Passive Tracking of an Inflatable Web along an Inflation Nozzle

Abstract

A system includes a supply of inflatable web (100) and a nozzle (240). The inflatable web includes a chamber (116), an inflation channel (112), and a transverse seal (114) between the inflation channel and the chamber. The inflatable web also includes a port (124) extending through the transverse seal to allow gas to pass from the inflation channel to the chamber. The nozzle has an outlet (242) configured to insert gas into the inflation channel as the inflatable web moves in a downstream direction. The system is configured to feed the inflatable web along a path from the supply and through the nozzle in a downstream direction. The system is configured to hold the supply of inflatable web relative to the nozzle such that the transverse seal contacts the nozzle and rides along a portion of the nozzle as the inflatable web moves in the downstream direction.

Description

Technical Field

[0001] The present disclosure belongs to the technical field of inflation and sealing machines for inflatable webs. More particularly, the present disclosure is directed to passive tracking of inflatable webs along inflation nozzles. Background Art

[0002] Inflated materials or structures such as cushions or sheets can be used to package items by wrapping the items in the material and placing the wrapped items in a shipping carton, or simply placing the inflated material inside the shipping carton along with the items to be shipped. The inflated material protects the packaged items by absorbing shock that might otherwise be transferred entirely to the packaged items during shipping, and can also restrict movement of the packaged items within the carton to further reduce the possibility of damage to the items.

[0003] Systems and machines for producing inflated material from inflatable webs at relatively high speeds would benefit from better alignment, tracking, and tension control of the inflatable web as it moves through the machine. This could help reduce one or more noises associated with web inflation, improve efficient use of inflation gas, increase inflation pressure efficiency, reduce wear on machine parts, reduce downtime, and avoid poorly inflated, uninflated, and / or poorly sealed inflated material, which could result in web loss and / or premature deflation or other failure of the protective packaging product. Therefore, there remains a need in the art for improvements in systems for inflating inflatable webs in the protective packaging field. Summary of the Invention

[0004] This summary is provided to introduce some concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0005] In a first embodiment, a system includes an inflatable web supply source and a nozzle. The inflatable web includes a chamber, an inflation channel, and a transverse seal between the inflation channel and the chamber. The inflatable web includes a port extending through the transverse seal to allow gas to pass from the inflation channel to the chamber. The nozzle has an outlet configured to insert gas into the inflation channel as the inflatable web moves in a downstream direction. The system is configured to feed the inflatable web along a path from the supply source and through the nozzle in a downstream direction. The system is configured to hold the inflatable web supply source relative to the nozzle such that the transverse seal contacts and rides along a portion of the nozzle as the inflatable web moves in a downstream direction.

[0006] In a second embodiment, the supply source of the first embodiment is arranged relative to the nozzle so that when the inflatable web is on the supply source, the top of the nozzle is located above the bottom of the transverse seal of the inflatable web.

[0007] In a third embodiment, the transverse seal of the second embodiment is biased towards the nozzle by gravity so that the transverse seal contacts the nozzle as the inflatable web is fed through the system.

[0008] In a fourth embodiment, the system of any one of the second and third embodiments further includes a sealing system configured to form a seal in the inflatable web across the port as the inflatable web is fed through the system.

[0009] In a fifth embodiment, the sealing system of the fourth embodiment is arranged relative to the nozzle such that the sealing system is configured to form a seal across the port in the inflatable web at a position above the top of the nozzle.

[0010] In a sixth embodiment, the system of either the fourth or fifth embodiment further includes an engagement system configured to maintain closed sides of the inflation passage between the outlet of the nozzle and the sealing system.

[0011] In a seventh embodiment, the engagement system of the sixth embodiment is configured to bring the two sides of the inflation channel together near the bottom of the nozzle.

[0012] In an eighth embodiment, the nozzle of any one of the second to eighth embodiments includes a portion extending from the support structure and a curved portion that curves in a downstream direction such that the outlet is oriented in the downstream direction.

[0013] In a ninth embodiment, the system of the eighth embodiment is configured to hold the supply of inflatable web relative to the nozzle such that initial contact of the cross seal with the nozzle occurs in a curved portion of the nozzle.

[0014] In a tenth embodiment, the nozzle of the ninth embodiment is configured so that after the transverse seal initially contacts the curved portion of the nozzle, the transverse seal rides along the top of the nozzle.

[0015] In an eleventh embodiment, the nozzle of any one of the second to tenth embodiments includes a block extending from a support structure and a tube extending from the block in a downstream direction such that the outlet is oriented in the downstream direction.

[0016] In a twelfth embodiment, the block of the eleventh embodiment includes an inclined surface extending upward in a downstream direction.

[0017] In a thirteenth embodiment, the system of the twelfth embodiment is configured to hold the supply of inflatable web relative to the nozzles such that initial contact of the cross seal with the nozzles occurs on the inclined surface of the block.

[0018] In a fourteenth embodiment, the nozzle of the thirteenth embodiment is configured so that after the trans-seal initially contacts the inclined surface, the trans-seal rides along the top of the tube.

[0019] In a fifteenth embodiment, the system of any one of the second to fourteenth embodiments further includes a spindle configured to hold a supply of inflatable web material, wherein the supply is in the form of a roll of inflatable web material.

[0020] In a sixteenth embodiment, the major axis of the fifteenth embodiment is arranged such that the major axis is at a non-straight angle relative to the vertical direction.

[0021] In a seventeenth embodiment, the system of any of the fifteenth or sixteenth embodiments further comprises a support member positioned below the supply source, the support member having a hub including a hole. A spindle extends through the hole in the hub of the support member. The support member is configured to rotate relative to the spindle. The support member comprises a plurality of arms extending away from the hub such that the plurality of arms extend beyond an outer circumference of the inflatable web roll.

[0022] In an eighteenth embodiment, the length of one of the transverse seals between two consecutive ports of any of the preceding embodiments is smaller than the length of at least one of the two consecutive ports.

[0023] In a nineteenth embodiment, the length of one of the transverse seals between two consecutive ports of any of the preceding embodiments is greater than the length of at least one of the two consecutive ports.

[0024] In a twentieth embodiment, the system of any of the preceding embodiments further comprises a guide member positioned such that when the inflatable web is fed in a downstream direction, the inflatable web passes around a portion of the guide member. The guide member is further configured to induce tension in at least a portion of the inflatable web downstream of the guide member. The at least portion of the inflatable web in which the guide member induces tension comprises the inflation channel. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The foregoing aspects and many of the attendant advantages of the disclosed subject matter will become more readily appreciated as they become better understood with reference to the following detailed description when taken in conjunction with the accompanying drawings, wherein:

[0026] Figure 1A depicts a front view of an embodiment of an inflatable web according to embodiments disclosed herein;

[0027] Figure 1B Depicted is a diagram of a process according to an embodiment disclosed herein. Figure 1A An embodiment of an inflated panel formed of an inflatable web is shown;

[0028] Figure 2 and Figure 3Adepicts a top view and a side view, respectively, of an embodiment of a system for inflating and sealing an inflatable web according to embodiments disclosed herein;

[0029] Figure 3B Depicts an embodiment according to the present disclosure Figure 3A Detailed view of a portion of the view in , showing the nozzle top located above the bottom of the transverse seal of the inflatable web;

[0030] Figure 4A Depicts feeding, inflating, and sealing an inflatable web according to embodiments disclosed herein. Figure 2 and Figure 3A An example of the system shown in ;

[0031] Figure 4B Depicted is an embodiment of the present disclosure in which an inflatable web is fed through a Figure 2 and Figure 3A Detailed view of the transverse seal in contact with the nozzle when the system is shown;

[0032] Figure 4C Depicts an embodiment according to the present disclosure Figure 4B a partial cross-sectional view of the system shown, including the outlet of the nozzle;

[0033] Figure 5A and Figure 5B depicts a partial top view and a side view, respectively, of another embodiment of a system for feeding, inflating, and sealing an inflatable web according to embodiments disclosed herein;

[0034] Figure 5C Depicts an embodiment according to the present disclosure Figure 5A and Figure 5B a partial cross-sectional view of the system shown, including the outlet of the nozzle;

[0035] Figure 5D Depicts a diagram of a circuit according to an embodiment disclosed herein. Figure 5A and Figure 5B A side view of the nozzle of the system shown, and the path of the transverse seal of the inflatable web if the inflatable web is fed through the nozzle;

[0036] Figure 6A and Figure 6B Depicts an embodiment of a system according to embodiments disclosed herein, the system being Figure 2 A. Figure 3. Figure 5A and Figure 5B A variation of the system shown in , which can be used with an inflatable web having closed inflation channels;

[0037] Figure 7A and Figure 7BDepicts the embodiment disclosed herein. Figure 2 and Figure 3A A side view of the system shown in FIG, which is different from Figure 1A and Figure 1B for use with an inflatable web of the type shown in ; and

[0038] Figure 8 Depicts an embodiment according to the present disclosure Figure 2 and Figure 3A The system shown, in which the support structure has been Figure 3A Installation at different angles shown. DETAILED DESCRIPTION

[0039] In some examples herein, the inflated panel formed from the inflatable web is a cushioning material known as an air cell material. As used herein, the term "air cell material" may refer to an air bubble cushioning material, such as the BUBBLE WRAP® air cushioning material sold by Sealed Air Corporation, in which a first film or laminate is formed (e.g., thermoformed, embossed, calendared, or otherwise processed) to define a plurality of cavities, and a second film or laminate is adhered to the first film or laminate to close the cavities. As used herein, the term "air cell material" may refer to an inflatable cushioning material, such as the BUBBLE WRAP® IB air cushioning material sold by Sealed Air Corporation or the FILL-AIR® air pillow void filling material sold by Sealed Air Corporation, in which an inflatable web can be inflated and sealed to form the air cell material. Examples of air cell materials are shown in U.S. Patent Nos. 3,142,599, 3,208,898, 3,285,793, 3,508,992, 3,586,565, 3,616,155, 3,660,189, 4,181,548, 4,184,904, 4,415,398, 4,576,669, 4,579,516 Nos. 6,800,162, 6,982,113, 7,018,495, 7,165,375, 7,220,476, 7,223,461, 7,429,304, 7,721,781, 7,950,433, 9,969,136, and 10,286,617, the disclosures of which are incorporated herein by reference in their entireties.

[0040] Figure 1AA front view of an embodiment of an inflatable web 100 is depicted. The inflatable web 100 comprises two juxtaposed sheets arranged such that the inflatable web 100 includes a longitudinal edge 102 and a longitudinal edge 104. The inner surfaces of the two sheets are sealed to one another in a pattern defining a series of chambers 116. In some embodiments, the seal between the two sheets includes a seal 118 defining the chambers 116. In the depicted embodiment, the chambers 116 are shaped to have a series of cells 120 and passageways 122. In some embodiments, the cells 120 have a greater width than the passageways 122. In the depicted embodiment, the cells 120 have a generally circular shape, such that after being inflated, the cells 120 have a three-dimensional "bubble" shape. In other embodiments, the cells 120 may have other shapes, such as rectangular, hexagonal, etc. In the depicted embodiment, adjacent ones of the chambers 116 are offset from one another such that the cells 120 of one chamber are aligned with the passages 122 of an adjacent chamber to enable the chambers 116 to be positioned immediately adjacent to one another.

[0041] In general, any of the sheets described herein may comprise any flexible material that can be manipulated to confine gas within the inflatable chambers described herein, including various thermoplastic materials, such as polyethylene homopolymers or copolymers, polypropylene homopolymers or copolymers, etc. Non-limiting examples of suitable thermoplastic polymers include polyethylene homopolymers, such as low-density polyethylene (LDPE) and high-density polyethylene (HDPE); and polyethylene copolymers, such as ionomers, EVA, EMA, heterogeneous (Zeigler-Natta catalyzed) ethylene / α-olefin copolymers, and homogeneous (metallocene, single-cite catalyzed) ethylene / α-olefin copolymers. Ethylene / α-olefin copolymers are copolymers of ethylene and one or more comonomers selected from C3 to C20 α-olefins, such as 1-butene, 1-pentene, 1-hexene, 1-octene, methylpentene, and the like, wherein the polymer molecules comprise long chains with relatively few side branches, including linear low-density polyethylene (LLDPE), linear medium-density polyethylene (LMDPE), very low-density polyethylene (VLDPE), and ultra-low-density polyethylene (ULDPE). Various other materials are also suitable, for example, polypropylene homopolymer or polypropylene copolymer (e.g., propylene / ethylene copolymer), polyester, polystyrene, polyamide, polycarbonate, and the like. The film may be monolayer or multilayer and may be prepared by any known coextrusion process by melting the component polymer(s) and extruding or coextruding them through one or more flat or annular dies.

[0042] In some embodiments, seal 118 further defines ports 124. Each of ports 124 allows a fluid, such as a gas (e.g., air), to pass from inflation channel 112 into one of chambers 116. In the depicted embodiment, seal 118 also forms a transverse seal 114 between inflation channel 112 and chamber 116. Ports 124 extend through transverse seal 114 to allow gas to pass from inflation channel 112 into chamber 116. In some embodiments, inflation channel 112 is "open" in that the two sheets are not connected at longitudinal edge 102. When inflation channel 112 is open, it can be positioned so that when inflatable web 100 is fed, a nozzle passes through inflation channel 112 between the two sheets. In some embodiments, inflation channel 112 is "closed" in that the two sheets are connected at longitudinal edge 102. When the inflation channel 112 is closed, the inflation channel 112 can be positioned so that, when the inflatable web 100 is fed, the nozzle is inserted into the inflation channel 112 between two sheets, and then the inflation channel 112 is slit to allow the two sheets to pass on the other side of the nozzle. Whether the inflation channel 112 is open or closed, the nozzle can inflate the chamber 116, inserting air into the inflation channel 112, through the port 124, and into the chamber 116.

[0043] In some embodiments, the chamber 116 extends in the transverse direction between the two longitudinal edges 102 and 104. In the depiction shown here, the transverse direction on the inflatable web and the inflated web is generally indicated by the arrows tr The longitudinal direction of the inflatable web and the inflated web is generally indicated by arrows lo Indicates. Typically, the longitudinal direction of the inflatable web is substantially parallel to the longitudinal edges 102 and 104, while the transverse direction of the inflatable web is substantially perpendicular to the longitudinal direction. In the depicted embodiment, chamber 116 has a proximal end 126 and a distal end 128. Proximal end 126 is the end of chamber 116 closest to longitudinal edge 102 and / or closest to inflation channel 112. Distal end 128 is the end of chamber 116 closest to longitudinal edge 104. In the depicted embodiment, distal end 128 of chamber 116 is closed. In other embodiments, distal end 128 may be in fluid communication with another inflation chamber located along longitudinal edge 104.

[0044] Figure 1B An embodiment of an inflated panel 130 formed from an inflatable web 100 is depicted. By inflating some of the chambers 116 of the inflatable web 100, a seal 132 is formed across the ports 124 of the chambers 116 and in the cross direction. trThe upper cutting sheet cuts inflated panels 130 from the inflatable web 100 to form inflated panels 130. The inflated panels 130 can be used as cushioning material and / or void filling material. For example, the inflated panels 130 can be placed in a shipping container to cushion products in the shipping container and / or fill gaps between the objects and the walls of the shipping container.

[0045] The location of the seal 132 can affect the performance and appearance of the inflated panel 130. In the depicted embodiment, the seal 132 is positioned in the longitudinal direction. lo The seal 132 extends through the transverse seal 114 and across the port 124. The seal 132 is not located in the inflation channel 112 or across any of the chambers 116. Figure 1B When the seal 132 is in the transverse direction tr If the seal 132 is formed lower, the seal 132 can be positioned across some of the cells 120. In this case, some of the cells 120 will not be fully inflated, resulting in a reduced width of cushioning provided by the inflated panel 130 and potentially making the inflated panel 130 aesthetically unpleasant to the user. Figure 1B If seal 132 is formed higher in the lateral direction, seal 132 may be located in inflation channel 112. In this case, port 124 will not close, and chambers 116 will remain fluidly coupled to each other via inflation channel 112. In some embodiments, the sides of inflated panel 130 may not be sealed from each other, such that the sides of inflation channel 112 are open. In these embodiments, if seal 132 is in inflation channel 112, chamber 116 will quickly deflate.

[0046] Some existing inflation and sealing machines have addressed the issue of proper seal position using active film control. For example, U.S. Patent No. 10,286,617 describes a positioning mechanism that controls the position of a supply roll of inflatable film on the main shaft of the inflation and sealing machine. The positioning mechanism controls the roll's position on the main shaft based on feedback from a web tracking sensor that detects the film's lateral position. Other existing inflation and sealing machines have addressed the issue of proper seal position using guides that project upstream into the inflation channel as the film passes through. For example, U.S. Patent No. 7,150,136 describes a system in which the supply roll rests on rollers with its axis substantially horizontal. The film is fed so that the bulbous end of the inflation tube is inserted into the film's inflation channel upstream of the nozzle outlet.

[0047] While existing membrane control solutions in inflation and sealing machines are capable of properly positioning the membrane, they also have drawbacks. In one example, inflation and sealing machines with active membrane tracking include components (e.g., sensors, actuators, etc.) that increase the cost of the machine. Furthermore, the time and effort required to install and maintain the machine increases due to active tracking. In another example, guides protruding upstream into the inflation channel can be problematic if the film is not properly fed ahead of them. If the membrane is not properly threaded, the inflation channel can become lodged against the guides, leading to blockage, physical deformation of the inflation channel, and / or rupture of the inflation channel.

[0048] Figure 2 and Figure 3A Depicted are top and side views, respectively, of an embodiment of a system 200 for inflating and sealing an inflatable web. System 200 includes a support structure 202. In some embodiments, components of system 200 are configured to couple to support structure 202. In some embodiments, support structure 202 includes a housing configured to house some of the components of system 200 and / or provide protection for a user of system 200 (e.g., a physical barrier from moving parts, electrical insulation from electrical components, etc.). In the depicted embodiment, support structure 202 includes raised surfaces 204 and 206 configured to hold certain components at a height relative to one another, as discussed in more detail below.

[0049] The system 200 includes a main shaft 210 configured to hold a supply 220 of inflatable web material 222. In the depicted embodiment, the main shaft 210 is oriented such that the axis of the main shaft 210 is substantially vertical. In other embodiments, the main shaft 210 can be oriented such that the axis of the main shaft 210 is at any non-vertical and non-horizontal angle (e.g., 10° relative to vertical, 20° relative to vertical, 30° relative to vertical, etc.). In the depicted embodiment, the supply 220 is a roll of inflatable web material 222 wound around a core 224. In other embodiments, the system 200 can include any other device for holding a supply of inflatable web material, such as a dispenser configured to hold a supply of inflatable web material in the form of a fan-folded stack of inflatable web material.

[0050] In the depicted embodiment, the main shaft 210 extends from the raised surface 204 of the support structure 202. In some embodiments, the main shaft 210 is fixedly coupled to the support structure 202, and the supply 220 of the inflatable web 222 is configured to rotate relative to the main shaft 210 when the inflatable web 222 is withdrawn from the supply 220. In other embodiments, the main shaft 210 is rotatably coupled to the support structure 202 such that the main shaft 210 rotates with the supply 220 of the inflatable web 222 when the inflatable web 222 is withdrawn from the supply 220. In the depicted embodiment, the main shaft 210 includes a support member 212 positioned below the supply 220. The support member 212 is positioned on the raised surface 204, and the main shaft 210 extends through a hole in the support member 212. In the depicted embodiment, the support 212 is not coupled to the support structure 202 or the spindle 210, such that the support 212 is movable relative to each of the support structure 202 and the spindle 210. When the supply source 220 is placed on the support 212, friction between the supply source 220 and the support 212 can cause the support 212 to rotate with the supply source 220 as the inflatable web 222 is withdrawn from the supply source 220. In the depicted embodiment, the support 212 includes a plurality of arms at various locations around the roll that extend away from the hub such that the arms extend beyond the outer circumference of the roll of inflatable web 222. In other embodiments, the support 212 can be a disk that extends beyond the outer circumference of the roll around the entire roll.

[0051] As in Figure 3A As can be seen, the inflatable web 222 in the depicted embodiment is similar to the inflatable web 222 described above with respect to FIG. Figure 1A and 1B 100. The depiction of the inflatable web 222 includes the reference numerals associated with the inflatable web 100, and it will be understood that those features of the inflatable web 222 are similar or identical to the corresponding features described with respect to the inflatable web 100. In other embodiments, the inflatable web 222 can be replaced with any number of other types of inflatable webs, such as inflatable air pillows, inflatable bubble bags, or any of the other inflatable air cell materials described in the references incorporated herein by reference. The inflatable web 222 is oriented such that the longitudinal edge 102 is positioned closer to the support structure 202 than the longitudinal edge 104. In this manner, the inflation channel 112 is positioned closer to the support structure 202 than the chamber 116 is.

[0052] The system 200 also includes a guide member 230. In the depicted embodiment, the guide member 230 extends from the raised surface 206 of the support structure 80. In some embodiments, the guide member 230 is fixedly coupled to the support structure 202 such that the guide member 230 does not move or rotate relative to the support structure 202 when the inflatable web 222 is withdrawn from the supply source 220. Figure 2 1 , a path 226 is depicted along which the inflatable web 222 is fed from the supply source 220. As can be seen, the guide member 230 is arranged so that the inflatable web 222 passes along the path 226 around a portion of the guide member 230. This allows the inflatable web 222 to pass along the same path 226 downstream of the guide member 230, regardless of whether the supply source 220 is full (as indicated by the path 226 upstream of the guide member 230) or partially full (as indicated by the path 226 upstream of the guide member 230). The guide member 230 is also configured to induce tension in the inflatable web 222 downstream of the guide member 230, at least in the inflation channel 112. Figure 3A In the depicted embodiment shown, the guide member 230 does not extend away from the support structure 202 until the longitudinal edge 104 is located, but rather extends further than the longitudinal edge 102 , the inflation channel 112 , and the transverse seal 114 forming the port 124 .

[0053] The system 200 includes a nozzle 240 configured to inflate the inflatable web 222. In some embodiments, the nozzle 240 is configured to direct the inflation gas into the inflation channel 112 and then into the chamber 116 via the port 124. In some embodiments, the nozzle 240 includes an outlet 242 from which the pressurized gas is discharged. In the depicted embodiment, as in Figure 3A As can be seen in FIG, the nozzle 240 extends from the raised surface 206 of the support structure 202 and then bends in the downstream direction so that the outlet 242 is oriented downstream. Figure 2 , the path 226 of the inflatable web 222 passes on both sides of the nozzle 240, indicating that both sides of the inflation channel 112 pass on either side of the nozzle 240. In the depicted embodiment, the inflation channel 112 is an open inflation channel, such that both sides of the inflation channel 112 can pass on either side of the nozzle 240. In other embodiments, as discussed below, the inflation channel 112 can be a closed inflation channel, and a cutting mechanism can be located upstream of the nozzle 240 to cut the closed inflation channel and allow both sides of the inflation channel 112 to pass on either side of the nozzle 240.

[0054] In some embodiments, the supply source 220 is held relative to the nozzle 240 by the spindle 210 such that the nozzle 240 is above the cross seal 114 . Figure 3B Shown Figure 3A A detailed view of a portion of a view. Figure 3B As shown, the top of nozzle 240 is positioned higher than the bottom of transverse seal 114. In the depicted embodiment, the top of nozzle 240 is positioned higher than the bottom of transverse seal 114 by an offset 244. In some embodiments, the dimensions of the components of system 200 (e.g., the dimensions of nozzle 240, the dimensions of support structure 202, the dimensions of spindle 210, the dimensions of supply source 220, etc.) are selected such that the top of nozzle 240 is positioned higher than the bottom of transverse seal 114 and / or the offset 244 is within a specific range.

[0055] System 200 also includes a joining system 250 configured to maintain the inflation channel 112 closed downstream of nozzle 240 until port 124 is sealed. Maintaining the inflation channel 112 closed prevents gas from escaping from chamber 116, thereby maintaining the inflated chamber 116. Furthermore, gas escaping between the two sides of the inflation channel 112 tends to create a reed effect, causing the sides of the inflation channel 112 to vibrate and generate a relatively loud noise. The volume and / or frequency of this reed effect noise can be particularly disturbing for people to be around for extended periods of time. Joining system 250 prevents the open end of the inflation channel 112 from creating a reed effect. In the depicted embodiment, joining system 250 includes a plurality of joining rollers 252, between which path 226 passes. In some embodiments, joining rollers 252 are positioned to minimize the distance between each pair of consecutive rollers and maximize the amount of contact between joining rollers 252 and inflatable web 222. In other embodiments, the engagement system 250 may include sprockets, belts, bearings, and / or any other device capable of maintaining the ends of the inflation channel 112 closed.

[0056] The system 200 also includes a sealing system 260 that is configured to form a seal across the port 124 to seal the closed chamber 116. In some embodiments, the sealing system 260 is configured to form a heat seal in the inflatable web 222. In the depicted embodiment, the sealing system 260 includes rollers 262 and 264 that form a nip through which the inflatable web 222 passes. The roller 262 includes a heating element 266 that passes around the circumference of the roller 262. The heating element 266 is configured to heat the inflatable web 222 as it passes through the nip between the rollers 262 and 264. The roller 264 serves as a backing for the heating element 266. As shown in Figure 3A, the heating element 266 is positioned above the bottom of the transverse seal 144 and below the cells 120 of the chamber 116, such that the seal formed by the heating element 266 is positioned above the bottom of the transverse seal 144 and below the cells 120 of the chamber 116. In other embodiments, the sealing system 260 may include a heating wire, a heating block, a drag sealer, or any other mechanism configured to form a seal in the inflatable web 222.

[0057] Figure 4A An example of the system 200 is shown when feeding, inflating, and sealing an inflatable web 222. The inflatable web 222 is fed from a supply source 220 around a guide member 230. From the guide member 230, the inflatable web 222 is fed to a nozzle 240, with the two sides of the inflation channel 112 passing on opposite sides of the nozzle 240. After the two sides of the inflation channel 112 pass through the nozzle 240, the two sides of the inflation channel are brought together and held closed by a joining system 250. The inflatable web 222 is also passed to a sealing system 260, where a seal 132 is formed in the inflatable web 222 across the port 124. In some embodiments, one or both of the joining system 250 or the sealing system 260 are driven to feed the inflatable web from the supply source 220 through the system 200. In the depicted embodiment, rollers 262 and 264 of sealing system 260 are driven to rotate in opposite directions and "pull" inflatable web 222 from a supply source through system 200. Similarly, engaging roller 252 of engaging system 250 can also be driven to pull inflatable web 222 from a supply source through system 200. In embodiments where rollers 262 and 264 and engaging roller 252 are driven, system 200 can include a computing device (e.g., a controller) configured to control the speeds of rollers 262 and 264 and engaging roller 252 so that rollers 262 and 264 and engaging roller 252 pull inflatable web 222 at the same rate. In other embodiments, engaging roller 252 can be driven at a slower speed than rollers 262 and 264 to induce tension in inflatable web 222.

[0058] As in Figure 4A As can be seen in Figure 4BAs seen in greater detail in the detailed view shown in FIG, the transverse seal 114 contacts the nozzle 240 as the inflatable web 222 is fed through the system 200. In the depicted embodiment, the transverse seal 114 initially contacts the curved portion of the nozzle 240 that curves downstream along the path 226 of the inflatable web 222. After this initial contact, the transverse seal 114 continues to pass along (or "rides") the portion of the nozzle 240 that extends downstream to the outlet 242. In some embodiments, the transverse seal 114 contacts the nozzle 240 because the top of the nozzle 240 is positioned higher than the bottom of the transverse seal 114 when the inflatable web 222 is on the supply 220. In this case, gravity biases the transverse seal 114 toward the nozzle 240, causing it to contact the nozzle 240 as the inflatable web 222 is fed through the system 200. In the depicted embodiment, the heating element 266 is positioned above the top of the nozzle 240 so that a seal 132 is formed in the inflatable web 222 above the bottom of the cross seal 114. In this manner, the nozzle 240 acts as a passive tracking mechanism to properly and passively align the inflatable web 222 relative to the heating element 266. Passive tracking occurs without requiring sensors to track the position of the inflatable web 222, actuators to move the supply 220, or any other components to track and / or move the inflatable web 222.

[0059] In addition to providing proper tracking of the inflatable web 222 , the contact between the cross seal 114 and the nozzle 240 also reduces the overall reed effect during inflation of the inflatable web 222 . Figure 4CA partial cross-sectional view of the system 200 is depicted, showing the outlet 242 of the nozzle 240, the inflatable web 222 at the end of the nozzle 240, and two of the joining rollers 252 at the end of the nozzle 240. As can be seen, the cross seal 114 of the inflatable web 222 rides on top of the nozzle 240, effectively minimizing the gap between the inflatable web 222 and the nozzle 240 above the nozzle 240. The joining rollers 252 are positioned relative to the bottom of the nozzle 240 so that the sides of the inflation channel 112 come together near the bottom of the nozzle 240, thereby minimizing the gap between the inflatable web 222 and the nozzle 240 below the nozzle 240. As described above, the gap in the inflatable web 222 between the joining rollers 252 is minimized, the gap between rollers 262 and 264 is minimized, and the gap between the joining roller 252 and rollers 262 and 264 is minimized. This arrangement essentially forms a pocket in the inflation channel 112 between the nozzle 240, the engaging roller 252, and the rollers 262 and 264. This pocket in the inflation channel 112 directs the pressurized gas exiting the outlet 242 into the chamber 116 via the port 124. This pocket in the inflation channel 112 also reduces the reed effect because the pressurized gas is prevented from exiting the pocket in the inflation channel 112 anywhere other than at the port 124.

[0060] Other embodiments of the nozzle may be used for passive tracking of the inflatable web. Figure 5A and Figure 5B , a partial top view and a side view, respectively, of another embodiment of a system 300 for feeding, inflating, and sealing an inflatable web 222 are depicted. System 300 includes components similar to system 200, such as spindle 210, guide member 230, engagement system 250, and sealing system 260. System 300 also includes a nozzle 340 having an outlet 342. Nozzle 340 includes a block 344 extending from raised surface 206 and a tube 346 extending from block 344. Figure 5C A partial cross-sectional view of the system 300 is depicted showing the outlet 342 of the nozzle 340 and two of the engaging rollers 252 at the end of the nozzle 340. Figure 5C As can be seen in FIG, the illustrated embodiment of block 344 includes a rounded top having a larger radius than tube 346. The top of block 344 also includes an inclined surface 348 extending upwardly in the downstream direction on the upstream side of block 344.

[0061] Figure 5DA side view of the nozzle 340 and the path 114' of the transverse seal 114 of the inflatable web 222 as it is fed through the nozzle 340 are depicted. Path 114' initially contacts the nozzle 340 on an inclined surface 348. As path 114' proceeds downstream, the inclined surface 348 deflects path 114' upward. Path 114' rides along the inclined surface 348 and the top of the block 344. As path 114' proceeds downstream past the block 344, it descends to the top of the tube 346 and rides along it. When path 114' is at the downstream end of the tube 346, the gap between the transverse seal 114 and the top of the tube 346 is minimized, and the gap between the bottom of the tube 346 and the engaging roller 252 in the inflatable channel 112 is also minimized. In this way, the nozzle 340 provides passive tracking for the transverse seal 114 and reduces the reed effect of the inflatable channel 112.

[0062] As noted above, the systems described herein can be used with inflatable webs having open or closed inflation channels. The embodiments of systems 200 and 300 have been described and depicted for use with inflatable web 222 in which the inflation channels 112 are open inflation channels. Systems 200 and 300 can be adapted for use with inflatable webs having closed inflation channels.

[0063] Figure 6A An embodiment of system 200' is depicted, which is a variation of system 200 but can be used with inflatable webs having closed inflation channels. System 200' includes components similar to system 200, such as a spindle 210, a guide member 230, a nozzle 240, a joining system 250, and a sealing system 260. System 200' also includes a cutting element 245 located upstream of nozzle 240. Cutting element 245 is configured to cut the closed inflation channel of the inflatable web as the inflatable web is fed through system 200'. Because cutting element 245 is located upstream of nozzle 240, it is configured to cut the closed inflation channel of the inflatable web before the inflatable web reaches nozzle 240, allowing two sides of the severed inflation channel to pass around opposite sides of nozzle 240.

[0064] Figure 6BAn embodiment of a system 300' is shown, which is a variation of system 300 but can be used with inflatable webs having closed inflation channels. System 300' includes components similar to system 300, such as spindle 210, guide member 230, engagement system 250, and sealing system 260. System 300' also includes nozzle 340', which is a variation of nozzle 340. Nozzle 340' includes an outlet 342, a block 344, a tube 346, and an inclined surface 348. Nozzle 340' also includes a cutting element 345 located upstream of block 344. Cutting element 345 is configured to cut the closed inflation channel of the inflatable web as it is fed through system 300'. Because the cutting element 345 is located on the upstream side of the block 340 , the cutting element 345 is configured to cut the closed inflation channel of the inflatable web so that both sides of the cut inflation channel can pass around opposite sides of the block 344 and other parts of the nozzle 340 .

[0065] In the depicted embodiment, cutting elements 245 and 345 are stationary blades configured to cut the closed inflation channel of the inflatable web. Furthermore, in the depicted embodiment, the blades of cutting elements 245 and 345 are angled downward in the downstream direction. This angling of the blades of cutting elements 245 and 345 causes the inflatable web to be biased downward when cut by the blades, further biasing the longitudinal channel toward the nozzle. Thus, in addition to the downward bias caused by gravity, cutting elements 245 and 345 can also bias the inflatable web downward. In other embodiments, cutting elements 245 and 345 may include one or more of rotating blades, any other type of blade, a heating wire, any other type of heating element, any other cutting element, or any combination thereof.

[0066] The above embodiments of the system for inflating and sealing an inflatable web have been described and depicted with respect to the inflatable web 100. Although the embodiments of the system described herein can be used with the inflatable web 100, the system described herein can also be used with other types of inflatable webs. Figure 7A and Figure 7B Depicted in FIG. 1 is a side view of a system 200 for use with a supply source 270 having an inflatable web 272 that is a different type than the inflatable web 100 .

[0067] The inflatable web 272 comprises two juxtaposed sheets arranged such that the inflatable web 272 includes a longitudinal edge 402 and a longitudinal edge 404. The inner surfaces of the two sheets are sealed to one another in a pattern defining a series of chambers 416. In some embodiments, the seal between the two sheets comprises a seal 418 defining the chambers 416. In the depicted embodiment, the chambers 416 are generally rectangular in shape. In other embodiments, the chambers 416 may have other shapes, such as hexagonal, circular, irregular, etc. In the depicted embodiment, the inflatable web 272 includes lines of weakness 436 between the chambers 416. The lines of weakness 436 are configured to allow a user to more easily separate the chambers 416 from one another after the chambers 416 are inflated. In some embodiments, each of the lines of weakness 436 comprises perforations, scores, slits, cuts, a series of retaining features, any other feature that enhances the user's ability to separate the chambers 416 from one another, or any combination thereof.

[0068] In some embodiments, seal 418 further defines ports 424. Each of ports 424 allows a fluid, such as a gas (e.g., air), to pass from inflation channel 412 into one of chambers 416. In the depicted embodiment, the ends of seal 418 also form transverse seals 414 between inflation channel 412 and chamber 416. Ports 424 pass between transverse seals 414 to allow gas from inflation channel 412 to enter chamber 416. In the depicted embodiment, ports 424 are significantly longer than transverse seals 414, unlike ports 124, which are significantly shorter than transverse seals 114 in inflatable web 100. In the depicted embodiment, inflation channel 412 is an open inflation channel. In other embodiments, inflation channel 412 may be a closed inflation channel.

[0069] In the depicted embodiment, the supply source 270 is a roll of inflatable web 272 wrapped around a core 274. In other embodiments, the system 200 may include any other device for holding the supply source of inflatable web, such as a dispenser configured to hold the supply source of inflatable web in a fan-folded stack. The core 274 and inflatable web 272 are not as wide as the core 224 and inflatable web 222. Therefore, when placed on the spindle 210, the core 274 and inflatable web 272 are "shorter" than the core 224 and inflatable web 222. Obviously, the spindle can provide the same function regardless of how "short" or "tall" the supply roll is placed on the spindle. In the depicted embodiment, the inflatable web 272 is oriented so that the longitudinal edge 402 is positioned closer to the support structure 202 than the longitudinal edge 404. As such, inflation channel 412 is positioned closer to support structure 202 than chamber 416 is located from support structure 202 .

[0070] In the depicted embodiment, the supply source 270 is held relative to the nozzle 240 by the spindle 210 such that the nozzle 240 is above the cross seal 414. Figure 7A As shown, the top of nozzle 240 is positioned higher than the bottom of transverse seal 414. In some embodiments, the dimensions of the components of system 200 (e.g., the dimensions of nozzle 240, the dimensions of support structure 202, the dimensions of spindle 210, the dimensions of supply source 220, etc.) are selected such that the top of nozzle 240 is positioned higher than the bottom of transverse seal 414 and / or the offset between the top of nozzle 240 and the bottom of transverse seal 414 is within a specified range.

[0071] Figure 7B An example of the system 200 is shown when feeding, inflating, and sealing an inflatable web 272. The inflatable web 272 is fed from a supply source 270 around a guide member 230. From the guide member 230, the inflatable web 222 is fed to the nozzle 240, with the two sides of the inflation channel 412 passing on opposite sides of the nozzle 240. After the two sides of the inflation channel 412 pass through the nozzle 240, the two sides of the inflation channel 412 are brought together and held closed by the joining system 250. The inflatable web 272 also passes to the sealing system 260, where a seal 432 is formed in the inflatable web 272 across the port 424. In some embodiments, one or both of the joining system 250 or the sealing system 260 are driven to feed the inflatable web from the supply source 220 through the system 200. In the depicted embodiment, rollers 262 and 264 of sealing system 260 are driven to rotate in opposite directions and "pull" inflatable web 272 from a supply source through system 200. Similarly, engaging roller 252 of engaging system 250 can also be driven to pull inflatable web 272 from a supply source through system 200. In embodiments where rollers 262 and 264 and engaging roller 252 are all driven, system 200 can include a computing device (e.g., a controller) configured to control the speeds of rollers 262 and 264 and engaging roller 252 so that rollers 262 and 264 and engaging roller 252 pull inflatable web 272 at the same rate. In other embodiments, engaging roller 252 can be driven at a slower speed than rollers 262 and 264 to induce tension in inflatable web 272.

[0072] As the inflatable web 272 is fed through the system 200, a transverse seal 414 forms. In the depicted embodiment, the transverse seal 414 initially contacts the curved portion of the nozzle 240 that curves downstream along the path 226 of the inflatable web 222. After initial contact, the transverse seal 414 continues to ride along the portion of the nozzle 240 that extends downstream to the outlet 242. In some embodiments, the transverse seal 414 contacts the nozzle 240 because the top of the nozzle 240 is positioned higher than the bottom of the transverse seal 414 when the inflatable web 272 is on the supply 270. In this case, gravity biases the transverse seal 414 toward the nozzle 240, causing it to contact the nozzle 240 as the inflatable web 272 is fed through the system. In the depicted embodiment, the heating element 266 is positioned higher than the top of the nozzle 240, so that a seal 432 is formed in the inflatable web 272 above the bottom of the transverse seal 414. In this manner, the nozzle 240 functions as a passive tracking mechanism to properly and passively align the inflatable web 272 relative to the heating element 266. Passive tracking occurs without requiring sensors to track the position of the inflatable web 272, actuators to move the supply 270, or any other components to track and / or move the inflatable web 272.

[0073] The transverse seals 414 in the inflatable web 272 are shorter and further apart than the transverse seals 114 in the inflatable web 100. Unlike the transverse seals 114 in the inflatable web 100, one of the transverse seals 414 will not come into contact with the nozzle 240 until the preceding transverse seal 414 has passed through the nozzle 240. In other words, as the inflatable web 272 is fed through the system 200, the nozzle 240 will have intermittent contact with the transverse seals 414 rather than continuous contact, as was the case with the inflatable web 100. Despite this intermittent contact with the transverse seals 414, the nozzle 240 will still passively guide the inflatable web 272. If the inflatable web begins to track improperly when the nozzle 240 is not in contact with any of the trans-seals 414, the nozzle 240 will return the inflatable web to the proper tracking position when the next of the trans-seals 414 contacts the nozzle 240. At normal feed rates, the time frame of possible improper tracking when the nozzle 240 is not in contact with any of the trans-seals 414 is short enough that the inflatable web 272 may not deviate from the proper tracking path beyond the time the nozzle 240 can return the inflatable web to the proper tracking path when the next of the trans-seals 414 contacts the nozzle.

[0074] It will be apparent that any of the systems described herein can operate in an orientation where the path of the inflatable web is not completely vertical. For example, Figure 8The system 200 and the inflatable web 222 are depicted wherein the support structure 202 is configured to be different from Figure 3A Install at the angle shown. Figure 8 In this embodiment, transverse seal 114 is angled non-straight relative to the horizontal, while the axis of main shaft 210 is angled non-straight relative to the vertical. Clearly, the top of nozzle 240 is still positioned "above" transverse seal 114 on supply source 220. Specifically, a plane passing through transverse seal 114 on supply source 220 intersects nozzle 240. In this manner, gravity still biases transverse seal 114 toward nozzle 240 as inflatable web 222 is fed through system 200. Other arrangements of system 200 are possible while maintaining the functionality of nozzle 240 as a passive tracking element. Other systems disclosed herein can likewise be mounted or positioned at various angles while maintaining the functionality of their respective nozzles as passive tracking elements.

[0075] For purposes of this disclosure, terms such as "upper," "lower," "vertical," "horizontal," "inwardly," "outwardly," "inner," "outer," "front," "rear," and the like should be construed as descriptive and not limiting the scope of the claimed subject matter. Additionally, as used herein, "including," "comprising," or "having" and variations thereof are meant to encompass the items listed thereafter and their equivalents as well as additional items. Unless otherwise limited, the terms "connected," "coupled," and "mounted," and variations thereof, are used broadly herein and encompass both direct and indirect connections, couplings, and mountings. Unless otherwise specified, the terms "substantially," "approximately," and the like are used to mean within 5% of a target value.

[0076] The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, the aspects of the present disclosure intended to be protected should not be interpreted as being limited to the specific embodiments disclosed. In addition, the embodiments described herein are considered to be illustrative rather than restrictive. It should be understood that modifications and changes may be made by others and equivalents may be adopted without departing from the spirit of the present disclosure. Therefore, it is expressly intended that all such modifications, changes, and equivalents fall within the spirit and scope of the present disclosure claimed.

Claims

1. A system for inflating an inflatable web, comprising: a supply of an inflatable web, wherein the inflatable web comprises a chamber, an inflation channel, and a trans-seal between the inflation channel and the chamber, wherein the inflatable web comprises a port through the trans-seal to allow gas to pass from the inflation channel to the chamber; and a nozzle having an outlet configured to insert gas into the inflation channel as the inflatable web moves in a downstream direction; wherein the system is configured to feed the inflatable web along a path from the supply source and past the nozzle in the downstream direction; wherein the system is configured to maintain the supply of the inflatable web relative to the nozzle such that when the inflatable web moves in the downstream direction, the transverse seal contacts the nozzle and rides along a portion of the nozzle; wherein the supply source is arranged relative to the nozzle such that when the inflatable web is on the supply source, the top of the nozzle is positioned above the bottom of the transverse seal of the inflatable web; wherein the nozzle comprises a block extending from a support structure and a tube extending from the block in a downstream direction such that the outlet is oriented in the downstream direction; Wherein, the block includes an inclined surface extending upward in the downstream direction.

2. The system for inflating an inflatable web according to claim 1, wherein The trans-seal is biased towards the nozzle by gravity so that it contacts the nozzle as the inflatable web is fed through the system.

3. The system for inflating an inflatable web according to claim 1 , further comprising: A sealing system is configured to form a seal in the inflatable web across the port as the inflatable web is fed through the system for inflating an inflatable web.

4. The system for inflating an inflatable web according to claim 3, wherein: The sealing system is arranged relative to the nozzle such that the sealing system is configured to form a seal in the inflatable web across the port at a location above a top of the nozzle.

5. The system for inflating an inflatable web according to claim 3, further comprising: An engagement system is configured to maintain closed sides of the inflation passage between the outlet of the nozzle and the sealing system.

6. The system for inflating an inflatable web according to claim 5, wherein the joining system is configured to bring two sides of the inflation channel together near the bottom of the nozzle.

7. The system for inflating an inflatable web according to claim 1, wherein the nozzle comprises a portion extending from a support structure and a curved portion that curves in a downstream direction such that the outlet is oriented in the downstream direction.

8. A system for inflating an inflatable web according to claim 7, wherein the system is configured to hold the supply of inflatable web relative to the nozzle so that initial contact of the cross seal with the nozzle occurs in the curved portion of the nozzle.

9. The system for inflating an inflatable web according to claim 8, wherein the nozzle is configured such that after the trans-seal initially contacts the curved portion of the nozzle, the trans-seal rides along the top of the nozzle.

10. The system for inflating an inflatable web according to claim 1 , wherein the system is configured to hold the supply of inflatable web relative to the nozzle such that initial contact of the cross seal with the nozzle occurs on the inclined surface of the block.

11. The system for inflating an inflatable web according to claim 10, wherein: The nozzle is configured such that after the trans-seal initially contacts the inclined surface, the trans-seal rides along the top of the tube.

12. The system for inflating an inflatable web according to claim 1 , wherein the system further comprises: a main shaft configured to hold the supply of inflatable web; wherein the supply source is in the form of a roll of the inflatable web.

13. The system for inflating an inflatable web according to claim 12, wherein the major axis is arranged such that the major axis is at a non-straight angle relative to vertical.

14. The system for inflating an inflatable web according to claim 12, further comprising: a support positioned below the supply source, the support having a hub including a hole; wherein said spindle passes through said hole in said hub of said support; wherein the support is configured to rotate relative to the spindle; and wherein the support comprises a plurality of arms extending away from the hub such that the arms extend beyond an outer circumference of the roll of inflatable web.

15. The system for inflating an inflatable web according to claim 1, wherein a length of one of the transverse seals between two consecutive ports is smaller than a length of at least one of the two consecutive ports.

16. The system for inflating an inflatable web according to claim 1, wherein a length of one of the transverse seals between two consecutive ports is greater than a length of at least one of the two consecutive ports.

17. The system for inflating an inflatable web of claim 1 , further comprising: a guide member positioned such that the inflatable web passes around a portion of the guide member as the inflatable web is fed in the downstream direction; wherein the guide member is further configured to induce tension in at least a portion of the inflatable web downstream of the guide member; and wherein at least a portion of the inflatable web in which the guiding member induces tension comprises the inflation channel.

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