Method for producing inflated dunnage

Abstract

A method for producing inflated dunnage on the site of use, comprising providing, in rolled form, a plurality of preformed plastic bags, each of the bags comprising two plastic sheets in facing relationship and sealed along three edges with one edge remaining open. Air is blown toward each of the open edges in sequence, causing each bag to inflate, and the fourth edge of each inflated bag is sealed, the bag being empty except for the air. At least one sealed inflated bag is separated from the roll and placed in a carton to serve as dunnage. In an alternate embodiment, the stock material is provided in a continuous tubular form, and an air inflation needle is used to puncture a surface of the tube for inflation purposes.

Description

BACKGROUND OF THE INVENTIONThe invention relates to a process for producing dunnage directly on the site of use.Materials with low density and high volume are commonly used as packing materials to insulate goods being shipped from shock. Among the materials used are polystyrene "peanuts," cups and "worms," pellets of foam rubber foam, plastics and expanded polyurethane foam. Air cushioning material is generally preferred over the above types of dunnage because it is lighter in weight, can be supplied and dispensed in a controlled manner, particularly in roll form, and applied to the product to be shipped in sheet form. The sheet form of material is also easier to dispose than the individual pieces of plastic dunnage after the product is removed, and the sheet form of material can be rewound for further use or disposed of by deflation.However, air cushioning material also presents a variety of problems, as large volumes of the material must be kept on hand, and due to the necessity o...

AI Technical Summary

Benefits of technology

It is a further object of the invention to provide dunnage on site by a method which can be operated easily by personnel without expertise in the production of dunnage.

Typically, a roll of bags will be provided which is segmented longitudinally, but a roll can also be provided which is segmented both longitudinally and laterally, to produce a roll with, for example, four bags across or eight bags across. The bags can be separated from the roll individually and placed in a carton, or can be separated in groups of at least two bags, and typically more. This is advantageous, as the dunnage which is produced can be wrapped around an object and taped together just as bubble wrap would be, and which is as easy to dispose of or reuse as bubble wrap. The inflated dunnage of the invention is, however, much easier to produce than bubble wrap.

Various types and thicknesses of material can be used to make the bags of the invention. Among these materials are nylon film, high density polyethylene and low density polyethylene. Nylon film will keep air trapped for a long period of time, while high density polyethylene is strong and also holds air for a long period of time. Low density polyethylene tends to be inexpensive and will typically be used. The thickness of the films can be adjusted to provide extra strength or light weight, depending on which properties are desired.

Problems solved by technology

However, air cushioning material also presents a variety of problems, as large volumes of the material must be kept on hand, and due to the necessity of shipping this material from the producer, shipping costs can be considerable.

However, the above methods of producing dunnage are somewhat disadvantageous, as the apparatus necessary to handle two separate sheets of plastic is somewhat complex and difficult to operate.

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