Shaped flexible shipping package and method of making

Abstract

A shipping package having a flexible inner sheet having a first surface and a second surface. The package has an article reservoir for accepting an article to be shipped and one or more expansion chambers. The expansion chambers can be inflated or otherwise expanded to provide structure to the package and to protect the article in the article reservoir.

What is claimed is: 
     
         1 . A shipping package for shipping one or more articles, the shipping package having a controlled post expansion shape and comprising:
 a. a flexible inner sheet having a first surface and a second surface, an inner sheet first portion and an inner sheet second portion;   b. a flexible outer sheet having an inner surface, an outer surface, an outer sheet first portion and an outer sheet second portion, at least a part of the inner surface of the outer sheet first portion being connected to the first surface of the inner sheet first portion to form one or more primary expansion chambers therebetween, the inner sheet second portion extending from the inner sheet first portion and being folded back onto the second surface of the inner sheet first portion to form an article reservoir between the inner sheet second portion and the inner sheet first portion, the article reservoir having a periphery where the first portion and the second portion of the inner sheet are joined together and a central area within the periphery, wherein at least a portion of the first surface of the inner sheet within the central area is joined to the inner surface of the outer sheet forming an expansion control tack that acts to control the expansion of the one or more first primary expansion chambers when an expansion material is introduced therein;   c. a flexible secondary outer sheet at least partially joined to the outer sheet outer surface to form one or more secondary expansion chambers;   d. an expansion port in fluid connection with the one or more primary expansion chambers and/or secondary expansion chambers through which an expansion material can be introduced into the one or more primary expansion chambers and/or secondary expansion chambers; and   e. a closeable opening through which the one or more articles may be inserted into the article reservoir.   
     
     
         2 . The shipping package of  claim 1  further including a vent disposed in fluid communication with the article reservoir. 
     
     
         3 . The shipping package of  claim 1  further including an article retrieval feature that allows a user to open the package and retrieve the one or more articles from the article reservoir. 
     
     
         4 . The shipping package of  claim 3  wherein the article retrieval feature, when activated, both opens the shipping package and deflates one or more of the one or more primary expansion chambers. 
     
     
         5 . The shipping package of  claim 3  wherein the article retrieval feature, when activated, both opens the shipping package and deflates one or more of the one or more secondary expansion chambers. 
     
     
         6 . The shipping package of  claim 3  wherein the article retrieval feature, when activated, opens the shipping package and deflates the one or more primary expansion chambers and the one or more secondary expansion chambers. 
     
     
         7 . The shipping package of  claim 3  wherein the article retrieval feature includes a tear strip. 
     
     
         8 . The shipping package of  claim 3  claims wherein at least one of the one or more primary expansion chambers is permanently destroyed upon activation of the article retrieval feature. 
     
     
         9 . The shipping package of  claim 1  wherein the expansion control tack also joins the outer sheet to the secondary outer sheet. 
     
     
         10 . The shipping package of  claim 1  having two or more primary expansion chambers, wherein at least some of the two or more primary expansion chambers are independent from each other or are in fluid communication with each other. 
     
     
         11 . The shipping package of  claim 1  wherein the one or more secondary expansion chambers provides structural rigidity and/or shape to the shipping package when in an expanded configuration. 
     
     
         12 . The shipping package of  claim 1  wherein the one or more secondary expansion chambers provide protection to the one or more articles disposed within the package from physical forces when the one or more secondary expansion chambers are in the expanded configuration. 
     
     
         13 . The shipping package of  claim 1  having two or more secondary expansion chambers, wherein at least some of the secondary expansion chambers are independent from each other or are in fluid communication with each other. 
     
     
         14 . The shipping package of  claim 1  wherein one or more of the primary expansion chambers or secondary expansion chambers is expanded to an internal pressure that is different from at least one other primary expansion chamber or secondary expansion chamber. 
     
     
         15 . The shipping package of  claim 1  wherein at least a portion of the inner sheet, the outer sheet and/or the secondary outer sheet is transparent, translucent or opaque. 
     
     
         16 . The shipping package of  claim 1  wherein the shipping package has a deflated thickness that is less than 1/10 of the expanded thickness. 
     
     
         17 . The shipping package of  claim 1  wherein the shipping package has an unexpanded thickness and an expanded thickness, and wherein the unexpanded thickness is less than 1/50 of the expanded thickness. 
     
     
         18 . The shipping package of  claim 1  wherein the at least a portion of the second surface of the inner sheet is in contact with the one or more articles when the one or more articles are disposed in the article reservoir. 
     
     
         19 . The shipping package of  claim 1  wherein the second surface of the inner sheet at least partially immobilizes the one or more articles within the article reservoir when the one or more primary expansion chambers are in an expanded configuration. 
     
     
         20 . The shipping package of  claim 1  wherein at least a portion of the inner sheet, the outer sheet and/or the secondary outer sheet is resistant to water. 
     
     
         21 . The shipping package of  claim 1  wherein at least a portion of the inner sheet, the outer sheet and/or the secondary outer sheet is printed. 
     
     
         22 . The shipping package of  claim 1  wherein at least one of the inner sheet, the outer and/or the secondary outer sheet is made of a material different than at least one other of the inside sheet, the outer and/or the secondary outer sheet. 
     
     
         23 . The shipping package of  claim 1  wherein the shipping package consists of or consists essentially of a flexible material. 
     
     
         24 . The shipping package of  claim 1 , wherein the package has no structural support feature other than the primary and/or secondary expansion chambers.