Roller sealing machine with wide backing roller

Abstract

A system is capable of advancing and sealing a web of an expandable container. The system includes a sealing roller comprising a sealing element positioned about a circumferential surface of the sealing roller. The system also includes a backing roller positioned relative to the sealing roller to form a nip between a circumferential surface of the backing roller and the circumferential surface of the sealing roller. The sealing roller and the backing roller counter-rotate to advance the web when a longitudinal edge of the web is positioned in the nip. The circumferential surface of the backing roller extends further into the web in an axial direction than the circumferential surface of the sealing roller extends into the web in the axial direction, such that the backing roller contacts the web at a lateral location that is further from the longitudinal edge of the web than the sealing roller contacts the web.

Description

TECHNICAL FIELD

[0001] The present disclosure is in the technical field of inflatable containers, such as inflatable packaging cushions. More particularly, the present disclosure relates to a simplified and improved machine for consistently producing such inflatable containers. BACKGROUND

[0002] Various machines for forming inflatable cushions, pillows, or other inflatable containers are known. For packaging applications, inflatable cushions are used to package articles by wrapping the article in the cushion and placing the wrapped article in a shipping carton, or simply placing one or more inflatable cushions inside a shipping carton along with the articles to be shipped. The cushion protects the packaged articles by absorbing impacts that might otherwise be fully transmitted to the packaged articles during shipping, and also constrains movement of the packaged articles within the carton to further reduce the likelihood of damaging the articles.

[0003] Earlier machines for forming inflatable cushions tended to be quite large, expensive, and complex. More recently, smaller, less expensive inflation machines have been developed that employ an inflatable web having a pre-formed container. However, many such machines suffer from alignment and tracking problems with the inflatable web as it moves through the machine, resulting in under-inflated, un-inflated, and / or poorly sealed cushions, which leads to wasted web and / or prematurely constricted cushions, or otherwise fail to protect the packaged product. In addition, such machines have less than ideal mechanisms for web loading, web feeding, and web sealing. With respect to the latter, poorly formed and / or incomplete heat seals typically result in constrictions of the cushion. In particular, under certain circumstances, the process of forming the heat seal can tear, stretch, or distort the web, which can allow some or all of the gas to escape the container. Unfortunately, this behavior has been found to frequently result in partial or complete constriction of the cushion, which can lead to product damage during shipping and / or storage due to ineffective product protection in the subsequently formed package.

[0004] Accordingly, there remains a need for a simple and reliable machine for producing gas-filled containers suitable for use as packaging cushions that addresses and overcomes one or more of the foregoing operational problems. SUMMARY

[0005] This summary provides an introduction to selected concepts of the application that will be further described below in the of the Invention. This summary is not intended to identify key features of the claimed subject matter, nor is it meant to be used in determining the scope of the claimed subject matter.

[0006] In a first embodiment, a system is configured to advance and seal a web of expandable containers. The containers include ports along longitudinal edges of the web. The system includes a sealing roller and a backing roller. The sealing roller includes a sealing element positioned around a circumferential surface of the sealing roller. The backing roller is positioned relative to the sealing roller to form a nip between a circumferential surface of the backing roller and the circumferential surface of the sealing roller. At least one of the sealing roller and the backing roller is driven such that when the longitudinal edges of the web are located in the nip, the sealing roller and the backing roller counter-rotate to advance the web. The circumferential surface of the backing roller extends further into the web in an axial direction than the circumferential surface of the sealing roller that contacts the web, such that the backing roller contacts the web at a lateral location that is further from the longitudinal edges of the web than the sealing roller.

[0007] In a second embodiment, the backing roller of the first embodiment includes a rubber material, and the circumferential surface of the backing roller is made of the rubber material.

[0008] In a third embodiment, the sealing roller and the backing roller of any of the preceding embodiments are arranged such that the axis of the sealing roller and the axis of the backing roller are substantially parallel to each other.

[0009] In a fourth embodiment, the system of the third embodiment is part of an expansion machine. The axis of the sealing roller and the axis of the backing roller are arranged at an oblique angle relative to a surface on which the expansion machine is located.

[0010] In a fifth embodiment, the surface on which the expansion machine of the fourth embodiment is located is substantially horizontal.

[0011] In a sixth embodiment, the backing roller of any of the preceding embodiments includes an inner lateral edge and an outer lateral edge, and wherein the inner lateral edge faces the containers of the web as the web is advanced, and wherein the backing roller is positioned relative to the sealing roller such that the inner lateral edge is positioned further from the sealing element than the outer lateral edge.

[0012] In a sixth embodiment, the circumferential surface of the backing roller of any of the preceding embodiments extends beyond the nip between the circumferential surface of the backing roller and the circumferential surface of the sealing roller.

[0013] In an eighth embodiment, a percentage of the circumferential surface of the backing roller that extends beyond the nip of the sixth embodiment is greater than or equal to at least one of 5%, 7.5%, 10%, or 12.5%.

[0014] In a ninth embodiment, the system of any of the preceding embodiments further includes a nozzle arranged to inflate the containers of the web prior to the web being advanced to the sealing roller and the backing roller.

[0015] In a tenth embodiment, the nozzle of the ninth embodiment is offset relative to the nip between the circumferential surface of the backing roll and the circumferential surface of the sealing roll such that the web contacts the backing roll before the web contacts the sealing roll as the web is advanced by the sealing roll and the backing roll.

[0016] In an eleventh embodiment, the sealing element of any of the preceding embodiments has a helical shape about the circumferential surface of the sealing roll.

[0017] In a twelfth embodiment, the sealing element of any of the first through tenth embodiments has an annular shape about the circumferential surface of the sealing roll. BRIEF DESCRIPTION OF DRAWINGS

[0018] Many of the foregoing aspects and attendant advantages of the disclosed subject matter will become more readily apparent when considered in connection with the following detailed description, when taken in conjunction with the accompanying drawings, by which the disclosure is illustrated, and by which the principles of the disclosure are best understood.

[0019] Figure 1A and Figure 1B depict a machine for expanding and sealing a web of expandable containers, and another example of the same machine for expanding and sealing an expandable web, respectively;

[0020] Figure 2A and Figure 2B depict a machine for expanding and sealing a web of expandable containers, and another example of the same machine for expanding and sealing an expandable web, respectively;

[0021] Figure 3 depicts a front view of an embodiment of a system for advancing and sealing a web of expandable containers;

[0022] Figure 4 depicts Figure 3 a side view of the system shown in FIG. 1, with the expansion nozzle visible in more detail;

[0023] Figure 5 depicts Figure 3 an exploded front view of the system shown in FIG. 1, with the sealing roll and backing roll spaced apart from one another;

[0024] Figure 6 depicts an embodiment of the system shown in FIG. 1 arranged at an upward angle relative to a horizontal plane; Figure 3

[0025] Figure 7 depicts Figure 3 a detailed view of the web and the nip between the sealing roll and the backing roll of the system shown in FIG. 1;

[0026] Figure 8 depicts Figure 7 ​a view of the web shown in FIG. 1 1, but with the system removed to more clearly show the state of the web;

[0027] Figure 9 depicts a front view of an embodiment of a system for advancing and sealing a web of inflatable containers according to embodiments disclosed herein;

[0028] Figure 10 depicts a perspective view of a system according to embodiments disclosed herein, Figure 9 depicts a side view of the system shown in FIG. 1 1, with the inflation nozzle more clearly visible;

[0029] Figure 11 depicts a perspective view of a system according to embodiments disclosed herein, Figure 9 depicts an exploded front view of the system shown in FIG. 1 1, with the sealing roller and backing roller spaced apart from one another;

[0030] Figure 12 depicts an embodiment of a system according to embodiments disclosed herein, arranged at an upward angle relative to a horizontal plane; Figure 9 depicts a perspective view of the system shown in FIG. 1 1, but with the system removed to more clearly show the state of the web.

[0031] Figure 13 depicts a detailed view of the web and nip between the sealing roller and backing roller of a system according to embodiments disclosed herein, and Figure 9 depicts a detailed view of the web and nip between the sealing roller and backing roller of a system according to embodiments disclosed herein, and

[0032] Figure 14 depicts a view of the web shown in FIG. 1 1, but with the system removed to more clearly show the state of the web. Figure 13 DETAILED DESCRIPTION

[0033] Figure 1A An example of a machine 10 for inflating and sealing a web of inflatable containers is depicted. The machine 10 includes a support structure 12, which can include a base 14 and a wall 16 extending upwardly from the base. The machine 10 also includes a spool 18 for rotatably supporting a roll of inflatable web, a web transport system 20 for conveying the inflatable web along a travel path 40, an inflation system 22 for inflating the inflatable web (and the containers therein), and a sealing device 24 positioned proximal the inflation system 22 for sealingly closing the inflated containers.

[0034] Figure 1B ​A machine 10 for inflating and sealing an inflatable web 26 is depicted. The web 26 is in the form of a roll 28 that is rotatably supported by a spool 18. The web 26 has opposite first and second longitudinal edges 30a and 30b and includes a series of inflatable containers 32. Each of the containers 32 is capable of holding a quantity of gas (e.g., air) therein and each has an opening 34 at the first edge 30a for receiving the gas.

[0035] The web 26 can also include a pair of juxtaposed sheets 36a and 36b (e.g., film sheets). In the illustrated embodiment, the first longitudinal edge 30a of the web 26 is open (e.g., unsealed) while the second longitudinal edge 30b is closed (e.g., sealed or folded). The web transport system 20 transports the inflatable web 26 along a travel path 40 that is generally parallel to the longitudinal edges 30a and 30b of the inflatable web 26.

[0036] The containers 32 can be defined between the sheets 36a and 36b and between a series of transverse seals 38. The seals 38 are described as "transverse" because they are aligned in a direction that is generally transverse to the longitudinal edges 30a and 30b of the web 26 and the travel path 40. As Figure 1B As shown in the middle, the seals 38 can be arranged in relatively closely spaced pairs 38a and 38b such that each chamber 32 is defined in the web 26 between an anterior transverse seal 38a from a downstream pair of seals 38 and a posterior transverse seal 38b from an adjacent upstream pair of such seals. In other words, from the perspective of the closely spaced pairs of seals, the upstream transverse seal of each pair of seals is labeled 38a while the downstream seal is labeled 38b.

[0037] The openings 34 of the containers 32 are formed by the open first edge 30a of the web 26 and the first end 42a of the transverse seals 38. The opposite second end 42b terminates at the closed second edge 30b. The first end 42a of the transverse seals is spaced from the first edge 30a so as to form a pair of opposite open (unattached) flanges in the sheets 36a and 36b that form an "open skirt" region 37 that allows the inflation system 22 (e.g., its nozzle 82) to be accommodated within the web 26 (e.g., between the film sheets 36a and 36b) so as to facilitate inflation. An example of such a web is disclosed in U.S. Patent No. 6,651,406, the contents of which are hereby incorporated by reference herein. To allow the individual or group of inflated containers to be separated from the web 26, a line of weakness 44 (such as a perforated line) can be included between each chamber 32. For example, the line of weakness 44 can be located between each upstream / downstream pair of transverse seals 38a and 38b as shown in the depicted embodiment.

[0038] Generally, the expandable web 26 may comprise any flexible film material that can be manipulated by the machines described herein (e.g., machines 10, 100) to encapsulate a gas or fluid 46 as described herein, including a variety of thermoplastic materials, such as polyethylene homopolymers or copolymers, polypropylene homopolymers or copolymers, etc. Non-limiting examples of suitable thermoplastic polymers include polyethylene homopolymers (such as low-density polyethylene (LDPE) and high-density polyethylene (HDPE)), and polyethylene copolymers (such as, for example, ionomers, EVA, EMA, heterogeneous (Ziegler-Natta catalyzed) ethylene / α-olefin copolymers, and homogeneous (metallocene, single-point catalyzed) ethylene / α-olefin copolymers). Ethylene / α-olefin copolymers are copolymers of ethylene with one or more comonomers selected from C3 to C20 olefins, including linear low-density polyethylene (LLDPE), linear medium-density polyethylene (LMDPE), very low-density polyethylene (VLDPE), and ultra-low-density polyethylene (ULDPE). Various other polymeric materials can also be used, such as, for example, polypropylene homopolymers or polypropylene copolymers (e.g., propylene / ethylene copolymers), polyesters, polystyrene, polyamides, polycarbonates, etc. The film can be single-layer or multi-layered and can be made by any known extrusion process (by melting (multiple) component polymers and extruding, co-extruding, or extruding them through one or more flat or annular dies).

[0039] like Figure 1B As shown, the web conveying system 20 advances the web 26 along the travel path 40 alongside the wall 16, wherein the web is oriented such that its first edge 30a is adjacent to the wall 16. The expansion system 22 is positioned to direct gas 46 (as indicated by the arrow) into the opening 34 of the container or chamber 32 as the web 26 is advanced along the path 40, thereby inflating the container.

[0040] If still Figure 1B As shown, the sealing device 24 can be positioned directly downstream of the expansion system 22 so that when the container 32 expands, the sealing device 24 seals and closes the opening 34 of the container 32 substantially simultaneously. The sealing device 24 seals and closes the opening 34 by creating a longitudinal seal 48 between the film sheets 36a and 36b, which also intersects with the transverse seals 38a and 38b near the first end 42a, to encapsulate the gas 46 within the container 32. In this way, the expandable container 32 of the web 26 is transformed into an expandable container 50.

[0041] exist Figure 1A and Figure 1BIn the depicted embodiment, the spool 18 has a proximal end 52a at which the spool is attached to the support structure 12 and an opposite distal end 52b that is spaced from the support structure 12. In some embodiments, the distal end 52b can be at a higher elevation relative to the proximal end 52a. In this manner, the spool 18 can have an upward angle as it extends away from the wall 16 when the machine 10 is placed on a generally horizontal surface. In this manner, the roll 28 is gravitationally biased toward the support structure 12 when it is mounted thereon. Such an upward angle of the spool 18 can facilitate the manual action of loading a new roll 28 of web material onto the spool, as the upward angle is often more ergonomic for roll loading and in which gravity helps slide the roll all the way onto the spool 18. The degree of elevation of the distal end 52b of the spool 18 can be such that the upward angle of the spool relative to a horizontal plane is between about 1 degree to about 45 degrees, such as from about 2 degrees to about 30 degrees, about 3 degrees to about 20 degrees, and so on. As an example, an upward angle of about 4 degrees above a horizontal plane can be suitable.

[0042] For these embodiments in which the spool 18 has an upwardly angled configuration, the resulting gravitational bias of the roll 28 toward the support structure 12 causes the first longitudinal edge 30a of the web material 26 to be drawn toward the web transport system 20, the inflation system 22, and the sealing device 24. Thus, the gravitational bias of the roll 28 toward the support structure 12 has the potential to facilitate the reliability of the machine 10 via improved tracking of the open edge of the web material 26 by the inflation and sealing operations. To accommodate the weight and diameter of a full roll 28, the support structure 12 can include an upright structure support 54 to which the spool 18 can be directly attached (e.g., via fasteners). As depicted, the upright support 54 can be secured to the wall 16 of the support structure 12 and can serve to elevate the spool 18 so that there is sufficient space between the spool 18 and the base 14 to accommodate a roll 28 having a desired maximum full-width diameter.

[0043] In the depicted embodiment, the distal end 52b of the spool 18 is not supported so that the spool is suspended from the upright support 54 on the wall 16. As an alternative, the distal end 52b can be supported by a suitable structural member, such as a column with a bracket, on which the distal end 52b rests. It can be desirable to support the distal end 52b of the spool 18 in embodiments in which large and / or heavy rolls of web material are to be used.

[0044] As mentioned above, the sealing device 24 is configured to seal the opening 34 of the closed container 32 by creating a longitudinal seal 48 between the film sheets 36a and 36b. The longitudinal seal 48 intersects the transverse seals 38a and 38b near the first end 42a to enclose the gas 46 within the container 32. In this manner, the inflatable container 32 of the web 26 is converted into an inflated container 50.

[0045] In the depicted embodiment, the sealing device 24 and the web transport system 20 are incorporated together as an integrated assembly. In some embodiments, the integrated assembly of the sealing device 24 and the web transport system 20 includes a pair of converging counter-rotating rotary components. In the depicted embodiment, the pair of rollers includes a sealing roller 62 and a backing roller 64. The sealing roller 62 includes a sealing element positioned about a circumferential surface of the sealing roller 62. The sealing roller 62 and the backing roller 64 can be positioned such that a nip (e.g., a region of tangential contact) is formed therebetween. At least one of the sealing roller 62 and the backing roller 64 can be coupled to a motor (e.g., a motor and gear box assembly) such that when power is supplied to one or both of the sealing roller 62 and the backing roller 64, and the web 26 is passed through the nip 65, the sealing roller 62 and the backing roller 64 counter-rotate to advance the web 26 along the path 40. As the web 26 is transported, the sealing element on the sealing roller 62 forms the longitudinal seal 48 at the nip between the sealing roller 62 and the backing roller 64 to close the opening 34 of the inflated container 32 / 50.

[0046] The sealing element can be an electrically heated resistive device (such as a strip or wire) that generates heat when an electrical current is passed through the device. The sealing element can be mounted on the circumferential outer surface. When the sealing element is heated, and the sealing roller 62 and the backing roller 64 are counter-rotated compressively against the web 26, the rotational contact between the sealing element and the web 26 forms the longitudinal seal 48 as the web 26 is transported along its path 40.

[0047] In some embodiments, the sealing element is in the form of a wire. The sealing roller 62 can be formed of any material capable of withstanding the temperature generated by the sealing element, such as a metal (e.g., aluminum), a high temperature resistant polymer (e.g., polyimide), a ceramic, or the like. A groove can be provided in the circumferential surface of the sealing roller 62 to accommodate the sealing element and hold it in place on the circumferential surface during sealing and transport.

[0048] The circumferential surface can include a roughened or knurled section to promote traction between the circumferential surface and the web in order to prevent or minimize slippage between the sealing roller 62 and the web 26 as the sealing roller 62 is rotated against the web 26 to transport the web 26 along the path 40. Web traction between the sealing roller 62 and the backing roller 64 can be further promoted by forming the backing roller 64 of a pliable material, such as rubber or RTV silicone.

[0049] Additional details regarding the integrated web conveying systems, sealing devices, and other components described herein are disclosed in U.S. Patent No. 7,225,599; U.S. Patent No. 8,991,141; U.S. Patent No. 10,286,617; and U.S. Patent Application Publication No. 2019 / 0009476 Al, the contents of each of which are hereby incorporated by reference in their entirety.

[0050] In the depicted embodiment, the longitudinal seal 48 is oriented in a direction generally parallel to the longitudinal edges 30a and 30b of the web 26, as well as along its direction of movement through the machine 10, its travel path 40. As shown, the longitudinal seal 48 can be a continuous longitudinal seal (e.g., a generally linear, uninterrupted seal) that is only interrupted when the sealing device 24 is stopped from creating the seal. Alternatively, the sealing device 24 can be adapted to create the longitudinal seal 48 as a discontinuous series of longitudinal seal segments. The discontinuous series of longitudinal seal segments can be created when the sealing element 66 has a helical pattern on the surface 72 of the sealing roller 62, resulting in an angular configuration of the longitudinal seal segments, such as disclosed in U.S. Patent No. 7,225,599. As yet another alternative, the sealing element can be arranged on the sealing roller 62 as an overlapping helical pattern (e.g., as a “double helix” as disclosed in U.S. Publication No. 2008 / 0250753 Al, the contents of which are hereby incorporated by reference in their entirety).

[0051] The machine 10 can include a housing 88, such as on a side of the wall 16 opposite the side associated with the web handling components (e.g., the mandrels 18, the expansion system 22, the rollers 62 and 64, etc.). The housing 88 can house various operational devices, some of which are described above (e.g., the motors), and some of which will be described below. The housing 88 can also house an operator interface thereon, such as a control panel 90. In some embodiments, the control panel 90 includes at least a start button or switch 91 and a stop button or switch 93, which allow an operator of the machine 10 to start and stop operation of the machine 10, respectively.

[0052] The machine 10 (or any of the embodiments of machines disclosed herein) can also include a controller configured to control the overall operation of the machine 10. The controller can be housed within the housing 88. The controller can be in operative communication with various subcomponents of the machine 10, particularly to control the flow of power (e.g., electricity) thereto. Such control can occur indirectly (e.g., by controlling the flow of power from a separate power management source to the subcomponents), or directly.

[0053] When the web 26 is in the form of a roll 28 (as shown), the force required by the web transport system 20 to draw the web from the roll can vary as the roll is depleted, such that the tension in the web 26 can change as the roll is depleted. Such changes in web tension can contribute to misalignment of the web relative to the inflation system 22 and the sealing device 24. Such misalignment can result in a number of inflation and / or sealing problems, including containers not inflating, containers inflating insufficiently, and sealing failures. Accordingly, the machine 10 can also include one or more tension control devices for controlling the tension in the web 26 as the web 26 is transported along the path 40 through the machine. Such devices can operate by applying a frictional resistance to the web 26 opposite the advancement of the web 26 by the transport system 20.

[0054] One such device is shown in Figure 1A and Figure 1B , in which a tension bar or arm 92 can be positioned between the roll 28 and the inflation system 22. The tension bar 92 can be structured and arranged to contact (e.g., slidingly contact) the web 26 as the web 26 is transported along the path 40. The sliding contact between the tension bar 92 and the web 26 provides a frictional resistance to the web 26 opposite the advancement of the web 26 along the path 40. The magnitude of such frictional resistance is directly proportional to the degree of contact between the web 26 and the tension bar 92. In the depicted arrangement, as the diameter of the roll 28 decreases as the supply of the web 26 therefrom is depleted, the area of contact between the web 26 and the bar 92 increases based on the increasing angle of approach of the web from the roll 28 to the bar. Conveniently, the tension bar 92 can also provide a guide bar function, as it directs the web 26 into the proper position over the inflation nozzles 82. The tension bar 92 can have a generally circular or elliptical cross-sectional shape, as shown. It will be understood that the tension bar 92 can have a variety of other cross-sectional shapes (e.g., square, rectangular, triangular, etc.).

[0055] Figure 2A and Figure 2BAnother embodiment of a machine 100 for expanding and sealing an expandable web or expandable web 126 is depicted. The machine 100 generally includes a driver 112, an expansion nozzle 122, a sealing device 116, and a sheet engagement device 118. The driver 112 can include a sealing roller 180 and a backing roller 182, which can be positioned such that when the driving roller and the backing roller are in contact, a nip (an area of tangential contact) is formed therebetween. At least one of the rollers, such as the sealing roller 180, can be linked to a motor to form the driver 112, such that when power is supplied to the motor, the driving roller rotates. The backing roller can also rotate when the sealing roller 180 is in contact with the backing roller 182. As will be described in detail below, this can advance the expandable web 126. The outer surface 192 of the sealing roller 180 can be roughened or knurled to facilitate traction with the expandable web 126 to minimize slippage as the driving roller rotates against the expandable structure to advance the expandable structure in the machine direction 140. To further facilitate advancement of the expandable web 126, the backing roller 182 can be formed of a pliable material, such as rubber or RTV silicone. Other materials, such as metal with a knurled surface, can also be used for the backing roller 182 as desired, particularly when the backing roller is mounted to the machine 100 using a suspension system that ensures the backing roller properly contacts the sealing roller 180 and the sealing device 116 during operation.

[0056] The sheet engagement device 118 can be configured to engage the first sheet 136a and the second sheet 136b forming the expandable web 126 together along the longitudinal edge 130 of the expandable web 126. For example, in the depicted embodiment, the sheet engagement device 118 includes a first belt 152 defining a plurality of teeth 154, and an opposing second belt 162 defining a plurality of teeth 164. The first belt 152 extends around the sealing roller 180, and also around the engagement roller 156. The opposing second belt 162 extends around the backing roller 182, and also around the opposing roller 166. Further, the teeth 154 and 164 of the first belt 152 and the opposing second belt 162 can be oriented such that they face outward from a first outer surface of the first belt 152 and a second outer surface of the opposing second belt 162, and such that they do not touch the respective rollers 180, 156, 182, 166. Alternatively, the teeth 154 from the first belt 152 engage with the teeth 164 from the opposing second belt 162 in a intermeshing manner. The sheet engagement device 118 can be rotatably coupled to the driver 112, such that when the motor rotates the driver (including the sealing roller 180), the sheet engagement device 118 also rotates. In alternative embodiments, instead of using a driver roller, the sheet engagement device can be used as a driver for the expandable structure, with both belts advancing the expandable structure in the machine direction. In such embodiments, a non-rotating sealing device, such as a flat sealing bar, and other similar known sealing devices can be used to seal the expandable structure.

[0057] While the teeth 154 and 164 are shown as being oriented generally perpendicular to the machine direction 140, the teeth 154 and 164 can be oriented in other directions. For example, the teeth 154 and 164 can be arranged in the longitudinal direction such that they are generally aligned with the machine direction 140. In such a configuration, when one of the first belt 152 or the opposing second belt 162 has longitudinally oriented teeth, the other of the first and second belts can include one or more longitudinally extending grooves. In such embodiments, the longitudinally extending teeth can engage the one or more longitudinally extending grooves. In alternative embodiments, one or both of the first outer surface of the first belt 152 and the second outer surface of the opposing second belt 162 can be toothless.

[0058] In the depicted embodiment, the machine 100 also includes an inflation nozzle 122 for inflating the inflatable web 126 with the fluid 146. The inflation nozzle 122 can be positioned such that the sheet engagement device 118 is adjacent to the inflation nozzle, which assists in the inflation of the inflatable web 126. The inflation nozzle 122 can take many different forms. The inflation nozzle 122 includes an outlet 120. The location of the outlet 120 can affect the efficiency of the inflation of the inflatable web 126. The inflation nozzle 122 can be adjacent to the sheet engagement device 118, such as where the first belt 152 and the second belt 162 are positioned between the nozzle 122 and the rest of the machine 100. The machine 100 can also include a plow 168 that separates the first sheet 136a of the inflatable web 126 from the second sheet 136b of the inflatable structure. Such a plow 168 can include an integrated part of the nozzle 122, as shown in the embodiment of the machine 100 depicted in Figure 2A and Figure 2B Alternatively, the plow 168 can be a component of the machine 100 that is separate from the inflation nozzle 122. In some alternative embodiments, the nozzle 122 can include a tubular structure that separates the first sheet 136a and the second sheet 136b.

[0059] The machine 100 can also define an engagement assembly 170 and an opposing assembly 172. The engagement assembly 170 can include a sealing roller 180, a sealing device 116, an engagement roller 156, and a first belt 152. The opposing assembly 172 can include a backing roller 182, an opposing roller 166, and a second belt 162. In the depicted embodiment, the machine 100 also includes release mechanisms 174 and 176 to which all or a portion of the opposing assembly 172 and / or the engagement assembly 170 are mounted. The release mechanisms 174 and 176 allow the opposing assembly 172 to be moved relatively toward and away from the engagement assembly 170. For example, a first release mechanism 174 can displace the backing roller 182 away from the sealing roller 180 and the sealing device 116, and vice versa, back into contact with the drive roller and the sealing device. Similarly, a second release mechanism 176 can move the opposing roller 166 away from the engagement roller 156, and vice versa, back into contact with the engagement roller.

[0060] In the depicted embodiment, the sealing device 116 is located on the sealing roller 180. The sealing device 116 includes a sealing element 184. The sealing element 184 can be a resistive element that generates heat when electricity is supplied to it, and can have any desired shape or configuration. As shown, the sealing element 184 is in the form of a wire. Thus, the sealing device 116 can be formed of any material capable of withstanding the temperature generated by the sealing element 184, such as a metal (e.g., electrically insulating aluminum), a high-temperature resistant polymer (e.g., polyimide), a ceramic, etc. A groove 193 in the peripheral surface of the sealing roller 180 can be provided to accommodate and hold the sealing element 184 in place to seal the expandable web 126. The engagement assembly 170 has the sealing device 116 with the sealing element 184 to engage the backing roller 182 from the opposing assembly 172 to seal the expandable web 126 therebetween.

[0061] Figure 2B A top view of the machine 100 for expanding and sealing the expandable web 126 is shown. In the depicted embodiment, the expandable web 126 has a longitudinal edge 130 and includes a series of preformed expandable containers or chambers 132 formed between a first sheet 136a and a second sheet 136b. Each of the expandable containers 132 is capable of holding an amount of fluid 146 (e.g., air or another gas) therein, and each of the expandable containers 132 has an opening 134 at the longitudinal edge 130 for receiving such fluid. As Figure 2BAs shown in FIGS. 1 1 and 12, the inflatable container 132 can be defined between the transverse seals 138. The openings 134 of the inflatable container 132 are formed near the longitudinal edges 130 of the inflatable web 126 at the ends 142 of the transverse seals 138. The ends 142 of the transverse seals 138 are spaced from the longitudinal edges 130 so as to accommodate the inflation nozzle 122 within the inflatable web 126 (e.g., between the sheets 136a and 136b), while the other ends of the transverse seals terminate at the closed edges of the inflatable web 126. The closed edges can be folds of the first and second sheets 136a and 136b, such as when a single piece of film forms the inflatable web 126, or the closed edges can include seals between separate sheets of material that are joined together.

[0062] To begin operation, the inflatable web 126 is fed between the engagement assembly 170 and the opposing assembly 172 from a roll of inflatable structure stored, for example, on a spool such as any of the spools and related systems or features described herein. In some embodiments, one or more of the spool, the engagement assembly 170, and / or the opposing assembly 172 can be angled relative to the horizontal such that the closed edges of the inflatable web 126 sit at an elevation higher than the longitudinal edges 130 of the inflatable structure as the inflatable structure is advanced through the machine 100. In such embodiments, alignment of the longitudinal edges 130 with the machine direction 140 can be improved.

[0063] Feeding of the inflatable web 126 between the engagement assembly 170 and the opposing assembly 172 can also be facilitated by use of the release mechanisms 174 and 176. As described above, the second release mechanism 176 can move the opposing roller 166 downward away from the engagement roller 156 and the first release mechanism 174 can move the backing roller 182 downward away from the sealing roller 180 by a user grasping and moving the second handle member 188 and the first handle member 186, respectively. Thus, the first release mechanism 174 and the second release mechanism 176 can facilitate feeding of the inflatable web 126 between the engagement assembly 170 and the opposing assembly 172, such as in the case of replacement of a roll of inflatable web 128 placed on a spool. In such cases, the new inflatable web can then be passed through the above-described components of the machine 100 in the machine direction 140. Once passage is complete, the first handle member 186 and the second handle member 188 are moved back to their operating positions (as shown in FIGS. 1 1 and 12) to bring the engagement assembly 170 and the opposing assembly 172 into compressive contact with opposite sides of the inflatable web 126 and ready to begin drawing the inflatable structure from the roll and advancing the inflatable structure in the machine direction 140. Figure 2A and Figure 2B As shown in FIGS. 1 1 and 12, the inflatable container 132 can be defined between the transverse seals 138. The openings 134 of the inflatable container 132 are formed near the longitudinal edges 130 of the inflatable web 126 at the ends 142 of the transverse seals 138. The ends 142 of the transverse seals 138 are spaced from the longitudinal edges 130 so as to accommodate the inflation nozzle 122 within the inflatable web 126 (e.g., between the sheets 136a and 136b), while the other ends of the transverse seals terminate at the closed edges of the inflatable web 126. The closed edges can be folds of the first and second sheets 136a and 136b, such as when a single piece of film forms the inflatable web 126, or the closed edges can include seals between separate sheets of material that are joined together.

[0064] As shown in FIGS. 1 1 and 12, the inflatable container 132 can be defined between the transverse seals 138. The openings 134 of the inflatable container 132 are formed near the longitudinal edges 130 of the inflatable web 126 at the ends 142 of the transverse seals 138. The ends 142 of the transverse seals 138 are spaced from the longitudinal edges 130 so as to accommodate the inflation nozzle 122 within the inflatable web 126 (e.g., between the sheets 136a and 136b), while the other ends of the transverse seals terminate at the closed edges of the inflatable web 126. The closed edges can be folds of the first and second sheets 136a and 136b, such as when a single piece of film forms the inflatable web 126, or the closed edges can include seals between separate sheets of material that are joined together. Figure 2A and Figure 2BAs seen, the longitudinal edges 130 of the expandable web 126 are open (e.g., unsealed) before the expandable web 126 travels between the joining assembly 170 and the opposing assembly 172. This enables the first and second sheets 136a, 136b to separate onto opposite sides of the land 168 and around the location of the nozzle 122 as the expandable web 126 is advanced in the machine direction 140. However, the first and second sheets 136a, 136b are joined together along the longitudinal edges 130 of the expandable web 126 by the joining assembly 170 and the opposing assembly 172. This all occurs as the sealing roller 180 rotates and thus advances the expandable web 126 in the machine direction 140 between the joining assembly 170 and the opposing assembly 172 with the expandable structure oriented such that the longitudinal edges 130 are adjacent to the machine 100.

[0065] The inflation nozzle 122 is positioned to direct the fluid 146 into the opening 134 of the expandable container 132 as the expandable web 126 is advanced in the machine direction 140 generally parallel to the longitudinal edges 130, thereby expanding the expandable container 132. By joining the first and second sheets 136a, 136b of the expandable web 126 together, expansion of the expandable container 132 can be facilitated as compared to an open edge. For example, with an open edge, fluid directed toward the opening in the expandable structure can partially escape through the open edge. Further, as the fluid is discharged from the nozzle 122, and as the escaping fluid passes through the open edge, the fluid can vibrate the sheets forming the edge due to a "reed effect," which can result in undesirable noise generation. Further, due to the vibration, the opening to the expandable container can not remain fully open during expansion. Thus, due to both the partially open opening, and the ability of some of the fluid to escape from the expandable structure, higher fluid pressure can be required to expand the expandable container. However, in some situations, the use of higher fluid pressure can not be desirable as it can require more complex or expensive components to generate the fluid pressure, and further, increased fluid pressure can exacerbate the noise problem by increasing the vibration.

[0066] Therefore, by joining the first sheet 136a and the second sheet 136b together along the longitudinal edge 130, the depicted embodiment of the machine 100 facilitates more efficient expansion of the container 132 and / or reduces noise during expansion. This reduces the ability of fluid 146 to escape through the longitudinal edge 130 and also reduces any vibration of the sheets 136a and 136b along the longitudinal edge 130. This allows the opening 134 of the expandable container 132 to remain more fully open. More fluid 146 can also be directed toward the opening 134, and less noise can be generated. Furthermore, as more fluid 146 travels more easily through the opening 134 into the expandable container 132, it is possible to use a lower fluid pressure to expand the expandable container 132 with respect to the desired final expansion pressure of the expansion chamber 132.

[0067] Various embodiments of the sheet bonding device 118 can be used, such as embodiments using toothed or toothless belts, as described above. When using a toothed belt (such as... Figure 2A and Figure 2B When the first strip 152 and the opposing second strip 162 are shown, the interlocking of the teeth 154 and 164 reduces the size of the longitudinal edge 130 of the expandable web 126 in the machine direction 140. The sheet joining device 118 can also emboss the expandable web 126 along the longitudinal edge 130, wherein a plurality of protrusions 194 and indentations 196 correspond to the teeth 154 and 164. The contraction of the length of the longitudinal edge 130 in the machine direction 140 provides an additional benefit, because when the expandable container 132 is filled, the remainder of the expandable web 126 may also tend to wrinkle in length in the machine direction, which can otherwise distort the openings 134 of the expandable container 132 so that they do not remain fully open. Therefore, by contracting the length of the longitudinal edge 130, the openings 134 can remain more fully open, which further promotes the expansion of the expandable container 132, as described above. In particular, distortion of the opening 134 can be avoided by shrinking the length of the longitudinal edge 130 to an amount roughly equal to the shortening of the length of the expandable portion of the expandable web 126 in the machine direction 140. Furthermore, when the longitudinal edge shrinks in the machine direction 140, the embossing of the longitudinal edge 130 further resists noise generated by the "reed effect" by eliminating the planar nature of the longitudinal edge.

[0068] In alternative embodiments, two belts having corresponding first and second exterior surfaces that are toothless can be used. In such embodiments, the length of the longitudinal edges 130 of the expandable web 126 can not be affected. Further, such embodiments can not emboss the expandable web 126, depending on the pressure applied to the expandable structure by the belts. However, even when the expandable web 126 is not embossed, this embodiment can provide beneficial results. For example, the sheet engagement device 118 can extend in the machine direction 140 such that the toothless first exterior surface of the first belt 152 and the toothless second exterior surface of the opposing second belt 162 engage the expandable web 126 therebetween from a point before the expandable container 132 passes the nozzle 122 until a point when the expandable container is sealed by the sealing device 116, as described herein. In such embodiments, the first sheet 136a and the second sheet 136b can remain separated at the longitudinal edges 130 as they exit the machine 100 and can not have embossing thereon.

[0069] As further shown in Figure 2B , the sealing device 116 can be positioned directly after the inflation nozzle 122 in the machine direction 140 such that the sealing device 116 substantially simultaneously seals the opening 134 of the expandable container 132 as the expandable container 132 is inflated. Thus, as the sealing element 184 is heated and the sealing roller 180 and backing roller 182 counter-rotate against the expandable web 126, rotational contact between the sealing element 184 and the expandable web 126 forms the longitudinal seal 148 as the expandable structure is advanced in the machine direction 140. In this manner, the sealing device 116 seals the opening 134 closed by creating the longitudinal seal 148 between the first sheet 136a and the second sheet 136b (see Figure 2B ). The longitudinal seal 148 also intersects the transverse seal 138 near the end 142 of the transverse seal 138 to enclose the fluid 146 within the expandable container 132. In this manner, the expandable container 132 of the expandable web 126 is converted into the inflated container 150. The longitudinal seal 148 can be a continuous seal (e.g., a substantially linear, uninterrupted seal) that is only interrupted when the sealing device 116 stops creating the seal, or it can form a discontinuous seal. The shape and pattern of the longitudinal seal 148 will depend on the shape and pattern of the sealing element 184 and thus various different seals can be created as will be apparent to those skilled in the art.

[0070] Figure 3 An embodiment of a system 200 for advancing and sealing a web of expandable containers is depicted in Figure 1A and Figure 1Bin the depicted machine 10, and in Figure 2A and Figure 2B in the depicted machine 100). The system 200 includes a sealing roller 202 and a backing roller 204. The sealing roller 202 includes a circumferential surface 206, and the backing roller 204 includes a circumferential surface 208. The sealing roller 202 and the backing roller 204 are arranged to form a nip 210 between the circumferential surface 206 of the sealing roller 202 and the circumferential surface 208 of the backing roller 204.

[0071] The sealing roller 202 is coupled to a shaft 212, and the backing roller 204 is coupled to a shaft 214. In some embodiments, the shafts 212 and 214 can be operatively coupled to a motor in such a way that, when the motor is operated, the motor drives the sealing roller 202 and the backing roller 204 in opposite directions. In some embodiments, only one of the shafts 212 and 214 is operatively coupled to a motor in such a way that, when the motor is operated, the motor drives the corresponding one of the sealing roller 202 and the backing roller 204. The other one of the shafts 212 and 214 can be permitted to rotate freely, such that, when the motor is operated to drive one of the sealing roller 202 and the backing roller 204, the interaction between the sealing roller 202 and the backing roller 204 causes the sealing roller 202 and the backing roller 204 to rotate in opposite directions. When one or both of the sealing roller 202 and the backing roller 204 are driven, and a longitudinal edge of the expandable web is located in the nip 210, the opposite rotation of the sealing roller 202 and the backing roller 204 propels the expandable web.

[0072] In the depicted embodiment, the sealing roller 202 includes a plurality of segments across the circumferential surface 206. The sealing roller 202 includes a rough segment 216. In the depicted embodiment, the rough segment 216 is knurled, so as to prevent or minimize slippage between the sealing roller 202 and the web.

[0073] The sealing roller 202 also includes a sealing segment 218, which includes a sealing element 220. In some embodiments, the sealing element 220 is in the form of a wire. The sealing segment 218 of the sealing roller 202 can be formed of any material capable of withstanding the temperatures generated by the sealing element, such as a metal (e.g., aluminum), a high-temperature resistant polymer (e.g., polyimide), a ceramic, or the like. A groove can be provided in the circumferential surface of the sealing roller 202 to accommodate the sealing element 220 and to hold it in place on the circumferential surface 206 during the propulsion and sealing of the web.

[0074] The sealing roller 202 also includes a cover section 222. The cover section 222 is part of a cover 224 that is secured to the side of the sealing roller 202 opposite the shaft 212. In the depicted embodiment, the cover 224 also includes a circular section 226. In some embodiments, the cover 224 is formed from a rigid material, such as a thermoset polymer, metal, ceramic, or other material. In the depicted embodiment, the rough section 216, the sealing section 218, and the cover section 222 of the circumferential surface 206 of the sealing roller 202 have approximately similar diameters. In this way, the web can contact the sealing roller across the circumferential surface 206.

[0075] In some embodiments, the portion of the backing roller 204 that includes the circumferential surface 208 is formed from an elastic material, such as rubber or RTV silicone. Such an elastic material can increase traction between the sealing roller 202 and the backing roller 204. In the depicted embodiment, the backing roller 204 includes an inner lateral edge 228 and an outer lateral edge 230. When the system 200 advances a web having inflatable containers, the inner lateral edge 228 faces the containers of the web as the web is advanced. In the depicted embodiment, the backing roller 204 has a chamfered corner between the inner lateral edge 228 and the circumferential surface 208, and a chamfered corner between the outer lateral edge 230 and the circumferential surface 208. In the depicted embodiment, the circumferential surface 208 is a surface having an approximately linear profile between the chamfered corners.

[0076] The system 200 also includes an inflation nozzle 232 arranged to inflate the containers of the web. Figure 4 A side view of the system 200 is depicted, with the nozzle 232 visible in more detail. In the depicted embodiment, the nozzle 232 is arranged to inflate the containers of the web before the web is advanced to the sealing roller 202 and the backing roller 204 as the web is advanced along a travel path 234. The inflation nozzle 232 includes an outlet 236 through which fluid (e.g., air or another gas) is inserted into the inflatable containers of the web. In some embodiments, the nozzle 232 is offset from the nip 210 by an offset distance 238. In the depicted embodiment, the nozzle 232 is offset from the nip toward the backing roller 204, such that the web fed along the nozzle 232 will contact the backing roller 204 before the web contacts the sealing roller 202 and the sealing element 220.

[0077] Figure 5 An exploded front view of the system 200 is depicted, with the sealing roller 202 and the backing roller 204 spaced apart from one another. In the depicted embodiment, the sealing roller 202 includes a shaft 212 and a circumferential surface 206. In the depicted embodiment, the circumferential surface 206 is a surface having an approximately linear profile. In some embodiments, the circumferential surface 206 is a surface having a profile that is not linear. In the depicted embodiment, the circumferential surface 206 includes a rough section 216 and a sealing section 218. In the depicted embodiment, the rough section 216 is a section of the circumferential surface 206 that is roughened to increase traction between the sealing roller 202 and the web. In the depicted embodiment, the sealing section 218 is a section of the circumferential surface 206 that is coated with a sealing material, such as a thermoplastic polymer, to form a seal with the web as the web is advanced along the travel path 234. Figure 5In the depicted embodiment, the width of the nip 210 is more clearly visible. In the depicted embodiment of the sealing roller 202, the nip 210 extends generally across the roughened section 216 and the sealing section 218. In the depicted embodiment of the backing roller 204, the nip 210 extends generally coextensively with the circumferential surface 208 of the backing roller 204. However, the circumferential surface 208 of the backing roller 204 does not extend across the cap section 222 of the circumferential surface 206 of the sealing roller 202. Thus, in the depicted embodiment, the nip 210 does not extend generally coextensively with the circumferential surface 206 of the sealing roller 202. Such a width of the nip 210 is considered appropriate in existing advancing and sealing apparatuses, as the roughened section 216 and the sealing section 218 of the sealing roller 202 are considered to provide the functionality required for advancing and sealing the web, while the cap section 222 of the circumferential surface 206, and more generally the cap 224, are not considered to play a role in the advancement or sealing of the web.

[0078] As mentioned above, some inflation machines have an upward angle of the axis of rotation that holds a web roll to assist with web loading and web alignment. In these embodiments, it can also be advantageous for the inflation machine to have an advancing and sealing system positioned at a similar upward angle to ensure proper inflation and sealing of the web. Figure 6 In the depicted embodiment, the system 200 is arranged at an upward angle 240 relative to a horizontal plane. In some cases, the system 200 can be part of an inflation machine, and the system 200 is positioned on the inflation machine such that the axis of the sealing roller 202 and the axis of the backing roller 204 are arranged at an oblique angle relative to a surface (e.g., a horizontal surface) on which the inflation machine is positioned. In various embodiments, the upward angle 240 can be between about 1 degree and about 45 degrees, between about 2 degrees and about 30 degrees, between about 3 degrees and about 20 degrees, etc. In the depicted embodiment, the upward angle is about 4 degrees above a horizontal plane.

[0079] Figure 6 A web 242 advanced and sealed by the system 200 is also depicted. The web 242 includes a first sheet 244 and a second sheet 246 that are juxtaposed and sealed together to form an inflatable container 248. In some embodiments, the web 242 has a closed longitudinal edge (e.g., the edge on the right when viewing Figure 6 the web 242). The closed longitudinal edge can be a fold in the film that makes up the web 242 (e.g., when the first sheet 244 and the second sheet 246 are formed from a single film), or a seal in the film that makes up the web 242 (e.g., when the first sheet 244 and the second sheet 246 are formed from two pieces of film that are sealed together along the closed longitudinal edge). In some embodiments, the web 242 has a longitudinal edge that includes a port for inflating the inflatable container 248 (e.g., when viewing Figure 6(At the left edge). In the depicted embodiment, the longitudinal edge of the web 242, including the port, is located in the roll gap 210 between the sealing roller 202 and the backing roller 204. The web 242 is advanced by the system 200 while one or both of the sealing roller 202 and the backing roller 204 are driven (e.g., by a motor), and a portion of the web 242 is located in the roll gap 210, and the sealing element 220 forms a seal in the web 242 to independently close the port of the expandable container 248. As the web 242 is advanced, and before the web 242 reaches the sealing roller 202 and the backing roller 204, the expansion nozzle 232 introduces fluid into the expandable container 248.

[0080] Detailed views of the web 242 and the roll gap 210 between the sealing roller 202 and the backing roller 204 are shown in Figure 7 As shown in the image. Figure 8 Describing as Figure 7 The image shows a view of the web 242, but with system 200 removed to more clearly show the state of the web 242. In the depicted embodiment, a portion of the web 242 is in the roll gap 210, and the portion of the web 242 including the expansion chamber 248 extends away from the roll gap 210 (e.g., when viewed from above). Figure 6 and Figure 7 (At the time, extending to the right side). The sealing element 220 forms a sealing portion 250 in the web 242 to close the port of the expandable chamber 248.

[0081] In the depicted embodiment, one of the problematic aspects of the system 200 is that the seal 250 is not always properly formed. In one instance, when the web 242 enters the nip 210, the expandable chamber 248 over-expands, and the force from the pressure in the expandable chamber 248 can cause excessive force on the portions of the first and second sheets 244, 246 in which the seal 250 is formed. In certain instances, such force can cause physical distortion of the seal 250 before the seal 250 cools, tearing of one or both of the first and second sheets 244, 246 near the seal 250, or other defects. In another instance, the material of the film in the first and second sheets 244, 246 can not be able to withstand the forces experienced by the web 242 during sealing and advancement by the system 200. Many efforts have been made to reduce the amount of polymeric-based material used, such materials can be in the form of modified plastic films (e.g., very thin plastic films) or plastic film alternatives (e.g., biodegradable films or recyclable films). However, these non-traditional films are especially unable to withstand such forces that also cause physical distortion of the seal 250 before the seal 250 cools, tearing of one or both of the first and second sheets 244, 246 near the seal 250, or other defects. Regardless of how the defects occur, these defects can result in loss of integrity of the seal 250 and / or deflation of the expandable chamber 248. Prior to the present disclosure, the causes of such defects and ways to address these causes were not known or understood.

[0082] Figure 8 Also depicted is a transverse location 252 on the web 242. The transverse direction is a direction that is generally perpendicular to the longitudinal direction (e.g., a left-right direction when viewing Figure 8 the depicted embodiment, the transverse location 252 is the farthest point away from the longitudinal edge at which the web 242 is in contact with at least one of the sealing roll 202 and the backing roll 204. As shown, the circumferential surface 208 and the nip 210 substantially coextend, and the transverse location 252 is located at substantially the edge of the circumferential surface 208 and the nip 210. Figure 8 Also depicted in the cross-sectional view is both a transverse distance 254 between the longitudinal edge of the web 242 and the seal 250 and a transverse distance 256 between the seal 250 and the transverse location 252 at which the web 242 is in contact with at least one of the sealing roll 202 and the backing roll 204. As can be seen in the depicted embodiment, the transverse distance 256 between the seal 250 and the transverse location 252 at which the web 242 is in contact with at least one of the sealing roll 202 and the backing roll 204 is less than the transverse distance 254 between the longitudinal edge of the web 242 and the seal 250.

[0083] Figures 9-14 Depicted is an embodiment of a system 300 for advancing and sealing a web of an inflatable container that addresses the problems with the system 200 described above. The system 300 includes a sealing roller 302 and a backing roller 304. The sealing roller 302 includes a circumferential surface 306 and the backing roller 304 includes a circumferential surface 308. The sealing roller 302 and the backing roller 304 are arranged to form a nip 310 between the circumferential surface 306 of the sealing roller 302 and the circumferential surface 308 of the backing roller 304.

[0084] The sealing roller 302 is coupled to a shaft 312 and the backing roller 304 is coupled to a shaft 314. In some embodiments, the shafts 312 and 314 are operatively coupled to a motor in such a way that when the motor is operated, the motor drives the sealing roller 302 and the backing roller 304 in opposite directions. In some embodiments, only one of the shafts 312 and 314 is operatively coupled to a motor in such a way that when the motor is operated, the motor drives the corresponding one of the sealing roller 302 and the backing roller 304. The other one of the shafts 312 and 314 can be allowed to freely rotate so that when the motor is operated to drive one of the sealing roller 302 and the backing roller 304, the interaction between the sealing roller 302 and the backing roller 304 causes the sealing roller 302 and the backing roller 304 to rotate in opposite directions. When one or both of the sealing roller 302 and the backing roller 304 are driven and a longitudinal edge of the inflatable web is located in the nip 310, the opposite rotation of the sealing roller 302 and the backing roller 304 advances the inflatable web.

[0085] In the depicted embodiment, the sealing roller 302 includes a plurality of segments across the circumferential surface 306. The sealing roller 302 includes a rough segment 316. In the depicted embodiment, the rough segment 316 is knurled so as to prevent or minimize slippage between the sealing roller 302 and the web.

[0086] The sealing roller 302 also includes a sealing segment 318 that includes a sealing element 320. In some embodiments, the sealing element 320 is in the form of a wire. The sealing segment 318 of the sealing roller 302 can be formed of any material capable of withstanding the temperatures generated by the sealing element, such as a metal (e.g., aluminum), a high temperature resistant polymer (e.g., polyimide), a ceramic, etc. A groove can be provided in the circumferential surface of the sealing roller 302 to accommodate the sealing element 320 and hold it in place on the circumferential surface 306 during advancement and sealing of the web. In some embodiments, the sealing element 320 has a spiral shape around the circumferential surface 306 of the sealing roller 320. In some embodiments, the sealing element 320 has a ring shape around the circumferential surface 306 of the sealing roller 320.

[0087] The sealing roller 302 also includes a cover section 322. The cover section 322 is part of a cover 324 that is secured to an opposite side of the sealing roller 302 from the shaft 312. In the depicted embodiment, the cover 324 also includes a circular section 326. In some embodiments, the cover 324 is formed from a rigid material, such as a thermoset polymer, metal, ceramic, or other material. In the depicted embodiment, the rough section 316, the sealing section 318, and the cover section 322 of the circumferential surface 306 of the sealing roller 302 have approximately similar diameters. In this way, the web can contact the sealing roller across the circumferential surface 306.

[0088] In some embodiments, the portion of the backing roller 304 that includes the circumferential surface 308 is formed from an elastic material, such as rubber or RTV silicone. Such an elastic material can increase traction between the sealing roller 302 and the backing roller 304. In the depicted embodiment, the backing roller 304 includes an inner lateral edge 328 and an outer lateral edge 330. In the depicted embodiment, the backing roller 304 is positioned relative to the sealing roller 302 such that the inner lateral edge 328 is positioned farther from the sealing element 320 than the outer lateral edge 330. When the system 300 advances a web having inflatable containers, the inner lateral edge 328 faces the containers of the web as the web is advanced. In the depicted embodiment, the backing roller 304 has a chamfered corner between the inner lateral edge 328 and the circumferential surface 308, and a chamfered corner between the outer lateral edge 330 and the circumferential surface 308. In the depicted embodiment, the circumferential surface 308 is a surface that has an approximately linear profile between the chamfered corners. In the depicted embodiment, the circumferential surface 308 of the backing roller 304 extends farther in the axial direction to the right (e.g., into the web as the web is in the nip 310) than the circumferential surface 306 of the sealing roller 302 extends in the axial direction to the right (e.g., into the web as the web is in the nip 310). In this way, the backing roller 304 contacts the web at a lateral location farther from the longitudinal edge of the web than the sealing roller 302 contacts the web as the longitudinal edge of the web is in the nip 310. In some embodiments, the percentage of the circumferential surface 308 of the backing roller 304 that extends beyond the nip 310 is greater than or equal to at least one of 5%, 7.5%, 10%, or 12.5%.

[0089] The system 300 also includes an inflation nozzle 332 that is arranged to inflate the containers of the web. Figure 10A side view of system 300 is depicted, with nozzle 332 visible in more detail. In the depicted embodiment, as the web is advanced along travel path 334, nozzle 332 is arranged to expand the container of the web before it reaches sealing roller 302 and backing roller 304. The expansion nozzle 332 includes an outlet 336 through which fluid (e.g., air or another gas) is inserted into the expandable container of the web. In some embodiments, nozzle 332 is offset from the roll gap 310 by an offset distance 338. In the depicted embodiment, nozzle 332 is offset from the roll gap toward backing roller 304 such that the web supplied along nozzle 332 contacts backing roller 304 before contacting sealing roller 302 and sealing element 320.

[0090] Figure 11 An exploded front view of system 300 is depicted, in which sealing roller 302 and backing roller 304 are spaced apart from each other. Figure 11 In the depicted embodiment, the width of the gap 310 is more clearly visible. In the embodiment depicting the sealing roller 302, the gap 310 extends substantially across the rough section 316, the sealing section 318, and the cover section 322 of the circumferential surface 306. The gap 310 also extends substantially concurrently with the circumferential surface 306 of the sealing roller 302. The circumferential surface 308 of the backing roller 304 extends laterally beyond the cover section 322 of the circumferential surface 306 of the sealing roller 302. Therefore, in the depicted embodiment, the gap 310 does not substantially concurrently extend with the circumferential surface 308 of the backing roller 304. The benefits of this arrangement of the backing roller 304 are discussed below.

[0091] As mentioned above, some expander machines have an upward angle relative to the axis of rotation that holds the web roll to aid in web loading and alignment. In these embodiments, it is also advantageous for the expander machine to have a propulsion and sealing system positioned at a similar upward angle to ensure proper expansion and sealing of the web. Figure 12 The illustration depicts an embodiment of system 300 positioned at an upward angle 340° relative to a horizontal plane. In some cases, system 300 may be part of an expansion machine, and system 300 may be located on the expansion machine such that the axes of the sealing roller 302 and the backing roller 304 are arranged at an angle relative to the surface on which the expansion machine is located (e.g., a horizontal surface). In various embodiments, the degree of the upward angle 340 may be between approximately 1 degree and approximately 45 degrees, between approximately 3 degrees and approximately 30 degrees, between approximately 3 degrees and approximately 30 degrees, and so on. In the illustrated embodiment, the upward angle is approximately 4 degrees above the horizontal plane. Those skilled in the art will understand that the upward angle is not a necessary aspect of system 300, and the axes of the sealing roller 302 and the backing roller 304 may be arranged horizontally or at any other angle.

[0092] Figure 12A web 342 propelled and sealed by the machine 300 is also depicted. The web 342 includes a first sheet 344 and a second sheet 346 that are juxtaposed and sealed together to form an inflatable container 348. In some embodiments, the web 342 has a closed longitudinal edge (e.g., the edge on the right when viewing Figure 12 ). The closed longitudinal edge can be a fold in the film that makes up the web 342 (e.g., when the first sheet 344 and the second sheet 346 are formed from a single film), or a seal in the film that makes up the web 342 (e.g., when the first sheet 344 and the second sheet 346 are formed from two pieces of film that are sealed together along the closed longitudinal edge). In some embodiments, the web 342 has a longitudinal edge that includes a port for inflating the inflatable container 348 (e.g., the edge on the left when viewing Figure 6 ). In the depicted embodiment, the longitudinal edge of the web 342 that includes the port is located in the nip 310 between the sealing roller 302 and the backing roller 304. When one or both of the sealing roller 302 and the backing roller 304 are driven (e.g., by a motor), and a portion of the web 342 is located in the nip 310, the web 342 is propelled by the system 300, and the sealing element 318 forms a seal in the web 342 to independently close the port of the inflatable container 348. While the web 342 is propelled, and before the web 342 reaches the sealing roller 302 and the backing roller 304, the inflation nozzle 332 introduces fluid into the inflatable container 348.

[0093] A detailed view of the web 342 and the nip 310 between the sealing roller 302 and the backing roller 304 is shown. Figure 13 Figure 14 A view of the web 342 as shown in Figure 13 , but with the system 300 removed to more clearly show the state of the web 342. In the depicted embodiment, a portion of the web 342 is in the nip 310, and a portion of the web 342 that includes the inflatable chamber 348 extends away from the nip 310 (e.g., to the right when viewing Figure 12 and Figure 13 ). The sealing element 320 forms a seal 350 in the web 342 to close the port of the inflatable chamber 348.

[0094] Figure 14 A transverse location 352 on the web 342 is also depicted. The transverse direction is a direction that is generally perpendicular to the longitudinal direction (e.g., the left-right direction when viewing Figure 14 ). In the depicted embodiment, the transverse location 352 is the farthest point away from the longitudinal edge at which the web 342 is in contact with at least one of the sealing roller 302 and the backing roller 304. As shown, the circumferential surface 306 and the nip 310 substantially coextend. However, with the web 342 in the depicted state, the circumferential surface 306 and the nip 310 do not coextend at the transverse location 352.​Figure 8 The lateral location 252 in the cross direction in the cross direction 252 is different than the lateral location 352, which is located outside of the nip 310. In the depicted embodiment, the lateral location 352 is located at an edge of the peripheral surface 308 of the backing roll 304. Figure 14 Also depicted in the cross direction is both a lateral distance 354 between a longitudinal edge of the web 342 and the seal 350 and a lateral distance 356 between the seal 350 and the lateral location 352, at which the web 342 is in contact with at least one of the sealing roll 302 and the backing roll 304. As can be seen in the depicted embodiment, the lateral distance 356 between the seal 350 and the lateral location 352, at which the web 342 is in contact with at least one of the sealing roll 302 and the backing roll 304, is greater than the lateral distance 354 between the longitudinal edge of the web 342 and the seal 350.

[0095] The arrangement of the system 300 addresses the above-identified problems with the system 200 in a number of ways. In one example, the backing roll 304 is wider than the backing roll 204, which means that the mass of the backing roll 304 is greater than the mass of the backing roll 204. The greater mass of the backing roll 304 results in a higher rate of heat transfer from the web 342 to the backing roll 304. The higher rate of heat transfer means that the seal 350 cools more quickly and solidifies more quickly from a molten or soft state to a hardened state. Thus, the amount of time for any damage to the seal 350 is reduced while the seal 350 is in the molten or soft state.

[0096] In another example, the lateral location 352 at which the web 342 is in contact with at least one of the sealing roll 302 and the backing roll 304 is outside of the nip 310. The lateral location 352 at which the web 342 is in contact with at least one of the sealing roll 302 and the backing roll 304 is a pressure or stress point, where any pressure or stress induced in the web 342 will be concentrated. By removing the lateral location 352 from the nip 310, the pressure or stress point is outside of the nip 310, the web 342 is able to flex and stretch in the area between the nip 310 and the lateral location 352, such that any forces on the portion of the web 342 in the nip 310 are reduced.

[0097] In another example, the lateral location 352 at which the web 342 is in contact with at least one of the sealing roll 302 and the backing roll 304 is further from the seal 350 than the lateral location 252 in the cross direction in the cross direction 252 is from the seal 250. The greater distance between the lateral location 352 and the seal 350 reduces the likelihood that any forces concentrated at the lateral location 352 will be sufficient to cause the web 342 to deform or break at the seal 350. In this way, it is more likely that the seal 350 will have the opportunity to cool and harden before being subjected to forces that would otherwise damage the seal 350 while in the molten or soft state. Figure 8 In the cross direction 252, the lateral location 252 is further from the seal 250 than the lateral location 352 at which the web 342 is in contact with at least one of the sealing roll 302 and the backing roll 304 is from the seal 350. The greater distance between the lateral location 352 and the seal 350 reduces the likelihood that any forces concentrated at the lateral location 352 will be sufficient to cause the web 342 to deform or break at the seal 350. In this way, it is more likely that the seal 350 will have the opportunity to cool and harden before being subjected to forces that would otherwise damage the seal 350 while in the molten or soft state.

[0098] For purposes of this disclosure, terms such as "upper," "lower," "vertical," "horizontal," "inwardly," "outwardly," "inner," "outer," "front," "rear," and the like shall relate to the subject matter as depicted in the figures, unless otherwise noted. In addition, the use of "including," "comprising," or "having" and variations thereof in this document shall be interpreted to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless otherwise restricted, the use of terms such as "connected," "coupled," and "mounted" and variations thereof in this document shall be interpreted in accordance with their broadest ordinary meaning consistent with the context in which they are used, and not confined to a direct connection, coupling, or mounting. Unless otherwise specified, the use of the term "about" in this document shall be interpreted to mean within 5% of the target value.

[0099] The principles, representative embodiments, and modes of operation of this disclosure have been described in the foregoing description. However, aspects of the disclosure intended to be protected are not to be construed as limited to the particular embodiments disclosed. Furthermore, the embodiments described herein are to be considered in all respects as illustrative only and not restrictive in character. It will be recognized that changes and modifications can be made by those skilled in the art without departing from the spirit of the disclosure. It is therefore intended that the scope of the disclosure be limited only by the appended claims.

Claims

1. A system for configuring a web of material to propel and seal an expandable container, wherein the container includes a port along a longitudinal edge of the web, the system comprising: A sealing roller, comprising a sealing element, wherein the sealing element is positioned around a circumferential surface of the sealing roller; as well as A backing roller, positioned relative to the sealing roller, to form a roll gap between the circumferential surface of the backing roller and the circumferential surface of the sealing roller; At least one of the sealing roller and the backing roller is driven such that when the longitudinal edge of the web is in the roll gap, the sealing roller and the backing roller rotate in opposite directions to advance the web; The circumferential surface of the backing roller extends further into the web than the circumferential surface of the sealing roller, such that the backing roller contacts the web at a laterally farther point from the longitudinal edge of the web compared to the contact of the sealing roller. The sealing roller and the backing roller are arranged such that the axis of the sealing roller and the axis of the backing roller are substantially parallel to each other. The system is part of an expansion machine, and the axes of the sealing roller and the backing roller are arranged at an inclined angle relative to the surface on which the expansion machine is located. The backing roller includes an inner transverse edge and an outer transverse edge, wherein, when the web is advanced, the inner transverse edge faces the container of the web, and wherein the backing roller is positioned relative to the sealing roller such that the inner transverse edge is positioned further away from the sealing element than the outer transverse edge.

2. The system according to claim 1, wherein, The backing roller comprises a rubber material, and the circumferential surface of the backing roller is made of the rubber material.

3. The system according to claim 1, wherein, The surface on which the expansion machine is located is substantially horizontal.

4. The system according to claim 1, wherein, The circumferential surface of the backing roller extends beyond the roll gap between the circumferential surface of the backing roller and the circumferential surface of the sealing roller.

5. The system according to claim 4, wherein, The percentage of the circumferential surface of the backing roller extending beyond the roll gap is greater than or equal to 5%.

6. The system according to claim 5, wherein, The percentage of the circumferential surface of the backing roller extending beyond the roll gap is greater than or equal to 7.5%.

7. The system according to claim 6, wherein, The percentage of the circumferential surface of the backing roller extending beyond the roll gap is greater than or equal to 10%.

8. The system according to claim 7, wherein, The percentage of the circumferential surface of the backing roller extending beyond the roll gap is greater than or equal to 12.5%.

9. The system according to claim 1, further comprising: A nozzle is arranged to inflate the container of the web before it is advanced to the sealing roller and the backing roller.

10. The system according to claim 9, wherein, The nozzle is offset relative to the gap between the circumferential surface of the backing roller and the circumferential surface of the sealing roller, such that when the web is advanced by the sealing roller and the backing roller, the web contacts the backing roller before contacting the sealing roller.

11. The system according to claim 1, wherein, The sealing element has a helical shape surrounding the circumferential surface of the sealing roller.

12. The system according to claim 1, wherein, The sealing element has an annular shape surrounding the circumferential surface of the sealing roller.

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