Reusable inflatable packing system with tab valve

Abstract

A reusable, inflatable packing system comprised of a multi-chambered shipping pad formed of first and second outer film layers and a third, central layer located between at least a portion of the outer layers, and having two or four discrete inflatable zones, wherein each zone is further comprised of a plurality of inflatable chambers, preferably conical in shape. The multi-chamber design facilitates absorption of impact upon the pad by permitting redistribution of an inflation gas, e.g., air, from an area of impact to a non-impacted area removed a distance therefrom within the same zone. The flow of inflation gas into and/or out of the pad zones is controlled by at least one tab valve assembly, each of which is comprised of a main and a working tab valve frame, which main frame is mounted within an outer film layer while the working frame is mounted in the central film layer. Sealing the central film along its opposed longitudinal ends to respectively, the first and second outer films forms air pockets adapted for directing air entering through the valve frames into respective zones of the pad. The tab valve assembly contains no moving parts and is closed or opened by snapping together or peeling apart the two valve frames comprising the assembly. When snapped together, the security of the snap seal is ensured by the use of a three point locking system molded into the valve frames.

What is claimed is:  
     
         1 . An impact-resistant packing system for protecting articles during shipping from shock and damage, said system including a reusable, inflatable shipping pad, said pad comprising first and second outer film layers and a third, central film layer interposed between said first and said second film layers, said first and said second film layers being secured together along an outer perimeter thereof to define an inner volume within said pad and said third, central film layer being secured at opposed ends to, respectively said first and said second film layers within said inner volume in a location selected to form at least two separate zones within said inner pad volume, said pad further comprising at least one tab valve assembly configured and adapted to permit repeated independent inflation and deflation of each said zone.  
     
     
         2 . The system of  claim 1 , wherein said pad comprises a single tab valve assembly configured and adapted to form two separately repeatedly inflatable and deflatable zones within said pad inner volume.  
     
     
         3 . The system of  claim 1 , wherein each said tab assembly comprises a first and a second tab valve frame, wherein said first frame is mounted in said first or said second outer film layer, and said second frame is mounted in said third, central film layer adjacent said first frame and positioned to permit a snap-locking engagement therewith.  
     
     
         4 . The system of  claim 3 , wherein each said tab valve frame comprises a frame portion provided with a tab portion extending therefrom, and wherein said frame portion further comprises a valve seat snap lock, a valve seat opening, an air portal, a valve seat locking ridge, and a valve seat body groove.  
     
     
         5 . The system of  claim 4 , wherein said valve frame tab portions are adapted to permit closing and opening of said valve assembly by respectively snapping together and pulling apart said valve frames by use of said tab portions.  
     
     
         6 . The system of  claim 4 , wherein said valve seat body groove is configured and adapted for capturing a valve seat locking ridge of a corresponding valve frame of said tab valve assembly to assist in securing said first and said second tab valve frames together.  
     
     
         7 . The system of  claim 4 , wherein said valve seat snap lock is configured and adapted to substantially completely seal an air portal of a corresponding valve frame of said tab valve assembly.  
     
     
         8 . The system of  claim 1 , wherein each said zone is comprised of a plurality of inflatable chambers configured and adapted to redistribute an inflation gas contained therein from one or more chambers compressed by an external impact to at least one contiguous chamber which is not impacted.  
     
     
         9 . The system of  claim 8 , wherein said chambers are each substantially conical in shape.  
     
     
         10 . The system of  claim 9 , wherein a height ratio of the conical chambers is balanced by alternating between restricted entry cones and open entry cones.  
     
     
         11 . The system of  claim 1 , wherein said pad further comprises a cut-out handle area adjacent one end of said pad, said handle area adapted for separating the inflatable zones and for creating an alternate relief area for inflation gas compressed due to an impact upon a remaining main fill area of the pad.  
     
     
         12 . The system of  claim 1 , wherein said first, said second and said third film layers are each formed from a plastic film-forming material.  
     
     
         13 . The system of  claim 1 , wherein said film layers are secured together by heat sealing, sonic welding or other electrical bonding process, by an adhesive, or by a chemical bonding process.  
     
     
         14 . An impact resistant packing system for protecting articles during shipping from shock and damage, said system including a reusable, inflatable two-zone shipping pad, said pad comprising first and second outer film layers secured together along an outer perimeter thereof to form an inner pad volume, and a third, central film layer interposed between said first and said second film layers within said pad volume and secured, at opposed ends, respectively to said first and said second film layers in a location selected to form two separate zones within said volume, said first, second and third film layers being comprised of a plastic film forming material, said pad further comprising a tab valve assembly comprising a first main valve frame and a second working valve frame, respectively, said valve frames configured and adapted to be snapped together and pulled apart to permit repeated independent inflation and deflation of each said zone.  
     
     
         15 . The system of  claim 1 , wherein said pad comprises two separate tab valve assemblies configured and adapted to form a total of four separately repeatedly inflatable and deflatable zones within said pad inner volume.  
     
     
         16 . The system of  claim 15 , wherein each said tab assembly comprises a first and a second tab valve frame, wherein said first frame is mounted in said first or said second outer film layer, and said second frame is mounted in said third, central film layer adjacent said first frame and positioned to permit a snap-locking engagement therewith.  
     
     
         17 . The system of  claim 16 , wherein each said tab valve frame comprises a frame portion provided with a tab portion extending therefrom, and wherein said frame portion further comprises a valve seat snap lock, a valve seat opening, an air portal, a valve seat locking ridge, and a valve seat body groove.  
     
     
         18 . The system of  claim 17 , wherein said valve frame tab portions are adapted to permit closing and opening of said valve assembly by respectively snapping together and pulling apart said valve frames by use of said tab portions.  
     
     
         19 . The system of  claim 17 , wherein said valve seat body groove is configured and adapted for capturing a valve seat locking ridge of a corresponding valve frame of said tab valve assembly to assist in securing said first and said second tab valve frames together.  
     
     
         20 . The system of  claim 17 , wherein said valve seat snap lock is configured and adapted to substantially completely seal an air portal of a corresponding valve frame of said tab valve assembly.  
     
     
         21 . The system of  claim 15 , wherein each said zone is comprised of a plurality of inflatable chambers configured and adapted to redistribute an inflation gas contained therein from one or more chambers compressed by an external impact to at least one contiguous chamber which is not impacted.  
     
     
         22 . The system of  claim 21 , wherein said chambers are each substantially conical in shape.  
     
     
         23 . The system of  claim 22 , wherein a height ratio of the conical chambers is balanced by alternating between restricted entry cones and open entry cones.  
     
     
         24 . The system of  claim 15 , wherein said pad further comprises a cut-out handle area adjacent one end of said pad, said handle area adapted for separating the inflatable zones and for creating an alternate relief area for inflation gas compressed due to an impact upon a remaining main fill area of the pad.  
     
     
         25 . The system of  claim 15 , wherein said first, said second and said third film layers are each formed from a plastic film-forming material.  
     
     
         26 . The system of  claim 15 , wherein said film layers are secured together by heat sealing, sonic welding or other electrical bonding process, by an adhesive, or by a chemical bonding process.  
     
     
         27 . An impact resistant packing system for protecting articles during shipping from shock and damage, said system including a reusable, inflatable four-zone shipping pad, said pad comprising first and second outer film layers secured together along an outer perimeter thereof to form an inner pad volume, and a third, central film layer interposed between said first and said second film layers within said pad volume and secured, at opposed ends, respectively to said first and said second film layers in a location selected to form four separate inflatable zones within said volume, said first, second and third film layers being comprised of a plastic film-forming material, said pad further comprising two tab valve assemblies, wherein a first said assembly is associated with a first and a second inflatable zone of said pad and a second said assembly is associated with a third and fourth inflatable zone of said pad, each said tab valve assembly comprising a first main valve frame and a second working valve frame, respectively, said valve frames configured and adapted to be snapped together and pulled apart to permit repeated independent inflation and deflation of each said zone associated therewith.