectional view of a portion of the bag of FIG. 6, taken along line 8-8 of FIG. 6;
FIG. 9 is a schematic plan view of an inflatable bag of one embodiment of the invention;
FIG. 10 is a schematic plan view of an inflatable bag of another embodiment of the invention;
FIG. 11 is a schematic plan view of an inflatable bag of another embodiment of the invention;
FIG. 12 is a schematic cross sectional view of a portion of the bag of FIG. 11, taken along line 12-12 of FIG. 11;
FIG. 13 is a cross sectional view of a portion of a side seal of a bag of the invention;
FIG. 14 is a schematic plan view of an inflatable bag of another embodiment of the invention;
FIG. 15 is an elevational view of an embodiment of an inflatable bag of the invention in an inflated state;
FIG. 16 is a schematic plan view of an inflatable bag of another embodiment of the invention; and
FIG. 17 is a perspective view of an embodiment of an inflatable bag of the invention in an inflated state.
Definitions
“Inflatable bag” herein refers to a bag, pouch, or similar product, including one made from a single tubular web or two webs that have been sealed together, the bag capable of being inflated by mechanical means. In one embodiment, the bag can be made by a C-fold arrangement, in which a single web of material is folded on itself to create a folded bottom (second end), and the two sides and top (first end) of the thus folded bag are sealed together at or near their respective edges. Typically, an inflatable bag will include a valve or other suitable means to inflate the bag when desired.
“Flat blank” herein refers to a flat piece of material die cut or otherwise prepared such that it can be constructed into a container such as a conventional shipping box. The flat blank can have any suitable size, geometry, and composition, with suitable score lines and cuts as needed to facilitate subsequent construction into a container. The flat blank can be made from any suitable material, including paperboard, polymeric foam, corrugated board, rigid plastic, etc. The flat blank can be monolayer or multilayer in composition, and can be made from more than one of the above-stated materials.
“Heat seal” herein refers to conventional impulse or constant heat sealing techniques, as well as alternative bonding processes, including without limitation RF (radio frequency) or ultrasonic sealing. Both continuous and discontinuous seals are included herein.
“Polymer” and the like herein refers to homopolymer, copolymer, terpolymer, etc.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 discloses a schematic plan view of a flat blank 20 of the prior art. Flat blank 20 includes a top box panel 22, a bottom box panel 24, side box panels 26, 28 and 30, end box panels 32 and 34, and 36 and 38, intermediate box panels 40 and 42, cuts 44, 46, 48, and 50, and score lines 52, 53, 54, 55, 56 and 58. Although cuts 44, 46, 48, and 50 are shown as having some dimension, i.e. having some gap between adjacent panels, those skilled in the relevant art will appreciate that these are typically simple cuts in the paperboard or other stock that are very narrow in one dimension. Score lines 52, 53, 54, 55, 56 and 58, like the cuts, facilitate fabrication of the box. Flat blank 20 is shown for illustrative purposes only, and it will be understood that the invention can be beneficially used in combination with a wide variety of containers made from paperboard, rigid foam, or other suitable materials die cut or otherwise prepared such that they can be constructed into a container such as a conventional shipping box. The flat blank can have any suitable size, geometry, and composition, with suitable score lines and cuts to facilitate subsequent construction into a container. For example, alternative flat blanks can be constructed into boxes having a round or triangular cross section.
FIG. 2 shows a perspective view of a completed box 60 made from the flat blank 20 of FIG. 1. As shown, box 60 includes top box panel 22, side box panel 30, and end box panel 36.
FIG. 2
a shows a perspective view of a completed box 62 that is similar in all respects to box 60 of FIG. 2, but additionally includes a slot 37 adapted to accommodate the terminal portion of a flexible valve.
FIG. 3 shows a schematic plan view of a conventional inflatable bag 70. A commercial example of such a bag is a RAPID FILL® bag available from Sealed Air Corporation. Inflatable bags of this type, including a flexible valve, are disclosed e.g. in U.S. Pat. No. 6,561,236 (Sperry et al.), incorporated herein by reference in its entirety.
The conventional bag is typically made with a monolayer, polyethylene construction. The bag can alternatively be made with a multilayer construction, and can optionally include one or more layers comprising a polymer that provides an oxygen barrier, such as polyamide. In multilayer embodiments of the bag, the material can be produced by known coextrusion processes, or alternatively by any other suitable process, including known lamination techniques.
Bag 70 includes a first wall 72 and a second wall 74 (see also FIG. 4). These walls are joined by a fold located at a second end 76 of bag 70. A heat seal 77, typically a trim seal, is disposed at or near a first side edge 78 of bag 70, and another heat seal 79, also typically a trim seal, is disposed at or near a second side edge 80 of bag 70. Bag 70 is thus made from a single ply of material that is folded on itself to create the first and second walls 72 and 74, and sealed along its edges 78 and 80. A valve 82 is disposed between walls 72 and 74 and projects from the first end 88 of the inflatable bag 70. This valve 82 is conventional and well known in the packaging art. Bag 70, and inflation valve 82, are further described in U.S. Pat. No. 6,561,236 (Sperry et al.). Any suitable valve can be employed in connection with the present invention. A heat seal 90 is disposed at or near the first end 88 of bag 70. Segment 84 of first wall 72, and segment 86 (see FIG. 4) of second wall 74, are defined by the material between seal 90 and edge 88. Segments 84 and 86 are not typically sealed together. It will be understood to those of skill in the art that alternatively a bag useful in connection with the present invention can be made from two discrete plies of material that are sealed together along all four edges of the respective plies.
FIG. 4 shows a cross sectional view of a portion of the bag 70 of FIG. 3, taken along line 4-4 of FIG. 3. First wall 72 and second wall 74 are connected at second bag end 76 by a fold. Seal 90, as described above, joins together the first and second wall 72 and 74 respectively near the first end 88 of the bag 70. Segments 84 and 86 form the extremity of walls 72 and 74 respectively at the first end 88 of the bag. As shown in FIG. 4, for the sake of clarity, first wall 72 is separated by a space from second wall 74. Although conventionally walls 72 and 74 are not sealed together except as described above, it will be understood that they may and often do in practice tend to remain together across much or most of their congruent contact before inflation of the bag. They will nevertheless move away from one another in unsealed regions when air or another filling medium is introduced through valve 82 to expand the bag 70.
FIG. 5 is a cross sectional view of a portion of bag 70 of FIG. 3, taken along line 5-5 of FIG. 3. First wall 72 is sealed to second wall 74 in the heat seal 79 located at or near the second side edge 80 of bag 70.
FIG. 6 is a schematic plan view of an inflatable bag 71 like that of FIG. 3, but in which the bag has been folded on itself, along fold 92, such that the first side edge 78 now overlays the second side edge 80. Bag 71 is otherwise in all relevant particulars like bag 70, but with the features described below with respect to FIGS. 7 and 8.
FIG. 7 is a cross sectional view of a portion of the bag of FIG. 6, taken along line 7-7 of FIG. 6. It can be seen that because of the folding over on itself of a portion of bag 70 to produce bag 71, second wall 74 now forms essentially the entire exterior surface of bag 71. FIG. 7 shows a first inflatable panel 73 overlying a second inflatable panel 75. Panels 73 and 75 form between them a mouth 94 that is shown with some separation between wall 72 of first inflatable panel 73, and wall 72 of second inflatable panel 75. It will be understood that walls 72 may tend to remain together across much or most of their congruent contact before inflation of the bag. Likewise, some space is shown between walls 72 and 74 of first panel 73, and between walls 72 and 74 of second panel 75, but in practice the respective walls may be in contact. Mouth 94 provides an access area for insertion of an article to be packaged. An unsealed area is thus provided between first and second panels 73 and 75.
FIG. 8 is a cross sectional view of a portion of the bag 71 of FIG. 6, taken along line 8-8 of FIG. 6. Heat seal 77 as shown overlies heat seal region 79. Again, mouth 94 is shown with some separation between walls 72, but walls 72 may tend to remain together across much or most of their congruent contact before inflation of the bag.
FIG. 9 is a schematic plan view of an inflatable bag 95 of another embodiment of the invention. The inflatable bag is like the folded inflatable bag of FIG. 6, but in which two heat seals 96 and 98 seal a portion of the first inflatable panel 73 to a portion of the second inflatable panel 75. It should be noted (see also FIG. 12) that seals 96 and 98 each bond the two inflatable panels together in the respective heat seal areas, and do not simply seal the two walls of the first panel together, or the two walls of the second panel together. In the embodiment of FIG. 9, the heat seals 96 and 98 each extend from the second side of the inflatable bag, and extend toward the first side of the folded inflatable bag defined by fold 92. However, the terminus of each of seals 96 and 98 will be spaced from fold 92. This allows inflation of the bag to be accomplished in the inflatable regions 100, 102, and 104 of the bag 95. The advantage of this is described further below.
FIG. 10 is a schematic plan view of an inflatable bag 106 of another embodiment of the invention. The inflatable bag is like the folded inflatable bag of FIG. 9, but additionally including heat seal 101. Like seals 96 and 98, heat seal 101 bonds the two inflatable panels together in the region of heat seal 101, and does not simply seal the two walls of the first panel together, or the two walls of the second panel together.
In the embodiment of FIG. 10, heat seal 101 extends substantially parallel to fold 92 and side edge 78. The panels are not sealed together, however, along the entire extent of the distance from the terminus of seal 96 to the terminus of seal 98. This permits an inflation medium such as air to circulate through the bag. An additional inflatable region 108 is defined by fold 92 and seal 101.
FIG. 11 is a schematic plan view of an inflatable bag 110 of another embodiment of the invention. The inflatable bag is like the folded inflatable bag of FIG. 10, but additionally including heat seal 112. Unlike seals 96, 98, and 101, heat seal 112 does not bond the two inflatable panels together in the region of heat seal 112, but simply seals the two walls of the first panel 73 together. A similar seal 114 (see FIG. 12) seals the two walls of the second panel 75 together. Seals 112 and 114 are in the portion of the inflatable bag where the article to be packaged can be inserted into the uninflated bag. The first and second panels 73 and 75 are therefore not sealed together here. In lieu of heat to bond the two walls of the first panel together at 112, or the second panels together at 114, an alternative is to hot glue the relevant walls together, or use a double sided tape.
Another alternative is to apply a non-sealable print surface to the facing surfaces of wall 72 in the region of the bag where the heat seals 112 and 114 are to be located. Upon application of a seal bar or the like to the bag, the two walls of the first panel 73 are sealed together, and the two walls of the second panel 75 are sealed together. However, because of the presence of the non-sealable print surface on the relevant portions of walls 72, the first and second panel 73 and 75 will not seal to each other. The glue, tape, or non-sealable print would require the application of the bonding medium to appropriate portions of the bag material at the time the bag is produced.
FIG. 12 shows in cross section a portion of the bag of FIG. 11, with seals 112 and 114, and seal 96. FIG. 12 is a cross sectional view of a portion of the bag of FIG. 11, taken along line 12-12 of FIG. 11.
FIG. 13 is a cross sectional view of a portion of a side seal 140 of another embodiment of an inflatable bag 142 of the invention. The inflatable bag is like the folded inflatable bag of FIG. 6, but in which a heat seal 140 at or near the side edge 78 of the folded bag seals the second side of the first inflatable panel 73 to the second side of the second inflatable panel 75 (see also FIG. 16). Seal 140 bonds the two inflatable panels together in the heat seal area.
FIG. 14 is a schematic plan view of an inflatable bag 115 of another embodiment of the invention. The inflatable bag is like the folded inflatable bag of FIG. 11, but the heat seals that seal panels 73 and 75 together in selected regions of the bag are discontinuous in nature. Thus, discontinuous heat seal 126 is like seal 96, but is shown as a series of localized heat seals, of any suitable shape, number and dimension, extending from the second side of the inflatable bag, and extending toward but spaced from the first side of the folded inflatable bag defined by fold 92.
Likewise, discontinuous heat seal 130 is like seal 98, but is shown as a series of localized heat seals, of any suitable shape, number and dimension, extending from the second side of the inflatable bag, and extending toward but spaced from the first side of the folded inflatable bag defined by fold 92.
Discontinuous heat seal 128 is like seal 101 of FIGS. 10 and 11, but is shown as a series of localized heat seals, of any suitable shape, number and dimension, extending substantially parallel to fold 92 and side edge 78. Discontinuous heat seal 132 is like seal 112 of FIG. 11, but is shown as a series of localized heat seals, of any suitable shape, number and dimension.
In one variation of this embodiment, one localized heat seal can be disposed in each of four locations on the bag, such that the four localized seals together define the corners of a rectangle or square. For example, in the drawing of FIG. 14, two of the four corner locations can be the seals marked 126 and 130.
FIG. 14 also discloses in another embodiment an optional closure flap 120 which can be formed either integrally as an extension of wall 74, or as a discrete member that is separately made and then adhered, e.g. by a suitable adhesive, heat sealing, etc., to the wall 74. The closure flap 120 includes a base member 122, the base member being longitudinally coextensive with bag 115. At least a portion of base member 122 can be coated with an adhesive 123. The adhesive used is e.g. a pressure sensitive adhesive, but can be any suitable adhesive, such as an adhesive activated by moisture or saliva. Suitable adhesives include thermoplastic hot melt adhesives, silicone adhesives, acrylic pressure sensitive adhesives, solvent cast adhesives, UV (ultraviolet) or EB (electron beam) cured acrylic adhesives, and the like. The adhesive can be covered with an optional but highly desirable release tape 124.
In FIG. 14, the closure flap 120 is shown in a flat, open position.
When the bag is to be used to ship an article such as pharmaceuticals, books, medical supplies, electronic parts, and the like, the article is placed in the interior of the bag, and the release tape 124 is peeled from the closure flap 120. This action exposes the adhesive 123. The closure flap 120, with the adhesive layer thus exposed, is then folded towards the first wall 72 of the bag, and the closure flap 120 is then pressed against the first wall 72 to close the bag.
FIG. 15 is an elevational view of an embodiment of an inflatable bag 106 of the invention in an inflated state. This bag is substantially an inflated version of the uninflated bag 106 of FIG. 9. An article 130 is held or encapsulated within the inflated bag. In some embodiments, the article may be completely encapsulated by the bag; in others, a portion of the article may be accessible from or exposed to the outside environment at the second side of the bag (in the case of FIG. 15, the side of the bag facing the viewer).
A feature of the inflated bag is that the seals 96 and 98 result, when the bag is inflated, in inflated terminal portions of the bag. These terminal portions, the result of the inflation of regions 102 and 104 of the bag 95 of FIG. 9, offer additional protection for the contents of the bag during shipping and storage.
FIG. 16 is a schematic plan view of an inflatable bag 142 of another embodiment of the invention. Bag 142 is like bag 71 of FIG. 6, but includes a side seal 140 that is disposed parallel to side seal 77. When inflated, bag 142 forms a substantially tubular sleeve or cylindrical member. In this embodiment, the interior of the bag can be accessed through either the opening 145 at the first end of the bag, or the opening 146 at the second end of the bag.
In one embodiment, bag 142 can optionally include a double sided tape 148 adhering relevant portions of interior facing walls 72 of bag 142, such that an article that is inserted through opening 145 will be guided by the inverted U-shape configuration of the double sided tape, and thus be beneficially located generally in the central area of the bag.
Centralized location of the article will generally maximize the cushioning protection afforded the article by the invention.
In an alternative embodiment, the double sided tape can be configured as a U shape (as viewed in FIG. 16), so that an article that is inserted through opening 146 will be guided by the U-shape configuration of the double sided tape, and thus be beneficially located generally in the central area of the bag.
FIG. 17 is a perspective view of an embodiment of an inflated bag 150. Bag 150 before inflation is similar in construction and features to bag 95.
The inflatable bag can be used in a number of alternative ways in connection with a flat blank. In one method, the bag of the invention, e.g. the bag of FIG. 9, in its uninflated state, can be adhered by glue, pressure sensitive adhesive, or any other suitable means, to a portion of a flat blank. As an example, a bag can be adhered to the bottom box panel 24 of FIG. 1. This can be done at a manufacturing site, or at the site where the packaging of articles will typically take place.
An article to be packaged can then be inserted into the mouth of the bag. Thereafter the bag can be inflated, and the box then closed. Alternatively, the box can be closed or nearly closed, and the bag then inflated. In one embodiment, a slot 37 can be included in the flat blank that can accommodate the valve 82. The box can be closed, with the valve 82 fed through the slot to provide access to the valve from outside the box, and the bag then inflated. Thereafter, if desired, the valve can be fed back through the slot, and if desired the slot can be covered.
Alternatively, an article can be inserted into an uninflated bag of the invention. Thereafter, at the same location or a separate location, the bag can be inflated, and the inflated bag with the article disposed therein can be placed in a shipper box or other suitable container, and the box or container closed.
Those skilled in the art will understand that modifications in the invention can be made without departing from the scope of the invention as claimed in the claims that follow. For example, in addition to the heat seals disclosed herein, the panels of the bag can be pre-printed with a graphic that visually guides the user in placing an article in the uninflated bag.
Patent Application
20060272288
