Inflatable Cellular Web with Multiple Panels

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Solution Overview

Problem

Conventional inflatable cellular cushioning products, such as BubbleWrap, have low product density due to air-filled cavities, leading to high shipping costs per unit weight, and existing inflatable packaging solutions do not efficiently utilize space during transport and storage.

Innovation Solution

An inflatable web with multiple inflatable panels in fluid communication through a common inflation zone, allowing for flexible configuration post-inflation, such as separation into individual sheets, forming a wider sheet, or creating a pouch, to optimize space utilization and reduce shipping costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional BubbleWrap cellular cushioning is used with air-filled cavities, then cushioning performance is achieved, but product density is low leading to high shipping costs

Engineering Contradiction:

Improvecushioning performanceVSAvoidshipping cost per unit weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The inflatable web is divided into multiple separate inflatable panels (first inflatable panel, second inflatable panel) that can be independently inflated and configured. This segmentation allows the packaging material to be shipped in a collapsed state and then configured into different densities and shapes after arrival, optimizing both cushioning performance and shipping efficiency.

Inventive Principle:

Principle #1Segmentation

2Reliability

If inflatable packaging is shipped inflated, then cushioning protection is provided, but space utilization during transport and storage is inefficient

Engineering Contradiction:

Improvecushioning protectionVSAvoidspace utilization during transport

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The inflatable panels are pre-configured with inflation zones and fluid communication pathways before shipping, but remain deflated during transport. The actual inflation action is performed preliminarily planned but deferred until after arrival, allowing efficient space utilization during transport while ensuring cushioning protection is activated when needed.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The packaging system transitions from a static inflated state to a dynamic system that can be inflated, deflated, and reconfigured. The inflatable panels can be inflated to provide cushioning protection or deflated to optimize space during transport and storage, creating a dynamic packaging solution that adapts to different operational requirements.

Inventive Principle:

Principle #15Dynamics

3Volume of stationary object

If multiple inflatable panels are used with a common inflation zone, then space utilization is optimized, but device complexity increases

Engineering Contradiction:

Improvespace utilizationVSAvoidinflation zone configuration

Core Design Contradiction:

Volume of stationary objectVSDevice complexity

Solution Approach 1:

Multiple inflatable panels share a common inflation zone that is in fluid communication with all panels. This merging of the inflation system allows a single inflation source to service multiple panels, reducing the complexity of requiring separate inflation systems for each panel while still enabling independent configuration and optimization of space utilization.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The inflatable web design enables efficient use of space during transport and storage, reducing shipping costs by allowing for multiple configurations that can double the width of a single panel or form separate inflated sheets, thereby addressing the low density issue of traditional products.

Implementation Method 1

The first and second sheets are sealed together to form a first plurality of inflatable chambers

Methodology Applied

Scientific EffectSealing:

Implementation Method 2

an inflation and sealing machine configured to direct gas into the first plurality of inflatable chambers and the second plurality of inflatable chambers via the inflation zone

Methodology Applied

Scientific EffectGas pressure: Pressure Increase

Data Source

PatentUS11305929B2Inflatable cellular web with multiple inflatable panels

Publication Date: 2022.04.19 SEALED AIR U S

AI summary

An inflatable web includes an inflation zone, a first inflatable panel in fluid communication with the inflation zone, and a second inflatable panel in fluid communication with the inflation zone. The first inflatable panel includes a first sheet juxtaposed on a second sheet. The first and second sheets are sealed together to form inflatable chambers. The second inflatable panel include a third sheet juxtaposed on a fourth sheet. The third and fourth sheets are sealed together to form inflatable chambers. The inflatable film is configured to be inflated by an inflation and sealing machine configured to direct gas into the inflatable chambers of the first and second inflatable panels via the inflation zone and to individually seal the inflatable chambers of the first and second inflatable panels.