Inflatable Mailer Liner with Integrated Inflation and Sealing Assembly
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Solution Overview
Problem
Current packaging methods for shipping small items, such as mail order goods, are inefficient due to the need for extensive labor and high costs associated with void-filling dunnage materials like foam peanuts and air cellular materials, which are often bulky and expensive to transport and store.
Innovation Solution
An inflatable mailer system comprising an outer pouch and an inner inflatable liner, where the liner can be inflated at the point of packaging using a dedicated inflation/sealing assembly, reducing cycle time and manufacturing complexity while minimizing material usage and storage needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional void-filling dunnage materials (foam peanuts, air cellular materials) are used to protect items during shipment, then protective capability is improved, but shipping costs and storage space requirements increase due to bulky material volume
Solution Approach 1:
The mailer is divided into an outer pouch and an inner inflatable liner that can be separately stored and assembled. The liner is supplied in a collapsed state and inflated at the point of use, separating the protective function from the bulk material storage requirement.
Solution Approach 2:
The packaging system transitions from a static bulky material to a dynamic inflatable structure. The liner can be compressed to minimal volume for storage and then expanded to provide full protective capability when needed, adapting its volume based on operational requirements.
2Strength
If padded mailers with air cellular material lining are used, then protective capability is improved, but manufacturing cost and storage space increase due to the air-filled structure
Solution Approach 1:
The packaging system separates the structural outer pouch from the protective inner liner, allowing each component to be manufactured independently using cost-effective processes and materials, then assembled at the point of use.
Solution Approach 2:
The inflatable liner is designed as a disposable component that can be manufactured at low cost and replaced with each use, eliminating the need for expensive durable materials while maintaining protective functionality throughout the product lifecycle.
3Strength
If Xpander Pak with vacuum-sealed foam walls is used, then protective capability is improved, but manufacturing cost increases due to complex vacuum sealing and foam compression processes
Solution Approach 1:
The system separates the protective function into a simple inflatable liner that can be manufactured without complex vacuum sealing or foam compression processes, reducing manufacturing complexity while maintaining protective capability through inflation rather than pre-compressed foam.
4Strength
If conventional packaging methods with separate assembly steps are used, then protective capability is ensured, but labor costs and cycle time increase due to extensive assembly requirements
Solution Approach 1:
The inflation and sealing operations are combined into a single integrated process step, where the liner is inflated and the pouch is sealed simultaneously, eliminating sequential operations and reducing overall cycle time while ensuring protective capability is achieved.
Solution Approach 2:
The inflatable liner automatically provides protective capability through its inflation process without requiring separate assembly operations. The liner inflates to conform to the product and provides cushioning, eliminating the need for manual placement of traditional dunnage materials.
5Volume of stationary object
If inflated mailer system is used, then shipping costs are reduced through minimized material volume, but device complexity increases due to inflation pathway and sealing requirements
Solution Approach 1:
The inflation pathway serves multiple functions: it allows gas to enter the liner for inflation, provides a sealing location, and acts as the interface between the outer pouch and inner liner. This multi-functionality reduces the need for separate components for each function.
Solution Approach 2:
The inflation pathway acts as an intermediary element that connects the outer pouch and inner liner, allowing them to be sealed together while providing the necessary inflation access. This intermediary structure simplifies the overall system by integrating multiple functions into a single component.
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 mailer system reduces shipping costs and labor by allowing for on-site inflation, thereby decreasing the volume of packaging materials required and simplifying the manufacturing process, while providing effective protection for shipped items.
Implementation Method 1
a portion of gas can be introduced into said inflatable liner
Data Source
Figure 1a
Figure 1b
Figure 2a~2b
AI summary
The presently disclosed subject matter is directed to an apparatus and method for inflating and sealing a mailer (10) comprising an inner inflatable liner (14) having at least one inflation means (104) through which a portion of gas can be introduced into the liner (14).