Method and apparatus for making dunnage

Abstract

An apparatus for manufacturing dunnage including a plurality of rollers for pulling a web of material through the machine, a nozzle with at least one port through which gas or liquid flows, a plurality of ceramic elements in opposing positions such that the web of material can pass between the plurality of ceramic elements. A heating element is routed through each of the plurality of ceramic elements such that heat will radiate through openings in the top surfaces of the ceramic elements that will melt the portion of the material that is passing between the opposing ceramic elements. The apparatus may be equipped to manufacture multiple pieces of dunnage simultaneously.

Description

FIELD OF INVENTION[0001]The invention relates to an improved process for producing dunnage, or “air pillows.”BACKGROUND OF THE INVENTION[0002]Various materials are used to insulate goods from shock during shipping. Solid materials such as polystyrene “peanuts,” cups and “worms,” pellets of foam rubber, plastics and expanded polyurethane foam are in common use as a shock protector. Air cushioning material, or “air pillows,” are generally preferred over the above types of dunnage because it is lighter in weight, can be supplied and dispensed in a controlled manner, and can be manufactured on site. Air Pillows are typically manufactured using rolls of sheet material, which is also easier to dispose of than the individual pieces of plastic dunnage after the product is removed.[0003]Air pillows are typically manufactured on site because it is inefficient to ship preformed air pillows since they take up considerably more volume than the sheet material. Various devices have been described ...

AI Technical Summary

Benefits of technology

"The invention is a method for producing air pillows on site without the need for heating elements to directly contact the air pillows to weld them shut. The method uses a ceramic element that transmits heat from a heating element to weld the air pillow material. The air pillows are sealed at improved operating speeds using a process that seals the air pillows at improved operating speeds. The invention also provides an apparatus for inflating and sealing plastic bags and a method for strengthening the welded seal by using a metal knurled wheel and a rubber second wheel. The technical effects of the invention include improved production efficiency, reduced labor costs, and improved quality of the air pillows."

Problems solved by technology

Air pillows are typically manufactured on site because it is inefficient to ship preformed air pillows since they take up considerably more volume than the sheet material.

However, these aforementioned processes and devices are disadvantageous in that because the heating elements must directly physically contact the plastic sheeting, they can become fouled from plastic that melts when the plastic sheeting stops moving through the devices.

When heating elements become fouled, the dunnage producing machines must be cleaned or the heating elements must be replaced, resulting in down time and lost production.

It is a further disadvantage that the aforementioned processes and devices are limited in their production speeds because of the need to allow the air pillow material to be physically melted between the heating elements to seal the air pillows, and because when the heating elements are fouled, speeds must be slower.

However the use of rubber wheels is disadvantageous because when the rubber wheels get dirty, slippage in the pillow material can occur.

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