Inflating and sealing device with web control

Abstract

The present disclosure relates to a web control guide for an inflation and sealing assembly of a protective packaging forming apparatus for inflating a web of web material into a chain of inflated cushions. The web control guide is positioned along a material path at a lateral spacing from a first compression element and restricts a first thickness of the material path measured in a longitudinal direction and a lateral direction that are perpendicular to the material path. The lateral spacing and the restricted thickness dimension are small enough to prevent lateral movement of the flexible material toward the first compression element, thereby avoiding excessive heating of the web material outside of a sealing zone.

Description

TECHNICAL FIELD

[0001] The present invention relates to packaging materials. More particularly, the present invention relates to apparatus and methods for manufacturing inflatable cushions for use as packaging materials. BACKGROUND

[0002] A variety of inflatable cushions are well known and used in a variety of packaging applications. For example, inflatable cushions are commonly used as protective packaging in a manner similar to or in place of foam peanuts, crumpled paper, and the like. For another example, inflatable cushions are commonly used as protective packaging in place of molded or extruded packaging components. A typical inflatable cushion is formed from a film having two plies that are joined together by a seal. The seal can be formed simultaneously with inflation to capture air therein, or formed prior to inflation to define a film configuration having an inflatable chamber. The inflatable chamber can be inflated with air or another gas, and then sealed to inhibit or prevent release of the air or gas. SUMMARY

[0003] Embodiments of the present invention can include a protective packaging forming apparatus. A protective packaging forming apparatus is disclosed. The apparatus includes a drive that advances a web of flexible material along a material path extending in a longitudinal direction. An inflation nozzle directs fluid between overlapping plies of the flexible web in the material path for inflating an inflatable chamber defined between the plies with the fluid. The apparatus includes a heat sealer having opposing first and second compression elements that are compressed against each other to compress the overlapping plies together along the material path at a sealing zone. A heating element is configured to provide heat to the sealing zone. The compression elements and the heating element are arranged and configured to cooperatively generate sufficient compression and heat in the compressed overlapping plies in the sealing zone to heat seal the overlapping plies together to seal the inflated inflatable chamber closed and trap the fluid therein. A web control guide is positioned along the material path at a location laterally spaced from the first compression element and limits a first thickness of the material path measured perpendicular to the longitudinal and lateral directions of the material path. The limited thickness dimension is sufficiently small to prevent lateral movement of the flexible material toward the first compression element to avoid overheating of the web outside the sealing zone.

[0004] In some embodiments, the inflation assembly includes a web material guide that includes a first web guide portion that contacts a first surface of the web material and a second web guide portion that contacts a second surface of the web material opposite the first portion. The inflation nozzle is disposed between the web material guide portions and is operable to be received within an inflation passage formed between the plies and to flow fluid therefrom into the inflation passage to inflate the chamber. The web material guide portions contact the web material along the material path upstream of the sealing region and extend in the transverse direction of the web material sufficient to engage the inflated portion of the chamber to maintain alignment of the transverse axis of the web material with the axis of the sealing element and the axis of the opposing compression element that seals the overlapping plies together. BRIEF DESCRIPTION OF DRAWINGS

[0005] Figure 1 is a top view of a web material that is not inflated;

[0006] Figure 2 is an isometric view of an embodiment of an inflation and sealing apparatus of a roll of web material loaded with Figure 1

[0007] Figure 3 is an isometric view of the apparatus of Figure 2 with a cover installed;

[0008] Figure 4 is a front view of the apparatus of Figure 2 with the cover removed;

[0009] Figure 5 is a rear view of the apparatus of Figure 2 with the cover removed;

[0010] Figure 6 is a partial detail view of the apparatus of Figure 4 illustrating an embodiment of a heat sealer of the apparatus of Figure 2

[0011] Figure 7 is a partial isometric cutaway view of the heat sealer of the apparatus of Figure 2

[0012] Figure 8 is a cutaway view of the heat sealer of the apparatus of Figure 2 in an unengaged configuration;

[0013] Figure 9 is a cutaway view of the heat sealer of the apparatus of Figure 2 in an engaged configuration;

[0014] Figure 10 is a partial exploded view of a rotating sealing element of the apparatus of Figure 2

[0015] ​​​​Figure 11 yes Figure 2 A partial cross-sectional view of the clamping rollers of the inflation and sealing assembly of the device;

[0016] Figure 12 yes Figure 2 A partial front view of an embodiment of the inflation and sealing components of the device;

[0017] Figure 13 yes Figure 2 A simplified isometric view of a portion of the inflation and sealing assembly of the device; and

[0018] Figure 14 yes Figure 2 A simplified top sectional view of a portion of the inflation and sealing components of the device. Detailed Implementation

[0019] This invention relates to protective packaging and systems and methods for converting inflatable materials into inflatable cushions that can be used as packing and transporting goods for cushioning or protection.

[0020] like Figure 1 As shown, a multilayer flexible web material 100 for an inflatable pad 121 is provided. The web material extends in a longitudinal direction 109 and a transverse direction 111. The longitudinal direction 109 generally corresponds to the direction in which the web material 100 is fed along a path 115 through a forming or inflating device, or the direction in which the web material 100 travels as it is removed from or added to a mass-supply of material (such as a stack or roll). The transverse direction 111 is generally orthogonal to the longitudinal direction 109 and extends in a direction along the width W of the web material 100. The web material 100 includes a first film sheet 105 having a first longitudinal edge 102 and a second longitudinal edge 104, and a second film sheet 107 having a first longitudinal edge 106 and a second longitudinal edge 108. The second film sheet 107 is aligned to overlap with the first film sheet 105 and can generally extend co-linearly with the first film sheet 105, i.e., at least the corresponding first longitudinal edges 102, 106 are aligned with each other and / or the second longitudinal edges 104, 108 are aligned with each other. In some embodiments, the sheets may partially overlap with the inflatable region in the overlapping area. Thus, the web material 100 extends in the thickness direction 113 to extend beyond the page along the thickness of the sheets, such as... Figure 1 As shown. The thickness direction 113 is generally orthogonal to the longitudinal direction 109 and the transverse direction 111.

[0021] Figure 1A top view of the web material 100 is illustrated having a first ply 105 and a second ply 107 bonded to define a first longitudinal edge 110 and a second longitudinal edge 112 of the web material 100. The first ply 105 and the second ply 107 can be formed from a single sheet of flexible material, a flat tube of flexible material with one edge having a slit or being open, or two sheets of flexible material that can be sealed along the longitudinal edges 104, 108 to define the longitudinal edges 112 of the flexible structure 100. For example, the first ply 105 and the second ply 107 can include a single sheet of flexible material that is folded to define the bonded second longitudinal edges 104, 108 (e.g., a "c-folded film"). In a more particular example, the edges 104, 108 are at the c-fold in such an implementation. Alternatively, for example, the first ply 105 and the second ply 107 can include a tube of flexible material (e.g., a flat tube) that is slit along the aligned first longitudinal edges 102, 106. Further, for example, the first ply 105 and the second ply 107 can include two separate sheets of flexible material that are bonded, sealed, or otherwise attached together along the aligned second longitudinal edges 104, 108.

[0022] In some implementations, the thickness of the web plies 105, 107 is between about 0.5 and 4 mils. In some implementations, the web plies 105, 107 are at least about 1 mil thick. In some implementations, the thickness of the web plies 105, 107 can be between about 2 and 3 microns.

[0023] In some implementations, the web plies 105, 107 are made from a co-extruded material that includes nylon. For example, the web plies 105, 107 can be made from polyethylene and nylon. The material containing nylon acts as a fluid barrier and retains air or other desired fluids during the shipping and storage cycle of the shoe. Other suitable materials and structures can be used.

[0024] The multi-ply web 100 can be made from a single or multi-layer polymeric film material. Each ply can be made from a single or multi-layer film. The single layer film is typically made from polyethylene, although other suitable polymers can be used. One or more layers of the multi-layer film embodiments can include polymers of different compositions. In some embodiments, the disclosed layers can be selected from ethylene, amide, or vinyl polymers, copolymers, and combinations thereof. The disclosed polymers can be polar or non-polar. The disclosed ethylene polymers can be polyethylene in a substantially non-polar form. In many cases, the ethylene polymers can be polyolefins made from copolymerization of ethylene and another olefin monomer (e.g., an alpha-olefin). The ethylene polymers can be selected from low, medium, or high density polyethylene, or combinations thereof. In some cases, the various polyethylenes can differ in density, but in many cases, the low density polyethylene can have a density of, for example, about 0.905 or less to about 0.930 g / cm3, the medium density polyethylene can have a density of, for example, about 0.930 to about 0.940 g / cm3, and the high density polyethylene can be, for example, about 0.940 to about 0.965 g / cm3or higher. Various polyethylenes of other suitable densities can be used. The ethylene polymers can be selected from linear density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), and high density polyethylene (HDPE), and blends thereof; and metallocenes, for example, metallocene LLDPE (mLLDPE), or metallocene MDPE (mMDPE). Other suitable materials and structures can be used, such as, for example, heat sealable and inflatable materials. For example, composites of materials can be used. The disclosed web material 100 can be wound on a hollow tube, a solid core, or folded in a fan-folded box, or in another desired form for storage and transport. Other suitable web materials can be used, which preferably include a sealing layer to heat seal to another similar layer.

[0025] In some embodiments, the polar polymer can be a non-polar polyethylene that can be modified to impart polar characteristics. In other embodiments, the polar polymer is an ionomer (e.g., a copolymer of ethylene and methacrylic acid, E / MAA), an EVA copolymer with a high vinyl acetate content, or other polymers with polar characteristics. In one embodiment, the modified polyethylene can be an anhydride-modified polyethylene. In some embodiments, maleic anhydride is grafted onto an olefinic polymer or copolymer. The modified polyethylene polymer can readily react when co-extruded with polyamide and other ethylene-containing polymers (e.g., EVOH). In some cases, a layer or sublayer comprising the modified polyethylene can form covalent bonds, hydrogen bonds, and / or dipole-dipole interactions with other layers or sublayers (e.g., a sublayer or layer comprising a barrier layer). In many embodiments, the modification of the polyethylene polymer can increase the number of atoms on the polyethylene that can be used for bonding. For example, modifying polyethylene with maleic anhydride adds acetyl groups to the polyethylene, which can subsequently bond with polar groups of a barrier layer (e.g., hydrogen atoms on a nylon backbone). The modified polyethylene can also form bonds with other groups on the nylon backbone as well as polar groups of other barrier layers (e.g., alcohol groups on EVOH). In some embodiments, the modified polyethylene can form chain entanglements and / or van der Waals interactions with unmodified polyethylene.

[0026] The layers of the ply 105, 107 can be adhered or otherwise attached together, e.g., by a tie layer. In other embodiments, one or more of the ply 105, 107 is a single layer of material, e.g., a polyethylene layer.

[0027] Mixtures of ethylene and other molecules can also be used. For example, ethylene vinyl alcohol (EVOH) is a copolymer of ethylene and vinyl alcohol. EVOH has polar characteristics that can help form a gas barrier. EVOH can be prepared by polymerizing ethylene and vinyl acetate, and then hydrolyzing to obtain an ethylene-vinyl acetate (EVA) copolymer. EVOH can be obtained by saponification of an ethylene-vinyl acetate copolymer. The ethylene-vinyl acetate copolymer can be produced by known polymerization, such as solution polymerization, suspension polymerization, emulsion polymerization, etc., and the saponification of the ethylene-vinyl acetate copolymer can also be performed by known methods. Typically, EVA resins are produced via autoclave and tubular processes at high pressure.

[0028] Polyamides are high molecular weight polymers that have amide linkages along the molecular chain structure. Polyamides are a type of polar polymer. Nylon polyamides, which are synthetic polyamides, have good physical properties: high strength, stiffness, abrasion resistance, and chemical resistance, as well as low permeability to gases (e.g., oxygen).

[0029] As Figure 1As shown, the web material 100 can include a series of transverse seals 118 arranged along the longitudinal extent of the web material 100. Each transverse seal 118 extends from the longitudinal edge 112 toward the inflation passage 114. In the illustrated embodiment, the inflation passage 114 extends along the first longitudinal edge 110 opposite the second longitudinal edge 112, and thus the transverse seals 118 extend from the longitudinal edge 112 toward the first longitudinal edge 110. In some embodiments, the flexible structure 100 can include an inflation passage 114 located at other positions with respect to the longitudinal edges 112 and / or 110. For example, the inflation passage can extend along the length of the structure 100 at a position intermediate (e.g., halfway between) the longitudinal edges 112 and / or 110. In some embodiments, the flexible structure 100 can additionally or alternatively include an inflation passage 114 along the second longitudinal edge 112. In the illustrated embodiment, each transverse seal 118 has a first end 122 proximate the second longitudinal edge 112 and a second end 124 spaced a transverse width 103 from the first longitudinal edge 110 of the web material 100. An inflatable chamber 120 is defined within the bounds formed by the seal or fold at the longitudinal edge 112 and the pair of adjacent transverse seals 118. When the chamber is inflated, and the plies 105, 107 of the web material 100 are sealed together to form a continuous longitudinal seal 170 (shown as a dashed line in FIG. 1) at, for example, the seal closing the inlet passage 125, the web material forms an inflated cushion 121. The web material can be converted to have different sealing patterns between the first and second plies, for example, to provide different types of void-fill or protective packaging cushions. For example, in some embodiments, the inflatable chamber is provided without an internal seal. In some cases, the converted web material has a sealing pattern without an internal seal and with a large aspect ratio to provide a larger inflatable pillow. Figure 1

[0030] Figure 1 Each transverse seal 118 of the embodiments in FIG. 1 is substantially straight and extends substantially perpendicular to the second longitudinal edge 112 in the transverse direction 111. In other embodiments, other arrangements of the transverse seals 118 can be used. For example, in some embodiments, the transverse seals 118 can have a wavy or zigzag pattern.

[0031] The transverse seals 118, as well as the sealed longitudinal edges 110, 112, can be formed by any of a variety of techniques known to those of ordinary skill in the art. Such techniques include, but are not limited to, adhesion, friction, welding, fusion, heat sealing, laser sealing, and ultrasonic welding.

[0032] ​An inflatable region, such as an enclosed passageway, can be provided, which can be a longitudinal inflation channel 114. Alternatively, the inflatable region can be provided by open lateral edges, such as flaps held above the transverse nozzles to blow air between the plies 105, 107. As Figure 1 shown, the longitudinal inflation channel 114 is disposed between the second end 124 of the transverse seal 118 and the first longitudinal edge 110 of the web material. Preferably, the longitudinal inflation channel 114 extends longitudinally along the longitudinal edge 110, and is provided with an inflation outlet 116 opening at at least one end of the longitudinal inflation channel 114. The longitudinal inflation channel 114 has a transverse width 103 corresponding to the transverse width between the longitudinal edge 110 and the second end 124 of the transverse seal 118.

[0033] The longitudinal edge 112 and the transverse seal 118 collectively define the boundaries of the inflatable chambers 120. As Figure 1 shown, each inflatable chamber 120 is in fluid communication with the longitudinal inflation channel 114 via an inlet passage 125 defined between the interior seal 123 and the transverse seal 118, opening toward the longitudinal inflation channel 114, thus allowing the inflatable chamber 120 to inflate, as further described herein. The inlet passage 125 has a transverse width 119 defined between respective end portions 131, 133 of the interior seal 123. The interior seal 123 has transverse end portions 142, 144. The transverse end portion 144 is adjacent the inflation channel 114, and the transverse end portion 142 defines the beginning of a first chamber portion 130 located transversely of the inflation channel 114. The inlet passage 125 has a longitudinal length 135 defined between the edges of the transverse seal 118 and the adjacent interior seal 123. The pattern of seals in the web material 100 can vary. For example, the longitudinal distance between adjacent transverse seals 118 can be smaller or larger depending on the desired properties of the finished pad 121. Smaller spacing between the transverse seals 118 can result in a pad 121 that is thinner and more flexible. Greater spacing between the transverse seals can result in a pad 121 that is thicker and relatively less flexible, but can provide more cushioning. In some embodiments, the longitudinal spacing between the transverse seals 118 is as low as ¼ or ½ inch, or as high as 1 inch, 2 inches, or greater than 10 inches. Alternatively, other suitable spacings can be selected.

[0034] The web material 100 includes a portion 151 extending from the first longitudinal edge 110 to about the longitudinal seal 170. As described below, this portion 151 is received within an inflation side gap 211 in the inflation and seal apparatus 101 formed between the sealer guide member 228 and the compression element. The web material 100 includes a portion 153 within which the longitudinal seal 170 is formed. The web includes a portion 157 received between the sealer guide member 222 and a portion of the compression element 204. The portion 153 is received between the opposing compression elements 204 and 206 of the heat sealer 202. The web material 100 includes a portion 155 received within a guide gap 269 defined by opposing faces 265, 267 of guide portions 264 and 266 of the web material guide 261 to align and support the web material 100 as it is inflated. The guide portions 264, 266 oppose one another on opposite sides of the thickness of the web material 100. In this embodiment, the guide portions 264, 266 extend laterally past the end of the inlet passage 125. The portions 151, 153, 155 and 157 extend longitudinally down the web 100. The portion 155 is also received in a web control gap 201 defined between the compression element 204 and the web control guide 212 at different longitudinal positions in the inflation and seal apparatus 101 to prevent lateral movement of the web material 100 as it is sealed in the heat sealer 202, as described below. The inflation nozzle 240 inserted in the inflation passage 114 can also prevent lateral movement of the web material 100 as it is sealed.

[0035] In Figure 1In one embodiment, the flexible structure 100 includes internal seals 123, 128 formed in the interior portion of the inflatable chamber 120. The internal seals 123, 128 are longitudinally separated from the transverse seals 118. In other embodiments, the internal seals 128 may be adjacent to or connected to the corresponding transverse seals 118 and extend toward or into the corresponding inflatable chamber 120. The internal seals 128 vertically define a lower region of the inflatable chamber 120, corresponding to a smaller width or limitation in the chamber's width, forming a bendable region that can be aligned to form bendable lines, thereby increasing the flexibility of the web material 100, making it easier to bend or fold. This flexibility allows the web material 100 to wrap around objects of regular and irregular shapes. The internal seals 123, 128 cooperate with the transverse seals 118 to define an inflated chamber portion 130 within the inflatable chamber 120, whose inflation height is generally higher than the rest of the inflatable chamber 120. The chamber portion 130 is in fluid communication with the adjacent chamber portion 130 via the internal passage 140, and with the inflation passage 114 via the inlet passage 125. The internal seal portion 128 presses down the sheets 105, 107, lowering the height of the chamber portion 130 and forming a hinge to allow the inflation pad 121 to conform to an object. The internal seal portion 128 can have any shape (e.g., rectangular, circular, oval, or any other regular or irregular shape as shown) or size. According to some embodiments, the lateral seal portion 118 is continuous and not interrupted by the internal seal portion 128, etc.

[0036] exist Figure 1 In the illustrated embodiment, the web material 100 includes weakening portions 126 (e.g., weakening lines, such as perforated lines) disposed along a longitudinal extent of the web material 100 and extending laterally through the first and second sheets of the web material 100. Each weakening portion 126 extends from a second longitudinal edge 112 toward a first longitudinal edge 110, for example, partially or entirely along the length of the transverse seal 118. In the illustrated embodiment, the weakening portion 126 is longitudinally offset from an adjacent transverse seal by a longitudinal distance 117, with inflatable chambers 120 therebetween to form a plurality of inflatable pads 121 that can be separated along the weakening lines 126. In other embodiments, the weakening portion may extend through a portion of the transverse seal 118. In the illustrated embodiment, the weakening portion 126 is in the form of a transverse weakening line, and each transverse weakening line in the flexible structure 100 is arranged between a pair of adjacent inflatable chambers 120. For example, each weakening line 126 is arranged between two adjacent transverse seals 118 and between two adjacent inflatable chambers 120, such as... Figure 1The transverse lines of weakness 126 facilitate separation of adjacent inflatable cushions 121. In some embodiments, a thicker transverse seal 118 can be used that defines the transverse seal portion, and the lines of weakness 126 can be provided along at least a portion of the transverse seal portion of the flexible structure 100.

[0037] The lines of weakness 126 can be provided in a variety of configurations known to those of ordinary skill in the art. For example, in embodiments where the lines of weakness 126 are provided as transverse lines of weakness 126 including a plurality of rows of perforations, where a row of perforations includes alternating ridges and slits spaced along the transverse extent of the row. The ridges and slits can occur at regular or irregular intervals along the transverse extent of the row. The ridges form small connections across the line of weakness 126. Alternatively, in some embodiments, the lines of weakness 126 can include score lines or the like formed in the flexible structure 100. Figure 1

[0038] The transverse lines of weakness 126 can be formed by a variety of techniques known to those of ordinary skill in the art. Such techniques include, but are not limited to, cutting (e.g., techniques using cutting or toothed elements such as bars, blades, blocks, rollers, wheels, etc.) and / or scoring (e.g., techniques that reduce the strength or thickness of the material in the first and second ply sheets such as electromagnetic (e.g., laser) scoring and mechanical scoring).

[0039] Preferably, the transverse width 129 of the inflatable chambers 120 is typically less than 50 inches. In some embodiments, the transverse width 129 is more than 10 inches. In some embodiments, the transverse width 129 is more than 12 inches. In some embodiments, the transverse width 129 is less than 10 inches. In some embodiments, the transverse width 129 is less than 15 inches. In some embodiments, the transverse width 129 is less than 48 inches. In one embodiment, the transverse width 129 is about 17 inches. In some embodiments, the transverse width 129 is at least 3 inches. Other embodiments have different transverse widths as desired. In some embodiments, the longitudinal length 127 between lines of weakness 126 is less than about 48 inches. In some embodiments, the length 127 is at least about 2 inches. In some embodiments, the length 127 is more than 5 inches. In some embodiments, the length 127 is more than 6 inches. In some embodiments, the length 127 is more than 10 inches. In some embodiments, the length 127 is less than 30 inches. Further, the inflated height of the inflatable chambers 120 can be at least about 1 inch to about 3 inches, and in some cases up to about 6 inches. It will be appreciated that other suitable dimensions can be used.

[0040] Turning now to Figures 2-14 ​, an inflation and sealing apparatus 101 is provided for converting a flexible structure 100 of uninflated material into a series of inflated cushions 121. The flexible structure 100 of uninflated material can be a bulk supply of uninflated material 134. For example, as shown in Figure 2 Figure 3

[0041] Figure 3 An embodiment of the inflation and sealing apparatus 101 is shown. As shown in Figure 3 Figure 5 Figure 2 ​​​​The processing elements support and guide the inflatable material web 100. The processing elements can include a supply support element 136 that supports a supply 134 of the web 100 in an uninflated state. The inflation and sealing assembly 200 is operable to inflate the web 100 with a fluid by directing the fluid between the superimposed plies 105, 107 of the web 100 and to seal the plies 105, 107 together to seal the fluid therein. Two of the web support portions (e.g., the spool 136 and the guide member 138) are arranged relative to the support structure 141 and to each other such that the supply material 134 is subjected to different amounts of tension along the transverse direction 111 as it passes from the first web support portion to the second web support portion. The relative positions of the two web support portions result in a difference in tension in two portions of the web 100 disposed transversely to each other at substantially the same longitudinal location along the path. In further implementations of the present disclosure, the difference in tension can be achieved by providing the guide member 138 with one or more expansion elements as further described below. In some examples, the final shape of the guide member 138 can be configured to define a longitudinal travel distance between adjacent first and second web support portions at one transverse end of the web that is slightly shorter than a longitudinal travel distance between adjacent first and second web support portions at another (e.g., opposite) transverse location of the web, as will be further described.

[0042] Referring back to Figure 3 , the inflation and sealing device 101 can include a bulk material support 136. A bulk supply 134 of uninflated material is supported by the bulk material support 136. In some implementations, the bulk material support is provided as a tray that is operable to hold the uninflated supply 134, which can be provided by, for example, a fixed surface or a plurality of rollers. To hold the roll 134 of material, the tray can be recessed around the roll, or the tray can be convex with the roll 134 hanging above the tray. The bulk material support 136 can include a plurality of rollers that suspend the supply of web material 100. The bulk material support 136 can include a single roller that accommodates the center of the roll 134 of web material 100, for example, as shown in Figure 2 . In this example, the bulk support material is a spool 136 that passes through the core or center of the roll 134 of material 100. Typically, the core is made of paperboard or other suitable material. The bulk material support 136 rotates about an axis 149.

[0043] The web material 100 is pulled through the inflation and sealing device 101 by the driver 160. In some implementations, an intermediate member, such as a guide member 138 (e.g., which can include a stationary bar or roller), can be positioned between the supply 134 and the driver 160. For example, the optional guide member 138 can extend generally perpendicularly from the support structure 141. The guide member 138 can be positioned to direct the flexible structure 100 away from the roll 134 of material 100 and along a material path 115, also referred to as a longitudinal path, along which the material is processed. As shown, the guide member 138 is disposed between the material support 136, which supports the supply of material, and the inflation and sealing components of the inflation and sealing device 101. The guide member 138 can be arranged to direct the web material 100 from the supply toward the inflation and sealing assembly 200 such that the web material 100 follows a curved longitudinal path. The guide member 138 can include one or more surfaces that define a web support surface (e.g., a surface that extends along a side of the guide member around which the web 100 bends as it traverses the path 115). In some examples, and as further described below, the guide member 138 can include one or more inflatable elements. The one or more inflatable elements provide at least a portion of the web support surface of the guide member and can configure the guide member to provide variable tension on the web material 100 at different lateral positions of the web material 100. Figure 3

[0044] ​The guide member 138, or a portion thereof, can be movably coupled to the inflation and sealing device 101 such that the guide member 138, or a movable portion thereof, can move (e.g., rotate, translate, oscillate, etc.) with respect to the support structure 141 as the web material 100 is drawn from the roll 134 by the drive 160. In some examples, the guide member 138 includes a guide roll that includes a shaft or stem portion 137 and a rotatable or roll portion 139 coaxially coupled to the stem portion 137 such that the roll portion 139 rotates about a common axis 148 of the stem and roll portions. The roll portion 139 provides a web support surface 150 that supports the web material 100, in this case, the web support surface 150 moves with the web material 100 as it is drawn from the roll 134. The moving web support surface 150 can reduce or eliminate sliding friction between the guide member 138 and the web material 100. However, in other implementations, guide members having stationary web support surfaces 150 are also contemplated. For example, the guide member can include a stem similar to the shaft 137 without a rotatable portion 139. A low friction material, such as polytetrafluoroethylene (PTFE), can be provided on at least a portion of the web support surface 150 of the non-rotatable stem (e.g., adhered to the web support surface 150 in the form of a coating or strip of material) to reduce sliding friction. In still other implementations, the non-rotatable portion or stem and the rotatable portion (e.g., roll) of the guide member can not be coextensive. For example, only the rotating portion of the guide member 138 can be the inflation element 152. The web support surface of the guide member that does not rotate as the web travels over it can be coated or otherwise provided with a friction reducing material. In some implementations, the guide member 138 can additionally or alternatively be coupled to the inflation and sealing device 101 such that it moves in a direction perpendicular to the longitudinal path 115 of the supply material travel.

[0045] In the illustrated implementation, the guide member 138 according to the present disclosure includes one or more inflation elements 152, as will be further described below. In some implementations, the inflation elements 152 provide some or all of the web support surface 150 of the guide member 138. Thus, the guide member 138 according to the principles of the present disclosure can be configured to control the web material 100, such as to prevent or reduce sagging of the web material 100 between the roll 134 and the inflation nozzles 240 of the inflation and sealing device 101.

[0046] In various embodiments, the inventory material (e.g., web material 100) can travel downstream from a material supply (such as roll 134) without engaging a guide roller, but can travel directly into the inflation and sealing assembly 200. As used herein, the terms upstream and downstream are used with respect to the direction of travel of the web material 100. It will be appreciated that other suitable structures can be used in addition to or as an alternative to the use of brakes, guide rollers, or web feed mechanisms in order to direct the web material 100 toward the sealing zone 276, which can form a portion of the sealing assembly 200. The sealing zone 276 can be a nip at which the plies 105, 107 of the web material are pressed or compressed and simultaneously heated so that they fuse together. An inflation fluid can also be supplied in the sealing zone 276. As noted, because the web material 100 can sag, bunch, drift along the guide roller 138, move out of alignment with the sealing zone 276, alternate between being taut and slack, or have other variations in delivery, the inflation and sealing assembly 200 can need appropriate adjustability to compensate for these variations.

[0047] The web material 100 is advanced through the inflation and sealing assembly 200 by a driver 160. The inflation and sealing assembly 200 can incorporate the driver 160 or the two systems can operate independently. The driver 160 includes one or more devices operable to push the flexible structure 100 through the inflation and sealing device 101. In the illustrated embodiment, the driver 160 includes a backing element (such as a backing wheel 214) driven by a motor 154 via a belt 158 (see, e.g., FIGS. 1 and 2). In other embodiments, the driver 160 can include different rollers, wheels, or cylinders, or more than one different roller, wheel, or cylinder. In other embodiments, the backing element can be stationary. In some embodiments, the driver 160 can include a belt driver, where the belt contacts a portion of the web 100. In some embodiments, multiple belts can be used to push the web material 100 through the inflation and sealing device 101. In other embodiments, a belt pushes the web material 100 along the material path and one or more rollers follow, driven by the movement of the web material 100. In other embodiments, a combination of belts, rollers, or cylinders move the web material 100 along the material path 115 through the inflation and sealing device 101. In some embodiments, various belts, cylinders, or rollers can be driven by a single motor and connected with other belts, pulleys, or gears to transfer rotational motion throughout the connected drive. In other embodiments, the belts, cylinders, or rollers can be driven by separate motors or servos. Figure 4 、 5 ) In other embodiments, the driver 160 can include different rollers, wheels, or cylinders, or more than one different roller, wheel, or cylinder. In other embodiments, the backing element can be stationary. In some embodiments, the driver 160 can include a belt driver, where the belt contacts a portion of the web 100. In some embodiments, multiple belts can be used to push the web material 100 through the inflation and sealing device 101. In other embodiments, a belt pushes the web material 100 along the material path and one or more rollers follow, driven by the movement of the web material 100. In other embodiments, a combination of belts, rollers, or cylinders move the web material 100 along the material path 115 through the inflation and sealing device 101. In some embodiments, various belts, cylinders, or rollers can be driven by a single motor and connected with other belts, pulleys, or gears to transfer rotational motion throughout the connected drive. In other embodiments, the belts, cylinders, or rollers can be driven by separate motors or servos.

[0048] For example, in various embodiments, the driver includes one or more motorized rollers that are operable to drive the flexible material 100 in the downstream direction along the material path 115. The one or more rollers or drums can be connected to a drive motor 154 such that the one or more rollers are driven systems. This embodiment is beltless. According to various embodiments, the driver 160 drives the web material 100 without a belt contacting the flexible structure. In another example, the system has a belt that does not contact the web material 100 but rather drives the rollers. In another example, the system has a belt on some of the driving elements but not on others. In another example, the system can have a belt interleaved across the entire roll, allowing the material to be driven through the system by the belt.

[0049] The inflation and sealing device 101 includes an inflation and sealing assembly 200. Preferably, the inflation and sealing assembly 200 is configured for continuous inflation of the web material 100 as it is unwound from the roll 134. The roll 134 preferably includes a plurality of inflatable chambers 120 arranged in series (e.g., in a chain). To begin manufacturing the inflated cushion 121 from the web material 100, the inflation outlet 116 of the web material 100 is inserted into the inflation assembly, such as an elongated guide 240, which is inserted into the inflation channel 114 for guiding the web material through the inflation and sealing device 101. The lateral width of the inflation channel 114 can be selected to fit appropriately close around the nozzle for sliding over the nozzle 240 and allowing fluid to flow into the inflatable chambers 120. In this embodiment, the elongated guide is also the inflation nozzle 240 and travels along the material path 115. The nozzle 240 has an elongated portion including one or more of a nozzle base 244, a flexible portion 242a, and / or a tip 242. The elongated portion can help guide the flexible structure 100 to the sealing zone 276. At the same time, the nozzle 240 can inflate the flexible structure through one or more fluid outlets 246a,b. In this embodiment, the fluid outlets 246a,b are openings in the nozzle 240. The one or more outlets 246a,b exit the inflation channel from one or more of the nozzle base 244, the flexible portion 242a, or the tip 242. The tip 242 includes a terminal portion 243, which can be used as a guide to initiate guiding the nozzle 240 into the inflation channel 114. The terminal portion 243 is a hemispherical plug in the illustrated embodiment, but other shapes are contemplated. In the embodiment shown in the figures, preferably, the web material 100 travels over the inflation nozzle 240 with the inflatable chambers 120 extending laterally relative to the inflation nozzle 240 and the side outlets 246a,b (in the direction of the arrow 250). In other embodiments, the web material 100 can travel alongside the inflation nozzle 240 with the inflatable chambers 120 extending laterally relative to the inflation nozzle 240 and the side outlets 246a,b (in the direction of the arrow 250). In other embodiments, the web material 100 can travel over the inflation nozzle 240 with the inflatable chambers 120 extending longitudinally relative to the inflation nozzle 240 and the side outlets 246a,b (in the direction of the arrow 250). In other embodiments, the web material 100 can travel alongside the inflation nozzle 240 with the inflatable chambers 120 extending longitudinally relative to the inflation nozzle 240 and the side outlets 246a,b (in the direction of the arrow 250). Figure 4 、 6(see FIGS. 12 and 13). The side outlets 246a, b direct fluid into the inflatable chambers 120 in a transverse direction relative to the nozzle base 244 to inflate the inflatable chambers 120 as the web material 100 travels in the longitudinal direction along the material path 115. In other embodiments, the outlets 246a, b direct fluid in other directions relative to the nozzle base 244. The inflation nozzle 240 inserts fluid, such as pressurized air, through the nozzle outlet into the uninflated web material 100 to inflate the material into the inflatable pads 121. The inflation nozzle 240 can include a nozzle inflation channel that fluidly connects a source of fluid entering at a fluid inlet with the nozzle outlet (e.g., the side outlets 246a, b). It can be appreciated that in other configurations, the fluid can be other suitable pressurized gas, foam, or liquid. The inflated web material 100 is then sealed by the sealing assembly 200 in the sealing zone 276 to form a chain of inflatable pads 121. Typically, the nozzle has an outer diameter of about ¼ to ½ inch. In this embodiment, the nozzle has an outer diameter of about 3 / 16 inch. Alternatively, other suitable nozzle diameters can be selected.

[0050] The side inflation zone 168 Figure 2 is shown as a portion of the inflation and sealing assembly along the path 115 adjacent the side outlets 246a, b in which fluid from the side outlets 246a, b can inflate the inflatable chambers 120. In some embodiments, the inflation zone 168 is a region disposed between the nozzle tip 242 and the sealing zone 276. The web material 100 is inserted around the inflation nozzle 240 at the nozzle tip 242 disposed at the forward-most end of the inflation nozzle 240.

[0051] The inflation nozzle 240 can be at least partially flexible. As Figure 3 shown, the inflation nozzle 240 includes a tip 242 having a flexible portion 242a that allows the nozzle 240 to accommodate the direction of the web material 100 as the structure is fed toward and over the nozzle 240, thereby making the nozzle 240 operable to compensate for or accommodate changes in the angle of feed, direction, and other changes encountered by the web material 100 as it is fed toward and over the nozzle 240. In some examples, as noted above, the guide rollers 138 can be moved laterally relative to the sealing assembly 200, such as to adjust or eliminate any variations in the delivery of the supply material.

[0052] As Figure 4 , 6-9 and 12-13, the side outlets 246a,b can extend longitudinally along the nozzle base 244 from the nozzle tip 242 for a longitudinal distance. In various embodiments, the side outlets 246a,b originate proximate to, or in some configurations overlap with, the sealer assembly, such that the side outlets 246a,b continue to inflate the inflatable chambers 120 approximately up to the time of sealing. This can maximize the amount of fluid inserted into the inflatable chambers 120 prior to sealing, and minimize the amount of dead chambers (i.e., chambers that do not have a sufficient amount of fluid). Although in other embodiments, the outlets 246a,b can extend downstream past the entrance to the sealing zone 276. The starting point of the web is upstream and it flows downstream as the web is inflated, sealed, cooled, and removed from the inflation and sealing apparatus 101.

[0053] The length of the side outlet 246a can be a slot having a length that extends a portion of the inflation nozzle 240 between the tip 242 and the sealing zone 276. In one example, the slot length can be less than half the distance from the tip 242 to the sealing zone 276. In another example, the slot length can be greater than half the distance from the tip 242 to the sealing zone 276. In another example, the slot length can be about half the distance from the tip 242 to the sealing zone 276. For example, the length of the side outlet 246a can be at least about 30% of the length of the inflation nozzle 240, and in some embodiments at least about 50% of the length of the inflation nozzle 240, or about 80% of the length of the inflation nozzle 240, although other relative dimensions can be used. The side outlets 246a,b expel fluid in a lateral direction relative to the inflation nozzle 240 from the lateral sides of the nozzle base 244 through the inlet passage 125 of each inflatable chamber 120 to inflate the inflatable chamber 120. The tip 242 of the inflation nozzle 240 can be used to pry apart and separate the plies 105, 107 in the inflation passage 114 as the material is forced across the tip 242. In some embodiments, in addition to or in the absence of lateral outlets such as the side outlets 246a,b, longitudinal outlets can be provided, which can be downstream of the lateral outlets and along the longitudinal sides of the nozzle wall of the nozzle base 244 of the inflation nozzle 240.

[0054] Fluid (such as air) can be supplied to the inflation and sealing device 101 via an external device (such as an air compressor, blower, indoor air system, foam system, etc.). In the illustrated embodiment, fluid is supplied to the inflation and sealing device 101 via a fluid connector 172. The fluid is then directed to nozzle 240 via an internal conduit (such as a pipe or conduit) (not shown). The fluid flow rate is typically about 2 to 20 cubic feet per minute (CFM). However, higher flow rates can be used; for example, when using a higher flow rate fluid source, the flow rate can exceed 100 cfm. In other embodiments, the inflation and sealing device 101 may include an internal fluid source, such as a blower or compressor.

[0055] While various examples are described herein and illustrated in the accompanying drawings, it should be understood that these examples are not intended to be limiting, and that the nozzle 240 and the inflation assembly can be configured according to any known implementation or an implementation developed based on the disclosure herein that can be applied by one of ordinary skill in the art based on and benefited from.

[0056] like Figure 3 , 4 As shown in 6, 12-14, the inflation and sealing device 101 includes a web material guide 261 with a pair of guide portions 264, 266 that extend in the longitudinal direction 109 of the material path 115 and are longitudinally positioned relative to the web control guide 212 (discussed below). The guide portions 264, 266 orient the web material 100 in the material path 115 to the lateral dimension of the web material 100 as it passes through the inflation nozzle 240. The guide portions 264, 266 orient the inlet channel 125 with respect to the outlets 246a, b of the nozzle 240. The guide portions 264, 266 extend laterally 271 from the support structure 141 (see...). Figure 14 This allows the inflatable portion of the web material 100 to engage during inflation before the web material 100 is sealed. As shown, guide portions 264, 266 extend vertically from the support structure 141, although in other embodiments, the guide portions may extend from the support structure at a non-vertical angle. The web material 100 passes between guide portions 264, 266 as it moves through the inflation and sealing device 101 in its longitudinal direction 109.

[0057] The guide portions 264, 266 include front ramps 273, 275. The front ramps 273, 275 are angled relative to each other, tapering in the longitudinal direction 109, such that the distance therebetween narrows as the web material 100 initially enters between the guide portions 264, 266 and subsequently passes therefrom in the longitudinal direction 109. The web material guide 261 includes an exit ramp 279 that ramps away from the web material 100 as the web material 100 exits between the guide portions 264, 266. The guide portions 264, 266 include transverse ramps 281, 283. The transverse ramps 281, 283 are angled relative to each other, tapering in the transverse direction 111, such that the guide gap 269 narrows or widens relative to the transverse portions of the web material 100. The transverse ramps 281, 283 thereby form a longitudinal slot 282 that receives a portion of the web material 100. In this embodiment, as shown, the chamber portion 130 closest to the inflation passage 114 is received between the ramps 281, 283 to orient the web material 100 relative to the exit 246a in the nozzle 240 and the sealing assembly 200. The various ramps 273, 275, 281, 283 can help initially thread the web material 100 through the inflation and sealing device 101. The ramps can help begin the alignment of the web material at the start of inflation, gradually guiding the material 100 into alignment to facilitate sealing of the plies 105, 107 and transport through the inflation and sealing device 101. Figure 14

[0058] In the illustrated embodiment, the nozzle 240 is positioned between the guide portions 264, 266. The opposing faces 265, 267 are equidistant from the centerline of the nozzle 240. In other embodiments, the centerline of the nozzle 240 can be closer to one of the opposing faces 265, 267 and further from the other of the opposing faces 265, 267, such that the nozzle is off-center relative to the web material 100 in the thickness direction.

[0059] As the web material 100 is inflated through the nozzle 240, the plies 105, 107 press against the respective opposing faces 265, 267. The opposing faces 265, 267 and / or the ramps apply a reaction force to the inflated portions of the web material 100, thereby maintaining the transverse axis of the web material 100 in alignment with the transverse axis of the components of the sealing assembly 200.

[0060] The guide portions 264, 266 align the web material 100 as it is inflated and sealed. The guide portions 264, 266 have respective opposing faces 265, 267 that are spaced apart from each other by the guide gap 269 to limit the thickness of the material path 115. In this embodiment, the guide gap 269 is greater than the height of the inlet passage 125 of the inflation, as shown in FIG. 3. Figure 14 ​embodiments, the guide gap 269 is less than the height of the inflated inlet passage 125 (when the passage 125 is not restricted). In other embodiments, the guide gap 269 is the same size as the height of the inflated inlet passage 125. The guide gap 269 can be selected based on the properties of the web material 100. For example, the longitudinal distance between the transverse seal portions 118 can affect the height or thickness dimension of the inflated chamber 120, the chamber portion 130, and / or the inlet passage 125. A relatively wide longitudinal spacing between the transverse seal portions 118 can result in a relatively thick inflated pad 121 in the thickness direction 113. Likewise, a closer longitudinal spacing between the transverse seal portions 118 results in a thinner inflated pad in the thickness direction 113. Likewise, the height of the inflation passage 114 during inflation can be affected by the lateral width of the inflation passage from the longitudinal edge 110 to the edge of the interior seal portion 123. The guide gap 269 can be selected accordingly to accommodate thicker or thinner pads 121 based on the longitudinal spacing between the transverse seal portions 118. In this embodiment, the guide gap 269 is less than the outer diameter of the nozzle 240. In this embodiment, the guide gap is greater than the height of the inflated inlet passage 125, but small enough that the inlet passage 125 is aligned with the outlet 246a and directs the remainder of the web material 100 when pressurized. As shown in FIG. 6, the opposing faces 265, 267 extend laterally from the outer surface of the nozzle 240 at the opening 246a by a guide gap width 227 to the narrowest portion of the longitudinal slot 282 formed by the lateral ramps 281, 283, and by a distance 229 to the widest portion of the longitudinal slot 282. In this embodiment, the guide gap width 227 and the distance 229 are such that the lateral edge 142 of the interior seal portion 123 is located at approximately the same lateral position as the narrowest portion of the slot 282. Thus, the chamber portion 130 of the inflation passage 114 that is laterally closest to the inlet passage 125 is received in the longitudinal slot 282, which directs the web material as it travels in the slot 282. In this embodiment, the ratio of the guide gap width 227 to the guide gap 269 is about 10: 1. In other embodiments, the ratio is at least 5: 1, 8: 1, or most preferably 9: 1-11: 1. In some embodiments, the ratio can be as high as about 15: 1. Other suitable ratios can be selected based on the seal pattern in the web material 100. In this embodiment, the guide gap 269 is about 1 / 4 inch. In other embodiments, the guide gap 269 can be at least 1 / 8, 1 / 2, or 1 inch or more. Other suitable guide gaps can be selected to suit the web material 100 being used. The guide gap 269, the guide gap width 227, the dimensions of the longitudinal slot 282, and the ratios between them can be selected to allow the web material 100 to pass through the web material guide 261 without bunching, tangling, wrinkling, kinking, wrapping, or burning. Figure 14 Likewise, a closer longitudinal spacing between the transverse seal portions 118 results in a thinner inflated pad in the thickness direction 113. Likewise, the height of the inflation passage 114 during inflation can be affected by the lateral width of the inflation passage from the longitudinal edge 110 to the edge of the interior seal portion 123. The guide gap 269 can be selected accordingly to accommodate thicker or thinner pads 121 based on the longitudinal spacing between the transverse seal portions 118. In this embodiment, the guide gap 269 is less than the outer diameter of the nozzle 240. In this embodiment, the guide gap is greater than the height of the inflated inlet passage 125, but small enough that the inlet passage 125 is aligned with the outlet 246a and directs the remainder of the web material 100 when pressurized. As shown in FIG. 6, the opposing faces 265, 267 extend laterally from the outer surface of the nozzle 240 at the opening 246a by a guide gap width 227 to the narrowest portion of the longitudinal slot 282 formed by the lateral ramps 281, 283, and by a distance 229 to the widest portion of the longitudinal slot 282. In this embodiment, the guide gap width 227 and the distance 229 are such that the lateral edge 142 of the interior seal portion 123 is located at approximately the same lateral position as the narrowest portion of the slot 282. Thus, the chamber portion 130 of the inflation passage 114 that is laterally closest to the inlet passage 125 is received in the longitudinal slot 282, which directs the web material as it travels in the slot 282. In this embodiment, the ratio of the guide gap width 227 to the guide gap 269 is about 10: 1. In other embodiments, the ratio is at least 5: 1, 8: 1, or most preferably 9: 1-11: 1. In some embodiments, the ratio can be as high as about 15: 1. Other suitable ratios can be selected based on the seal pattern in the web material 100. In this embodiment, the guide gap 269 is about 1 / 4 inch. In other embodiments, the guide gap 269 can be at least 1 / 8, 1 / 2, or 1 inch or more. Other suitable guide gaps can be selected to suit the web material 100 being used. The guide gap 269, the guide gap width 227, the dimensions of the longitudinal slot 282, and the ratios between them can be selected to allow the web material 100 to pass through the web material guide 261 without bunching, tangling, wrinkling, kinking, wrapping, or burning.

[0061] In this embodiment, the opposing faces 265, 267 are substantially flat and smooth. The opposing faces 265, 267 are preferably parallel to each other or at a slight angle and positioned and spaced apart sufficient to orient the lateral axis of the path 115 as desired. In some embodiments, the guider gap 269 is curved in conjunction with the curved path required in this area.

[0062] After the web material passes between the guider portions 264, 266, it enters the sealing assembly 200, where the webs 105, 107 are sealed to form a continuous longitudinal seal 170 to trap the fluid and form the pad 121. Preferably, the web material 100 is continuously advanced along the material path 115 through the sealing assembly and past the heat sealer 202 at the sealing zone 276 to form the continuous longitudinal seal 170 along the web material 100 by sealing the first and second webs 105, 107 together. Preferably, the longitudinal seal 170 is disposed a lateral distance from the first longitudinal edge 102, 106, and most preferably, the longitudinal seal 170 is disposed along the inlet 125 of each inflatable chamber 120.

[0063] The inflation and sealing assembly 200 includes a heat sealer 202 to form the longitudinal seal 170 in the web material 100 in the sealing zone 276 to trap the fluid between the webs 105, 107 and thus form the pad 121. The heat sealer 202 includes opposing compression elements 204, 206 that compress against each other to compress the overlapping webs 105, 107 together in the sealing zone 276. The heat sealer 202 includes a heating element 270 that provides heat energy to the sealing zone 276. The opposing compression elements 204, 206 and the heating element 270 cooperate to create sufficient compression and heat in the compressed overlapping webs 105, 107 in the sealing zone 276 to heat seal the overlapping webs 105, 107 together to seal the inflated inflatable chamber 120 closed and trap the fluid. Other suitable sealers can be used, such as ultrasonic welders or adhesive sealers.

[0064] In the illustrated embodiment, the compression element 206 is provided as a rotating sealing element 216. The rotating sealing element 216 is positioned such that the compression element 206 contacts one side of the web material 100 (e.g., one of the webs 105, 107) and is opposite the compression element 204 that contacts the opposite side of the web material 100 (e.g., the other of the webs 105, 107) in the sealing zone 276 to form the longitudinal seal 170 to trap the inflation gas in the inflatable chamber 120. Figures 7-9 is a cross-sectional view showing the rotating sealing element 216 having opposing narrow protrusions of the compression element 206 formed around its circumference. In this embodiment, the rotating sealing element 216 is provided as a rotating drum having a plurality of narrow protrusions 218 formed around its circumference.Figure 7 In particular, the rotating sealing element 216 is shown partially retracted from the compression element 204 relative to the sealing position, for example as shown in Figure 9 Certain components of the inflation and sealing device 101 are visible behind the web material 100. The transverse walls 207, 209 extend inwardly from the ledge toward the axis of rotation of the sealing element 216. The right-hand portion of the web material 100, as shown in Figures 8-9 The right-hand portion of the web material 100, as shown in

[0065] As shown, the heating element 270 is a plug or cartridge heater that is electrically powered. The heating element 270 can be electrically heated, for example, by providing an electrical resistance that converts electrical energy into heat energy. The heating element 270 can be powered by direct current or alternating current, which can be a single or three phase power supply. The heat generated in the heating element conducts heat from the heating element 270 to the rotating sealing element 216 and to the compression element 206, and can be conducted through convection.

[0066] The heating element 270 can be any material or design suitable for sealing the adjacent plies 105, 107 together. In various embodiments, the heating element 270 can be a wire or foil. The wire or foil can be formed of nickel-chromium alloy, iron-chromium-aluminum, cupronickel, or other metals suitable for forming and operating the heating element under conditions for sealing plies of flexible material together, allowing the heating element 270 to fuse, meld, join, bond, or unite the two plies 105, 107 together. In some embodiments, the heating element 270 is formed of about 80% nickel and 20% soft annealed chromium. In other embodiments, the heating element 270 can be a thin film heating element. The thin film heating element 270 can be formed of barium titanate and lead titanate composites or other materials suitable for forming and operating the heating element under conditions that allow the heating element 270 to obtain sufficient heat to seal the plies together.

[0067] In the illustrated embodiment, the sealing element 216 is mounted such that its axis is fixed relative to the support structure 141. In other embodiments, it can be mounted such that it can be moved toward and away from the compression element 204 manually or with mechanical assistance.

[0068] It may be necessary to retract the sealing element 216 away from the web material 100, for example, when the operation of the inflation and sealing device 101 is interrupted, to prevent the web material 100 from burning. Figure 5 As shown, the position of the sealing element 216 can be adjusted to increase or decrease the pressure between the compression elements 206 and 204. For example, the actuator 230 actuates the cam 231 via belt 156. The cam follower 232 straddles the cam 231 to displace the sealing element 216, thereby compressing or decompressing the spring 233 to generate more or less sealing force between the compression elements 204 and 206, respectively. For example, the sealing pressure can be adjusted to accommodate web materials 100 of different thicknesses, materials, or number of layers.

[0069] In the illustrated embodiment, the sealing element 216 is idle, for example, rotated by the movement of the web material 100 pressed against the sealing element 216. In other embodiments, instead of an idle sealing element 216, a motor may be provided for coordinating the rotation of the sealing element 216 with other drive mechanisms.

[0070] Figure 10 An exploded view of the sealing element in the inflation and sealing device 101 is shown. A high-temperature bearing or bushing 262 is fitted into the sealing element 216. The sealing element 216 is held by a retainer 272 (such as a washer), which is held in place by fasteners 274 (such as screws, rivets, bolts, etc.). In some embodiments, the sealing element 216 may be made of a metal (such as aluminum, steel, brass, bronze) or other suitable material. Thus, the sealing element 216 may have a significant thermal mass. For example, the sealing element 216 may have sufficient thermal mass to maintain a sufficiently consistent temperature to continuously seal the sheets 105, 107 as they travel through the sealing zone 276. The bushing 262 is positioned above a shaft 263, which includes an opening suitable for receiving a heating element 270. A temperature sensor 268 (such as a thermistor or thermocouple) is provided to sense and allow control of the temperature of the heat sealer 202. The temperature of the heat sealer 202 can be controlled at approximately 100-450°C, preferably 260-310°C, or more preferably 280-290°C. According to various embodiments, the heat sealer 202 is heated to a temperature as high as approximately 150°C to 250°C. In some embodiments, the heat sealer 202 reaches approximately 200°C. The peripheral portion of the heat sealer 202 can reach a lower temperature between approximately 50°C and 100°C.

[0071] like Figures 7-9 As shown, the compression element 204 is disposed on the backing roller 214. The compression element 204 is an elastic member extending circumferentially around the backing roller 214. The backing roller 214 is driven by a motor 154, as shown... Figure 4 andFigure 5 As depicted in the illustration. In other embodiments, the backing wheel may idle and be driven by a drive wheel that frictionally engages with the compression element 204. The compression element 204 includes a crown portion 208 to assist in holding the web material 100 flat in the sealing zone 276 as the web material 100 is fed through the inflation and sealing assembly 200. The crown portion 208 has a raised rectangular profile extending circumferentially from the shoulder portion 210 of the compression element 204. In other embodiments, the crown portion may have other profiles, such as protruding or recessed profiles. The radius of the crown portion 208 is greater than the radius of the shoulder portion 210. In the illustrated embodiment, the compression element 204 includes two shoulder portions 210, with the crown portion 208 laterally disposed between the two shoulder portions 210. In other embodiments, the compression element 204 may have one shoulder portion 210, or may have a flat cross-section such that it does not have a shoulder portion 210 or a crown portion 208.

[0072] Compression element 204 is typically made of an elastic material (e.g., natural rubber or synthetic rubber such as silicone rubber). The elastic surface partially conforms to compression element 206, which improves the sealing quality and increases the seal residence time. Figure 9 As shown, when compression elements 204 and 206 engage and press against each other, compression element 206 is pressed into crown portion 208, deforming it into a recessed profile that matches the protruding profile of compression element 206. Non-limiting examples of compression element 206 include rollers, plates, wheels, boxes, and other surfaces made of metal or other rigid materials. Backing wheel 214 may have an elastic material applied to one or more of its surfaces to serve as compression element 204. For example, compression element 204 can be formed by vulcanizing a rubber layer (e.g., 1 / 4 inch thick) onto an aluminum or steel wheel or other backing element. Alternatively, compression element 204 may be pre-configured as an elastic strip and stretched on a backing element. The thickness of compression element 204 is typically in the range of about 1 / 8 to about 1 / 4 inch. The elastic material should be selected such that the web material 100 does not excessively adhere to compression element 204. Furthermore, the elastic material should be selected such that it does not degrade under heat. Suitable elastic materials typically have a Shore A hardness of about 20 to about 95, usually about 45 to about 75, and more often about 50 to about 70. For example, silicone rubber with a hardness of 60 can be used.

[0073] In other embodiments, the compression element 204 may be a stationary element that does not rotate. The surface of such a compression element 204 may be curved along the material path 115. The apex of the curve may be located approximately at the center of the backing element 214, for example, where the sealing element 216 contacts the web material 100. The curved surface of the backing element 214 effectively lengthens the path of the web material 100, which helps compensate for dimensional changes in the web material 100 during its processing. In particular, the length of the web material 100 decreases slightly when the inflatable chamber 120 is inflated (due to the expansion of the web material 100 in the thickness direction). However, the edge portions of the web material 100 sealed by the heat sealer 202 are not inflated, and therefore the length of the edge portions does not decrease when the inflatable chamber 120 is inflated. As a result, the edge portions of the web material 100 tend to converge when the inflatable chamber 120 is inflated (e.g., in an "accordion-like" manner). The curved surface of the backing element 214 increases the length of the material path 115, which helps to keep the web material 100 flat as it is fed through the inflation and sealing assembly 200.

[0074] like Figures 6-9 As shown, the seal guide member 222 is disposed adjacent to the backing wheel 214. The seal guide member 222 has a guide body 234. The guide body 234 has an inlet portion 235 and an outlet portion 237. The inlet portion 235 has an inlet guide surface 223 spaced from a portion of the compression member 204 to define an inlet gap 213. The outlet portion 237 has an outlet guide surface 225 spaced from a portion of the compression member 204 to define an outlet gap 215. In this embodiment, the inlet guide surface 223 defines the inlet gap 213 between the shoulder portion 210 of the compression element 204 and the seal guide member 222 upstream of the sealing region 276. In this embodiment, the outlet guide surface 225 defines the outlet gap 215 between the shoulder portion 210 of the compression element 204 and the seal guide member 222 downstream of the sealing region 276. The outlet guide surface 225 and the outlet gap 215 may be disposed similarly to the inlet guide surface 223 and the inlet gap 213. The inlet shoulder portion 236 provides a smooth transition from the inlet guide surface 223 to the rest of the guide body 234. The outlet shoulder portion 238 provides a smooth transition from the outlet guide surface 225 to the rest of the guide body 234. The sealer guide member 222 receives the web material 100 as it exits the web material guide 261 and holds the web material 100 against the compression member 204. The sealer guide member 222 and the compression member 204 cooperate to force a bend in the material path 115 so that the backing roller 214 can drive the web material 100 along the material path 115.

[0075] like Figure 6As shown, as the web material 100 passes from the web material guide 261 and into the inlet gap 213, the web 100 begins to bend laterally over the crown portion 208 of the compression element 204, creating tension in the web material 100 to align it for sealing. The inlet guide face 223 holds the web material 100 against the compression element 204 to provide control and traction of the web material 100. In this embodiment, the inlet guide face begins to bend the web material 100 around the compression element 204 upstream of the sealing zone 276. In this embodiment, the inlet gap 213 and the outlet gap 215 are less than the height 219 of the radial wall 221 of the crown portion 208 defined between the shoulder portion 210 and the crown portion 208 of the compression element 204. In this embodiment, the inlet gap 213 is sized to push the web material 100 against the crown portion 208 and / or the shoulder portion 210. In other words, the inlet guide face 223 is at a lower height than the crown portion 208, and the crown portion 208 and the inlet guide face 223 preferably cooperate to push the inlet passage 125 against the crown portion 208, causing the web material 100 to bend laterally around the crown portion 208. Preferably, the height of the inlet guide face 223 above the shoulder portion 210 is at most the height of the crown portion 208 plus the height of the inflated inlet passage 125. A lower inlet guide face 223 height relative to the crown portion 208 results in a more acute lateral bend of the web material 100. The bend increases friction and creates tightness in the area of the web material leading to the sealing zone 276. In some embodiments, the inlet guide face 223 is at a height relative to the compression element 204 that does not result in a lateral bend of the web material 100.

[0076] In other embodiments, the inlet gap 213 and / or the outlet gap 215 can be the same as the height 219. In other embodiments, the inlet gap 213 can be greater than the height 219. In this embodiment, the inlet gap 213 is wider than the height of the inflated inlet passage 125, such that the inflation chamber 120 can still receive pressure from the outlet 246a,b. In other embodiments, the inlet gap 213 and the outlet gap 215 can be the same size as the height of the inflated inlet passage 125. In other embodiments, the inlet gap 213 can be less than the height of the inlet passage 125, such that the gap limits the height of the inlet passage 125 and further presses the inflated web material against the compression element 204. In embodiments where the height of the inlet passage 125 is less than the inlet gap 213, the inlet passage 125 can still receive pressure from the outlet 246a,

[0077] Transitions from the inlet gap 213 and the outlet gap 215 to the web control surface 220 are provided by an inlet ramp 224 and an outlet ramp 226, respectively. The inlet ramp 224 is disposed upstream of the point of contact between the compression elements 204, 206 to align and confine the web material 100. The inlet ramp narrows the inlet gap 213 to a distance less than the height of the crown portion 208 above the shoulder portion 210. In this embodiment, the portions of the inlet ramp 224 and the outlet ramp 226 and the gap between the shoulder portion 210 of the compression element 204 are less than the height of the inflated inlet channel 125, but do not completely collapse the inlet channel 125 so that the inflated inlet channel 125 can still receive pressure from the outlets 246a, b. In other embodiments, the inlet ramp 224 and the outlet ramp 226 can narrow the inlet gap 213 and the outlet gap 215 to a distance greater than the height of the inflated inlet channel 125.

[0078] In this embodiment, the guide body 234 includes a web control guide 212 positioned longitudinally between an inlet portion 235 and an outlet portion 237. The web control guide 212 extends from the sealer guide member 222 in the thickness direction 113. The sealer guide member 222 receives the web 100 and establishes the material path 115 in the sealing zone 276. In this embodiment, the sealer guide member 222 is configured as a static slide. In other embodiments, the sealer guide member 222 and / or the web control guide 212 can be provided as a rotating or moving element, such as a wheel or belt. In other embodiments, the web control guide 212 can be located in the inlet portion 235, the outlet portion 237, or both, and between the two. In other embodiments, the web control guide 212 can be included in a sealer guide member 228 located opposite the sealer guide member 222 in the sealing zone 276 and can be provided in a similar manner to the web control guide 212 included in the sealer guide member 222.

[0079] The web control guide 212 has a web control surface 220 that is spaced from the compression member 204 to define a web control gap 201. The web control guide 212 is positioned along the material path 115 so that the web control gap 201 confines the material path 115 to the sealing zone 276 and bends the web material 100 in the lateral direction along the path 115. In this embodiment, the web control gap 201 is wider than the overlapping plies 105, 107 of the web 100, thus leaving the inlet channel 125 slightly open to the sealing zone 276. In other embodiments, the web control gap can be small enough to close the inlet channel 125 from the sealing zone 276 and completely collapse the inlet channel 125 from the sealing zone 276.

[0080] In this embodiment, the web control gap 201 has a lateral gap portion 205 that extends between the shoulder portion 210 of the compression element 204 and the web control guide 212. The web control gap 201 has a radial gap portion 203 between the sealer guide member 222 and the radial wall 221 of the crown portion 208 of the compression element 204. Thus, the web control gap in this embodiment causes lateral bending in the web material 100. In other embodiments, the web control gap 201 can be straight with respect to any lateral, longitudinal, or thickness direction of the material 100. In some embodiments, the web control gap 201 can be curved about one or more axes, or can have a tapered or wavy profile. The lateral gap portion 205 and the radial gap portion 203 are named with respect to the structure of the sealing assembly 200 for clarity. Both the lateral gap portion 205 and the radial gap portion 203 limit the thickness of the material path 115 in the lateral direction of the web material 100. The web control gap 201 is smaller than the plenum height of the inlet channel 125.

[0081] The web control gap 201, including the lateral gap portion 205 and the radial gap portion 203, aligns and restricts the web material 100 from lateral movement toward the compression element 206 to avoid over-heating of the web 100 outside of the sealing zone 276. The web control gap 201, the lateral gap portion 205, and the radial gap portion 203 can induce tension in the web material 100, pulling it straight and flat, and are small enough to prevent such lateral movement of the web material 100. For example, the pressurized fluid within the plenum 120 can tend to push the plies 105, 107 of the web material 100 toward the heat sealer 202, causing the material to bunch up and burn near the heat sealer. In addition, the compression elements 204 and 206 can stretch the web material 100, pulling it into the heat sealer 202. The radial gap portion 203 and the first lateral gap portion 205 are also small enough to limit the fluid within the plenum 120 from entering the sealing zone 276. For example, as the web 100 moves through the guide portions 264, 266, the plenum 120 is inflated with pressurized fluid from the nozzle 240 via the outlets 246a, b.

[0082] Figure 9An inflated web 100 is shown joined in a sealing zone 276. The inlet passage 125 is confined in the radial gap portion 203 and the lateral gap portion 205. The chamber portions 130 are shown in fluid communication with one another via the intra-chamber passage 140. The lateral seal 118 is shown defining the longitudinal edges of the inflatable chamber 120. The radial gap portion 203 and the lateral gap portion 205 confine the thickness of the material path 115 in the thickness direction 113. In this embodiment, the lateral gap portion 205 confines the first thickness of the material path 115 in the thickness direction 113 and aligns the thickness direction of the web material 100 with the respective axis of the compression elements 204 and 206. For example, in this embodiment, the lateral gap portion 205 aligns the web material 100 with an axis parallel to the axis of rotation of the backing wheel 214. Likewise, the lateral gap portion 205 aligns the web material 100 with an axis parallel to the axis of rotation of the rotating seal element 216. In this embodiment, the radial gap portion 203 constrains the thickness direction of the material path 115 and aligns the web material 100 with an axis perpendicular to the axis of rotation of the backing wheel 214 and / or the rotating seal element 216. The radial gap portion 203 can also align the web material 100 parallel to the lateral walls 207, 209 of the rotating seal element 216.

[0083] In some embodiments, pressurized fluid tends to escape from the inflatable chamber 120 toward the lower pressure, back pressure at the compression elements 204, 206 as the plies 105, 107 are sealed together. This back pressure can result in poor seal quality, seal porosity, weak or incomplete seals, and increased power consumption in the heating element 270 due to unnecessarily cooling from back blow action. The radial gap portion 203 and the lateral gap portion 205 confine the expansion of the inlet passage 125 after inflation to prevent or reduce back pressure during the sealing process.

[0084] As Figures 6-9As shown, in the preferred embodiment, the web control gap 201, the radial gap portion 203, and the lateral gap portion 205 defined by the shoulder portion 210 and the web control surface 220 are between about 5 and 25 mils (thousandths of an inch) in the preferred embodiment. In some embodiments, the web control gap is at least 2.5 to 50 mils, typically 5 to 15 mils or 5 to 25 mils. In other embodiments, the radial gap portion 203 and the lateral gap portion 205 can be less than 1 mil. In other embodiments, the radial gap portion 203 and the lateral gap portion 205 can be as large as 60 mils or 100 mils. In some embodiments, the lateral gap portion 205 and / or the radial gap portion 203 can be selected based on the thickness, number of plies, or type of web material 100 being fed into the inflation and sealing device 101. For example, if each of the plies 105, 107 is 1 mil thick, the web material 100 will be about 2 mils thick. If it is desired that the lateral gap portion 205 have a total clearance of 2 mils over the thickness of the web 100, the lateral gap portion 205 can be about 4 mils. Thus, the web control guide 212 does not compress the web 100, but rather prevents the web 100 from moving laterally into the heat sealer 200. The radial gap portion 203 and the lateral gap portion 205 can be the same as each other or they can be different. Likewise, in embodiments having more than one web control guide, each web control guide can provide different radial gap portions 203 and lateral gap portions 205 as desired.

[0085] The first lateral gap portion 205 is generally less than the guide gap 269 between the opposing faces 265, 267 of the guide portions 264, 266. In the embodiment shown, the web control guide 212 is downstream of the guide portions 264, 266. In other embodiments, the web control guide 212 is upstream of the guide portions 264, 266.

[0086] In other embodiments, the web control guide 212 can be spaced a radial or lateral gap 203, 205 from the compression element 206 rather than from the compression element 204. In other embodiments, more than one web control guide can be provided along the material path 115, for example, at other points where it is desired to align the web material 100 or prevent blowback.

[0087] The web control guide 212 and the sealer guide members 222, 228 can be made of a suitable material, such as aluminum, aluminum coated with hard anodizing, hardened tool steel, or an insert in aluminum or some other material. The web control guide 212 and the sealer guide members 222, 228 can be made of carbon-filled nylon or molded plastic such as PEEK. The web control guide 212 and the sealer guide members 222, 228 can be coated with a low-friction, high-temperature coating such as PTFE to reduce the wrapping, bunching, or gathering of the web material 100 in the radial gap portion 203 and the lateral gap portion 205.

[0088] In the illustrated embodiment, the second sealer guide member 228 is disposed laterally to a side of the compression element 206 opposite the sealer guide member 222. In the illustrated embodiment, the second sealer guide member 228 does not include a web control guide 212. The second sealer guide member 228 defines an inflation side gap 211 with respect to one of the shoulder portions 210. A portion 151 of the web material 100 (see Figure 1 ) is received in the inflation side gap 211. In other embodiments, a web control guide 212 can be disposed on the sealer guide member 228. In some embodiments, a web control guide 212 can be disposed on one or both of the sealer guide members 222, 228. In some embodiments, as illustrated, a web control guide 212 can be disposed above the web material 100 in addition to or instead of below the web material 100.

[0089] The sealer guide members 222, 228 are positioned along a portion of the backing element 214 near the sealing element 216. In this embodiment, the sealer guide members 222, 228 are positioned near the rotating sealing element 216 along a portion of the circumference of the backing wheel 214, as Figures 6-9 illustrated. In some embodiments, the longitudinal length of the web control guide is a significant portion of the length of one of the compression elements 204, 206. The sealer guide members 222, 228 have an arcuate shape that follows the circumference of the wheel 214 in some portions. As Figures 7-9 illustrated, the sealer guide members 222, 228, along with the crown portion 208 of the compression element 204, present the web material 100 to the sealing element 216 in a smooth, flattened state without wrinkling the web material 100, thereby reliably forming the longitudinal seal 170 to trap inflation gas within the inflatable chamber 120. In other embodiments, the sealer guide members 222, 228 follow the shape of the compression element 204.

[0090] As Figure 4 , 6As shown in Figure 11, a downstream seal trimmer (such as a clamping roller 218) defines a portion of the material path 115 downstream of the sealing zone 276. The clamping roller 218 is mounted on a shaft 217 extending from the support structure 141. After the web 100 contacts the heat sealer 202, the clamping roller 218 engages the shoulder portion 210 of the compression member 204 and stretches the material around the crown portion 208, compressing and stretching the web material 100 therebetween. When the web material 100 contacts the clamping roller 218, the material may still be at least partially melted or softened from the heat sealer 202. The clamping roller 218 can thus further solidify the longitudinal seal 170 and level the web material 100. The clamping roller 218 can also cool the web material as it is compressed to strengthen and complete the formation of the seal 170. The clamping roller 218 may have a profile adapted to mate with the compression member 204.

[0091] The inflation and sealing device 101 includes a cutting assembly 250 for cutting the web material 100. The cutting assembly 250 includes a cutter 252 positioned to cut the inflation channel 114 from the nozzle 240. The cutter 252 may include a stationary or rotating cutting element. The cutter 252 may be sharp, typically by slicing; abrasive, by abrasion; or other suitable cutting mechanisms.

[0092] like Figure 13 As shown, in this embodiment, the cutter 252 is a blade with a sharp cutting edge 253, which is sharp enough to cut the web material 100 as it is pulled along the material path 115 past the cutting edge 253. In this embodiment, the cutting assembly 250 is positioned to cut the web 100 at a lateral location between the first longitudinal edge 110 of the inflatable chamber 120 and the inlet channel 125; however, in alternative embodiments, other locations may be used, such as around the inflation nozzle. The cutter 252 cuts the web material 100 to open the inflation channel 114 of the web material 100 and allow the web to exit the inflation nozzle 240. In various embodiments, the inflation channel 114 of the flexible structure 100 may be located at the center of the web 100 or elsewhere, and the configuration of the inflation, sealing, and cutting mechanisms changes accordingly.

[0093] The cutter 252 cuts the web material 100 at cutting position 251, where the cutting edge 253 is adjacent to the outside of the nozzle 240. At cutting position 251, the cutting edge 253 faces upstream and cuts the web material 100 as it moves along path 115 past cutting position 251, allowing the inflation channel 114 to disengage from the nozzle 240. Figures 7-9As shown in FIGS. 13 and 14, the cutter 252 projects into the interior of the nozzle 240 via a cutter-receiving aperture 257 formed in the nozzle 240. As shown, the cutter-receiving aperture 257 can be provided as a cutter-receiving slot.

[0094] As shown in FIGS. 13 and 14, the cutter 252 projects into the interior of the nozzle 240 via a cutter-receiving aperture 257 formed in the nozzle 240. As shown, the cutter-receiving aperture 257 can be provided as a cutter-receiving slot. Figure 9 In this embodiment, the cutting location 251 is at a common station that is transverse to the seal assembly 200. The seal zone 276 in this embodiment longitudinally overlaps the longitudinal location of the cutting location 251. In other embodiments, the cutting location 251 is downstream of the seal zone 276. In other embodiments, the cutting location 251 can be slightly ahead of the seal zone 276, preferably near the longitudinal start of the seal location, to minimize pressure loss from the inflatable chamber.

[0095] In this embodiment, the pressure-maintenance outlet 246b is provided as an opening in the nozzle that longitudinally overlaps the cutting location 251. The pressure-maintenance outlet 246b is also preferably longitudinally overlapping the seal zone 276. In other embodiments, the longitudinal locations of the pressure-maintenance outlet 246b and the cutting location 251 are downstream of the seal zone 276.

[0096] The cutting location 251 is at an angular location about the longitudinal axis 241 of the nozzle and relative to the material path 115. The pressure-maintenance outlet 246b is preferably aimed transverse to the web 100 and path 115 to direct the flow direction 260 of the flow transversely into the inlet passage 125 of the web 100 and, in this embodiment, transverse to the seal zone 276. This directs the flow from the pressure-maintenance outlet 246b directly at the inlet passage 125 to help maintain the pressure in the inlet passage 125 and directly counteract any fluid escaping from the pressurized inflatable chamber. This angular location can vary, and in some embodiments, the flow direction 260 of the pressure-maintenance outlet 246b can be at an angle of up to 45° to the transverse direction 111 of the web material 100, although other suitable angles are contemplated. In other embodiments, the circumferential width of the pressure-maintenance outlet 246b can be such that a portion of the opening of the pressure-maintenance outlet 246b is transverse at the inlet passage 125 and a portion is in another direction, such as in the thickness direction of the path or web. In such embodiments, for example, a portion of the flow can be diverted from the transverse direction, but preferably some portion of the flow is in the transverse direction to the inlet passage 125.

[0097] The cutting location 251 preferably angles the cutting location displacement angle 259 out of the pressure-maintenance outlet 246b from the fluid flow direction 260. As shown in FIGS. 13 and 14, the cutting location displacement angle 259 is preferably at least 10°, and more preferably at least 20°, and even more preferably at least 30°, and even more preferably at least 45°, and even more preferably at least 60°, and even more preferably at least 75°, and even more preferably at least 90°, and even more preferably at least 105°, and even more preferably at least 120°, and even more preferably at least 135°, and even more preferably at least 150°, and even more preferably at least 165°, and even more preferably at least 180°, and even more preferably at least 195°, and even more preferably at least 210°, and even more preferably at least 225°, and even more preferably at least 240°, and even more preferably at least 255°, and even more preferably at least 270°, and even more preferably at least 285°, and even more preferably at least 300°, and even more preferably at least 315°, and even more preferably at least 330°, and even more preferably at least 345°, and even more preferably at least 360°. Figure 9In the illustrated embodiment, the cut location displacement angle 259 is about 90°. In various embodiments, the cut location displacement angle 259 is at least 30°, but is preferably 80°, or about 90° or greater. In some embodiments, the cut location is on a lateral side of the nozzle opposite the pressure maintenance outlet 246b. The pressure maintenance outlet 246b in the illustrated embodiment is a different opening than the cutter receiving aperture, and the cut location displacement angle 259 is sufficient to prevent or minimize fluid from the pressure maintenance aperture from escaping directly from the opening cut into the web by the cutter, and to maximize the re-pressurization effect of the fluid from the pressure maintenance aperture in the inlet channel.

[0098] In some embodiments, upon completion, the fluid pressure in the inflatable chamber 120 is above atmospheric pressure, typically in the range of 2-3 psig. Although in some embodiments, the pressure can range from less than 1 psig to as high as 5 or 10 psig, or more. In other embodiments, the inflatable chamber 120 is filled to separate and inflate the ply, but is not pressurized above atmospheric pressure. Other pressure ranges can be used for other resulting inflated protective packages.

[0099] As the web material 100 passes through the cut location 251 and the inflation channel 114 is cut, a leak is formed in the web material 100. It has been found that the overlapping longitudinal position of the cut location and the pressure maintenance outlet 246b, and the orientation of the transverse flow direction 260 relative to the cut location 251 (i.e., the cut location displacement angle 259) helps to increase the pressurization of the inflatable chamber 120, as the flow from the pressure maintenance outlet 246b resists pressure decay in the inflatable chamber 120 as the inflation channel 114 is cut. The overlap of the cut location 251, the seal zone 276, and the pressure maintenance outlet 246b resists pressure decay as the longitudinal seal 170 is formed and the inflatable chamber 120 is sealed. In some embodiments, it has been found that the pressure increase within the finished pad 121 is significant, on the order of 1 psig during testing when the inflatable chamber is inflated to about 3 psig. In some embodiments, the pressure increase has been found to be about 30% as compared to a cut location 251 positioned spaced from the nozzle outlet.

[0100] The cutting assembly 250 includes a carriage 254 that allows the cutter 252 to be aligned and changed as needed. The cutting assembly includes a positioning element 256, and a magnet 258 (hidden behind the cutter 252 in Figure 13 The positioning element 256, magnet 258, and carriage 254 provide precise alignment of the cutter 252. This precise alignment can allow the use of a more durable, but brittle (and thus more susceptible to damage from misalignment) hardened cutter 252 (e.g., made of hardened tool steel or tungsten carbide, etc.).

[0101] Any and all references specifically identified in the specification of the present application are expressly incorporated herein by reference in their entirety. As used herein, the term“about” shall generally be construed to refer to the corresponding numbered and ranged numerals. Additionally, all numerical ranges herein should be interpreted as including each and every integer within the range, except where otherwise indicated.

[0102] Having described several embodiments, it will be recognized by those of skill that various modifications, alternative constructions, and equivalents can be used without departing from the spirit of the current disclosure. The various examples and embodiments can be employed alone or in combination with one another and matched in any iteration to form alternatives. Additionally, numerous well-known processes and elements have not been described in order to avoid unnecessarily obscuring the present disclosure. Accordingly, the above description should not be taken as limiting the scope of the present application. Those of skill will understand that the presently disclosed embodiments are taught as examples and not limitations. The contents of the above description and the drawings herein are to be construed as illustrative and not restrictive. The appended claims are intended to cover all generic and specific features of the present method and system described herein, and all statements of the scope of the present method and system, as language that can be construed as falling under the two.

Claims

1. A protective packaging forming apparatus, comprising: A driver is configured to propel a flexible material web along a material path extending in the longitudinal direction during operation. An inflation nozzle is configured to direct fluid between overlapping layers of web material in the material path during operation to inflate an inflatable chamber defined between the layers with the fluid. Heat sealer, heat sealer includes: The first and second compression elements are opposite each other and are configured to compress the overlapping sheets together at the sealing area along the material path during operation. A heating element is configured to provide heat to the sealing area during operation, wherein a first compression element, a second compression element, and a heating element are arranged and configured to collaboratively generate sufficient compression and heat in the compressed overlapping layers in the sealing area during operation to thermally seal the overlapping layers together, thereby sealing and closing the inflatable chamber and trapping fluid in the inflatable chamber. A seal guide member, comprising a web control guide positioned along the material path at a lateral distance from the first compression element, and configured to limit a first thickness of the material path measured perpendicular to both the longitudinal and lateral directions of the material path during operation, wherein the limited thickness is small enough to prevent lateral movement of the web material toward the first compression element, thereby avoiding overheating of the web outside the sealing area; and A web material guide that extends in the longitudinal direction of the material path and is longitudinally positioned relative to a web control guide is configured to limit a second thickness of the material path during operation, such that the second thickness is greater than the first thickness.

2. The protective packaging forming apparatus according to claim 1, wherein, The web material guide is located upstream of the web control guide.

3. The protective packaging forming apparatus according to claim 1, wherein, The web material guide is located downstream of the web control guide.

4. The protective packaging forming apparatus according to claim 1, wherein, The first compression element is wider than the second compression element in the lateral direction, and the web control guide is disposed opposite to the first compression element to limit the first thickness between the web control guide and the first compression element.

5. The protective packaging forming apparatus according to claim 1, wherein, The transition between the web control guide and the seal guide is provided by a ramp.

6. The protective packaging forming apparatus according to claim 1, wherein, The first thickness is between 5 mils and 25 mils.

7. The protective packaging forming apparatus according to claim 1, wherein, The web control guide is also configured to bend the flexible material web in the lateral direction along the material path during operation.

8. The protective packaging forming apparatus according to claim 1, wherein, The restricted thickness dimension is small enough to prevent the flexible material from moving laterally toward the first compression element, thereby avoiding overheating of the web outside the sealing area.

9. A protective packaging forming apparatus, comprising: A driver is configured to propel a flexible material web along a material path extending in the longitudinal direction during operation. An inflation nozzle is configured to direct fluid between overlapping layers of web material in the material path during operation to inflate an inflatable chamber defined between the layers with the fluid. Heat sealer, heat sealer includes: The first and second compression elements are opposite each other and are configured to compress the overlapping sheets together at the sealing area along the material path during operation. A heating element is configured to provide heat to the sealing area during operation, wherein a first compression element, a second compression element, and a heating element are arranged and configured to collaboratively generate sufficient compression and heat in the compressed overlapping layers in the sealing area during operation to thermally seal the overlapping layers together, thereby sealing and closing the inflatable chamber and trapping fluid in the inflatable chamber. A web control guide is positioned along the material path at a lateral distance from the first compression element and is configured to limit a first thickness of the material path measured perpendicular to both the longitudinal and lateral directions during operation. The limited thickness is small enough to prevent lateral movement of the web material toward the first compression element, thereby avoiding overheating of the web outside the sealing area. The second compression element is a heating block, which includes a heating protruding circumferential portion, a heating transverse wall extending from the heating protruding circumferential portion, and a restricted thickness dimension that allows the web material to contact the protruding circumferential portion while preventing contact with the heating transverse wall.

10. A protective packaging forming apparatus, comprising: A driver is configured to propel a flexible material web along a material path extending in the longitudinal direction during operation. An inflation nozzle is configured to direct fluid between overlapping layers of web material in the material path during operation to inflate an inflatable chamber defined between the layers with the fluid. Heat sealer, heat sealer includes: The first and second compression elements are opposite each other and are configured to compress the overlapping sheets together at the sealing area along the material path during operation. A heating element is configured to provide heat to the sealing area during operation, wherein a first compression element, a second compression element, and a heating element are arranged and configured to collaboratively generate sufficient compression and heat in the compressed overlapping layers in the sealing area during operation to thermally seal the overlapping layers together, thereby sealing and closing the inflatable chamber and trapping fluid in the inflatable chamber. A web control guide is positioned along the material path at a lateral distance from the first compression element and is configured to limit a first thickness of the material path measured perpendicular to the longitudinal and lateral directions of the material path during operation, wherein the limited thickness dimension is small enough to prevent the web material from moving laterally toward the first compression element, thereby avoiding overheating of the web outside the sealing area; and wherein the second compression element is a heating wheel, and the web control guide bends to follow the curve of the heating wheel.

11. The protective packaging forming apparatus according to claim 10, wherein, The first compression element is operatively connected to the backing element.

12. The protective packaging forming apparatus according to claim 11, wherein, The backing element is a backing roller, and the backing roller is positioned such that the first compression element contacts the second compression element, clamping the web material between the first compression element and the second compression element.

13. The protective packaging forming apparatus according to claim 12, wherein, One of the backing rollers or heating rollers is driven by a motor to pull the web material through the device.

14. A system comprising: Protective packaging forming apparatus according to claim 1; and A web material supply source is loaded into the device. The web material includes overlapping sheets, an inflatable chamber is defined between the overlapping sheets, and the sheets define the web thickness, wherein a first thickness is greater than the web thickness.

15. The system according to claim 14, wherein, The first thickness is chosen such that the inflatable chamber causes the sheet to expand to contact the relative boundary of the restricted first thickness.

16. A protective packaging forming apparatus, comprising: A driver is configured to propel a flexible material web along a material path extending in the longitudinal direction during operation. An inflation nozzle is configured to direct fluid between overlapping layers of web material in the material path during operation to inflate an inflatable chamber defined between the layers with the fluid. Heat sealer, heat sealer includes: The first and second compression elements are opposite each other and are configured to compress the overlapping sheets together at the sealing area along the material path during operation. A heating element is configured to provide heat to the sealing area during operation, wherein a first compression element, a second compression element, and a heating element are arranged and configured to collaboratively generate sufficient compression and heat in the compressed overlapping layers in the sealing area during operation to thermally seal the overlapping layers together, thereby sealing and closing the inflatable chamber and trapping fluid in the inflatable chamber. A web control guide is positioned along a material path at a lateral distance from a first compression element and is configured to limit a first thickness of the material path measured perpendicular to both the longitudinal and lateral directions of the material path during operation, wherein the limited thickness dimension is small enough to prevent lateral movement of the web material toward the first compression element, thereby avoiding overheating of the web outside the sealing area; and wherein the web control guide includes a web control surface spaced from the first compression element to define a web control gap having a limited thickness dimension.

17. The protective packaging forming apparatus according to claim 16, wherein, The web control gap has a radial gap portion and a transverse gap portion.

18. The protective packaging forming apparatus according to claim 17, wherein, The radial and lateral clearance portions are small enough to limit fluid from entering the inflatable chamber into the sealed area.

19. The protective packaging forming apparatus of claim 17, further comprising a sealer guide member, wherein: The web control guide extends from the sealer guide member along the first thickness direction; The first compression element has a shoulder portion and a crown portion including radial walls; The lateral clearance portion is defined by the web control guide and the shoulder portion of the first compression element; and The radial clearance portion is defined by the radial walls of the seal guide member and the crown portion.

20. The protective packaging forming apparatus according to claim 18, further comprising a backing wheel, wherein: The first compression element is mounted on the backing roller; The lateral gap portion is configured to align the flexible material web with the axis of rotation parallel to the axis of rotation of the backing wheel and with the axis of rotation parallel to the axis of rotation of the second compression element during operation. and The radial clearance portion is configured to align the flexible material web with an axis perpendicular to the axis of rotation of the backing wheel and / or the second compression element during operation, and to align the web material parallel to the transverse wall of the second compression element.

21. The protective packaging forming apparatus according to claim 17, wherein, The radial clearance portion and the transverse clearance portion are also configured to restrict the expansion of the inlet passage to the inflatable chamber during operation after the inflatable chamber is inflated, in order to prevent or reduce back pressure during the sealing of the inflatable chamber.

22. A method for forming a protective packaging forming apparatus, comprising: Provide drive; A actuator is used to move the flexible material web along a material path that extends in the longitudinal direction; Provide inflation nozzles; Using an inflation nozzle, fluid is directed between overlapping layers of web material in the material path to inflate the inflatable chambers defined between the layers. A heat sealer is provided, comprising: a first compression element and a second compression element that are mutually compressed; and a heating element; Using a heat sealer: compresses the overlapping sheets together along the material path at the sealing area; provides heat to the sealing area; and generates sufficient compression and heat in the compressed overlapping sheets in the sealing area to heat seal the overlapping sheets together, thereby sealing the inflatable chamber and trapping fluid in the inflatable chamber. Provides a web control guide positioned along the material path at a lateral distance from a first compression element, the web control guide including a web control surface spaced from the first compression element to define a web control gap; and The web control surface of the web control guide restricts the thickness of the material path measured in the longitudinal and transverse directions perpendicular to the material path, wherein the web control gap has a restricted thickness dimension that is small enough to prevent the web material from moving laterally toward the first compression element, thereby avoiding overheating of the web outside the sealing area.

23. A protective packaging forming apparatus, comprising: A driver is configured to propel a flexible material web along a material path extending in the longitudinal direction during operation. and An inflation assembly configured to direct fluid between overlapping layers of a web during operation to inflate inflatable chambers between the layers, the inflation assembly comprising: A web material guide, comprising: a first guide portion configured to contact a first surface of a web material during operation; and a second guide portion configured to contact a second surface of the web material during operation. An inflation nozzle is disposed between the guide portions and configured to be received during operation in an inflation channel formed between the overlapping sheets, and configured to allow fluid to flow from it into the inflation channel to inflate the inflatable chamber. The first and second guide portions are configured to contact the web material upstream of the sealing area along the material path during operation and to extend sufficiently in the transverse direction of the web material to engage the inflatable portion of the inflatable chamber, thereby maintaining alignment of the transverse axis of the web material with the axis of the sealing element and the axis of the opposing compression element, which seals the overlapping sheets together.

24. The protective packaging forming apparatus according to claim 23, wherein, The first guide section and the second guide section are configured to orient the inflation channel of the inflatable chamber toward the outlet of the inflation nozzle.

25. The protective packaging forming apparatus according to claim 23, wherein, The first guide portion and the second guide portion each include a front ramp, wherein the front ramps are inclined relative to each other and taper in the longitudinal direction, such that the distance between the front ramps gradually narrows as the web material passes through the first guide portion and the second guide portion in the longitudinal direction during operation.

26. The protective packaging forming apparatus according to claim 23, wherein, The first guide section and the second guide section each include a transverse ramp, wherein the transverse ramps are inclined relative to each other and gradually narrow in the transverse direction, such that the guide gap gradually narrows or widens relative to the transverse portion of the web material.

27. The protective packaging forming apparatus according to claim 26, wherein, The transverse slope forms a longitudinal groove, which is configured to receive a portion of the web material during operation.

28. The protective packaging forming apparatus according to claim 25, wherein, The first guide portion and the second guide portion are configured such that, during operation, when the web material is inflated by the inflation nozzle, the overlapping sheets press against the corresponding opposing surfaces of the first guide portion and the second guide portion; and the corresponding opposing surfaces, the front bevel, and / or the corresponding transverse bevel are configured to apply a reaction force to the inflated portion of the web material during operation, thereby keeping the transverse axis of the web material aligned with the axis of the sealing element and the axis of the opposing compression element.

29. The protective packaging forming apparatus according to claim 28, wherein, The corresponding opposing surfaces of the first guide portion and the second guide portion, as well as the transverse ramp, are configured such that the internal sealing portion of the web material is located at a transverse position approximately corresponding to the narrowest portion of the longitudinal groove, which is configured to receive a portion of the web material during operation.

30. The protective packaging forming apparatus according to claim 23, wherein, The first guide section and the second guide section each include their respective opposing surfaces, which are spaced apart from each other by a first distance to limit the thickness of the material path.

31. The protective packaging forming apparatus according to claim 30, wherein, The first distance is selected based on the longitudinal distance between the transverse sealing parts in the web material.

32. The protective packaging forming apparatus according to claim 30, wherein, The first distance is selected based on the lateral width of the air channel between the longitudinal edge and the internal seal of the web material.

33. The protective packaging forming apparatus according to claim 23, further comprising: Heat sealer, heat sealer includes: The opposing first and second compression elements compress each other to compress the overlapping sheets together at the sealing area along the material path, and A heating element, configured to provide heat to the sealed area during operation, and a compression element and a heating element are arranged and configured to cooperate in generating sufficient compression and heat within the compressed overlapping layers in the sealed area to thermally seal the overlapping layers together, thereby sealing and closing the inflatable chamber and trapping fluid within the inflatable chamber; and A web control guide is positioned along the material path at a lateral interval from the first compression element and is configured to limit a first thickness of the material path measured perpendicular to the longitudinal and lateral directions of the material path during operation, wherein the limited thickness dimension is small enough to prevent the flexible material from moving laterally toward the first compression element, thereby avoiding overheating of the web outside the sealing area.

34. A method for forming a protective packaging forming apparatus, comprising: A driver is provided, which is configured to travel a flexible material web along a material path extending in the longitudinal direction during operation; and An inflation assembly is provided, configured to direct fluid between overlapping layers of web material during operation to inflate inflatable chambers between the layers, the inflation assembly comprising: Web material guide, the web material guide includes: a first guide portion that contacts a first surface of the web material, and a second guide portion that contacts a second surface of the web material, and An inflation nozzle, disposed between the guide portions, is configured to be received during operation within an inflation channel formed between the overlapping layers, allowing fluid to flow from it into the inflation channel to inflate the inflatable chamber. Using the first guide section and the second guide section, the inflatable section of the inflatable chamber is engaged to keep the transverse axis of the web material aligned with the axis of the sealing element and the axis of the opposing compression element, which seals the overlapping sheets together.

35. A protective packaging forming apparatus, comprising: A driver, configured to propel a flexible material web along a material path extending in the longitudinal direction during operation, the flexible material including air channels; An inflation nozzle is received in an inflation channel. The inflation nozzle includes a pressure sustaining outlet configured to guide fluid between overlapping layers of flexible material in the material path during operation, thereby inflating an inflatable chamber defined between the layers. A sealer configured to seal overlapping sheets together in a sealing area during operation; and A cutter, located adjacent to the inflation nozzle at the cutting position and configured to cut open the inflation channel during operation, wherein: The pressure maintains the longitudinal overlap between the outlet and the cutting position; and The pressure maintains the outlet orientation in the outlet direction, and the cutting position is set at an angle of at least 30 degrees to the outlet direction around the longitudinal axis of the inflation nozzle.

36. The protective packaging forming apparatus according to claim 35, wherein, The cutting location overlaps with the sealing area or is located downstream of the sealing area.

37. The protective packaging forming apparatus according to claim 35, wherein, The cutting location overlaps with the sealing area.

38. The protective packaging forming apparatus according to claim 37, wherein, The overlap of the pressure maintenance outlet, cutting position, and sealing zone works together to resist pressure decay in the inflatable chamber when it is sealed.

39. The protective packaging forming apparatus according to claim 35, wherein, The cutter is configured to cut open the inflation channel during operation, allowing the inflation channel to detach from the inflation nozzle.

40. The protective packaging forming apparatus according to claim 35, wherein, The cutter is configured to extend into the interior of the air-filled nozzle via a cutter receiving orifice formed in the air-filled nozzle.

41. The protective packaging forming apparatus according to claim 35, wherein, The cutter includes a cutting edge located outside the adjacent inflation nozzle and facing upstream relative to the material path.

42. The protective packaging forming apparatus according to claim 35, wherein, The cutter is positioned to cut the web material at a transverse position between the first longitudinal edge of the web material and the air channel during operation.

43. The protective packaging forming apparatus according to claim 35, wherein, The pressure sustaining outlet is configured to direct fluid in the transverse direction of the web material during operation.

44. The protective packaging forming apparatus according to claim 35, wherein, The pressure sustaining outlet is configured to direct fluid at an angle of 0 to 45 degrees relative to the transverse direction of the web material during operation.

Images